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RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/255,519 filed Feb. 22, 1999, now U.S. Pat. No. 6,090,120, which is a divisional of U.S. patent application Ser. No. 09/059,072, filed Apr. 13, 1998 now U.S. Pat. No. 5,897,523.
FIELD OF THE INVENTION
The present invention relates, in general, to surgical instruments and, more particularly, to an articulation and actuation mechanism for surgical instruments.
BACKGROUND OF THE INVENTION
This application is related to the following copending patent applications: application Ser. No. 08/770,550 filed Dec. 23, 1996; application Ser. No. 08/808,652 filed Feb. 28, 1997; application Ser. No. 091255,519 filed Feb. 22, 1999; and application Ser. No. 09/464,973 filed Dec. 16, 1999 which are hereby incorporated herein by reference.
Ultrasonic instruments, including both hollow core and solid core instruments, are used for the safe and effective treatment of many medical conditions. Ultrasonic instruments, and particularly solid core ultrasonic instruments, are advantageous because they may be used to cut and/or coagulate organic tissue using energy in the form of mechanical vibrations transmitted to a surgical end-effector at ultrasonic frequencies. Ultrasonic vibrations, when transmitted to organic tissue at suitable energy levels and using a suitable end-effector, may be used to cut, dissect, or cauterize tissue. Ultrasonic instruments utilizing solid core technology are particularly advantageous because of the amount of ultrasonic energy that may be transmitted from the ultrasonic transducer, through the waveguide, to the surgical end-effector. Such instruments are particularly suited for use in minimally invasive procedures, such as endoscopic or laparoscopic procedures, wherein the end-effector is passed through a trocar to reach the surgical site.
Solid core ultrasonic instruments adapted for use in surgery and, more particularly, for use in minimally invasive surgery, are well known in the art. For example, U.S. Pat. No. 5,322,055 illustrates an ultrasonic surgical shears that utilizes solid core ultrasonic technology, while U.S. Pat. No. 5,324,299 illustrates an ultrasonic hook blade end-effector for use in surgical applications. In addition, articulating instruments for use in minimally invasive surgery are also known in the art. For example, U.S. Pat. No. 5,409,498 describes an articulating endocutter for use in cutting and stapling tissue.
Many ultrasonic surgical instruments used for cutting and coagulation rely upon relatively stiff, solid core ultrasonic waveguides to efficiently deliver energy from the transducer to the end-effector. In such instruments it may be desirable to articulate the end-effector in order to provide the surgeon with flexibility in engaging hard to reach structures. However, the relatively stiff solid core ultrasonic waveguides and the limited structural space available in minimally invasive instruments make it difficult to design appropriate mechanisms for articulating end-effectors in such devices. One option, which is illustrated and described in U.S. patent application Ser. No. 08/770,550 previously incorporated herein by reference, involves separating the waveguide into two or more segments which may be moved independently to provide articulation.
Flexible high power ultrasonic surgical instruments are also available. Flexible ultrasonic surgical instruments such as atherosclerosis treatment devices, thrombolysis devices, or some stone crushing devices are typically thin wires encased in a polymeric sheath, are relatively flexible, and articulate if assisted with known flexible endoscopy articulation means. For example, U.S. Pat. No. 5,380,274 describes a flexible ultrasonic catheter, and U.S. Pat. No. 4,108,211 describes a flexible endoscope mechanism.
It would, therefore, be advantageous to design an improved mechanism for articulating and actuating surgical instruments. It would further be advantageous to design an improved mechanism for articulating and actuating surgical instruments wherein the end-effector is both rotatable and articulatable. It would further be advantageous to design an articulating solid core ultrasonic surgical instrument which could be passed through a trocar or other surgical access device and the end-effector could be articulated utilizing a handle positioned outside of the surgical access device. The present invention incorporates improvements to known ultrasonic surgical instruments to provide these advantages.
SUMMARY OF THE INVENTION
An improved actuation mechanism for a surgical instrument is described. The mechanism includes an actuating arm and a collar operatively connected to the actuating arm. The collar converts rotation of the actuating arm into a plurality of actuations of the surgical instrument. In one embodiment the collar includes two ranges of motion, where the first range is used to articulate the surgical instrument, and the second range is used to actuate the surgical instrument.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to organization and methods of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective partial cutaway view illustrating a surgical instrument including an articulatable ultrasonic surgical shears according to the present invention, wherein the surgical instrument is illustrated in combination with an ultrasonic transducer;
FIG. 2 is an exploded perspective view of a surgical instrument according to the present invention;
FIG. 2A is a perspective view of the distal end of the ultrasonic waveguide illustrated in FIG. 2;
FIG. 3 is a perspective view of the rotation driver of the articulation and actuation mechanism shown in FIG. 4;
FIG. 4 is a perspective view of an actuation mechanism internal to the surgical instrument shown in FIG. 1;
FIG. 5 is a perspective partial view illustrating the distal end of the actuating arm of a surgical instrument according to the present invention;
FIG. 6 is a perspective view illustrating a distal portion of the waveguide collar of a surgical instrument according to the present invention;
FIG. 7 is a perspective view illustrating a proximal portion of the waveguide collar of a surgical instrument according to the present invention;
FIG. 8 is a side sectioned view sectioned through the articulation collar illustrating the ultrasonic waveguide surrounded by the articulation collar positioned within the inner-tube and outer-tube of the ultrasonic surgical shears in accordance with the present invention;
FIG. 9 illustrates the device of FIG. 8 in its articulated position;
FIG. 10 is a cutaway perspective view illustrating a distal portion of the surgical instrument according to the present invention with the end-effector in the articulated position; and
FIG. 11 illustrates the device shown in FIG. 10 with the end-effector in the articulated position and the end-effector sheared.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a surgical instrument 10 including an end-effector, designated as a shear blade 38 that may be both articulated and actuated according to the present invention. In FIG. 1, surgical instrument 10 is illustrated in combination with ultrasonic transducer 12 . Surgical instrument 10 includes instrument handle 14 , ultrasonic transmission rod assembly 16 and ultrasonic shear blade 38 . Ultrasonic transducer 12 includes generator housing 17 , which may also be referred to as a handpiece, and power supply cable 20 . Ultrasonic transducer 12 houses transduction elements, preferably piezeoceramic elements, for converting an electrical signal, for example, a 55,500 Hz sinusoidal waveform, into a mechanical longitudinal vibration. A suitable ultrasonic handpiece is available from Ethicon Endo-Surgery Inc. in Cincinnati Ohio, as make ULTRACISION® and model HP051. Instrument handle 14 includes finger grip 22 , actuation trigger 24 and rotation knob 26 .
FIG. 2 illustrates the elements and interconnection of instrument handle 14 , ultrasonic transmission rod assembly 16 and ultrasonic shear blade 38 . Instrument handle 14 includes left housing half 42 and right housing half 44 . Left housing half 42 includes finger grip 22 . Actuation trigger 24 is rotatably mounted on pivot pin 46 between left housing half 42 and right housing half 44 . Actuation trigger 24 includes thumb ring 48 , pivot 50 , yoke 52 , yoke arms 54 and detent pins 56 . Driver collar 58 is positioned in yoke 52 and rotatably engaged by detent pins 56 . Driver collar 58 comprises drive teeth 71 , engageable with drive threads 69 of rotation driver 65 . Rotation knob 26 is rotatably positioned between left housing half 42 and right housing half 44 at the distal end of instrument handle 14 . Rotation knob 26 includes rotation disk 60 , rotation channel 62 , rotation drive tube 64 and rotation knob connector pin holes 66 .
In FIG. 2 ultrasonic transmission rod assembly 16 includes outer sheath 28 , ultrasonic waveguide 30 , and actuating arm 34 . Outer sheath 28 is affixed to ultrasonic waveguide 30 , actuating arm 34 and rotation drive tube 64 by rotation connector pin 68 which passes through rotation knob connector pin holes 66 , waveguide connector pin hole 70 , outer sheath connector pin holes 67 , and actuation arm connector pin slot 74 . Outer sheath 28 includes proximal tube 76 , and wrench flats 78 . Actuating arm 34 is positioned within and extends from the proximal to the distal end of outer sheath 28 . Actuating arm 34 includes actuation arm connector pin slot 74 and actuation slot 82 at the proximal end. Actuation arm 34 is adapted to engage rotation driver 65 via keys 83 and keyways 85 . Actuating arm 34 is positioned on ultrasonic waveguide 30 within outer sheath 28 .
In FIG. 2 ultrasonic waveguide 30 includes node isolator 88 , connector segment 86 , transmission segment 90 , pivoting node 93 , shear blade 38 , fixed node 91 , and articulation segment 92 . Articulation segment 92 is bounded by fixed node 91 at the proximal end thereof and pivoting node 93 at the distal end thereof. Pivoting node 93 is surrounded by waveguide collar 43 comprising an articulation collar 45 and an actuation collar 47 . Articulation segment 92 is generally thinner than transmission segment 90 and, more particularly, preferably has a diameter of 20 to 70 percent of the diameter of the narrowest portion of transmission segment 90 . In addition, or as an alternative, articulation segment 92 may include a bend or curve to facilitate rotational movement of pivoting node 93 . Rotation is facilitated by reducing the force required to bend articulation segment 92 . Ultrasonic waveguide 30 is preferably fabricated from a solid core shaft constructed out of material which propagates ultrasonic energy efficiently, such as a titanium alloy (e.g., Ti-6A1-4V) or an aluminum alloy.
FIG. 2A illustrates first arm 122 and second arm 124 extending from the distal portion of ultrasonic waveguide 30 . First arm 122 and second arm 124 are bifurcated from ultrasonic waveguide 30 near pivoting node 93 . This bifurcation may be accomplished by cutting the distal portion of ultrasonic waveguide 30 using a laser cutting tool, EDM machine, or other methods known in the art. During actuation of shear blade 38 , first arm 122 and second arm 124 may be made to move normally to their length in a scissoring action, cutting any tissue therebetween.
As illustrated in FIG. 3, rotation driver 65 includes drive threads 69 , latch 59 , and keys 83 . Latch 59 is insertable into actuation slot 82 of actuating arm 34 (see FIG. 2 ). Threads 69 are angled along the length of rotation driver 65 to cause rotation driver 65 to rotate as driver collar 58 is moved forward over rotation driver 65 as further illustrated in FIG. 4 .
FIG. 4 illustrates handle actuation mechanism 51 of surgical instrument 10 . In handle actuation mechanism 51 , actuation trigger 24 is pivotally connected to driver collar 58 by yoke 52 . Yoke arms 54 of yoke 52 spring load detent pins 56 in collar rotation channel 57 . The proximal end of ultrasonic waveguide 30 extends through central aperture 61 of rotation driver 65 . The proximal end of actuating arm 34 extends into collar central aperture 61 .
Referring to FIGS. 2 through 4, latch 59 of rotation driver 65 engages actuation slot 82 that is positioned at the proximal end of actuating arm 34 . The proximal end of ultrasonic waveguide 30 is rotationally and axially affixed to rotation knob 26 by rotation connector pin 68 that passes through rotation drive tube 64 . The proximal end of actuating arm 34 is rotatably affixed to rotation knob 26 by rotation connector pin 68 which passes through rotation drive tube 64 and actuation arm connector pin slot 74 of actuating arm 34 . Drive teeth 71 of driver collar 58 engage drive threads 69 of rotation driver 65 . As driver collar 58 is driven over rotation driver 65 by yoke 52 , actuating arm 34 is rotated within outer sheath 28 . Rotation of actuating arm 34 within outer sheath 28 may be independent of rotation of ultrasonic transmission rod assembly 16 as a whole.
FIGS. 5 through 11 illustrate how ultrasonic shear blade 38 is made to both articulate and shear through actuation of thumb ring 48 via handle actuation mechanism 51 (FIG. 4 ). In FIG. 5, the distal end of actuating arm 34 comprises thread tabs 29 A and 29 B and shear tabs 49 A and 49 B. Thread tabs 29 A and 29 B and shear tabs 49 A and 49 B may be formed from actuating arm 34 by processes such as, for example, cutting and forming the thread tabs 29 A and 29 B and shear tabs 49 A and 49 B from actuating arm 34 . Actuating arm 34 also comprises an opening 53 .
FIG. 6 illustrates the actuation collar 47 of the waveguide collar 43 of a surgical instrument 10 according to the present invention. Actuation collar 47 comprises tab faces 55 A and 55 B, contact lobes 73 A and 73 B, and a collar aperture 77 . Collar aperture 77 accommodates ultrasonic shear blade 38 to be positioned within and extend from actuation collar 47 .
FIG. 7 illustrates articulation collar 45 , the proximal portion of the waveguide collar 43 . Articulation collar 45 includes an attachment portion 102 , articulation portions 104 and 106 , bore 108 , and keyway 110 . Articulation collar 45 and actuation collar 47 are rotatably coupled, and work together to both articulate and actuate ultrasonic shear blade 38 , as will be described below.
FIG. 8 illustrates the distal end of surgical instrument 10 showing ultrasonic shear blade 38 in a non-articulated and non-actuated condition. Shear blade 38 extends straight and longitudinally from ultrasonic waveguide 30 . Ultrasonic waveguide 30 is located within actuating arm 34 by waveguide collar 43 . Actuating arm 34 is located within outer sheath 28 . Key 111 of ultrasonic waveguide 30 rigidly locates articulation collar 45 onto a nodal attachment point 114 of ultrasonic waveguide 30 . Attachment portion 102 of articulation collar 45 is shown coupled to groove 112 of actuation collar 47 . Articulation portions 104 and 106 are shown contacting thread tabs 29 B and 29 A respectively.
As illustrated in FIG. 9, articulation of ultrasonic end-effector 38 is achieved by rotation of actuating arm 34 about ultrasonic waveguide 30 . The distal end of surgical instrument 10 is illustrated with ultrasonic shear blade 38 in an articulated, but non-actuated condition. As thumb ring 48 is moved toward finger grip 22 (illustrated in Figure 2 ), drive teeth 71 are pressed over drive threads 69 , causing actuating arm 34 to rotate. Rotation of actuating arm 34 through the first (30) to (60) degrees articulates ultrasonic shear blade 38 (10) to (20) degrees from longitudinal axis 116 . After (30) to (60) degrees of rotation, articulation portions 104 and 106 change from an angled region 118 A and 118 B to non-angled regions 120 and 121 , as illustrated in FIG. 7 . Articulation of shear blade 38 is accomplished by bending articulation segment 92 of ultrasonic waveguide 30 as described in U.S. patent application Ser. No. 09/255,519 previously incorporated herein by reference.
Now referring to FIGS. 2, 6 , and 10 , the actuation of shear blade 38 is illustrated. As actuating arm 34 continues to rotate past (30) degrees to (60) degrees, actuation collar 47 causes shear blade 38 of ultrasonic shear blade 38 to shear. Actuation collar 47 rotates freely with articulation collar 45 until shear tabs 49 A and 49 B contact tab faces 55 A and 55 B respectively. As rotation continues, contact tabs 73 A and 73 B apply a force to shear blade 38 .
FIGS. 10 and 11 illustrate shear blade 38 moving from an articulated non-actuated state to an articulated actuated state. Shear tabs 49 A and 49 B contact tab faces 55 A and 55 B respectively and apply a force to shear blade 38 causing shear blade 38 to shear as illustrated in FIG. 11 . During actuation, contact tab 73 A forces first arm 122 in one direction, while contact tab 73 B forces second arm 124 in the opposite direction causing shear blade 38 to shear. Counter-rotation of actuating arm 34 then allows first arm 122 and second arm 124 to return to their original non-actuated state.
Referring back to FIG. 2, shear blade 38 may be both articulated and actuated by moving actuation trigger 24 of instrument handle 14 toward finger grip 22 . When actuation trigger 24 is moved toward finger grip 22 , pivot 50 of actuation trigger 24 pivots on pivot pin 46 , forcing yoke 52 to move toward the proximal end of instrument handle 14 . Proximal movement of yoke 52 is transmitted to driver collar 58 by yoke arms 54 and detent pins 56 which engage rotation driver 65 . Thus when actuation trigger 24 is moved toward finger grip 22 , driver collar 58 is moved axially in a distal to proximal direction over rotation driver 65 .
Axial movement of driver collar 58 is converted to rotation of rotation driver 65 , that subsequently rotates actuating arm 34 by applying a force through latch 59 which engages actuation slot 82 in actuating arm 34 . Actuation arm connector pin slot 74 in actuating arm 34 is elongated to ensure that rotation connector pin 68 and node isolator 88 do not interfere with the rotational movement of actuating arm 34 . Thus, distal to proximal axial movement of driver collar 58 forces actuating arm 34 to rotate and, since rotation driver 65 is free to move with respect to the proximal end of ultrasonic waveguide 30 , axial movement of actuating arm 34 does not result in axial movement of the proximal end of ultrasonic waveguide 30 .
In order to properly position shear blade 38 prior to or after it is articulated, surgical instrument 10 is also adapted to allow shear blade 38 to be rotated around a central axis. Axial rotation of shear blade 38 is accomplished by moving rotation knob 26 . When rotation disk 60 of rotation knob 26 is rotated, rotational force is transmitted through rotation drive tube 64 to rotation connector pin 68 . As illustrated in FIG. 2, rotation channel 62 is mounted between left housing half 42 and right housing half 44 such that rotation knob 26 may be freely rotated but will not move axially with respect to instrument handle 14 . Rotation connector pin 68 passes through rotation knob connector pin holes 66 , outer sheath connector pin holes 67 , mounting arm connector pin-slot 72 , waveguide connector pin hole 70 and actuation arm connector pin slot 74 , thus transmitting rotational forces from rotation knob 26 to outer sheath 28 , ultrasonic waveguide 30 and actuating arm 34 . Rotational forces are, in turn transmitted back to rotation driver 65 by the interconnection of actuation slot 82 and latch 59 .
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims. | An improved articulation mechanism is described in conjunction with a therapeutic ultrasound instrument. Ultrasonic vibrations, when transmitted to organic tissue at suitable energy levels and using a suitable end-effector, may be used for the safe and effective treatment of many medical conditions. The mechanism includes an actuating arm with a collar operatively connected to the actuating arm. The collar converts rotation of the actuating arm into a plurality of actuations of the surgical instrument. In one embodiment the collar includes two ranges of motion, where the first range is used to articulate the surgical instrument, and the second range is used to actuate the surgical instrument. Such instruments are particularly suited for use in minimally invasive procedures, such as endoscopic or laparoscopic procedures. | 0 |
FIELD OF THE INVENTION
The invention relates to a transflective liquid crystal display (LCD) comprising a patterned quarter wave foil (QWF) and having improved chromaticity.
BACKGROUND AND PRIOR ART
The demand for colour mobile displays that are thin, light weight, low power, but clear and bright in all ambient light conditions has been increasing due to the increasing popularity of mobile phones, personal digital assistants (PDAs), digital cameras and laptop computers. The fact that these devices are required to work in varied ambient conditions and need high battery power has raised interest in transflective colour liquid crystal displays, which use a backlight to illuminate the display, but can reduce power consumption by making use of the ambient light in bright conditions.
In prior art transflective displays of twisted and non-twisted modes like TN (twisted nematic) and ECB (electrically controlled birefringence) are disclosed, wherein each pixel is split into a reflective and a transmissive subpixel (see for example Kubo et al., IDW 1999, page 183-187; Baek et al., IDW 2000, page 41-44; Roosendaal et al., SID Digest 2003, page 78-81 and WO 2003/019276 A2). The transmissive subpixel has transparent front and back electrodes whereas the reflective subpixel has a transmissive front electrode and a reflective back electrode, requiring a patterned electrode structure which is achieved for example by “hole-in-mirror” technology.
As the transmissive mode uses half-wave (λ/2) optical modulation (λ=wavelength of incident light) and the reflective mode uses quarter wave (λ/4) optical modulation it was suggested to use a different cell gap (or LC layer thickness) for the subpixels, so that the reflective subpixel has about half the cell gap of the transmissive subpixel.
In order to make the reflective sub-pixel work with the transmissive subpixel, an achromatic (or “wide-band”) quarter wave foil (AQWF) is required to produce circularly polarised light (an AQWF exhibits an optical retardation of λ/4 for a wide wavelength band preferably encompassing the entire visible spectrum, and is formed for example by combining a QWF with a half wave foil (HWF, having an optical retardation of λ/2)). The AQWF also covers the transmissive pixel, hence requiring that an equivalent AQWF is placed on the backlight side of the cell.
However, the use of circularly polarised light in the transmissive portion of the display has the disadvantageous side-effect that twisted LC modes are less efficient at converting circular polarised light to the opposite handedness, thus reducing the brightness of the display and making the 90° twisted mode less effective.
To address the problems with circularly polarised light in the transmissive portion of the transflective display, it was proposed to use a patterned QWF having a pattern of areas with QWF retardation covering the reflective subpixels and non-retarding areas covering the transmissive subpixels (WO 03/019276; Van der Zande et al., Proc. of the SID 2003, page 194-197). This allows the reflective and transmissive subpixels to be optimised separately and hence allows the use of linearly polarised light in the transmissive portion.
Reducing the number of films and manufacturing process steps in a display is of great importance to reduce cost and make the manufacturing process easier. The ideal situation would be to develop a patterned AQWF, as this would mean that the transmissive and reflective portions of the display could be optimised independently and no unnecessary films would be required on the backlight side of the cell, reducing the number of films by two. However, there are great technical difficulties of patterning two layers that are aligned at different angles. Therefore, the use of a single patterned QWF would be preferred. This introduces the problem of how to achieve an achromatic reflective mode. This can be achieved by using an external HWF that will combine with the patterned QWF to produce an AQWF, but this affects the contrast and colour of the transmissive state, hence a second HWF is required on the backlight side to compensate (see Roosendaal et al., Proceedings of the SID 2003, page 78-81). On the other hand, using a patterned transflective 90° twist cell with a single patterned QWF in a standard set up produces too great an angular colour shift and reduces reflective contrast.
Hence, there is still a need for a transflective display comprising a patterned QWF which does not have the drawbacks of prior art displays described above.
It was an aim of the present invention to provide a display that does not have the above mentioned disadvantages, shows high contrast, good brightness and low colour shift over a large range of viewing angles and is easy to manufacture in a time- and cost-effective way. Other aims of the present invention are immediately evident to the person skilled in the art from the following detailed description.
The inventors of the present invention have found that these aims can be achieved by providing displays according to the present invention. These displays use a specific combination of a 90°-twisted transflective cell with a patterned QWF that produces reduced chromaticity in the reflective mode, without the need for a half wave foil to complete the AQWF. Rotation of the 90°-twisted cell relative to the polarisers, so that the director of the LC molecules at the surface of the LC cell is oriented at specific angles relative to the polarisation direction of the respective adjacent polariser, effectively reduces or cancels the chromaticity due to the single chromatic QWF.
DEFINITION OF TERMS
The term ‘film’ includes rigid or flexible, self-supporting or free-standing films with mechanical stability, as well as coatings or layers on a supporting substrate or between two substrates.
The term ‘liquid crystal or mesogenic material’ or ‘liquid crystal or mesogenic compound’ means materials or compounds comprising one or more rod-shaped, board-shaped or disk-shaped mesogenic groups, i.e. groups with the ability to induce liquid crystal (LC) phase behaviour. LC compounds with rod-shaped or board-shaped groups are also known in the art as ‘calamitic’ liquid crystals. LC compounds with a disk-shaped group are also known in the art as ‘discotic’ liquid crystals. The compounds or materials comprising mesogenic groups do not necessarily have to exhibit an LC phase themselves. It is also possible that they show LC phase behaviour only in mixtures with other compounds, or when the mesogenic compounds or materials, or the mixtures thereof, are polymerised.
For the sake of simplicity, the term ‘liquid crystal material’ is used hereinafter for both mesogenic and LC materials.
Polymerisable compounds with one polymerisable group are also referred to as ‘monoreactive’ compounds, compounds with two polymerisable groups as ‘direactive’ compounds, and compounds with more than two polymerisable groups as ‘multireactive’ compounds. Compounds without a polymerisable group are also referred to as ‘non-reactive’ compounds.
The term ‘reactive mesogen’ (RM) means a polymerisable mesogenic or liquid crystal compound.
The term ‘director’ is known in prior art and means the preferred orientation direction of the long molecular axes (in case of calamitic compounds) or short molecular axis (in case of discotic compounds) of the mesogenic groups in an LC material.
In films comprising uniaxially positive birefringent LC material the optical axis is usually given by the director.
The term ‘homeotropic structure’ or ‘homeotropic orientation’ refers to a layer of LC molecules oriented substantially perpendicular to the plane of the layer.
The term ‘planar structure’ or ‘planar orientation’ refers to a layer of LC molecules oriented substantially parallel to the plane of the layer.
Unless stated otherwise, the term “polarisation direction” of a linear polariser means the polariser extinction axis. In case of stretched plastic polariser films comprising e.g. dichroic iodine based dyes the extinction axis usually corresponds to the stretch direction.
SUMMARY OF THE INVENTION
The invention relates to a transflective liquid crystal display (LCD), preferably of the twisted nematic (TN) mode, comprising one or more pixels that are divided into a reflective and a transmissive subpixel and comprise
an LC layer sandwiched between a front and a back electrode, being switchable between different orientations upon application of an electric field and having a twist angle φ when no field is applied, a front and a back polariser sandwiching the LC layer and having front and back polarisation directions, at least one quarter wave retardation film (QWF) between the front polariser and the LC layer, which has an optical axis parallel to its film plane, comprises a pattern of regions with quarter wave (λ/4) retardation and regions with substantially no retardation, and is arranged such that the λ/4-regions do essentially cover only the reflective subpixels,
characterized in that
the optical axis of the QWF is oriented at an angle of approximately 45° to the front and back polariser direction, the director of the LC layer at the surface facing the front electrode is oriented at an angle θ1 from 5° to 45° relative to the polarisation direction of the front polariser, and the director of the LC layer at the surface facing the back electrode is oriented at an angle θ2 from 5° to 45° relative to the polarisation direction of the back polariser.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a transflective LCD according to the present invention.
FIG. 2 shows the relative orientation of optical layers in a transflective LCD according to prior art.
FIG. 3 shows the relative orientation of optical layers in a transflective LCD according to the present invention.
FIG. 4 shows the stack of optical layers in a transflective LCD according to examples 2 and 3.
FIGS. 5A and 5B show the calculated angular luminance (A) and chromaticity (B) for a transflective LCD according to example 2.
FIGS. 6A and 6B show the calculated angular luminance (A) and chromaticity (B) for a transflective LCD according to example 3.
DETAILED DESCRIPTION OF THE INVENTION
In a display according to the present invention, in the field-off state the LC layer has planar and twisted orientation, i.e. the LC molecules are oriented parallel to the plane of the layer and twisted at an angle φ around an axis perpendicular to the layer. The LC layer typically comprises LC molecules with positive dielectric anisotropy, which upon application of an electric field are switched into homeotropic or tilted homeotropic orientation, i.e. they are perpendicular or oriented at a tilt angle relative to the plane of the layer.
The LC display according to the present invention is preferably a twisted nematic (TN) display having a twist angle φ from 40° to 110°, very preferably from 80° to 100°, in particular of 90°. Another preferred embodiment relates to highly twisted nematic (HTN) displays having a twist angle φ from >90° to <270°, preferably of 180°. Another preferred embodiment relates to supertwisted nematic (STN) displays having a twist angle φ from >180° to <360°, preferably of 270°.
The patterned QWF comprises regions having a defined on-axis retardation and regions having a different or no on-axis retardation. In the retarding regions of the film the optical axis is preferably parallel to the film plane (A-plate symmetry). In the non-retarding regions the film comprises for example an optically isotropic material, or the optical axis is for example perpendicular to the film plane (C-plate symmetry).
The patterned QWF is preferably provided between the substrates forming the switchable LC cell and containing the switchable LC medium (“incell” application). Compared to conventional displays where optical retarders are usually placed between the LC cell and the polarisers, incell application of an optical retarder has several advantages. For example, a display where the optical retarder is attached outside of the glass substrates forming the LC cell usually suffers from parallax problems, which can severely impair viewing angle properties. If the retarder is prepared inside the LC display cell, these parallax problems can be reduced or even avoided.
Preferably the QWF is positioned between the colour filter and the LC medium, very preferably between the colour filter and the corresponding proximate electrode layer, or if a planarisation layer is present, between the colour filter and the planarisation layer.
The thickness of the QWF is preferably from 0.5 to 3.5 microns, very preferably from 0.6 to 3 microns, most preferably from 0.7 to 2.5 microns.
The on-axis retardation (i.e. at 0° viewing angle) of the QWF is preferably from 90 to 200 nm, most preferably from 100 to 175 nm.
A preferred LCD according to the invention comprises
an LC cell comprising the following elements
a first and a second substrate plane parallel to each other, at least one of which is transparent to incident light, an array of nonlinear electric elements provided on one of said substrates which can be used to individually switch individual pixels of said LC cell, said elements being preferably active elements like transistors, very preferably TFTs, a colour filter array provided on one of said substrates, preferably on the substrate opposite to that carrying the array of nonlinear elements, and having a pattern of different pixels transmitting one of the primary colours red, green and blue (R, G, B), said colour filter optionally being covered by a planarisation layer, a first electrode layer provided on the inside of said first substrate, a second electrode layer provided on the inside of said second substrate, optionally first and second alignment layers provided on said first and second electrodes, an LC layer sandwiched between the electrodes or alignment layers, which is switchable between different orientations by application of an electric field and has a twist angle φ when no field is applied,
a first linear polariser on the first side of the LC cell, a second linear polariser on the second side of the LC cell, and at least one QWF positioned between the first and second substrate of the LC cell, having an optical pattern of regions having different retardation,
wherein the orientation directions of the polarisers, QWF and LC layer are as defined above and below.
The assembly of an LCD according to a preferred embodiment of the present invention is schematically depicted in FIG. 1 . The top of FIG. 1 corresponds to the front side of the display, i.e. the side of the viewer. The bottom of FIG. 1 corresponds to the back side of the display, i.e. the side of the backlight. FIG. 1 exemplarily shows one pixel 10 of the LCD, comprising a layer of a switchable LC medium 12 confined between two transparent, plane parallel substrates 11 a/b , like for example glass substrates, and two polarisers 13 a/b with crossed polarisation directions sandwiching the substrates.
The display further comprises a transparent electrode 14 c on the front side of the LC layer and a pattern of reflective electrodes 14 a and transparent electrodes 14 b on the back side of the LC layer, thereby forming two sets of reflective subpixels 10 a and transmissive subpixels 10 b . The transparent electrodes 14 c / 14 b are for examples layers of Indium Tin Oxide (ITO). The reflective electrode 14 a comprises for example an ITO layer 14 a 1 and a reflective layer 14 a 2 which redirects light transmitted through the LC medium back towards the viewer (indicated by the curved arrow). The reflective layer 14 a 2 is for example a metal layer (e.g. Al) or can be formed as a mirror with holes (the mirror areas being in the reflective subpixels and the holes in the transmissive subpixels). The electrode layer 14 a 1 and the mirror 14 a 2 can be adjacent layers, or spatially separated as shown in FIG. 1 .
The display further comprises a colour filter 15 with red, green and blue pixels and a patterned incell QWF 16 . The QWF 16 has a pattern of regions 16 a having a defined retardation (with a value <0 or >0) and regions 16 b having no on-axis retardation. The retarding regions 16 a cover the reflective subpixels 10 a and the non-retarding regions 16 b cover the transmissive subpixels 10 b.
If the display is of the active-matrix type, as shown in FIG. 1 , it also comprises an array of nonlinear electric elements 17 which are used to individually switch individual pixels, like for example TFTs, on one side of the LC cell, preferably on the side opposite to that of the colour filter 15 . It is possible that the TFT layer 17 is on the back side and the colour filter 15 on the front side, as shown in FIG. 1 , or vice versa.
In colour active matrix displays, the mirror 14 a 2 can be built for example on the TFT layer (if the colour filter is on the front substrate) or on the colour filter layer (if the TFT layer is on the front substrate).
The reflective and transmissive subpixels 10 a/b preferably have different cell gaps, as indicated by the double arrows in FIG. 1 . Preferably the cell gap of the transmissive subpixel 10 b is two times the cell gap of the reflective subpixel 10 a.
To achieve a different cell gap, the reflective subpixel comprises for example a step 18 which can be formed e.g. from a clear resin (like a photoresist). The step 18 can be present on the colour filter side of the LC layer, or on the side of the LC layer opposite to that of the colour filter as shown in FIG. 1 .
The electrodes 14 a/b/c may also be covered by alignment layers (not shown) to induce or enhance the desired surface alignment in the LC medium 12 . Optionally there is also an alignment layer (not shown) provided between the colour filter 15 and the patterned incell QWF 16 . The display also comprises a backlight (not shown) on its back side.
The linear polarisers 13 a/b are for example standard absorption polarisers comprising e.g. stretched, dye-doped plastic films. It is also possible to use linear polarisers comprising a polymerised LC material with uniform planar orientation and a dichroic dye absorbing visible light, as described for example in EP-A-0 397 263. The polarisers 13 a/b can be attached to the substrates 11 a/b by adhesive layers (not shown), like commercially available PSA films (pressure sensitive adhesives).
The operation of a transflective LCD according to the present invention and as shown in FIG. 1 is exemplarily described below for 90° twist angle and a patterned incell QWF 16 having QWF regions 16 a and zero retardation regions 16 b.
In the bright state (without an electric field applied) in the reflective subpixels 10 a ambient light entering the display from the top is polarised by the front linear polariser 13 a . The linear polarised light is converted to circularly polarised light by the QWF regions 16 a of the patterned incell retarder and passes through the LC medium 12 .
Due to the smaller cell gap of the reflective subpixel, which is preferably half the cell gap of the transmissive subpixel, light passing the LC medium 12 experiences a retardation of d/ 2 ·Δn, wherein d is the cell gap and Δn is the birefringence of the LC medium. As a consequence the circularly polarised light is converted into substantially linear polarised light. Depending on the cell parameters the light may not be completely linear but slightly elliptically polarised.
The mirror 14 a 2 reflects the light back while preserving its polarisation state and direction. The light passes again through the LC medium 12 where it is converted back to circularly polarised light, and passes again through the patterned incell QWF 16 which converts it to linear polarised light. This linear polarised light can then pass again through the front polariser 13 a and is seen by an observer.
The transmissive subpixels in the bright state behave like a standard TN cell. The regions of retarder 16 b covering the transmissive subpixels have no on-axis retardation for visible wavelengths and do not change the polarisation state of the light. Thus, light emitted from the backlight enters the display from the back side and is polarised by the back linear polariser 13 b . When passing through the LC medium 12 it experiences a retardation of d·Δn and remains linear polarised, however its plane of polarisation is twisted at 90° so that it passes the front polariser 13 a and is seen by an observer.
In the dark state (with an electric field applied, not shown) in the reflective subpixels ambient light entering from the top is polarised by the front linear polariser 13 a . It is converted to circularly polarised light by the patterned incell QWF 16 a and passes through the homeotropically oriented LC medium 12 with its polarisation state and direction substantially unchanged. When reflected back from the mirror 14 a 2 it remains circularly polarised but its polarisation sense is reversed. It is then converted by the patterned incell QWF 16 a to linear polarised light, but now with perpendicular polarisation direction so that it is blocked by the crossed front polariser 13 a.
In the dark state the transmissive subpixels also behave like a standard TN cell. Light emitted from the backlight is polarised by the back linear polariser 13 b and passes through the non-retarding regions of the patterned incell retarder 16 b and through the LC medium 12 with its polarisation direction substantially unchanged, so that it is blocked by the crossed front polariser 13 a.
A transflective LCD according to the present invention is characterized in that the optical layers like the polarisers, LC layer and QWF, and optional further retardation films, are arranged with their optical axes oriented at specific angles relative to each other. In particular, rotation of the LC layer relative to the polarisers and the QWF effectively reduces the chromaticity caused by the single chromatic QWF. Hence an additional HWF (to form an AQWF) is not necessary and the number of optical layers can be reduced, leading to lower thickness, higher brightness and lower manufacturing cost of the display.
The orientation of the optical components in a transflective TN display according to prior art is exemplarily illustrated in FIG. 2 , which shows an expanded view of the reflective subpixel in the field-off state, including front and back polarisers 13 a/b , a reflector 14 , a patterned QWF 16 , and a TN cell 12 comprising an LC layer with a twist angle φ of 90° and having a front surface 12 a and a back surface 12 b . The polarisation directions of the polarisers 13 a/b are +45° and −45°, respectively. The optical axis of the QWF 16 is oriented at 90°. All angles are given relative to a reference axis x (direction of 0°) shown in FIG. 2 .
The director of the LC layer in the TN cell 12 at the front and back surface 12 a/b is oriented at +45° and 45°, i.e. parallel to the respective adjacent polariser transmission axis. This orientation of the LC layer is hereinafter also referred to as ‘standard alignment’.
The orientation of the optical components in a transflective TN display according to the present invention is exemplarily illustrated in FIG. 3 , which shows an expanded view of a reflective subpixel having the components shown in FIG. 2 in the field-off state. The orientations of the front and back polarisers 13 a/b and of the patterned QWF 16 are as shown in FIG. 2 . However, the complete TN cell 12 is now rotated at an angle relative to the above described standard alignment.
In the foregoing and the following, this angle is also referred to as ‘rotation angle’ or θ. In case of a TN display with a twist angle φ of 90° and crossed polarisers, θ corresponds to the angle between the surface director of the LC layer and the polarisation axis of the respective adjacent polariser when no field is applied.
For example, in the preferred embodiment of the present invention as shown in FIG. 3 , the rotation angle θ is −15° in the direction of twist (i.e. 15° opposite to the twist direction as the stack is observed from the view point of the user). As the LC layer in the TN mode has a twist angle φ of 90°, the director of the LC layer in the TN cell 12 at the front and back surface 12 a/b is now oriented at +30° and −60°, respectively.
In a display according to the present invention, rotation of the LC layer relative to the polarisers allows to reduce the chromaticity of the reflective state and foregoes the need for an achromatic QWF. In particular, the rotation of the LC layer leads to a reduced on-axis and off-axis chromaticity of the display in the reflective mode, whilst maintaining or even improving the brightness of the display. The exact values of the angles θ, θ1 and θ2 can be varied depending on the chromaticity of the QWF used. Thus, chromaticity will increase up to a maximum by increasing the rotation angle θ up to 45°.
In a display according to the present invention, in particular in a TN display, the angles θ, θ1 and θ2 are preferably from 5° to 45°, very preferably from 10° to 20°, most preferably 15°.
The selection and optimization of further display parameters like the cell gap d, the twist angle φ and birefringence Δn of the LC layer, can be achieved as described in prior art.
In a preferred embodiment, the patterned incell QWF additionally exhibits a pattern of R-, G- and B-pixels with three different retardations covering the reflective subpixels, wherein the retardation in the R-, G- and B-pixels of the film is selected such that the efficiency of converting linearly polarised light into circularly polarised light is optimised for the colour red (R), green (G) or blue (B), respectively. The QWF is positioned such that its R-, G- and B-pixels cover the corresponding reflective R,- G- and B-subpixels of the display.
In such a retardation film the retardation values in the R-, G- and B-pixels are preferably selected as follows:
For red light of a wavelength of 600 nm the retardation is from 140 to 190 nm, preferably 145 to 180 nm, very preferably 145 to 160 nm, most preferably 150 nm. For green light of a wavelength of 550 nm the retardation is from 122 to 152 nm, preferably 127 to 147 nm, very preferably 132 to 142 nm, most preferably 137 nm. For blue light of a wavelength of 450 nm the retardation is from 85 to 120 nm, preferably 90 to 115 nm, very preferably 100 to 115 nm, most preferably 112 nm.
The QWFs used in the LCD according to this invention are preferably films comprising polymerised LC material, optionally with a retardation and/or orientation pattern. These can be applied incell (i.e. inside the substrates forming the LC cell) to avoid parallax problems and patterned using UV light to form an isotropic region over the transmissive portion of the display. Principally any patterned retarder which is applicable incell can be used as QWF.
Patterned retarders that are suitable for use in the LCD according to the present invention have been described in prior art. For example, the retarders disclosed in WO 2003/019276 A, WO 2004/083913 A and Van der Zande et al., Proceedings of the SID 2003, p. 194-197 can be used.
Especially preferred are patterned optical retardation films as described in WO 2004/090025 A1. Preferably such patterned films are prepared by a process comprising the following steps:
a) providing a layer of a polymerisable LC material comprising at least one photoisomerisable compound onto a substrate, b) aligning the layer of LC material into planar orientation, c) exposing the LC material in the layer, or in selected regions thereof, to photoradiation that causes isomerisation of the isomerisable compound, preferably UV radiation, d) polymerising the LC material in at least a part of the exposed regions of the material, thereby fixing the orientation, and e) optionally removing the polymerised film from the substrate,
wherein the retardation and/or orientation of the LC material is controlled by varying the amount and/or type of the photoisomerisable compound, and/or by varying the intensity of the photoradiation and/or the exposure time.
Preferably the LC material is exposed to radiation that causes photoisomerisation and photopolymerisation, wherein the steps of photoisomerisation and photopolymerisation are carried out under different conditions, in particular under different gas atmospheres, especially preferably wherein photoisomerisation is carried out in the presence of oxygen and photopolymerisation is carried out in the absence of oxygen.
Apart from the specific conditions and materials described in this invention, the steps a) to e) can be carried out according to standard procedures that are known to the expert and are described in the literature.
The polymerisable LC material comprises a photoisomerisable compound, preferably a photoisomerisable mesogenic or LC compound, very preferably a photoisomerisable compound that is also polymerisable. The isomerisable compound changes its shape, e.g. by E-Z-isomerisation, when exposed to radiation of a specific wavelength, e.g. UV-radiation. This leads to disruption of the uniform planar orientation of the LC material, resulting in a drop of its birefringence. Since the optical retardation of an oriented LC layer is given as the product d·Δn of the layer thickness d and the birefringence Δn of the LC material, the drop in birefringence also causes a decrease of the retardation in the irradiated parts of the LC material. The orientation and retardation of the LC material is then fixed by in-situ polymerisation of the irradiated regions or of the entire film.
Polymerisation of the LC material is achieved for example by thermal or photopolymerisation. In case photopolymerisation is used, the type of radiation used for photoisomerisation and for photopolymerisation of the LC material may be the same or different. In case radiation, e.g. UV-radiation, of a wavelength is used that can cause both photoisomerisation and photopolymerisation of the LC material, the steps of photoisomerisation and photopolymerisation are preferably carried out under different conditions, in particular under different gas atmospheres. In this case preferably photoisomerisation is carried out in the presence of oxygen, like e.g. in air, and photopolymerisation is carried out in the absence of oxygen, especially preferably under an inert gas atmosphere of e.g. nitrogen or a noble gas like argon. If the isomerisation step is performed in the presence of oxygen or in air, the oxygen scavenges the free radicals produced from the photoinitiator present in the material and thus prevents polymerisation. In the next step oxygen or air is removed and replaced by an inert gas such as nitrogen or argon, thereby allowing polymerisation to occur. This allows better control of the process steps.
The degree of isomerisation and thus the birefringence change in the layer of LC material can be controlled e.g. by varying the radiation dose, i.e. the intensity, exposure time and/or power of the radiation. Also, by applying a photomask between the radiation source and the LC layer it is possible to prepare a film with a pattern of regions or pixels having specific values of the retardation that differ from each other. For example, a film comprised of two different values of retardation can be created using a simple, monochrome mask. A more complicated film exhibiting multiple regions of different retardation can be created using a grey-scale mask. After the desired retardation values are achieved the LC layer is polymerised. In this way it is possible to create a polymer retardation film with values of retardation ranging from that of the initial LC layer to zero. The value of retardation for the initial layer of LC material is controlled by appropriate selection of the layer thickness and the type and amounts of the individual components of the LC material.
The polymerisable LC material is preferably a nematic or smectic LC material, in particular a nematic material, and preferably comprises at least one di- or multireactive achiral RM and optionally one or more than one monoreactive achiral RMs. By using di- or multireactive RMs a crosslinked film is obtained wherein the structure is permanently fixed, and which exhibits high mechanical stability and high stability of the optical properties against external influences like temperature or solvents. Films comprising crosslinked LC material are thus especially preferred.
Polymerizable mesogenic mono-, di- and multireactive compounds used for the present invention can be prepared by methods which are known per se and which are described, for example, in standard works of organic chemistry such as, for example, Houben-Weyl, Methoden der organischen Chemie, Thieme-Verlag, Stuttgart.
Examples of suitable polymerizable mesogenic compounds that can be used as monomers or comonomers in a polymerizable LC mixture are disclosed for example in WO 93/22397, EP 0 261 712, DE 195 04 224, WO 95/22586, WO 97/00600 and GB 2 351 734. The compounds disclosed in these documents, however, are to be regarded merely as examples that shall not limit the scope of this invention.
The examples below serve to illustrate the invention without limiting it. In these examples, all temperatures are given in degrees Celsius and all percentages are given as percentage by weight unless stated otherwise. Simulations of optical performance, like luminance, chromaticity and contrast plots, are carried out using a Berreman 4×4 matrix calculations.
EXAMPLE 1
Preparation of a Patterned QWF
The following polymerisable LC mixture is formulated
(13)
14.4%
(24)
18.0%
(35)
17.0%
(46)
17.0%
(57)
32.0%
Irgacure 651
1.0%
Fluorad FC171
0.6%
Compounds (1) to (5) are described in prior art. Irgacure 651 is a commercially available photoinitiator (from Ciba AG, Basel, Switzerland). Fluorad FC 171 is a commercially available non-ionic fluorocarbon surfactant (from 3M).
The mixture is dissolved to create a 50 wt % solution in xylene. This solution is filtered (0.2 μm PTFE membrane) and spin coated onto a glass/rubbed polyimide slide (low pretilt polyimide JSR AL1054 from Japan Synthetic Rubber). The coated film is exposed to 20 mWcm −2 365 nm radiation in air through a grey-scale (0:50:100% T) mask.
Subsequently, the film is photopolymerised using 20 mWcm −2 UV-A radiation, for 60 seconds in an N 2 -atmosphere, to give a patterned film having a pattern of regions with different retardations.
EXAMPLE 2
(Comparison Example) Prior Art Transflective TN Display
The optical performance of a prior art pixelated transflective TN LCD with standard alignment of the optical components as described in FIG. 2 is calculated.
A cross section of the stack of optical components of the LCD used as basis for the calculation is schematically depicted in FIG. 4 , including an LC layer divided into reflective subpixels 12 a and transmissive subpixels 12 b , front and back polarisers 13 a/b , a patterned QWF with quarter wave pixels 16 a and optically isotropic pixels 16 b , and a reflector 14 a.
The parameters of the components are as follows:
Front polariser direction:
−45°
Back polariser direction:
+45°
Twist angle φ of LC layer:
90°
LC director at front surface:
−45°
LC director at back surface:
+45°
Retardation of LC layer
238 nm
(reflective subpixel):
Retardation of LC layer
475 nm
(transmissive subpixel):
Optical axis of QWF
+90°
(reflective subpixel):
Retardation of QWF
140 nm
(reflective subpixel):
The angular luminance (A) and chromaticity (B) of the display are shown in FIGS. 5A and 5B . The on-axis luminance is 39.5%, the chromaticity is 4.5%.
EXAMPLE 3
Transflective TN Display According to the Invention
The optical performance of a pixelated transflective TN LCD according to the present invention, with alignment of the optical components as described in FIG. 3 , is calculated. The stack of optical components is as shown in FIG. 4 .
The parameters of the components are as follows:
Front polariser direction:
−45°
Back polariser direction:
+45°
Twist angle φ of LC layer:
90°
Rotation angle θ of LC layer
−15°
(relative to polarisers):
θ1, θ2:
−15°
LC director at front surface:
−60°
LC director at back surface:
+30°
Retardation of LC layer
238 nm
(reflective subpixel):
Retardation of LC layer
456 nm
(transmissive subpixel):
Optical axis of QWF
+90°
(reflective subpixel):
Retardation of QWF
140 nm
(reflective subpixel):
The patterned QWF can be made for example as described in Example 1.
Compared to Example 2, the reflective TN cell is rotated at an angle θ of −15° in the direction of twist (i.e. 15° opposite to the twist direction as the stack is observed from the view point of the user).
The angular luminance (A) and chromaticity (B) are shown in FIGS. 6A and 6B . The on-axis luminance is 40.8%, the chromaticity is 2.9%. The display has considerably lower chromaticity than that of Example 2, and also improved luminance. | The invention relates to a transflective liquid crystal display (LCD) comprising a patterned quarter wave foil (QWF) and having improved chromaticity. | 6 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to detection and measurement of gas entrapped in drilling fluids during oil well drilling operations. In particular, the invention relates to methods and apparatuses for extracting and sampling gas from the drilling fluids.
[0002] During drilling operations, drilling mud is pumped down the inner diameter of the rotating drill string. The drilling fluid lubricates and cools the drilling bit as it exits the bit at the bottom of the drill string. The drilling fluid carries cuttings to the surface up the annulus defined between the drill string and the borehole. Thus, the drilling fluid is circulated in a loop, wherein it is pumped from a mud tank, down-hole to the drilling bit, up-hole to the surface, and back to the mud tank.
[0003] As the drilling fluid is circulated down-hole, it entraps oil, gas and water from the penetrated earth formations. Gas entrained in the drilling fluid, such as carbon dioxide and hydrogen sulfide, may contain information indicative of formations containing hydrocarbons. Gas chromatography techniques have been used to separate and quantify different light hydrocarbon gases, such as methane through pentanes. Catalytic combustion, thermal conductivity, and flame ionization detectors have also been used to analyze the extracted gases. The gas content of the drilling fluid may also indicate the pore pressure of the drilled formation to assist in the identification of “oil shows” and “pay zones.” Drilling operators analyze the entrained gas: (1) to determine whether a formation of interest has been penetrated; and (2) to provide warning of dangerous underbalanced drilling conditions indicated by increased gas returns. This process is called “mud logging.”
[0004] To analyze the entrained gas, the gas is first extracted from the drilling fluid. Gas traps with mechanical agitators have been used to liberate the gas from the drilling fluid in a header tank before the drilling fluid flows into the main mud tank. The liberated gas is subjected to a gas analyzer to produce a signal whose value corresponds to the concentration of the component in the gas mixture. By measuring the carrier gas volume flowing into the mud/gas separation device, the flow rate of the mud into the separation device, and the component gas signal, a continuous concentration signal representing the concentration of the component gas in the drilling mud may be obtained.
[0005] Gas traps typically divert a portion of the mud returning from the well bore through an enclosure which provides some mechanism for gas release or separation. The release or separation mechanism may be passive, such as a mud-spreading plate, or may contain a mechanical agitator or vibrator to increase the mud/air contact. The liberated gas is transmitted to analytical equipment by a sample line attached to the enclosure of the trap. To provide continuously updated gas readings, mud residence time within the trap enclosure is typically very short. Only a fraction of the gas is liberated from the fluid. Gas traps designed to allow the observed gas in the sample stream to be easily related to the actual gas content of the return mud provide quantitative operation.
[0006] While the liberated gas is typically transmitted to analytical equipment by a sample line attached to the enclosure of the trap, pumps have been implemented to move the gas through the sample line. These pumps are usually positioned on the downstream side of the sample line and create a slight suction in the sample line and enclosure of the trap.
SUMMARY OF THE INVENTION
[0007] This invention relates to detection and measurement of gas entrapped in drilling fluids during oil well drilling operations. In particular, the invention relates to methods and apparatuses for extracting and sampling gas from the drilling fluids.
[0008] According to one aspect of the invention, there is provided a method for liberating gas from drilling mud, the method having the following steps: agitating the drilling mud with an agitator powered by a motor, whereby gas is liberated from the drilling mud; enclosing the liberated gas in an enclosure; and pumping the liberated gas from the enclosure with a pump powered by the motor of the agitating.
[0009] Another aspect of the invention provides a gas trap having: an enclosure comprising an orifice through which fluid enters the enclosure; an agitator of fluid, positioned within the enclosure; a gas pump in fluid communication with the enclosure; and a motor in power transmitting communication with the agitator and the gas pump.
[0010] According to a further aspect of the invention, there is provided a mud logging system having: a gas trap made up of several components including: a means for enclosing a fluid; a means for agitating fluid inside the means for enclosing so that a gas is liberated from fluid and enclosed within the means for enclosing a fluid; a means for pumping the liberated gas from within the means for enclosing a fluid; and a single means for simultaneously transmitting power to the means for agitating and the means for pumping, and a gas detector.
[0011] The objects, features, and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the embodiments which follows.
BRIEF DESCRIPTION OF THE FIGURES
[0012] The present invention may be better understood by reading the following description of non-limitative embodiments with reference to the attached drawings wherein like parts of each of the several figures are identified by the same referenced characters, and which are briefly described as follows.
[0013] FIG. 1 is a perspective view of a gas trap of the present invention having an enclosure, a motor and a gas pump.
[0014] FIG. 2 is a side view of a gas trap of the present invention having an enclosure, a motor and a gas pump.
[0015] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0016] This invention relates to detection and measurement of gas entrapped in drilling fluids during oil well drilling operations. In particular, the invention relates to methods and apparatuses for extracting and sampling gas from the drilling fluids.
[0017] Referring to FIG. 1 , a perspective view of a gas trap embodiment of the present invention is illustrated. The gas trap 1 has an enclosure 2 , a motor 3 and a gas pump 4 . The enclosure 2 is partially submerged into drilling mud 5 , which is contained in a header tank 6 . The enclosure 2 has an orifice 7 in its bottom to allow drilling mud 5 to flow through the orifice 7 into the interior of the enclosure 2 . The enclosure 2 also has a mud return pipe 8 which extends from a side of the enclosure 2 which allows drilling mud 5 to flow from the interior of the enclosure 2 back to the header tank 6 . An agitator drive shaft 10 extends from the motor 3 into the enclosure 2 . An agitator 9 is attached to the distal end of the agitator drive shaft 10 . The agitator 9 is positioned near the orifice 7 so as to swirl the drilling mud 5 as it enters through the orifice 7 . The gas trap 1 also has a gas pipe 11 that extends from the enclosure 2 to the gas pump 4 . A sample line 12 extends from the down stream side of the gas pump 4 . A pump drive shaft 13 extends from the motor 3 and is connected to the gas pump 4 .
[0018] The gas trap 1 operates by drawing a portion of the drilling mud 5 from the header tank 6 into the enclosure 2 . The agitator 9 is rotated by the agitator drive shaft 10 and the motor 3 . The agitator 9 swirls the drilling mud 5 as it is pulled through the orifice 7 in the bottom of the enclosure 2 . As the drilling mud 5 is agitated within the enclosure 2 , gas liberated from the drilling mud occupies the upper portion of the enclosure 2 . After the drilling mud 5 has been agitated and has released at least a portion of the gas trap therein, the drilling mud 5 returns to the header tank 6 through the mud return pipe 8 . The liberated gas collected in the upper portion of the enclosure 2 is drawn by the gas pump 4 out of the enclosure 2 through the gas pipe 11 . The gas pump 4 then pumps the liberated gas through the sample line 12 to the gas analytical equipment or gas detector (not shown).
[0019] During operation of the gas trap 1 , the motor 3 simultaneously drives the pump drive shaft 13 and the agitator drive shaft 10 . Thus, flow of the drilling mud 5 through the enclosure 2 and flow of the liberated gas from the enclosure 2 to the sample line 12 are simultaneously powered by the motor 3 .
[0020] In the illustrated embodiment, the agitator drive shaft 10 and the pump drive shaft 13 are rotated at the same speed because they are direct power outputs from the motor 3 . In an alternative embodiment, a transmission is incorporated into the apparatus to modify the output speed of either the pump drive shaft 13 or the agitator drive shaft 10 . Depending on the particular embodiment of the invention, the drive speed of the gas pump may be reduced or increased by implementing a transmission between the motor 3 and the gas pump 4 . Similarly, the speed at which the agitator 9 is rotated may be reduced or increased by implementing a transmission between the motor 3 and the agitator 9 .
[0021] Referring to FIG. 2 , a side view of an alternative embodiment of a gas trap is illustrated. The gas trap 1 has an enclosure 2 , a motor 3 , and a gas pump 4 . The enclosure 2 is partially submerged in drilling mud 5 . The enclosure 2 is a cylindrical shaped housing structure that has an open orifice 7 at the bottom. The enclosure 2 also has a plurality of vertical slits 14 in the side walls of the enclosure 2 . An agitator drive shaft 10 extends from the top along the longitudinal central access of the enclosure 2 . A plurality of agitators 9 extend from the agitator drive shaft 10 in the vicinity of the slits 14 . The agitator drive shaft 10 is connected to the motor 3 so as to rotate the agitators 9 . Two gas columns 15 extend from the top of the enclosure 2 on opposite sides of the motor 3 . The gas columns 15 merge together at the top where a gas pipe 11 is connected to the gas columns 15 where the gas columns 15 merge. The opposite end of the gas pipe 11 is connected to the gas pump 4 . The gas columns 15 also contain internal filters 16 . The output of the gas pump 4 is connected to the sample line 12 . A pump drive shaft 13 extends from the motor 3 to the gas pump 4 . A drive guard 17 encircles the pump drive shaft 13 to prevent inadvertent contact with the rotating pump drive shaft 13 .
[0022] The gas trap 1 , illustrated in FIG. 2 , operates by allowing drilling mud 5 to enter into the enclosure 2 through the orifice 7 and/or slits 14 . The motor 3 rotates the agitator drive shaft 10 so that the agitators 9 stir the drilling mud 5 within the enclosure 2 . As the drilling mud 5 is agitated, gas trapped within the drilling mud 5 is liberated and moves to the upper portion of the enclosure 2 . By pump drive shaft 13 , the motor 3 also drives the gas pump 4 . The gas pump 4 draws gases from the upper portion of the enclosure 2 through the gas columns 15 and the gas pipe 11 . The pump 4 creates a slight vacuum, relative to atmospheric pressure, so that the liberated gas in the upper portion of the enclosure 2 is drawn through the internal filters 16 , the gas columns 15 , and the gas pipe 11 . The gas pump 4 then pumps the liberated gas under positive pressure through the sample line 12 to gas analytical equipment or gas detector 18 . The gas analytical equipment may include any gas detector known to persons of skill including a gas chromatograph. In particular, it may include an explosion proof IR gas detector having a sample filter and water dropout. The gas detector 18 may output a signal in response to the detected gas level to a computer 19 .
[0023] In alternative embodiments, the motor may be placed above both the gas pump 4 and the agitator 9 . In particular, a pump drive shaft 13 may extend from the motor 3 down to the gas pump 4 and the agitator drive shaft 10 may extend from the gas pump 4 down to the agitator 9 . In these embodiments, power is transmitted from the motor 4 to the agitator 9 through the gas pump 4 , such that the gas pump 4 has drive shafts extending from both sides of the pump.
[0024] Many of the components of the gas traps of the present invention may be off-the-shelf parts manufactured by various entities known to persons of skill in the art. Further, the components may take a variety of forms and be made of various materials depending on the particular application of the gas trap. For example, the enclosure may take any form so as to allow fluid to flow through one portion of the enclosure and to allow liberated gas to collect in another portion of the enclosure. The enclosure may be made of metal, fiberglass, plastic, or any other material known to persons of skill in the art. The motor may be powered by compressed air, electricity, combustible fuel or any other power source known to persons of skill. The gas pipe and sample lines may be any size and material known to persons of skill. The internal filters in the gas columns may be any filters known to persons of skill capable of trapping solid particulates and allowing the liberated gas to pass therethrough.
[0025] Therefore, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those that are inherent therein. While the invention has been depicted and described with reference to embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alternation, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects. | A method for liberating gas from drilling mud, the method having the following steps: agitating the drilling mud with an agitator powered by a motor, whereby gas is liberated from the drilling mud; enclosing the liberated gas in an enclosure; and pumping the liberated gas from the enclosure with a pump powered by the motor of the agitating. A gas trap having: an enclosure comprising an orifice through which fluid enters the enclosure; an agitator of fluid, positioned within the enclosure; a gas pump in fluid communication with the enclosure; and a motor in power transmitting communication with the agitator and the gas pump. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national phase application of PCT International Application No. PCT/EP2007/063367, filed Dec. 5, 2007, which claims priority to German Patent Application No. DE102006057700.0, filed Dec. 7, 2006 and German Patent Application No. DE102007058928.1, filed Dec. 5, 2007, the contents of such applications being incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method for the internal monitoring of addressing circuits in semiconductor memories or data processing systems and to a semiconductor memory or a data processing system for carrying out the method.
[0004] 2. Description of the Related Art
[0005] Error monitoring methods in semiconductor memories are known which can be used to recognize and possibly correct errors in data bits loaded in memory cells. These inherently known monitoring methods can recognize erroneous memory cell contents with a very high degree of coverage. This involves the use of error-recognizing and error-correcting codes such as ECC (Error Correction Codes), for example. For the protection of addressing circuits in semiconductor memories, these known methods cannot readily be used, however.
[0006] It is known that addressing circuits can be monitored by incorporating address bits into the calculation of redundant bits. However, this principle does not recognize addressing errors which were already present before the write address. By way of example, if a defective address decoder selects an incorrect word line, the word to be written is stored at an incorrect address. Upon subsequent read access using the same destination address, the word is read without the error which has occurred being recognized by means of the redundant bits calculated for the address.
[0007] In the method described in U.S. Pat. No. 6,754,858, error-recognizing and error-correcting codes are calculated and stored for the write addresses in synchronous dynamic RAM stores (SDRAM: Synchronous Dynamic Random Access Memory). To this end, a bit pattern is generated and also stored for a succession of write access operations. The value of this bit pattern is dependent on the individual write addresses and also on the order thereof. For the purpose of error recognition, a succession of read access operations is followed by comparison of a modeled bit pattern with the stored bit pattern. Errors which occur or are present in the addressing circuits usually prompt errors in a plurality of bits. The error recognition rate for multibit errors is too low for safety-critical applications, however.
[0008] In addition, the error recognition in line with U.S. Pat. No. 6,754,858 is based on the assumption that the addressing circuits are error-free during a write access operation. Particularly in the case of volatile memories, however, errors occur with not negligible frequency even in this case. In the case of nonvolatile memories, such as Flash ROMs, on the other hand, it is possible to check the memory in offline operation, which is unrewarding in the case of volatile memories.
[0009] In the self-test device for memories which is described in DE 43 17 175 A1, word lines are monitored by means of a current sensor. A current flowing through the sensor line is intended to indicate an error if a plurality of selection lines are activated simultaneously. However, the circuit arrangement described cannot recognize an internal error in the address decoder if a single, incorrectly addressed word line is selected. In addition, the method described deals merely with the monitoring of word lines downstream of the address decoder and address lines upstream of the address decoder. The address decoder may likewise produce errors, however, in which a single incorrect word line is selected despite correctly applied address lines. This type of error is not recognized using the method described, since the method is designed to recognize the selection of a plurality of word lines.
[0010] In addition, the precaution described provides a robust functionality only if each word line is connected to the sensor line only at a single point, however, for example when 2″ test lines are being used for 2″ word lines. However, when monitoring 2 ″ word lines with n test lines, the problem of competing discharging and charging processes on the sensor line arises, the end result being dependent on many factors, such as on the address encoding of the word line under consideration, MOS process parameters and parasitic capacitances. If a word line is connected by a plurality of transistors on the sensor line, one transistor can discharge the sensor line on account of the error that is present while other transistors simultaneously charge the sensor line. An incorrect word line selection can be recognized using the methods described in U.S. Pat. No. 4,912,710 and in the publication “Efficient UBIST Implementation for Microprocessor Sequential Parts”, M. Nicolaidis, IEEE International Test Conference, June 1990. In U.S. Pat. No. 4,912,710, an incorrect word line selection is recognized by comparing the actually selected address and the applied address. Nevertheless, the method presented in U.S. Pat. No. 4,912,710 cannot recognize a short circuit between selection lines, which involves the address bits of one selection line masking the other address bits. An example which may be mentioned in this context is a short circuit between the word lines which are selected using the address bits “111111 . . . 111” (all have the value one) and “110000 . . . 000”.
[0011] In the above publication by Nicolaidis, the actually selected address is identified using a simple code and not using the address bits which are to be expected. To ensure a high degree of coverage for the recognition of addressing errors, as few bit positions as possible in the codes have a logic value “1”. In the case of the cited example with what are known as “1-of-n codes”, each code comprises a single logic “1” value and a plurality of logic “0” values. Particularly in large memories, this method results in disadvantageously long codes, because the longer a code is the higher the hardware implementation costs of the method. By way of example, 1024 address test lines are required in order to monitor 10 address bits. Added to this also is the fact that testing the correspondence between the applied address and the recovered code becomes likewise more complex. For these reasons, the method described in the publication is also associated with a very high level of hardware implementation complexity.
SUMMARY OF THE INVENTION
[0012] The invention relates to an object of specifying a method which allows reliable error monitoring of addressing circuits and generally memory access operations in semiconductor memories without a high level of implementation complexity.
[0013] According to aspect of the invention, in order to recognize errors in the addressing circuit or in a selected addressing path, logic levels on the addressing lines, particularly on the terminations thereof, are first of all tapped off. In addition, the actually selected address or subaddress is represented is additional address bit lines. The actually accessed address/subaddress is then recovered using the address bit lines. By comparing the actually selected address/subaddress with the applied addresses/subaddresses, obtained from the additional address bit lines, it is finally possible to recognize errors in the addressing circuit or in a selected addressing path. In other words, the error recognition involves, by way of example, representation of the actually selected address by the externally reproduced address bits and comparison of the actually selected address with the applied address.
[0014] In line with the invention, error recognition involves tapping off the electrical signal on the addressing lines. This can preferably be done at the ends (terminations) of the row selection lines and/or the column selection lines for the memory cells.
[0015] The actually accessed address/subaddress is preferably recovered in the form of bit complements (logic complementary value). The comparison of the recovered address/subaddress and its complement is an internal consistency check for the recovery of the address/subaddress.
[0016] The method according to aspects of the invention affords the advantage that errors which occur can actually be recognized directly after a memory access operation. In addition, it is possible to recognize addressing errors not only after a read operation, as in previously known methods, but also after a write operation in the course of operation. A further advantage is that the error recognition method for recognizing addressing errors can be applied not only to the single error model but also to the recognition of multiple errors, such as short circuits between more than two addressing lines.
[0017] Particularly preferably, recovering the address/subaddress involves a first consistency check being performed between the recovered address/subaddress and the complement thereof and also a subsequent second consistency check being performed between the recovered and the applied address/subaddress, the second consistency check being performed particularly only in the event of successful conclusion of the first consistency check. The effect achieved by this is that the masking process for addresses and the complements thereof can proceed differently, and therefore different results are also possible.
[0018] On the basis of a first exemplary embodiment, the complemented and uncomplemented bits are processed such that the complemented and uncomplemented bits are supplied to OR gates. With particular preference, respective groups of complemented bits are supplied to a plurality of OR gates for the complement, and respective groups of uncomplemented bits are supplied to a plurality of OR gates for the uncomplemented signal. The outputs of the OR gates with the complement and the outputs with the uncomplemented signals are supplied particularly to one or more XNOR gates. The first exemplary embodiment is distinguished by low complexity of additional electronic components and is particularly advantageous for a small number of selection lines.
[0019] On the basis of a second exemplary embodiment, the complemented and uncomplemented bits are processed such that besides the memory matrix an additional encoding matrix and an additional complement encoding matrix are provided. The number of additional bit lines corresponds to twice the number of the address lines. The crossover points in these matrices contain address echo cells, particularly in a suitable manner. The address echo cells are preferably one or more semiconductor components which are connected up to the crossed lines forming the matrices such that signal bits or complement signal bits are produced. The second exemplary embodiment is advantageous when a large number of selection lines (for the rows and/or columns) are required in the memory. The second exemplary embodiment also allows particularly rapid processing with little clock cycle consumption, since the internal check on the addresses takes place at the same time as the memory cells are accessed. This allows the number of latent errors to be reduced in semiconductor memories, for example. Conventional monitoring methods mean that an error which has occurred as a result of corrupted addressing remains in the memory until it is recognized following a read access operation to the affected address. It is also advantageous that the complexity of test algorithms for semiconductor memories can be significantly reduced.
[0020] Preferably, the method involves the recovery of the actually accessed address also being monitored by virtue of an independent recovery of the binary complement of the actually accessed address being performed.
[0021] Preferably, addressing errors and data errors are distinguished explicitly and so as to be able to be recognized as such. This means that the method is appropriate as a suitable addition to the inherently known error recognition methods based on redundant bits, which have previously been used exclusively for error recognition in the data bit area.
[0022] In line with one exemplary variant of the method, the addressing check is performed in the same access cycle as a read or write operation. This means that the result of the error check is already available during the read or write cycle, which means that the reaction time in the case of an addressing error is kept very short. This advantage applies both to volatile and to nonvolatile semiconductor memories.
[0023] In line with another exemplary variant of the method, the read-back address actually accessed during a memory access operation and/or the complementary actually accessed read-back address is/are stored in a or a respective register. A memory access operation is considered error-free if the register content corresponds to the access address or to the complement of the access address.
[0024] The ever decreasing feature sizes from semiconductor processes result in volatile semiconductor memories becoming ever more susceptible to what are known as soft errors. Errors of this type, in which individual bits “overturn”, are essentially caused by alpha particles or cosmic radiation. The rate of occurrence of soft errors can be estimated for a newly developed memory in advance by virtue of said memory being subjected to increased suitable irradiation. To date, test methods of this type have involved counting and logging all errors which occur. In this case, it is usually disregarded that addressing circuits and memory cells in a semiconductor memory that is present can be affected by soft errors in different ways. In accordance with one exemplary embodiment of the method, provision is therefore made for an explicit distinction to be drawn between soft errors in data bits and soft errors in the addressing circuits. A nonreproducible error is particularly preferably classified as a soft error in the addressing circuits precisely when the complementary and noncomplementary recovered addresses/subaddreses exhibit consistency and at the same time are not appropriate to the actually applied address, and a soft error is associated with a data bit if bit errors are recognized by means of an error recognition mechanism during proper recovery of the address/subaddress.
[0025] The invention also relates to a semiconductor memory or a data processing system which is designed particularly such that the error recognition method described further above is executed therein. The semiconductor memory, which is particularly part of the data processing system, comprises not only the addressing circuit as a core structure but also a memory matrix which is addressed by the addressing circuit.
[0026] The semiconductor memory according to aspects of the invention contains circuit means which allow internal recognition and of addressing errors by monitoring the addressing circuit contained therein. It is preferable for recognition means for memory errors also to be present in addition to said recognition means for addressing errors.
[0027] The semiconductor memory according to aspects of the invention with error monitoring also preferably has an addressing circuit having at least one feedback path for the monitoring. This achieves an improvement in the error monitoring and generally in memory access operations. Starting from the writing or reading microprocessor, the feedback path comprises particularly the address lines up to the memory, the memory to be monitored and a return path from the peripheral address area back to the processor.
[0028] The access by the processor core to a memory module is known to be accomplished by a memory controller. The processor core and the memory controller are preferably part of a data processing system, particularly of a microcontroller.
[0029] Known memory controllers usually already contain registers which contain configuration data. These store values with the number of wait cycles, for example. The registered set of the memory controller is preferably supplemented with at least one address echo register for monitoring the address decoder. The semiconductor memory in line with the invention is thus preferably connected to a memory controller or contains a memory controller which comprises one or more configuration registers for monitoring the address decoder. After every memory access operation, the actually accessed address can be entered particularly into the address echo register.
[0030] Alternatively or in addition, the memory controller preferably comprises a complement address echo register. The complementary accessed memory address is written to the address echo register. The complement address register reflects error messages (“error flags”) from the check on the addressing circuits. The microprocessor system expediently comprises means which allow the address echo register or the complement address echo register to be read.
[0031] The data processing system, which is connected to the memory controller, preferably comprises not only memory access means and address read-back means but also at least one comparison means, particularly at least one error recognition means, which recognizes an addressing circuit as error-free if the content of the address echo register or of the complement address echo register reproduces the address from the last memory access operation and, in particular, there is no error message. The microprocessor can perform this check at any time or preferably at regular intervals of time. The invention therefore also relates separately to an appropriately extended data processing system.
[0032] The address echo register and/or the complement address echo register preferably contains the following bit(s), with one or more of the bits being preferred individually or in any combination:
[0033] a) Address error bit. The address error bit forces an error when the address is recovered.
[0034] b) Complementary error bit. The complementary error bit forces an error when the complementary address is recovered.
[0035] c) Address mode bit. The address mode bit stipulates whether the address echo register is used for all memory access operations or just for erroneous memory access operations. In the latter case, the response applies not only to addressing errors but also to data errors, such as ECC errors.
[0036] d) Complement address mode bit. The complement address mode bit stipulates whether the complement address echo register is used for all memory access operations or just for erroneous memory access operations. In the latter case, the response applies not only to addressing errors but also to data errors, such as ECC errors.
[0037] With the forced errors, the processor can particularly easily check the integrity of the arrangement for monitoring addressing circuits at any time or preferably at regular intervals of time.
[0038] An important advantage of the embodiment described above is that a very high level of error coverage is achieved when monitoring addressing circuits without changes in the processor and in the interfaces thereof. The extensions in the memory and in the memory controller can be ported to any platforms without restriction.
[0039] The semiconductor memories according to aspects of the invention are preferably read/write memories or flash ROMs.
[0040] Preferably, the semiconductor memory also contains hardware means, such as particularly error storage means, such as error memories or error registers, which can be used to recognize errors in the addressing circuits following a memory access operation. This results in a short recognition time for addressing errors, which is particularly advantageous for applications with real-time capability and safety-critical applications. Particularly preferably, the actually accessed address and the applied address are stored in an error store immediately after an addressing error has been recognized, the error store being read for subsequent error analysis at a later time. Quite particularly preferably, this involves all available address values (i.e. actually applied address/subaddress, complementary and noncomplementary recovered address/subaddress) being stored in registers in the memory interface whenever an addressing error has been recognized.
[0041] In addition, the semiconductor memory according to aspects of the invention preferably contains hardware counting means which can be used to quantitatively ascertain the frequency of addressing errors. In addition, it is preferred for further hardware counting means to be present which can also be used to quantitatively ascertain the frequency of memory cells. The aforementioned counting means are present particularly in combination with one another.
[0042] For the error recognition, an additional bit line is preferably applied in the semiconductor memory for each bit position in the address. The addressing circuit also preferably comprises both row selection lines and column selection lines, with the relevant address bits being able to be reproduced externally by terminating the row and column selection lines using OR gates and/or address echo cells. This makes it possible to keep down the complexity for recovering address bits.
[0043] To form an address echo cell, a semiconductor element (for example a MOS transistor) is preferably connected at the crossover points between the additional bit line and an appropriate row or column selection line. Said semiconductor element expediently switches on if the relevant bit position is active for the row or column selection line under consideration. When a selection line is actively driven, a current flows through the additional bit line.
[0044] Additionally, sense amplifiers for the signals on the bit lines, which reproduce the actual access address, are also preferred.
[0045] The above semiconductor memory will preferably perform the safety-critical functions in microprocessor-controlled motor vehicle regulatory systems, or is used in computer-controlled real-time systems.
[0046] These and other aspects of the invention are illustrated in detail by way of the embodiments and are described with respect to the embodiments in the following, making reference to the Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The invention is best understood from the following detailed description when read in connection with the accompanying drawing. Included in the drawing are the following figures:
[0048] FIG. 1 shows a schematic illustration of the error recognition portion in the semiconductor memory according to aspects of the invention,
[0049] FIG. 2 shows an error recognition portion of a memory according to aspects of the invention that has been modified in comparison with FIG. 1 ,
[0050] FIG. 3 shows an address echo cell in the error recognition portion from FIG. 2 ,
[0051] FIG. 4 shows an example of the incorporation of the error recognition portion shown in FIG. 2 into a conventional architecture of a semiconductor memory,
[0052] FIG. 5 shows a data processing system extended in accordance with aspects of the invention,
[0053] FIG. 6 shows an extended addressing circuit for stimulating addressing errors using configuration bits, and
[0054] FIG. 7 shows a further addressing circuit for stimulating addressing errors that has been simplified in comparison with FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] FIG. 1 shows eight column selection lines 1 (A, B, C, D, E, F, G and H) within an address decoder, as used in a semiconductor memory as shown in FIG. 4 . From three applied address bits X, Y and Z, an address decoder (see FIG. 4 —not shown in FIG. 1 , respectively selects one of the eight selection lines 1 . In this case, the selection lines 1 (A, B, C, D, E, F, G and H) respectively correspond to the addresses “000”, “001”, “010”, “011, “100”, “101”, “110” and “111”. The terminations of the eight selection lines 1 have the inputs of the OR gates 2 , 2 ′ and 2 ″ connected to them. The outputs of the OR gates 2 , 2 ′ and 2 ″ produce recovered address bits eX, eY and eZ from the address lines in accordance with the following scheme:
[0000]
eZ=B+D+F+H
[0000]
eY=C+D+G+H
[0000]
eX=E+F+G+H
[0056] Accordingly, only every second line is supplied to an OR gate. The comparator 4 performs a first consistency check with the signals eX, eY and eZ, wherein the recovered address bits eX, eY and eZ are compared with the actually applied address bits X, Y and Z. If the compared bits do not all match, an address error is signaled on line 20 .
[0057] However, there are address error patterns which cannot be recognized during the first consistency check by comparator 4 . If a short circuit occurs between the selection lines E and F, for example, the corresponding address bits are respectively “100” and “101”. The first consistency check can detect this short circuit as an address error only if memory access to the selection line E takes place. In the event of memory access to the selection line F, the first consistency check alone cannot recognize a short circuit between the two selection lines E and F. To obtain an even higher degree of coverage for the recognition of addressing errors, the error recognition is also performed on the basis of the complements using the additional OR gates 21 , 21 ′ and 21 ″, the inputs of which are likewise connected to the terminations of the eight selection lines A, B, C, D, E, F, G and H, wherein the association with the lines is complementary with respect to the association of the gates 2 . In this case, the lines which are omitted from the gates 2 are used. The three additional OR gates 21 , 21 ′ and 21 ″ form the three complementary address bits eXc, eYc and eZc in accordance with the following association:
[0000]
eZc=A+C+E+G
[0000]
eYc=A+B+E+F
[0000]
eXc=A+B+C+D
[0058] The recovered address bits eX, eY and eZ and their derived complementary values eXc, eYc and eZc are then supplied to a group of exclusive-OR gates 3 for a second consistency check (dashed block 5 ). The outputs 22 of the group of exclusive-OR gates 3 are supplied to the input of OR gate 23 . The second consistency check 5 signals an error whenever the bits eX, eY, eZ and the bits eXc, eYc, eZc are not complementary with respect to one another. Overall, for eight selection lines, the second consistency check requires only seven OR gates with four respective inputs, an exclusive OR gate and an exclusive NOR gate (XNOR). On account of this small number of logic gates, the method according to aspects of the invention allows the addressing circuits to be checked in the same access cycle as the ongoing read or write operation. The error recognition circuit can also be applied to a higher number of selection lines on the basis of the above principle. However, it is then necessary to accept longer checking periods.
[0059] The error recognition portion of the semiconductor memory as shown in FIG. 2 corresponds very largely to the principle of the circuit in FIG. 1 , but the circuit implementation has been optimized even further. There are essentially differences here with respect to the logic combinations, shown in FIG. 1 , for the selection lines using OR gates 2 and 21 . The error recognition circuit in FIG. 2 allows error recognition even with a much higher number of row selection lines (for example more than 256) within a single read/write cycle. The circuit shown is based in principle on the error recognition device in FIG. 1 , but with the circuit being extended. For the purpose of simplified illustration, only eight row selection lines A, B, C, D, E, F, H and G are shown (reference symbol 1 ′). In addition to the circuit in FIG. 1 , the address lines have bit lines 13 connected to them on the basis of the principle of a bit matrix. Each crossover point between row selection line (bit line; for example point 24 ) contains an address echo cell 10 . The address echo cells 10 result in firm programming of the address bits at the end of each individual row selection line and form a structure with logic NOR functions.
[0060] Within the encoder 8 , the bit lines 13 connected to the row address lines are amplified by means of sense amplifiers 11 and 11 ′. Sense amplifier 11 ′ comprises logic inverters, since the OR function is output in negated form in the address echo cells 10 . A bit value “1” or a bit value “0” can be read in an address echo cell 10 . Sense amplifier 11 ′ for the address lines corresponds very largely to the design of a conventional data sense amplifier 12 , but with slight adjustments being required.
[0061] A further encoder 9 stipulates the complementary bits for the row address. In this case too, an inverting sense amplifier 11 is connected to the address echo cells 10 . Encoder 8 forms the input lines eX, eY and eZ shown in FIG. 1 for the first consistency check 4 . Encoder 9 forms the complementary lines eXc, eY and rZc for the second consistency check 5 . It will be noted here that the arrangement of address encoding modules 8 and 9 at the terminations of the selection lines allows complete addressing paths to be monitored.
[0062] The speed advantage of the circuit in FIG. 2 results from the required address information being obtained from the memory matrix 7 in a very similar manner to data bits.
[0063] FIG. 3 shows the design of an address echo cell 10 . Address echo cell 10 comprises a single MOS transistor 25 . The gate connection of the MOS transistor is connected to row selection line 1 ′, while the drain electrode is connected to the bit line 13 ′. The source electrode is connected to a reference potential.
[0064] The illustration in FIG. 4 shows the implementation of the error recognition portion shown in FIG. 2 in an inherently known architecture of a semiconductor memory (SRAM, DRAM, ROM, Flash ROM). The memory cells 16 are situated at the crossover points between the row selection lines 1 and the column selection lines 26 , 26 ′. For a word length of N bits, the architecture is split into N submatrices 7 a . 0 . . . 7 a .N, so that each submatrix stores a bit position for a word which is to be written or to be read. The submatrix ( 7 a . 0 ) therefore stores all the bits at position zero for all the words.
[0065] For a number comprising Q row selection lines 1 , log 2 Q row selection bits 29 are required from the address bits 27 . These are decoded by row decoder 6 and join row selection lines 1 ′. At the terminations 28 of the row selection lines 1 ′, the error recognition circuit shown in FIG. 2 is connected. The encoders 8 and 9 and also the sense amplifiers 11 and 11 ′ have likewise already been explained in connection with FIG. 2 . The first and second consistency checks (reference symbols 4 and 5 ) also correspond to the circuit example in FIG. 2 .
[0066] The memory shown in FIG. 4 also comprises a column decoder 14 which is connected to column selection lines 1 ″. The column selection lines 1 ″ are used to actuate the column multiplexers 15 . In line with the error monitoring for the row selection lines 1 ′, it is now also possible to monitor the column selection lines 1 ″ on the basis of the principle in FIG. 1 or 2 . For P column selection lines, log 2 P column address bits 30 are required.
[0067] Usually, the number of column selection lines 1 ″ is much smaller than that of row selection lines 1 ′. In cases of memory architectures with a small number of column selection lines, the circuit example in FIG. 1 may be advantageous over the circuit example in FIG. 2 at least for the error recognition for the column selection lines.
[0068] FIG. 5 is used to show the basic hardware architecture of an exemplary data processing system, which is a microcontroller, in particular. Processor 503 is connected to bus matrix 504 by means of bus 510 . By way of example, bus 510 may be implemented on the basis of the AHB (Advanced High-Performance Bus) protocol. The slave end of the bus matrix 504 may have various modules connected. For the sake of simplicity, only the two slave modules that are the peripheral bridge 505 and the memory controller 502 are shown. The buses 511 and 512 can use the same bus protocol as bus 510 . Memory controller 502 and memory 501 are connected by means of the local bus 514 . In many known architectures, the registers of the memory controller 502 connected to memory 501 can be read and written to as registers from the peripheral units 506 n , 506 m , 506 j and 506 i using the peripheral bus 513 and the peripheral bridge 505 . The number of wait cycles for memory access operations by means of configuration register can be set in the memory controller 502 .
[0069] Memory controller 502 has the following registers:
address echo configuration register 520 , address echo test register 521 and complementary address echo register 522 .
[0073] The address echo configuration register 520 contains the following bits:
address error bit 201 complementary error bit 202 address mode bit 203 .
[0077] Similarly, appropriate bits are also provided in the registers 521 and 522 . The address error bit 201 forces an error during recovery of the address. The complementary error bit 202 forces an error during the recovery of the complementary address. The address mode bit 203 stipulates whether the address echo test register 521 is used for all memory access operations or only for erroneous memory access operations. In the latter case, the method is valid not only for addressing errors but also for data errors, such as ECC errors. The complement address mode bit 223 stipulates whether the complementary address echo register 522 is used for all memory access operations or only for erroneous memory access operations. In the latter case, the method is valid not only for addressing errors but also for data errors, such as ECC errors.
[0078] Following a memory access operation, values of address bits can be held in the address echo test register 521 . Values of the complementary address bits can accordingly be held in the complementary address echo register. For this, the interface 120 which is present between the memory controller 502 and the memory 501 is extended by the echo address lines 130 .
[0079] Microprocessor 503 can use the signal path denoted by the with the reference symbols 510 , 504 , 512 , 505 and 513 to check whether the addressing circuit in memory 501 is working properly. In this case, the address lines and the progression thereof through the bus matrix 504 and the memory controller 502 are also checked. The checking loop arising (access from the processor to memory and values of the actual accessed address back to the processor) together with the means for monitoring the addressing circuit which are implemented in the memory provide a higher level of error coverage than known methods.
[0080] FIGS. 6 and 7 show two exemplary variants of circuits for monitoring the memory addressing circuit within the memory 501 . The basic design of the memory is described further above in connection with FIG. 2 . The actually accessed address is returned to the memory controller 502 by means of the echo address lines 130 . The complement value of the actually accessed address is returned in the same manner (not shown in FIG. 6 ). Addressing errors can be injected manually, that is to say as provoked or stimulated errors, by means of the additional selection lines 141 and 142 . To this, the line drivers 161 and 162 are connected. Driver 161 is actuated by means of the address error bit 201 in the address echo configuration register 520 . Accordingly, the complementary error bit 202 in the address echo configuration register 520 actuates the driver 162 .
[0081] Apart from the area around the row decoder 6 , the memory addressing circuit in FIG. 7 corresponds to the circuit in FIG. 6 . For some implementations, the address space associated with the memory may be larger than the actually implemented memory address area. In this case, two unused address lines of the row decoder 6 are connected to the selection lines 141 and 142 . In this way, it is possible to provoke addressing errors with the address decoder. The configuration bits that are the address error bit 201 and the complementary error bit 202 are no longer required in the circuit shown in FIG. 7 .
[0082] While preferred embodiments of the invention have been described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. It is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention. | A semiconductor memory and a data processing system having hardware for carrying out a method for the improved internal monitoring of addressing circuits in semiconductor memories or in a data processing system, in which logic levels addressing lines are tapped off, the actually selected address or subaddress is represented by additional address bit lines, the actually accessed address/subaddress is recovered using the address bit lines, and the actually selected address/subaddress is compared with the applied address/subaddress, obtained from the additional address bit lines, in order to recognize an error in the addressing circuit. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/076,746, filed on Feb. 14, 2002.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to storage units, such as coolers and refrigerators, and in particular, the invention relates to refrigeration units with improved storage and accessibility features.
[0004] Cold storage units, such as refrigerators, freezers and beverage coolers, are well known, virtually indispensable appliances. There has thus been numerous refinements and improvements made to these devices to address and correct deficiencies in the prior art. One problem that has been addressed concerns the operation of the door. Industrial and in-home refrigeration units, for example, have large hinged doors. It is common for these doors to include shelving for holding, for example, condiments, beverages and other bottled goods, which can substantially increase the weight of the door. As a result, the door can become cumbersome to close and keep open. Moreover, if the door does not close and seal properly cool air will escape and raise the temperature in the cabinet, thus causing the compressor to run continuously and waste energy.
[0005] Various hinge assemblies have been developed to address these problems. For example, U.S. Pat. Nos. 3,628,845; 4,090,274 and 5,500,984 disclose refrigerators with opposing cam members at one or more hinges that have ramped surfaces operating to bias the door closed when it is open at some acute angles. U.S. Pat. Nos. 4,774,740 and 4,864,691 provide hinge assemblies that include opposing cams that provide staged rotation of the door to hold it at predetermined open positions. While these systems provide the intended benefit, they require rather complex assemblies.
[0006] Another problem with conventional refrigeration units is that the shelves are sometimes immovable or are difficult to remove or reposition. Also, the door shelves are often too small to hold common items, such as beverages in liter and gallon containers, and if they are deep enough to accommodate such sized items, they often interfere with items on the cabinet shelving. This can cause items to be spilt or damaged by the door shelving and more importantly, it can interfere with the door closing and sealing properly.
[0007] Another issue primarily of concern to home owners, is that because refrigeration units are not made of wood, they do not match adjacent cabinetry, thus creating an unpleasant appearance by some standards. One known solution is to conceal the appliance with one or more panels of the same wood and stain of neighboring cabinets. Usually, such panels are mounted directly to the door, however, this can require considerable retrofitting.
SUMMARY OF THE INVENTION
[0008] The present invention provides a solution to the above problems of the prior art.
[0009] One aspect of the invention provides a refrigeration unit in which the cabinet has opposite inner walls defining a pair of vertically aligned rests for a planar shelf. One of the inner walls defines a concave recess adjacent an upper side of the rest such that the shelf can be pivoted upward about the opposite rest so that the shelf can be dislocated from both rests and removed from the cabinet without the door being swung totally clear of the opening. Preferably, a thermoformed plastic insert liner forms the inner wall of the cabinet and has a plurality of vertically aligned rests spaced apart at different heights within the storage cavity so as to support a plurality of shelves.
[0010] The shelves can have an indication of the approximate location of the innermost extension of one or more door shelves when the door is closed. Preferably, the shelf includes graphical and/or textual indicia corresponding to the location of the door shelf when the door is closed, such as graphics shaped to follow the contour of the door shelf. The shelf can be transparent so that the indicia can be applied to the underside of the shelf by any suitable means such as etching, printing or adhesion. The shelf can also have an edge guard mounted to a front edge of the shelf that is contoured to correspond to the door shelf.
[0011] Another aspect of the invention provides a refrigeration unit in which the door has a handle, framing and a floating face panel to which can be mounted an overlay panel for concealing the refrigeration unit. The handle and framing define a retaining lip extending around the perimeter of the face panel to retain the face panel in the door. Preferably, the handle includes upper and lower handle components, with the lower handle component defining a portion of the retaining lip. Filler material disposed behind the face panel biases the face panel against the retaining lip.
[0012] The foregoing and other objects and advantages of the invention will appear from the following description. In this description reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration preferred embodiments of the invention. Such embodiments do not necessarily represent the full scope of the invention, however, and reference must be made therefore to the claims for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a front perspective view of the refrigeration unit of the present invention;
[0014] FIG. 2 is a perspective view of the refrigeration unit similar to FIG. 1 albeit with its door shown opened;
[0015] FIG. 3 is a perspective view of the refrigeration unit with the door hinged at the right side of the refrigeration unit and opened;
[0016] FIG. 4 is a perspective view similar to FIG. 3 albeit with the shelves and crisper shown in FIG. 3 removed;
[0017] FIG. 5 is a front plan view thereof with the door closed;
[0018] FIG. 6 is a right side view thereof;
[0019] FIG. 7 is rear view thereof;
[0020] FIG. 8 is a front view of the refrigeration unit with the door removed;
[0021] FIG. 8A is an enlarged view of a shelf and a scooped portion of a liner;
[0022] FIG. 9 is a side cross-sectional view taken along line 9 - 9 of FIG. 5 ;
[0023] FIG. 10 is a partial front perspective view of an upper door hinge assembly with the door opened;
[0024] FIG. 11 is a partial exploded assembly view of the upper door hinge assembly;
[0025] FIG. 12 is an enlarged partial side cross-sectional view within arc 12 - 12 of FIG. 9 ;
[0026] FIG. 13 is an exploded assembly view of the door including an overlay panel, a handle and the upper and lower door hinge assemblies;
[0027] FIG. 14 is an enlarged partial exploded assembly view within arc 14 - 14 of FIG. 13 ;
[0028] FIG. 15 is a side cross-sectional assembly view taken through line 15 - 15 of FIG. 13 ;
[0029] FIG. 16 is a partial front perspective view of a lower door hinge assembly with the door opened;
[0030] FIG. 17 is a partial exploded perspective view within arc 17 - 17 of FIG. 13 ;
[0031] FIG. 18 is a partial front view of the assembled lower door hinge assembly including a door cam assembly;
[0032] FIG. 19A is a partial right side view showing the lower door hinge assembly;
[0033] FIG. 19B is front cross-sectional view taken along line 19 B- 19 B of FIG. 19A ;
[0034] FIG. 20 is a perspective view of the door in isolation and the assembly of a door shelf;
[0035] FIG. 21 is a partial perspective view of an end of the door shelf within arc 21 - 21 of FIG. 20 ;
[0036] FIG. 22 is a partial side view of a boss mount for the door shelf within arc 22 - 22 of FIG. 20 ;
[0037] FIG. 23 is a partial top cross-sectional view taken along line 23 - 23 of FIG. 20 ;
[0038] FIG. 24 is a partial side cross-sectional view within arc 24 - 24 of FIG. 9 ;
[0039] FIG. 25 is a top view of a shelf looking down from line 25 - 25 of FIG. 2 ;
[0040] FIG. 26 is a side cross-sectional view taken along line 26 - 26 of FIG. 25 , showing a food or beverage item in phantom;
[0041] FIG. 27 is an exploded view of an alternate hinge assembly with a pivot stop; and
[0042] FIG. 28 is a cross-section view showing the hinge assembly of FIG. 27 with the door in a fully open position in which the stop member abuts a mounting bracket to prevent further rotation of the door.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] FIGS. 1-7 show a refrigeration unit 10 , the term used herein to mean any self-contained storage unit, for example, a refrigerator, freezer and a wine or beverage cooler. The refrigeration unit 10 generally includes a thermally insulated cabinet 12 defining a storage cavity with an access opening at the front face of the cabinet 12 . The opening is sealed by a thermally insulated door 14 pivotally mounted to the front of the cabinet 12 by upper 16 and lower 18 door hinge assemblies. Reversible door hinge assemblies mount the door 14 either to the left side (see FIGS. 1 and 2 ) or the right side (see FIGS. 3 and 4 ) of the cabinet 12 . The refrigeration unit 10 includes a compressor, a capillary tube and interior and exterior heat exchanger coils containing a standard refrigerant, as known in the art, for lowering the temperature of the air inside the cabinet 12 . The compressor, exterior coils and associated electronics are contained in a compartment in the bottom of the cabinet 12 accessible from the back side of the unit (see FIGS. 7 and 9 ). A thermostatic control 20 is provided to set the storage cavity air temperature to be maintained. The inside of the cabinet 12 is fit with an insert liner 22 supporting a plurality of shelves 24 (three are shown in the drawings) and defining a recess for a crisper drawer 26 . The door 14 is also lined and includes a plurality of door shelves 28 (two are shown in the drawings). The perimeter of the door 14 mounts a flexible magnetic seal 27 typically used with conventional refrigerators.
[0044] Turning now to FIGS. 8-8A , a unique feature of the refrigeration unit 10 of the present invention is that the shelves 24 can be dislocated from their horizontal resting position for removal or repositioning within the cabinet 12 without requiring the door 14 to be swung completely clear of the front of the door opening. That is the shelves 24 can be repositioned or removed with the door 14 opened approximately 90 degrees. The liner 22 is formed with aligned pairs of rests 30 supporting opposite side edges of the shelves 24 . On one side (the right side in the drawings), the liner 22 is formed with a dished or scooped recesses 29 extending up from outer edges of the shelf rests 30 . The recesses 29 extend from the access opening at the front of the cabinet 12 back a distance less than the length of the corresponding edges of the shelves 24 . As shown in FIG. 8A , this allows the right side of the shelves 24 to be freely lifted and pivoted up along the opposite side of the shelf resting on the opposite rest 30 when each shelf is pulled out slightly so that the back end of the shelf 24 is just in front of the back of the recess 29 . Each shelf 24 can be pivoted until its effective lateral dimension is less than that of the inside of the cabinet 12 , between lateral sides of the liner 22 , and the pivot edge of the shelf 24 can be dislocated from its rest 30 . Each shelf 24 then can be removed from the cabinet 12 for cleaning or remounted at a different height by reversing the steps for removing the shelf 24 .
[0045] Another unique feature of this refrigeration unit pertains to the mounting of upper and lower door shelves 28 , shown in FIGS. 2-4 , 9 and 20 - 23 . The door shelves 28 have a bottom and a generally U-shaped side rail 32 having a front and opposite ends 34 extending away from the cabinet 12 generally perpendicular to the door 14 . Each end 34 is formed with a raised track 36 . The tracks 36 open at the terminal end of the side rail 32 and extend forward first in a straight path and then upward at approximately 45 degrees to closed ends. The tracks 36 have inwardly extending nibs 37 that decreases the width of each track at the bend. The tracks 36 are designed to receive a pair of boss mounts 38 extending inwardly from shelf support uprights 40 formed in a door liner 42 . The door shelves 28 can thus be mounted to the door 14 by aligning the openings in the tracks 36 with the boss mounts 38 and pushing the door shelf 28 toward the door 14 until the closed end of the tracks 36 rest on the boss mounts 38 . The door shelves 28 can be removed by pivoting them upward and pulling them away from the door 14 to pass the nibs 37 by the mounts 38 . The nibs 37 act to capture the boss mounts 38 in the tracks 36 and thereby inhibit inadvertent dislocation of the door shelves 28 .
[0046] As shown in FIG. 20 , the shelf support uprights 40 preferably include three sets of boss mounts 38 at different heights of the door 14 . The top two sets of boss mounts 38 are used allow the upper door shelf to be repositioned or to mount two such door shelves. Also, it should be noted that the shelf support uprights 40 are of increased depth at the bottom ends. The door liner 42 also is formed with a small ledge 44 that combines with the bottom of the door shelf 28 to form a deeper overall shelf. Still further, the door liner 42 is formed with a dished bottle recess 46 to accommodate large bottles, such as standard 2-liter soda bottles.
[0047] Referring now to FIG. 9 , the upper shelves 24 are sized small enough not to interfere with the upper door shelf 28 when the door 14 is closed. However, the bottom shelf 24 is larger because it acts as a cover for the crisper drawer 26 (see also FIG. 24 ). The bottom shelf would extend into the space occupied by the bottom door shelf 28 if they were not at a different heights. As shown in FIGS. 25-26 , the bottom shelf has a raised edge guard 48 around its perimeter that includes a contoured portion 50 corresponding to the side wall 32 of the bottom door shelf 28 . Adjacent the contoured portion 50 is indicia 52 similarly contoured and indicating approximately the innermost extension of the bottom door shelf 28 . This indicia 52 is preferably graphics and/or text formed at the underside of the bottom shelf by a suitable printing or etching process. The indicia 52 thus provides visual notification that items should not be stored beyond that point so as not to interfere with the closure of the door 14 . The bottom shelf and the door shelf thus cooperate to avoid the refrigeration unit 10 from being used in a way that results in the stored items being damaged or the door 14 being left ajar.
[0048] Another aspect of the refrigeration unit of the present invention is that the door hinges include a unique cam assembly that provides a door close-assist feature. Referring to FIGS. 16-19B , the lower door hinge assembly 18 includes an L-shaped lower pivot bracket 54 that mounts to the front face of the cabinet 12 by three bolts to support the bottom end of the door 14 . The lower door hinge assembly 18 also includes a rectangular mounting plate 56 that mounts to the underside of bottom corner of the door 14 with two bolts inserted through two slots 57 that allow for adjustment of the position of the mounting plate 56 with respect to the door. A cam assembly 58 mounts between the bracket 54 and the mounting plate 56 . The cam assembly 58 includes an upper cam 60 and a lower cam 62 . The upper cam 60 has a face surface that defines two raised plateaus 64 and two smaller recessed valleys 66 between which are two sets of ramp surfaces 68 . The lower cam 62 has a face surface that defines two raised plateaus 65 sized to fit in the valleys 66 of the upper cam 60 and two recessed valleys 67 between which are two sets of ramp surfaces 69 . The back side of each cam 60 and 62 has a pair of key pins 70 that are disposed 180 degrees apart. Each cam 60 and 62 also has an axial opening 72 therethrough and the upper cam 60 also defines a cylindrical sleeve member 74 at the back side. The pins 70 of the lower cam 62 fit into a pair of keyways 76 at the tip of bracket 54 attached to the cabinet 12 . Similarly, the pins 70 of the upper cam 60 fit into a pair of keyways 78 at the outer end of the mounting plate 56 on the door 14 , the sleeve member 74 fits through a larger opening 80 (see FIG. 19B ). The pins 70 prevent the cams 60 and 62 from rotating with respect to the mounting plate 56 and the bracket 54 , respectively. The cams 60 and 62 are mounted 90 degrees offset from each other so that the plateaus of one cam engage the valleys of the other cam when the door 14 is closed. The cams 60 and 62 are held together by gravity under the weight of the door 14 and a hinge pin 82 that extends along a pivot axis through the axial openings 72 in the cams (and the sleeve member 74 in the upper cam 60 ). The hinge pin 82 has an enlarged head that threads into a threaded opening 84 in the bracket 54 .
[0049] Referring to FIGS. 10 and 11 , the upper door hinge assembly 16 has an upper pivot bracket 86 that mounts to the front face of the cabinet 12 by three bolts. The bracket 86 includes an opening 88 in which a hinge pin 90 is inserted along the pivot axis to fit within an opening 92 in a handle 94 at the top of the door 14 . The pin 90 has an enlarged threaded head that threads into the opening 88 to secure it to the bracket 86 . The bracket 86 is spaced a distance from the top of the handle to allow the door 14 to float between the upper 86 and lower 54 brackets and be raised and lowered as needed when being opened and closed.
[0050] As mentioned, this arrangement helps to close the door 14 . Specifically, as the door 14 is opened from the closed position, it pivots about the pivot axis extending through the hinge pins 82 and 90 . This causes the upper cam 60 to rotate with respect to the lower cam 62 . As it does, opposing ramp surfaces 68 and 69 engage and cause upward axial translation of the upper cam 60 (and thus the door 14 ). The raised position of the door 14 is opposed by gravity which will bias the upper cam 60 to rotate back to its initial position (in the absence of a counter-acting force) when the ramp surfaces 68 and 69 are engaged. Thus, the cam assembly 58 biases the door 14 closed when partially open, for example, 25 to 35 degrees or when the free edge of the door 14 is approximately eight to ten inches from the cabinet 12 . When the door 14 is swung open far enough, approximately 60-90 degrees, the cams 60 and 62 will engage at the raised plateaus 64 and 65 . Since these surfaces are flat, friction will keep the door 14 at this opened position in the absence of an external force (either opening the door 14 further or closing it). In this way, the cam assembly 58 also helps hold the door 14 open.
[0051] Also, as shown in FIGS. 2 and 3 , the door can be mounted to either side of the cabinet using the same hinge assemblies. The hinge assemblies are reversible in that the lower bracket 54 (see FIG. 17 ) and the upper bracket 86 (see FIG. 11 ) for the right-side mounted door of FIG. 3 can be interchanged and mounted to the left side of the cabinet for the left-side mounted door of FIG. 2 . Thus, only one set of hinge assembles is needed to change the pivot of the door. Additionally, the one of the hinge assemblies can be made to include a stop member. In one embodiment, as shown in FIGS. 27-28 , the mounting plate 56 A can have an increased length with a downwardly depending stop member 63 . The stop member 63 is disposed in front of (and spaced from) the lower mounting bracket 54 when the door is closed. As the door is opened, the stop member 63 swings around the front right corner of the bracket 54 (the left front corner for a left-side mounted door). At some angle, for example 85 degrees, the stop member 63 abuts the right edge of the bracket 54 so as to prevent further rotation of the door.
[0052] Referring to FIGS. 13-15 , the refrigeration unit 10 of the present invention also provides easy attachment of an overlay panel 96 to the door 14 that can be made of a material and design that matches neighboring cabinetry, thereby concealing the refrigeration unit. When an overlay panel 96 is to be mounted to the door 14 , deeper upper 86 A and lower 54 A pivot brackets and mounting plate 56 A are used to increase the pivot radius and accommodate for the added thickness of the door so that the overlay panel 96 so that the door 14 can maintain zero clearance with an adjacent wall or cabinet so that the corner of the panel 96 next to the hinge does not swing out and interfere with the adjacent wall or cabinet. This also requires the upper hinge pin 90 to be disposed in a recess in 98 the overlay panel 96 . Since the overlay panel 96 is most often made of wood, a metal L-bracket 100 is used to add support at the pivot connection. The recess 98 is sized to receive the L-bracket so that it is flush with the back side of the overlay panel 96 . Threaded inserts 102 can be used to mount the L-bracket 100 to the overlay panel 96 .
[0053] Because overlay panels 96 are designed to match the stain and ornamental elements of neighboring cabinetry, they are ordinarily assembled in the field. Thus, a kit including the larger hinge assemblies and a modified upper handle component 104 can be purchased and installed onto the unit. To do this, the hinge pins 82 and 90 are removed and the door 14 is dismounted from the cabinet 12 . The original door hinge assemblies are removed and the supplied larger door hinge assemblies are mounted to the cabinet 12 and the L-bracket 100 is installed onto the back side of the overlay panel 96 . The original upper 106 and lower 108 components of the handle 94 are then unscrewed from the door 14 . This permits a floating face panel 110 to be slid up and disengaged from a retaining lip 112 defined by the inner edge of the lower handle component 108 and door framing 116 . As shown in FIG. 12 , the face panel 110 is held against the lip 112 by filler material 118 , such as cardboard. The face panel 110 then can be screwed onto the back of the overlay panel 96 with spacers 114 providing a gap therebetween to accommodate for the thickness of the lip 112 . The overlay panel 96 and face panel 110 assembly can then be reattached to the door 14 by sliding the face panel 110 behind the lip 112 . The lower handle component 106 then can be reattached with its lip disposed between the back side of the overlay panel 96 and the front side of the face panel 108 . The supplied upper handle component 104 can then be fastened to the lower handle component 108 . This upper handle component 104 is identical to the original upper handle component 106 , however, the curved grip area has been removed so the handle is flush with the front of the door 14 and does not interfere with the overlay panel 96 . Since the lip has been removed and the handle is covered by the overlay panel 96 , a separate pull (not shown) can be fastened to the front or side of the overlay panel 96 . The pull can, for example, match that of neighboring cabinetry.
[0054] In one preferred embodiment, the cam elements 60 and 62 are preferably nylon or other low-friction, lubricious material, such as Delrin® or Celcon® and the hinge brackets and pins are steel. The liner 22 and the door liner 42 are made of thermoformed high impact polystyrene. The door shelves 28 are a durable injection molded plastic, such as ABS. The shelves 24 are a transparent, tempered glass with an ABS plastic edge guard 48 . The crisper drawer 26 is a clear hard plastic. The face panel 110 of the door 14 is a vinyl clad sheet steel and the framing is a very hard extruded plastic. The upper handle component 106 (and 104 ) are a rigid thermoset plastic and the lower handle component 108 is an injection molded plastic.
[0055] Illustrative embodiments of the invention have been described in detail for the purpose of disclosing a practical, operative structure whereby the invention may be practiced advantageously. However, the apparatus described is intended to be illustrative only, and the novel characteristics of the invention may be incorporated in other structural forms without departing from the scope of the invention. Accordingly, to apprise the public of the full scope of the invention, the following claims are made: | A refrigeration unit with improved storage and accessibility features has a thermally insulated cabinet and door defining a storage space with a plurality of support elements. The support elements include easily removable door shelves and horizontal cabinet shelves that can be removed or repositioned without the door being fully opened due to dished regions adjacent the shelf supports that allow the shelves to be pivoted and removed rather than slid straight out of the cabinet. Indicia on one of the shelves follows the contour of one of the door shelves to indicate approximately the shelf space occupied by an adjacent door shelf and thus where items can be set without interfering with the closure of the door. The refrigeration unit also includes a cam assembly at the lower door hinge which biases the door closed when open approximately 35 degrees or less. The refrigeration unit also includes features for attaching an overlay panel to the door easily. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention claimed herein generally pertains to a method for a network having one or more hosts, wherein it is desired to bind applications to selected ports of the hosts. More particularly, the invention pertains to a method of the above type wherein a socket option may be set that allows multiple applications to bind to the same port. Even more particularly, the invention pertains to a method of the above type wherein a confidential key or the like is used to limit access to the port to certain pre-specified applications.
[0003] 2. Description of the Related Art
[0004] In order to enable multiple applications within a single network host to use Transmission Control Protocol (TCP) communication facilities simultaneously, the TCP provides a set of ports within each host. A port may be thought of as a logical connection place. Each port is uniquely identified by a port number, and the number of a particular port may be used to specify an application program associated with the particular port. As a further concept, a socket is a type of file descriptor that may be used with a port, as an application interface, in order to establish connection between the application and a host. An application may bind a socket to a particular port, by registering the socket and the particular port number with the host operating system.
[0005] When an application binds a socket to a port in the above arrangement, no other application is generally allowed to thereafter bind to that port, unless the original application sets a socket option known as SO_REUSEPORT. However, once the original application has set this socket option, it can no longer prevent other applications from sharing the port, whenever desired. Thus, when the SO_REUSEPORT socket option is set for a port, any application that wants to may also bind to that same port.
[0006] It will be readily apparent that either use or non-use of the above socket option can create problems, in regard to making connections between multiple applications and a single port. For example, Dynamic Host Configuration Protocol (DHCP) is an Internet protocol for automating the configurations of computers that use TCP/IP. When DHCP sets the conventional SO_REUSEPORT socket option, it only wants two applications, the binld (boot server) and pxed (proxy DHCP) applications, to be able to share the port. However, other applications are not prevented from also accessing the port. The DHCP application has no way of informing the operating system sockets mechanism that port access should be restricted to the binld and pxed applications.
[0007] Clearly, it would be beneficial to provide a technique whereby two or more specified applications could share a particular port, while at the same time all non-specified applications were denied access to the port.
SUMMARY OF THE INVENTION
[0008] In accordance with the invention, when an original application initially binds to a port, the application designates a confidential key, usefully comprising a cookie. The application also sets a socket option, referred to by way of example as SO_SECURE_REUSEPORT. The confidential key, together with the port number, is registered with the operating system of a host associated with the port. In order for another application to subsequently bind to the port, such application must provide the operating system with a key that is identical to the confidential key. In one useful embodiment of the invention, directed to a method for a network that includes a host having an operating system, a first application binds a socket to a particular port associated with the host. A specified key is registered with the operating system, and a second application is allowed to bind to the particular port only if the second application can furnish the operating system with a key that matches the specified key.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0010] FIG. 1 is a block diagram showing a network that includes a host client and a host server adapted to implement an embodiment of the invention.
[0011] FIG. 2 is a block diagram showing a data processing system that could be used to configure both the host client and the host server of FIG. 1 .
[0012] FIG. 3 is a chart illustrating features and characteristics of an embodiment of the invention.
[0013] FIG. 4 is a flow chart depicting respective steps in carrying out the embodiment of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring to FIG. 1 , there is shown a number of data processing systems 104 - 110 and a data storage unit 112 , respectively connected to a network 102 . Network 102 is a medium used to provide communication links between various devices and computers that are respectively included in data processing systems 104 - 110 . Network 102 may include connections using wire, wireless communication links, or fiber optic cables.
[0015] In an embodiment of the invention, data processing system 104 usefully comprises a host server connected to network 102 , along with storage unit 112 . Similarly, systems 106 , 108 , and 110 usefully comprise host clients, also connected to network 102 . These clients 106 , 108 , and 110 may be, for example, personal computers or network computers. In the depicted example, server 104 provides data, such as boot files, operating system images, and applications to clients 106 - 110 , and such clients are clients to server 104 . The network configuration shown in FIG. 1 may, of course, include additional servers, clients, and other devices not shown.
[0016] In the example depicted in FIG. 1 , network 102 is the Internet, and thus includes a worldwide collection of networks and gateways that use the TCP/IP suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers, consisting of thousands of commercial, government, educational and other computer systems that route data and messages. Of course, network 102 may also be implemented as another type of network, such as an intranet, a local area network (LAN), or a wide area network (WAN). FIG. 1 is intended as an example, and not as an architectural limitation for the present invention.
[0017] In accordance with an embodiment of the invention, it is assumed that a first application is running on server 104 , and has binded a socket to a particular port. A second application, at client 106 , is authorized to connect to the first application. Such connection can be made by implementing an embodiment of the invention, as described hereinafter. The embodiment may include the second application sending a message to the server, requesting permission to bind to the particular port. The message would include the identifying number of the particular port and a key that matches specified key.
[0018] Referring to FIG. 2 , there is shown a block diagram of a data processing system 200 in which aspects of the present invention may be implemented. More particularly, data processing system 200 is an example of a computer which may be adapted for use either as server 104 or client 106 in FIG. 1 , and in which computer usable code or instructions implementing processes for embodiments of the present invention may be located. System 200 employs a peripheral component interconnect (PCI) local bus architecture, although other bus architectures, such as Micro Channel and ISA, may alternatively be used.
[0019] Processor 202 and main memory 204 are connected to PCI local bus 206 through PCI bridge 208 . PCI bridge 208 may also include an integrated memory controller and cache memory for processor 202 . Additional connections to PCI local bus 206 may be made through direct component interconnection or through add-in boards. In the depicted example, local area network (LAN) adapter 210 , SCSI host bus adapter 212 , and expansion bus interface 214 are connected to PCI local bus 206 by direct component connection. Audio adapter 216 , graphics adapter 218 , and audio/video adapter (A/V) 234 are connected to PCI local bus 206 by add-in boards inserted into expansion slots. Expansion bus interface 214 provides a connection for a keyboard and mouse adapter 220 , modem 222 , and additional memory 224 .
[0020] In the depicted example, SCSI host bus adapter 212 provides a connection for hard disk drive 226 , tape drive 228 , CD-ROM drive 230 , and digital video disc read only memory drive (DVD-ROM) 232 . Typical PCI local bus implementations will support three or four PCI expansion slots or add-in connectors.
[0021] An operating system runs on processor 202 and is used to coordinate and provide control of various components within system 200 of FIG. 2 . The operating system may be a commercially available operating system, such as OS/2, which is available from International Business Machines Corporation. _OS/2_ is a trademark of International Business Machines Corporation.
[0022] An object oriented programming system, such as Java, may run in conjunction with the operating system, providing calls to the operating system from Java programs or applications executing on system 200 . Instructions for the operating system, the object-oriented operating system, and applications or programs are located on a storage device, such as hard disk drive 226 , and may be loaded into main memory 204 for execution by processor 202 .
[0023] Those of ordinary skill in the art will appreciate that the hardware in FIG. 2 may vary depending on the implementation. The depicted example is not meant to imply architectural limitations with respect to the present invention. For example, the processes of the present invention may be applied to multiprocessor data processing systems.
[0024] Referring to FIG. 3 , there is shown a chart illustrating results that respectively occur, when efforts are made to bind Applications A-D to a port in accordance with an embodiment of the invention. The port is usefully associated with server 104 of FIG. 1 , and is arbitrarily selected to have the port number 962 .
[0025] Event 302 of FIG. 3 indicates that Application A is the first application that attempts to bind port 962 . Accordingly, Application A successfully binds port 962 , by means of a socket. Application A then sets the socket option identified herein as SO_SECURE_REUSEPORT, although such option could alternatively be given a different name. Application A also registers a unique key AABBCC with the operating system of server 104 . This key usefully comprises a conventional cookie, and is to be maintained in confidence or otherwise made known to only a limited number of users.
[0026] By setting the socket option SO_SECURE_REUSEPORT, other applications besides Application A can bind port 962 , provided that such applications are authorized to do so. In order to demonstrate that it is authorized, an application must furnish a key that is identical to the registered key to the operating system of server 104 . By requiring applications after the first or original application to provide the correct key, access of different applications to port 962 can be controlled or restricted as desired.
[0027] At event 304 , Application B attempts to bind to port 962 . However, the port 962 is already in use by Application A. Moreover, Application B does not provide a key to the host operating system. Accordingly, the attempt of Application B to bind to port 962 is seen to fail.
[0028] Application C, at event 306 , attempts to bind to port 962 and provides a key BDBDBD. However, this key does not match the key required by Application A, and the attempt of Application C is also seen to fail.
[0029] Referring further to FIG. 3 , event 308 shows Application D attempting to bind to port 962 . Application D also furnishes the key AABBCC to the operating system. Since this key matches the registered key, Application D is authorized to bind to port 962 . Its effort to do so is therefore successful.
[0030] Referring to FIG. 4 , there are shown respective steps of a procedure carried out by operating system 402 of server 104 , when a given application seeks to bind to a port such as port 962 . This procedure may be implemented to achieve the results described above in connection with FIG. 3 . As shown by decision block 404 , the first step in the procedure is to determine whether or not the port is already being used by a previous application. If not, the port is available, and the given application binds the associated socket to the port, as shown by function block 406 . The procedure then concludes, with success for the given application being returned.
[0031] If the port is being used by a previous application, so that decision block 404 produces a response of “YES”, it becomes necessary to determine whether the previous application has set the socket option SO_REUSEPORT. As stated above, SO_REUSEPORT is a conventional option that allows any application to share a port with one or more other applications. However, if this option has not been set, no application is allowed to bind the port, if a prior application has already bound the socket thereto. This is shown by function block 410 , which indicates failure of the given application to share the port.
[0032] Referring further to FIG. 4 , decision block 412 shows that if the SO_REUSEPORT socket option was set, it is necessary to further determine whether the SO_SECURE_REUSEPORT socket option was also set. As described above, this option allows any authorized application, but only authorized applications, to share a port with the original application. Thus, if the SO_REUSEPORT option has been set, but the SO_SECURE_REUSEPORT option has not been set, the given application can bind the port, as indicated by function block 414 .
[0033] If the SO_SECURE_REUSEPORT option is set, a final inquiry must be made, as shown by decision block 416 . That is, if decision block 412 produces a “YES” response, it is necessary to determine whether the given application can provide a key to the operating system that matches the registered key. If there are matching keys, the given application is allowed to bind to the port, as shown by function block 420 . Otherwise, the effort to bind the port fails for the given application, as shown by function block 418 .
[0034] The invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, etc.
[0035] Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any tangible apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0036] The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) and DVD.
[0037] A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
[0038] Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers.
[0039] Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
[0040] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | In a method comprising an embodiment of the invention, an original application initially binds to a port, and selects or designates a confidential key, which usefully may be a conventional cookie. The invention also sets a socket option, referred to by way of example, as SO_SECURE_REUSEPORT. The confidential key, together with the port number, is then registered with the operating system of a host associated with the port. In order for another application to subsequently bind to the port, such application must provide the operating system with a key that is identical to the confidential key. In one useful embodiment of the invention, a first application binds a socket to a particular port associated with the host. A specified key is registered with the operating system, and a second application is allowed to bind to the particular port only if the second application can furnish the operating system with a key that matches the specified key. | 7 |
FIELD OF THE INVENTION
This invention relates to a method for making an art work from colored adhesives.
BACKGROUND OF THE INVENTION
Various materials have been used for arts and crafts for children. Typical arts and crafts include such items as paints, adhesive, wood, cloth and other material. Typically children use these materials to paint scenes on paper, wood and other materials, to adhere different materials together, such as wood, toothpicks and foods of various types. However, these conventional materials can cause the children to lose interest and thus there is a need for products and method to maintain or increase these interests.
SUMMARY OF THE INVENTION
Briefly, an embodiment used to carry out the method of the present invention includes a unit comprising a plurality of at least partially transparent and resilient squeeze bottles. Contained in and visible through each bottle in the unit is a quantity of non-toxic water and soap washable and removable colored adhesive, that is curable to a hardened colored state at room temperature. Each bottle has a different color adhesive and a tube for dispensing the colored adhesive from the bottle.
Briefly, a method, according to one embodiment of the invention, is for creating an art and craft object from at least one material and includes the steps of dispensing through a tube from a transparent and resilient squeeze bottle, a quantity of nontoxic, water and soap washable and removable, colored adhesive; applying the dispensed adhesive to the material causing the colored adhesive to form a visible scene on the at least one material; and causing the colored adhesive in the scene to cure to a hardened state at room temperature.
In a second embodiment, the adhesive being dispensed is applied to various materials in an art and craft object to both color and adhere the materials together. The present invention offers endless possibilities for simulating new fun activities for the child. It is found that the creativity and inventiveness of the child blossoms when the present invention is used. Eye-hand coordination, sensory motor skills and color recognition, all precursors to reading, are readily experienced by the young child through the use of the present invention. The child may use scraps of anything, including wood, paper, styrofoam, plastic, cardboard and turn those objects into beautiful works of art. The invention encourages the child to experiment with colors and designs in a way never thought possible before. Even so the material involved is economical and does not require fancy expensive accessories. Since the colored adhesive, when in a liquid or viscous state, is water and soap washable and removable, it is easily cleaned from clothes, furniture and hands. Since the colored adhesive is non-toxic, children will not be injured by placing the adhesive in their mouth during use. When the adhesive hardens it forms a stable non-smearing substance on the surface, thereby, serving both as a paint and as an adhesive for gluing parts together in a scene.
By the use of a squeeze bottle with a tube it is possible to dispense a fine stream or measured amount of the colored adhesive to the desired parts. By providing the colored adhesive in transparent or semi-transparent squeeze bottles, the adhesive is attractive to the users and the right color can easily be selected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a shrink wrap package showing three bottles of colored adhesive used in carrying out the present invention;
FIG. 2 depicts an art and craft object made using a method according to the present invention; and
FIG. 3 depicts another art and craft object made using a method according to the present invention.
DETAILED DESCRIPTION
FIG. 1 depicts an art and craft product used to carry out the method of the present invention. Three units, 10, 12 and 14 are depicted, each unit includes a resilient squeeze bottle which is formed of a partially, preferably highly, transparent material. Contained in and visible through the side of each of the bottles is a quantity of non-toxic, water and soap washable and removable colored adhesive 18. Each container has a top 20 with a tapered tube dispenser 22 which allows the colored adhesive in the bottle to be dispensed in a fine thin line.
Preferably the product has a plurality of the units 10, 12 and 14 in a plastic shrink wrapped package of the conventional type well known in the art. The plastic is generally indicated at 24 and attaches the three units 10, 12 and 14 to the a front surface of a rectangular piece of cardboard 26.
Each of the bottles contains a different color of adhesive visible through the bottle, by way of example, unit 10 contains red adhesive, unit 12 contains blue adhesive and unit 14 contains yellow adhesive.
The adhesive is a substance which has a liquid or viscous state in which the substance sticks to materials and sticks materials together, dries in air at room temperature and, when dried, assumes a hard non-smear surface characteristic, adheres two surfaces or objects together by surface attachment and is colored. Preferably, in the dried state, the adhesive is substantially the same color as in the liquid or viscous state.
The non-toxic characteristic of the adhesive is important, since it will not harm children who may intentionally or inadvertently place the adhesive in their mouth.
The primary colors red, blue and yellow are included, since the secondary colors can be made from these colors. Also, the secondary colors may be included. Significantly, the red, blue and yellow colors are bright acrylic colors which are attractive to children, when contained in the bottle, after dispensing and after drying to the hardened state.
Preferably the adhesive is, when in a liquid state, a non-toxic and water washable and removable adhesive, such as a polyvinyl acetate based slow drying adhesive. Preferably the dye or colorant in the adhesive is a non-toxic water washable and removable, acrylic dye or pigment such as Ceram Coat Acrylic Craft coloring manufactured by Delta Technical Coatings containing a pigmented acrylic emulsion.
A preferred colored adhesive is a blend of a polyvinyl acetate based slow drying adhesive, an acrylic organic dye emulsion and a sorbitan trioleate food based emulsifier. A preferred ratio of the ingredients in the blend are about 12% by volume of the acrylic organic dye emulsifier and about 11/2% by volume of the sorbitan trioleate emulsifier.
The blend is selected, preferably, so that the color will be uniform and will not separate. It is found that the preferred blend set forth above is particularly advantageous for preventing color separation. It would be obvious to those skilled in the art that other adhesives may be used, provided the blend, including the adhesive and pigment and other ingredients, have similar properties of adhering to and adhering together such materials as porous and semi-porous objects and yet is non-toxic to individuals if placed in the mouth and, when in a liquid or viscous state, is washable and removable from fabrics and other materials with soap and water.
Consider the method for creating an art and craft object according to the present invention. FIG. 3 shows a Santa Claus figure 30 cut from a thin sheet of flexible translucent tissue paper 32. The design on the tissue paper 32 may be predrawn in pencil and is then completed by squeezing the squeeze bottle in unit 14 containing the yellow colored adhesive around the pencil line in the pattern indicated at 34. After the adhesive dries the previously flexible tissue paper is stiffened due to the hardened characteristic of the dried adhesive, which is still a bright yellow color. The areas between the yellow lines 34 may be left clear or colored by a felt tip pen or other coloring medium or, if desired, filled in with other colors of colored adhesive. In FIG. 2 the feet are filled in with black and the vertically lined areas are filled in with red felt tip pens. The white areas are left uncolored. Thus, a scene has been formed which is visible after drying of the adhesive.
Refer now to the art and craft object depicted in FIG. 3 formed using a process embodying the present invention. The materials used are a thin sheet of wood or wood base 40, a plurality of toothpicks 42, wood dowels 43, a rectangular block of wood 44, two triangular shaped blocks of wood 46 and 48, a generally rectangular block of wood 50 which is triangular shaped at the upper edge, an elongated stick 52, cotton batting 54, dried plant clippings 56, granulated or sand particles 58, an elongated stick 59 and a triangular piece of cloth 60. Using a method according to the invention, the aforementioned materials are coated with adhesive from the bottles. More specifically, adhesive is dispensed through the small opening in the tube from the transparent and resilient squeeze bottles and applied to the various materials to both color and adhere the materials together. The red colored adhesive is applied to and smeared over the entire outer surface of the wood block 44. A mixture of blue and yellow adhesives, to form a green color, is applied over the top surface of the wood 40. The block 44 is then set endwise on the board 40 thereby, gluing the surfaces together. The yellow colored adhesive is applied to the blocks 46 and 48 and the blocks are set on the upper edge of the block 44 adjacent each other, thereby, gluing the blocks 46 and 48 together and gluing them to the block 44. The red adhesive is also applied over the entire surface of the block 50 completely coloring it and it is placed on the top of block 44 gluing them together. The toothpicks 42 and the sticks 43 are completely coated or immersed in the blue colored adhesive and are then placed together in the form depicted to form a fence. A darker green mixture formed by the blue and yellow adhesives are applied to the wood 40, around the bottom of the fence, thereby, gluing the toothpick fence to the board 40 and forming the appearance of a green border.
A pattern or rectangular grid of lines 66 is formed on the blocks 44 and 50 and granulated or sand particles 58 are sprinkled on the red adhesive on blocks 44 and 50 forming the appearance of red brick. The blue and yellow adhesives are mixed together to form a green color and are applied to the cotton batting 54 in sufficient quantity to form a moldable mass of material which is then molded into the shape of a spruce tree around the outside of the stick 52. The green adhesive mixture is also applied at 66 to secure the stick 52 to the board 40. A different mixture of the blue and yellow adhesive 18 forming a lighter color is applied along the walkway 68 along the front of the picket fence, along the left side of the fence and approaching the doorway of the house and the granulated or sand particles are sprinkled to form a textured appearance.
The dark blue colored adhesive is applied at 70 in square patterns to form windows and at 78 to form a door knob. The yellow adhesive 18 is applied in a rectangular array at 72 to form a door. The red colored adhesive 18 is applied to the triangular shaped cloth material 60 and it, in turn, is then wrapped around and, thereby, attached by means of the adhesive to the stick 59 forming a flag on a pole. Similarly, a yellow adhesive is previously applied to the stick 59 coloring it and attaching it to the block 44. The green mixture of colored adhesive is applied between the fence and the house and the walkway 68 and the plant clippings 56 are sprinkled on the adhesive to form an appearance of a lawn. A rock 76 is also attached to the adhesive in the lawn area.
After the adhesive has dried, all of the parts, which are covered with adhesive, are colored presenting the desired artistic appearance. Additionally, the adhesive flowing continuously from the visible surface to the abutting surfaces of the materials, after drying, adheres the parts together. Further, when the adhesive dries, the surfaces of the adhesive are hard non-smearing and cause the cloth material 60 and the cotton material 54 to be stiff and hold their shape.
A method has thus been disclosed for creating an art and craft object from various materials. The steps include the steps of dispensing through a tube from a transparent and resilient squeeze bottle, a quantity of non-toxic, water and soap washable and removable, colored adhesive. The dispensed colored adhesive is applied to the material, causing the colored adhesive to form a visible scene on the material. The colored adhesive is then allowed to cure to a hardened state in air at room temperature to form the finished art and craft object. Significantly, the applied adhesive is formed as a substantially continuous film between two of the materials, to thereby adhere the materials together, to a visible part of the scene formed by the adhesive. The entire surface of the material may be coated, such as the blocks, to thereby form the appearance of paint.
Application of the colored adhesive may also be done by dipping, rubbing or brushing onto a surface.
In addition, as described with reference to FIG. 3, the colored adhesive can be used, when dried and hardened, to stiffen a flexible piece of material which, itself, may form a scene.
It would be obvious to those skilled in the art that the present invention may be used for decoration of tennis shoes, picture frames, gift wrapping, Christmas ornaments, greeting cards, pins, earrings, bracelets, refrigerator magnets, toys, etc.
Preferably the bottles depicted in FIG. 1, including the tube, are approximately 4 inches long from top to bottom, the bottle is about 11/8 of an inch in diameter and the small upper end of the tube is about 3/16 of an inch. Preferably the bottle is made from a low density polyethylene type of flexible plastic which is easy for children to squeeze and dispense viscous materials, such as adhesives or other liquids.
The foregoing description should not be read as pertaining only to the precise structures and techniques described, but rather should be read consistent with, and as support for, the following claims, which are to have their fullest fair scope. | An embodiment of the present invention is an art and craft product is made using colored adhesives. The method of making the product comprises using a plurality of at least partially transparent squeeze bottles, each containing a different color of a non-toxic water and soap washable and removable adhesive which dries at room temperture to a hardened stable substance of the same color. A substantially continuous film of the colored adhesive is dispensed from one or more of the squeeze bottles and applied to individual structural parts of a visible scene in an art and craft object so that the adhesive being dispensed both forms a colored portion of the scene and bonds together the structural parts forming the visible scene. Contained in and visible through the bottle in the unit is a quantity of non-toxic, water and soap washable and removable colored adhesive, that is curable to a hardened colored state at room temperature. Included in the unit is a tube for dispensing the colored adhesive from the bottle. | 1 |
FIELD OF THE INVENTION
This invention relates generally to cooling of electronic components and more particularly to a fitting for coupling tubes containing cooling fluid to a fluid manifold system.
BACKGROUND OF THE INVENTION
Since the development of electronic digital computers, efficient removal of heat has played a key role in insuring the reliable operation of successive generations of computers. In many instances the trend toward higher circuit packaging density to provide reductions in circuit delay time (i.e., increased speed) has been accompanied by increased power dissipation requirements.
One approach to cooling such electronic components was to utilize hybrid air-to-water cooling in otherwise air-cooled machines to control cooling air temperatures. With the precipitous rise in both chip and module powers that occurred throughout the 1980s, it was determined that the most effective way to manage chip temperatures in multichip modules was through the use of indirect water-cooling.
The increased use of complementary metal oxide semiconductor (CMOS) based circuit technology in the early 1990s led to a significant reduction in power dissipation and a return to totally air-cooled machines. However, this was but a brief respite as power and packaging density rapidly increased, first matching and then exceeding the performance of the earlier machines. These increases in packaging density and power levels have resulted in unprecedented cooling demands at the package, system and data center levels, leading to a return of water cooling.
Many large scale computing systems contain multiple dual core processor modules, often as many as 16 or more. An assembly of an equal number of cold plates is often used to cool the processors. The assembly in one prior system consists of the cold plates (one cold plate for each processor module), tubing that connects groups of cold plates in series, tubing that connects each grouping of cold plates, or quadrant, to a common set of supply and return lines, and two hoses that connect to system level manifolds in the rack housing the processor modules or nodes.
The ability to remove a node from the liquid cooling system without adversely affecting the operation of the remaining system is provided by fluid couplers that can be uncoupled quickly and easily with virtually no liquid leakage (i.e. “quick connects”).
However, due to the ever increasing demand for computing capacity and often limited available space, more processor nodes are placed in closer proximity to one another with less and less available free space for the cooling systems. As such, known quick connect fittings used in prior cooling systems often do not fit in the allocated space. Other than known quick connect fittings, other options use a nut to seal either an O-ring, or a compression ring that pinches the tubing to make a seal. These connectors are often not feasible due to the extreme size of the components and the fact that there is no available tool or wrench clearance to connect and disconnect these types of fitting. Additionally, tightening these types of fittings produces a high torque on the delicate brazed tube assembly connected to the cold plates. The twisting torque could damage tubing, or put stress on electronic modules that the cold plates interface with.
Therefore, an improved fitting assembly that overcomes these problems in the prior art while still offering durable and reliable connect and disconnect operations in a minimum of available space is needed.
BRIEF SUMMARY OF THE INVENTION
According to various embodiments, this invention includes a fluid cooling system for an electronic component, the electronic component with a fluid cooling system and a fitting assembly for use in a fluid cooling system for an electronic component that overcomes the above described problems and others in the prior art.
In one embodiment, this invention includes a cooling system for an electronic component, such as a multi-processor computer including a number of cold plates each cooling one of the processors using a cooling medium. Cooling tubes are each routed through one of the cold plates to carry the liquid cooling medium there through. A manifold assembly has a manifold tube in communication with each of the cooling tubes to transmit the liquid cooling medium to and from each of the cold plates. A number of fitting assemblies connect the various cooling tubes to the manifold assembly. In one embodiment, each fitting assembly includes a manifold with the manifold tube passing there through. A port in the manifold is in fluid communication with the manifold tube. A fitting is sized and configured to mate with the port and is in fluid communication with the associated cooling tubes of one of the cold plates. A latch is pivotally mounted to the manifold mount for movement to and between a first position in which the latch secures the fitting to the manifold mount and a second position in which the fitting is capable of being connected and disconnected from the manifold.
In one embodiment, the latch is generally U-shaped with a pair of legs each extending from a central portion of the latch and the legs are pivotally coupled to opposite sides of the manifold. The central portion of the latch captures the fitting onto the manifold when the latch is in the first position. The fitting assembly may include a load screw threadably inserted through the central portion of the latch to engage the fitting when the latch is in the first position to thereby secure the fitting to the manifold. In one embodiment, a longitudinal axis of the load screw is aligned with a longitudinal axis of the port when the latch is in the first position to align the holding force of the fitting with the manifold. A bearing plate may be mounted on the fitting and positioned to be engaged by the load screw when the latch is in the first position to thereby alleviate stress and avoid damage to the fitting. A pair of spaced channels may be formed on opposite sides of the fitting to assist in installation and removal of the fitting relative to the manifold. The same fitting assembly design according to one embodiment of this invention may be utilized for either the supply side of the cooling fluid medium for the cold plate or the return side of the cooling fluid medium for the cold plate.
The invention in various embodiments includes a fluid cooling system for electronic components such as computers, electronic components or computers with a fluid cooling system and a fitting assembly for use in such environments. The fitting assembly provides the advantages of offering easy and reliable connect and disconnect operations while doing so in a minimum amount of available space without the need for extensive tool operation space or damaging the associated components of the electronic device, computer or cooling system.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view of a cooling system for a number of electronic components according to one embodiment of this invention;
FIG. 2 is an enlarged view similar to FIG. 1 showing a fitting assembly coupled to a manifold of the cooling system;
FIG. 3A is an enlarged view of the fitting assembly of FIGS. 1-2 partially disassembled;
FIG. 3B is a view similar to FIG. 3A with the fitting assembly in a substantially assembled configuration;
FIG. 4 is a cross-sectional view taken along line 4 - 4 of FIG. 3B of the fitting assembly; and
FIG. 5 is a schematic drawing of an exemplary electronic component and associated fluid cooling system in which the fitting of this invention may be used.
DETAILED DESCRIPTION OF THE INVENTION
Various embodiments and aspects of this invention are shown in the attached drawings in which FIG. 5 schematically shows a cooling system 10 for an electronic component 12 such as a computer rack subsystem or the like. The electronic component or computer rack subsystem 12 may include a number of nodes 14 , each of which includes a dual core-processor. During operation of the processors, heat is generated which is dissipated by the cooling system 10 according to various embodiments of this invention. The cooling system 10 according to one embodiment of this invention utilizes a liquid cooling medium 16 such as water, although other liquid cooling mediums may be utilized within the scope of this invention. The cooling medium 16 is supplied to the cooling system 10 via a supply line 18 and extracted from the cooling system 10 via a return line 20 . According to the exemplary cooling system shown in FIG. 5 , the cooling medium supply line 18 is fed to one of two water conditioning units 22 , although another number of water conditioning units 22 may be utilized. The cooling medium 16 is discharged from the water conditioning units 22 into a supply side manifold assembly 24 . The supply side manifold assembly 24 distributes the cooling medium 16 to a number of cold plates 26 ( FIG. 1 ) which are juxtaposed to the various nodes 14 of the electronic component or computer 12 to thereby cool the associated component via heat transfer to the cooling medium. Any number of nodes may be present in the electronic component 12 . The heated cooling medium 16 is extracted from the cold plates 26 through a return side manifold assembly 25 and processed through a heat exchanger 28 , after which the cooling medium 16 is discharged through the water conditioning units 22 to the return line 20 of the cooling system 10 . As will be appreciated, the exemplary electronic component cooling system 10 shown in FIG. 5 is for illustration only and other designs of cooling systems, for electronic components or computers may be utilized within the scope of this invention.
Referring to FIGS. 1 and 2 , one embodiment of the cold plate 26 for the node 14 of the electronic component 12 coupled to the cooling system 10 according to this invention is shown. The supply side manifold assembly 24 is shown in FIG. 1 for simplicity; however, the return side manifold assembly 25 likewise includes the same components and elements as those shown in FIG. 1 with comparable functions in a return mode as opposed to a supply mode for the cooling fluid medium 16 . The supply side manifold assembly 24 includes dual front end manifold lines 30 , 32 for the cooling medium 16 , each of which project from a downstream junction block 36 . An upstream junction block 38 has an assembly manifold disconnect fitting 39 through which the fluid cooling medium 16 enters the supply side manifold assembly 24 . A manifold tube 34 extends between the upstream and downstream junction blocks 38 , 36 of the manifold assembly 24 . Each cold plate 26 shown schematically in FIGS. 1 and 2 includes first and second cooling tubes 40 each coupled to a fitting assembly 42 mounted on the manifold tube 34 . In one embodiment, the cooling tubes 40 are brazed to a fitting 44 sitting atop the fitting assembly 42 so that the cooling medium 16 may pass from the manifold tube 34 through the fitting assembly 42 and into the cooling tubes 40 of the associated cold plate 26 and to thereby cool the processor node associated with the cold plate 26 . The fitting 44 of each fitting assembly 42 is mounted atop a manifold 46 . The fitting assembly 42 includes a longitudinal passage 48 there through for the manifold tube 34 . According to one embedment of this invention, the fitting 44 is securely retained atop the manifold 46 by a latch 50 pivotally coupled to the manifold 46 which captures the fitting 44 securely on the manifold 46 . As previously noted, the fitting assembly 42 of this invention is readily employed in the supply side manifold assembly 24 as shown in FIGS. 1-2 as well as the return side manifold assembly 25 ( FIG. 5 ).
Referring to FIGS. 3A-4 , one embodiment of the fitting assembly 42 according to this invention is shown in various configurations. Each fitting assembly generally includes the manifold 46 , the fitting 44 , and the latch 50 in one embodiment. The manifold 46 includes an upper manifold mount 52 having an upper face 54 with a port 56 oriented generally vertically in the manifold 46 . A chassis mount aperture 58 is provided in the lower portion of the manifold 46 for securing the fitting assembly 42 in the electronic component cooling system 10 as appropriate for the supply or return of the cooling fluid medium 16 . The port 56 is in communication with the cooling medium 16 in the manifold tube 34 . The port 56 is sized and configured to receive a downwardly extending projection 60 on the fitting 44 as shown particularly in FIG. 4 . A main cooling fluid passage 62 extends through the projection 60 and the fitting 44 and is in communication with the cooling tubes 40 , two of which are shown in an upper and lower configuration in the embodiment presented in the drawings. The projection 60 includes an outer annular groove 64 into which is seated a first O-ring 66 which seals the projection 60 against a throat 68 of the manifold 46 as shown in FIG. 4 . Additionally, a lower flange 70 surrounding the projection 60 on the fitting 44 includes an annular groove 72 in which is seated a second O-ring 74 to seal the fitting against the upper face 54 of the manifold mount 52 .
The fitting 44 includes an upper groove 76 sized and configured to receive a bearing plate seated 78 in the groove 76 . The bearing plate 78 has a central seat 80 on its upper face. The bearing plate 78 may be easily installed and adhesively retained in the groove 76 in the fitting 44 as needed. The bearing plate 78 may be selectively removed from the fitting 44 as needed for replacement, repair, repositioning or the like. Pair of undercut channels 82 are each on one opposite faces of the fitting 44 . These channels 82 are available for convenient and secure installation and removal of the fitting onto the manifold 46 without damaging the various components of the system. For example, a tool, such as the jaws of pliers or other device, may be seated within the spaced channels 82 for securely gripping and manipulating the fitting 44 for installation and removal relative to the manifold 46 .
The latch 50 is pivotally coupled to the manifold mount 52 as shown generally in FIGS. 3A-3B . In one embodiment, the latch 50 has a generally inverted U-shape with a pair of legs each extending from a central portion 86 of the latch 50 . A distal end portion of each leg 84 is pivotally coupled to one of two opposite faces of the manifold mount 52 . A pivotal connector, such as a rivet 88 or other device, pivotally secures the leg to the manifold mount. As such, the latch 50 may be pivoted to and between a first position in which the latch 50 captures and overlies the fitting 44 when it is mounted to the manifold mount 52 as shown in FIG. 3B . In this orientation, the latch 50 extends generally vertically and is aligned with the longitudinal axis 90 of the fitting 44 and the manifold 46 . The latch 50 may be likewise pivoted to a second position as shown in FIG. 3A in which the upper face 54 of the manifold mount 52 is exposed and the latch 50 is in generally a horizontal orientation to provide access to the manifold mount 52 and port 56 for installation and removal of the fitting 44 . Naturally, the orientation of the latch 50 in the configuration shown in FIG. 3A is opposite from the face of the fitting 44 on which the cooling tubes 40 are joined to the fitting 44 so as to provide access and operation for these components as described.
The central portion 86 of the latch 50 includes a threaded hole 92 sized and configured to receive therein a load screw 94 . With the fitting 44 initially seated on the manifold 46 and the projection 60 of the fitting 44 extending into the port 56 , the latch 50 is pivoted into the position shown in FIG. 3B with the load screw 94 retracted in the hole 92 . The load screw 94 is threadably advanced through the hole 92 and a terminal end of the load screw 92 contacts the seat 80 on the bearing plate 78 . Continued rotation and advancement of the load screw 94 toward the bearing plate 78 forces the bearing plate 78 and fitting 44 downwardly into a secure and mating relationship with the manifold 46 . The bearing plate 78 distributes the forces delivered by the load screw 94 evenly across the fitting 44 so as to avoid any damage to the fitting 44 which, in one embodiment, is constructed of copper. Moreover, the load screw 94 , bearing plate 78 , fitting projection 60 and port 56 are generally aligned along the longitudinal axis 90 of the fitting assembly 42 as shown generally in FIG. 4 such that the force delivered by the latch 50 and load screw 94 is axially aligned with the projection 60 of the fitting 44 and the port 56 to provide a secure, stable and reliable connection between the fitting 44 and the manifold 46 for fluid communication of the cooling medium 16 through the assembly.
Moreover, the cooling medium 16 flowing through the fitting 44 is inhibited from leaking as a result of the dual O-rings 66 , 74 on different surfaces between the mating fitting 44 and manifold 46 . In one embodiment, the O-rings 66 , 74 are positioned on respective sealing surfaces that are not co-planar and, in one embodiment, are orthogonal or perpendicular to one another to form sealing interfaces between the fitting and the manifold mount for enhanced sealing effectiveness. The copper fitting 44 in one embodiment of the cooling system 10 is brazed to the terminal ends of the cooling tubes 40 for reliability during operation of the cooling system 10 . The load delivered by the latch 50 creates a seal along the longitudinal axis 90 as shown in FIG. 4 in a top-down actuation position as shown in FIG. 3B . The load screw 94 and latch 50 deliver the load directly along the longitudinal axis 90 and eliminate the need for multiple fasteners as in prior art fitting assemblies. Moreover, the fitting 44 and latch 50 of various embodiments of this invention eliminate the need for tool or wrench clearance in a horizontal, vertical or other orientation to actuate a large nut or other mechanical device and effectuate a sealing engagement between the fitting 44 and manifold 46 . Commonly, two wrenches are required to secure a known fitting assembly to the manifold in a cooling system for an electronic component, one wrench to tighten the fitting and one to keep the assembly from twisting during the tightening motion. The limited space constraints and accessibility of the electronic component and associated cooling system components limit the utility of such prior fitting assemblies for a cooling system. The latch 50 and fitting assembly 42 of various embodiments of this invention offer the direct top-down axial fitting actuation without the need for tool access other than in the axial direction for a screwdriver, Allen wrench or the like for the load screw 94 . Tool access off of the longitudinal axis 90 ( FIG. 4 ) is not required, thereby allowing for tighter and more compact arrangement of the components of the electronic component cooling system 10 according to this invention. The fitting 44 may be manually pushed into the port 56 on the manifold mount 52 and once the O-rings 66 , 74 seal to the manifold mount 52 , the latch 50 is pivoted into the position shown in FIG. 3B . The load screw 94 is retracted to provide for clearance when the latch 50 is pivoted from the position shown in FIG. 3A to the position shown in FIG. 3B . Once in position as in FIG. 3B , the load screw 94 evenly engage the bearing plate 78 which in one embodiment is stainless steel, on the top of the fitting 44 . The bearing plate 78 prevents debris and excess wear on the copper fitting 44 by the actuation of the load screw 94 . The relatively small contact area of the load screw 94 against the bearing plate 78 along the longitudinal axis 90 of the fitting 44 decouples the screw torque from the remainder of the assembly. This protects the cooling tubes 40 from being damaged and from putting tension on the fitting 44 that could impact proper alignment and positioning of the cooling tubes 40 . The load screw 94 is driven downwardly to a fixed torque that is sufficient to bring the base of the fitting 44 in direct contact with the upper face 54 of the manifold mount 52 . Advantageously, the fitting 44 of this invention provides redundancy because the various mating surfaces and O-rings 66 , 74 between the manifold mount 52 and the fitting 44 are in different planes and proper positioning of the various components can be visually inspected and determined when the fitting 44 is appropriately seated on the manifold mount 52 .
Nonetheless, those of ordinary skill in the art may appreciate that based on the principles of this invention that modifications and changes may be made to the embodiments of the invention shown and described herein without departing from the scope of this invention. Therefore, the invention lies in the claims hereinafter appended. | A fluid cooling system and associated fitting assembly for an electronic component such as a multi-processor computer offer easy and reliable connect and disconnect operations while doing so in a minimum amount of available space without damaging associated components of an electronic device, computer or cooling system. One exemplary fitting assembly includes a manifold mount with a port that is in fluid communication with a manifold tube. A fitting is sized and configured to mate with the port and is in fluid communication with associated cooling tubes of a cold plate. A latch is pivotally mounted to the manifold mount for movement to and between a first position in which the latch secures the fitting to the manifold mount and a second position in which the fitting is capable of being disconnected from the manifold mount. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of application Ser. No. 10/775,381, filed Feb. 10, 2004, now U.S. Pat. No. 7,093,649 which is incorporated herein in entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to flat heat exchanger plates for use in heat exchangers. More particularly, relating to a flat exchanger plates, a method and apparatus of cleaning flat heat exchanger plates and a bulk material heat exchanger using the same.
2. Description of the Prior Art
Typically, in processing bulk materials, such as pellets, granules, powders or the like, heat exchangers are employed to either cool or heat the material during the processing thereof. The heat exchangers employed consist of an array of heat exchanger plates arranged side-by-side in spaced relationship and are positioned in an open top and open bottom housing. The like ends of each heat exchanger plate are connected to together by means of a manifold and a heat exchange medium, such as water, oil, glycol or the like is caused to flow through the plates. Generally, the material treated by the heat exchanger is allowed to gravity flow through the housing and the spaces between the spaced plates. During the progression of the material through the heat exchanger, the material is caused to contact the walls of the plates thereby effecting heat transfer between the material and the plates. The rate at which the material flows through the heat exchanger and ultimately across the plates can be controlled by restricting the flow of the material at the outlet of the heat exchanger.
The heat exchanger plates are constructed by attaching metal sheets together along the edges thereof and this is normally accomplished by seam welding the sheets together to form a fluid tight hollow plate. Heretofore, heat exchanger plates have been constructed to operate under internal pressure caused by pumping the heat exchange medium through the plate. To resist internal pressure and to prevent the sides of the plates from deforming, depressions or dimples are formed along the plate. An example of similar heat exchanger plates and their use are described in U.S. Pat. No. 6,328,099 to Hilt et al. and U.S. Pat. No. 6,460,614 to Hamert et al.
During the normal operation of the heat exchanger the bulk material tends to accumulate within the dimples or spot welds and continues to collect to a point where the efficiency of the heat exchanger is greatly reduced and must be cleaned to remove the material residue from the dimples and surrounding exterior surface of the plates. In some circumstances, the material is allowed to collect to a point where the material will bridge between adjacent plates; this not only reduces the heat transfer efficiency of the heat exchanger, but also restricts the flow of the material through the heat exchanger. These circumstances are very undesirable because the operation of heat exchanger must be shut down for a period of time to clean the plates, which many times means the material production line is also shut down, resulting in loss of production and ultimately loss in profits.
Therefore, a need exists for a new and improved flat heat exchanger plate that can be used for bulk material heat exchangers which reduces the tendency for the material to accumulate on the plates. In this regard, the present invention substantially fulfills this need. In this respect, the flat heat exchanger plate according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of increasing the efficiency of bulk material heat exchangers and reducing down time thereof.
SUMMARY OF THE INVENTION
In general in one aspect, an apparatus for removing accumulated material between adjacent heat exchanger plates arranged side-by-side in a spaced relationship in a bulk material heat exchanger is provided. The apparatus includes a support member for supporting the heat exchanger plates and a lift means for lifting each heat exchanger plate, the lift means operable to raise each heat exchanger plate a predetermined distance and lower each heat exchanger plate the predetermined distance to cause material that has accumulated on the exterior surfaces of the heat exchanger plates to be dislodged from the exterior surfaces.
In general in another aspect, an apparatus for removing material accumulated on the exterior surfaces of adjacent heat exchanger plates arranged side-by-side in a spaced relationship in a bulk material heat exchanger is provided. The apparatus includes a support member for supporting the heat exchanger plates and a lift means for lifting each heat exchanger plate, the lift means operable to raise each heat exchanger plate a predetermined distance and lower each heat exchanger plate the predetermined distance to cause material that has accumulated on the exterior surfaces of the heat exchanger plates to be dislodged from the exterior surfaces. The lift means operates to lift the support member carrying each heat exchanger plate therewith it and to abruptly drop the support member the predetermined distance to develop a shock wave through each plate heat exchanger
In general in another aspect, an apparatus for removing material accumulated on the exterior surfaces of adjacent heat exchanger plates arranged side-by-side in a spaced relationship in a bulk material heat exchanger is provided. The apparatus includes a support member for supporting the heat exchanger plates and a lift means for lifting each heat exchanger plate, the lift means operable to raise each heat exchanger plate a predetermined distance and lower each heat exchanger plate the predetermined distance to cause material that has accumulated on the exterior surfaces of the heat exchanger plates to be dislodged from the exterior surfaces. The lift means includes at least one cam, a motor operating to rotate the at least one cam, and at least one cam follower in rolling contact with at least one cam.
In general in another aspect, an apparatus for removing material accumulated on the exterior surfaces of adjacent heat exchanger plates arranged side-by-side in a spaced relationship in a bulk material heat exchanger is provided. The apparatus includes a support member for supporting the heat exchanger plates and a lift means for lifting each heat exchanger plate, the lift means operable to raise each heat exchanger plate a predetermined distance and lower each heat exchanger plate the predetermined distance to cause material that has accumulated on the exterior surfaces of the heat exchanger plates to be dislodged from the exterior surfaces. The lift means further includes a plurality sleeves each open at both ends with one each positioned through each heat exchanger plate such that the open ends of each of said plurality of sleeves are in cooperating alignment with one another. A cam follower attached to each of the plurality of sleeves and a plurality of cams spaced along the support member and in rolling contact with a respective cam follower. A motor is drivingly coupled to the support member.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.
Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. In this respect, before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction, the materials of construction or to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a side elevation view of an embodiment of flat heat exchanger plate of the present invention.
FIG. 2 is an isometric view of the preferred embodiment of the bulk material heat exchanger constructed in accordance with the principles of the present invention in use with the flat heat exchanger plate of the present invention.
FIG. 3 a is a cross sectional view of an end of an embodiment of the flat heat exchanger plate of the present invention illustrating one possible method of adjoining the sheets of the plate.
FIG. 3 b is a cross sectional view of an end of an embodiment of the flat heat exchanger plate of the present invention illustrating a second possible method of adjoining the sheets of the plate.
FIG. 3 c is a cross sectional view of an end of an embodiment of the flat heat exchanger plate of the present invention illustrating a third possible method of adjoining the sheets of the plate.
FIG. 3 d is a cross sectional view of an end of an embodiment of the flat heat exchanger plate of the present invention illustrating a fourth possible method of adjoining the sheets of the plate.
FIG. 3 e is a cross sectional view of an end of an embodiment of the flat heat exchanger plate of the present invention illustrating a fifth possible method of adjoining the sheets of the plate.
FIG. 4 illustrates a pressure resistor and a possible attachment method thereof to the flat heat exchanger plate of the present invention.
FIG. 5 a illustrates a pressure restraint member and a possible attachment method thereof to the flat heat exchanger plate of the present invention.
FIG. 5 b illustrates a pressure restraint member and a possible alternate attachment method thereof to the flat heat exchanger plate of the present invention.
FIG. 5 c illustrates an alternate pressure resistor attached to a single side of the flat heat exchanger plate of the present invention.
FIG. 5 d illustrates the pressure resistor of FIG. 5 c and a possible arrangement method thereof to the flat heat exchanger plate of the present invention.
FIG. 5 e illustrates the pressure resistor of FIG. 5 c used as a pressure restraint member and a possible attachment method thereof to the flat heat exchanger plate of the present invention.
FIG. 6 a is a cross sectional view taken across a flow diverter of the plate in FIG. 1 .
FIG. 6 b is a cross sectional view taken across an alternate flow diverter of the plate in FIG. 1 .
FIG. 6 c is a cross sectional view taken across an alternate flow diverter of the plate in FIG. 11 , discussed below.
FIG. 7 is a side elevation view of an alternate embodiment of the flat heat exchanger plate of the present invention.
FIG. 8 a is a cross sectional view taken through a flow diverter of the plate in FIG. 7 .
FIG. 8 b illustrates an alternate embodiment of FIG. 8 a.
FIG. 9 is a side elevation view of the tapered embodiment of the flat heat exchanger plate of the present invention.
FIG. 10 a is a cross sectional view of the plate in FIG. 9 .
FIG. 10 b illustrates an alternate embodiment of FIG. 10 a.
FIG. 11 is a side elevation view of an alternate embodiment of flat heat exchanger plate of the present invention.
FIG. 12 is a front elevation view of the flat heat exchanger plate of FIG. 11 .
FIG. 13 a is an isometric view of an alternate embodiment of a combined flow diverter and pressure resistor of the present invention.
FIG. 13 b is a front elevation view of an alternate embodiment of the flat heat exchanger plate of the present invention.
FIG. 13 c is an isometric view of an alternate combined flow diverter and pressure resistor of the plate in FIG. 13 b.
FIG. 14 is a front elevation view of an alternate embodiment of the flat heat exchanger plate of the present invention.
FIG. 15 is a cross sectional view of the plate in FIG. 14 .
FIG. 16 illustrates the method of incorporating a removable seal between adjacent flat heat exchanger plates.
FIG. 17 is a side elevation view of an embodiment of the flat heat exchanger plate of the present invention illustrating the typical placement of support holes for supporting the plate.
FIG. 18 is a cross sectional view of one support hole of FIG. 17 .
FIG. 19 is a side elevation view of an embodiment of the flat heat exchanger plate of the present invention illustrating a typical placement of location lugs, indents, support lugs and lifting lug for the plate.
FIGS. 20 a and 20 b illustrate a method of automated cleaning of the flat heat exchanger plates of the present invention.
FIGS. 21 a , 21 b and 21 c illustrate an alternate method of automated cleaning of the flat heat exchanger plates of the present invention.
FIG. 22 a illustrates an additional alternate method of automated cleaning of the flat heat exchanger plates of the present invention, where a plurality of cam elements are positioned along the length of a support bar.
FIG. 22 b illustrates one possible cam arrangement for use in the method of automated cleaning of the flat heat exchanger plates illustrated in FIG. 22 a.
FIG. 22 c illustrates a second one possible cam arrangement for use in the method of automated cleaning of the flat heat exchanger plates illustrated in FIG. 22 a.
FIG. 23 illustrates an example of a cam arrangement to provide horizontal, back and forth movement of the flat heat exchanger plates.
FIG. 24 illustrates an example of a cam arrangement to provide horizontal side-to-side movement of the flat heat exchanger plates.
The same reference numerals refer to the same parts throughout the various figures.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and particularly to FIGS. 1-2 , a preferred embodiment of the flat heat exchanger plate of the present invention is shown and generally designated by the reference numeral 10 .
In FIGS. 1 and 2 a new and improved flat heat exchanger plate 10 of the present invention for the purpose of increasing the efficiency of bulk material heat exchangers and reducing down time thereof is illustrated and will be described. More particularly, in FIG. 1 , the flat heat exchanger plate 10 has a flat, generally rectangular metal body 12 having two opposing side sheets 14 , two opposing longitudinal edges 16 , and two opposing transverse edges 18 . The two side sheets 14 are sealed to each other along the borders of the two longitudinal and two transverse edges 16 and 18 defining an open interior space. FIGS. 3 a - 3 d illustrate possible methods of seaming the edges of the flat heat exchanger plate 10 . Heat exchange medium inlet and exit nozzles 20 and 22 are provided in fluid communication with the open interior space and can be arranged for example along a common longitudinal edge 16 .
Each side sheet 14 is substantially smooth and free of depressions and/or dimples or the like. The phrase “substantially smooth” is to be defined in the context of this application for U.S. Letters Patent as free from ridges, depressions, and dimples or the like created in the sides of the flat heat exchanger plate during the manufacture thereof.
Prior art heat exchanger plates are manufactured with dimples and/or depressions formed on the sides thereof and welded together to increase the resistance of the sides from bowing outward due to a positive internal operating pressure created by pumping a heat exchange medium through the plate. These dimples are a drawback to prior art plates because in service bulk material tends to accumulate in these dimples which has a negative two fold effect. First, the heat transfer between the bulk material and the plate is reduced by a loss of effective surface area of the plate and second the bulk material may be allowed to accumulate to a point where the material bridges between adjacent plates thereby impeding the flow of the material through the heat exchanger. Once this occurs, the heat exchanger must be removed from service and cleaned, which results in undesirable down time of the material production line. To over come the drawbacks of the prior art, the flat heat exchanger plate 10 of the present invention is designed to operate under a negative internal pressure, thereby eliminating the need to create dimples on the sides of the plate.
Turning to FIG. 2 , numerous flat heat exchanger plates 10 are illustrated in an exemplary in-use arrangement positioned within a typical bulk material heat exchanger 24 . The flat heat exchanger plates 10 are arranged side-by-side in a spaced relationship within the shell of the bulk material heat exchanger 24 . The inlet nozzle 20 of each plate 10 is connected to a common heat exchange medium supply manifold 26 and the exit nozzle 22 of each plate is also connected to a common heat exchange medium return manifold 28 . The inlet nozzle 20 and the exit nozzle 21 can be formed to any suitable shape, such as but not limited to a rectangle or a circle. In operation, a vacuum source is provided at the heat exchange return manifold 28 and the flow of the heat exchange medium is indicated by arrows 30 , where the heat exchange medium enters the supply manifold 26 and is distributed to each of the inlet nozzle 26 of each plate 10 . The heat exchange medium is then drawn up and through each plate 10 and ultimately out of the heat exchange medium return manifold 28 . Arrows 32 indicate the flow of the bulk material, and the material flows through the heat exchanger and across the plates 10 , typically under the force of gravity. With this arrangement, the bulk material heat exchanger 24 operates as a counter flow type heat exchanger.
The flat heat exchanger plate 10 as indicated above, is designed to operate under a negative internal pressure or vacuum as low as about 10 psi (70 kPa) on a vacuum gage. To prevent the side sheets 14 of the flat heat exchanger plate 10 from collapsing at least one pressure resistor member 34 is positioned and strategically arranged within the interior space of the plate. During non-operational periods of the plate 10 , a positive internal pressure may be present due to the hydrostatic pressure of the heat exchange medium present within the plate in a static state. To prevent inflation or deforming of the sides of the plate 10 , at least one pressure restraint member 36 can be included and is positioned and strategically arranged within the interior space of the plate.
At least one flow diverter 38 is positioned within the flat heat exchanger plate 10 to a create flow passage for the circulating heat exchange medium to flow through. Preferably, flow diverters 38 are arranged to create a serpentine-like flow path for the heat exchange medium. The flow diverters 38 can also aid the pressure resistor members 34 in preventing the sides of the plate 10 from collapsing.
FIG. 4 illustrates a pressure resistor member 34 positioned between the interior surfaces 40 of the side sheets 14 of the flat heat exchanger plate 10 . The pressure resistor member 34 is generally cylindrical and is attached at one end to one interior surface 40 of a single side sheet 14 . Preferably, the pressure resistor member 34 is attached at one end to the interior surface 40 by a weld 42 with the opposite end of the pressure resistor member free from attachment to the opposing interior surface of the other side sheet. In a preferred embodiment, the pressure resistor member 34 is of a length equal to the distance between the interior surfaces 40 of the plate side sheets 14 . In the manufacture of the plate 10 , a predetermined number and arrangement of pressure resistors 34 are first attached in a desired pattern to the interior surface 40 of the side sheets 14 before the side sheets are assembled with the plate 10 .
Turning to FIG. 5 a , one possible embodiment of a pressure restraint member 36 is illustrated and will be described. The pressure restraint member 36 is attached at one end to one interior surface 40 of one side sheet 14 by weld 44 . The opposite end of the pressure restraint member is plug welded 46 to the opposite side sheet 14 through a hole 48 formed therethrough and dressed flush with the exterior surface 54 of the side sheet. In this embodiment, the pressure restraint member 36 is cylindrical in shape and is of a length equal to the distance between the interior surfaces 40 of the side sheets 14 .
Now turning to FIG. 5 b , an alternate embodiment of a pressure restraint member 36 is illustrated and will be described. The pressure restraint member 36 is attached at one end to one interior surface 40 of a side sheet 14 by a weld 44 . In this embodiment, the pressure restraint member 36 is of a length to pass through a hole 50 formed through the opposite side sheet 14 and is welded 52 around the hole 50 . In this application, the weld 52 and the end of the pressure restraint member are dressed flush with the exterior surface 54 of the side sheet 14 .
Referring to FIGS. 5 c - 5 e , an alternate embodiment of a pressure resistor member 34 and a pressure restraint member 36 is illustrated and will be described. The pressure resistor member 34 and the pressure restraint member 36 have a cylindrical body, closed at one end 56 and a flanged end 58 . Application of the pressure resistor member 34 is illustrated in FIG. 5 d , where the flanged end 58 is attached to the interior surface 40 of one side sheet 14 by a circular weld 60 . The pressure resistors 34 can be attached to the interior surfaces 40 of the side sheets 14 in an alternating pattern as illustrated. Application of the pressure restraint member 36 is illustrated in 5 e , where the flanged end 58 is attached to the interior surface 40 of one side sheet 14 by a circular weld 60 . Then on assembly with the other side sheet 14 , the cylindrical body 56 is weld thereto by weld 62 . The pressure restraint member s 36 can be attached to the interior surfaces 40 of the side sheets in an alternating pattern as illustrated.
Turning now to FIG. 6 a , which is a cross sectional view of the flat heat exchanger plate 10 as illustrated in FIG. 1 . This figure shows an example of one possible form of a flow diverter 38 positioned within the plate 10 and between the side sheets 14 . In this example, the flow diverter 38 is a strip of material having a bend of approximately 90 degrees along a centerline thereof. The flow diverter 38 includes a plurality of holes 64 formed therethrough along the centerline thereof. The holes 64 allow the flow diverter 38 to be positioned about an arrangement of pressure resistors 34 and/or pressure restraint members 36 . Referring back to FIG. 1 , which illustrates the placement of multiple flow diverters 38 about the pressure resistors 34 and pressure restraint member s 36 to create a serpentine flow path for the heat exchange medium. The positioning of the flow diverters 38 as illustrated is for exemplary purposes only as the flow diverters can be arranged in any manner to create a desired flow path for the heat exchange medium.
FIG. 6 b illustrates an example of a combined flow diverter and pressure resistor 38 positioned within the flat heat exchanger plate 10 between the side sheets 14 . In this example, the combined flow diverter and pressure restraint 38 is a strip of material having opposed edges bent orthogonal to the side sheets 14 to form two legs 15 . These legs act as pressure resistors to prevent the collapse of the plate 10 when operated under a negative pressure. The diagonal web 17 includes a plurality of locating holes 64 , and creates to flow passages 19 for the heat exchange medium.
FIG. 6 c illustrates an additional example of a combined flow diverter and pressure resistor 38 in the form of a corrugated formed sheet of material positioned within the flat heat exchanger plate 10 and secured to the interior surfaces 40 of the side sheets 14 .
Turning to FIGS. 7 , 8 a and 8 b an alternate embodiment of the flat heat exchanger plate 10 and flow diverters 38 of the present invention is illustrated and now will be described. In this embodiment, the flow diverters 38 are formed from a solid rod or tube, which are bent and positioned within the plate 10 to create a desired heat exchange medium flow path. The pressure resistors 34 and the pressure restraint member s 36 are strategically positioned and attached to the side sheets 14 of the plate 10 to aid in the correct placement of the formed flow diverters 38 . Preferably, the pressure resistors 34 and restraints 36 are positioned to alternate from side to side of the flow diverters 38 , as illustrated in FIG. 7 . FIG. 8 a is an enlarged partial cross section of the plate 10 illustrated in FIG. 7 and this figure shows a flow diverter formed from a solid rod and illustrates the method of positioning the pressure resistors 34 and/or restraints 36 on opposite sides of the flow diverter 38 to aid in the positioning and retention thereof. FIG. 8 b illustrates an alternate embodiment of the flow diverter 38 illustrated in FIG. 8 a . In this embodiment, the flow diverter is a tube. The flow diverters 38 illustrated in FIGS. 7 , 8 a and 8 b are of a material having a circular cross section for exemplary purposes only and should not limit the possibility of using material of other cross sectional shapes.
Referring now to FIGS. 9 , 10 a and 10 b , which illustrate an additional embodiment of the flat heat exchanger plate 10 of the present invention. In this embodiment the thickness of the plate 10 decreases in the direction from one transverse edge to the second transverse edge. Preferably, the thickness of the plate 10 decreases in the direction of the flow of bulk material across the coil. Preferably in this particular embodiment incremental steps 66 decrease the thickness of the plate 10 . Most preferably, the steps 66 and thickness of the plate 10 correspond with the various diameters of rod or tube used for the flow diverters 38 . FIG. 9 also illustrates an additional possible arrangement of the flow diverters 38 to create a serpentine flow path for the heat exchange medium. As in all of the aforementioned embodiments of the flat heat exchanger plate 10 , the flow diverters in this embodiment can aid the pressure resistors 34 in preventing the side sheets 14 of the plate 10 from collapsing. During the manufacture of this embodiment of the flat heat exchanger plate 10 the longitudinal edges 16 are cut to match the step profile of the side sheets 14 of the plate. Preferably, the longitudinal edges 16 are laser cut to match the step profile of the side sheets 14 .
FIG. 10 a is a side elevation view illustrating an example of one method of creating a tapered flat heat exchanger plate 10 . In this example, the side sheets 14 of the plate 10 are formed by overlapping sections of sheet metal 68 , as illustrated, which are then welded together. The thickness of the flow diverters 38 are equal to the distance between the interior surfaces 40 of the side sheets 14 for each step 66 of the plate 10 . For exemplary purposes only, the flow diverters in this figure are illustrated as solid rods.
FIG. 10 b illustrates a side elevation view illustrating an example of a second method of creating a tapered flat heat exchanger plate 10 . In this example, a single sheet is used for each side sheet 14 and the sheet is bent inward at various positions along the length thereof to create the required stepped profile of the side sheet. The thickness of the flow diverters 38 are equal to the distance between the interior surfaces 40 of the side sheets 14 for each step 66 of the plate 10 . For exemplary purposes only, the flow diverters in this figure are illustrated as tubes.
Referring now to FIGS. 11 , 12 and 13 , which illustrate a third embodiment of the flat heat exchanger plate 10 of the present invention and an additional example of a flow diverter assembly 38 for use with a tapered or parallel plate. The flow diverter assembly 38 of this embodiment includes a plurality of tapered flow diverter strips 70 which are interlocked with a plurality of flow control strips 72 . Preferably, the flow control strips 72 and the tapered flow diverter strips 70 are interlocked orthogonal to each other. The flow control strips 72 include a plurality of reduced sections 74 , which are formed to be positioned between adjacent tapered flow diverter strips 70 and serve to control the amount of heat exchange medium that passes each flow control strip. The flow diverter 38 of this embodiment is also used to prevent the tapered plate 10 from collapsing under negative operating pressure. Pressure restraint members 36 (not illustrated) may also be used in the same manner as described previously to prevent inflation of the plate 10 and to help position the flow diverter 38 within the plate.
Referring to FIGS. 13 b and 13 c , which illustrate a fourth embodiment of the flat heat exchanger plate 10 of the present invention and an additional example of a plurality of flow diverters 38 for use with tapered or parallel flat heat exchanger plate. The flow diverter 38 of this example is a tapered or parallel strip of material formed in a serpentine shape and includes a heat exchange medium flow control leg 39 . The flow control leg 39 restricts the flow of heat exchange medium into each chamber 41 to ensure an even flow rate of heat exchange medium within each chamber across the plate. The flow diverter 38 of this example is also used to prevent the plate 10 from collapsing under negative operating pressure. In addition to the flow diverters 38 , pressure restraint members 36 . not illustrated, can be used in the same manner as previously described to prevent inflation of the plate 10 and to aid in the positioning of the flow diverters 38 within the plate.
Turning to FIGS. 14 and 15 a fifth method of creating a tapered flat heat exchanger plate 10 is illustrated. The flat side sheets 14 are in parallel planes and increase in width in a direction from one transverse edge 18 of the plate 10 to second transverse edge 18 of the plate. Preferably, the thickness of the plate 10 remains constant along the length of the plate. The gradual increase in width of the plate 10 creates a greater volume between adjacent plates in a bulk material heat exchanger, which releases pressure build-up in particulate material flowing through the heat exchanger. The flow diverters 38 of this example are of an open channel material having a closed side 76 and an open side 78 that includes a pair of flanges 80 . The flat heat exchanger plate 10 is constructed by first attaching a plurality of flow diverters 38 to the interior surface 40 of one side sheet 14 by welds 82 . The plurality of flow diverters 38 are attached to the side sheet 14 in a desired pattern to create a flow path for the heat exchange medium. Then the second side sheet 14 is attached to the plate 10 and the flow diverters 38 by welds 84 from the exterior side of the second sidewall. Preferably, the welds are laser welded. This method of construction provides for the placement of the flow diverters 38 within the plate and allows the flow diverters to function as pressure resistors and restraints.
Now turning to FIG. 16 , a removable seal 86 may be positioned between adjacent flat heat exchanger plates 10 to retain the flow of material 88 therebetween. The seal may be removed to help facilitate the cleaning of the plates 10 or by adjusting the vertical angle of the seal to control the flow of material 88 between the plates.
Referring to FIGS. 17 and 18 , which illustrate a typical placement of support holes 90 through the flat heat exchanger plate 10 . The support holes 90 , which may be of any desired shape, are formed through both side sheets 14 . A tubular sleeve 91 is placed in the support holes 90 then welded to both side sheets 14 and then dressed flushed with the exterior surfaces of the side sheets. The support holes 90 are typically used in supporting the flat heat exchanger plate 10 within a heat exchanger.
Now turning to FIG. 19 , which illustrates the capability of incorporating the placement of location lugs 92 , which extend from the ends of the flat heat exchanger plate 10 , indents 94 formed into the ends of the plate, support lugs 96 extending from the edges of the body of the plate and a lifting lug 98 extending from the top of the plate. Currently, plate heat exchangers are manufactured with supports below the plates which can impede the flow of bulk material and also increase the overall height of the heat. The incorporation of location lugs 92 , indents 94 , support lugs 96 , or a lifting lugs 98 eliminates the need for the supports below the plates 10 and improves the flow path for the bulk material. The overall height of the heat exchanger can be reduced correspondingly.
Referring to FIGS. 20 a and 20 b , an additional embodiment the flat heat exchanger plate 10 is illustrated and will be described. In this embodiment, the flat heat exchanger plate 10 is designed and manufactured such that upon removal of the negative operating pressure the flat heat exchanger plate sides 14 will slightly inflate due to a positive internal pressure created exerted by the heat exchange medium. Isolating the vacuum source and allowing the heat exchange medium to develop a desired hydrostatic pressure within the flat heat exchanger plates 10 can achieve the slight inflating of the plate coil sides 14 . Upon reestablishing the negative operating pressure, the flat heat exchanger plate sides 14 return to a non-inflated position. Preferably, the hydrostatic pressure is allowed to reach a about 5 PSI (34 kPa) and is only applied for a short duration. The duration is at least 1 second. Preferably the duration is from about 1 to about 10 seconds and most preferably, the duration is about 5 seconds. An automated pulsing system 100 can be incorporated in the heat exchange medium system 102 to cause the inflation-deflation cycle of the flat heat exchanger plates 10 at a predetermined frequency.
Incorporating the above cyclic inflation of the flat heat exchanger plates 10 in, for example a bulk material heat exchanger would be beneficial in processing fine particulate materials which tend to bridge across narrow spaces such as the gaps between adjacent flat heat exchanger plates, which creates blockages in the flow of the material. By inflating the flat heat exchanger plate sides 14 by a small fraction of an inch the gap between adjacent flat heat exchanger plate decreases thus compressing any bulk material in the gap. On returning the flat heat exchanger plate sides 14 to the non-inflated position, the gap between adjacent flat heat exchanger plate increases to the normal operation gap and the compressed bulk material is dislodged from the sides. This system provides for the automated, self-cleaning of flat heat exchanger plates 10 , which reduces operating costs and service time of the flat heat exchanger plates.
In an additional embodiment of the flat heat exchanger plate system of providing automated, self-cleaning flat heat exchanger plate 10 is illustrated in FIGS. 21 a , 21 b and 21 c . In this embodiment, the self-cleaning system includes a lift means 106 for lifting the flat heat exchanger plate 10 to aid in the removal of any bulk material that has accumulated on the exterior surfaces of the flat heat exchanger plate. In one example, the flat heat exchanger plates 10 are supported on a bar 104 passing through sleeves 91 , which can be extended as illustrated to maintain the flat heat exchanger plate spacing. Referring back to FIG. 2 , a flexible connection is incorporated between the flat heat exchanger plate inlet nozzles 20 and the inlet manifold 26 , and a similar flexible connection is incorporated between the flat heat exchanger plate exit nozzles 22 and the outlet manifold 28 . In FIGS. 21 a and 21 b , the ends of the bar 104 are supported by the casing of the bulk material heat exchanger 24 . The lift means 106 for lifting and rapidly dropping the bar 104 and the flat heat exchanger plates 10 is attached to the bar. The lift means 106 would raise the bar 104 off of its supports 105 by a fraction of an inch, as illustrated in FIG. 21 a and then allowed to fall under the effect of gravity back onto the supports as illustrated in FIG. 21 b . By the lift means 106 , the flat heat exchanger plates 10 supported by the bar 104 are raised and dropped developing a shock wave through the flat heat exchanger plates. The resultant shock wave will dislodge any present bulk material blockage between adjacent flat heat exchanger plates 10 .
The lift means 106 could incorporate, for example a cam 108 that is driven by motor 110 . The cam 108 is in contact with the cam follower 112 attached to the end 114 of the bar 104 . The cam 108 can include a gradual lift profile about a predetermined number of degrees of rotation and a flat profile about a predetermined number of degrees of rotating. FIG. 21 c illustrates an example of a cam profile that could be used. The lift profile of the cam 108 will gently raise the support bar 104 and the flat heat exchanger plates 10 to a maximum predetermined lift that is a fraction of an inch. The flat profile 109 of the cam 108 will cause the bar 104 to free fall under the force of gravity the distance it was originally raised causing the bar to impact its support 105 , thereby forming a shock wave through the flat heat exchanger plates 10 .
Referring to FIGS. 22 a , 22 b and 22 c , an additional example of the lift means 106 is illustrated and will be described. A cam 116 for each flat heat exchanger plate 10 can be incorporated into the support bar 104 and a cam follower 118 can be incorporated into each sleeve 91 . Upon rotation of the support bar 104 , for example by attaching an end 114 of the support bar to the shaft of a motor, the flat heat exchanger plates 10 are raised and lowered based upon the profile of each cam 116 . Preferably, the maximum lift of each cam 116 is sequentially offset so that each flat heat exchanger plate 10 will be raised and lowered in predetermined sequence thus creating a shearing effect in the material between each adjacent flat heat exchanger plate. Turning to FIG. 22 b , the cam profile of the cam 116 can include a steep profile section 120 which would cause the flat heat exchanger plate 10 to fall under the force of gravity a predetermined distance in accordance with the profile section 120 . This fall would send a shock wave through the flat heat exchanger plate 10 and aid in the removal of the material from of the exterior surface thereof.
FIG. 22 c illustrates an additional example of a cam profile for the cam 116 that could be used. In this example, the flat heat exchanger plates 10 would be raised and lowered in a predetermined sequence thus creating a shearing effect the material between each adjacent flat heat exchanger plate. The incorporation of a scraper element 122 into the bearing surface of the sleeve 91 would act to keep the surface of the cam 116 clear of material debris that could impede the operation of the cam.
Referring to FIG. 23 , which illustrates an example of a cam arrangement including an eccentric cam 116 and cam followers 118 incorporated into the sleeve 91 of a plate coil. In this example, upon rotation of the support bar 104 the cam followers 118 would follow the profile of the cam 116 and flat heat exchanger plate 10 would translate horizontally back and forth. Such as described above a plurality of cams 116 would be incorporated along the length the support bar 104 with the maximum lift of each cam 116 offset from each other to create a shearing effect in material between each adjacent flat heat exchanger plate.
Referring to FIG. 24 , which illustrates an additional cam arrangement example including a plurality of lateral cams 116 cut into the support bar 104 and a cam follower 118 incorporated into the sleeve 91 of each flat heat exchanger plate 10 . In this example, upon rotation of the support bar 104 the cam follower 118 would follow the profile of the lateral cam 116 cut into the support bar 104 and the flat heat exchanger plates 10 would translate horizontally from side-to-side in unison. In addition, the sleeves are extended to provide spacing for adjacent flat heat exchanger plates 10 . The side-to-side, unison movement of the plate coils 10 aids in dislodging bulk material accumulated between adjacent flat heat exchanger plates.
A method of automated cleaning of the exterior surfaces of adjacent flat heat exchanger plate 10 is provided and includes the steps of providing at least two flat heat exchanger plates 10 arranged side-by-side in a spaced relationship, wherein the flat heat exchanger plates include a heat exchange medium inlet nozzle and an exit nozzle 20 and 22 . Attaching the heat exchange medium inlet 20 and exit nozzles 22 to a heat exchange medium supply system 102 , wherein the supply system includes a vacuum source which is attached to the heat exchange medium exit nozzles for creating a negative operating pressure within the flat heat exchanger plates. Isolating the vacuum source allowing the heat exchange medium to develop a predetermined desired hydrostatic pressure within the flat heat exchanger plates 10 to slightly inflate the flat heat exchanger plates to reduce the space between the flat heat exchanger plates and compress any bulk material that is accumulated on the exterior surfaces of the sides of the flat heat exchanger plates. And reconnecting the vacuum source to reestablish the negative operating pressure and thus deflating the flat heat exchanger plates 10 to increase the space between the plates and dislodge the compressed bulk material.
This method may also include connecting a pulsing 100 system between the vacuum source and the exit nozzles of the flat heat exchanger plates 10 to isolate the vacuum source and reconnect the vacuum source in a cyclic manner having a predetermined frequency.
While a preferred embodiment of the flat heat exchanger plate 10 has been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An apparatus removing material accumulated on the exterior surfaces of adjacent heat exchanger plates arranged side-by-side in a spaced relationship in a bulk material heat exchanger and a bulk material heat exchanger incorporating the apparatus is provided. In one aspect, the apparatus develops vibratory shock waves through each coil to dislodge material that has accumulated on the surfaces of the heat exchanger plates. In another aspect, the apparatus translates each heat exchanger plate in a sequential back-and-forth motion to create a shearing effect in material that has accumulated between the adjacent surfaces of heat exchanger plates. In one aspect, the apparatus includes a driven cam and a cam follower, where the cam or cam follower includes a profile to achieve the desired motion of each heat exchanger plate. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to drive systems for transmitting rotational power to an output and more particularly, to a sectional drive system which is characterized by multiple, splined, interlocking drive segments that each include truncated and tapered exterior splines extending from one surface of a round segment base and interior splines extending from the opposite surface of the segment base and having interior spline seats located between the interior splines, which interior spline seats are substantially complementary to the configuration of the exterior splines. The drive segments are nested and interlocked by inserting the exterior splines of one drive segment in the congruent interior spline seats between adjacent interior splines of the adjacent drive segment, and are rotated in concert as a drive string in a selected path. The path may be straight or curved and in the latter case, the interlocking drive segments are capable of slight angular shifting on each other while maintaining a drive configuration of high integrity to dampen the drive vibration, define the chosen curved drive path and facilitate transmission of rotation from a drive mechanism to an output device with considerable torque and thrust. The nested drive segments can be interconnected interiorly by means of a cable or rod or exteriorly by floating collars and therefore, can be used as a drive train in any application in which a transfer of rotation is required in a straight line or at substantially any angle or deviation from a straight line. The sectional drive system may, for example, be used to effect horizontal drilling or coring of producing hydrocarbon intervals in oil and gas wells, utilizing the multiple, stacked and tapered, interlocking drive segments driven by a downhole drilling motor at one end of the drive string to operate a drill bit connected to the opposite end of the drive string. Retrieval of the drive string from the interval may be typically facilitated by a cable extended through openings in the drive segments. Consequently, the sectional drive system of this invention can be used in a downhole drilling apparatus to more efficiently effect drilling deviation in a controlled manner from a vertical well bore and provide a primary horizontal deviation or a lateral deviation from an existing vertical well bore. In a preferred embodiment of the invention, a drill bit having a removable center bit insert is mounted on the bottom one of the drive segments on the drive string, and is characterized by multiple interior splines which engage the companion exterior splines of the drive segment.
While capable of being operated in an extremely efficient manner to permit horizontal or angular drilling of drain hole perforations in oil wells, the sectional drive system of this invention can also be implemented to transmit rotational power from substantially any drive system to an output apparatus, drive or other system under circumstances where the rotational power is to be transmitted in an offset or a curved line. Accordingly, the sectional drive system of this invention is preferably designed with truncated drive segments and is capable of being used to transmit rotation from an engine, motor or other power source to automobiles, mud motors and like apparatus and equipment, as well as to dental drills, robotic devices and material-handling equipment, in non-exclusive particular.
2. Description of the Prior Art
Conventional techniques for effecting the transmission of rotational power between a power source and an output under circumstances where the power is to be transmitted in an offset or curved manner, includes the use of coupling mechanisms such as a universal or “CV” joint which are well known to those skilled in the art. For example, many devices have been designed for lowering into an oil or gas well for the purpose of boring and drilling holes at right angles to the well bore at the production interval, but many problems have been encountered using these systems. Typically, the relatively low bit rotational speed generally necessitated by using curved shafts of various design sometimes requires excessive time to achieve significant penetration, and increasing the bit rotational speed and torque load frequently causes failure of the shafts. Accordingly, these conventional horizontal drilling devices have not proved capable of sustaining the high compressive loads necessary to penetrate the well casing, concrete sheath, rock and producing interval in a well within an economical time frame without failure. Other problems have been encountered, such as impediments to bit retrieval and reduced freedom of rotation of the drilling string in such application.
Among the directional drilling apparatus designed to achieve this function are those detailed in the following U.S. Patentes: U.S. Pat. No. 1,367,042, to Granville; U.S. Pat. No. 2,516,421, to Robertson; U.S. Pat. No. 2,539,047, to Arutunoff; U.S. Pat. No. 2,726,847, to McCune; U.S. Pat. No. 2,778,603, to McCune; U.S. Pat. No. 3,667,556, to Henderson; U.S. Pat. No. 3,903,974, to Cullen; U.S. Pat. No. 3,958,649, to Bull et al; U.S. Pat. No. 4,051,908, to Driver; U.S. Pat. No. 4,185,705, to Bullard; U.S. Pat. No. 4,368,986, to Cousins; U.S. Pat. No. 4,442,908, to Stenbock; U.S. Pat. No. 4,601,353 to Schuh et al; U.S. Pat. No. 4,625,815, to Spies; U.S. Pat. No. 4,658,916, to Bond; U.S. Pat. No. 4,699,224, to Burton; U.S. Pat. No. 4,880,067, to Felsma; U.S. Pat. No. 5,337,839, to Warren et al; U.S. Pat. No. 5,373,906, to Braddick; U.S. Pat. No. 5,392,858, to Peters et al; U.S. Pat. No. 5,413,184, to Landers; U.S. Pat. No. 5,699,866, to James E. Cousins et al; U.S. Pat. No. 5,911,283 to James E. Cousins.
It is an object of this invention to provide a sectional drive system for transmitting rotational power in a straight path or a deviated, curved or offset path to an output of selected character.
Another object of this invention is to provide a sectional drive system for transmitting rotational power in a straight path or in a curved path offset from a source of power to an output, which sectional drive system includes multiple, splined, interlocking drive segments that are stacked and nested to rotate as a drive string responsive to application of rotational power to one end of the drive string in order to rotate the output at the opposite end of the drive string.
A still further object of this invention is to provide a sectional drive system of selected length and size, the drive system including multiple, splined, interlocking drive segments which each includes a round segment base having multiple protruding, tapered and truncated exterior splines, as well as alternating interior splines and interior spline seats in the base for receiving the projecting, tapered and truncated exterior splines of an adjacent drive segment. Multiple exterior base splines provided at the bases of the exterior splines on one drive segment engage multiple interior base splines provided on the adjacent drive segment. The drive segments are stacked and nested as a drive string within or without a guide path such as a tube, with the segments typically interconnected by a cable, rod or floating “collar” for dampening drive mechanism vibration and transmitting rotational power between the drive system and an output.
Yet another object of this invention is to provide a sectional drive system having drive segments with asymmetrical splines and coupled to a drill bit for drilling one or more drain holes of selected depth and angle into a producing interval of an oil or gas well to increase the flow of hydrocarbons or gas from the interval into the well bore.
A still further object of this invention is to provide a self-contained sectional drive system characterized by multiple, splined and interlocking drive segments which can be stacked and nested, optionally on a cable, shaft or rod as a drive string, or fitted with locking grooves and cooperating external floating collars, in a straight or curved guide path. One end of the drive string is connected to a drive apparatus such as a mud motor and the opposite end to an output such as a drill bit. The drive string is typically rotated by the mud motor to drill a hole through the well casing, cement sheath and damaged formation and undamaged production formation and increase the flow of hydrocarbons into the well bore of an oil or gas well.
Still another object of the invention is to provide a transverse down-hole drilling system which is self-contained and includes multiple, cable-mounted, splined and interlocking drive segments. The drive segments each have a round base and multiple, asymmetrical, tapered and truncated exterior splines each having a drive face and spline support face of unequal area projecting from one surface of the base, and companion interior spline seats which alternate with interior splines that extend from the opposite surface of the base. The drive segments nest and rotate in concert as a drive string, and adjacent drive segments are capable of pivoting or positioning at an angle on each other in a curved guide path to define a corresponding configuration of the drive string while maintaining an interlocking configuration of high integrity. The curved guide path may be shaped in such a manner as to permit sufficient lateral movement to traverse a path bend at any predetermined angle with an output such as a drill bit attached to the lower end of the string and an input such as a downhole electric or hydraulic drilling motor coupled to the upper end of the drive string for effecting rotation of the drive string and drill bit. The drive segments may be interconnected by means of an internal cable, a rod or shaft or multiple internally-flange floating collars, to define the drive string.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved sectional drive system for transmitting rotational power from a drive source or apparatus of selected character to an output device of selected design, such as a drill bit, in a straight guide path or in a curved guide path in any angle from 0 to 90° under circumstances where the drive apparatus and the output device are misaligned. The sectional drive system is characterized by multiple, splined and interlocking drive segments which typically include eight spaced-apart asymmetrical, tapered and truncated exterior splines extending from one surface of a round base and each having a drive face and an angular spline support face of unequal area. Typically eight asymmetrical interior splines extend from the opposite surface of the base and define interior spline seats between the interior splines for receiving the congruent or complementary exterior splines of an adjacent drive segment in driving relationship. Multiple exterior base splines are provided at the bases of the respective exterior splines, and the exterior base splines of one drive segment mesh with respective interior base splines provided at the extending ends of the respective interior splines of an adjacent drive segment. The drive segments may be optionally slidably mounted on a cable or rod or externally connected by internally flange floating collars mounted in corresponding locking grooves of the drive segments and stacked and nested as a rotatable drive string, one end of which drive string is attached to a drive mechanism and the opposite end to an output device. In a preferred embodiment of the invention, the output device is a drill bit having a removable center bit insert, and is characterized by multiple interior splines which engage the companion exterior splines of the terminal drive segment of the drive string.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the accompanying drawings, wherein:
FIG. 1 is a side view of a drive string of a typical sectional drive system of this invention, connected at one end to a suitable drive apparatus for rotating the entire segment string and an output device on the opposite end of the drive string, with the drive segments of the drive string connected by a segment cable;
FIG. 2 is a side view of a typical sectional drive system, with the drive segments of the drive string connected by a rod or shaft;
FIG. 3 is a rear perspective view of a typical drive segment element of the sectional drive system illustrated in FIG. 1;
FIG. 4 is a front perspective view of the drive segment element illustrated in FIG. 3;
FIG. 5 is a side view of the drive segment illustrated in FIGS. 3 and 4;
FIG. 6 is a sectional view taken along line 6 — 6 of the drive segment illustrated in FIG. 3;
FIG. 7 is a rear view of the drive segment illustrated in FIGS. 3-5, more particularly illustrating the interior splines and intervening interior spline seats of the drive segment;
FIG. 8 is a front view of the drive segment illustrated in FIG. 7, more =particularly illustrating the exterior splines and intervening exterior spline seats of the drive segment;
FIG. 9 is a rear perspective view of a preferred embodiment of a drill bit element of the sectional drive system of this invention;
FIG. 10 is a perspective view, illustrated in phantom, of the sectional drive system, with the drill bit illustrated in FIG. 9 mounted on the output end of the drive string of the sectional drive system;
FIG. 11 is a front perspective view of the drill bit illustrated in FIG. 9;
FIG. 12 is a sectional view, taken along line 12 — 12 in FIG. 11, of the drill bit, more particularly illustrating a preferred technique for mounting the drill bit on a segment cable extending through the drive string of the sectional drive system;
FIG. 13 is an exploded, perspective view of the drill bit, more particularly illustrating a preferred, retainer bolt and retainer washer technique for removably mounting a center bit insert in the drill bit;
FIG. 14 is a sectional view of the drill bit, more particularly illustrating a preferred technique for mounting the drill bit on the segment cable of the sectional drive system;
FIG. 15 is an enlarged sectional view, taken along section line 15 in FIG. 3, of a drive section element of the sectional drive system; and
FIG. 16 is an enlarged sectional view, taken along section line 16 in FIG. 9, of the drill bit element of the sectional drive system of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIGS. 1-8 of the drawings, the sectional drive system of this invention is generally illustrated by reference numeral 1 . The sectional drive system 1 is characterized by a drive string 10 , formed by stacking multiple, splined drive segments 17 on a segment cable 33 , as illustrated in FIG. 1, or alternatively, on an elongated rod or shaft 45 , as illustrated in FIG. 2 and hereinafter described. Each of the drive segments 17 includes a flat, disc-shaped segment base 18 and multiple tapered, truncated, asymmetrical exterior splines 19 , extending from a flat front base surface 18 a of the segment base 18 , as illustrated in FIGS. 4-6. In a preferred embodiment of the invention, each of the drive segments 17 is shaped to include eight exterior splines 19 , each having a drive face 19 a and an angular spline support face 19 b . The exterior splines 19 define eight intervening exterior spline slots 20 in a repetitive, geometric pattern which resembles an eight-point star when viewed from the front as illustrated in FIG. 8 . As particularly illustrated in FIGS. 4 and 5, each of multiple sloped base surfaces 34 angles into the segment base 18 from the flat front base surface 18 a to form a sloped boundary of each exterior spline seat 20 , and each sloped base surface 34 extends between the spline support face 19 b of one of the exterior splines 19 and the facing drive face 19 a of the adjacent exterior spline 19 . Each of the sloped base surfaces 34 further defines an exterior base spline 28 at the base of the drive face 19 a of each exterior spline 19 . As illustrated in FIG. 5, the plane of each sloped base surface 34 is disposed at an angle “B” of from about 15 degrees to about 20 degrees, and preferably, about 17 degrees with respect to the plane of the corresponding adjacent front base surface 18 a . As illustrated in FIG. 8, the bottom edge of each spline support face 19 b which meets the corresponding sloped base surface 34 is typically disposed at an angle “D” of from about 10 degrees to about 45 degrees with respect to the bottom edge of the drive face 19 a for optimum strength. The exterior splines 19 taper from the front base surface 18 a to a flat truncated tip 21 , which is coplanar with the converging sets of exterior splines 19 , and a tip aperture 22 is typically provided in the center of the tip 21 , as illustrated in FIGS. 3 and 6. As further illustrated in FIG. 8, the angle “C” defined by the drive faces 19 a of adjacent external splines 19 is typically about 45 degrees for optimum driving characteristics. Moreover, the vertical drive face angle “LF” (FIG. 5) measured between the plane of the front base surface 18 a and the plane of the drive face 19 a of each exterior spline 19 , is typically about 90 degrees, whereas the plane of each spline support face 19 b of each exterior spline 19 is disposed at an obtuse angle with respect to the corresponding sloped base surface 34 . As illustrated in FIG. 8, the angle “F” defined by each drive face 19 a and the flat edge of the corresponding exterior spline 19 is typically about 90 degrees.
Referring again to FIGS. 3-7 and to FIG. 15 of the drawings, multiple interior splines 25 and intervening spline dividers 35 (FIG. 15) extend from the flat rear base surface 18 b of the segment base 18 of the drive segment 17 , to define a central segment interior 23 which communicates with the tip aperture 22 of the drive segment 17 as illustrated in FIG. 6 . As illustrated in FIG. 15, each of the interior splines 25 is characterized by a flat drive face 25 a and a flat spline wall 25 b . An interior spline seat 24 is defined between adjacent interior splines 25 , by the recessed interior divider face 35 b of each intervening spline divider 35 , the drive face 25 a of one interior spline 25 and the facing spline wall 25 b of the adjacent interior spline 25 b . As illustrated in FIG. 5, an exterior spline face 25 c of each interior spline 25 is disposed at an angle “A” of from about 15 degrees to about 20 degrees and preferably, about 17 degrees, with respect to an exterior divider face 35 a of the corresponding adjacent spline divider 35 , which angle “A” is the same as the angle “B” between each sloped base surface 34 and the front base surface 18 a . The sloped exterior spline face 25 c of each interior spline 25 defines an interior base spline 30 adjacent and substantially perpendicular to each exterior divider face 35 a . As illustrated in FIG. 7, the plane of the drive face 25 a of each interior spline 25 is typically disposed at an angle “D” of from about 10 degrees to about 45 degrees with respect to the exterior edge 27 of the facing spline wall 25 b of the adjacent interior spline 25 b . The interior splines 25 and intervening spline dividers 35 extend outwardly from the rear base surface 18 b of the segment base 18 , to substantially conform to the taper angle of the exterior splines 19 . Moreover, the exterior splines 19 are complementary in shape to the interior spline seats 24 , and the interior splines 25 are complementary in shape to the exterior spline seats 20 , respectively. Accordingly, the drive segments 17 will nest, stack and interlock and yet are capable of being positioned at an angle on each other in driving relationship to shape the drive string 10 as illustrated in FIG. 1, with the exterior splines 19 and interior splines 25 of one drive segment 17 inserted in the interior spline seats 24 and exterior spline seats 20 , respectively, of respective adjacent drive segments 17 . Furthermore, the exterior base splines 28 of one drive segment 17 engage the respective companion interior base splines 30 of an adjacent drive segment 17 . This interlocking registration of the drive segments 17 is not rigid, but permits pivoting movement of the drive segments 17 in the interlocking and nested configuration, such that the drive string 10 can easily bend to conform to the bend illustrated in FIG. 1, and yet maintain an interlocking driving relationship of high integrity due to the drive faces 19 a of the exterior splines 19 and matching drive faces 25 a of the interior splines 25 b . The interlocking registration of the drive segments 19 also serves to dampen any excessive vibration of a mud motor (not illustrated) or other drive mechanism (not illustrated) at the input 12 of the drive string 10 .
Referring again to FIGS. 7 and 8 of the drawings, each drive segment 17 is designed such that the internal spline seats 24 are rotatably offset with respect to the respective exterior splines 19 thereof. This offset is preferably at a rotational angle, “G”, illustrated in FIG. 7, in the range of from about 0.5 degrees to about 12 degrees and most preferably, about six degrees. This rotational angle “G” facilitates proper meshing of the exterior splines 19 of one drive segment 17 and the interior spline seats 24 of an adjacent drive segment 17 in the drive string 10 . In application as hereinafter described, torque is applied to the top of the drive string 10 by means of an input 12 of selected design to rotate the drive string 10 and the output 42 attached to the opposite end of the drive string 10 , as further illustrated in FIG. 1 .
Referring again to FIG. 6 of the drawings, in a most preferred embodiment of the invention the angle “H” of taper of the spline dividers 35 and the exterior splines 19 with respect to the plane of the truncated tip 21 of the exterior splines 19 , is in the range of from about 20 degrees to about 40 degrees and most preferably, about 30 degrees, when one of the drive segments 17 is viewed as illustrated in FIG. 5 . This structuring of the drive segment 17 facilitates a drive string 10 which is capable of bending with a separation angle “E”, illustrated in FIG. 1, of from about zero to about 10 degrees for each one of the drive segments 17 utilized in the drive string 10 , to facilitate traversal of the bend illustrated in FIG. 1 and yet maintain optimum interlocking contact between the exterior splines 19 of each drive segment 17 and interior splines 25 of the adjacent drive segment 17 , to effect driving rotation of the selected output 42 responsive to power applied to the drive string 10 by the selected input 12 .
Referring now to FIGS. 1 and 2 of the drawings, in a preferred embodiment of the invention a set of drive segments 17 may be slidably strung on the flexible segment cable 33 (FIG. 1) or on the stiff segment shaft 45 (FIG. 2) and nested with each other, with the exterior splines 19 (FIGS. 4 and 5) of each drive segment 17 inserted in the respective interior spline seats 24 (FIG. 15) of the adjacent drive segment 17 , and the exterior base splines 28 engaging the respective interior base splines 30 . One end of the segment cable 33 or the segment shaft 45 may be fitted with a cable stay or anchor (not illustrated) or otherwise fixed inside the output 42 and the other end threaded through the registering tip apertures 22 of the nested drive segments 17 for similar attachment to the input 12 to maintain the drive segments 17 in nested configuration in the drive string 10 . The drive string 10 utilizing the straight rod or shaft 45 illustrated in FIG. 2 is typically rotated in a straight guide path or tube of selected design under circumstances in which the input 12 is in an aligned position with respect to the output 42 , with the drive faces 19 a (FIG. 4) of the exterior splines 19 on one of the drive segments 17 engaging the drive faces 25 a (FIG. 15) of the respective interior splines 25 of an adjacent drive segment 17 , and the exterior base splines 28 engaging the respective interior base splines 30 . Alternatively, the drive string 10 can be rotated in a curved guide path or tube of desired curvature under circumstances in which the input 12 is disposed in an offset position with respect to the output 42 , as illustrated in FIG. 1 . When the output 42 is configured as a drill bit, for example, one or more lateral or horizontal drain holes (not illustrated) can be drilled in a hydrocarbon formation (not illustrated) in a vertical oil or gas well, according to the procedure outlined in U.S. Pat. No. 5,699,866, and the drive string 10 can be retrieved from the drain hole by application of the segment cable 33 , illustrated in FIG. 1 . In a most preferred embodiment of the invention the drill bit may be typically about twenty percent larger than the drive segment 17 to better facilitate retrieval of the drive string 10 and to facilitate removal of debris from the drain hole as the drive string 10 and the drill bit are removed from the drain hole. In a preferred embodiment of the invention, the tip aperture 22 of each drive segment 17 is about ½″ in diameter, whereas the segment cable 33 or shaft 45 is about ½″ in diameter to facilitate sufficient clearance between the segment cable 33 or shaft 45 and the edge of the tip aperture 22 for the passage of drill fluid (not illustrated) through the drive segments 17 of the drill string 10 for purposes which will be hereinafter described. It will be further appreciated by those skilled in the art that the drive segments 17 illustrated in FIGS. 1-8 of the drawings may alternatively be used in connection with multiple “floating collars” of the design and in the manner outlined in our U.S. Pat. No. 5,911,283, for the purposes outlined in that patent. Accordingly, under circumstances in which the drive string 10 is to be left in the drain hole and not retrieved and the drive segments 17 are connected by means of the “floating collars”, the segment cable 33 may be omitted.
Referring again to FIGS. 7 and 8 of the drawings, it will be further appreciated by those skilled in the art that substantially any number of exterior splines 19 , exterior spline seats 20 , exterior base splines 28 , interior spline seats 24 , interior splines 25 and interior base splines 30 can be provided in the design of the drive segment 17 . However, in a most preferred embodiment of the invention, eight exterior splines 19 , exterior base splines 28 and exterior spline seats 20 and matching interior spline seats 24 , interior base splines 30 and interior splines 25 are provided for each one of the drive segments 17 , as illustrated. In a most preferred embodiment, the taper of the eight exterior splines 19 and the configuration of the interior splines seats 24 are complementary, as heretofore described, and the exterior splines 19 and interior splines 25 are typically about two percent to about five percent smaller than the interior spline seats 24 and the exterior spline seats 20 , respectively, for optimum smoothness and meshing during bending of the drive string 10 while operating the sectional drive system 1 typically as illustrated in FIG. 1 .
It will be further appreciated by those skilled in the art that other applications of the sectional drive system 1 may include the application of torque and thrust in a straight line or along a deviation from a straight line up to or even beyond ninety degrees, wherein the drive segments 17 shift or pivot on each other, utilizing either the segment cable 33 , the segment shaft 45 or the floating collars (not shown) as described in U.S. Pat. No. 5,911,283, in any desired direction. Torque may also be applied to the drive segments 17 as the latter lie in a curved guide tube or path (not illustrated), as desired. Accordingly, typical applications include “CV” joints and mechanical couplings in vehicles, mud motors and other applications involving misaligned drive and driven systems. Application to dental drills may also be effected under circumstances where the dental drill drive train must be curved over a selected adjustable or fixed radius from the drive motor to the application or drill end. The device may also be used in tools such as flexible-shaft screwdrivers and similar applications, in non-exclusive particular.
It will be appreciated by those skilled in the art that the drive segments 17 can be constructed of substantially any desired material, depending upon the application. Furthermore, the drive segments 17 are typically applied where the deviation, offset or curved between the input 12 and the output 42 of the drive string 10 , is significant.
Referring next to FIGS. 9-14 and 16 of the drawings, in a preferred embodiment the drill bit of this invention is generally illustrated by reference numeral 51 . The drill bit 51 is designed for attachment to the drive string 10 (illustrated in phantom in FIG. 10) of the sectional drive system 1 heretofore described with respect to FIGS. 1-8, as hereinafter described. The drill bit 51 is characterized by a substantially cylindrical drill bit head 52 , having a convex or dome-shaped cutting face 52 a typically studded with multiple diamond bits 52 b in a selected pattern, in conventional fashion. Multiple water course grooves 57 are typically provided in spaced-apart relationship in the circumference of the drill bit head 52 for facilitating passage of drilling fluid (not illustrated) between the drill bit head 52 and the well casing, cement sheath, producing interval (not illustrated) or other medium as the medium is drilled using the drill bit 51 as hereinafter described. Additional diamond bits 52 b are typically provided on the drill bit head 52 between the water course grooves 57 . As illustrated in FIG. 13, a center bit bore 53 extends centrally through the drill bit head 52 and receives a center bit insert 75 having an insert head 76 which is tapered in cross-section as illustrated in FIG. 12, and an insert shaft 77 extends from the insert head 76 . Opposing drive lugs 58 of the drill bit head 52 protrude toward each other into the center bit bore 53 for engaging complementary lug grooves 78 provided in opposite sides of the insert shaft 77 and insert head 76 of the center bit insert 75 . As illustrated in FIG. 12, an annular bit shoulder 54 is defined by the drill bit head 52 between broad and narrow portions of the center bit bore 53 , and the insert head 76 of the center bit insert 75 seats on the bit shoulder 54 in the broad portion of the center bit bore 53 whereas the insert shaft 77 extends through the narrow portion of the center bit bore 53 , beyond the bit shoulder 54 . A cable ball cavity 56 , the purpose of which will be hereinafter described, continues rearward extension of the narrow portion of the center bit bore 53 in the drill bit head 52 , and a retaining washer shoulder 55 is defined between the cable ball cavity 56 and the smaller-diameter narrow portion of the center bit bore 53 . As illustrated in FIGS. 12 and 13, the center bit insert 75 is typically removably mounted in the center bit bore 53 by means of a retaining bolt 81 , extended through a retaining washer 80 and threaded into the insert shaft 77 of the center bit insert 75 with the retaining washer 80 engaging the retaining washer shoulder 55 . As illustrated in FIG. 11, the lug grooves 78 (FIG. 13) of the center bit insert 75 define a lug space 73 between the center bit insert 75 and the drive lugs 58 , which lug space 73 communicates with the cable ball cavity 56 of the drill bit head 52 to facilitate flow of drilling fluid (not illustrated) through the drill bit head 52 as hereinafter described.
As illustrated in FIGS. 12 and 14, an annular base flange 71 having a tapered interior 71 a extends rearwardly from the drill bit head 52 , and the complementary tapered base nose 62 of a cylindrical drill bit base 59 is typically threaded (FIG. 14 ), welded (FIG. 12) or otherwise fixedly or removably attached to the base flange 71 of the drill bit head 52 at the tapered interior 71 a . As illustrated in FIG. 14, the drill bit base 59 includes a central bushing seat 63 which extends through the base nose 62 and is provided with multiple interior seat threads 64 and extends rearwardly from the cable ball cavity 56 . Multiple, spaced-apart interior splines 25 , adjacent ones of which are separated by a spline divider 35 defining an interior spline seat 24 (FIG. 16) between adjacent interior splines 25 , extend rearwardly from the base nose 62 of the drill bit base 59 in surrounding relationship to a base interior 60 which communicates with the bushing seat 63 . The interior spline seats 24 , interior splines 25 and interor base splines 30 of the drill bit base 59 are similar in number, size and configuration to those respective elements of the drive segments 17 of the drive string 10 heretofore described with respect to FIGS. 1-8 and 15 . Accordingly, the exterior splines 19 (FIG. 4) of the drive segments 17 are complementary in size and shape to the interior spline seats 24 of the drill bit base 59 . Thus, the exterior splines 19 of the terminal drive segment 17 a (FIG. 10) on the drive string 10 are capable of insertion in the complementary interior spline seats 24 between the adjacent interior splines 25 of the drill bit base 59 , with the exterior base splines 28 of the terminal drive segment 17 a engaging the respective interior base splines 30 of the drill bit base 59 , to engage the respective interior splines 25 and rotate the drill bit 51 with the rotating drive string 10 , as hereinafter described. As further illustrated in FIGS. 12 and 14, multiple water course passages 31 typically extend through the base nose 62 of the drill bit base 59 , and communicate with the cable ball cavity 56 (which communicates with the lug spaces 73 , FIG. 11) and base interior 60 to facilitate flow of drilling fluid (not illustrated) through the drill bit 1 during use as hereinafter described.
Referring again to FIGS. 10, 12 and 14 of the drawings, in typical application the drill bit 51 is typically removably mounted by means of the segment cable 33 (FIG. 1) on the drill string 10 of the sectional drive system 1 , which segment cable 33 extends through the registering tip apertures 22 (FIG. 4) of the nested drive segments 17 in the drive string 10 . That portion of the segment cable 33 protruding from the tip aperture 22 (FIG. 4) of the terminal drive segment 17 a (FIG. 10) extends through a cable bushing 67 (illustrated in section in FIGS. 12 and 14) and terminates on a cable ball 33 a , typically welded or otherwise attached to the segment cable 33 . The cable ball 33 a is extended through the threaded bushing seat 63 of the drill bit base 59 and positioned in the cable ball cavity 56 while the cable bushing 67 is threaded in the bushing seat 63 by operation of the seat threads 64 and companion bushing threads 68 on the cable bushing 67 . The exterior splines 19 of the terminal drive segment 17 a (FIG. 10) on the drive string 10 are inserted in the respective interior spline seats 24 (FIG. 16) in the base interior 60 of the drill bit 51 , and the exterior base splines 28 (FIG. 5) of the terminal drive segment 17 a engage the respective interior base splines 30 (FIG. 9) on the respective interior splines 25 of the drill bit 51 . In application of the sectional drive system 1 and drill bit 51 typically according to the procedure outlined in U.S. Pat. No. 5,699,866, the drive faces 19 a (FIG. 4) of the exterior splines 19 of the terminal drive segment 17 a in the drive string 10 engage the drive faces 25 a (FIG. 16) of the respective interior splines 25 of the drill bit 51 as the drive string 10 is rotated by means of the input 12 (FIG. 1 ). The weight of the rotating drive string 10 and other drilling components (not illustrated) engaging the input drive segment 17 b (FIG. 10 ), attached to the input 12 shown in FIG. 1, bears against the drill bit 51 at the drill bit base 59 as the rotating drill bit 51 drills a perforation or drain hole (not illustrated) in a hydrocarbon-producing interval (also not illustrated). It will be appreciated from a consideration of FIG. 12 that the drill bit 51 is securely mounted on the drive string 10 since the cable ball 33 a , having a larger diameter than that of the cable bushing 67 , is prevented from pulling out of the cable ball cavity 56 by seating against the cable bushing 67 as the terminal drive segment 17 a remains nested in the base interior 60 of the drill bit base 59 .
It will be appreciated by those skilled in the art that drilling fluid (not illustrated) can be continuously circulated through the drive string 10 and attached drill bit 51 during operation of the sectional drive system 1 , for purposes of cooling and preventing accumulation of drilling fragments in the drive string 10 and drill bit 51 . Accordingly, the drilling fluid (not illustrated) is injected through the tip aperture 22 (FIG. 4) of the input drive section 17 b of the drive string 10 , and flows through the registering tip apertures 22 of the remaining drive segments 17 and terminal drive segment 17 a . The drilling fluid then enters the multiple water course passages 31 of the drill bit base 59 and flows through the cable ball cavity 56 and finally, from the drill bit head 52 through the lug spaces 73 (FIG. 11 ). The drilling fluid is capable of removing particulate drilling fragments from the hydrocarbon-producing interval as the drilling fluid flows between the drill bit head 52 and the interval, through the water course grooves 57 in the outer circumference of the drill bit head 52 .
Referring again to FIGS. 12 and 14 of the drawings, it will be appreciated by those skilled in the art that a worn or damaged center bit insert 75 of the drill bit 51 can be removed from the drill bit head 52 and replaced, as desired, by initially unthreading the cable bushing 67 from the drill bit base 59 and removing the cable ball 33 a from the cable ball cavity 56 ; unthreading the retaining bolt 81 from the center bit insert 75 ; removing the center bit insert 75 from the drill bit head 52 and securing a replacement center bit insert 75 in the drill bit head 52 using the retaining bolt 81 and retaining washer 80 ; and replacing the cable bushing 67 in the drill bit base 59 and the cable ball 33 a in the cable ball cavity 56 . By increasing the “rake angle”, or cutting angle, of the drill bit 51 at the center relative to the peripheral areas of the cutting face 52 a , the center bit insert 75 enhances the cutting efficiency of the drill bit 51 relative to drill bits having a constant cutting angle across the entire diameter of the cutting face thereof. It is understood that any mechanism known to those skilled in the art other than the retaining bolt 81 and retaining washer 80 described above can be used for removably mounting the center bit insert 75 in the drill bit head 52 . It is further understood that the drill bit base 59 can be constructed in one piece with the drill bit head 52 or alternatively, either removably attached to the drill bit head 52 typically at the base flange 71 typically by threaded attachment, or welded or otherwise fixedly mounted on the drill bit head 52 typically at the base flange 71 .
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A sectional drive system for transmitting rotational power to an output, which system includes multiple splined drive segments which are nested and interlocked as a drive string that is rotatable in a selected straight or curved path. The top one of the drive segments cooperates with a drive mechanism to effect rotation of the nested drive segments in concert, and the bottom one of the drive segments connects to a suitable output such as a drill bit. Multiple, tapered and truncated exterior splines on each of the drive segments mesh with complementary interior splines on the adjacent drive segment to enable slight angular positioning of the drive segments on each other and facilitate dampening of drive vibration and bending of the drive string in or out of the chosen path in any desired direction as the drive string transmits rotational power in a curved path of desired magnitude from the drive mechanism to the output. The drive segments are typically connected internally by means of a cable or shaft, or may be connected by floating “collars”, to form the drive string. In a preferred embodiment, a drill bit having a removable center bit insert is mounted on the bottom one of the drive segments on the drive string, and is characterized by multiple interior splines which engage the companion exterior splines of the drive segment. | 4 |
The present invention concerns a linear or rotary actuator comprising a member rotated by an electric motor for the displacement of a member to be controlled. The member may more particularly be a nut in a screw and nut mechanism for the linear displacement of a member to be controlled.
BACKGROUND OF THE INVENTION
Linear actuators are very common and are used in many different applications, with examples being described in the European patent applications EP-A-468 920 and EP-A-987 477. The devices described in these publications comprises a step motor driving a screw and nut mechanism for the linear displacement of a shaft integral with a screw. The step motor allows the screw shaft to be rapidly displaced and positioned with few mechanical carts and using relatively simple controls.
In EP-A-468 920, a pinion mounted on the motor axle engages with a wheel that is integral with the nut. A hub of the wheel is sandwiched between flanges of a housing for axial positioning of the wheel. This axial bearing is not very rigid and performs poorly owing to friction. In certain applications, on the other hand, the electric motor must be separated from the member to be displaced, for reasons of sealing or safety such as are present in supply systems for combustible gases or liquids. A device such as that described in EP-A-468 920 cannot be used, since the separation between motor and screw is insufficient.
In EP-A-987 477, permanent magnets are mounted on the nut which thus is driven directly by the magnetic field created by the coils of the motor. The nut is mounted in the motor on just one bearing. The axial and radial support of the nut is very loose and thus unstable, both with respect to static and with respect to dynamic forces. Yet in many applications, stability is an important criterion, since the screw is coupled to the nut that at the same time serves as a guide determining the stability and the axial and radial positioning of the screw.
It is necessary not only to improve the efficiency and reliability of an actuator of the type cited, but also to reduce the price and size of these devices.
The device described in EP-A-987 477 is provided with a partition wall between the coils of the motor and the magnets mounted on the nut, for applications where a seal between the motor and the member to be controlled is necessary. This partition wall comprises a flange resting on a housing of the motor's stator part on one hand, and on a seal of the type of an O-ring sandwiched between the flange and a cover part of the actuator on the other hand. The reliability of sealing thus depends on the quality of the seal, which may deteriorate with time, may move when exposed to impacts, or may be poorly installed, for instance at the time of manufacturing of the motor. It will be advantageous to improve the reliability and safety of such devices, particularly in applications involving combustible liquids.
SUMMARY OF THE INVENTION
It is an object of the invention to realize an actuator that is efficient, reliable and not very expensive.
It will be advantageous for applications where sealing or separation is required between the electric motor and the member to be controlled, to realize an actuator that has reliable sealing.
It will be advantageous, moreover, to realize a device having few parts so as to reduce manufacturing and assembly costs.
It will also be advantageous to realize a linear or rotary actuator that is compact yet rigid and precise.
Objects of the invention have been realized by an actuator according to claim 1 .
In the present invention, an actuator for the linear displacement of a member to be controlled comprises a motor part and an actuating device part including a screw moving linearly, and a rotary member having a threaded portion matching the screw's thread that can be rotated by the motor part, the rotary member being supported by bearings in the form of thrust ball bearings having four contact points located on each axial side of a threaded portion of the rotary member so as to axially and radially guide this member, the raceways of the balls being directly integrated, on one hand into the rotary member and on the other hand into the housing or housing parts of the actuator.
The raceways are preferably formed from stamped steel metal that may be hardened by a tempering operation. The raceways may be attached to the rotary member and to the portions of the housing or flange by elastic tongues that allow parts to be snapped in an axial direction corresponding to the direction of the axis of rotation of the rotary member while the screw, the balls and the flanges may also all be mounted in an axial direction on the motor part. The raceways may also be glued, welded or molded to said nut and to the housing or housing parts.
This design advantageously allows the costs of manufacture of the parts and of assembly to be appreciably reduced. The thrust ball bearings with four contact points present on each side of the rotary member yield a highly rigid, stable, precise and compact design.
The points of contact between the balls and the surfaces inclined radially inward and radially outward are arranged so as to satisfy the relation: A/B=C/D, where D and C are the radii of the contact points radially inward and radially outward from the axis of rotation of the rotary member, and B and A are the diameters of the trajectories of the contact points radially inward and radially outward on the ball. This arrangement of the contact points ensures that the balls will roll on the raceways without slipping.
According to another aspect of the present invention, an actuator for the linear or rotary displacement of a member to be controlled comprises a motor part, an actuating device part with a rotary member having magnetized portions, the rotary member being able to be driven by the motor part, an air gap being formed between the magnetized portions and the motor part, the actuator in addition comprising a continuous partition wall between the motor part and the actuating part and having a portion located in said air gap, characterized by the fact that a portion of the partition wall has the shape of an outer flange that can be mounted onto a support or onto a assembly wall of a device to be controlled.
This economic design has the advantage of providing a reliable separation between the motor part and the actuating part constituting a seal, not only with respect to fluid leakage but also from an electric point of view. Electric arcs originating in the electric motor part are thus highly effectively and reliably separated from the actuating part.
The actuating part can be designed as part of a screw and nut mechanism comprising a screw with linear displacement driven by a nut forming the rotary member coupled to the motor.
The magnetized portions may comprise one or several magnets fixed to or integral with the nut. The magnets on the rotary member preferably are permanent magnets but may also be electromagnets.
The partition wall or at least the portion located in the air gap may be made of a magnetic material so as to boost the magnetic flux across the air gap.
The partition wall may be made of an electro-conductive material such as a steel sheet that on one hand is strong and inexpensive and on the other hand ensures an electric and physical separation of the motor part from the screw and nut mechanism.
The partition wall may advantageously function as a structural element for the assembly and positioning of the motor part and of the actuating part.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantageous aspects of the invention will become apparent from the claims and description and from the appended drawings in which:
FIG. 1 is a sectioned view of a linear actuator according to a first embodiment of the invention;
FIG. 2 is a detailed sectioned view of one of the bearings of an actuator according to the invention;
FIG. 3 is a detailed sectioned view of another embodiment of a bearing of an actuator according to the invention;
FIG. 4 is a perspective view of the bearing according to FIG. 3 ; and
FIG. 5 is a detailed sectioned view of a variant of a bearing according to FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , an actuator 1 comprises an electric motor part 2 , an actuating part 3 and a partition wall 4 . The electric motor part 2 in these examples comprises a step motor having aspects similar to those of conventional step motors, such as the stator 5 with two portions 6 with coils separated by an air gap 7 of permanent magnets 8 mounted on a rotary member 9 of the actuating part 3 . The use of a step motor is advantageous inasmuch as it allows an easy, rapid setting of the position of the member to be controlled in a compact, not very expensive design. Nevertheless, other types of reversible motors may be used in the present invention.
The actuating part 3 comprises the rotary member 9 provided with a threaded portion 10 engaging with a matching member in the form of a screw 11 having a threaded portion 12 , a cover part 13 , a housing part 14 and bearings 15 , 16 supporting the rotary member 9 when rotating.
In the embodiment illustrated, rotation of the rotary member 9 causes axial displacement of the screw 11 that is provided with axial guiding elements 17 cooperating with a matching axial guiding shape or elements of cover part 13 blocking rotation of the screw. The screw 11 may be coupled to a member to be displaced (not illustrated), for instance by fastening it to a threaded portion 18 of the screw protruding beyond the cover part 13 .
Other variants are possible, however, without going beyond the scope of the invention. For example, the rotary member may be integral with a screw that linearly displaces a nut coupled to the member to be controlled, or being itself part of the member to be controlled. In another variant the screw may be replaced by other members, for instance an axle for rotary actuation of the member to be controlled.
In the variant illustrated, screw 11 may for instance be coupled to a member controlling the flow rate of a fuel gas in a fuel supply or draining system, a specific example being a system for adjusting the flow rate in gas burners.
For reasons of safety, it will be important in such applications to separate the electric motor part from the part actuating the valve or other member in or near a combustible fluid.
In the present invention, the partition wall 4 arranged between the actuating part 3 and the motor part 2 is continuous, and extends to the outside of the actuator, thus forming a very efficient and reliable separation between these parts.
In advantageous embodiments, the partition wall 4 is formed by a conducting wall such as metal sheet that can be connected electrically to the installation being controlled (and to ground) so that there will be no electric potential difference between this wall and the installation being controlled.
The wall allows the motor part to be separated from the screw and nut mechanism by a physical and electric seal, particularly when the wall is electrically conducting.
The partition wall 4 comprises a cylindrical portion 19 in the air gap 7 between stator 5 and the magnets 8 on the rotary member 9 , a bottom part 20 and an external part 21 in the form of a flange having a surface 32 to be mounted on a support or on a wall of a device to be controlled. The partition wall 4 or at least the portion 19 in the air gap may be made of a material having a good magnetic permeability, so as to boost the magnetic flux between the stator 5 and the magnets 8 .
The stator 5 of the motor is disposed around the partition wall 4 , and the actuating part 3 is disposed inside the cylindrical portion 19 through an axial and a radial positioning surface 33 , 34 of the housing part 14 and through positioning surfaces 35 of the cover part 13 , all these surfaces resting against the partition wall.
The cover part 13 is retained by mechanical fastening means such as an elastic ring or a check spring 36 engaged, on one hand with the cover part and on the other hand with the partition wall.
Advantageously, the partition wall is at once a structural element allowing the motor part to be assembled with the actuating part 3 .
Bearings 15 , 16 of the rotary member are thrust ball bearings with three or four contact points for the axial and radial positioning of the rotary member, one bearing being located on each side of the threaded portion 10 of the rotary member. One of the bearings 15 is located between the cover part 13 and the rotary member 9 , the other bearing 18 is located between the rotary member and the housing part 14 that is mounted to the partition wall 4 . The raceways 22 , 23 of the ball bearing 15 are integral with the cover part 13 and rotary member 9 , respectively, while the raceways 24 , 25 of the thrust ball bearing 16 are integral with the rotary member 9 and housing part 14 , respectively.
The raceways are advantageously made of stamped steel metal. They may then be welded, glued, molded, or mechanically attached to the cover part, rotary member or housing part. Advantageously, this yields a particularly compact and rigid design having economic manufacturing costs. In fact, the actuator consists of few parts that are easy to assemble, which strongly reduces the manufacturing costs. It should be noted, for instance, that parts such as the ball bearings, the rotary member, the cover part, the partition wall and the motor may be assembled in an axial direction, thus facilitating the automation of the actuator assembly procedures.
Referring now to FIG. 2 , the inclined walls radially inward 26 and radially outward 27 of the raceways are arranged so as to satisfy the relation: A/B=C/D, where D and C are the radii of the contact points radially inward 28 and radially outward 29 from the axis of rotation 30 of the rotary member, while B and A are the diameters of the trajectories of the contact points radially inward 28 and radially outward 29 on the ball. When this relation is obeyed, the balls 31 will roll on the raceways 22 , 24 and 23 , 25 without slipping, and hence with a minimum of wear and resistance.
FIGS. 3 and 4 show another embodiment of the bearings in which the axis of rotation 37 of the balls 31 is inclined relative to the plane 38 passing through the centers of the balls. One of the raceways 22 ′ is located radially outward from the balls, the other raceway 23 ′ is located radially inward from the balls. In this embodiment, the inclined walls radially inward 26 ′, 26 ″ and radially outward 27 ′, 27 ″ of the raceways are again arranged so as to satisfy the relation: A/B=C/D, where D and C are the radii of the contact points radially inward 28 ′ and radially outward 29 ′ from the axis of rotation 30 of the rotary member, while B and A are the diameters of the circles travelled by the contact points radially inward 28 ′ and radially outward 29 ′ on the ball 31 . When this relation is obeyed, the balls will roll on the raceways without slipping. This arrangement of the raceways, which leads to the inclination of the axis of rotation 37 of the balls, allows the bearings to sustain higher radial forces than the bearings according to FIG. 2 . In other words, the bearings according to FIGS. 3 and 4 have a higher radial rigidity than the bearings according to FIG. 2 .
The inner raceway 23 ′ can be replaced by a spherical surface such as that shown in FIG. 5 , or by a conical surface, so that there will be no more than three contact points between each ball and the raceways. The conical or spherical surface may be realized by a raceway, for instance made of stamped steel metal and hardened by tempering, or machined or otherwise formed, directly on the rotary member 9 . | An actuator ( 1 ) for the linear displacement of a member to be controlled comprising a motor part ( 2 ) and an actuating device part ( 3 ) including a threaded screw ( 11 ) with linear displacement, and a rotary member ( 9 ) provided with a threaded portion ( 10 ) matching the screw thread, the rotary member capable of being driven in rotation by the motor part and being supported by bearings ( 15,16 ) in the form of roller bearing stops with four contact points arranged on either axial side of said threaded portion to guide the rotary member axially and radially. The raceways of the balls are directly in the rotary member and integral with parts of the body ( 14 ) or the cover ( 13 ) of the actuator. | 5 |
BACKGROUND OF THE INVENTION
The invention relates generally to a wet press of a paper making machine and more particularly to a wet press having a tiltable felt-tightening roll.
Wet presses of paper-making machines having the following elements for treating paper webs are known: a pair of first rolls defining a roll or press gap through which the paper web is conducted, second rolls defining a closed loop path which includes the roll gap, a belt-shaped felt guided by and revolving around said second rolls in the closed loop path with the web and felt being simultaneously conducted through the roll gap, the second rolls including a tightening roll pivotally supported at one end with the felt being looped around the tightening roll with a section of the felt running toward the tightening roll and a section of the felt running away from the tightening roll and a manually operable means for tilting the tightening roll by a given tilt angle which lies in a plane located in the space between the felt sections and which passes through the longitudinal axis of the tightening roll.
In such wet presses, as the felt and paper web to be drained are simultaneously conducted through the roll gap, water is pressed out of the paper web and is transferred onto the felt web. The absorbed water is removed from the felt at another point along its closed loop path by, for instance, a suction roll.
The pair of rolls forming the roll gap, along with their guides which engage roll journals and the elastically resilient felt, form a vibrating system with a large number of resonance vibrations that can be excited during operation of the wet press. Vibrations in the range of about 20 to 150 Hz typically occur and manifest themselves as a loud humming sound.
Such phenomena becomes particularly pronounced if at least one of the rolls of the pair is a flexure-controlled roll, i.e., a hydraulically supported rotatable hollow roll having a stationary crosspiece extending through the hollow roll and forming a small clearance space therewith which contains the supporting liquid. The vibration problem is exacerbated with flexure-controlled rolls because such rolls comprise several parts which add to the number of vibratory degrees of freedom.
The vibrations and noise produced are not only a nuisance, but also have a negative effect on the operation of the wet press. This problem applies particularly to so-called "beaten path vibrations" which either occur in the plane connecting the axes of the rolls forming the roll gap or have a component in this plane. When the rolls vibrate toward each other in this plane, the portion of felt located in the roll gap at the instant the vibration occurs is greatly compressed and forms a mark in the felt. During the remaining times when the rolls vibrate away from each other little or no compression results. Under certain geometric conditions, after some period of operation the marks develop in the felt in a line pattern which extends transverse to the direction of felt motion and becomes permanently impressed on the felt. These marks can excite resonate frequencies of the wet press thereby causing amplification of the vibrations.
The felt compression along the lines also hampers the absorption characteristics of the felt. The felt has a reduced service life when vibrations occur because its drainage action is reduced due to the line pattern which results in linear hardened zones. Therefore, the felt must be replaced sooner than if it was uniformly stressed under diminished vibratory conditions. The generation of the vibratory marks in the transverse line pattern greatly reduces the service life of the felt which would be otherwise possible. Furthermore, these irregularities in the absorption capability of the felt adversely affect the treated paper web as uneven draining of the paper web results therefrom. Additionally, the transverse line pattern remains Visible after the paper is completely dry. Hence, these vibrations lead to diminished paper quality.
The foregoing problems indicate that there is great interest in preventing the occurrence of the self-amplifying vibrations in a wet press generated by the transverse line pattern in the felt. In known wet presses of the prior art means are provided to attenuate the excitation of vibrations by transverse marks in the felt web. Typically this is accomplished by tightening the felt by means of a pivotally supported tightening roll. Tilting of the tightening roll tightens the felt into a generally parallelogram-like shape which prevents the vibratory marks from forming in a transverse direction, i.e., perpendicular to the running direction of the felt. The marks are now formed at a certain angle and the entire length of a mark does not reach the roll gap simultaneously. This largely cancels the excitation effect of the marks arriving at the roll gap.
If the tightening roll is tilted and the felt is not lengthened on its other side, destruction of the felt and in particular, lateral run-off of the felt would occur due to the shear stress induced. Therefore, the effects of the displacement or tilting of the tightening roll at one edge must be compensated by corresponding displacement at the other edge or by other similar measures.
In the known wet presses discussed above, the tightening roll is tilted manually by a spindle. The machine operator recognizes, from experience, by the noise generated by the wet press when tilting intervention is necessary. He then operates the spindle to tilt the tightening roll by a certain amount until the noise is reduced. After several hours or days, the felt has run-in in its new tightened position and new marks begin to form which excite the corresponding resonance vibrations of the roll arrangement and lead to amplified vibrations At such time, more intervention is required.
One of the problems With the prior art arrangement is that continuous monitoring and correspondingly great experience of the machine operator are required in order to maintain efficient, orderly and vibration-free operation of the wet press. The present invention solves this problem by providing for operation of the vibration suppression means in the known wet press independent of the continuous attention and intervention of the machine operator.
SUMMARY OF THE INVENTION
This is accomplished by provision of a controllable positioning device which is operable to tilt the tightening roll and means for automatically varying the tilt angle operably coupled to the controllable positioning device. In this manner, vibration suppression is obtained by operation of the controllable positioning device, which may comprise an electric motor, by the means for automatically varying the tilt angle to change the tilt angle in accordance with suitable criteria. The automatic tilt angle varying means may comprise a controller which operates the motor at predetermined time intervals independent of the actual vibratory condition prevailing in the press at a given instant. This prevents development of distinct vibratory marks in the felt. The tilt angle may be increased in equal steps in one direction up to a limit angle and then in an opposite direction in the same or similar steps up to an opposite limit angle via a contact arrangement forming part of the controller.
According to another embodiment the automatic tilt angle varying means comprises a controller which operates in dependence on the actual vibratory condition sensed at the pair of rolls. If .he sensed vibratory condition does not increase over a predetermined reference value the controller does not operate the motor to change the tilt angle of the tightening roll. A vibration sensor is provided for at least one of the pair of rolls and may comprise an acceleration sensor. In the case of hydraulically supported hollow rolls of the type previously mentioned, the acceleration sensor may be advantageously mounted at one or more of the ends of the crosspiece protruding from the hollow roll. Mounting the sensor at this position is advantageous because the accelerations occurring at the ends of such a roll are at a maximum value and therefore, measurement at the ends is more accurate than at other points along the roll. The controller of this embodiment may include means for calculating a mean value of the acceleration over a longer time interval than that calculated by the sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a wet press of a papermaking machine constructed according to the principles of invention.
FIG. 2 is a partial top view of the press taken along section IV--IV in FIG. 1.
FIG. 3 is an enlarged partial view of the roll or press gap.
FIG. 4 is a schematic view shown partially in cross section, of the controller for the controllable positioning device taken along section III--III in FIG. 1.
DETAILED DESCRIPTION
The wet press, generally designated in FIG. 1 as 100, comprises a pair of rolls 10 forming a roll or press gap 1 between upper roll 2 and the lower roll 3. One or more of the rolls 2, 3 are flexure-controlled, i.e. comprise a stationary crosspiece extending through a hollow rotatable roll to form a clearance space therewith. The clearance space is supplied with a liquid for hydraulically supporting the hollow roll. The protruding ends of the crosspiece are supported in a paper-making machine frame by swinging levers or other guiding devices which are not shown in FIG. 1.
Both the paper web 4 to be drained and the belt-shaped felt 5, which is at least as wide as the paper web 4, are simultaneously conducted through the gap 1. The felt 5 runs in the manner shown in FIG. 1 in a closed loop path generally defined by guiding and deflection rolls 6, 7, 8 and 9. Rolls 6 and 7 are arranged at about the same elevation relative to the upper roll 2 such that the felt 5 is looped around the upper roll 2 at an angle of about 140° .
The guiding and deflection rolls 8, 9 are arranged vertically above the pair of rolls 10. The felt 5 is guided by rolls 8 and 9 over a tightening roll 20 which is arranged such that the section 5' of the felt 5 approaching the tightening roll 20 and the section 5" leaving the tightening roll 20 form an angle of about 25° with each other. The tightening roll 20 can be tilted in a plane 11 located within the acute angle formed by sections 5', 5" of the felt 5 and passing through the axis of the tightening roll 20. As can be seen from FIG. 2 the tightening roll 20 is pivotally supported at one end on a pivot 12 while the other end of the tightening roll can be displaced in plane 11 by a spindle 13 in the manner shown in FIG. 2. A controllable positioning device, such as electric motor 14, drives the spindle 13. The motor is automatically operated by a controller 30 or 40 which automatically varies the angle by which roll 20 is tilted.
The normal position of the tightening roll 20 is indicated in FIG. 2 by dashed-dotted lines. In this position, the longitudinal axis of the tightening roll 20 is perpendicular to the longitudinal direction of the felt 5. A tightened position is shown in FIG. 2 by solid lines. In this position the right end of the tightening roll 20 is displaced downwardly by the angle α . To ensure that felt 5 remains in the center of the tightening roll 20 and does not laterally run off the roll 20 despite movement to a tightened position, a control roll 15 is provided at another point along the felt 5. Control roll 15 counteracts the tendency of felt 5 to run-off resulting from the tilting of the tightening roll 20.
The tightening roll 20 can also be displaced upwardly as shown in FIG. 2 by the dashed-double-dot lines. A displacement of the tightening roll 20 into the position shown in FIG. 2 by solid lines deforms the felt 5 into a generally parallelogram-like shape as shown in FIG. 2. Marks 16, which previously extended exactly transversely to the felt and gap 1 when roll 20 occupied its dashed-dotted line position, are now formed at an angle relative to the gap in the manner shown. Use of a tightening roll 20 of about 6 m long and a felt 5 of corresponding width, while displacing the right end of the tightening roll at the spindle 13 by about 100 mm upwardly or downwardly, produces about a 50 cm displacement of the marks 16 relative to the edge of the felt. Thus, rather considerable angular positions of the marks 16 can be achieved by relatively slight displacements of the right end of the tightening roll 20.
In FIG. 3, the conditions existing at the roll gap 1 are shoWn in a greatly enlarged manner. At the instant illustrated in FIG. 3, if a vibration is excited in rolls 2, 3, leading to relative motion of the rolls 2, 3 to decrease the roll gap (as shown by the direction of the arrows 17) a compression point in the felt 5 results. As the vibration continues, the next instant is followed by less compressed regions as the rolls 2, 3 move away from each other in a direction opposite to arrows 17. Thus, the compression points produces marks 16 in the felt at given spacings which can be calculated from the frequency of the vibration excited. The marks 16 extend transversely to the longitudinal running direction of the felt 5 and are conducted into the roll gap again in the manner shown in FIG. 3 (after the felt has made one complete revolution) in a rhythm or frequency which corresponds exactly to the resonance vibration of the rolls 2, 3 in the direction of the arrows 17. In this manner, after the marks 16 have been formed, the resonance vibrations of the rolls 2, 3 are additionally excited at exactly the right frequency and are thus amplified. However, this occurs only if the entire length of the marks 16 is conducted into the roll 1 at the same instant, i.e, the marks extend exactly transverse to felt 5 and parallel to gap 1 as the marks pass through the gap 1.
If the entire length of the marks 16 does not run into the roll 1 simultaneously, the excitation effect of the marks 16 practically no longer exists. The angular position of the marks 16 shown in FIG. 2 is generated to avoid this excitation effect.
After the tightening roll 20 has been tilted into one of the positions indicated in FIG. 2 to generate an angular position of the marks 16, new marks which extend exactly transverse to the felt 5 are formed after the passage of time by a new excitation of the resonance vibrations of the rolls 2, 3 in the direction of the arrows 17. These vibrations are quickly amplified by the newly formed transversely extending marks. Therefore, after some time, the felt 5 must again be set at an angle to eliminate the newly formed transversely extending line pattern.
In the wet press 100 of the invention, repeated changes in the tilt angle setting takes place automatically due to a controller 30 or 40. Two alternative controller embodiments for accomplishing automatic angle variation are shown in FIG. 4. In the embodiment indicated by dash-dotted lines, the control device 30 comprises a simple timing switch which, following a given timing program, for instance, switches on the motor 14 at uniform time intervals for a short time period. This causes displacement of spindle 13 and corresponding tilting of the tightening roll 20 by a certain angular amount. Operatively associated with roll 20 and forming part of the controller is a contact 18 which is operably connected to the roll 20 and moves simultaneously therewith. The tilting occurs in the same direction until contact 18 is moved into abutment with one of the spaced stationary contacts 19 and 20. In these positions a limiting angle of tilting has been reached and the closing of the contacts completes a circuit operable upon the next actuation of the motor to reverse the direction of rotation of the motor 14 until movable contact 18 abuts against the other of the contacts 19 and 21 and the cycle is repeated. Thus any tilting of roll 20 that occurs after the contacts 18, and 19 or 21 first abut, occurs in the opposite direction. In this manner, the pivoting end of the tightening roll 20 swings back and forth between the fixed contacts 19, 21 and the relative tightness of the felt 5 and the angular position of the respectively formed marks 16, changes again and again over time.
In the embodiment shown as controller 40 (solid lines in FIG. 4) a fixed timing program is not provided, but rather the actuation of the motor 14 depends upon the actual vibrations present at the rolls 2, 3 at a given point in time. In this embodiment, controller 40 comprises an acceleration sensor 23 attached to the protruding end 22 of the crosspiece of the upper roll 2. The signal of sensor 23 is amplified in a measuring amplifier 24, sent to a bandpass filter 25 and then a rectifier 26. A rectified signal from rectifier 26 is fed to a memory-programmable control device 27 which also receives, from a d-c voltage source 28, a d-c voltage signal which can be set via a potentiometer 29. The d-c voltage signal represents a given reference value which corresponds to a preset vibration intensity limit. If the signal of the acceleration sensor 23 exceeds this reference value memory-programmable control device 27 switches on the motor 14 for a given period of time to produce a tilting displacement of the tightening roll 20 by a given angular step. As with use of controller 30, the motor 14 in this embodiment also runs at constant speed when it is switched "on" and the angular limit positions are determined by abutment of the movable contact 18 with one of the fixed contacts 19, 21 which causes reversal of the tilting direction.
In practice, the value measured by the acceleration sensor 23 is determined as the mean value of the acceleration over a given short period of time, for instance one second. The memory-programmable control device 27 extrapolates this mean value at certain longer time intervals, for instance 10 minutes. Only if, upon such extrapolation the mean value is above the reference value does the controller 40 intervene to operate motor 14 to cause a displacement of the tightening roll 20. | A wet press of a paper-making machine includes a pair of rolls defining a roll gap through which the paper to be treated and belt-shaped felt are simultaneously conducted. The felt is guided in a closed loop path by additional rolls which include a tightening roll. The tightening roll can be tilted to reduce roll vibrations by tightening the felt to set vibratory marks formed in the felt at an angle relative to the transverse width of the felt and the roll gap. A controllable positioning device is provided which includes a motor operated by a controller during predetermined time intervals or as a function of actual vibrations sensed at the pair of rolls forming the roll gap to automatically vary the tilt angle. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation as to all subject matter common to U.S. application Ser. No. 194,696, now abandoned and filed Oct. 6, 1980 by Carlton M. Slough and Edwin L. Colling, Jr. and assigned to Texaco Inc., assignee of the present invention, and a continuation-in-part for additional subject matter.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to monitors in general and, more particularly, to monitors for monitoring paraffin and the effectiveness of paraffin inhibitors and dispersants.
SUMMARY OF THE INVENTION
A paraffin monitor includes a source which periodically provides pulses. A circuit adapted to be immersed in a medium having paraffin is connected to the source and energized by the source so that when immersed in the medium the output signal from the circuit will be representative of the paraffin growth affecting the circuit.
The objects and advantages of the invention will appear more fully hereinafter from a consideration of the detailed description which follows, taken together with the accompanying drawings wherein one embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for illustration purposes only and are not to be construed as defining the limits of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial block diagram and a partial schematic of a paraffin monitor constructed in accordance with the present invention.
FIGS. 2 and 3 are diagrams of voltage E2 wave forms occurring during the operation of the monitor shown in FIG. 1.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a container 3 heated by a heater wire 7 from a heater source, not shown, contains a medium having paraffin. For the purpose of the present invention, the word "medium" will be used to denote a liquid containing some crude oil having paraffin or a liquid that is substantially all, if not 100 percent, crude oil or waxy oil which is usually present in refineries. A magnetostriction oscillator 8 which includes a wire 10 wrapped around a metal rod 11 in which the wire has a center tap connected to ground 14 so as to form two coils 10A and 10B. One end of the coil 10A is connected to a square wave timer 16 which may be of the type manufactured by Signetics as their model number NE555 which is also connected to ground 14. One end of coil 10B is connected to an oscilloscope 20 which in turn is connected to ground 14.
Although magnetostriction oscillators are old and well known in the art they have not been applied as is being done with the present invention. An explanation of how these oscillators operate may be in order. Magnetostriction in metals is somewhat analogous to the piezoelectric affect in quartz crystal. There is an expansion or contraction of magnetic material as a result of magnetization and conversely a change of magnetic permeability as a result of mechanical stress. Metallic rods exhibit resonance characteristics just as crystals do and the frequency of resonance depends on the material and the physical size of the rod. If a rod of magnetostrictive material is placed in a suitable alternating field the rod will vibrate longitudinally at a frequency which is twice that of the exciting field. Under this condition the exact center of the rod is a nodal point.
One end of the rod 11 may be excited with a coil wrapped around that end of the rod and a second coil wrapped around the other end may be used as a pick-up coil. As shown in FIG. 1, coil 10A is an excitation coil, while coil 10B is being used as a pick-up coil. The resonant frequency is given by f=v/2L where f is frequency, v is velocity of sound in rod 11 and L is the length of rod 11. With magnetostriction oscillator 8 submerged in a medium the excitation coil 10A is pulsed causing rod 11 to vibrate at its resonant frequency and to exhibit characteristic Q (efficiency), damping and decay behavior.
Deposition of paraffin from the medium on rod 11 changes the Q, damping and decay parameters. These changes are detected and analyzed using oscilloscope 20.
In operation, timer 16 provides a square wave pulse E1 to oscillator 8, causing oscillator 8 to provide a decaying oscillating signal E2, as shown in FIG. 2. Over a period of time, the paraffin in the medium builds-up on rod 11 and affects the Q, damping and decay behavior of oscillator 8 to the extent that when a pulse E1 from timer 16 has been applied to the oscillator, the frequency and decay time of signal E2 changes as shown in FIG. 3, which may be viewed on oscilloscope 20.
When monitoring a paraffin inhibitor or dispersant, the rate of growth of the paraffin film on magnetostriction oscillator 8 is representative of the effectiveness of the paraffin inhibitor or dispersant.
The present invention hereinbefore described is a monitor which monitors the rate of growth of paraffin or the effectiveness of paraffin inhibitors and dispersants. A square wave pulse is applied to a magnetostriction oscillator which, in turn, provides an oscillating signal decaying to zero after termination of the pulse and that over a period of time, as the paraffin affects the operation of the oscillator, the decay time and the frequency of the oscillating signal will change. | A paraffin monitor includes a pulse source periodically providing pulses. Apparatus, adapted to be immersed in a medium having paraffin, provides an output signal in response to each pulse in accordance with a paraffin film grown on said apparatus while the apparatus is immersed in the medium. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority based on Provisional Application Ser. No. 60/877,683, filed Dec. 28, 2006, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to methods and apparatus for feeding powder to a powder dispensing device. The powder dispensing device may dispense controlled quantities of powder into cartridges or other containers. The powder can contain a drug, but the invention is not limited in this respect.
BACKGROUND OF THE INVENTION
Powders are used in a variety of applications, including medical applications. In one example, it has been proposed to deliver certain types of drugs to patients by inhalation of a powder as a delivery mechanism. One particular example uses diketopiperazine microparticles known as TECHNOSPHERE® microparticles. The TECHNOSPHERE microparticles have a platelet surface structure and can be loaded with a drug. One use of these microparticles is the delivery of insulin by inhalation. An inhaler having a replaceable cartridge or capsule containing the drug powder is used for drug delivery.
In the commercialization of drug delivery by inhalation, large numbers of cartridges containing the drug must be produced in an efficient and economical manner. In particular, the cartridges must be filled with precisely controlled quantities of the powder. While TECHNOSPHERE microparticles are highly effective for drug delivery by inhalation, the platelet surface structure causes TECHNOSPHERE powders to be cohesive and somewhat difficult to handle.
One prior art cartridge filling system includes a feed chamber which delivers powder to a dosing wheel. The dosing wheel, in turn, dispenses controlled quantities of powder into cartridges. The prior art system utilizes vibration and a large paddle wheel to facilitate the flow of powder from a hopper through the feed chamber to the dosing wheel. While the prior art system is generally functional, the energy imparted to the Technosphere microparticles causes the powder to compress and performance to be highly variable. The performance of the prior art system depends, at least in part, on the cohesiveness of the powder being handled, which may range from highly cohesive to free flowing.
Accordingly, there is a need for improved powder feeding methods and apparatus.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, a powder feed system comprises a housing that defines a feed chamber to hold powder, the feed chamber having a powder inlet and a powder outlet, at least one feed wheel in the feed chamber, the feed wheel rotating about a feed wheel axis, at least one agitator positioned in the feed chamber to move the powder from the feed wheel to the powder outlet of the feed chamber, the agitator rotating about an agitator axis, and a drive mechanism to rotate the feed wheel about the feed wheel axis and to rotate the agitator about the agitator axis.
The feed wheel can include a feed wheel hub and pins that extend radially from the feed wheel hub. The agitator can include an agitator hub and agitator elements, such as J-shaped pins, that extend from the agitator hub. The drive mechanism can include a feed wheel motor and an agitator motor. The feed chamber can be configured to limit dead space where powder can accumulate and become compacted.
According to a second aspect of the invention, a method for feeding powder comprises loading powder into a feed chamber having a powder outlet, rotating a feed wheel in the feed chamber, and rotating an agitator in the feed chamber, wherein the agitator is positioned to move powder from the feed wheel to the powder outlet.
According to a third aspect of the invention, a powder fill system comprises a powder feed system and a powder dispensing device. The powder feed system includes: a housing defining a feed chamber, a powder inlet and a powder outlet; a feed wheel and an agitator positioned in the feed chamber to move powder from the powder inlet to the powder outlet; and a drive mechanism to rotate the feed wheel and the agitator. The powder dispensing device is positioned below the powder outlet to dispense a controlled quantity of powder to a powder container.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference is made to the accompanying drawings, in which:
FIG. 1A is a perspective view of a powder fill system in accordance with the first embodiment of the invention;
FIG. 1B is a cross-sectional front elevation view of the powder fill system of FIG. 1A ;
FIG. 2 is a cross-sectional top view of the powder feed system shown in FIGS. 1A and 1B ;
FIG. 3 is a cross-sectional side elevation view of the powder feed system of FIGS. 1A and 1B ;
FIG. 4 is a schematic front elevation view of the feed wheel;
FIG. 5 is a schematic cross-sectional view of the powder feed system;
FIG. 6 is a perspective view of a powder feed system in accordance with a second embodiment of the invention; and
FIG. 7 is a schematic cross-sectional view of a powder feed system in accordance with a third embodiment of the invention.
DETAILED DESCRIPTION
A powder fill system in accordance with a first embodiment of the invention is shown in FIG. 1 . The powder fill system includes a powder feed system 10 , which supplies powder to a dispensing device, such as a dosing wheel 12 . Dosing wheel 12 , in turn, dispenses controlled quantities of powder to cartridges 22 . The powder feed system is shown in greater detail in FIGS. 2-5 .
The dosing wheel 12 includes a series of dosing holes 20 , which can be spaced apart, for example, at 90° intervals and which retain powder by suction. As the dosing wheel 12 rotates, the powder is delivered to a cartridge 22 in a holder 24 . The powder dose delivered to each cartridge 22 from dosing hole 20 is typically in a range of 1 to 100 milligrams, but need not be limited to this range. In a practical system, multiple cartridges 22 in holders 24 move along a conveyor 26 and are filled by dosing wheel 12 . It will be understood that different powder dispensing devices can be used within the scope of the invention. In some embodiments, the powder dispensing device can comprise a dosing disk. Furthermore, retention of powder in the dosing hole by suction is not essential. In addition, the powder fill system can dispense powder to any type of powder container.
An embodiment of powder feed system 10 is described with reference to FIGS. 1-5 , where like elements have the same reference numerals. The powder feed system of FIGS. 1-5 includes a hopper 30 , a housing that defines a feed chamber 62 , a feed wheel 40 , and an agitator 42 . Feed wheel 40 and agitator 42 are located in feed chamber 62 . In the embodiment of FIGS. 1-5 , housing components include a feed frame 32 , a flange plate 34 and chamber inserts 50 and 52 .
The hopper 30 provides a flared opening to feed frame 32 and permits powder to be easily loaded into the system. The feed chamber of the powder feeding system 10 is relatively narrow, and in the absence of hopper 30 , it would be difficult to load powder into the system without spillage. Hopper 30 defines a powder inlet 60 .
Feed chamber 62 extends from powder inlet 60 to a powder outlet 64 . Powder is supplied through powder outlet 64 to dosing wheel 12 or another dispensing device. In the embodiment of FIGS. 1-5 , feed chamber 62 is partially enclosed by one or more components of the fill system to which the feed system is mounted. Thus, feed chamber 62 is defined by housing components including feed frame 32 , flange plate 34 , a housing plate 66 ( FIG. 5 ) and chamber inserts 50 and 52 . Housing plate 66 is a component of the powder fill system in this embodiment. It will be understood that the housing which defines feed chamber 62 may have different configurations within the scope of the invention. In the embodiment of FIGS. 1-5 , feed chamber 62 has an internal thickness of 0.75 inch. It will be understood that the feed chamber thickness can be varied based on the physical characteristics of the powder being handled and the components of the powder feed system.
In the embodiment of FIGS. 1-5 , flange plate 34 serves as a frame for mounting of components of the powder feed system 10 . Hopper 30 , feed frame 32 , feed wheel 40 , agitator 42 and chamber inserts 50 and 52 are mounted to the front side, or inboard side, of flange plate 34 . Drive motors for the feed wheel 40 and the agitator 42 can be mounted to the back side, or outside, of flange plate 34 . The flange plate 34 also functions as an adaptor plate for mounting of the powder feed system 10 to an existing powder fill system. The configuration of the flange plate 34 can be changed within the scope of the invention for mounting to other powder fill systems. For example, flange plate 34 can be replaced with a housing which encloses feed chamber 62 .
Feed wheel 40 includes a feed wheel hub 70 that rotates about a feed wheel axis 72 . Feed wheel pins 74 , or spokes, extend radially from feed wheel hub 70 . In the embodiment of FIGS. 1-5 , feed wheel 40 includes twelve pins 74 that are straight and that have lengths of 2.5 inches. In one example, feed wheel hub 70 is a stainless steel disk having a diameter of 1.25 inches and a thickness of 0.75 inch. The overall diameter of feed wheel 40 can extend from the top of feed frame 32 and 0.375 inch into the tip radius of agitator 42 .
As shown in FIG. 4 , the configuration of feed wheel pins 74 can include a first pin set 80 of six pins and a second pin set 82 of six pins. The pin sets 80 and 82 are axially spaced apart along feed wheel axis 72 . The first pin set 80 can be positioned on one side of feed wheel hub 70 , with the six pins spaced 60° apart. The second pin set 82 can be positioned on the other side of feed wheel hub 70 , with the six pins spaced 60° apart. The pin sets 80 and 82 can be offset by 30° in a circumferential direction to provide an equal spacing of the twelve pins around feed wheel hub 70 . Volumes 80 a and 82 a through which respective pin sets 80 and 82 travel are shown in FIG. 5 .
The feed wheel 40 and the agitator 42 can rotate in the same direction so that powder is transferred from the feed wheel 40 to the agitator 42 . The number, size, shape, location on the hub and diameter of the pins 74 can be varied to optimize the configuration for powders with different physical characteristics. The rotational speed of the feed wheel 40 can also be varied depending on the flow characteristics of the powder. The agitator 42 can interact with the feed wheel 40 so that powder is conveyed from one to the other. The feed wheel 40 provides a continuous supply of powder to the agitator 42 , so that the agitator is not deprived of powder. The feed wheel prevents the creation of a void in the powder bed over the powder outlet 64 . The feed wheel 40 removes the pressure that would otherwise be imparted to the powder near the agitator 42 by an uninterrupted, relatively high powder bed height.
Agitator 42 can include an agitator hub 90 that rotates about an agitator axis 92 , and agitator elements 94 affixed to agitator hub 90 . Agitator axis 92 can be parallel to feed wheel axis 72 . In the embodiment of FIGS. 1-5 , agitator 42 includes three agitator elements 94 equally spaced around agitator hub 90 . Each of the agitator elements 94 can be a J-shaped pin, as best shown in FIG. 5 . The J-shaped agitator elements 94 are positioned between first pin set 80 and second pin set 82 of feed wheel 40 . This configuration permits the agitator 42 to capture powder and convey it to a position over powder outlet 64 . The J-shape of the agitator elements allows a small amount of powder to be plowed into position above powder outlet 64 .
In one embodiment, agitator 42 includes a stainless steel disk having a diameter of 1.25 inches and three J-shaped stainless steel agitator elements 94 . In some embodiments, the J-shaped agitator elements 94 include intersecting straight sections 94 a , 94 b and 94 c , as shown in FIG. 5 . The J-shaped agitator elements can be dimensioned so that a straight section 94 b at the base of the J-shaped agitator element pushes powder into powder outlet 64 . The agitator elements are mounted 120° apart and move directly over the powder outlet 64 in a continuous motion, thereby filling the outlet with powder. The agitator hub 90 of agitator 42 fits into a hole in flange plate 34 , and the hole can be sealed with a PTFE seal, for example.
The agitator 42 rotates in the opposite direction with respect to dosing wheel 12 in this embodiment. In other embodiments using different dispensing devices, the rotation can be reversed, if necessary. The number, size, shape, location on the hub and diameter of the agitator elements 94 can be varied to optimize the configuration for powders with different physical properties. The rotational speed of agitator 42 can also be varied depending on the flow characteristics of the powder and the dispensing device being utilized.
In some embodiments, the agitator 42 and the feed wheel 40 interact so that powder is conveyed from one to the other and over the powder outlet 64 . In particular, the outer diameters of the feed wheel 40 and the agitator 42 can overlap, but the devices are configured to avoid physical contact. In the embodiment of FIG. 5 , the agitator elements 94 can rotate between pin sets 80 and 82 , thus overlapping the rotation of feed wheel 40 and agitator 42 while avoiding physical contact. In the embodiment of FIG. 5 , the outer diameters of feed wheel 40 and agitator 42 overlap by a distance D.
As shown in FIGS. 1-3 , agitator 42 is positioned below and to the right of feed wheel axis 72 , in the case of counterclockwise rotation of these elements. Feed wheel 40 pushes powder along the sloping surface of insert 52 toward agitator 42 , which in turn pushes the powder into powder outlet 64 . In this embodiment, powder outlet 64 is a space, at the bottom of feed chamber 62 , between inserts 50 and 52 .
As shown in FIG. 5 , a drive module 100 can include an enclosure 102 mounted to the back side of flange plate 34 . Enclosure 102 can enclose a feed wheel motor 110 and an agitator motor 112 . Feed wheel motor 110 is coupled to feed wheel 40 and produces rotation of feed wheel 40 about feed wheel axis 72 . Agitator motor 112 is coupled to agitator 42 and produces rotation of agitator 42 about agitator axis 92 .
In one embodiment, each of the motors 110 and 112 is a brushless DC gear motor. Other types of motors, such as AC motors, can be utilized within the scope of the invention. Furthermore, feed wheel motor 110 and agitator motor 112 can be replaced with a single motor and a gear assembly to drive feed wheel 40 and agitator 42 at the required rotational speeds. The gear assembly establishes a desired ratio of the feed wheel rotational speed to the agitator rotational speed. In general, any suitable drive mechanism can be utilized to drive feed wheel 40 and agitator 42 at the required rotational speeds.
The rotational speed of feed wheel 40 and the rotational speed of agitator 40 are selected to optimize powder feed performance for a given powder or a given range of powder characteristics. The rotational speeds of the feed wheel and the agitator and the ratio of rotational speeds can be based on the flow characteristics of the powder being processed. In some embodiments, the rotational speed of feed wheel 40 is in a range of 0.1 to 2 rpm and the rotational speed of agitator 42 is in a range of 30 to 40 rpm. However, the rotational speeds are not limited to these ranges and can be varied depending on the flow characteristics of the powder.
In some embodiments, the dosing wheel 12 rotates intermittently in 90° increments (for a dosing wheel having four dose holes spaced apart by 90°), with each 90° rotation being considered a fill cycle. The dosing wheel stops with dosing hole 20 positioned under powder outlet 64 . In other embodiments, the dosing wheel 12 can rotate continuously relative to powder outlet 64 . In each case, the rotation speed of agitator 42 can be set such that at least one of agitator elements 94 passes over dosing hole 20 when it is positioned under powder outlet 64 .
The drive module can be designed to bring the motor shafts into precise alignment with the agitator shaft and the feed wheel shaft. This allows the couplings on the motors to engage slots in the shafts, creating mechanical drive couplings. The motors are mounted in the drive module using spring-loaded hubs so that it is not necessary to align the slot in the shaft with the motor coupling. When the motors are started, the couplings engage as soon as they rotate into alignment with the slots in the respective shafts.
The size and shape of the feed chamber 62 can be configured to enhance performance of the powder feed system. In particular, the feed chamber 62 can be configured to limit dead space where powder can accumulate and become compacted, so that powder moves through the feed chamber 62 in a short time and does not remain in feed chamber 62 for extended periods. In some embodiments, the feed chamber walls are configured to match or conform to the volumes through which feed wheel 40 and agitator 42 rotate. For example, the feed chamber 62 can have an inside wall that, adjacent to feed wheel 40 , is slightly larger in diameter than feed wheel 40 and, adjacent to agitator 42 , is slightly larger in diameter than agitator 42 to permit rotation of these components without contacting the chamber wall. In further embodiments, the walls of feed chamber 62 can have a shape, such as a linear ramp, that does not conform to the outer diameter of feed wheel 40 or agitator 42 but which guides powder toward powder outlet 64 . In some embodiments, the size and shape of feed chamber 62 is determined during the initial design of the powder feed system. In other embodiments, the size and shape of feed chamber 62 is determined by providing one or more chamber inserts, such as chamber inserts 50 and 52 , to modify an existing feed chamber.
The chamber inserts 50 and 52 limit the size of the feed chamber 62 , which in turn limits the amount of powder in the chamber at any given time, so that a controlled bed height over the power outlet 64 is maintained. This improves the powder filling consistency. Chamber insert 50 establishes the right side boundary of feed chamber 62 on the upstroke of feed wheel 40 , and chamber insert 52 establishes the left side boundary of feed chamber 62 on the downstroke of feed wheel 40 , as shown in FIG. 1 .
The rotation of the feed wheel 40 moves powder toward an upstroke surface of upstroke chamber insert 50 . The upper section of insert 50 is concave in shape with a relatively steep rise and can have a radius of curvature that is slightly larger than the radius of the feed wheel 40 . This shape reduces dead space in the feed chamber 62 and allows powder that did not transfer to agitator 42 to recirculate. The lower portion of insert 50 is vertical or nearly vertical with a gradual inward curvature toward powder outlet 64 near the bottom. This shape insures that powder is directed down toward powder outlet 64 . The bottom of insert 50 can have a radius of curvature that is slightly larger than the radius of agitator 42 . While the lower section of insert 50 should be vertical or nearly vertical, the upper section can be modified to accommodate different feed wheel designs, but insert 50 should be generally vertical in overall shape and should limit dead space. The underside of insert 50 can be shaped to accommodate a scraper to prevent escape of powder from the feed chamber.
Downstroke chamber insert 52 also limits dead space in the feed chamber 62 . The rotation of feed wheel 40 moves powder away from insert 52 and into the agitator 42 In the embodiment of FIGS. 1A-5 , chamber insert 52 has a downwardly sloping downstroke surface that defines a linear ramp. The chamber insert 52 has a relatively steep angle that permits the feed wheel 40 to clear insert 52 and provides a straight path for powder to be fed down into agitator 42 , which captures and pushes the powder over the powder outlet 64 . The angle of insert 52 can be varied to accommodate different feed wheel designs and powders with different physical characteristics.
In other embodiments, the housing that defines feed chamber 62 is designed to provide a feed chamber shape as described above, without the use of separate inserts. As noted, the feed chamber can be sized and shaped to thereby limit dead space where powder can accumulate and become compacted. The thickness of the feed chamber 62 can be selected to accommodate the axial dimensions of feed wheel 40 and agitator 42 , while avoiding dead space in the feed chamber.
In some embodiments, two or more sets of feed wheels 40 and agitators 42 are provided for increased powder feeding capacity. Each set including a feed wheel and an agitator forms a powder feed section of the powder feed system. The two or more sets of feed wheels and agitators can be mounted in one or more larger chambers or can be mounted in subchambers of the feed chamber. In some embodiments, the thickness of feed chamber 62 can be increased and subchambers can be defined by dividing walls spaced along the axis of rotation of the feed wheel. In further embodiments, two or more sets of feed wheels and agitators can be spaced circumferentially around the dosing wheel, as shown in FIG. 7 and described below. One or more drive mechanisms can be used to drive the two or more sets of feed wheels and agitations.
In operation, powder is loaded into the hopper 30 until the powder reaches the tips of the feed wheel pins 74 . The motors 110 and 112 are energized and the agitator rotates at a speed that allows filling of the powder outlet 64 by an agitator element 94 passing over the outlet at least once on each fill cycle and in the same direction as the surface of the dosing wheel 12 . The feed wheel 40 rotates in the same direction and at a slower speed to prevent compacting of the powder but keeping the agitator 42 supplied with powder. The feed wheel pins extend into the tip radius of the agitator pins to insure sufficient transfer of powder and at the same time moving excess powder over the agitator and maintaining a consistent pressure on the outlet area to maintain accurate dosing. By minimizing compression of the powder, it will deaggregate more reproducibly, for example in an inhaler, and give more consistent performance.
A second embodiment of a powder feed system is shown in FIG. 6 . A powder feed system 200 includes a feed frame 232 , a flange plate 234 , a feed wheel 240 , an agitator 242 , an upstroke chamber insert 250 and a downstroke chamber insert 252 . Feed frame 232 is part of a housing which defines a feed chamber 262 . Powder feed system 200 can include a hopper (not shown in FIG. 6 ) as described above.
Feed wheel 240 includes a feed wheel hub 270 that rotates about a feed wheel axis 272 and feed wheel pins 274 extend radially from feed wheel hub 270 . In the embodiment of FIG. 6 , feed wheel 240 includes 16 pins 274 , including a first pin set 280 of 8 pins and a second pin set 282 of 8 pins. The pin sets 280 and 282 are axially spaced apart along feed wheel axis 272 . The pins of each pin set can be spaced apart at 45° intervals. In the embodiment of FIG. 6 , the pins of pin sets 280 and 282 are circumferentially aligned.
Agitator 242 can include an agitator hub 290 that rotates about an agitator axis 292 , and agitator elements 294 affixed to agitator hub 290 . The agitator 242 can be configured as described above in connection with agitator 42 .
Upstroke chamber insert 250 can include a curved edge 330 having a curvature that is based on the diameter of agitator 242 . Downstroke chamber insert 252 can include a curved edge 332 that is based on the diameter of feed wheel 240 and a curved edge 340 having a curvature that is based on the diameter of agitator 242 . Together, curved edge 330 of chamber insert 250 and curved edge 340 of chamber insert 252 define a U-shaped volume of feed chamber 262 that contains agitator 242 . A gap between chamber inserts 250 and 252 defines an outlet 342 of feed chamber 262 . As in the first embodiment, the feed wheel 240 provides a continuous supply of powder to agitator 242 , so that the agitator is not deprived of powder.
Powder feed system 200 can further include auxiliary pins 350 and 352 which are affixed to upstroke chamber insert 250 and which extend upwardly at an angle above agitator 242 and between pin sets 280 and 282 of feed wheel 240 . Auxiliary pins 350 and 352 direct powder being moved by a feed wheel 240 downwardly toward agitator 242 and thereby enhance performance of the powder feed system.
A schematic diagram of a powder fill system in accordance with a third embodiment of the invention is shown in FIG. 7 . The powder fill system includes a powder feed system 400 which supplies powder to a dosing wheel 412 . Dosing wheel 412 , in turn, dispenses controlled quantities of powder to containers 422 . The dosing wheel 412 includes a series of dosing holes 420 around its periphery. The dosing holes 420 retain powder by suction.
Powder feed system 400 includes a feed frame 432 for receiving a powder, and powder feed sections 434 , 436 and 438 . Each of powder feed sections 434 , 436 and 438 includes a feed wheel 440 and an agitator 442 positioned in a feed chamber 462 , and a drive mechanism (not shown) for rotating feed wheel 440 and agitator 442 . Each of the powder feed sections 434 , 436 and 438 may be configured as described above. Feed sections 434 , 436 and 438 include powder outlets for delivering powder to respective holes 420 on dosing wheel 412 . The powder feed system 400 of FIG. 7 can provide increased throughput in comparison with powder feed systems having a single powder feed section.
Having thus described several aspects of several embodiments of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only. | A fine powder is reliably dispensed from a hopper into containers on a moving conveyor belt with the assistance of a powder feed system. The hopper serves as a powder inlet that dispenses by gravity into a feed chamber that is form fitted to the sweep of a relatively slow rotating feed wheel with two spaced sets of pins. A relatively fast rotating agitator is located below the feed wheel which has a series of agitating blades that rotate between the span of the feed wheel pins, the blades in at least one embodiment resemble a J-shape. The agitator is located directly above a rotary trap chamber wheel, which has recesses that take doses of powder and dispense them into awaiting containers moving on a conveyor belt below. | 1 |
FIELD OF THE INVENTION
The present invention relates to a system for the open-loop control of a positioning unit in a motor vehicle.
BACKGROUND OF THE INVENTION
VDI Reports 612, Electronics in Automotive Construction describes a so-called CAN system. This system introduces the use of networked subsystems instead of the use of single, separate control units. The CAN system has separate control units that assume various functions, such as controlling the fuel injection process, automatic transmission control, as well as other tasks. In this type of system, all of the control units are connected to each other, as well as to all of the sensors and actuators. Difficulties arise in such a system when the various control units send conflicting control signals to the performance-regulating servo unit. Thus, one control unit may call for a decrease in the power output, while another control unit for an increase in the power output.
German Published Patent Application 33 31 297 (U.S. Pat. No. 4,583,611) describes a device for preventing the drive wheels of a motor vehicle from rotating by setting a power-regulating positioning unit in a direction of lesser power output. Such a device is commonly referred to as a drive slip control (ASR). Typically in such systems, however, the brakes are also controlled.
German Published Patent Application 28 48 624 (U.S. Pat. No. 4,266,447) describes a method for controlling automatic transmissions. According to this method, when the gear unit is actuated, a power-regulating positioning unit is controlled in a particular manner.
In systems which employ an automatic transmission control in addition to a drive slip control, it is possible for the drive slip control and the automatic transmission control to influence the quantity of fuel to be injected at the same time or at overlapping times. Any interventions, i.e., adjustments, in the fuel quantity by the automatic transmission control must not be hindered by the interventions of another control unit, otherwise, the gear of the transmission will not be able to be engaged. Similarly, intervention by the drive slip control must not be hindered by other power-regulating interventions.
One of the objects of the present invention is to provide a system to determine which of a plurality of control units acting simultaneously on a power-regulating positioning unit will actually control the positioning unit.
SUMMARY OF THE INVENTION
The present invention provides a system for the open-loop control of a positioning unit in a motor vehicle. The system according to the present invention determines clearly which control unit affects the position of a power-regulating positioning unit when several control units intervene. Moreover, in the case of an intervention, an automatic transmission control can not only decrease power output, but also increase it. Thus, an intervention increasing the power output is possible during an intervention by a drive slip control.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the system according to the present invention.
FIG. 2 is a block diagram of a first control unit of the system o FIG. 1, showing the interaction of various control signals.
FIG. 3 is a flowchart of the operation of the system according to the present invention.
FIGS. 4a, 4b and 4c show various signals plotted as a function of time.
DETAILED DESCRIPTION OF THE INVENTION
The system according to the present invention is described in association with a self-ignitable internal-combustion engine. In such an engine, the quantity of fuel that is supplied to the engine determines the power. In the case of self-ignitable internal-combustion engines, instead of a control signal, a signal relative to the throttle-valve position, or another signal which defines the power output of the internal-combustion engine, is selected. For example, such a signal can be a suitable firing signal. The system according to the present invention can also be advantageously applied to other types of internal-combustion engines.
FIG. 1 is a block diagram of the system according to the present invention. An internal-combustion engine 10 is coupled to a positioning unit 20. A first set of sensors 30 measures operating parameters in the internal-combustion engine 10. A second set of sensors 35 detects environmental conditions, such as air pressure and air temperature.
A first control unit (EDC) 40 delivers a control signal QK to the positioning unit 20. A second control unit, in particular an automatic transmission control (GS) 60, delivers a control signal QKG to the first control unit 40, as well as to a gear unit 55. A third control unit, in particular a drive slip control (ASR) 70, also delivers a control signal QKA to the first control unit 40, as well as to a brake 65. In other words, all of the control signals are fed to the first control unit 40, which determines which of the control signals actually controls the position of the positioning unit 20. The control units 40, 60, and 70, the sensors 30 and 35, the positioning unit 20, the gear unit 55 and the brake 65 are intercoupled via a common line. This line is used for signal transfer.
If one of the sensors 30 or 35 receives a signal, the signal is available to all of the control units 40, 60 and 70 via the common line. If one of the control units 40, 60 or 70 emits a signal, that signal is available to the positioning unit 20. The system requires only one line to transmit all of the data. Such systems, in which all of the components are intercoupled, are commonly referred to as CAN systems.
FIG. 2 is a block diagram of the first control unit 40 which shows the interaction of various control signals. A first maximum selection unit 205 outputs the larger of the output signals from a driving performance unit 215 and an intermediate speed controller 210. A cruise controller can replace the intermediate speed controller 210. The output signal from the first maximum selection unit 205 is received by a first minimum selection unit 220, which outputs the smaller of the output signals from the first maximum selection unit 205 and a speed limitation unit 222. The output signal of the first minimum selection unit 220 is referred to as a driver request signal QKF.
In a second minimum selection unit 225, the driver request signal QKF is compared with the control signal QKA from the drive slip control 70 and to the control signal QKG from the automatic transmission control 60. The smallest of these signals is fed to a switching device 230 via a signal QKAF. If the automatic transmission control 60 emits a priority signal PS, the switching device 230 is positioned as indicated by the dotted line. Depending upon the state of the priority signal PS, the switching device 230 transfers either the signal QKAF or the control signal QKG of the automatic transmission control 60 to a first input of a summing device 235.
The output signal QKL from an idle-speed controller 240 is applied to a second input of the summing device 235. The sum of these two signals is then applied to a third minimum selection unit 245, which compares the sum of output from the summing device 235 with the output signal QKB from a limiting device 250. The smaller of these two signals determines the position of the power-regulating positioning unit 20.
In the case of an internal combustion engine 10, the output signal from selection unit 245 is the current fuel quantity QK. Depending upon this signal QK, a pump unit determines the control variables for the power-regulating positioning unit 20. In the case of a diesel engine, this is a regulating rod position, or a solenoid valve that influences the injection period.
The output signal from the switching device 230, as well as the output signal from the limiting device 250, are received by a fourth minimum selection unit 255, which supplies a control signal to the drive slip control 70. The output signal QKF from the first minimum selection unit 225 and the output signal QKB from the limiting device 250 are received by a fifth minimum selection unit 260, which supplies a limited driver request signal QKFB.
The functioning of the system of the present invention is as follows. If the automatic transmission control 60 emits a priority signal PS, the switching device 230 is positioned as indicated by the dotted line. This means that the driving performance unit 215, the speed limitation unit 222, and the drive slip control 70 no longer have control over the positioning unit 20. Rather, the control signal QKG from the automatic transmission control 60 controls the positioning unit 20. In addition to the fuel quantity required by the automatic transmission control 60, the idling signal QKL is applied to the summing device 235. This ensures that the speed of the internal-combustion engine 10 does not fall below the idling speed. The sum of the control signal QKG from the automatic transmission control 60 and the idling signal QKL is limited by the third minimum selection unit 245 to a value less than or equal to the full-load, or the smoke emission limit.
FIG. 3 is a flowchart of the operation of the system according to the present invention. In step 300, the smaller of the driver request signal QKF, the control signal QKA from the drive slip control 70, and the control signal QKG from the automatic transmission control 60 determines the fuel quantity to be injected.
In step 310, it is determined whether a priority signal PS from the automatic transmission control 60 is present. If no such signal is present, the output signal QKAF from the second minimum selection unit 225 is applied, via the switching device 230 and the summing device 235, to the third minimum selection unit 245. In this case, the smaller of the driver request signal QKF, the control signal QKG from the automatic transmission control 60, the control signal QKA from the drive slip control 70, the output signal QKB from the limiting device 250, and the output signal QKL from the idle-speed controller 240 determines the fuel quantity to be injected. This corresponds to the normal operation of step 300.
On the other hand, if the inquiry unit 310 recognizes the existence of a priority signal PS from the automatic transmission control 60, the switching device 230 is shifted, in step 320, to the position indicated by the dotted line. In this manner, the control signal QKG from the automatic transmission control 60 is applied to the third minimum selection unit 245 via the summing device 235, and, therefore, the quantity of fuel supplied to the internal-combustion engine 10 is determined to a significant extent by the automatic transmission control 60.
For small control signal values QKG of the automatic transmission control 60, the idling signal QKL also has an effect, because it is added to control signal QKG in the summing device 235. For large control signal values QKG, the signal QK is limited in the third minimum selection unit 245 to the output signal QKB from the limiting device 250. This ensures that specified limiting values, for example relative to the full load and/or the smoke emission limit, are not exceeded.
The priority signal PS from the automatic transmission control 60 is released at the beginning of the switching operation. The priority signal PS is canceled when it is determined that a gear has been engaged or that there is a power transmission between the drive train and the wheels.
It is particularly advantageous for the priority signal PS to be released only after the control signal QKG has been decreased to zero. The advantage is that the drive slip control 70 is capable of further decreasing the signal during the time that the signal decreases as a result of the automatic transmission control 60.
If the inquiry unit 330 determines that a priority signal PS is no longer present, step 300 follows. In this case, the up-to-date signal is applied as the starting value for a fuel-quantity intervention. If the inquiry unit 330 determines that a priority signal PS is present, step 320 follows.
During the time that the priority signal PS from the automatic transmission control 60 is present, the drive slip control 70 continues to control. It continues to acquire the input variables and calculate a manipulated variable. However, it does not have any effect on the quantity of fuel to be injected. This means that the drive slip control 70 supplies a control signal QKA that does not have any influence on the quantity of fuel to be injected, as shown in FIG. 2, in that the switch device 230 is positioned as indicated by the dotted line.
FIGS. 4a, 4b and 4c show various signals plotted as a function of time. In part 1 of these Figures, the control signals from the various control units are plotted. The limited driver request signal QKFB is drawn as a dotted line. The control signal QKA from the slip control 70 is drawn as a dot-dash line. The control signal QKG from the automatic transmission control 60 is drawn as a broken line. The up-to-date signal QK that is supplied to the pump unit is drawn as a solid line.
A rotational speed N is drawn in part 2 of FIGS. 4a, 4b and 4c as a solid line, and an idling speed NLL is drawn as a broken line. The priority signal PS is plotted as a function of time in part 3 of FIGS. 4a, 4b and 4c. A signal indicative of slippage at the wheels is drawn in part 4 of FIGS. 4a, 4b and 4c.
At instant T1, the drive slip control 70 recognizes a spinning of the drive wheels, and, therefore, decreases the quantity of fuel to be injected. Starting from the driver request value QKF, the injected fuel quantity decreases at a linear rate, until a runaway value QKO is reached. If the value QKF is reached and the drive slip control 70 still recognizes that the wheels are spinning, the quantity of fuel to be injected remains constant at the runaway value QKO. At the same time, the rotational speed N decreases slightly. If slippage no longer occurs, the drive slip control 70 slowly increases the quantity of fuel to be injected.
At instant T2, the automatic transmission control 60 emits the priority signal PS. Thereafter, the automatic transmission control 60, together with the idle-speed controller 240, determines the quantity of fuel to be injected. The quantity of fuel to be injected again decreases linearly to the runaway value QKO, until the end of the frictional connection is recognized, which occurs when the uncoupling is complete and there is no power transmission from the engine to the drive wheels. At this instant, the automatic transmission control 60 increases the quantity of fuel to be injected. Following the increase, and immediately before instant T3, there is a sharp decrease in the quantity of fuel to be injected. In the switching operation phase, in which there is an increase in the quantity of fuel to be injected, there is no power transmission to the drive wheels. Driving conditions critical to safety cannot occur if, during this time, a decrease in fuel injection or no fuel injection was necessary because of the spinning of the drive wheels.
At instant T3, the priority signal PS from the automatic transmission control 60 is canceled, and the switching operation is ended. During the time that the priority signal PS is present, the rotational speed N decreases slightly and then increases to a higher value. At instant T4, the drive slip control 70 recognizes a renewed spinning of the drive wheels. A decrease in the quantity of fuel to be injected follows by means of the drive slip control 70. At instant T5, the control signal QKG from the automatic transmission control 60 again corresponds to the driver request signal QKF.
In FIG. 4a, the various signal are shown for the case when the priority signal PS is present and the drive slip control 70 has no effect on the quantity of fuel to be injected. During this time, the drive slip control 70 is active and continuously calculates an up-to-date control signal QKA, which is drawn as a dot-dash line. However, this control signal QKA has no influence on the up-to-date signal QK. After the switching operation has ended, the automatic transmission control 60 increases the control signal QKG to the limited driver request signal QKFB. Between instants T2 and T3, i.e., when the priority signal PS from the automatic transmission control 60 is present, the up-to-date signal QK corresponds to the control signal QKG from the automatic transmission control 60.
At instant T3, starting from when the priority signal PS is canceled, the smaller of the control signals QKA, QKG and QKFB determines the up-to-date signal QK. If at instant T4 the drive slip control 70 once again recognizes that the drive wheels are spinning, it decreases the quantity of fuel to be injected. The drive slip control 70 starts at the up-to-date control signal QKA of the drive slip control 70 or at the up-to-date signal QK. At instant T4, the drive slip control 70 again determines the up-to-date signal QK.
If there is a priority signal PS from the automatic transmission control 60, the automatic transmission control 60 determines the quantity of fuel to be injected. If there is no priority signal PS from the automatic transmission control 60, the signal QKA from the drive slip control 70, the driver request QKFB, or the signal QKG from the automatic transmission control 60 determines the quantity of fuel QK to be injected, if it is recognized that the drive wheels are spinning.
An advantage of the system according to the present invention is that when the priority signal PS is present, the drive slip control 70 has an effect until the control signal QKA from the drive slip control 70 is greater than the control signal QKG from the automatic transmission control 60. If this condition is satisfied, the drive slip control 70 is switched off, i.e., it is set in its initial state, and does not supply a control signal.
FIG. 4b shows the various signals in the case when the drive slip control 70 is inactive due to the presence of the priority signal PS. At instant T2, starting from when the priority signal PS is available, the control signal QKA from the drive slip control 70 remains constant, until there is no longer a priority signal PS. At the instant it is recognized that the drive wheels are no longer spinning, the control signal QKA from the drive slip control 70 increases at a linear rate until instant T6. When the priority signal PS is canceled, the drive slip control 70 is "thawed", i.e., it continues its control operations with the old values of the control signal QKA.
After the drive slip control 70 thaws, the smaller of the control signals QKA, QKG and QKFB determines the up-to-date signal QK. In this example, it is the control signal QKA from the drive slip control 70.
FIG. 4c shows the various signals in the case when the drive slip control 70 is reset due to the existence of a priority signal PS from the automatic transmission control 60. At instant T1, the drive slip control 70 recognizes that the drive wheels are spinning. The result is that the drive slip control 70 emits a control signal QKA which decreases from the limited driver request value QKFB to the runaway value QKO. At instant T2, the automatic transmission control 60 emits a priority signal PS. This signal causes the drive slip control 70 to be reset, i.e., the drive slip control 70 shifts to the passive state in which it is found when the spinning of the drive wheels has not been recognized for a long period of time. In other words, the drive slip control 70 does not emit a control signal.
The priority signal PS from the automatic transmission control 60 is canceled at instant T3. This means that it is possible for the drive slip control 70 to intervene. At instant T4, the drive slip control 70 again recognizes that the drive wheels are spinning. As a result, it reduces the quantity of fuel to be injected. The drive slip control 70 starts with the up-to-date injected quantity QK and decreases it linearly over time until the zero value is reached. So long as the automatic transmission control 60 supplies a control signal QKG smaller than the driver request signal QKF, the drive slip control 70 starts with the control signal QKG from the automatic transmission control 60. | A system for controlling a positioning unit in a motor vehicle includes various control units that influence the positioning unit coupled thereto. A drive slip control and an automatic transmission control both supply a control signal. Yet another control signal is dependent upon a driver request signal. For a period of time, the control signal from the automatic transmission control takes precedence over the other control signals. | 1 |
FIELD OF THE INVENTION
[0001] The present invention is directed to a system for storing hydrogen in a confined area and to power systems such as back-up power systems incorporating such hydrogen storage systems.
BACKGROUND OF THE INVENTION
[0002] The storage of hydrogen requires great care due to the explosive properties of the gas. As hydrogen becomes a preferred choice as an alternative fuel to fossil fuels there is a need for systems for storing hydrogen in a safe manner at a confined location such as within a building. This is particularly desirable for use in conjunction with a hydrogen fueled power system, for instance a back-up power system, for a facility. Commercially feasible systems for storing and using hydrogen in this manner are not currently available.
SUMMARY OF THE INVENTION
[0003] In one aspect the invention provides a hydrogen storage system comprising:
[0004] a) at least one hydrogen storage container disposed in a confined area;
[0005] b) a vent line extending from said at least one storage container to a location outside the confined area, said vent line having an operable valve;
[0006] c) at least one sensor disposed in said confined area for detecting one or more predetermined unsafe conditions relating to the storage of hydrogen in the confined area; and
[0007] at least one actuator in communication with said sensor for actuating said operable valve of said vent line to release hydrogen from said hydrogen storage container to a location outside of said confined area at a minimum pre-determined release rate in response to a signal received from said sensor relating to a sensed unsafe condition.
[0008] In another aspect the invention provides a power system for providing back-up power to a facility comprising:
[0009] a) a generating system disposed at the facility having at least one hydrogen generator and at least one hydrogen powered electrical generator.
[0010] b) a storage system disposed at the facility having at least one storage container for receiving hydrogen from said hydrogen generator;
[0011] c) a conduit for hydrogen from said at least one hydrogen generator to said storage system;
[0012] d) a conduit for supplying hydrogen from said storage system to said at least one electrical generator;
[0013] e) a sensor for sensing the supply of electric power from a primary electric power source;
[0014] f) an actuator in communication with the sensor for actuating said at least electrical generator to generate electricity in response to a signal from said sensor indicating an interruption in the supply of electricity from said primary electric power source.
[0015] In another aspect the invention provides a power system for a facility comprising:
[0016] a) hydrogen generator for producing hydrogen;
[0017] b) a hydrogen powered electrical generator for producing electricity;
[0018] c) a storage system comprising at least one storage container for storing hydrogen produced by said hydrogen generator, said storage container being connected to said hydrogen powered electrical generator to produce electricity from hydrogen stored in said storage system; and a fuel station connected to said storage system, said fuel station comprising at least one fuel dispensing device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a schematic view of a power system with a hydrogen storage system in accordance with the present invention.
[0020] [0020]FIG. 2 is an elevation view of a generator room and a storage room for one embodiment of the system of FIG. 1.
[0021] [0021]FIG. 3 is a plan view of the generator room for the system of FIG. 2.
[0022] [0022]FIG. 4 is a plan view of the storage room for the system of FIG. 2.
[0023] [0023]FIG. 5 is an elevation view of a fueling station for the system of FIG. 2.
[0024] [0024]FIG. 6 is a front elevation view of a fuel dispensing device for the fueling station of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0025] A power system in accordance with the present invention is depicted generally at 10 in FIGS. 1-6. The system 10 includes a generation system 12 comprising at least one hydrogen generator 14 and at least one hydrogen fueled electrical generator 16 . The system 10 also includes a hydrogen storage system 18 comprising at least one hydrogen storage container 20 . The hydrogen generator 14 receives electrical power from a power source 22 and water from a water source 24 The hydrogen generator 14 then operates in known manner to produce hydrogen that is then transferred to the storage system 20 . The stored hydrogen may then be used to fuel the electrical generators 16 to produce back-up power for a facility or the hydrogen may be used for other purposes such as for fueling a hydrogen receiving device at a fuel station 200 .
[0026] The generation system 12 of the preferred embodiment has a hydrogen generator 14 that is a CFA 450 Community Fueler Appliance (TM) manufactured by Stuart Energy Systems Corporation which is able to generate 450 scfh of hydrogen at up to 6,000 psig operating pressure and two hydrogen fueled electrical generators 16 that are Ford Power Products (FPP) hydrogen fueled, packaged internal combustion engine/generator sets (ICE) that will provide up to 135 kW of electrical output each complete with the necessary electrical equipment to produce electricity in a form compatible with the critical building circuits to be powered. Each of the above preferred electrical generator 16 requires 13,000 cfm of air to satisfy the integrated radiator's requirements and an additional 600 cfm for combustion air. Each electrical generator 16 also requires approximately 5250 scfh of hydrogen fuel at 75 psig when running at full load.
[0027] The hydrogen storage system 18 of the preferred embodiment has a number of high pressure hydrogen storage containers 20 of sufficient total capacity to supply fuel to the electrical generator 16 to run for a desired period of time (eg. two hours) under desired power conditions. Preferably, the storage containers 20 are conventional cylinders for receiving compressed gas where each storage container 20 has a capacity of 1550 scf at a pressure of 5,000 psig. The storage containers 20 will be designed to restrict the flow from each cylinder to 10 scfs and the total from each bank to 50 scfs, maximum.
[0028] The components of the system 10 are mostly disposed in a generator room 30 and a storage room 32 . The generator room 30 houses the hydrogen generator 14 and the electrical generators 16 and the storage room 32 houses the storage containers 20 . The embodiment depicted in FIGS. 2-6 demonstrates one arrangement for the rooms 30 and 32 however it will be appreciated that numerous alternate arrangements are possible while still meeting the objectives of the invention. Thus, in FIGS. 2-6, the roof 33 of the storage room 32 is constructed with sufficient structural strength to serve as a mezzanine area 35 over the generator room 30 where the electrical generators 16 are located. The hydrogen generator 14 will occupy most of the ground floor of the generator room 30 .
[0029] A viewing room 34 is also depicted in the FIGS. 2-5 for viewing the generator room 30 . This is an optional element that is advantageous mainly to provide demonstrations of the operation of the system 10 . The viewing room 34 is equipped with observation windows 36 and access stairs 38 to the generator room 30 . The floor level in the viewing room 34 is above the floor level in the generator room 30 to provide optimum viewing. A master control panel 40 for the system 10 may be located in the viewing room 34 for ease of operation during facility demonstrations or it may be located at any convenient location outside the storage room 32 .
[0030] Referring more specifically to the generator room 30 , a ventilation plenum 50 is provided for introducing make-up air ventilation into the room from outdoors. The ventilation plenum 50 preferably delivers approximately 30,000 cfm of unconditioned make-up air and is sized to ensure that the static pressure drop across the radiator fans 52 for the electrical generators 16 is not more than ½ inches of water column, total system. The ventilation plenum 50 preferably extends through the roof 53 and is capped with a Greenheck Model WIH (trademark) pre-fabricated louvered penthouse 54 complete with roof curb 56 and motorized dampers 58 (or equivalent).
[0031] A generator room exhaust fan 60 is mounted on the roof 53 and the intake is preferably flush with the underside of the roof deck such that the fan 60 will remove any fugitive hydrogen emissions that may collect in the upper corners of the room. The generator room exhaust fan 60 provides 10,000 cfm of capacity at ½ inch static pressure, total system. The exhaust fan 60 is preferably a Greenheck TAUB (trademark) tube axial flow “upblast” belt drive fan complete with non-sparking impellers and integrated butterfly dampers (or equivalent). The fan 60 is fitted with an appropriately classified electric motor.
[0032] The generator room exhaust fan 60 is preferably a start/stop model which is thermostatically controlled to attempt to maintain the room temperature below a desired level (eg. 77° F.). The exhaust fan 60 is also activated by the control system PLC 62 such that the exhaust fan 60 runs for a desired period of time (eg. at least 5 minutes) every hour for general room exhausting. In addition, the fan 60 may be controlled by other devices that are integrated into the system 10 .
[0033] A discharge pipe 64 is connected to the hydrogen generator 14 for the venting of excess oxygen and water vapour created by the hydrogen generator 14 during its operation. The discharge pipe 64 extends through the inside of the ventilation plenum 50 and discharges at the roof 53 through the curb box 56 of the pre-fabricated penthouse 54 . The pipe 64 is sized to ensure that the hydrogen generator 14 is not exposed to a pre-determined excessive back pressure (eg. greater than or equal to 4″ water column).
[0034] A second discharge pipe 68 is connected to the hydrogen generator 14 for venting excess, low-pressure hydrogen and water vapour. The second discharge pipe 68 preferably extends to the ceiling of the generator room 30 and then is routed through the roof 53 through the curb box 56 of the penthouse 54 . The pipe 68 is sized to ensure that the hydrogen generator 14 is not exposed to a pre-determined excessive back pressure (eg. greater than or equal to 4″ water column).
[0035] A supply line 70 extends from the hydrogen generator 14 to the storage containers 20 in the storage room 32 to transfer hydrogen at a desired pressure (eg. 5000 psig). This is described in more detail with reference to the storage room 32 structure.
[0036] The electrical generators 16 are placed on a mezzanine in the generator room 30 as depicted in FIGS. 2 and 3. As discussed above, alternate room arrangements are also contemplated.
[0037] Combustion air for the electrical generators 16 is preferably sourced from within the general space 72 of the generator room 30 . The exhausts 74 for the engines 76 of the electrical generators 16 are preferably discharged through the roof 53 via two separate pipes 78 and 80 complete with critical grade mufflers 82 and gravity-activated caps 84 .
[0038] The electrical generators 16 are oriented such that their radiators 90 will discharge through two separate suitably sized exhaust plenums 92 disposed in the wall. The exhaust plenums 92 are preferably equipped with outlet dampers 94 and re-circulation air discharge dampers 96 to re-circulate air from the electrical generators 16 back into the generator room 30 under cold weather conditions. The outlets 94 and 96 of the plenums 92 may be fitted with discharge air louvers 98 , complete with drains. The louvers 98 are preferably sized to fill the entire wall area above the mezzanine floor. Any louver area not required for exhaust purposes may be fitted with blanking panels 100 .
[0039] Hydrogen fuel for the electrical generators 16 may be provided at a desired pressure (eg. 75 psig) from a pressure regulator station 102 disposed inside the storage room 32 . A single supply line 104 from the storage room 32 extends through the mezzanine floor and branches to a connection point on each engine for the electrical generators 16 .
[0040] The generator room 30 is preferably equipped with a thermostatically controlled space heating device 106 that will maintain the temperature in the generator room 30 above a desired level (eg. 68° F.).
[0041] The generator room 30 may be equipped with a large access door 108 sized such that the large equipment that will be located in the generator room 30 and any equipment necessary to service that equipment is able to gain access through this door 108 .
[0042] Referring now to the storage room 32 , a sufficient number of storage containers 20 are provided to supply enough hydrogen to allow the electrical generator 16 to run for a desired minimum time period (eg. 2 hours) under desired power conditions. In the embodiment depicted in the figures, fifteen containers 20 arranged in three banks 110 are provided. Each container 20 preferably has a capacity of 1550 scf at a pressure of 5,000 psig. The storage containers 20 are designed to restrict the flow from each container 20 to 10 scfs and the total from each bank 110 to 50 scfs, maximum.
[0043] The containers 20 are racked horizontally with the bottom 112 of the containers 20 located along a louvered wall and the manifold tubing 114 located facing an opposing wall. The cylinder rack is covered by a sheet metal enclosure 116 that is designed to collect and direct any hydrogen leaks in the containers 20 or manifold piping upward to the opening 118 in the enclosure's roof. The primary hydrogen and temperature sensors 120 are mounted in this opening. This minimizes the detection time of a leak or fire in the storage bank arrangement.
[0044] Make-up air intake louvers 130 are located at the lower portion of the outside wall area of the storage room. A louvered, exterior access door 132 , opening outward is also located along this wall. Preferably, none of the louvers 130 and 132 shall have back draft dampers. The louvers 130 and 132 deliver a desired amount (eg. 18,000 cfm) of unconditioned make-up air to the storage room 32 and are sized to ensure that the static pressure drop across the two fans 134 described below is not more than a desired amount (eg. ¼ inches of water column, total system). The louvers 130 and 132 are preferably designed to nominally deliver 250 cubic feet per minute of make-up air per square foot of louver and will require 75 square feet of louvered wall, including the exterior access door 132 .
[0045] Storage room exhaust fans 134 are preferably mounted on the roof. The intake for the fans 134 is located in the storage room 32 ceiling at a location that will remove any hydrogen accumulation from the room. The exhaust intake 136 connects to an exhaust air plenum 138 that is preferably constructed of two hour rated dry wall, acoustically lined (or equivalent).
[0046] The storage room exhaust fans 134 preferably provide 9,000 cfm of capacity each with a total capacity of 18,000 cfm at ¼ inch static pressure, total system. The fans are preferably two identical Greenheck TAUB (trademark) tube axial flow “upblast” belt drive fans complete with non-sparking impellers and integrated butterfly dampers (or equivalent). The fans 134 are fitted with an appropriately classified electric motor.
[0047] The storage room exhaust fans 134 are start/stop models and are activated by the control system PLC 62 such that at least one of the fans 134 runs for a desired period of time (eg. at least 2 minutes every 60 minutes) for general room exhaust. The fan 134 that is activated for this function is preferably alternated such that the running hours of each fan 134 is accumulated approximately equally. In addition, the fans 134 will be controlled by other devices that are integrated into the system 10 .
[0048] A pressure relief valve 140 is provided in the fuel line 142 between the outlet 144 of the pressure reducing station and the inlet 146 to the electrical generator fuel line 148 . Each bank of storage containers 20 also requires a high-pressure relief vent line 150 , 152 and 154 . The hydrogen generator 14 also includes a vent line 156 to vent fugitive oxygen and hydrogen emissions and the associated water vapour. This venting will require the installation of four lines constructed of high-pressure steel tubing suitably sized and compatible fittings and valves plus the two lines 64 and 68 described in the generator room 30 section above for the low pressure hydrogen and oxygen and associated water vapour.
[0049] The high-pressure relief vent line from the hydrogen generator 14 is an integral part of the hydrogen generator design. Its primary purpose is to maintain adequate back-pressure on the outlet of the hydrogen compressors to ensure proper operation. If an overpressure situation occurs in the storage supply line from the hydrogen generator 14 , the overpressure relief line is discharged into a “blow down” pressure vessel 160 . This vessel 160 is of adequate strength and size to effectively accept the low flow, high-pressure hydrogen from the storage supply line and reduce it to low pressure. The blow down pressure vessel 160 is equipped with a relief valve 162 that allows the low pressure hydrogen and associated water vapour to vent to atmosphere via the hydrogen/water vapour vent line 64 and 68 described in the generator room 30 section above. All other hydrogen relief lines preferably exit the storage room at a desired level (eg. about 7.0 ft) above grade.
[0050] The high-pressure hydrogen relief system preferably consists of one pressure relief valve for the hydrogen generator fuel line and three pressure relief valves, one for each of the three banks of storage containers. The hydrogen generator fuel line relief valve is set to relieve at a desired pressure (eg. at 83 psig (110% of design pressure)). The storage relief valves are also set to relieve at a desired pressure (eg. 5,500 psig (110% of design pressure)).
[0051] In addition, the high-pressure lines from the three banks of storage are teed and piped to 3 Class 1, Zone 2 rated electrically actuated/pneumatically operated ball valves 166 . These valves provide a closed-loop storage dump capability that is controlled by the system 10 complete with a manual override capability.
[0052] The outlets of all four vent lines are connected to a common vent stack 168 . The vent stack 168 is installed at the point where all of the high-pressure vent lines exit the storage room (eg. about 7.0′ above grade). The vent stack 168 is affixed to the exterior wall of the building and extends to a sufficient height (eg. approximately 20.0 ft above grade) where it terminates in an elbow 170 that directs the hydrogen away from the building and is covered with a gravity actuated rain cap 172 .
[0053] The Safety Control System (SCS) 174 employs several strategies to ensure that the release of hydrogen into either the generator room 30 or the storage room 32 is avoided. In the unlikely event that a major hydrogen leak occurs, the SCS uses several redundant sensors 174 and associated closed-loop control devices 176 to mitigate the event. The mitigation strategy includes the manual or automatic dumping of a desired amount (eg. at least 95%) of all hydrogen in storage to atmosphere in a desired time period (eg. in less than 5 minutes).
[0054] In addition, manually actuated/electrically operated Emergency Stop Devices (ESDs) 180 and Emergency Dump Devices (EDDs) 182 complemented with visual/audible alarm beacons 184 are located in the viewing room, the generator room 30 and outdoors adjacent to the exterior access door to the storage room 32 . The cabinet 188 located adjacent to the exterior storage room door that houses the EDD, 182 also contains a pressure gauge 190 that directly measures the pressure in each of the three banks of storage containers. The gauge allows emergency personnel or qualified operations personnel to ensure that each bank of the storage containers is fully relieved of pressure when the EDD 182 is activated. The EDD 182 can be by-passed by a manual valve 192 located in the same cabinet.
[0055] The generator room 30 and the storage room 32 are also equipped with a network of temperature sensors 194 and fusible links 196 to manage the operation of all equipment and safety devices under all fault situations.
[0056] Referring to FIG. 6, a fuel station 200 is shown having at least one hydrogen fuel dispensing device 202 . The fuel dispensing device is connected to the storage containers 20 by a supply line 204 . The dispensing device includes a nozzle 206 and a control device 208 for dispensing hydrogen fuel at a pre-determined pressure to a receiving apparatus such as a vehicle.
[0057] The hydrogen-fueled back-up power system thus provides an advantageous alternative to diesel, and other forms of fuel, for back-up electrical power systems. Such a system has industrial, institutional and commercial uses primarily although other uses may become feasible in future. An advantage of the system is that the stored hydrogen can be utilized for other purposes as well provided that the storage maintains a minimum desired amount for providing the back up power system functionality. For instance, the hydrogen may be used for onsite vehicle fueling.
[0058] It is to be understood that what has been described is a preferred embodiment to the invention. If the invention nonetheless is susceptible to certain changes and alternative embodiments fully comprehended by the spirit of the invention as described above, and the scope of the claims set out below. | There is provided a hydrogen storage system having one or more hydrogen storage containers disposed in a confined area with a vent line extending from the one or more storage containers to a location outside of the confined area. One or more sensors are disposed in the confined area for detecting one or more pre-determined unsafe conditions relating to the storage of hydrogen in the contained area and at least one actuator is provided for actuating an operable valve of the vent line to release the hydrogen from the hydrogen storage container to a location outside the confined area at a pre-determined release rate in response to a signal from the sensor indicating an unsafe condition. A power system incorporating a hydrogen storage system as described above is also provided. | 5 |
CROSSREFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2002-282015, filed on Sep. 26, 2002; the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a server device, a client device, and a system for realizing video hypermedia by combining local video data and metadata on a network.
[0003] Hypermedia is a system in which a connection called a hyperlink is defined among media including a moving image, a still image, audio, and text, and which allows mutual or one-way reference. For example, HTML home pages which can be viewed through the Internet include text and still images, for which links are defined everywhere. Designating the link allows related information of link-destination to be immediately displayed. Since related information can be accessed by directly indicating a word or a phrase of interest, it is easy and intuitive to operate.
[0004] On the other hand, in hypermedia for video, not for text and still images, links are defined from people and objects in video to related contents including text and still images for describing them. Accordingly, when the viewers indicate the objects, the related contents are displayed. In this case, it becomes necessary to provide data (object-area data) indicating a spatiotemporal area of the object in the video.
[0005] For the object-area data, it is possible to use methods of describing a binary or more mask image sequence, arbitrary shape coding by MPEG-4 (ISO/IEC 14496), and describing the locus of the feature of a figure, which is described in JP-A-11-20387.
[0006] In order to achieve the video hypermedia, in addition to those, it becomes necessary to provide data (script data) that describes an action of displaying related contents when an object is indicated, contents data to be displayed and so on. These data are called metadata in contrast to video.
[0007] For the viewers to enjoy video hypermedia, for example, it is desirable to provide video CDs and DVDs in which both the video and the metadata are recorded. Also, the use of streaming distribution through a network such as the Internet allows the viewers to view video hypermedia by receiving both of the video and the metadata.
[0008] However, since already-owned video CDs and DVDs have no metadata, the viewers cannot enjoy hypermedia with such videos. One of methods for enjoying video hypermedia with the video CDs and DVDs having no metadata is to newly produce metadata for the videos and to distribute them to the viewers.
[0009] The metadata may be distributed while being recorded in CDS, flexible discs, DVDs and so on; however, it is most convenient to distribute the metadata through a network. When the viewers can access the network, they can easily download the metadata at home, which allows the viewers to view video CDs and DVDS that could only be played back previously as hypermedia and to view their related information.
[0010] However, when only the metadata is downloaded through a network, the viewers must wait to play back the video until the completion of downloading when the metadata is large in volume. In order to play back the video without a wait, there is a method of receiving video data and metadata by streaming distribution. However, videos that can be sent by streaming distribution have low image quality, and high-quality videos in the video CDs and DVDs in viewer's possession cannot be well utilized.
[0011] As described above, in order to enjoy video hypermedia by combining videos in possession and metadata on a network, the videos in viewer's possession must be utilized and also the viewer's waiting time for downloading the metadata must be eliminated.
BRIEF SUMMARY OF THE INVENTION
[0012] Accordingly, it is an object of the present invention to provide devices and a system for eliminating viewer's waiting time for downloading metadata when viewers enjoy hyper media by combining videos in viewer's possession and metadata on a network.
[0013] According to embodiments of the present invention, a client device is provided which is capable of accessing a. hypermedia-data server device through a network. The client device includes a playback unit to play back a moving image; a time-stamp transmission unit to transmit the time stamp of the image in playback mode to the server device; a metadata receiving unit to receive metadata having information related to the contents of the image at each time stamp from the server device by streaming distribution in synchronization with the playback of the moving image; and a controller to display the received metadata or performing control on the basis of the metadata in synchronization with the playback of the image.
[0014] According to embodiments of the present invention, a server device is provided which is capable of accessing a hypermedia-data client device through a network. The server device includes a metadata storage unit to store metadata having information related to the contents of an image corresponding to each time stamp of a moving image to be played back by the client device; a time-stamp receiving unit to receive the time stamp of the image to be played back, the time stamp being transmitted from the client device; and a metadata transmission unit to transmit the stored metadata to the client device by streaming distribution in synchronization with the playback of the image in accordance with the received time stamp.
[0015] According to embodiments of the present invention, a method for playing back a moving image in a client device is provided which is capable of accessing a hypermedia-data server device through a network. The method includes a playback step of playing back the moving image; a time-stamp transmission step of transmitting the time stamp of the image in playback mode to the server device; a metadata receiving step of receiving metadata having information related to the contents of the image at each time stamp from the server device by streaming distribution in synchronization with the playback of the moving image; and a control step of displaying the received metadata or performing control on the basis of the metadata in synchronization with the playback of the image.
[0016] According to embodiments of the present invention, a method for transmitting data in a server device is provided which is capable of accessing a hypermedia-data client device through a network. The method includes a time-stamp receiving step of receiving the time stamp of an image to be played back, the time stamp being transmitted from the client device; and a metadata transmission step of transmitting metadata having information related to the contents of an image corresponding to each time stamp of a moving image to be played back by the client device to the client device by streaming distribution in synchronization with the playback of the image on the basis of the received time stamp.
[0017] According to embodiments of the present invention, even videos in viewer's possession can receive new metadata through a network. Therefore, the viewer can enjoy it as video hypermedia.
[0018] The viewer receives metadata by streaming distribution through a network in synchronization with the playback of the video. Accordingly, there is no need for the viewer to wait for the playback of the video unlike when downloading the metadata.
[0019] Furthermore, since videos in viewer's possession are used, high-quality images can be enjoyed as compared with images by streaming distribution for each video.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a block diagram showing the structure of a hypermedia system according to an embodiment of the present invention;
[0021] [0021]FIG. 2 is a diagram showing an example of the structure of object data according to an embodiment of the invention;
[0022] [0022]FIG. 3 is a diagram showing an example of the screen display of a hypermedia system according to an embodiment of the invention;
[0023] [0023]FIG. 4 is a diagram of an example of server-client communication according to an embodiment of the invention;
[0024] [0024]FIG. 5 is a flowchart of the process of determining the scheduling of metadata transmission according to an embodiment of the invention;
[0025] [0025]FIG. 6 is a diagram of an example of the process of packetizing object data according to an embodiment of the invention;
[0026] [0026]FIG. 7 is a diagram of an example of the structure of packet data according to an embodiment of the invention;
[0027] [0027]FIG. 8 is a diagram of another process of packetizing object data according to an embodiment of the invention;
[0028] [0028]FIG. 9 is a diagram of an example of sorting a metadata packet according to an embodiment of the invention;
[0029] [0029]FIG. 10 is a flowchart of the process of determining the timing of packet transmission according to an embodiment of the invention;
[0030] [0030]FIG. 11 is a diagram of an example of an access-point table of a packet according to an embodiment of the invention;
[0031] [0031]FIG. 12 is a flowchart for making an access-point table of a packet according to an embodiment of the invention;
[0032] [0032]FIG. 13 is a flowchart of another method of determining the position of starting the transmission of metadata by a streaming server when a jump command is sent from a streaming client to the streaming server, according to an embodiment of the invention;
[0033] [0033]FIG. 14 is a flowchart for starting metadata transmission when an access-point table for packets formed by the method of FIG. 13 is used, according to an embodiment of the invention; and
[0034] [0034]FIG. 15 is a diagram of an example of an object-data schedule table according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] An embodiment of the present invention will be described hereinafter with reference to the drawings.
[0036] (1) Structure of Hypermedia System
[0037] [0037]FIG. 1 is a block diagram showing the structure of a hypermedia system according to an embodiment of the present invention. The function of each component will be described with reference to the drawing.
[0038] Reference numeral 100 denotes a client device; numeral 101 denotes a server device; and numeral 102 denotes a network connecting the server device 101 and the client device 100 . Reference numerals 103 to 110 designate devices included in the client device 100 ; and numerals 111 and 112 indicate devices included in the server device 101 .
[0039] The client device 100 holds video data, and the server device 101 records metadata related to the video data. The server device 101 sends the metadata to the client device 100 through the network 102 by streaming distribution at the request from the client device 100 . The client device 100 processes the transmitted metadata to realize hypermedia together with local video data.
[0040] The word, streaming distribution, means that when audio and video images are distributed on the Internet, they are played back not after the user has completed to download the file but while the user are downloading it. Accordingly, even motion-video and audio data with large volume of data can be played back without a wait.
[0041] A video-data recording medium 103 , such as a DVD, a video CD, a video tape, a hard disk, and a semiconductor memory, holds digital or analog video data.
[0042] A video controller 104 controls the action of the video-data recording medium 103 . The video controller 104 issues an instruction to start and stop the reading of video data and to access a desired position in the video data.
[0043] A video decoder 105 decodes inputted video data to extract video pixel information when the video data recorded in the video-data recording medium 103 is digitally compressed.
[0044] A streaming client 106 receives the metadata transmitted from the server device 101 through the network 102 and sends it to a metadata decoder 107 in sequence. The streaming client 106 controls the communication with the server device 101 with reference to the time stamp of video in playback mode inputted from the video decoder 105 . Here, the word, time stamp, denotes the time of playback from the initial time when a head moving image is played back, which is also called video time.
[0045] The metadata decoder 107 processes the metadata inputted from the streaming client 106 . Specifically, the metadata decoder 107 produces image data to be displayed with reference to the time stamp of the video in playback mode inputted from the video decoder 105 , and outputs it to a renderer 108 , determines information to be displayed for the input through a user interface 110 by the user, or deletes metadata that has become unnecessary from a memory.
[0046] The renderer 108 draws the image inputted from the video decoder 105 onto a monitor 109 . To the renderer 108 , an image is inputted not only from the video decoder 105 but also from the metadata decoder 107 . The renderer 108 composes both the images and draws it on the monitor 109 .
[0047] Examples of the monitor 109 are displays capable of displaying moving images, such as a CRT display, a liquid crystal display, and a plasma display.
[0048] The user interface 110 is a pointing device for inputting coordinates on the displayed image, such as a mouse, a touch panel, and a keyboard.
[0049] The network 102 is a data communication network between the client device 100 and the server device 101 , such as a local-area network (LAN) and the Internet.
[0050] A streaming server 111 transmits metadata to the client device 100 through the network 102 . The streaming server 111 also draws up a schedule for metadata transmission so as to send data required by the streaming client 106 at a proper timing.
[0051] A metadata recording medium 112 , such as a hard disk, a semiconductor memory, a DVD, a video CD, and a video tape, holds metadata related to the video data recorded in the video-data recording medium 103 . The metadata includes object data, which will be described later.
[0052] The metadata used in the embodiment includes areas of people and objects in video, which are recorded in the video-data recording medium 103 , and actions when the objects are designated by the user. The information for each object is described in the metadata.
[0053] (2) Data Structure of Object Data
[0054] [0054]FIG. 2 shows the structure of one object of object data according to an embodiment of the invention.
[0055] An ID number 200 identifies an object. Different ID numbers are allocated to respective objects.
[0056] Object display information 201 gives a description of information about an image display related to the object. For example, the object display information 201 describes information on whether the outline of the object is to be displayed while being overlapped with the display of video in order to clearly express the object position to the user, whether the name of the object is to be displayed like a balloon near the object, what color is to be used for the outline and the balloon, and which character font is to be used. The data is described in JP-A-2002-183336.
[0057] Script data 202 describes what action should be taken when an object is designated by the user. When related information is displayed by clicking on an object, the script data 202 describes the address of the related information. The related information includes text or HTML pages, still images, and video.
[0058] Object-area data 203 is information for specifying in which area the object exists at any given time. For the data, a mask image train can be used which indicates an object area in each frame or field of video. More efficient method is MPEG-4 arbitrary shape coding (ISO/IEC 14496) in which a mask image train is compression-coded. When the object area may be approximated by a rectangle, an ellipse, or a polygon having a relatively small number of apexes, the method of Patent Document 1 can be used.
[0059] The ID number 200 , the object display information 201 , and the script data 202 may be omitted when unnecessary.
[0060] (3) Method for Realizing Hypermedia
[0061] A method for realizing hypermedia using object data will then be described.
[0062] Hypermedia is a system in which a connection called a hyperlink is defined among media including a moving image, a still image, audio, and text, and which allows mutual or one-way reference. Hypermedia realized by the present invention defines a hyperlink for an object area in a moving image, thus allowing reference to information related to the object.
[0063] The user points an object of interest with the user interface 110 during viewing a video recorded in the video-data recording medium 103 . For example, with a mouse, the user puts a mouse cursor on a displayed object for clicking. At that time, the positional coordinates of a clicked point on the image is sent to the metadata decoder 107 .
[0064] The metadata decoder 107 receives the positional coordinates sent from the user interface 110 , the time stamp of the video that is now displayed sent from the video decoder 105 , and object data sent from the streaming client 106 through the network 102 . The metadata decoder 107 then specifies an object indicated by the user using these information. For this purpose, the metadata decoder 107 first processes the object-area data 203 in the object data and produces an object area at the inputted time stamp. When object-area data is described by the MPEG-4 arbitrary shape coding, a frame corresponding to the time stamp is decoded, and when the object area is approximately expressed by a figure, a figure at the time stamp is specified. It is then determined whether the inputted coordinates exist within the object. In the case of the MPEG-4 arbitrary shape coding, it is sufficient to determine the pixel value at the coordinates. When the object area is approximately expressed by a figure, it can be determined by a simple operation whether or not the inputted coordinates exist within the object (for more detailed information, refer to Patent Document 1). Performing the process also for other object data in the metadata decoder 107 allows a determination on which object is pointed by the user or whether the object pointed by the user is out of the object area.
[0065] When an object pointed by the user is specified, the metadata decoder 107 allows an action described in the script data 202 of the object, such as displaying a designated HTML file and playing back a designated video. The HTML file and the video file may be ones sent from the server device 101 through the network 102 , or ones on the Internet.
[0066] To the metadata decoder 107 , metadata is successively inputted from the streaming client 106 . The metadata decoder 107 can start the process at a point of time when data sufficient to interpret the metadata has been prepared.
[0067] For example, the object data can be processed at a point of time when the object ID number 200 , the object display information 201 , the script data 202 , and part of the object-area data 203 have been prepared. The part of the object-area data 203 is, for example, one for decoding a head frame in the MPEG-4 arbitrary shape coding.
[0068] The metadata decoder 107 also deletes metadata that has become unnecessary. The object area data 203 in the object data describes the time during which a described object exists. When the time stamp sent from the video decoder 105 has exceeded the object existing time, the data on the object is deleted from the metadata decoder 107 to save a memory.
[0069] When contents to be displayed when an object is designated have been sent as metadata, the metadata decoder 107 extracts a file name included in the header of the contents data, records data following the header, and gives the file name.
[0070] When data of the same file is sent in sequence, arriving data is added to the previous data.
[0071] The contents file may also be deleted at the same time when object data that refers the contents file is deleted.
[0072] (4) Display Example of Hypermedia System
[0073] [0073]FIG. 3 shows a display example of a hypermedia system on the monitor 109 .
[0074] Reference numeral 300 denotes a video playback screen, and numeral 301 designates a mouse cursor.
[0075] Reference numeral 302 indicates an object area in a scene extracted from an object area described in object data. When the user moves the mouse cursor 301 to the object area 302 and clicks thereon, information 303 related to the clicked object is displayed.
[0076] The object area 302 may be displayed such that the user can view it, or alternatively, may not be displayed at all.
[0077] How to display it is described in the object display information 201 in the object data. The methods of display include a method of surrounding the object with a line and a method of changing the lightness and the color tone between the inside of the object and the other areas. When displaying the object area by such methods, the metadata decoder 107 produces an object area at the time according to the time stamp inputted from the video decoder 105 , from the object data. The metadata decoder 107 then sends the object area to the renderer 108 to display a composite video playback image.
[0078] (5) Method for Sending Metadata
[0079] A method for sending metadata in the server device 101 to the client device 100 through the network 102 will be now described.
[0080] [0080]FIG. 4 shows an example of a communication between the streaming server 111 of the server device 101 and the streaming client 106 of the client device 100 .
[0081] An instruction of playing back a video from the user is first transmitted to the video controller 104 .
[0082] The video controller 104 instructs the video-data recording medium 103 to play back the video and sends an instruction to play back the video, the time stamp of its starting position, and information for specifying video contents to be played back to the streaming client 106 . The video-contents specifying information includes a contents ID number and a file name recorded in the video.
[0083] Upon receiving the video-playback start command, the time stamp of the video-playback starting position, and the video-contents specifying information, the streaming client 106 sends reference time, the video-contents specifying information, and the specifications of the client device 100 to the server device 101 .
[0084] The reference time is calculated from the time stamp of the video-playback starting position, for example, which is obtained by subtracting a certain fixed time from the time stamp of the video-playback starting position. The specifications of the client device 100 include a communication protocol, a communication speed, and a client buffer size.
[0085] The streaming server 111 first refers to the video-contents specifying information to check if the metadata of the video to be played back by the client device 100 is recorded in the metadata recording medium 112 .
[0086] When the metadata has been recorded, the streaming server 111 sets a timer to the sent reference time and checks if the specifications of the client device 100 satisfies conditions for communication. When the conditions are satisfied, the streaming server 111 sends a confirmation signal to the streaming client 106 .
[0087] When the metadata of the video to be played back by the client device 100 is not recorded or the conditions are not satisfied, the streaming server 111 sends a signal indicating that there is no metadata or communication is unavailable to the streaming client 106 , thus communication is completed.
[0088] The timer in the server device 101 is a watch for the streaming server 111 to schedule the transmission of data, which is adjusted so as to synthesize with the time stamp of the video to be played back by the client device 100 .
[0089] The streaming client 106 then sends a playback command and the time stamp of a playback starting position to the streaming server 111 . Upon receiving them, the streaming server 111 specifies data that is necessary at the received time stamp from the metadata, and transmits packets including the metadata therefrom to the streaming client 106 in sequence.
[0090] The method for determining the position to start the transmission and the process of scheduling packet transmission will be specifically described later.
[0091] Even when the video controller 104 sends a video-playback start command to the streaming client 106 , video playback is not immediately started. This is for the purpose of waiting for the metadata necessary at the start of video playback to be accumulated in the metadata decoder 107 . When all the metadata necessary for starting video playback has been prepared, the streaming client 106 notifies the video controller 104 that the preparation has been finished, and the video controller. 104 then starts to playback the video.
[0092] The streaming client 106 periodically sends delay information to the streaming server 111 when receiving packets including metadata. The delay information indicates how long the timing at which the streaming client 106 receives the metadata is delayed from the time for playing back the video. On the contrary, it may be information that indicates how long the timing is fast. The streaming server 111 uses the information to advance the timing of transmitting the packets including the metadata when delayed, and on the other hand, to delay the timing when advanced.
[0093] The streaming client 106 also periodically transmits the reference time to the streaming server 111 when receiving packets including the metadata. The reference time at that time is the time stamp of a video in playback mode and is inputted from the video decoder 105 . The streaming server 111 sets the timer for receiving the reference time to synchronize with the video in playback mode in the client device 100 .
[0094] Finally, after the video has been play backed to the end or when the stop of the video playback is inputted from the user, a command to stop the video playback is sent from the video controller 104 to the streaming client 106 . Upon receiving the command, the streaming client 106 sends a stop command to the streaming server 111 . Upon receiving the stop command, the streaming server 111 finishes the data transmission. The transmission of all metadata sometimes finishes before the streaming client 106 sends the stop command. In such a case, the streaming server 111 sends a message to tell that the data transmission has been finished to the streaming client 106 , and thus the communication is finished.
[0095] In addition to the playback command and the stop command, which have already been described, the commands sent from the client device 100 to the server device 101 include a suspend command, a suspend release command, and a jump command. When a suspend command is issued from the user during the reception of metadata, the command is sent to the streaming server 111 . Upon receiving the command, the streaming server 111 suspends the transmission of metadata. When a suspend release command is issued from the user during the suspension, the streaming client 106 sends the suspend release command to the streaming server 111 . Upon receiving the command, the streaming server 111 restarts the suspended transmission of metadata.
[0096] The jump command is sent from the streaming client 106 to the streaming server 111 when the user instructs the video in playback mode to be played back from a position different from the current playback position. At the same time, the time stamp of a new video playback position is also sent together with the jump command. The streaming server 111 immediately sets the timer at the time stamp, specifies data necessary at the received time stamp from metadata, and successively transmits packets including metadata therefrom to the streaming client 106 .
[0097] (6) Method of How to Schedule Packet Transmission
[0098] Next, there will be described how the server device 101 schedules packet transmission including metadata.
[0099] [0099]FIG. 5 shows a flowchart of the process of metadata transmission by the streaming server 111 .
[0100] (6-1) Packetizing Metadata (step S 500 )
[0101] First, in step S 500 , metadata to be transmitted is divided into packets. Object data included in the metadata is packetized as shown in FIG. 6.
[0102] Referring to FIG. 6, reference numeral 600 represents object data for one object.
[0103] A header 601 and a payload 602 construct one packet.
[0104] The packet always has a fixed length, and the header 601 and the payload 602 also have a fixed length. The object data 600 is divided into parts of the same length as that of the payload 602 and inserted into the payloads 602 of the packets.
[0105] Because the length of the object data is not always a multiple of that of the payload 602 , the rearmost data of the object data is sometimes shorter than the payload. In such a case, dummy data 603 is inserted to the payload to produce a packet of the same length as other packets. When the object data is shorter than the payload, the object data is inserted in one packet.
[0106] [0106]FIG. 7 illustrates the structure of the packet more specifically.
[0107] Referring to FIG. 7, reference numeral 700 denotes an ID number. Packets produced from the same object data are assigned the same ID number.
[0108] A packet number 701 describes the ordinal number of the packet among the packets produced from the same object data.
[0109] A time stamp 702 describes the time at which data stored in the payload 602 becomes necessary. When the packet stores object data, the object-area data 203 includes object-existence time data. Therefore, object-appearance time extracted from the object-existence time data is described in the time stamp 702 .
[0110] When the object-area data 203 is partial data, even packets produced from the same object data may bear different time stamps. FIG. 8 shows the structure.
[0111] Referring to FIG. 8, reference numerals 800 to 802 indicate one object data and reference numerals 803 to 806 denote packets produced from the object data.
[0112] The partial data 800 includes the ID number 200 , the object display information 201 , and the script data 202 , and may also include part of the object-area data 203 .
[0113] The partial data 801 and 802 include only the object-area data 203 . Letting T 1 be object appearance time, the client device 100 needs the partial data 800 by the time T 1 . Therefore, the packets 803 and 804 including the partial data 800 are given the time stamp of T 1 .
[0114] On the other hand, among data included in the partial data 801 , letting T 2 be the time for data that is earliest required by the client device 100 , the time stamp of the packet 805 including the partial data 801 is T 2 .
[0115] While the packet 804 includes both the partial data 800 and 801 , the earlier time T 1 is used. Similarly, among data included in the partial data 802 , letting T 3 be the time for data that is earliest required by the client device 100 , the time stamp for the packet 806 including the partial data 802 is T 3 .
[0116] When the object-area data 203 is described by the MPEG-4 arbitrary shape coding, a different time stamp can be given for each interval between the frames by intra-frame coding (intra-video object plane: I-VOP).
[0117] When the object-area data 203 is described by the method of Patent Document 1, different time stamps can be given in units of the interpolating function of the apexes of a figure that indicating an object area.
[0118] When the script data 202 included in the object data describes that, when an object is designated by the user, other contents related to the object, such as an HTML file and a still image file are displayed, the related contents can be sent to the client device 100 as metadata. Here it is assumed that the contents data includes both header data describing the file name of the contents and data on the contents in themselves. In such a case, the contents data is packetized as well as the object data. The ID numbers 700 of packets produced from the same contents data are given the same ID number. The time stamp 702 describes the appearance time of a related object.
[0119] (6-2) Sorting (Step S 501 )
[0120] After the packetizing process in step S 500 has been finished, sorting is performed in step S 501 .
[0121] [0121]FIG. 9 shows an example of a packet-sorting process in order of time stamps.
[0122] Referring to FIG. 9, it is assumed that metadata includes N object data and M contents data.
[0123] Reference numeral 900 denotes object data and reference numeral 901 denotes contents data to be transmitted. Packets 902 produced from the data are sorted in order of the time stamp 702 in the packets 902 .
[0124] Here, the sorted packets that are made into a file are called a packet stream. The packets may be sorted after a metadata transmission command has been received from the client device 100 . For decreasing the amount of process, however, it is desired to produce the packet stream in advance.
[0125] (6-3) Transmitting (Step S 502 )
[0126] After the sorting process of step S 501 has been finished, a transmitting process is performed in step S 502 .
[0127] When a packet stream has been produced in advance in steps S 500 and S 501 , processes after the metadata transmission command has been received from the client device 100 may be started from step S 503 . FIG. 10 shows a flowchart of the detailed process of step S 503 .
[0128] In step S 1000 , it is determined whether a packet to be transmitted exists. When all the metadata required by the client device 100 has already been transmitted, there is no packet to be transmitted, and thus, the process is finished. On the other hand, when there is a packet to be transmitted, the process proceeds to step S 1001 .
[0129] In step S 1001 , among packets to be transmitted, a packet having the earliest time stamp is selected. Here, since the packet has already been sorted by the time stamp, it is sufficient to select a packet in sequence.
[0130] In step S 1002 , it is determined whether the selected packet should be immediately transmitted. Here, reference symbol TS denotes the time stamp of the packet; reference symbol T indicates the timer time of the server device 101 ; and reference symbol Lmax represents a maximum transmission-advance time, which indicates a limit of the transmission advance time when the packet is sent earlier than the time of the time stamp in the packet. The value may be determined in advance, or alternatively, may be calculated from a bit rate and a buffer size described in client specifications which is sent from the streaming client 106 . Alternatively, the value may be directly described in the client specifications. Reference symbol ΔT designates time that has passed from the timer time at which the immediately preceding packet is sent to the current timer time. Reference symbol Lmin denotes a minimum packet-transmission interval, which can be calculated from the bit rate and the buffer size described in the client specifications which is sent from the streaming client 106 . Only when both of two conditional expressions described in step S 1002 are satisfied, the process of S 1004 is performed. When one or both of the two conditional expressions are not satisfied, the process in step S 1004 must be performed after the process of step S 1003 .
[0131] The process of step S 1003 is a process of waiting the transmission of a packet until a packet in selection can be transmitted. Reference symbol MAX(a,b) denotes a larger one of a and b. Therefore, in step S 1003 , packet transmission is waited by the larger time out of TS-Lmax-T and Lmin-ΔT.
[0132] Finally, in step S 1004 , the packet in selection is transmitted, and the processes from step S 1000 are repeated again.
[0133] (7) Method for Determining Metadata-transmission Starting position by Streaming Server 111
[0134] A method will then be described by which a metadata-transmission starting position by the streaming server 111 is determined when a jump command is sent from the streaming client 106 to the streaming server 111 .
[0135] [0135]FIG. 11 shows an access-point table for packets used for the streaming server 111 to determine a transmission start packet.
[0136] The table is prepared in advance and recorded on the server device 101 . A column 1100 indicates access times and a column 1101 shows offset values corresponding to the access times on the left.
[0137] For example, when a jump to a time 0:01:05:00F is requested from the streaming client 106 , the streaming server 111 searches the access time train for the closest time after the jump destination time. The example in FIG. 11 shows a search result, time 0:01:06:21F. The streaming server 111 then refers to an offset value corresponding to the retrieved time.
[0138] In the example of FIG. 11, the offset value is 312 . The offset value indicates the ordinal number of a packet to be transmitted. Therefore, when a packet stream has been produced in advance, it is preferable to start to transmit the 312th packet in the packet stream.
[0139] The access point table for the packets is produced as in the flowchart of FIG. 12.
[0140] In step S 1200 , it is first determined on the ordinal number of the head packet of each object data and contents data in order of the time stamp after sorting. This can be performed in synchronization with the step S 501 in FIG. 5.
[0141] In step S 1201 , the orders of packets including the head packet in each object data and contents data are set to offset values, and are listed with the time stamps of the packets, thereby the table is produced. The table sometimes has different offset values corresponding to the same time stamp. Therefore, in step S 1202 , only a minimum offset value is left and other overlapping time stamps are deleted.
[0142] By the above processes, the access point table for the packets is produced. In the access point table, the packet in the table of offset values always corresponds to the head of the object data or the contents data. Therefore, starting the transmission by the streaming server 111 from the packet allows the client device 100 to obtain object data or contents data which is necessary at the video playback position.
[0143] (8) Another Method for Determining Metadata-transmission Starting Position by Streaming Server 111
[0144] Another method will be described by which a metadata-transmission starting position by the streaming server 111 is determined when a jump command is sent from the streaming client 106 to the streaming server 111 .
[0145] A packet access point table is first prepared by a method different from that in FIG. 12. FIG. 13 shows a flowchart of the procedure.
[0146] In step S 1300 , the orders (offset values) of all the packets that have been sorted in order of the time stamps and the time stamps of the packets are first listed to produce the table.
[0147] In step S 1301 , overlapping time stamps are deleted. More specifically, when the produced table includes an overlapping offset value at the same time stamp, only a minimum offset value is left and other overlapping time stamps and offset values are deleted.
[0148] In order to start metadata transmission using the access point table for packets thus produced, a method different from that of FIG. 12 must be used. The method will be described hereinafter.
[0149] [0149]FIG. 14 shows a flowchart for starting metadata transmission using the access-point table for packets produced by the method of FIG. 13.
[0150] In step S 1400 , among the object data, an object existing in the video at a playback start time required by the client device 100 is specified. For this purpose, an object scheduling table is referred. The table is prepared in advance and recorded in the client device 100 .
[0151] [0151]FIG. 15 shows an example of the object scheduling table.
[0152] Object ID numbers 1500 correspond to the object-data ID numbers 200 .
[0153] Start time 1501 describes the time when the object area in the object-area data 203 starts.
[0154] End time 1502 describes the time when the object area in the object-area data 203 ends.
[0155] An object file name 1503 specifies the file name of the object data.
[0156] The example of FIG. 15 shows that, for example, an object having an object ID number 000002 appears on the screen at time 0:00:19:00F and disappears at time 0:00:26:27F, and the data about the object is described in a file Girl- 1 .dat.
[0157] In step S 1400 , an object is selected which includes a playback start time required by the client device 100 between the start time and the end time on the object scheduling table.
[0158] In step S 1401 , the file name of the selected object is taken from the object scheduling table, from which object data other than the object-area data 203 is packetized and transmitted.
[0159] In step S 1402 , a transmission start packet is determined. In the process, among the sorted packets, a transmission start packet is determined with reference to the access point table for packets produced by the process of FIG. 13.
[0160] Finally, in step S 1403 , packets are transmitted from the transmission start packet in sequence.
[0161] On the packet access point table produced by the procedure of FIG. 13, the packet indicated by the offset value does not always correspond to the head of the object data. Accordingly, when the transmission is started from a packet designated by the offset value, important information such as the ID number 200 and the script data 202 in the object data is omitted. In order to prevent the omission, only the important information in the object data is first transmitted, and other packets are then transmitted in order of designation by the offset values on the packet access point table.
[0162] [Modification]
[0163] Although object data and contents data are used as metadata in the above description, other metadata can be processed such that the metadata is sent from the server device 101 to the client device 100 and it is processed in synchronization with the playback of video or audio contents held in the client device 100 .
[0164] For example, the invention can be applied to all metadata in which different contents are described for each time, such as video contents or audio contents. | In order to eliminate viewer's waiting time for downloading metadata on a network when enjoying hypermedia by combining videos in viewer's possession and the metadata, a client device holds video data, metadata related to the video data is recorded in a server device; the server device sends the metadata to the client device through the network at the request from the client device; and the client device processes the sent metadata, thus realizing hypermedia together with local video data. | 7 |
[0001] This application claims priority from German patent application serial no. 10 2016 200 992.3 filed Jan. 25, 2016.
FIELD OF THE INVENTION
[0002] The invention concerns a power-split transmission device for a vehicle and a method for operating such a transmission device, such that the transmission device can in particular be used in a mobile working machine.
BACKGROUND OF THE INVENTION
[0003] Vehicle drive-trains of mobile working machines, in particular wheel loaders, are more and more often built with continuously variable power-split transmission devices which are made with a variator, a reversing transmission and range clutches. In the area of the reversing transmission spur gear stages or planetary gearsets are usually provided, such that the travel direction of the working machine is determined by the corresponding engagement of disk clutches. Driving ranges, within which a transmission ratio of the power-split transmission can be varied continuously by means of the variator, are obtained by coupled planetary gearsets or spur gear stages. To obtain driving range changes, as a rule disk clutches are used as the shifting elements. Furthermore, the variator is often designed as a hydrostatic transmission with hydrostatic units that can in each case be operated as a pump or a motor in combination with a power-splitting arrangement.
[0004] When the transmission ratio of the power-split transmission device is adjusted, for example starting from small transmission ratios toward larger transmission ratios, in each case one or more driving ranges are respectively passed through in part or totally, and for this the hydrostatic unit has to be swiveled several times over the complete driving range. For example, if two driving ranges which have to be completely passed through are considered, then around 0.5 to 1.0 seconds are needed for passing through the driving ranges and a further 150 to 200 ms are needed for the necessary driving range change, so that in total approximately 0.65 to 1.2 seconds pass by until a maximum transmission ratio is produced in the area of the transmission device. When a wheel loader drives onto a pile or heap, the load imposed from outside increases, in particular the deceleration, in less than 0.2 seconds. The control speed or speed of change of the transmission ratio in the area of the transmission device is therefore, disadvantageously, too low to avoid unacceptable decelerations of the rotational speed of a drive engine when driving onto a heap. Owing to the high control speeds of the hydrostatic unit required in combination with the unavoidable dead time associated with a driving range change, new methods are needed in order to satisfy the strict requirements for dynamics and for the protection of the engine and the transmission.
[0005] For example, DE 10 2013 222 693 A1 discloses a method for operating a vehicle drive-train with a drive engine and a power-split transmission device that can be brought, on the input side, into functional connection with the drive engine, which on its output side can be connected to a drive output, and whose transmission ratio in the area of a variator can be varied continuously, and with a shifting element which is arranged in the power flow of the vehicle drive-train between the drive engine and the drive output and whose transmission capacity can be varied continuously. The transmission capacity of the shifting element is varied as a function of the torque to be transmitted at the time in the drive-train between the drive engine and the drive output, and if the torque applied is greater than a defined threshold value, the shifting element changes to slipping operation.
SUMMARY OF THE INVENTION
[0006] The purpose of the present invention is to provide a power-split transmission device and a method for operating the transmission device, which show greater deceleration dynamics in order to protect the transmission device and the drive engine in unfavorable operating situations.
[0007] This objective is achieved by the transmission device and method for operating the same as described below.
[0008] According to the invention, the power-split transmission device for a vehicle is provided in order to connect a drive engine arranged on its input side to a drive output arranged on its output side. The transmission device comprises a hydrostatic unit for the continuous adjustment of a transmission ratio and at least one range clutch for coupling the transmission device to the drive output, wherein the transmission device is designed to be operated with a first and a second deceleration logic such that the second deceleration logic has a higher deceleration dynamic than the first deceleration logic, and wherein the second deceleration logic is provided in order to immediately open a closed range clutch so as to reduce the transmission ratio by means of the hydrostatic unit with maximum dynamic.
[0009] Preferably, the transmission ratio of the hydrostatic unit is displaced toward zero transmission ratio with maximum gradient regardless of the driving range at the time. In particular the drive engine is an internal combustion engine, preferably a Diesel engine and serves to propel the vehicle. The transmission ratio of the transmission device is adjusted by active displacement of the hydrostatic unit. In particular, for this a yoke of the hydrostatic unit is moved between a zero position and a maximum deflection. Moreover, the at least one range clutch is provided in order to couple a driving range of the hydrostatic unit, within which the transmission ratio can be varied continuously, to the drive output. Furthermore, it is conceivable for the transmission device to have a plurality of range clutches, each range clutch being provided in order to couple a respective driving range to the drive output.
[0010] The first deceleration logic represents essentially a normal operating condition of the transmission device. During normal operation when the vehicle decelerates, for example when it is braked from a high speed down to rest, all the driving ranges are passed through. Thus, depending on the number of driving ranges, a plurality of driving range changes are carried out. An actual reciprocal transmission ratio follows a nominal transmission ratio set by the hydrostatic device. By definition the actual reciprocal transmission ratio is equal to the quotient of the drive output rotational speed and the drive input rotational speed of the transmission device.
[0011] In contrast, the second deceleration logic represents an emergency shift of the transmission device provided in order to protect the transmission device and the drive engine. During the second deceleration logic the nominal transmission ratio follows the actual reciprocal transmission ratio. In particular, the second deceleration logic is activated for highly dynamic driving movements of the vehicle. A highly dynamic driving movement is understood to mean, for example, when a wheel loader climbs up a solid heap at speed. In such a case a high deceleration dynamic occurs whose result is that the nominal transmission ratio cannot follow the actual reciprocal transmission ratio. The second deceleration logic has higher deceleration dynamics than the first deceleration logic. When the second deceleration logic is activated a closed range clutch is opened immediately. This separates the transmission device and the drive engine from the drive output. Moreover, this makes it possible for the nominal transmission ratio to be reduced by means of the hydrostatic unit with the maximum dynamics. Thus, the various driving ranges are no longer passed through. Maximum dynamics is understood to mean that a maximum nominal transmission ratio gradient is used. This makes it possible for the nominal transmission ratio to follow the reciprocal transmission ratio.
[0012] According to a preferred embodiment, three range clutches are provided in order to obtain three driving ranges, such that in each driving range the transmission ratio can be adjusted continuously by means of the hydrostatic unit. To accelerate the vehicle, the first range clutch is closed and the nominal transmission ratio is adjusted by means of the hydrostatic unit to the synchronous transmission ratio for the driving range change. During the driving range change from the first driving range to the second driving range the first and second range clutches are synchronized with one another, and the second range clutch is closed while the first range clutch is opened. As soon as the driving range change has been completed, the nominal transmission ratio in the second driving range is adjusted by means of the hydrostatic unit to the synchronous transmission ratio for the next driving range change. During the driving range change from the second to the third driving range, the second and third range clutches are synchronized with one another and the third range clutch is closed while the second range clutch is opened. As soon as this driving range change has been completed, the nominal transmission ratio in the third driving range is adjusted by means of the hydrostatic unit. During deceleration, in particular when braking the vehicle from the third driving range down to rest, the three driving ranges are passed through in the reverse sequence.
[0013] The method according to the invention for operating the above-mentioned power-split transmission device comprises essentially the following process steps: monitoring of various vehicle parameters while the vehicle is operated with a first deceleration logic, detection that while the vehicle is being operated with the first deceleration logic at least one established limit value has been exceeded, activation of the second deceleration logic whereby a closed range clutch is opened immediately, maximum reduction of a transmission ratio by means of the hydrostatic unit, wherein the hydrostatic unit is displaced with a maximum dynamic, and closing the range clutch and activation of the first deceleration logic. Thus, the second deceleration logic is activated as soon as it is seen from the vehicle parameters monitored that the deceleration dynamics of the first deceleration logic no longer suffice for the nominal transmission ratio to be adapted to the actual reciprocal transmission ratio. To assess when the deceleration dynamics of the first deceleration logic are no longer sufficient, limit values for various vehicle parameters are defined. These vehicle parameters are monitored and if at least one established limit value is exceeded, the second deceleration logic is activated. In other words, the exceeding of at least one established limit value serves as the triggering condition for activating the second deceleration logic.
[0014] Below, preferred triggering conditions for activating the second deceleration logic are described. Preferably, the second deceleration logic is activated when at least one triggering condition has been fulfilled. According to a further preferred embodiment, the second deceleration logic is activated when all the triggering conditions have been fulfilled. It is conceivable, moreover, to weight the various triggering conditions to different extents. In particular, it is envisaged that several more highly weighted triggering conditions bring about the activation of the second deceleration logic. Advantageously the activation of the second deceleration logic can be countermanded in some circumstances, particularly when information about a lifting frame or scoop position of the vehicle is known.
[0015] Preferably, the second deceleration logic is activated when at least one actual drive output rotational speed gradient is smaller than a fixed limit value. The actual drive output rotational speed gradient is in particular a measure of the deceleration of the vehicle and describes how quickly the drive output rotational speed is changing and especially how quickly the vehicle is decelerating.
[0016] Preferably, the second deceleration logic is activated when at least one high pressure in the transmission device is higher than an established limit value. The high pressure in the transmission device is a measure for the loading of the hydrostatic unit and must not exceed a maximum limit value in order not to compromise the function of the hydrostatic unit. If the high pressure in the transmission device is above a transmission-damaging maximum pressure for a certain time, an emergency shift is triggered. Thus, the triggering condition is a maximum operating time above the transmission-damaging maximum pressure. For this, when the maximum pressure is exceeded a count value is incremented. When the high pressure falls below the maximum pressure, the count is decremented. If the maximum operating time is reached, the second deceleration logic is activated.
[0017] Preferably, the second deceleration logic is activated when at least an engine rotational speed and/or an engine rotational speed gradient is smaller than an established limit value. The drive engine is operated at an engine rotational speed that is within an acceptable range. A reduction of the engine rotational speed below the acceptable range can result in stalling of the engine or, in the worst case, to engine damage. Moreover, the engine rotational speed gradient describes how quickly the engine rotational speed is changing. Preferably, the second deceleration logic is activated when at least a reduction of the engine rotational speed is larger than an established limit value.
[0018] Preferably, the second deceleration logic is activated when at least a load on the drive engine is greater than an established limit value. The loading of the drive engine is preferably expressed as a percentage.
[0019] Preferably, the second deceleration logic is activated when at least a nominal reciprocal transmission ratio gradient is smaller than an established limit value. Thus, the second deceleration logic is activated in order to increase the nominal reciprocal transmission ratio gradient. This makes it possible for the nominal reciprocal transmission ratio to follow the actual reciprocal transmission ratio.
[0020] Preferably, when the second deceleration logic is activated the range clutch is reduced to a filling equalization pressure, in order thereafter, from that pressure level, to begin a torque-controlled engagement of the range clutch. In that way the range clutch operates without emptying completely, so that a torque can be built up more rapidly at the range clutch.
[0021] According to a preferred example embodiment, the range clutch is closed as soon as the actual reciprocal transmission ratio reaches a limit value. In particular, a zero position is defined as the limit value. Moreover, the limit value can also be larger than zero and then the range clutch is designed more efficiently.
[0022] In a further preferred example embodiment, a range clutch is closed as soon as a rotational speed difference reaches a limit value. The limit value of the rotational speed difference depends on the power of the range clutch. This, the range clutch can be closed even with a larger rotational speed difference if the range clutch is correspondingly more efficient and can perform the necessary shifting work and shifting power.
[0023] Preferably, the opening of the closed range clutch when the second deceleration logic is activated, is associated with an actuation of the brakes of the vehicle. When the second deceleration logic is activated, owing to the opening of the range clutch the drive-train is free, and the vehicle can therefore roll backward. To enable backward rolling and a more rapid closing of the range clutch, the activation of the second deceleration logic is associated with an actuation of the vehicle's brakes. In particular, the brakes are actuated below a certain drive output rotational speed. The brake of the vehicle can be both a holding brake and a service brake.
[0024] Preferably, conditions are also envisaged which allow activation of the first deceleration logic while the vehicle is being operated with the second deceleration logic. In particular, the first deceleration logic is activated again when the friction performance and/or the friction work at the range clutch exceeds a limit value. Furthermore, the first deceleration logic is activated again when a maximum time of operating with the second deceleration logic has been exceeded. Preferably, the maximum time for operating the vehicle with the second deceleration logic amounts to a few seconds. In addition, the first deceleration logic is activated again when, after a maximum operating time of the second deceleration logic, an actual drive output rotational speed has fallen to a certain value.
[0025] In particular, the power-split transmission device according to the invention can be used for providing drive power, and therefore in a mobile working machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Below, an example embodiment of the invention is described in more detail with reference to the drawings, in which the same or similar elements are provided with the same indexes and which show:
[0027] FIG. 1 : A very schematic block circuit representation of a vehicle drive-train comprising a power-split transmission device according to the invention with a hydrostatic device,
[0028] FIG. 2 : A diagram to illustrate a variation of a transmission ratio of the hydrostatic unit and an actual reciprocal transmission ratio that depends on it,
[0029] FIG. 3 : A diagram to illustrate a variation of a nominal reciprocal transmission ratio, the transmission ratio of the hydrostatic unit, and the actual reciprocal transmission ratio that depends on it, when the second deceleration logic is activated in a third driving range,
[0030] FIG. 4 : A diagram to illustrate a variation of a nominal reciprocal transmission ratio, the transmission ratio of the hydrostatic unit, and the actual reciprocal transmission ratio that depends on it, when the second deceleration logic is activated in a second driving range,
[0031] FIG. 5 : A diagram to illustrate a variation of a nominal reciprocal transmission ratio, the transmission ratio of the hydrostatic unit, and the actual reciprocal transmission ratio that depends on it, when the second deceleration logic is activated in a first driving range,
[0032] FIG. 6 : A diagram to illustrate a variation of the nominal reciprocal transmission ratio and the actual reciprocal transmission ratio when the second deceleration logic is activated, and
[0033] FIG. 7 : A diagram to illustrate the variation of the closing torque at a first range clutch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] As shown in FIG. 1 , a vehicle drive-train comprises a drive engine 2 and a continuously variable power-split transmission device 1 that can be coupled thereto. In this case the drive engine 2 is in the form of an internal combustion engine, but in other embodiments of the drive-train it can also be an electric machine or a combination of an internal combustion engine and an electric machine. On the transmission output side the transmission device 1 is in functional connection with a drive output 3 so that a drive torque produced by the drive engine 2 , converted in accordance with the transmission ratio set in the area of the transmission device 1 , is provided as the drive output torque in the form of a corresponding traction force. The transmission device 1 comprises a hydrostatic unit 4 for the continuous adjustment of the transmission ratio, three range clutches 5 a, 5 b, 5 c for coupling the transmission device 1 to the drive output 3 , and a reversing clutch 9 for enabling the vehicle to drive in the forward and in the reversing direction. Embodiments with only one range clutch 5 a, 5 b, 5 c are also conceivable. Usually, a clutch (not shown here) for forward driving and a clutch (also not shown) for driving in reverse are arranged in the reversing clutch. However, the reversing clutch can also be in the form of a dual shifting element, which means that for the respective actuation of the clutches for driving forward or in reverse a single, common actuator is operated. Furthermore, in the area between the drive engine 2 and the transmission device 1 , an auxiliary power take-off 6 in the form of a working hydraulic system can be acted upon by torque from the drive engine 2 ,. According to the invention, the transmission device 1 is designed to be operated with a first and a second deceleration logic such that the second deceleration logic has higher deceleration dynamics than the first deceleration logic. For this the second deceleration logic is designed so as to immediately open whichever range clutch 5 a, 5 b, 5 c is closed, in order to reduce the transmission ratio by means of the hydrostatic unit 4 with the maximum dynamic. During this the reversing clutch remains constantly dosed in the shifting position for forward driving.
[0035] According to FIGS. 2, 3, 4 and 5 , starting from a high transmission ratio the transmission device 1 is in each case adjusted in the direction toward lower transmission ratios. In the diagrams, time is plotted along the abscissa and the transmission ratio along the ordinate.
[0036] FIG. 2 shows how a transmission ratio 10 of the hydrostatic unit 4 is adjusted in the respective driving range 7 a, 7 b, 7 c in accordance with a first deceleration logic in order to reduce an actual reciprocal transmission ratio 11 . The transmission ratio 10 of the hydrostatic unit 4 is understood to be a nominal transmission ratio of the hydrostatic unit 4 , namely a desired transmission ratio of the hydrostatic unit 4 . By definition, the actual reciprocal transmission ratio 11 is equal to the quotient of a drive output rotational speed and a drive input rotational speed of the transmission device 1 , the drive output rotational speed and the drive input rotational speed preferably being measured by a sensor in each case. During any driving range change 8 a, 8 b the actual reciprocal transmission ratio 11 and the transmission ratio 10 of the hydrostatic unit 4 cannot be adjusted. In a third driving range 7 c the transmission ratio 10 of the hydrostatic unit 4 is adjusted from high transmission ratios, analogously to the actual reciprocal transmission ratio 11 , in the direction of a first synchronous point 13 a toward lower transmission ratios. In a first driving range change 8 a the third and second range clutches 5 c, 5 b are synchronized. The second range clutch 5 b is closed and the third range clutch 5 c is opened. The second driving range is activated. In the second driving range 7 b the actual reciprocal transmission ratio 11 decreases toward a second synchronous point 13 b, whereas the transmission ratio 10 of the hydrostatic unit 4 increases to higher values. In a second driving range change 8 b the second and first range clutches 5 b, 5 a are synchronized. The first range clutch 5 a is closed and the second range clutch 5 b is opened. The first driving range 7 a is activated. In the first driving range 7 a the transmission ratio 10 of the hydrostatic unit 4 is adjusted from a high transmission ratio, analogously to the actual reciprocal transmission ratio 11 , in the direction of the stationary point toward lower transmission ratios. The first deceleration logic is provided for normal deceleration operation, wherein the actual reciprocal transmission ratio 11 is set in accordance with the transmission ratio 10 of the hydrostatic unit 4 . Accordingly, the actual reciprocal transmission ratio 11 follows the transmission ratio 10 of the hydrostatic unit 4 .
[0037] When higher dynamics are required, in particular as regards the adjustment dynamics of the transmission ratio, the first deceleration logic comes up against its limits. In other words, in the event of an exceptional deceleration the transmission ratio cannot be adjusted quickly enough so the transmission ratio 10 of the hydrostatic unit 4 cannot follow the actual reciprocal transmission ratio 11 . As a result, either the rotational speed of the drive engine 2 is reduced too much or a high pressure in the hydrostatic unit 4 reaches unacceptably high values which can damage the transmission device 1 . According to the invention, it is then proposed to operate the transmission device 1 with a second deceleration logic having higher deceleration dynamics than the first deceleration logic.
[0038] FIG. 3 shows how, when the second deceleration logic has been activated in the third driving range 7 c, the transmission ratio 10 is adjusted in order to obtain a desired nominal reciprocal transmission ratio 15 which substantially matches the actual reciprocal transmission ratio 11 . When the second deceleration logic is activated the third, closed range clutch 5 c is opened immediately so that the stress on the drive engine 2 and the transmission device 1 is reduced. The reversing clutch 9 remains closed. During a waiting period 12 , the transmission ratio 10 of the hydrostatic unit 4 is adjusted with the existing nominal dynamic until the second range clutch 5 b is fully open so that the second range clutch 5 b no longer transmits any torque. After the end of the waiting period 12 , the transmission ratio 10 of the hydrostatic unit 4 is adjusted directly to the zero position with the maximum dynamic. Thereafter, the first range clutch 5 a is engaged and the first driving range 7 a is activated, so that there is no traction force interruption.
[0039] FIG. 4 shows how, when the second deceleration logic in the second drive range 7 b has been activated, the transmission ratio 10 of the hydrostatic unit 4 is adjusted in order to obtain the desired nominal reciprocal transmission ratio 15 in such manner that it substantially matches the actual reciprocal transmission ratio 11 . When the second deceleration logic is activated the second, closed range clutch 5 b is opened immediately, such so that the load on the drive engine 2 and the transmission device 1 is reduced. The reversing clutch 9 remains closed. During a waiting period 12 , the transmission ratio 10 of the hydrostatic unit 4 is not adjusted, but is unchanged, since here a normal adjustment would be accompanied by an increase in the transmission ratio 10 of the hydrostatic unit 4 in the direction of the second synchronous point 13 b during the deceleration. After the end of the waiting period 12 , the transmission ratio 10 of the hydrostatic unit 4 is adjusted directly to the zero position with the maximum dynamic. The first range clutch 5 a is then engaged and the first drive range 7 a is activated such that no or only a small interruption of the traction force take place.
[0040] FIG. 5 shows how, when the second deceleration logic in the first drive range 7 a has been activated, the transmission ratio 10 of the hydrostatic unit 4 is adjusted in order to obtain the desired nominal reciprocal transmission ratio 15 in such manner that it substantially matches the actual reciprocal transmission ratio 11 . This adjustment of the transmission ratio 10 of the hydrostatic unit 4 is identical to the adjustment of the transmission ratio 10 of the hydrostatic unit 4 in the third drive range 7 c according to FIG. 3 . When the second deceleration logic is activated the first, closed range clutch 5 a is opened immediately. The reversing clutch 9 remains closed. During a waiting period 12 , the transmission ratio 10 of the hydrostatic unit 4 is adjusted with the existing nominal dynamic. After the end of the waiting period 12 , the transmission ratio 10 of the hydrostatic unit 4 is adjusted directly to the zero position with the maximum dynamic. The first range clutch 5 a is then engaged again.
[0041] FIG. 6 is a diagram showing the respective variations of the nominal transmission ratio 10 and the actual transmission ratio of the hydrostatic unit 4 , with time plotted along the abscissa and transmission ratio along the ordinate. The actual transmission ratio of the hydrostatic unit 4 represents a real variation of the transmission ratio, whereas the nominal transmission ratio 10 of the hydrostatic unit 4 is a desired variation of the transmission ratio of the hydrostatic unit 4 . When the second deceleration logic has been activated the transmission ratio of the hydrostatic unit 4 is adjusted in the direction toward zero. This return is carried out with the gradient 16 a as far as a threshold value 17 a. Thereafter, a yoke of the hydrostatic unit 4 —not shown here—is readjusted as a function of the actual transmission ratio of the hydrostatic unit 4 . During this readjustment of the actual transmission ratio of the hydrostatic unit 4 , the nominal transmission ratio of the hydrostatic unit 4 is adjusted with a second gradient 16 b, which is smaller than the first gradient 16 a, in order to achieve smooth regulation. FIG. 6 describes the case in which after passing through zero the vehicle rolls slightly backward. In that case the nominal transmission ratio below the zero position is set to the lowest threshold value 17 b. In other words, the hydrostatic unit 4 overshoots. This reduces a rotational speed difference when the first range clutch 5 a is engaged.
[0042] FIG. 7 is a diagram showing a variation of a closing torque of the first range clutch 5 a, wherein time is plotted along the abscissa and closing torque along the ordinate. When the second deceleration logic has been activated and the closed range clutch 5 a, 5 b, 5 c concerned has been opened, the first range clutch 5 a is engaged. This engagement of the first range clutch 5 a follows an exactly defined, torque-controlled process. The loading limits of the first range clutch 5 a in relation to friction performance and friction work must not be exceeded. Due to the starting by means of the first range clutch 5 a, traction force is quickly built up again in the forward direction. To begin with, an initial first closing torque 18 a is applied at the first range clutch 5 a. Starting from that closing torque 18 a, the torque is increased during a time interval as far as a second closing torque 18 b, whereby the first range clutch 5 a produces a frictional connection between the transmission device 1 and the drive output 3 . The second closing torque 18 b is chosen such that a predetermined friction performance is not exceeded, but at the same time sufficient closing torque is built up to stop the vehicle from rolling backward and bring it to rest. After a minimum time interval 19 , the first range clutch 5 a is closed in that the closing torque is increased to a third closing torque 18 c by way of a maximum gradient. However, this only takes place if after the lapse of the minimum time interval 19 a predefined maximum rotational speed difference of the clutch is not exceeded. If the rotational speed difference at the clutch is exceeded, the torque is maintained until the rotational speed difference falls below the predefined maximum rotational speed difference of the clutch and only then is the clutch closed completely. Accordingly the range clutch 5 a is closed, whereby the first deceleration logic is activated again.
Indexes
[0000]
1 Transmission device
2 Drive engine
3 Drive output
4 Hydrostatic unit
5 a to 5 c Range clutch
6 Auxiliary power take-off
7 a to 7 c Driving range
8 a, 8 b Driving range change
9 Reversing clutch
10 Nominal transmission ratio
11 Actual reciprocal transmission ratio
12 Waiting time
13 a, 13 b Synchronous point
14 Actual transmission ratio
15 Nominal reciprocal transmission ratio
16 a, 16 b Gradient
17 a, 17 b Threshold value
18 a to 18 c Closing torque
19 Minimum time interval | A power-split transmission which is designed to be operated with either first or second deceleration logics. The second deceleration logic has a higher deceleration dynamic than the first deceleration logic, and is designed to disengage an engaged range clutch immediately so as to reduce the transmission ratio by way of a hydrostatic unit with a maximum dynamic. A method of operating the transmission includes: monitoring various vehicle parameters while the vehicle is operated with the first deceleration logic; detecting that at least one set limit value has been exceeded while the vehicle operated with the first deceleration logic; activating the second deceleration logic, to immediately disengage an engaged range clutch; reducing a transmission ratio to a maximum using the hydrostatic unit, the hydrostatic unit being displaced with a maximum dynamic; and engaging the range clutch and activating the first deceleration logic. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates to device emulation, and more particularly to dynamically changing device descriptors of a USB device from a host to emulate a new device using a simple hardware emulator.
BACKGROUND OF THE INVENTION
[0002] There are circumstances in which it would be useful to have a device emulate or simulate behavior and operations of another device. One such situation is for testing of a new and yet unavailable target device under development, such as printers, MFPs, peripherals, digital cameras, etc. The number of these new devices being developed is constantly increasing, and demands shorter and more efficient development and testing cycles. If an existing device can be made to emulate a target device, then installation and other testing can begin without waiting for completion of the target device. The present invention arose out of the above perceived needs and concerns associated with device emulation. The present invention proposes a method by which a host recognizes a device as a different, target device.
SUMMARY OF THE INVENTION
[0003] Methods, computer program products, computing and printing systems for changing USB device descriptors from host to emulate a new device are described. The methods enable dynamically changing device descriptors of a USB device from a host to emulate a new device using a simple hardware emulator.
[0004] The method for changing operation of a device comprises of: sending target device descriptors to the device's device emulator, which processes and stores the descriptors as the current descriptors in memory, and the device emulator responding to a query from a host simulating operation of the target device.
[0005] The methods also include USB device enumeration, making a print job containing extended PJL commands and sending it using a generic device driver, emulator firmware analyzing and storing the descriptors in registers, sending a line reset command to simulate device detachment and reattachment, and meeting timing requirements of USB detached and attached states.
[0006] The invention will be more fully understood upon consideration of the detailed description below, taken together with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a simplified block diagram showing connection of a computing system to a printer, in accordance with a preferred embodiment of the present invention.
[0008] FIG. 2 is a block diagram showing a host device and the connected device containing a hardware device emulator, in accordance with a preferred embodiment of the present invention.
[0009] FIG. 3 is a block diagram showing the components of a hardware device emulator, in accordance with a preferred embodiment of the present invention.
[0010] FIG. 4 is a flowchart showing the processing steps for sending device descriptors using PJL commands, and simulating a line reset, in accordance with a preferred embodiment of the present invention.
[0011] FIG. 5 shows some sample extended PJL commands specifying target device descriptors, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one of ordinary skill in the art that these specific details need not be used to practice the present invention. In other instances, well known structures, interfaces, and processes have not been shown in detail in order not to unnecessarily obscure the present invention.
[0013] FIG. 1 is a simplified block diagram showing connection of a computing system to a printer, in accordance with a preferred embodiment of the present invention. FIG. 1 shows a general printing system setup 100 that includes a host computer 110 and a printer 150 . Here, the printer 150 may be any device that can act as a printer, e.g. an inkjet printer, a laser printer, a photo printer, or an MFP (Multifunction Peripheral or Multi-Functional Peripheral) that may incorporate additional functions such as faxing, facsimile transmission, scanning, and copying.
[0014] The host computer 110 includes an application 120 and a printer driver 130 . The application 120 refers to any computer program that is capable of issuing any type of request, either directly or indirectly, to print information. Examples of an application include, but are not limited to, commonly used programs such as word processors, spreadsheets, browsers and imaging programs. Since the invention is not platform or machine specific, other examples of application 120 include any program written for any device, including personal computers, network appliance, handheld computer, personal digital assistant, handheld or multimedia devices that is capable of printing.
[0015] The printer driver 130 is a software interfacing with the application 120 and the printer 150 . Printer drivers are generally known. They enable a processor, such as a personal computer, to configure an output data from an application that will be recognized and acted upon by a connected printer. The output data stream implements necessary synchronizing actions required to enable interaction between the processor and the connected printer. For a processor, such as a personal computer, to operate correctly, it requires an operating system such as DOS (Disk Operating System) Windows, Unix, Linux, Palm OS, or Apple OS.
[0016] A printer I/O (Input/Output) interface connection 140 is provided and permits host computer 110 to communicate with a printer 150 . Printer 150 is configured to receive print commands from the host computer and, responsive thereto, render a printed media. Various exemplary printers include laser printers that are sold by the assignee of this invention. The connection 140 from the host computer 110 to the printer 150 may be a traditional printer cable through a parallel interface connection or any other method of connecting a computer to a printer used in the art, e.g., a serial interface connection, a remote network connection, a wireless connection, or an infrared connection. The varieties of processors, printing systems, and connection between them are well known.
[0017] The present invention is suited for printer drivers, and it is also suited for other device drivers. The above explanations regarding FIG. 1 used a printer driver rather than a general device driver for concreteness of the explanations, but they also apply to other device drivers. Similarly, the following descriptions of the preferred embodiments generally use examples pertaining to printer driver, but they are to be understood as similarly applicable to other kinds of device drivers.
[0018] FIG. 2 is a block diagram showing a host device and the connected device containing a hardware device emulator, in accordance with a preferred embodiment of the present invention. The invention is composed of four main components. The hardware emulator 210 emulates the target hardware. The firmware 220 runs in the device emulator. A generic device driver 230 enables communication on the device emulator to set up the required hardware descriptors and emulate the target hardware. The host device 240 performs the installation and set-up of the device emulator. This host device will effectively test the device driver.
[0019] The host device 240 will contain the device driver, a low level USB Driver 242 and the USB Host Port 241 . The low level USB driver 242 is usually packaged with the host system. The USB Host Port 241 monitors for any new device attachment on the USB lines. Once an attachment is detected it will notify the host device using the low level USB drivers of the host system. This will result in the host performing the enumeration on the device to select the correct device driver by the user or the host system. The host will then load the selected device driver using the configuration received from the descriptors.
[0020] In any computer based systems found in homes and offices there is a prevalence of peripheral devices that perform the functionality of various standard office functions. Printers, scanners, fax and human interfaces devices are increasingly seen as essential components and have emerged as de-facto standard of such systems. As more and more homes and offices are acquiring such systems, the trend of such devices is focusing on bundled equipment known as multi-functional products (or peripherals).
[0021] Competition on these peripheral devices has prompted most design companies to do parallel development of hardware and software components of these products. Demand for such peripheral devices mandates the use of the Universal Serial Bus (USB) support due to the ease of integration of these devices into existing systems and USB being an accepted standard on device interfaces. However, parallel development of hardware and software components has its benefits and drawbacks. Product development time is indeed improved but new bottlenecks emerge and challenge the project schedules. For example, while the actual hardware device is still in development, some software components that are finished ahead of the hardware are pended until the hardware component becomes available. This imposes delays on testing of components due to unavailability of required modules.
[0022] Components such as the plug and play functionality of the drivers, an important feature of the USB protocol, can actually proceed with testing if a device can be available that emulates the actual target hardware. This device emulator would be useful even if it is limited only to the installation part of the software driver intended for the target hardware device. From the USB interface point of view, testing of the software components that are responsible for the configuration and setting up of the device can be carried out. The software components responsible in carrying out the actual functionality intended for the device will have to wait until the actual device is available.
[0023] From the above concerns and discussion, the need to implement some form of device emulator to enable the development of the components (especially for the device driver) of the peripheral devices to proceed is essential. By taking advantage of the USB protocol specifications, the device emulator can be built to serve as a test jig for the installation and set up of such devices. Installation and set up of these devices is done during the configuration and set-up protocol of the USB device. If the device emulator meets all the requirements for the device configuration and set up, the host will be made to believe that the device emulator is the actual device with all the functionality ready for the user. In other words, a USB device can still be seen by the USB host controller as a fully operational device during initialization as long as the USB device gives the correct replies to the host.
[0024] Configuration and set up of the device is initiated after the detection of the attachment of the device to the host device 240 . This detection is handled by the special circuitry in the USB protocol and should be followed by any USB compliant hardware. After the host 240 detects the device attachment, it initiates the device enumeration. The device enumeration is a host activity that processes the device. This is done by identifying the device and assigning a unique address to that device. Once the unique address is assigned, the host then sends a series of commands to set up the communication pipes of the device. This series of commands will establish the detailed identity of the USB device. It will also inform the host of its capabilities and gives the host the ability to correctly assign the device driver that will work for the device. All of these are possible by the use of the device descriptors. The device descriptors are data structures in the device that describe the device capabilities and how these capabilities will be used. Every time there a disconnection-reconnection of the device, the host will automatically perform the device enumeration but will skip the device driver installation once it senses that the same device is being reconnected to the host.
[0025] On the device side, a default set of device descriptors is provided. The default set of descriptors are stored in the memory of the device or the device emulator 210 . Upon power up, the default set of descriptors are copied into the volatile memory called registers allotted for the current set of descriptors. The current descriptors are used for replies to the host. This allows the device to perform the configuration and set up step successfully. This permits the device emulator to meet all the USB requirements in this step. The default set of descriptors enables the host to initialize the device and establish the communications between the host and the device at the beginning of the process.
[0026] FIG. 3 is a block diagram showing the components of a hardware device emulator, in accordance with a preferred embodiment of the present invention. The hardware emulator is composed of a microprocessor (CPU) 310 , memory 320 , registers 330 , USB Device Port 340 , and a firmware coordinating the operations of all the modules. The USB Device Port in turn, is composed of the USB controller 350 , and the USB Interface 360 . A set of registers 330 mentioned earlier is provided. These registers are volatile memory that will hold the descriptors. At power up, the register contents are initialized with the default descriptors. The default descriptors are stored in the non-volatile memory. An internal data bus 370 connects the USB interface 360 , the registers 330 , and memory 320 . A USB line 380 connects an external device, such as a host, and the device emulator through the USB interface 360 . The USB Device Port 340 controls the signaling requirements of the USB line. Simulation of the detachment and attachment of the USB cable can be performed by the USB Device Port. This is done by manipulating the USB signal lines to perform the required signaling as defined by the USB 2.0 Device Specifications.
[0027] The USB Controller 350 on the other hand detects the commands coming from the host into the USB Interface 360 . At the same time, the USB Controller 350 organizes the responses to the host. The USB Controller 350 basically enables the hardware emulator to communicate to the Host using the USB protocol. The TJSB Controller 350 is directly responsible for the responses to the host during plug and play event by sending the appropriate responses during device enumeration. The microprocessor runs the firmware residing on the hardware emulator. The firmware running in the device emulator in turn handles the power up and initialization of the hardware emulator and more importantly processes the PJL commands that trigger the modification of the device descriptors of the hardware emulator. When the host sends a new set of PJL commands, the firmware checks the commands for changes to the device descriptors. When new descriptors are sent, the contents of the registers are updated. Subsequently the descriptors are stored into the memory. The memory serves as storage of the current device descriptors when the device is powered down or a reset is performed. The buffers serve as the fast access memory for the enumeration step of the host.
[0028] The device emulator, at the minimum, should support the eleven standard requests for Control Transfers. These standard requests listed below are enough to perform the configuration and set up of the device. Details on the definition and descriptions of the standard device requests are available in the USB Specifications.
[0029] 1. Get Status—Request to get the current status of the features of a device.
[0030] 2. Clear Feature—Request to disable the feature on a device.
[0031] 3. Set Feature —Request to enable the feature on a device.
[0032] 4. Set Address—Request used to assign a specific address to the device.
[0033] 5. Get Descriptor—Request for a specific descriptor.
[0034] 6. Set Descriptor—Request to add a descriptor or update an existing descriptor.
[0035] 7. Get Configuration—Request to get the value of the current device configuration.
[0036] 8. Set Configuration—Request to the device to use the selected configuration.
[0037] 9. Get Interface—Request the current setting of the interface.
[0038] 10. Set Interface—Request to the device to use the specific interface setting.
[0039] 11. Synch Frame—Request for the device to set and report the endpoint synchronization frame.
[0040] To meet the requirements of the standard device requests listed above, the device emulator implements the following default device descriptors.
[0041] 1. Device Descriptor—provides the basic information of the device. This descriptor provides additional information to the host on how to retrieve additional information from the device.
[0042] 2. Device Qualifier Descriptor—this descriptor provides the speed characteristic of the device, the configurations that the device support and device class codes.
[0043] 3. Configuration Descriptor—this descriptor defines in details the characteristics of each configuration defined in the Device Qualifier Descriptor. This descriptor essentially describes the device's features and abilities.
[0044] 4. Endpoint Descriptor—each endpoint will have this descriptor. This describes in detail each endpoint specified in the Configuration Descriptor.
[0045] 5. String Descriptor—This descriptor contains texts that can describe the device in detail (usually used for manufacturer's ID, serial number of the device, and product ID).
[0046] Device emulation can be achieved by changing the responses given by the device emulator to the host. By sending a new set of device descriptors, the host senses that a new device is connected to the USB port. To be able to do device emulation in this context, a method to change the device descriptor of the device emulator is employed. The method effectively changes the device descriptors in the device emulator so that the next time the host enumerates the device, a different set of descriptor is passed on to the host. To trigger the re-enumeration of the device emulator, an event is generated within the device emulator that resets the USB connection of the device emulator system. This event can be initiated by the host or by the user. The resulting action simulates the disconnection and reconnection of a device. From the host point of view a new device is connected to the host.
[0047] FIG. 4 is a flowchart showing the processing steps for sending device descriptors using PJL commands, and simulating a line reset, in accordance with a preferred embodiment of the present invention. In this flowchart, the methods to carry out the operation of changing the device descriptor of the device emulator are summarized.
[0048] In step 410 , the Host Device detects that a new device is connected to the USB port. This device detection is handled by the USB Host Port circuitry and the USB Host driver software. The Host Device is informed by the USB Host driver software through system interrupts.
[0049] In step 420 , after the host senses a new device connection, it runs the enumeration process to initialize the device emulator into the host system. Host assigns a unique address to the device. Host then retrieves the device descriptors that will enable the host to select the correct device driver. The default device descriptors will have to indicate that the device is a printer device. Host then searches for the correct device driver. Host assigns the generic driver to the device emulator. At this point a generic driver is assigned to the device to establish communication between the host and the device.
[0050] In step 430 , the user then creates a text file composed of the extended PJL commands. The commands chosen correspond to the extended PJL commands that will change the appropriate device descriptors in the device emulator. This text file is then sent to the device emulator, like a simple print job, using the assigned generic driver. The new device descriptors being sent to the device will describe the target device of the driver under test.
[0051] In step 440 , the firmware running in the device emulator receives the print job and interprets the PJL commands within the print job. After checking the commands for errors, firmware saves the new device descriptors in the memory and registers provided. The saving of the new descriptors will overwrite the current descriptors but will not overwrite the default descriptors. Current descriptors are the descriptors that are being sent to the host when the host sends the enumeration commands.
[0052] In step 450 , the last PJL command that the host sends is another extended PJL command to reset the USB lines. The firmware then calls the USB line reset sequence. This USB line reset sequence forces the device emulator to place the USB lines to a detached state. This is accomplished by meeting the requirements of the USB specifications on detached state. After meeting the duration timing requirements for a detached state, the attached state is then assumed by the USB lines.
[0053] In step 460 , from the point of view of the host, the sequence in step 5 will be seen as a new device is connected to the USB port. The host then performs an enumeration and discovers that a new device is connected to the port since a new set of device descriptors is sent by the device emulator. Host then selects the driver appropriate for this new device which triggers the installation of the driver being tested.
[0054] FIG. 5 shows some sample extended PJL commands specifying target device descriptors, in accordance with a preferred embodiment of the present invention. The example shows the commands to perform a change in the Manufacturer's names (1), changing the model name (2), modifying the number of interfaces (3), assigning the class codes of the device (4), assigning the sub-class codes of the device (5) and assigning a device name (6). The device emulator firmware will parse these commands and determine which of the reconfigurable items are to be replaced in the descriptors.
[0055] To change the device descriptors of the hardware emulator, the methods of this invention utilize the PJL (Printer Job Language) commands supported by the devices under test. PJL was developed to have job level control of the print jobs. Through PJL, it is possible to switch from one printing language to another on the job level. It also provides job status to the host computer. PJL was implemented using a standard set of commands. From the standard set of PJL commands, a set of new PJL commands are implemented. This new set of commands extends the current PJL commands to include the modification of the device descriptors of the device emulator. Due to this, reconfiguring the device can be carried out from the host side through the PJL commands. When the modification is complete, the device emulator will be responding to the host with the new set of device descriptors when the host re-enumerates the device. This re-enumeration can be triggered by the device driver under test through another PJL command that will initiate the reset of the USB port of the device emulator. The user can also trigger the device re-enumeration by detaching the device from the USB port and re-attaching the device.
[0056] Although this invention has been largely described using terminology pertaining to printer drivers, one skilled in this art could see how the disclosed methods can be used with other device drivers. The foregoing descriptions used printer drivers rather than general device drivers for concreteness of the explanations, but they also apply to other device drivers. Similarly, the foregoing descriptions of the preferred embodiments generally use examples pertaining to printer driver settings, but they are to be understood as similarly applicable to other kinds of device drivers.
[0057] Although the terminology and description of this invention may seem to have assumed a certain platform, one skilled in this art could see how the disclosed methods can be used with other operating systems, such as Windows, DOS, Unix, Linux, Palm OS, or Apple OS, and in a variety of devices, including personal computers, network appliance, handheld computer, personal digital assistant, handheld and multimedia devices, etc. One skilled in this art could also see how the user could be provided with more choices, or how the invention could be automated to make one or more of the steps in the methods of the invention invisible to the end user.
[0058] While this invention has been described in conjunction with its specific embodiments, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. There are changes that may be made without departing from the spirit and scope of the invention.
[0059] Any element in a claim that does not explicitly state “means for” performing a specific function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. 112, Paragraph 6. In particular, the use of “step(s) of” or “method step(s) of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6. | A method for changing operation of a device, comprising: sending target device descriptors to the device's device emulator, which processes and stores the descriptors as the current descriptors in memory, and the device emulator responding to a query from a host simulating operation of the target device. Using the method, the host recognizes the device as a different, target device, such as printers, MFPs, peripherals, digital cameras, etc. Device emulation enables installation and other testing of a new and yet unavailable target device under development. The methods also include USB device enumeration, making a print job containing extended PJL commands and sending it using a generic device driver, emulator firmware analyzing and storing the descriptors in registers, sending a line reset command to simulate device detachment and reattachment, and meeting timing requirements of USB detached and attached states. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a multicolor developing devices, and, more particularly, to multicolor developing devices of the type in which magnetic developing particles retained by magnetic forces are caused to adhere to an electrostatic latent image to thereby develop the same into a visible image in multicolor.
2. Description of the Prior Art
A developing unit of the type in which a magnetic roller is rotatably supported within a non-magnetic sleeve and magnetic developing particles are carried along the outer periphery of the sleeve by the magnetic forces produced by the magnetic roller to be adhered to an electrostatic latent image formed on a recording sheet is disclosed in U.S. Pat. No. 3,455,276 granted to Glenn R. Anderson July 15, 1969 (Assignee, Minnesota Mining and Manufacturing Company; Filed, May 23, 1967, Ser. No. 640,720). A plurality of such developing units will be required if in a copying machine it is desired to develop an electrostatic latent image in multicolor or in any desired color. Such a copying machine will be constructed such that one of the developing units developers containing developing particles of any desired color therein is brought to the developing position to perform developing.
In the meantime it is desirable that the respective developing units be arranged in equidistant spaced relation with the electrostatic latent image forming station and the developing station. The reason for this is that it is preferable to keep constant the time required for conveying a recording sheet to the developing station after the formation of electrostatic latent images to thereby make the amount of leakage of the static charge equal for all the colors. Also, when a plurality of developing units are used, it is essential to make a developing apparatus compact in size by reasonably arranging the developing units.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compact developing device having a plurality of developing units mounted therein.
It is another object of the present invention to provide a developing device in which a single drive motor can be commonly used for controlling the operation of a plurality of developing units.
It is still another object of the present invention to provide a developing device in which any one of the plurality of developing units can be moved to a predetermined developing station.
Other objects and features of the present invention will become apparent from the detailed description of a preferred embodiment thereof with reference to the accompanying drawings.
The outstanding feature of the present invention resides in that a power transmitting gear unit is provided in meshing engagement with gears each mounted on rotatable shafts of a plurality of developing units so that developing particles can be conveyed and rotation of the power transmitting gear unit can be transmitted to the developing units to move any desired developing unit to the developing station.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view showing essential portions of one embodiment of the developing device in accordance with the present invention;
FIG. 2 is a sectional view taken along the line II--II of FIG. 1; and
FIG. 3 is a sectional view taken along the line III--III of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, designated by the reference numeral 1 is a base plate which has two side plates 2 and 3 attached thereto and disposed at opposite ends thereof. The side plates 2 and 3 have mounted therein ball bearings 4 and 5 respectively for rotatably supporting a shaft 6. Designated by the reference numerals 7 and 8 are support members each of which includes a boss for securing each support member to the shaft 6 and a flange. Arranged between the flanges of the two support members 7 and 8 are channel-shaped rails 11, 12 and 13 for supporting developing units 14, 15 and 16 respectively thereon. As shown in FIG. 3, the guide rails 11, 12 and 13 are disposed radially equidistantly with respect to the axis of the shaft 6 and spaced apart from one another by 120° . As the three developing units 14, 15 and 16 are identical in construction, the explanation will hereinafter be given for one developing unit 14.
The developing unit 14 comprises a case 14a slidably received in the guide rail 11 along the inner surfaces of the guide rail 11. The case 14a is defined at opposite ends thereof by end plates 14b and 14c to provide a developing box as shown in FIG. 1. The developing box is open at one side thereof, and a non-magnetic sleeve 14d of a hollow cylindrical shape is attached to the end plates 14b and 14c in such a manner that the sleeve 14 partly protrudes beyond the open side of the developing box. A magnetic roller 14e is rotatably journaled by a pair of ball bearings 14f within the sleeve 14d. Guide plates 14g and 14h extend from the opposite inner side surfaces of the case 14a toward the sleeve 14d and are spaced apart at their forward ends from the outer periphery of the sleeve 14d with a very small clearance existing therebetween. The guide plates 14g and 14h and the case 14a define a space or a compartment 14i for containing developing particles 14j. A cover 14k is detachably attached to the case 14a to cover an opening through which developing particles 14j can be fed to the storing compartment 14i.
The magnetic roller 14e is securely supported by a shaft 14l which extends at one end portion thereof outside the support member 8, and a gear 14m is mounted on the one end portion of the shaft 14l. There is formed an access opening 2a in the side plate 2 for allowing the developing unit 14 to be inserted therethrough along the guide rail 11 as shown in FIG. 1. The flange of the support member 8 is formed therein with a cutout 8a to permit the gear 14m to pass therethrough. In the drawings, the developing unit 14 is shown in the developing station in which the developing particles 14j carried along the outer periphery of the sleeve 14d by the magnetic forces form a tuft which is brought into sweeping engagement with a recording sheet 17 to effect developing of a latent image formed on the recording sheet 17. It is to be understood that other developing units 15 and 16 are identical in construction with the unit 14, the only difference residing in that the developing particles stored therein differ from one another in color.
A drive mechanism will now be described. In FIGS. 1 and 2, the drive gear mechanism comprises an output gear 21, an input gear 22 and a drive-side clutch disk 23, all of which are connected together as by rivets or screws 24. The output gear 21 is rotatably mounted on the shaft 6 by means of a ball bearing 25, and is maintained in meshing engagement with gears 14m, 15m and 16m of the respective developing units 14, 15 and 16. A driven-side clutch disk 26 is keyed to the shaft 6 so that it can rotate integrally with the latter. The friction engaging surface of the disk 26 faces the disk 23. An actuating magnet 27 includes a magnetic path and a winding which are positioned on the opposite side of the friction engaging surface of the driven-side clutch plate 26 and attached to the side plate 3 so that it is disposed concentrically with the shaft 6.
Upon energizing the winding of the actuating magnet 27, the driven-side clutch disk 26 is magnetized by the magnetic path of the magnet 27 and attracts the drive-side clutch disk 23 into engagement therewith. Thus the rotational force of the input gear 22 is transmitted to the shaft 6. To this end the clutch disk 23 preferably includes friction member supported for axial movement and a magnetic member for producing an axially biasing force by magnetic forces. The input gear 22 is driven by the motor 28 through a gearing (not shown).
Braking means designated by the reference numeral 31 comprises a rotary disk 31a keyed to the shaft 6, a stationary magnetic disk 31c supported through a holder 31b by the side plate 3, and an electromagnet 31d mounted in the stationary magnetic disk 31c. When energized, the electromagnet 31d causes the rotary disk 31a to be attracted into engagement with the fixed disk 31c to thereby apply the brake to the shaft 6. Designated by the reference numeral 32 is a rotational angle detector for detecting the positions of the developing units 14, 15 and 16. Detailed explanation of the construction of the detector 23 is omitted, it being apparent to those skilled in the art that the use of a cam and the like readily enables them to provide the detector of the type described.
In operation of the device described above, the movement of developing units 14, 15 and 16 to the developing station will now be described. First of all, the rotary disk 31a of the braking means 31 is released to make the shaft 6 freely rotatable. Then, a current is passed to the winding of the actuating magnet 27 to attract the drive-side clutch disk 23 into engagement with the driven-side clutch disk 26 so as to transmit drive power from the motor 28 to the shaft 6. This causes the support members 7 and 8 to rotate together with the shaft 6, so that the developing units 14, 15 and 16 can rotate about the axis of the shaft 6. In the drawings, the developing unit 14 is shown in the developing station. If it is desired to perform developing in the color of the developing particles contained in the unit 15, then the shaft 6 is rotated till the unit 15 is brought to the developing station. The rotational angle detector 32 detects when the unit 15 reaches the developing station, and deenergizes the actuating magnet 27 to release the drive-side clutch disk 23 from engagement with the driven-side clutch disk 26 to cut off transmission of the rotational force to the shaft 6. At the same time, the electromagnet 31 is excited to attract the rotary disk 31a into engagement with the fixed disk 31c, thereby braking the shaft 6. Upon continuation of the attraction of the disk 31a, the unit 15 is maintained in the developing station.
Description will now be given of rotation of the magnetic roller 14e of the unit 14 (15, 16). Assuming that the unit 14 is held in the developing station, rotation of the motor 28 will be transmitted through the gears 22, 21 and 14m to the shaft 14l supporting the roller 14e. Thus the roller 14e is rotated, and the magnetic forces of the roller 14e causes the developing particles 14j adhering to the outer periphery of the sleeve 14d to move along the outer periphery of the sleeve in a direction opposite to the direction of rotation of the roller 14e. Thus, the developing particles 14j forming a tuft adapted to be in contact with the recording shaft 17 are replenished with fresh developing particles, thereby preventing the lowering of the developing ability due to consumption of the coloring particles.
As seen from the embodiment of the developing device in accordance with the present invention, all the parts of the device are reasonably arranged to make the entire construction of the device compact in size. In addition, as rotation of the magnetic roller of each developing unit and the selective movement of the respective units to the developing station can be controlled by means of a single electric motor it is possible to reduce production cost. The fact that there is only one developing station for all the developing units permits the developing characteristics in the respective developing units to coincide with one another. This contributes to improved quality of the developed color image.
The invention has been described with reference to an embodiment in which the magnetic roller of each developing unit is caused to rotate. It is to be understood, however, that the sleeve of each developing unit can be made to rotate while rendering the magnetic roller stationary without departing from the spirit and scope of the invention. It will also be apparent to those skilled in the art that the number of the developing units can be increased or decreased as desired within the scope of the invention. | A multicolor developing device having a plurality of developing units interposed between a pair of rotary plates and disposed radially equidistantly relative to the axis of the rotation of the rotary plates, said each developing unit having a magnetic roller rotatably supported by a non-magnetic sleeve for carrying magnetic developing particles along the outer periphery of the non-magnetic sleeve by means of the magnetic forces developed by the magnetic roller so as to cause the particles to adhere to an electrostatic latent image to thereby develop the same into a visible image, and wherein the rotation of the rotary plates causes any one of developing units to register in facing relation with the electrostatic latent image. | 6 |
BACKGROUND OF THE INVENTION
This invention is related to telescopic sight mountings and more particularly to an improved mounting of the type that permits the firearm user to use either a telescopic sight or the firearm's iron sights.
Some commercial mountings for telescopic sights support the sight in a raised position above the firearm barrel so that the user can view either the iron sight mounted on the barrel or the telescopic sight. An improved form of such a sight was disclosed in my U.S. Pat. No. 3,835,565 which issued Sept. 17, 1974 in which a pair of spaced lower walls of the mounting member are clamped on opposite sides of a base plate attached to the firearm. Such an arrangement reduced the conventional mounting structure between the telescopic sight and the barrel that might interfere with the line of sight of the user when employing the iron sights.
SUMMARY OF THE INVENTION
The broad purpose of the present invention is to provide a dual sight mounting in which the telescopic sight is clamped between the upper half of a pair of laterally separable mounting members, and the firearm is clamped between the lower edges of the two mounting members. The two mounting members are formed from a pair of identically shaped elements that are then drilled and tapped to receive a pair of threaded fasteners. Such a dual sight mounting not only employs fewer fasteners than conventional commercial dual sight mountings, but is easier to mount on the firearm barrel, provides a much more attractive mounting, and reduces manufacturing costs.
Still further objects and advantages of the present invention will become readily apparent to those skilled in the art to which it pertains upon reference to the following detailed description.
DESCRIPTION OF THE DRAWINGS
The description refers to the accompanying drawings in which like reference characters refer to like parts throughout the several views, and in which:
FIG. 1 is a perspective view of a rifle having a telescopic sight supported by a dual sight mounting illustrating the preferred embodiment of the present invention;
FIG. 2 is a view as seen along line 2--2 of FIG. 1;
FIG. 3 is an exploded view of one of the pair of sight mountings;
FIG. 4 is an enlarged view of the mid-section of the preferred mount;
FIG. 5 is an end view of another embodiment of the invention;
FIG. 6 is an exploded view of the embodiment of FIG. 5;
FIG. 7 is the end view of still another embodiment of the invention; and
FIG. 8 is an end view of still another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, FIGS. 1 and 2 illustrate a conventional rifle 10 having an elongated barrel 12. Iron sights 14 and 16 are mounted along barrel 12 in the manner well known to those skilled in the art. A conventional telescopic sight 18 is supported by mounting means 20 on the receiver portion of barrel 12 such that sight 18 is spaced above the receiver and parallel to the barrel.
Mounting means 20 includes a pair of cooperating mounting members 26 and 28 mounted near one end of scope 18, and a second pair of cooperating mounting members 30 and 34 mounted near the opposite end of scope 18. Mounting members 30 and 34 are identical with respect to mounting members 26 and 28 and cooperate in the same manner to support the telescopic sight except with respect to their locations along barrel 12.
Referring to FIGS. 2 and 3, mounting member 30 has an upper wall with a substantially semi-cylindrical surface 36 receiving one lateral side of sight 18. Mounting member 34 has a substantially cylindrical surface 38 engaging the opposite side of sight 18 in an opposed relationship with respect to surface 36. It is to be noted that the upper edge of mounting member 30 is spaced from the upper edge of mounting member 34 so that sight 18 is clamped between the upper halves of the two mounting members.
Mounting member 30 has a lower half forming a curved wall 40 spaced from a similarly shaped curved wall 42 on the lower half of mounting member 34. Walls 40 and 42 are so spaced as to form an opening between them for viewing iron sights 14 and 16 as can be seen in FIG. 2. The lower edge of mounting member 30 is received in a substantially V-shaped groove 44 along the upper side of barrel 12. The lower edge of mounting member 34 is received in a V-shaped groove 46 that is spaced from and parallel to groove 44. The two V-shaped grooves 44 and 46 are elongated so that mounting members 30 and 34 can be slidably adjusted along the barrel to a selected position.
A pair of threaded fasteners 48 and 50 are mounted on the mid-section of mounting member 30 and threadably connected to the mid-section of mounting member 34 so as to be operative to move mounting member 34 toward mounting member 30 when sight 18 is being clamped between them. It is to be noted that the mid-section of mounting member 34 is spaced from the mid-section of mounting member 30 and that the upper and lower walls of each of the mounting members is resilient. Thus as the user manipulates fasteners 48 and 50 to move one mounting member toward the other, the two mounting members cooperate to clamp sight 18 between their upper halves and to clamp the base plate between their lower edges. This arrangement simplifies the mounting procedure because of the reduced number of fastening members. In addition, the arrangement also provides a much more streamlined appearance with respect to commercially available mountings.
Referring to FIG. 4, both mounting members 30 and 34 are preferably formed of aluminum in a resilient construction such that as the mid-section of mounting member 34 is drawn from the position illustrated in phantom at "A" toward the mid-section of mounting member 30 and its position illustrated in solid lines at "B", the telescopic sight is clamped between the upper half of the two mounting members and the mounting grooves 44 and 46 are clamped between the lower halves of the two mounting members. Thus only two screws are required to mount sight 18 on the barrel 12 as opposed to at least four on most commercially-available sight mountings. In the embodiment of the invention illustrated in FIGS. 1-4, the two mounting members are spaced from one another and both at their upper ends, their lower ends, as well as their mid-sections. This allows the user to apply whatever necessary clamping force is necessary to tighten threaded fasteners 48 and 50 to take advantage of the resilient nature of the walls of the two mounting members.
Referring to FIGS. 5 and 6, a second embodiment of the invention comprises a pair of mounting members 100 and 102. This embodiment is mounted on a base plate 104 that is attached to barrel 106 of a conventional firearm. Base plate 104 is also conventional and comprises an elongated metal base member having parallel V-shaped grooves 108 and 110 running the full length of the base member. Base plate 104 has openings 112 for receiving threaded fasteners 114 (only one shown) for attaching the base plate to barrel 106. The base plate has a pair of slots 116 and 118 disposed in the upper surface of the base plate transverse to its length.
Mounting member 100 has an upper curved wall 120 adapted to engage one side of telescopic sight 18 and a lower wall 122 which supports the sight a predetermined distance above base plate 104. Similarly, mounting member 102 has an upper wall 124 adapted to receive the opposite side of sight 18 and a lower wall 126 which is curved in a manner similar to wall 122. Mounting members 100 and 102 are both formed of a resilient material.
Upper wall 120 terminates in a flange 128, and upper wall 124 terminates in a flange 130. The two flanges are joined together by a pair of threaded fasteners 132 and 134. As illustrated in FIG. 5, each of the threaded fasteners 132 and 134 has a head seated in an opening 136 such that its opposite end is threadably engaged with a threaded opening 138. When the walls 120 and 124 are engaged on opposite sides of sight 18, the flanges 128 and 130 are disposed in contact one with the other by threaded fasteners 132 and 134. In this position, a slight gap or opening 140 is formed between the mid-sections of mounting members 100 and 102 as illustrated in FIG. 5.
A pair of threaded fasteners 142 and 144 are received in openings 146 and 148 so as to be operative to move the lower walls 122 and 126 toward one another so that lower lips 150 and 152 are received in grooves 108 and 110 respectively.
Referring to FIG. 6, a pin 154 is carried adjacent the lower edge of wall 122 and a similar pin 156 is carried adjacent the lower edge of wall 126. The two pins are aligned with one another so as to be received in slot 116 to precisely locate the two mounting members on the base plate.
FIG. 7 illustrates still another embodiment of the invention used for mounting a sight 200 on a firearm barrel 202 having a raised portion 204 with parallel grooves 206 and 208 in a manner similar to firearm barrel 12 illustrated in FIG. 1. This embodiment of the invention is useful for a sight having longitudinal grooves 210 and 212 along the bottom of the sight parallel to its longitudinal axis.
A pair of similarly shaped mounting members 214 and 216 are mounted on barrel 202. Mounting member 214 has a lower wall 218 which cooperates with a lower wall 220 on mounting member 216 to form an opening for iron sights 222 and 224. A pair of threaded fasteners 228 (only one illustrated) is mounted on the mid-section of the two mounting members to draw one toward the other to clamp raised portion 204 between the lower edges of the two mounting members. Mounting member 214 has a lip 230 received in slot 210 and mounting member 216 has a lip 232 received in slot 212 so that the telescopic sight can be clamped between the upper halves of the two mounting members as the firearm barrel is clamped between their lower edges.
FIG. 8 illustrates still another embodiment of the invention similar to the embodiment of FIG. 7 in which a pair of mounting members 300 and 302, of a resilient construction, are mounted on firearm 202 to support a sight 200.
In this embodiment of the invention, the lower edges of mounting members 300 and 302 are received in slots 206 and 208, respectively, as a threaded fastener means 304, mounted on the mid-section of the mounting members is manipulated by the user to move one mounting member toward the other. Mounting member 300 has a lip 306 received in slot 210 of the sight, and mounting member 302 has a lip 308 received in the opposite lip 212 of the sight. The mounting member 300 also has a curved wall 310 which embraces the opposite side of the telescopic sight in such a manner that the sight is clamped between walls 310 and 312 in a manner similar to that of the embodiment of FIG. 1.
It is to be noted that in each of the embodiment of the invention I have disclosed a pair of mounting members that are drawn together by a pair of threaded fasteners supported substantially in the mid-section of the mounting members. The two mounting members are slightly spaced one from the other to take advantage of the resiliency of the two mounting members in clamping the telescopic sight between the upper halves of the mounting members as the firearm barrel is clamped between the lower halves of the two mounting members. In each embodiment, the sight is spaced a sufficient distance away from the firearm barrel to enable the user to employ the irons sights independently of the telescopic sight. In addition, it is to be noted that in each embodiment the two mounting members are formed of a pair of halves which are identical except that one has an opening for receiving the head of a pair of threaded fasteners while the other has a tapped opening for engaging the threaded end of the fasteners. By employing only two components for each mounting device, except for the threaded fasteners, results in a substantial reduction in manufacturing costs, as well as a reduction in the time for mounting the sight and also provides an arrangement having an attractive appearance. | A dual sight mounting for supporting a telescopic sight on a firearm having iron sights. Several embodiments are illustrated, each mounting comprising a pair of laterally spaced mounting members, each member having an upper wall which cooperates with a similarly formed upper wall on the other member to engage the telescopic sight between them. A fastener mounted on the mid-section of the two members is operative to clamp the sight between their upper walls as the firearm is clamped between the lower halves of the two mounting members. The telescopic sight is supported to form an opening between the barrel and the telescopic sight permitting the user to view the iron sights along a line of sight passing between the lower halves of the two mounting members. | 5 |
This application claims benefit of Provisional Application 60/026,430 filed Aug. 23, 1996.
FIELD OF THE INVENTION
This invention relates to reducing the toxicity of carboplatin (cis-diammine-1,1-cyclobutanedicarboxylato-platinum II, CBDCA, JM-8 and NSC 241240), using a dithioether as a protective agent.
BACKGROUND OF THE INVENTION
Carboplatin (hereinafter also referred to as "CBDCA" or CBP") is a widely used anticancer drug which is normally used in combination with other anticancer drugs in the treatment of cancers of the lung, head and neck, ovary, esophagus, bladder, testis, and others. One of the most important and common dose limiting toxicities of carboplatin is hematological toxicity. In particular, myelosuppression (depression of blood elements formed within bone marrow) is often manifested in the form of thrombocytopenia, neutropenia, leukopenia, and various forms of anemia. The other major carboplatin-induced toxicity is gastro-intestinal (causing nausea and vomiting).
In order for carboplatin to react with certain nucleic acid sequences in cellular DNA, it must first undergo chemical conversion to an active species by the partial or complete displacement of the cyclobutanedicarboxylato (CBDC) ligands, respectively, by chloride. The chloro and dichloro species are believed to act against cancer cells by reacting with the imidazole nitrogens on DNA. These chloro species are believed to be metabolised in vivo to active hydroxy species.
Carboplatin, unlike cisplatin, is relatively stable in the body. Its cyclobutanedicarboxylato (CBDC) group makes it much less susceptible to displacement by incoming nucleophiles. It is less active than cisplatin towards DNA. Indeed, it is generally given in combination with other anti-cancer drugs. Although less prone to cause the nephrotoxicity associated with cisplatin, it is highly myelotoxic and has gastrointestinal toxicity. It might at first be thought that carboplatin, with its active chloro species, should behave similarly to cisplatin and therefore be further metabolised in the same way. However, this is not so: the body cells most adversely affected by carboplatin-induced toxicity (bone marrow and GI tract cells) are different from those most adversely affected by cisplatin (kidney cells). Thus, the metabolic species responsible for the toxicity cannot be the same. Finding a protective agent for carboplatin therefore represents a new and separate problem from that presented by cisplatin.
SUMMARY OF THE INVENTION
It has now been found that a dithioether having the formula R 1 --(CH 2 ) n --S--S--(CH 2 ) m --R 2 (I) wherein:
each of R 1 and R 2 individually is SO 3 H or PO 3 H 2 ; and
each of m and n is individually 1, 2, 3 or 4; or a pharmaceutically acceptable salt thereof, is a suitable protective agent for carboplatin.
This invention can be represented in different ways according to local patent law. Thus, it includes the use of the dithioether in the manufacture of a medicament for administration in combination with carboplatin to a patient, at substantially the same time or sequentially, whereby the dithioether and the carboplatin become co-present in the blood of the patient and the dithioether serves to reduce the toxicity of the carboplatin. It further includes a method of treating a patient suffering from a cancer susceptible to carboplatin therapy, which comprises administering the dithioether to the patient at the above-recited time. Also within the invention is a medicament for treating cancer in combination with carboplatin therapy, comprising the dithioether.
The preferred dithioether is sodium 2,2'-dithiobis(ethanesulfonate), herein abbreviated to dimesna.
The invention is useful in relation to any cancer treatable by a therapy consisting of or including administration of carboplatin, especially the cancers specifically listed above.
The invention also includes a composition suitable for administration to patients with cancer, comprising carboplatin and a dithioether as defined above, especially in the form of a sterile injectable solution, preferably of pH 2 to 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The carboplatin formulation used in the invention will typically be a solution. It can take any form appropriate to or conventional for formulation of carboplatin. The type of formulation will of course depend on the route of administration, which will normally be parenteral, especially intravenous, and preferably by injection. The preferred solvent is aqueous, since carboplatin has a water-solubility of 14 mg/mL. The formulation will normally contain from 0.05 mg/mL up to the maximum solubility of carboplatin. It may also include mannitol (a preservative) . It may contain other excipient(s) and/or diluent(s).
The carboplatin formulation will normally have a pH of from 2 to 6; a neutral pH of about 7 is much less preferred. Any pharmaceutically acceptable acid, including hydrochloric acid, may be used to adjust the pH. However, a formulation which is substantially free of added chloride ions, or, at least, free of chloride ions from added sodium chloride, has been shown to have improved stability. Cisplatin, by contrast, is preferably formulated in a chloride ion solution, such as isotonic or hypertonic saline for injection.
The dithioether protective agent is formulated separately from the carboplatin. For oral administration, it may be formulated as a tablet, capsule, caplet, colloidal suspension or solution, or other form which is easily ingested by the patient. For parenteral administration it is preferably formulated as a sterile injectable solution, as described above. The oral and/or parenteral formulation may be stored as an aqueous solution or as a lyophilized powder suitable for reconstitution with water or another solvent.
Hereinafter, the dithioether will be discussed mainly with reference to disodium 2,2'-dithiobis(ethanesulfonate) (dimesna), but the person skilled in the art will readily be able to use the principles of this invention in relation to other dithioethers of formula (I), especially a compound of formula (I) in which m and n are from 1 to 3, in the form of a sodium salt.
The preferred dithioethers are the sulfonates, especially the disodium salts thereof, but including the monosodium, monopotassium, sodium-potassium, dipotassium, calcium and magnesium salts of the sulfonate. Further, since it is the dithio group which must provide a reactive nucleophile for quenching the reactive species of carboplatin and the sulfonate group confers water-solubility on the molecule, it follows that the sulfonate group could be replaced by phosphonate. Thus, disodium and tetrasodium 2,2'-dithiobis(ethanephosphonates) are also preferred dithioethers for use in the invention.
For the dithioether formulation, the preferred solvent is aqueous, since the dithioethers are also water-soluble, e.g. up to 300 mg/mL for dimesna. The concentration of dithioether is normally from 1 mg/mL up to the maximum solubility. In principle, higher amounts of the dithioether are usable, e.g. up to 500 mg/mL, although, of course, solubility problems may arise. The formulation may contain excipient(s) and/or diluent(s).
The carboplatin/dithioether combination can be administered to human or non-human patients as a treatment for various types of cancer, as described in the effectiveness profile for carboplatin. It may be administered as a "single drug therapy" (carboplatin being the sole cytotoxic or anti-cancer therapeutic agent) or in combination with other cytotoxic, anti-cancer or other chemotherapeutic agents.
Typically, the carboplatin and the dithioether formulations will be prepared as for intravenous injection in sterile, single-dose containers. Both could be administered orally.
Preferably the dithioether is administered before the carboplatin, especially from 5 minutes to 1 hour before. For dimesna, from 15 to 30 minutes before has been found very effective. Administration of the combination of carboplatin and the dithioether may require adjustments in one or both of timing and/or dosage. The goal in the treatment is to match the peak in vivo concentration of the dithioether with that of the toxic metabolites of carboplatin. Although carboplatin reacts slowly in vivo to produce the active nucleophilic species which ultimately cause damage in certain cells, especially bone marrow and GI tract cells, it has been found that at least the greater proportion of the dose of dithioether should be given before the carboplatin, although it will sometimes be helpful to give the remaining, smaller proportion, of the dose of dithioether after the carboplatin, in order to combat the effects of slowly-generated or long-lasting active nucleophilic species of carboplatin. Carboplatin has a relatively long half-life in the body. Desirability and necessity of additional doses of protective agent is determined by carefully monitoring the patient's excretion of platinum to estimate the rate of drug elimination from the body.
The invention includes the possibility of administering at least a part of the dithioether in the form of a composition comprising the carboplatin and the dithioether components, preferably as an aqueous solution of pH 2 to 6. Features of preference of such compositions are as recited above for the individual components.
The carboplatin can be administered in any conventional dose. It may be possible to exceed the conventional dose of carboplatin, as this is frequently limited by the toxicity problem which the present invention mitigates. The carboplatin dose will normally be in the range 0.3 to 45 mg/kg (a corresponding dose of dithioether would then be from 20 to 2500 mg/kg, increasing roughly proportionately with the carboplatin dose). In terms of body surface area, ranges of 100 to 1000 mg/m 2 of carboplatin and 1000 to 40,000 mg/m 2 of dithioether are suggested.
Since the toxicity of the protective agent is very low (the parenteral and oral LD 50 values for all of the dithioethers of formula I are generally higher than that of common table salt, and all are rapidly eliminated through excretion in the urine), large amounts of the protective agent may be given either orally or parenterally to provide constant and safe protection against any residual carboplatin toxicity. Thus, typically the weight ratio of carboplatin to dithioether used in the therapy is from 6:1 to 1000:1, most especially 25:1 to 700:1.
The following non-limiting Examples illustrate the invention. The vials referred to are "amber vials", which protect the carboplatin from exposure to light. Although Examples 1 to 4 relate to solutions of carboplatin and the dithioether together, it will be appreciated that they can be formulated separately, with the carboplatin at acidic pH and each active component at the concentration indicated in the solutions of the Examples.
EXAMPLE 1
(a) Preparation of 2,2'-dithiobis(ethanesulfonate) (dimesna)
Disodium 2,2'-dithiobis(ethanesulfonate) was prepared by oxidizing 2-mercaptoethanesulfonate in water with an equimolar amount of iodine as previously reported by L. Lamaire and M. Reiger, J. Org. Chem. 26, 1330-1, (1961). The other sulfonate and phosphonate dithioethers of formula (I) can be prepared analogously.
(b) Stability of dimesna
50 mg of the dimesna thus prepared were dissolved in 1 mL of water and the pH of the solution adjusted to 1.5, 2.0, 3.0, 4.0, 5.0 and 6.0 by adding in hydrochloric acid in water or the pH adjusted to 8.0 and 9.0 by adding 1 N sodium hydroxide in water. The solution was then stirred for 24 hours at room temperature, the water was removed at reduced pressure and the residue dissolved in spectral grade D 2 O. The proton NMR spectrum gave only peaks corresponding to the starting material. Heating the pH 1.5 solution to 100° C. for 10 minutes gave no change in the proton NMR spectrum. These data indicate that dimesna is stable in aqueous solution at pH 1.5 to 9.0.
(c) Preparation of a sterile solution of carboplatin and dimesna
Pure hydrochloric acid (99.999%) was added to a sterile, injectable, Lactated Ringer's (LR) solution (US Pharmacopoeia grade), to give a pH in the range 2.0 to 6.0. 1 mg of pure carboplatin/mL of the above LR solution was added and allowed to completely dissolve by agitation (1500-2500 rpm) at room temperature, for approximately 60 to 90 minutes in the dark. Then, 15 mg of dimesna, prepared above, per mL of solution were added and the mixture agitated until complete dissolution occurred. The final pH was adjusted to within the range pH 2.0 to 6.0 by adding further pure hydrochloric acid. The solution was sterilized by filtration through a sterile 0.2 micrometre filter (obtained from VWR Scientific) and stored in sterile injection vials. Each vial contained approximately 0.9 mg of carboplatin and 14.3 mg of dimesna per mL of solution.
EXAMPLE 2
To a sterile injectable aqueous solution of LR solution(USP grade) were added 15 mg of dimesna/mL of solution. The dimesna was allowed to dissolve completely by agitation (1500-2500 rpm) at room temperature, for 5-10 minutes. The pH of the solution was adjusted to within the range 2.0 to 6.0 by adding pure (99.999%) hydrochloric acid. 1 mg/mL of dimesna solution of pure (98.0%) carboplatin was added and the mixture agitated in the dark until complete dissolution occurred. The remaining steps were as in Example 1 (c), giving a solution of the same approximate composition. Each vial contained approximately 1.0 mg of carboplatin and 14.3 mg of dimesna per mL of injection solution.
EXAMPLE 3
Example 1(c) was repeated except that 0.5 mg/rnL of carboplatin and 30 mg/mL of dimesna were used. Each vial contained 0.5 mg of carboplatin and 12.9 mg of dimesna per mL of injection solution.
EXAMPLE 4
Example 1(c) was repeated except that pure mannitol (99+% purity, from Aldrich Chemical Company) was dissolved in the LR solution, to give a concentration of 1.0% w/v mannitol, and also that 30 mg/mL of dimesna were used. Each vial contained approximately 1.0 mg of carboplatin and 12.9 mg of dimesna per mL of injection solution.
EXAMPLE 5
Use of Dimesna to Reduce Carboplatin Toxicity
Experiments were performed to determine the efficacy of dimesna in reducing the toxicity of carboplatin in adult beagle dogs. Toxic effects were tested at varying dose levels of carboplatin, with or without administration of dimesna. The carboplatin used was an aqueous solution from vials of "Paraplatin" (Bristol Myers Squibb) and injected i.v. by a slow drip over 5 to 10 minutes. Lyophilised dimesna was reconstituted in water and injected i.v. 30 minutes before the carboplatin.
Table 1 gives the dosing schedule followed in the experiments, with two animals, one male and one female in each group.
TABLE 1______________________________________ CarboplatinGroup Dimesna (mg/kg)______________________________________ (mg/kg)1 0 452 453 304 305 206 207 138 139 0______________________________________
The animals were closely observed after the dose was administered, and euthanized on day 30 for tissue necropsy. Tissues were trimmed, processed, and stained slides were prepared of the following: thymus, heart, lung, stomach, duodenum, jejunum, colon, pancreas, liver, kidney, urinary bladder, testis, ovary, spleen, mesenteric and mandibular lymph nodes, bone marrow, ischiatic nerve, and all gross lesions. Lesions found were graded from one to five based upon severity.
Results
Three dogs, the two from control Group 1 which received only a 45 mg/kg dose of carboplatin, and the female from control Group 3 (30 mg/kg carboplatin only), died or were sacrificed because of their moribund condition prior to day 30. Most of the other dogs from control Groups 3, 5 and 7 exhibited moderate to severe cellular depletion of femoral bone marrow, moderate to severe lymphoid depletion of the thymus, and other microscopic lesions, particularly in the gastrointestinal tract. The dogs from the Groups 2, 4, 6 and 8, which were given dismesna, all survived for the duration of the experiment. Dogs from Groups 4, 6 and 8 showed no cellular depletion of the femoral bone marrow or lymphoid depletion in the thymus. The dogs from Group 2, which received in essence, a lethal dose of carboplatin, both survived and exhibited only mild lymphoid depletion, with no evident cellular depletion of bone marrow. Group 9 control dogs which received only dimesna showed no physiological changes. | To reduce the toxic effect of carboplatin, particularly myelosuppression and emesis, a dithioether having the formula R 1 -(CH 2 ) n --S--S--(CH 2 ) m --R 2 (I) wherein:
each of R 1 and R 2 individually is SO 3 H or PO 3 H 2 ; and
each of m and n is individually 1, 2, 3 or 4;
or a pharmaceutically acceptable salt thereof, preferably disodium 2,2'-dithiobis(ethane sulfonate) (dimesna), is administered in combination with carboplatin to a patient, at substantially the same time or sequentially, whereby the dithioether and the carboplatin become co-present in the blood of the patient. Compositions comprising carboplatin and the dithioether are included in the invention. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cooling system for an internal combustion engine, and more particularly to a cooling system which cools an internal combustion engine by allowing coolant to flow inside annular grooves provided on an outer surface of a cylinder.
2. Description of the Related Art
Conventionally, there is disclosed a cooling system of a cylinder liner, for example in Japanese Laid-Open Utility Model Application No. 63-168242. The cooling system disclosed in this Application, so called groove cooling, includes a plurality of grooves formed on and along an outer surface of a cylinder liner in a direction roughly perpendicular to an axis of the cylinder liner. The system also includes two connecting grooves connecting these grooves and extending in the direction of the axis of the cylinder liner. The later grooves are positioned in 180 degree opposition from each other along a diameter of the cylinder liner. Continuing passages for coolant are formed between each of the grooves on the outer surface of the cylinder liner and the inner surface of a bore of a cylinder block by fitting the cylinder liner to the bore of the cylinder block.
FIGS. 1A and 1B show an example cooling system for an internal combustion engine; FIG. 1A is a plane view and FIG. 1B is a cross sectional view taken along a line B--B of FIG. 1A. A plurality of square cross-sectioned annular grooves 3 1 ˜3 4 are formed on an outer surface of a cylinder liner 2. The annular grooves 3 1 ˜3 4 , extending in a direction roughly parallel to the circumference of the cylinder liner, are equally spaced along a direction of the axis of the cylinder liner 2 that is fitted to a cylinder block 1. When the cylinder liner 2 is fitted to the bore of the cylinder block 1, these annular grooves 3 1 ˜3 4 form annular passages between an outer surface of the cylinder liner 2 and an inner surface 4 of a bore of the cylinder block 1.
Longitudinal grooves 5 and 6 connecting the grooves 3 1 ˜3 4 are formed, extending in a direction of an axis of the cylinder liner 2, in positions where the cylinder liner 2 and the cylinder block 1 face each other. In the cylinder block 1, an inlet port 7, which is connected to the longitudinal groove 5, and an outlet port 8, which is connected to the longitudinal groove 6, are formed.
A coolant delivered from a pump (not shown) is supplied to the inlet port 7. The coolant supplied to the inlet port 7 flows through the longitudinal groove 5 and is delivered to the annular grooves 3 1 ˜3 4 . Then the coolant flows through the grooves 3 1 ˜3 4 while absorbing heat from the cylinder liner 2, and eventually flows into the longitudinal groove 6. The coolant flows together in the longitudinal groove 6, outflows from the outlet port 8, and is returned to the pump via a radiator (not shown).
In the system mentioned above, heat generated in a combustion chamber and transfered from a cylinder head to the cylinder liner 2 can be eliminated by cooling a wall of the cylinder liner 2. The wall of the cylinder liner 2 has an incoming heat distribution such that the incoming heat at the uppermost part of the cylinder liner 2 is highest. The amount of heat decreases toward the lower part of the cylinder liner 2. Therefore, the amount of coolant flow in the annular groove 3 1 closest to a combustion chamber is maximized and the flow decreases as it flows to the grooves 3 2 ˜3 4 from the uppermost groove 3 1 , so as to uniformly cool down the wall of the cylinder liner 2.
In the conventional system mentioned above, as shown in FIG. 2, a coolant flows into the inlet port 7, and almost directly enters into the uppermost groove 3 1 via the longitudinal groove 5. Some coolant flows into the grooves 3 2 ˜3 4 , which are lower than the uppermost groove 3 1 . Part of the flow into grooves 3 2 ˜3 4 is bent perpendicularly, as indicated by arrows a and b in FIG. 2. However, since the coolant flows at high velocity, due to an inertia, it is difficult for the coolant to change a flow direction to a perpendicular direction thereof. Accordingly, in the grooves 3 2 ˜3 4 located below than the uppermost groove 3 1 , a stagnation of the coolant is generated in an upstream position of each groove as indicated by arrows c and d. This stagnation is largest at the second groove 3 2 and tends to be reduced toward lower positions of the grooves. This is because the velocity of the coolant is higher at the entrance of the longitudinal groove 5 and decreases toward the downstream side due to reduced coolant flow. The result is that in inertia of the coolant flow is higher at the entrance of the second groove 3 2 and lower towards the downstream position.
If stagnation of the coolant is generated at the upper portion of the cylinder liner 2, where the amount of incoming heat is considerably large, the coolant receives an excess amount of heat and begins boiling. If the vapor generated by the boiling of the coolant flows into a circulation pump for the coolant, the amount of coolant discharged from the pump will be reduced and result in an overheating of the internal combustion engine.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide an improved cooling system for an internal combustion engine in which the above-mentioned disadvantages are eliminated.
A more specific object of the present invention is to provide a cooling system in which a stagnation of a coolant flow generated at an entrance of each annular groove is eliminated so as to prevent boiling of the coolant, and thus prevent a decrease of a cooling effect of a cylinder liner of an internal combustion engine.
The above-mentioned objects of the present invention are achieved by a cooling system comprising:
a supply source of a coolant cooling a cylinder liner;
a plurality of annular passages, formed between a cylinder block and the cylinder liner fitted in the cylinder block along a circumference of an outer surface of the cylinder liner, the annular passages spaced apart from each other in an axial direction of the cylinder liner;
an inflow and an outflow passage for a coolant, connecting the plurality of annular passages, extending in a direction of an axis of the cylinder liner, and provided at diametrically opposite sides of the cylinder liner;
an inlet passage supplying a coolant to the inflow passage; and
introducing means for a coolant, provided so as to prevent generation of a stagnation of the coolant introduced to the annular passages.
According to the present invention, the introducing means eliminates any stagnation in the coolant flowing into each annular passage. As a result, a sufficient amount of coolant flows through the annular passages of the cylinder liner. Therefore, heat of the cylinder liner can be appropriately eliminated, and thus the wall of the cylinder liner can be cooled efficiently.
Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show an example of a conventional cooling system for an internal combustion engine; FIG. 1A is a plane view and FIG. 1B is a cross sectional view taken along a line B--B of FIG. 1A;
FIG. 2 is a partial cross sectional view of the conventional cooling system for explaining a flow of a coolant;
FIG. 3 is a plane view of a first embodiment of the present invention;
FIG. 4 is a partial cross sectional view of a first embodiment of the present invention;
FIG. 5 is a partial cross sectional view of a second embodiment of the present invention;
FIG. 6 is a partial cross sectional view of a variation of the second embodiment of the present invention;
FIG. 7 is a plane view of a third embodiment of the present invention;
FIG. 8 is a partial cross sectional view of a third embodiment of the present invention;
FIG. 9 is a partial cross sectional view of a fourth embodiment of the present invention;
FIG. 10 is a partial cross sectional view of a fifth embodiment of the present invention;
FIG. 11 is a plane view of a sixth embodiment of the present invention;
FIG. 12 is a partial cross sectional view of a sixth embodiment of the present invention;
FIG. 13 is a partial cross sectional view of a variation of the sixth embodiment of the present invention;
FIG. 14 is a partial cross sectional view of a seventh embodiment of the present invention; and
FIG. 15 is a partial cross sectional view of a variation of the seventh embodiment of the present invention;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description will now be given of a first embodiment of the present invention with reference to FIG. 3 and FIG. 4. A plurality of annular grooves 13 1 ˜13 3 circumferentially formed on an outer surface of a cylinder liner 12 are spaced apart from each other in a direction of the axis of the cylinder liner 12. The annular grooves 13 1 ˜13 3 and an inner surface of a bore of a cylinder block 11 jointly form annular passages for a coolant.
Longitudinal grooves 14 and 19 ar formed on an inner surface of the cylinder block 11, and on the outer surface of the cylinder liner 12. The grooves 14,19 extend in the direction of the axis of the cylinder liner 12 and are located at diametrically opposite sides of the liner 12. The plurality of annular grooves 13 1 ˜13 3 are connected to each other by the grooves 14,19. The groove 14 serves as an inflow passage of a coolant and the groove 19 serves as an outflow passage of the coolant.
An inlet passage 15 is connected to the groove 14 and an outlet passage 17 is connected to the groove 19. The conjunction of the inlet passage 15 and the groove 14 functions as an introducing passage part for an inflowing coolant to the annular grooves 13 1 ˜13 3 . The inlet passage 15 is formed so as to be approximately an extension in the radial direction of the annular groove 13 1 , which is one of the annular grooves 13 1 ˜13 3 , located on the uppermost portion of the cylinder liner 12. The grooves 13 2 , 13 3 located below the uppermost groove 13 1 are not in an extension position of the inlet passage 15. Accordingly, a portion of coolant flowing into the grooves 13 2 , 13 3 is bent so as to flow perpendicular to the longitudinal direction of the groove 14.
This embodiment features guiding members 16 1 and 16 2 , as introducing means for a coolant, provided at the portions of the groove 14 close to the respective entrance portions of the annular groove 13 2 and 13 3 . Each of the guiding members 16 1 and 16 2 has a square cross section and triangular shape with a vertex that directs flow to the grooves 13 2 and 13 3 . As shown in FIG. 4, the guiding member 16 1 is positioned within the upper half 1/2L of a width L of the annular groove 13 2 so that a portion of coolant is led to the upstream portion of the annular groove 13 2 . The guiding member 16 2 is provided in the same manner as that of the guiding member 16 1 .
Flow of the coolant in this embodiment is explained below. A coolant, delivered from a pump (not shown), flows into the inlet passage 15, as indicated by an arrow I. A portion of the coolant flows into the groove 14 then, without changing its direction of flow, enters the uppermost groove 13 1 as indicated by an arrow II. The rest of the coolant flows inside the longitudinal groove 14, as indicated by an arrow III, and a portion thereof is led into the upstream portion of the entrance of the groove 13 2 by the guiding member 16 1 . This portion of coolant flows downstream the groove 13 2 . The remaining coolant flows into the lower part of the longitudinal groove 14. In the same manner, a portion of the coolant is led to the upstream portion of the groove 13 3 , as indicated by an arrow IV.
After the coolant enters the annular grooves 13 1 ˜13 3 , the coolant flows along the grooves 13 1 ˜13 3 , while absorbing heat from the cylinder liner 12, then the coolant in each groove 13 1 ˜13 3 enters the longitudinal groove 19. The coolant from the grooves 13 1 ˜13 3 flows together in the groove 19 and the joined coolant flows out via the outlet passage 17.
As mentioned above, in the conventional cooling system, a stagnation is generated at the upstream portion of the annular groove 13 2 because the direction of the coolant flow can not be acutely bent to the direction of the groove 13 2 due to the high velocity thereof. On the other hand, in this embodiment, the coolant is positively led to the upstream portion of the groove 13 2 by the guiding member 16 1 , and thus the coolant flows smoothly throughout the entire groove 13 2 and stagnation is not generated. Coolant flow the groove 13 3 proceeds in the same manner as in the groove 13 2 . Therefore, the boiling of the coolant is eliminated and overheating of the engine is prevented.
FIG. 5 is a partial cross sectional view of a second embodiment of the present invention. In FIG. 5, those parts that are the same as corresponding parts in FIG. 4 are designated by the same reference numerals, and descriptions thereof will be omitted.
This embodiment features guiding members 21 1 and 21 2 , as introducing means for a coolant, provided at the portions of the groove 14 close to the respective entrances of the annular groove 13 2 and 13 3 , in a manner similar to that in the above mentioned first embodiment of the present invention. Each of the guiding members 21 1 and 21 2 has a triangular cross section and a triangular shape with a vertex directed toward the grooves 13 2 and 13 3 respectively. As shown in FIG. 5, the guiding member 21 1 is positioned within the upper half (1/2L where L is the width of the passage) of the annular groove 13 2 so that a portion of coolant is led into the upstream portion of the annular groove 13 2 . The guiding member 21 2 is provided in the same manner as that of the guiding members 21 1 .
Apparent from FIG. 5 and the above description, this embodiment has the same effect for a coolant flow as explained in the description of the first embodiment mentioned above. In addition, each of the guiding members 21 1 and 21 2 of this embodiment has a slanting surface which allows the coolant to be smoothly led to the grooves 13 2 and 13 3 with less pressure loss than in the previous embodiment.
The present invention is not limited to the above mentioned first and second embodiments, for example, as shown in FIG. 6, a guiding member is provided also to the uppermost groove 13 1 for the system in which an inlet passage 33 is formed in a cylinder head 32 which passage lies in an extension direction of a longitudinal groove 31 corresponding to the longitudinal groove 14 of FIG. 5. Guiding members 34 2 and 34 3 are provided for the grooves 13 2 and 13 3 respectively.
Additionally, those guiding members may be applied to a cooling system in which an inlet passage is formed at a portion most distant from a cylinder head. In this case the same effect as in the embodiments above is expected.
A description will now be given of a third embodiment of the present invention with reference to FIG. 7 and FIG. 8. In FIGS. 7 and 8, those parts that are the same as corresponding parts in FIGS. 3 and 4 are designated by the same reference numerals, and descriptions thereof will be omitted.
This embodiment features connecting ports 41 1 ˜41 3 , as introducing means for a coolant, provided on walls between annular grooves 13 1 ˜13 3 . As shown in FIG. 7, the connecting ports 41 1 ˜41 3 are located within an angle range of 10°˜30° from the line A, which line A is a line passing through the center of a vertical cross section of a longitudinal groove 14 and the center of the circular cross section of a cylinder liner 12, symmetrically on both sides of the line A.
Each of the connecting ports 41 1 ˜41 3 comprises a notch formed on a wall between the grooves, so as to connect two adjacent grooves, such as the grooves 13 1 and 13 2 , the grooves 13 2 and 13 3 , the groove 13 3 and the lower groove not shown. The angle range of 10°˜30° is obtained from the results of an experiment that a stagnation is generated within that angle range.
The area of the cross section of each of the connecting ports 41 1 ˜41 3 is reduced toward the lower portion of the cylinder. In other words, the area of the cross section of the connecting port 41 1 is largest, and that of the port 41 2 is smaller than that of the port 41 1 , and that of the port 41 3 is smaller than that of the port 41 2 .
Flow of the coolant in this embodiment is explained below. A coolant, delivered from a pump (not shown), flows into the inlet passage 15, as indicated by an arrow I. A portion of the coolant flows into the groove 14 and enters, without changing direction, into the uppermost groove 13 1 , as indicated by an arrow II. The rest of the coolant flows inside the longitudinal groove 14, as indicated by an arrow III, and a portion thereof flows into the groove 13 2 and the remaining flows to the lower part of the longitudinal groove 14. In the same manner, a portion of the coolant flows into the groove 13 3 , as indicated by an arrow V.
After the coolant enters the annular grooves 13 1 ˜13 3 , the coolant flows along the grooves 13 1 ˜13 3 , while absorbing heat from the cylinder liner 12, then the coolant in each groove 13 1 ˜13 3 enters the longitudinal groove 19. The coolant from the grooves 13 1 ˜13 3 flows together in the groove 19 and the joined coolant flows out via the outlet passage 17.
In this embodiment, a portion of the coolant, entering into the annular grooves 13 1 at a high velocity, is introduced to the upstream portion of the groove 13 2 , where stagnation is generated in the conventional cooling system, via the connecting port 41 1 . Accordingly, a stagnation of the coolant is eliminated in the groove 13 1 . The coolant entering the lower grooves flows in the same manner as that in the groove 13 1 .
As mentioned above, in the conventional cooling system, a stagnation is generated at the upstream portion of the annular groove 13 2 because the direction of the coolant flow can not be acutely bent to match the direction of the groove 13 2 due to the high velocity of the fluid. On the other hand, in this embodiment, the coolant entered into the groove 13 1 is led to the upstream portion of the groove 13 2 via the connecting port 41 1 , and thus the coolant flows smoothly through the entire groove 13 2 and a stagnation, shown in FIG. 2, is not generated. Coolant flow to the groove 13 3 flows in the same manner as that in the groove 13 2 . Therefore, the boiling of the coolant is eliminated and overheating of the engine is prevented.
In addition, since the area of the cross section of the connecting ports 41 1 ˜41 3 becomes larger towards the upper portion of the cylinder liner 12, a distribution of the amount of the coolant flowing in the grooves 13 1 ˜13 3 can be matched to a distribution of the incoming heat of the cylinder liner 12. This results in a cooling effect which allows for maintaining a uniform temperature of the cylinder liner 12.
FIG. 9 is a partial cross sectional view of a fourth embodiment of the present invention. In FIG. 9, those parts that are the same as corresponding parts in FIG. 4 are designated by the same reference numerals, and descriptions thereof will be omitted.
This embodiment features connecting ports 42 1 ˜42 3 , as introducing means for a coolant, provided on walls between annular grooves 13 1 ˜13 3 . Similarly to the connecting ports 41 1 ˜41 3 in the third embodiment, the connecting ports 42 1 ˜42 3 are located within an angle range of 10°˜30° from the line A in FIG. 7, which line A is a line passing through the center of a vertical cross section of a longitudinal groove 14 and the center of a circular cross section of a cylinder liner 12, symmetrically on both sides of the line A.
Each of the connecting ports 42 1 ˜42 3 comprises a notch formed on a wall between the grooves, so as to connect two adjacent grooves, such as the grooves 13 1 and 13 2 , the grooves 13 2 and 13 3 , the groove 13 3 and the lower groove not shown. Unlike the connecting ports 41 1 ˜41 3 in the third embodiment, the area of the cross section of each connecting ports 41 1 ˜41 3 is the same, but the positions of the connecting ports 42 1 ˜42 3 are varied. The position of connecting ports 42 1 is closest to the longitudinal groove 14 and the distance between the groove 14 and other connecting ports increases toward the lower portion of the cylinder liner 12.
According to the results of an experiment, the stagnation areas, generated in progressively higher grooves, occur at positions progressively closer to the longitudinal groove 14 of the cylinder liner 12. The reason for this arrangement of the connecting ports 42 1 ˜42 3 is to match the positions of the connecting ports 42 1 ˜42 3 to the positions where stagnation is generated.
Apparently, by this embodiment, the coolant entering the groove 13 1 is led to the upstream portion of the groove 13 2 via the connecting port 42 1 , and thus the coolant smoothly flows through the entire groove 13 2 , and a stagnation, shown in FIG. 2, is not generated. A coolant flow to the groove 13 3 flows in the same manner as that in the groove 13 2 . Therefore, the boiling of the coolant is eliminated and overheating of the engine is prevented.
FIG. 10 is a partial cross sectional view of a fifth embodiment of the present invention. In FIG. 10, those parts that are the same as corresponding parts in FIG. 4 are designated by the same reference numerals, and descriptions thereof will be omitted.
This embodiment features connecting ports 43 1 ˜43 3 , 44 1 , 44 2 , and 45 1 , as introducing means for a coolant, provided on walls between annular grooves 13 1 ˜13 3 . Similarly to the connecting ports 41 1 ˜41 3 in the third embodiment, the connecting ports 43 1 ˜43 3 , 44 1 , 44 2 , and 45 1 are located within angle range of 10°˜30° from the line A in FIG. 7, which line A is a line passing through the center of a vertical cross section of a longitudinal groove 14 and the center of a circular cross section of a cylinder liner 12, symmetrically on both sides of the line A.
Each of the connecting ports 43 1 ˜43 3 , 44 1 , 44 2 , and 45 1 comprises a notch formed on a wall between grooves, so as to connect two adjacent grooves, such as the grooves 13 1 and 13 2 , the grooves 13 2 and 13 3 , the groove 13 3 and the lower groove not shown. Unlike the connecting ports 41 1 ˜41 3 in the third embodiment, the area of the cross section of the each connecting ports 43 1 ˜43 3 , 44 1 , 44 2 , and 45 1 is the same, but the positions of connecting ports 43 1 ˜43 3 , 44 1 , 44 2 , and 45 1 are varied.
Three connecting ports 43 1 ˜43 3 are located on a wall between the grooves 13 1 and 13 2 . Two connecting ports 44 1 and 44 2 are located on a wall between the grooves 13 2 and 13 3 . A single connecting groove 45 1 is located on a wall between the grooves 13 3 and the lower groove not shown. As mentioned above, a number of connecting ports provided becomes larger toward the upper portion of the cylinder liner 12. As shown in FIG. 10, toward the lower portion of the cylinder liner 12, the position of connecting ports closest to the longitudinal groove 14 progressively increases away from the longitudinal grove 14. The reason for this arrangement of the connecting ports 43 1 ˜43 3 , 44 1 , 44 2 , and 45 1 is so as to match the positions of the connecting ports to the positions where a stagnation is generated.
Apparently, by this embodiment, the coolant entering into the groove 13 1 is led to the upstream portion of the groove 13 2 via the connecting port 42 1 , and thus the coolant smoothly flows through the entire groove 13 2 and a stagnation, shown in FIG. 2, is not generated. A coolant flow to the groove 13 3 flows in the same manner as that in the groove 13 2 . Therefore, the boiling of the coolant is eliminated and overheating of the engine is prevented.
In addition, since the total area of the cross section of each of the connecting ports provided on the same wall becomes larger toward the upper portion of the cylinder liner 12, a distribution of the amount of the cooling flowing in the grooves 13 1 ˜13 3 can be matched to a distribution of the incoming heat of the cylinder liner 12. This results in a cooling effect which allows uniform temperature of the cylinder liner 12 to be maintained.
A description will now be given of a sixth embodiment of the present invention with reference to FIG. 11 and FIG. 12. In FIGS. 11 and 12, those parts that are the same as corresponding parts in FIGS. 3 and 4 are designated by the same reference numerals, and descriptions thereof will be omitted.
In this embodiment the upper side of the wall between grooves protrudes at the coolant entrance portion. This protrusion serves as a coolant introducing means. A protrusion 51 is formed on the wall between the grooves 13 1 and 13 2 . A protrusion 52 is formed on the wall between the grooves 13 2 and 13 3 . A protrusion 53 is formed on the wall between the groove 13 3 and the lower groove not shown. The protrusions 51 has the largest height and the height of other protrusions becomes progressively smaller toward the lower portion of the cylinder liner 12. Each of the protrusions 51˜53 has a smooth curve that matches the stream line of the coolant flow around the entrance of the respective grooves.
Flow of the coolant in this embodiment is explained below. A coolant, delivered from a pump (not shown), flows into the inlet passage 15, as indicated by an arrow I. A portion of the coolant flows into the groove 14, then enters, without changing direction, into the uppermost groove 13 1 , as indicated by an arrow II. The rest of the coolant flows inside the longitudinal groove 14, as indicated by an arrow III, and a portion thereof flows into the groove 13 2 . The remaining coolant flows to the lower part of the longitudinal groove 14. In the same manner, a portion of the coolant flows into the groove 13 3 , as indicated by an arrow V.
After the coolant enters into the annular grooves 13 1 ˜13 3 , the coolant flows along the grooves 13 1 ˜13 3 , as indicated by arrows VI and VII in FIG. 11, while absorbing heat from the cylinder liner 12, then the coolant in each groove 13 1 ˜13 3 enters the longitudinal groove 19. The coolant from the grooves 13 1 ˜13 3 flows together in the groove 19 and the joined coolant flows out via the outlet passage 17.
In this embodiment, the protrusion 51 is formed on the upper side of the wall, where a stagnation is generated in the conventional cooling system. The coolant flows along the protrusion 51 and the direction of flow is smoothly changed to the direction of the groove 13 1 . Accordingly, a stagnation of the coolant is not generated in the groove 13 1 . The coolant entering the lower grooves flows in the same manner as that in the groove 13 1 . Therefore, the boiling of the coolant is eliminated and overheating of the engine is prevented.
Additionally, the protrusions 51˜53 being formed near the longitudinal groove 14 results in that a wall of the cylinder liner 12 is thicker at this particular portion; rigidity of the cylinder liner 12 is increased and thus the reliability of the cooling system is improved.
FIG. 13 is a partial cross sectional view of a variation of a sixth embodiment of the present invention. In FIG. 13, those parts that are the same as corresponding parts in FIG. 4 are designated by the same reference numerals, and descriptions thereof will be omitted.
A cylinder liner 12', having a plurality of annular grooves 28 1 ˜28 3 , is fitted in a cylinder block 11. An inlet passage 26 is formed on the bottom side of the cylinder block 11 and is connected to the longitudinal groove 27. The grooves 28 1 ˜28 3 , inlet passage 26 and groove 27 respectively correspond to grooves 13 1 ˜13 3 , inlet passage 15 and groove 14 in FIG. 12. However, in this system, a coolant is introduced to the longitudinal groove 27 from the bottom side of the cylinder liner 12'. Accordingly, the highest protrusion 54 is formed on the wall between the grooves 28 1 and 28 2 , the second highest between the grooves 28 2 and 28 3 , the third highest between the groove 28 3 and the lower groove, not shown, and so on.
Obviously, this system has the same coolant flow as that in the sixth embodiment mentioned above with respect to prevention of a stagnation of a coolant.
A description will now be given of a seventh embodiment of the present invention with reference FIG. 11 and FIG. 14. In FIG. 14, those parts that are the same as corresponding parts in FIG. 4 are designated by the same reference numerals, and descriptions thereof will be omitted. FIG. 11 is used, for the sake of convenience, because a plane view of the seventh embodiment appear the same as that of the sixth embodiment.
A plurality of annular grooves 61 1 ˜61 3 correspond to the annular grooves 13 1 ˜13 3 of FIG. 4. Each of the grooves 61 2 and 62 3 has a slanting surface of the cylinder liner 12, which surface serves as introducing means for coolant. A slanting angle θ 1 of the groove 61 2 is larger than a slanting angle θ 2 of the groove 61 3 . In other words, a depth of the groove 61 2 along the wall of the upstream side, indicated by an arrow d, is deeper than that of the groove 61 3 . The slanting angle θ becomes progressively smaller toward the lower portion of the cylinder liner 12.
Flow of the coolant in this embodiment is explained below. A coolant, delivered from a pump (not shown), flows into the inlet passage 15, as indicated by an arrow I. A portion of the coolant flows into the groove 14, then enters, without changing direction, into the uppermost groove 61 1 , as indicated by an arrow II. The rest of the coolant flows inside the longitudinal groove 14, as indicated by an arrow III, a portion thereof flows into the groove 61 2 , and the remaining coolant flows to the lower part of the longitudinal groove 14. In the same manner, a portion of the coolant flows into the groove 61 3 , as indicated by an arrow V.
After the coolant enters the annular grooves 61 1 ˜61 3 , the coolant flows along the grooves 61 1 ˜61 3 , as indicated by arrows VI and VII in FIG. 11, while absorbing heat from the cylinder liner 12, then the coolant in each groove 61 1 ˜61 3 enters the longitudinal groove 19. The coolant from the grooves 61 1 ˜61 3 flows together in the groove 19 and the joined coolant flows out via the outlet passage 17.
In this embodiment, the coolant, flowing into the groove 61 1 and having a high velocity, flows preferentially along the upper portion of the groove 61 1 , where a stagnation is generated in the conventional cooling system, rather than flowing along the lower portion of the groove because a cross section of the passage for the coolant is larger in the upper portion due to the slanting surface of the cylinder liner 12 along the groove 61 1 . Accordingly, a stagnation of the coolant is not generated in the groove 61 1 . The coolant entering the lower grooves flows in the same manner as that in the groove 61 1 . Therefore, the boiling of the coolant is eliminated and overheating of the engine is prevented.
In addition, a rigidity of the cylinder liner 12 is increased as compared to that of the conventional cooling system, because the slanting surfaces of the cylinder along the annular grooves results in a thicker wall of the cylinder liner 12. Thus a reliability of the cooling system is improved.
Further, since the area of the cross section of each of the grooves 61 1 ˜61 3 becomes progressively smaller towards the lower portion of the cylinder liner 12, a distribution of the amount of the coolant flowing in the grooves 61 1 ˜61 3 can be matched to a distribution of the incoming heat of the cylinder liner 12. This results in a cooling effect which allows uniform temperature of the cylinder liner 12 to be maintained.
FIG. 15 is a partial cross sectional view of a variation of the seventh embodiment of the present invention. In FIG. 15, those parts that are the same as corresponding parts in FIG. 14 are designated by the same reference numerals, and descriptions thereof will be omitted.
Unlike the seventh embodiment mentioned above, this cooling system includes an inlet passage 33, formed in a cylinder head 32, extending in a direction along a longitudinal groove 31. In this construction, the uppermost annular groove 61 1 ' also has a slanting surface with a slanting angle θ 0 which angle is larger than θ 1 of the lower groove 61 2 . This is because a direction of a coolant entering into the groove 61 1 ' is also changed approximately 90° and the largest stagnation is generated at an entrance of the groove 61 1 '.
This cooling system has the same effect as that of the seventh embodiment mentioned above.
It should be noted that the introducing means, described in the above embodiments, can be applied to a cooling system in which an inlet passage is formed at a portion most distant from a cylinder head, that is a lower portion of the cylinder liner. In this case the same effect as is in the embodiments above will be realized.
The present invention is not limited to the specifically disclosed embodiments, and variations and modifications may be made without departing from the scope of the present invention. | A cooling system for an internal combustion engine eliminate stagnation of a coolant flowing in a plurality of annular passages formed between a cylinder block and a cylinder liner along a circumference of an outer surface of the cylinder linear. Inflow and outflow passages, connected to the annular passages, are provided extending in a direction of an axis of the cylinder liner. An inlet passage, supplying a coolant to the inflow passage, is provided. A guiding member is provided at an entrance of each of the annular passages so as to lead a portion of a coolant to an upstream side of each of the annular passages. Sufficient amount of coolant flows through the annular passages of the cylinder linear, and thus the wall of the cylinder liner can be cooled efficiently. | 5 |
[0001] The present application claims the benefit of prior U.S. Ser. No. 61/191,947, filed Sep. 12, 2008.
FIELD OF THE INVENTION
[0002] The present invention is directed to a construction system employing non-woven, polymer fiber-based panels. More specifically, the present invention is directed to a construction system employing resilient, light-weight panels formed from recycled materials.
BACKGROUND OF THE INVENTION
[0003] In the US most residential and low- to mid-rise commercial buildings are made by framing, also known as stick construction. This is a building technique based around structural members, usually called studs, which provide a stable frame to which interior and exterior wall coverings are attached, and then covered by a roof comprising horizontal joists or sloping rafters covered by various sheathing materials.
[0004] Recently, the US Department of Housing and Urban Development and the National Association of Home Builders has been urging the construction industry to develop and design panelized systems. Thus, manufacturers are reinventing the process of home construction using assembly line automation and prefabricated panels made from a wide variety of materials. The installed panels form a structural envelope that eliminates the need for conventional framing, provides integral insulation, and can be assembled swiftly by less skilled laborers.
[0005] Newer panelized systems incorporate a variety of materials such as light gauge steel, aluminum, concrete, and fiberglass.
[0006] Most of the new panelized systems provide improved insulation, specifically improved air tightness and thermal performance, as compared to traditional stick construction. Conventional wood framing creates a structure where a minor thermal bridge occurs at each vertical stud and gaps can exist between insulation batts and stud surfaces that allow air leaks. Conversely, panel systems offer a dense, uniform and continuous air barrier with few thermal bridges and little opportunity for internal convection.
[0007] Further, industrialization of the construction process is also an advantage for panel manufacturers. Typically, panels can be produced in an automated factory environment, using computer controlled equipment that transfers panel-cutting instructions directly from digital CAD (computer aided design) drawings. The resulting components can be precisely engineered and are easy to inspect for quality control. Once the panels are shipped to the jobsite, they can be quickly assembled, speeding the onsite construction schedule and allowing homes to be placed under roof more quickly.
[0008] Recently developed panelized systems take many forms. The most widely used panels are made from an expanded polystyrene core adhered to oriented strand board (OSB) or plywood skins. The foam alone has little strength, but when bonded to the plywood, it acts as a bridge, or web, to augment structural capacity and resist buckling. Known as structural insulated panels, these panels function quite well but the available geometry is that of a flat panel only and they tend to be quite heavy. Although for certain end-use applications these panels function quite well, the only available geometry is that of a flat panel and the panels are extremely heavy.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention is directed to a construction system based on a plurality of interlocking panels, where each panel is formed of a non-woven, needle-punched, thermo-mechanically compacted fabric, each panel has a first outer surface and an opposed second outer surface, and each panel has dual density gradients, a first density gradient extending from the first outer surface to the center of panel and a second density gradient extending from the center of the panel to the outer surface, such that less dense sections of each panel provide acoustic and thermal insulating properties and more dense sections of each panel provide strength and load-bearing properties. Preferably, the fibers of the non-woven fabric comprises are formed of at least one polymer selected from polyolefins, polyesters, PET and copolymers thereof, PBT, polyamides, aramids, cotton, flax, and hemp. Optionally, at least one of the first outer surface and the second outer surface further includes a coating selected from the group consisting of polyolefins, polyesters, PET and copolymers thereof, PBT, polyamides, and aramids.
[0010] In a preferred embodiment at least some of the panels contain a piezoelectric material in fiber or film form to render the panel capable of sensing and responding to at least one form of environmental stimulation such as sound waves, other pressure waves, and temperature.
[0011] It is also within the scope of the present invention that at least some of the fibers of the non-woven fabric have co-linear channels that extend along the fiber length for improved thermal and acoustic insulation and moisture transport.
[0012] In one embodiment the dual density gradient of at least some of the panels is formed by the panel comprising two thinner panels sandwiched together wherein the sandwiched panels are of at least two differing densities, thereby providing the density gradient.
[0013] Further, the panels can be cut or formed into shapes that allow direct construction of non-traditionally shaped buildings such as orthogonal, angular, and dome-like buildings.
[0014] Furthermore, the present invention is directed to a construction method which includes the steps of providing a plurality of interlocking panels, each panel having a first outer surface and an opposed second outer surface, each panel made by the process which includes the steps of forming a non-woven fabric from individual fibers, needle-punching the non-woven fabric in order to further entangle the fibers, and thermo-mechanically compacting the needle-punched, non-woven fabric, each panel having dual density gradients, a first density gradient extending from the first outer surface to the center of the panel and a second density gradient extending from the center of the panel to the second outer surface, wherein less dense sections of each panel provide acoustic and thermal insulating properties and more dense sections of each panel provide strength and load-bearing properties, and assembling a low-rise building by interlocking the panels.
[0015] Preferably, the non-woven fabric is formed of fibers derived from at least one polymer selected from polyolefins, polyesters, PET and copolymers thereof, PBT, polyamides, aramids, cotton, flax, and hemp.
[0016] In a preferred embodiment the non-woven fabric is formed of thermoplastic fibers and the construction method further includes the step of forming raceways within the interlocked panels with a hot bar, the hot bar having a temperature exceeding the melting temperature of the thermoplastic fibers, the raceways providing means for running utility lines and plumbing throughout the building.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] In accordance with the present invention a construction system is provided which employs non-woven, polymer fiber-based panels, which are, preferably formed from recycled materials. Thus, FIG. 1 illustrates one particular preferred embodiment in which panel A is formed to be slidably interlocked with panel B. That is, the panels A and B possess a tongue and groove arrangement such that in use, when interlocked, there is transmission of load across the joints formed by the tongue and groove configuration of the interlocking panels, thereby substantially eliminating differential deflection between adjoining panel edges.
[0018] Because these panels are textiles, they can be integrated with advanced materials in order to achieve desired design characteristics resulting in, essentially, an “intelligent” building. For example, embedding piezoelectric fibers into the non-woven fabric of the panel can result in a stiffening of the panel construction or actuate a shape memory function. Optical fibers can provide for illumination sensing and control. Phase change materials can provide thermal management capabilities, although even without such the present panels possess thermal insulations properties approaching and, depending on density, exceeding that of conventional fiberglass insulation. Capillary channeled fibers can provide acoustic insulation. Kevlar® or similar fibers can render the present panels bullet-proof. Further, when formed from preferred thermoplastic materials such as recycled PET the present construction panels have been found to be more fire resistant than traditional stick construction, as PET is essentially self-extinguishing.
[0019] Optionally, the present panels may be reinforced with any of a variety of materials including fiberglass or even steel. Further, films providing specific functions such as moisture or gas barriers, or even decorative finishes, may be laminated to one or both surfaces of the panels.
[0020] In a less preferred embodiment, the present panels may serve as the core layer of an insulated panel having plywood or OSB outer layers.
[0021] The present panels have a dual density gradient, preferably with a high density on the side that will form the exterior surface (providing stiffness and moisture barrier properties) and a low density on the side that will form the interior surface (providing thermal and acoustic insulation), although other arrangements of the density gradients are also within the scope of the present invention. For example, each panel may include areas of high density on each surface sandwiching an area of low density in the middle. Alternatively, each panel may be formed of alternating layers of differing densities. The differing layers may be formed individually and laminated together or, more preferably, they may be formed during the thermo-mechanical compaction step of the manufacturing process, as is discussed in greater detail below.
[0022] Thus, in a most preferred embodiment, fibers are spun from resin pellets derived from a recycled material such as PET (polyethylene terephthalate) from plastic bottles. The fibers are then formed into one or more non-woven web layers. The webs then are needle-punched to interconnect the webs or to further entangle the fabric fibers. An exemplary needle-punching machine 70 is shown in FIG. 2 . The machine includes a web feeding mechanism 72 , a needle beam 74 with a needle board and needles, a stripper plate 76 , a bed plate 78 , and a fabric take-up mechanism 80 . The fiber web, sometimes carried or reinforced by a scrim or other fabric, is guided between the metal bed and the stripper plates, which have openings corresponding to the arrangement of needles in the needle board. During the down stroke of the needle beam each barb carries groups of fibers, corresponding in number to the number of needles and the number of barb per needle, into subsequent web layers a distance corresponding to the penetration depth. During the upstroke of the needle beam 74 , the fibers are released from the barbs and interlocking is established. At the end of the upstroke, the fabric is advanced by the take-up mechanism and the cycle is repeated. Needle density is typically determined by the distance advanced and the number of penetrations per stroke.
[0023] It is preferred that the needles used have from one to three barbs (although 6, 9 or even more barbs may be used), and that the needle not penetrate completely through the layers of the webs, but instead penetrate to a depth within about one or two millimeters of the underlying surface of the lowermost web layer. Avoiding full penetration of the needles can reduce the probability of connecting pores from one surface of the non-woven fabric to the other.
[0024] Thereafter, the needle-punched non-woven fabric is thermo-mechanically compacted. This is the process step which sets the physical properties of the panel and renders the web rigid and capable of use in load bearing applications.
[0025] A variety of low density sample panels were produced by the above-described method. Property test results are set forth in Table 1, below.
[0000]
TABLE 1
Test Method
Sample
Property Tested
ASTM
Units
1500
2000
2800
Density
D 1622-03
pcf
3.81
4.96
7.97
Thickness
inches
0.956
0.947
0.935
Nail Pull Resistance Method A
C473-06a
lbf @ max load
52.0
80.1
205.4
Mini-Wall Racking
max load (lbf)
257.60
433.50
862.00
Thermal Resistance (75° F.)
C 518-04
K-Factor
Btu*in/h*ft2*° F.
0.2513
0.2435
0.2429
R-Value
° F.*ft2*h/Btu
3.803
3.888
3.850
R/inch (actual)
° F.*ft2*h/Btu*in
3.979
4.106
4.118
[0026] From these early tests it is clear that the present inventive panels can achieve an insulation R-value close to that of current fiber glass: at an R/inch value of 4, a 3 inch thick panel in accordance with the present invention would achieve an R-value of 12, where a 3 inch sample of fiberglass insulation is typically R-13. The present panels would, of course be heavier than fiberglass, but would provide structural integrity, which fiberglass does not provide.
[0027] Although the present invention has been described in connection with the preferred embodiments, it is to be understood that modifications and variations may be utilized without departing from the principles and scope of the invention, as those skilled in the art will readily understand. Accordingly, such modifications may be practiced within the scope of the following claims. Moreover, Applicant hereby discloses all subranges of all ranges disclosed herein. These subranges are also useful in carrying out the present invention. | A construction system is based on a plurality of interlocking panels, each panel formed of a non-woven, needle-punched, thermo-mechanically compacted fabric, each panel having dual density gradients, a first density gradient extending from the first outer surface to the center of panel and a second density gradient extending from the center of the panel to the outer surface, wherein less dense sections of each panel provide acoustic and thermal insulating properties and more dense sections of each panel provide strength and load-bearing properties. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International Application No. PCT/EP2010/070613 filed Dec. 22, 2010, claiming priority based on Spanish Patent Application No. 200902399, filed Dec. 29, 2009, the contents of all of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the use of a series of sulphated disaccharides for the preparation of a medicament for the treatment of a neurodegenerative and/or neurovascular disease, as well as for the treatment of a traumatic brain or spinal cord injury. The present invention also relates to the use of said sulphated disaccharides for the preparation of a neuroprotective medicament.
BACKGROUND OF THE INVENTION
Neurodegenerative diseases, neurovascular diseases and traumatic brain and spinal cord injuries are one of the most important causes of disability and death in the population. Alzheimer's disease, Parkinson's disease, amyotrophic lateral sclerosis and stroke stand out among these diseases.
These diseases are generally characterized by a loss of neurons, which translates into the onset of language and memory disorders in Alzheimer's disease, movement coordination disorders in Parkinson's disease, paralysis of the voluntary muscles involved in motility, speech and respiration in amyotrophic lateral sclerosis (ALS), hemiplegias and sensory losses in stroke and paralysis in traumatic brain and spinal cord injuries.
Oxidative cell stress is involved in various neurodegenerative and neurovascular diseases. The central nervous system, and specifically the brain, has a high oxygen requirement. Oxygen consumption leads to the overproduction of so-called reactive oxygen species (ROS), such as superoxide or hydroxyl type free radicals or non-radical oxygen such as hydrogen peroxide (H 2 O 2 ), which cause damage both in neuronal and in vascular cells ( Oxidative neurotoxicity in rat cerebral cortex neurons: synergistic effects of H 2 O 2 and NO on apoptosis involving activation of p 38 mitogen - activated protein kinase and caspase -3, J. Y. Wang et al., J. Neurosci. Res. 72, 508-519 (2003)). To control the levels of these oxidant compounds, cells have antioxidant systems, such as superoxide dismutase, glutathione peroxidase, transferrin or vitamin E. Under normal physiological conditions there is an equilibrium between these antioxidant systems and reactive oxygen species. However, problems may arise when said equilibrium is altered due to a decrease of the antioxidant defenses and/or to an overproduction of reactive oxygen species. Under those conditions, oxidative stress can cause cell damage and subsequent cell death, neurons being particularly vulnerable cells.
It is known that oxidative stress is one of the main cell death mechanisms in different cytotoxic models, such as that of glutamate ( Glutamate induces oxidative stress and apoptosis in cerebral vascular endothelial cells: contributions of HO -1 and HO -2 to cytoprotection , H. Parfenova et al., Am. J. Physiol. 290: C1399-C1410 (2006)) or in the H 2 O 2 -induced cytotoxicity model ( Distinct protective mechanisms of HO -1 and HO -2 against hydroperoxide - induced cytotoxicity , Y. S. Kim et al., Free Radic. Biol. Med. 38, 85-92 (2005)) and in neurodegenerative and neurovascular diseases such as Alzheimer's disease, Parkinson's disease, amyotrophic lateral sclerosis, stroke and arteriosclerosis ( Oxidative stress in brain aging, neurodegenerative and vascular diseases: an overview , E. Mariani et al., J. Chromatogr. B Analyt. Technol. Biomed. Life Sci. 827, 65-75 (2005); Oxidative stress and neuronal death/survival signaling in cerebral ischemia , A. Saito et al., Mol. Neurobiol. 31, 105-116 (2005); Oxidative stress in the context of acute cerebrovascular stroke , M. M. H. El Kossi et al., Stroke 31, 1889-1892 (2000); The oxidant stress hypothesis of atherogenesis , L. Iuliano, Lipids 36, suppl: S41-44 (2001)).
The compounds of the present invention are disaccharides containing one or more sulphate groups in their structure, first described in patent EP 1300411 (U.S. Pat. No. 6,680,304). They are useful in the treatment of arthrosis (patent EP 1300411) and in the treatment of tendon, ligament and bone diseases (patent application WO 2008/151898).
The basic structure of these compounds contains the monosaccharides glucuronic acid and glucosamine, bonded by means of β-(1→3) bonds, and with a sulphate group in C-4 and/or in C-6 of the monosaccharide glucosamine.
In view of the above, it is of great interest to find drugs capable of protecting neurons under oxidative stress conditions and of reducing the generation of reactive oxygen species. Said drugs could be highly useful as therapeutic tools for the treatment of neurodegenerative and/or neurovascular diseases, as well as for the treatment of traumatic brain or spinal cord injuries.
The use of the sulphated disaccharides of the present invention in the treatment of a neurodegenerative disease and/or of a neurovascular disease as well as in the treatment of a traumatic brain or spinal cord injury has not been described up until now.
DISCLOSURE OF THE INVENTION
The present inventors have surprisingly found that the compounds described in patent EP 1300411, defined by formula (I), reduce the formation of reactive oxygen species and have neuroprotective activity, protecting against cell death induced by oxidative stress, or by oxygen and glucose deprivation. These compounds also have neuroprotective activity in an in vivo cerebral infarction or stroke model. Furthermore, said compounds do not have cell toxicity and reduce the release of inflammatory markers by astrocytes. The compounds of formula (I) can therefore be used in the treatment of neurodegenerative and/or neurovascular diseases, of a traumatic brain injury or of a traumatic spinal cord injury, and also as neuroprotectors.
The present inventors have also found that the process for obtaining the disulphated disaccharide Ic described in the present invention has the advantage of obtaining said compound with a higher yield with respect to the process previously described in patent EP 1300411.
Thus, the present invention relates to the use of a compound of formula (I):
or a pharmaceutically acceptable salt, prodrug or solvate thereof,
wherein:
R 1 is selected from hydrogen, linear or branched C 1 -C 4 alkyl, phenylalkyl of less than ten carbon atoms and —COCH 3 ;
R 2 is selected from hydrogen, —COCH 3 and —SO 3 Y;
R 3 is selected from hydrogen, linear or branched C 1 -C 4 alkyl, phenylalkyl of less than ten carbon atoms, —COCH 3 and —COPh, wherein Ph is phenyl;
G is selected from —COOR 4 and —COOY;
A and B are independently selected from hydrogen, —SO 3 H, —SO 3 Y and —COCH 3 ,
wherein either A or B is necessarily either —SO 3 H or —SO 3 Y;
R 4 is selected from hydrogen, C 1 —O 2 alkyl and arylalkyl of less than sixteen carbon atoms,
Y is an organic or inorganic cation,
for the preparation of a medicament for the treatment or prevention of a neurodegenerative and/or neurovascular disease, of a traumatic brain injury or of a traumatic spinal cord injury in a mammal, especially in humans.
In a preferred embodiment, the compounds of formula (I) are those wherein R 1 is selected from hydrogen and linear C 1 -C 4 alkyl and G is selected from —COOR 4 and —COOY, wherein R 4 is hydrogen or C 1 -C 2 alkyl and Y is an inorganic cation.
In a more preferred embodiment, the compounds of formula (I) are those wherein: R 1 is hydrogen, R 2 is —COCH 3 and R 3 is hydrogen. The compounds of formula (I) wherein R 1 is methyl, R 2 is —COCH 3 and R 3 is hydrogen are likewise preferred.
In a particularly preferred embodiment, the compounds of formula (I) are those wherein: A is hydrogen, B is —SO 3 Y and G is —COOY, wherein Y is an inorganic cation. The compounds of formula (I) wherein: A is —SO 3 Y, B is hydrogen and G is —COOY, wherein Y is an inorganic cation, are also particularly preferred. The compounds of formula (I) wherein: A and B are —SO 3 Y and G is —COOY, wherein Y is an inorganic cation, are likewise particularly preferred.
An especially preferred individual compound of the invention is: methyl 2-acetamido-2-deoxy-3-O-(β-D-glucopyranosyluronic acid)-4-O-sulpho-α-D-glucopyranoside, disodium salt, of formula:
Another especially preferred individual compound of the invention is: methyl 2-acetamido-2-deoxy-3-O-(β-D-glucopyranosyluronic acid)-6-O-sulpho-α-D-glucopyranoside, disodium salt, of formula:
Another especially preferred individual compound of the invention is: methyl 2-acetamido-2-deoxy-3-O-(β-D-glucopyranosyluronic acid)-4,6-di-O-sulpho-α-D-glucopyranoside, trisodium salt, of formula:
In another preferred embodiment, the neurodegenerative and/or neurovascular disease is associated with oxidative stress.
In another also preferred embodiment, the neurodegenerative and/or neurovascular disease is associated with neuroinflammation.
In another also preferred embodiment, the medicament is an antioxidant medicament.
In another also preferred embodiment, the medicament is a neuroprotective and/or neuroreparative medicament.
In another also preferred embodiment, the medicament is a medicament for promoting neurogenesis, the emission of neurites or neuronal plasticity in the treatment or prevention of a neurodegenerative and/or neurovascular disease, of a traumatic brain injury or of a traumatic spinal cord injury.
In another also preferred embodiment, the treatment or prevention results in the treatment or prevention of neuroinflammation associated with a neurodegenerative or neurovascular disease.
The treatment or prevention preferably results in the treatment of prevention of a neurodegenerative and/or neurovascular disease selected from the group consisting of Alzheimer's disease, Parkinson's disease, amyotrophic lateral sclerosis, multiple sclerosis, stroke, transient ischemic brain attack, Huntington's disease, Friedreich's ataxia, spongiform encephalopathies, dementia with Lewy bodies, Pick's disease, mild cognitive impairment, epilepsy, migraine, schizophrenia, bipolar disorder, vascular dementia and arteriosclerosis. From among these diseases, the most preferred are: Alzheimer's disease, Parkinson's disease, amyotrophic lateral sclerosis and stroke.
The treatment or prevention preferably results in the treatment or prevention of a traumatic brain or spinal cord injury.
The present invention also relates to the use of a compound of formula (I) defined above, or a pharmaceutically acceptable salt, prodrug or solvate thereof, for the preparation of a neuroprotective and/or neuroreparative medicament.
The present invention also relates to the use of a compound of formula (I) defined above, or a pharmaceutically acceptable salt, prodrug or solvate thereof, for the preparation of an antioxidant medicament, preferably useful in the treatment of age-related macular degeneration.
Likewise, the present invention also relates to the use of a compound of formula (I) defined above for the preparation of a medicament for the treatment or prevention of a disease caused by oxidative stress, of a disease requiring neuroprotection or of a disease requiring neurogenesis in a mammal.
The medicament is preferably suitable for oral or topical administration or is presented in injectable form.
The present invention also relates to the use of a compound of formula (I) defined above in the preparation of a reagent for biological assays of oxidative stress in cells or of oxygen and glucose deprivation in tissues.
The present invention also relates to a process for the preparation of the compound of formula (Ic),
characterized in that it comprises the following stages:
(a) reacting the compound of formula (Va)
with the SO 3 .pyridine complex;
(b) treating the intermediate compound obtained in stage (a) with sodium hydroxide;
(c) purifying by precipitation in water/isopropyl alcohol; and
(d) in the event that after stage (c) the compound of formula (Ic) still contains salts, optionally purifying it by column chromatography.
The present invention also relates to a compound represented by formula (I) defined above, or a pharmaceutically acceptable salt, prodrug or solvate thereof, for use in the treatment or prevention of a neurodegenerative and/or neurovascular disease, of a traumatic brain injury or of a traumatic spinal cord injury. The neurodegenerative and/or neurovascular disease is preferably selected from the group consisting of Alzheimer's disease, Parkinson's disease, amyotrophic lateral sclerosis, multiple sclerosis, stroke, transient ischemic brain attack, Huntington's disease, Friedreich's ataxia, spongiform encephalopathies, dementia with Lewy bodies, Pick's disease, mild cognitive impairment, epilepsy, migraine, schizophrenia, bipolar disorder, vascular dementia and arteriosclerosis.
Likewise, the present invention also relates to a compound represented by formula (I) defined above, or a pharmaceutically acceptable salt, prodrug or solvate thereof, for use as a neuroprotector and/or antioxidant.
The compounds of formula (I) used in the present invention have an anomeric carbon in their structure, so the anomeric forms α and β, as well as mixtures thereof, are included in the present invention.
The compounds of formula (I) of the present invention can be in crystalline form as free compounds or as solvates. Suitable solvates are pharmaceutically acceptable solvates. The solvate is preferably a hydrate.
The compounds of formula (I) of the present invention have purity levels as active ingredients greater than 70%, preferably greater than 95%.
The preparation of the compounds of formula (I), according to the present invention, can be carried out following the synthetic routes described in patent EP 1300411.
Depending on the nature of cation Y (organic or inorganic, and among the latter preferably metal cations), organic or inorganic salts can be obtained. Examples of inorganic salts include sodium, potassium, calcium, magnesium, aluminium, ammonium and lithium salts, for example. Examples of organic salts include, ethanolamine, triethanolamine and basic amino acid salts, for example.
Furthermore, the present invention describes an improved process in a pilot plant for obtaining compound Ic from the intermediate compound Va, since a drawback of the process described above for that synthetic stage was the low yield.
From the intermediate compound Va, which can be prepared by means of the process described in patent EP 1300411, the two sulphate groups are introduced using the SO 3 .pyridine complex and, without isolating the intermediate formed, the removal of the pivaloyl protecting groups is carried out to obtain compound Ic. The purification of the compound Ic is carried out by precipitation followed, if desired, by a column chromatography.
The modifications introduced in the preparation of compound Ic from Va, with respect to the process described in patent EP 1300411, are the following:
use of the sulphur trioxide-pyridine (SO 3 .pyridine) complex in the presence of pyridine as a solvent, instead of using the sulphur trioxide-trimethylamine (SO 3 .NMe 3 ) complex in N,N-dimethylformamide; elimination of a stage in the synthetic process, since the intermediate with the two sulphate groups and the pivaloyl protecting groups is not isolated; and purification of the product by precipitation with water/isopropyl alcohol mixtures.
With these modifications in the process for obtaining compound Ic from intermediate compound Va, a 31% yield was obtained instead of the 13.8% yield described above (two synthesis steps).
When a prodrug is mentioned in the present invention it refers to those derivatives which, in vivo, become the compounds of the present invention. Those prodrugs which increase the bioavailability of the compounds of the present invention when they are administered to a patient, or which increase the release of the compound of formula (I) in the brain, for example, are preferred.
When a neuroprotective medicament is mentioned in the present invention it refers to a medicament for protecting vulnerable neurons in neurodegenerative, neurovascular diseases and in traumatic brain and spinal cord injuries.
When a neuroreparative medicament is mentioned in the present invention it refers to a medicament for repairing damaged neurons in neurodegenerative, neurovascular diseases and in traumatic brain and spinal cord injuries.
When neurogenesis is mentioned in the present invention it refers to the formation of new neurons and new neurites and interneuronal connections.
When an antioxidant medicament is mentioned in the present invention it refers to an anti-reactive oxygen species or anti-free radical medicament.
When neuroinflammation is mentioned in the present invention it refers to the astrogliosis presented in the nervous system of patients with neurodegenerative and/or neurovascular diseases or with traumatic brain or spinal cord injuries.
For using in the treatment or prevention of a neurodegenerative disease, of a neurovascular disease, of a traumatic brain injury, of a traumatic spinal cord injury, of a disease caused by oxidative stress, of a disease requiring neuroprotection or neurogenesis, in the treatment or prevention of neuroinflammation associated with a neurodegenerative or neurovascular disease, as an antioxidant medicament or as a neuroprotective and/or neuroreparative medicament, the compounds of formula (I) are formulated in suitable pharmaceutical compositions, using conventional techniques and excipients or carriers, such as those described in Remington: The Science and Practice of Pharmacy 2000, edited by Lippincott Williams and Wilkins, 20th edition, Philadelphia. The pharmaceutical compositions comprise at least one compound of formula (I) of the present invention, or a pharmaceutically acceptable salt, prodrug or solvate thereof with a pharmaceutically acceptable carrier for the administration to the patient. Said pharmaceutical compositions can be administered to the patient in required doses. The administration of the pharmaceutical compositions can be carried out through different routes, for example, oral, intravenous, intraperitoneal, intralesional, perilesional, intratendinous, peritendinous, intrathecal, subcutaneous, intramuscular, topical, sublingual, transdermal or intranasal route. The pharmaceutical compositions of the invention include a therapeutically effective amount of active compound of formula (I), said amount depending on many factors, such as for example the physical condition of the patient, age, sex, particular compound to be used, administration route, administration frequency or severity of the disease. Furthermore, it will be understood that said dosage of active compound of formula (I) can be administered in single or multiple dose units to provide the desired therapeutic effects.
The pharmaceutical preparations of the invention will generally be in solid form, liquid form or as a gel. The pharmaceutical preparations in solid form that can be prepared according to the present invention include powders, pellets, microspheres, nanoparticles, tablets, dispersible granules, capsules, seals and suppositories. The preparations in liquid form include solutions, suspensions, emulsions, syrups and elixirs. The preparations in solid form which are to be converted, immediately before being used, into preparations in liquid form are also contemplated. Said liquid forms include solutions, suspensions and emulsions.
In the figures and examples described below, compound Ic is:
And compound Ib is:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts, at four concentrations (0.001, 0.003, 0.01, and 0.03 μM), the effect of compound Ic on the release of LDH (lactate dehydrogenase) into the extracellular medium as an indicator of cell death induced by the combination of rotenone and oligomycin as a toxic stimulus. The effect of compound Ic was compared with the effect of chondroitin sulphate (CS) at two concentrations (10 and 60 μM) and with the effect exerted by trolox at two concentrations (30 and 300 μM). The baseline (SH-SY5Y cells in the absence of compound Ic and of toxic stimulus) and the control (SH-SY5Y cells cultured in the absence of compound Ic and in the presence of rotenone+oligomycin) are also included.
FIG. 2 depicts, at four concentrations (0.001, 0.003, 0.01 and 0.03 μM), the effect of compound Ib on the release of LDH into the extracellular medium as an indicator of cell death induced by the combination of rotenone and oligomycin as a toxic stimulus. The effect of compound Ib was compared with the effect of chondroitin sulphate at two concentrations (10 and 60 μM) and with the effect exerted by trolox at two concentrations (30 and 300 μM). The baseline (SH-SY5Y cells in the absence of compound Ib and of toxic stimulus) and the control (SH-SY5Y cells cultured in the absence of compound Ib and in the presence of rotenone+oligomycin) are also included.
FIG. 3 depicts, at two concentrations (0.01 and 0.1 μM), the effect of compound Ic on the generation of intracellular reactive oxygen species (ROS) at 30 and 60 minutes after exposing the SH-SY5Y cells (incubated with compound Ic) to hydrogen peroxide (H 2 O 2 ). The baseline (cells in the absence of compound Ic and of H 2 O 2 ) and the control (cells in the absence of compound Ic and with H 2 O 2 ) are also included.
FIG. 4 also depicts, at two concentrations (1 and 10 μM), the effect of compound Ic on the release of LDH into the extracellular medium as an indicator of cell death in rat hippocampal slices subjected to one hour of oxygen and glucose deprivation (OGD) and two hours of reoxygenation. The baseline (slices without compound Ic and without OGD) and the control (slices in the absence of compound Ic and with OGD) are also included.
FIG. 5 depicts, at two concentrations (0.3 and 1 μM), the effect of the compound Ic on cell viability (quantified by means of MTT reduction) in rat hippocampal slices subjected to 15 minutes of OGD and two hours of reoxygenation. The effect of compound Ic was compared with the effect of N-acetylcysteine (NAC) at 10 mM. The baseline (slices in the absence of compound Ic and of OGD) and the control (slices in the absence of compound Ic and with OGD) are also included.
FIG. 6 depicts, at two concentrations (1 and 3 μM), the effect of compound Ib on cell viability (quantified by means of MTT reduction) in rat hippocampal slices subjected to 15 minutes of OGD and two hours of reoxygenation. The effect of compound Ib was compared with the effect of N-acetylcysteine at 10 mM. The baseline (slices in the absence of compound Ib and of OGD) and the control (slices in the absence of compound Ib and with OGD) are also included.
FIG. 7 depicts the effect of compound Ic (0.03 μM) on TNFα production after exposing the rat cerebral cortex astrocytes (incubated with compound Ic) to lipopolysaccharide (LPS) for two hours. The effect of compound Ic was compared with the effect of chondroitin sulphate at 10 μM. The baseline (cells in the absence of compound Ic and LPS) and the control (cells in the absence of compound Ic and in the presence of LPS) are also included.
FIG. 8 depicts the reduction of the cortical infarction volume, expressed in percentage, in the animals treated with 10 mg/kg of compound Ic. The effect of compound Ic was compared with the effect of melatonin at 15 mg/kg. The data represent the mean and the standard deviation of the number of animals which are shown in the parentheses above each bar of the figure. **p<0.05 and ***p<0.001, with respect to the animals treated with saline.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples are merely illustrative and do not represent a limitation of the scope of the present invention.
Examples
Example 1
Improved process for the preparation of methyl 2-acetamido-2-deoxy-3-O-(β-D-glucopyranosyluronic acid)-4,6-di-O-sulpho-α-D-glucopyranoside, trisodium salt, (compound Ic) from intermediate compound Va
4.7 L of pyridine were introduced in a dry reactor under a slight nitrogen stream and at room temperature. 900 g (1.475 moles) of methyl 2-acetamido-2-deoxy-3-O-(methyl 2,3,4-tri-O-pivaloyl-β-D-glucopyranosyluronate)-α-D-glucopyranoside (intermediate compound Va) and 864 g (6.031 moles) of the SO 3 .pyridine complex were added. The mixture was heated at 40° C. for 5 hours with stirring. Then, it was cooled at 20° C., 0.9 L of water were added and a solution of 216 g of sodium hydroxide in 5.4 L of water was slowly added for 30 minutes, cooling at 15-20° C. Then, it was distilled under vacuum to dryness, and the pyridine remains were removed by adding water and distilling under vacuum without exceeding a temperature of 55° C. The resulting residue was dispersed in 3.8 L of methanol and 0.9 L of water and cooled at 0° C., then adding a solution of 324 g of sodium hydroxide in 2.7 L of water for 30 minutes and at 0° C. The temperature was allowed to reach 20° C., it was heated at 40° C. for 2 hours, and subsequently left at room temperature with stirring overnight. Then, 99 mL of glacial acetic acid were added until pH 8 and most of the solvent was distilled under vacuum, without exceeding a temperature of 55° C. Then, and under stirring, 9 L of isopropyl alcohol were added. The mixture was heated at 55° C. for 15 minutes and cooled at room temperature. After stirring for 2 hours, it was filtered in a Büchner funnel to obtain, after drying, 875 g of product containing compound Ic and salts. Compound Ic was purified by means of precipitation to remove the salts. To that end, 875 g of reaction product were dissolved in 1,800 mL of deionized water, heating at 45-50° C. Subsequently, 900 mL of isopropyl alcohol were added, it was slowly cooled at room temperature, and it was left at this temperature and under stirring for one hour. After that time, it was cooled at 0-5° C. for 2 hours, the solid formed, made up of salts, was filtered, washing with a cold solution of water-isopropyl alcohol (2:1). The mother liquor obtained was precipitated by adding isopropyl alcohol with vigorous stirring which was maintained for 2 hours, a product which still contained salts being obtained after filtering and drying the solid at 40° C. in the vacuum oven. The precipitation was repeated again, 271 g of product with a low salt content being obtained. Finally, purification was carried out by means of chromatography in a Dowex 50WX2 column (200-400 mesh) in calcium form (eluent: water), 265 g (31% yield) of pure Ic being obtained.
Optical Rotation: [α] D +18.5° (c 0.54, H 2 O). It was obtained at λ=589 nm, 20° C. and a 10 cm cell with a capacity for 1 mL.
MS: calculated for C 15 H 22 NO 18 S 2 Na 2 : 614.4. Found: m/z 613.7 [M − -Na].
1 H-NMR spectrum-(400 MHz, D 2 O): δ ppm 4.76 (d, 1H, J 12 =3.6 Hz, H-1), 4.60 (d, 1H, J 12 =7.6 Hz, H-1′), 4.52-4.58 (m, 1H, H-6a), 4.36 (dd, 1H, J 34 =10.0 Hz, J 32 =8.8 Hz, H-3), 4.26-4.29 (m, 4H, H-4, H-2, H-6b, H-5), 3.64-3.69 (m, 1H, H-5′), 3.56 (m, 1H, H-4′), 3.37-3.49 (5H, H-3′, OCH 3 , H-2′), 2.03 (s, 3H, COOCH 3 ).
13 C-NMR spectrum (100 MHz, D 2 O): δ ppm 176.61, 174.93 (2×C, COONa, COOCH 3 ), 101.77 (C-1′), 98.46 (C-1), 77.63 (C-5′), 76.22 (C-3′), 75.97 (C-4), 73.41 (C-2′), 73.23 (C-3), 72.52 (C-4′), 69.59 (C-5), 68.29 (C-6), 56.07 (OCH 3 ), 53.91 (C-2), 22.84 (COOCH 3 ).
The NMR spectra were recorded in a 400 MHz Varian instrument. All the assignments were made using standard 1 H- 1 H-COSY and HMQC (Heteronuclear Multiple Quantum Coherence) experiments.
Example 2
Toxicity Studies
The cell toxicity studies were performed on the SH-SY5Y human neuroblastoma cell line, incubating said cells for 48 hours with the compound under study. The cell viability was assessed by quantifying the release of lactate dehydrogenase (LDH), which is a cytoplasmic enzyme which is released into the extracellular medium when the integrity of the cytoplasmic membrane is lost. Compounds Ic and Ib did not show toxicity at the 100 μM dose.
Example 3
Neuroprotective Effect of the Compounds of Formula (I) Against Cell Death Induced by Oxidative Stress
It is known that oxidative stress is involved in neurodegenerative and neurovascular diseases, therefore the objective was to determine the neuroprotective effect of the compounds of formula (I) when the SH-SY5Y human neuroblastoma cells are exposed to oxidative stress.
An oxidative stress model consists of blocking mitochondrial respiratory chain complexes I and V by means of the combination of rotenone plus oligomycin-A, respectively. As a result of the interruption of the mitochondrial respiratory chain, the cell is unable to continue producing ATP, and the free radicals are generated exceeding the capacity of the cell to neutralize them, and as a result, cell death occurs.
Furthermore, for comparison purposes, the neuroprotective effect of chondroitin sulphate (CS), a sulphated glycosaminoglycan with a polymeric structure characterized by a disaccharide which is repeated, made up of N-acetylgalactosamine and D-glucuronic acid, was determined. Most of the N-acetylgalactosamine units are sulphated. The chondroitin sulphate used in the assay of the present invention was mostly a mixture of 4-chondroitin sulphate and 6-chondroitin sulphate. It is known that chondroitin sulphate protects neurons against damage induced by glutamate ( A protective action of chondroitin sulfate proteoglycans against neuronal cell death induced by glutamate , Okamoto et al., Brain Res. 637, 57-67 (1994)), as well as that chondroitin sulphate protects SH-SY5Y human neuroblastoma cells subjected to oxidative stress ( Chondroitin sulfate protects SH - SY 5 Y cells from oxidative stress by inducing heme oxigenase -1 via phosphatidylinositol 3- kinase/Akt , (N. Cañas et al., J. Pharmacol. Exp. Ther. 323(3), 946-953 (2007)).
Finally, the effect of the trolox (a component of vitamin E with antioxidant activity) in the same oxidative stress model was also determined for comparison purposes.
Materials and Methods
SH-SY5Y human neuroblastoma cells were cultured in a monolayer in 75 cm 2 flasks with a vented stopper. The culture medium used was Dulbecco's Modified Eagle's Medium (DMEM) with a high glucose content (4.5 mg/L) and supplemented with 10% foetal bovine serum, 2 mM L-Glutamine, 50 IU/mL penicillin and 50 μg/mL streptomycin.
The cell cultures were maintained in an incubator at 37° C. in a humid environment, with 5% CO 2 and 95% air. The culture medium was changed twice a week, performing 1:4 passages when the cells reached 70-80% confluence. To perform the passages, the cells were detached by means of their treatment with trypsin-EDTA.
For the cell viability assays, the cells were seeded in sterile 48-well plates at a density of 80,000 cells/well. The experiments were performed 24-48 hours after their seeding.
To evaluate the neuroprotective effect of the compounds, the SH-SY5Y cells were preincubated for 24 hours with the compound under study, and subsequently incubated for 24 hours with the compound under study in the presence of the toxic substances (a combination of 10 μM rotenone and 1 μM oligomycin-A); at the end of this period the cell viability was evaluated by quantifying the release of the LDH enzyme.
The assessment of this enzyme was performed by means of a commercial kit (Cytotoxicity detection kit-LDH; Roche) following the instructions of the company. The samples were colorimetrically analyzed in a plate reader (Labsystems iEMS Reader MF), using the suitable filter at 490-600 nm and obtaining the absorbance values.
The % of cell death was defined as the % of LDH released into the extracellular medium with respect to the total (sum of intra- and extracellular LDH).
Compounds Ic and Ib were studied at four concentrations (0.001, 0.003, 0.01 and 0.03 μM), chondroitin sulphate (supplied by Bioibérica, S.A.) was assayed at two concentrations (10 and 60 μM) and trolox (Sigma Aldrich) was assayed at two concentrations (30 and 300 μM). The experiment also included the baseline (SH-SY5Y cells in the absence of compound and of toxic stimulus) and the control (SH-SY5Y cells cultured in the absence of compound and in the presence of the toxic stimulus rotenone plus oligomycin).
Results
FIGS. 1 and 2 show the results of neuroprotection of compounds Ic and Ib against cell death (% of released LDH) induced by the combination of rotenone and oligomycin. Said figures also show the comparative results of chondroitin sulphate and of trolox.
Compound Ic ( FIG. 1 ) achieved the maximum statistically significant protection (47%) at the concentration of 0.03 μM.
Compound Ib ( FIG. 2 ) also achieved the maximum statistically significant protection at the concentration of 0.03 μM, although in this case the protection was of 40%.
As can be observed in FIGS. 1 and 2 , compounds Ic and Ib were more effective than chondroitin sulphate and than trolox in terms of their protective effects, although chondroitin sulphate and trolox reduced cell death induced by rotenone and oligomycin, this protective effect was detected at substantially higher concentrations (10 and 60 μM for chondroitin sulphate; 30 and 300 μM for trolox) than the concentrations required for compounds Ic and Ib.
Example 4
Effect of the Compounds of Formula (I) on the Generation of Reactive Oxygen Species (ROS)
The overproduction of ROS leads to damages both in neuronal cells and in the vascular endothelium, due to the destruction of the lipid membrane and to the rupture of DNA.
The objective was to determine the capacity of the compounds of formula (I) to reduce the generation of ROS after exposing the cells to hydrogen peroxide.
Hydrogen peroxide was used as a producer of free radicals for the purpose of inducing a cell lesion by oxidative stress.
To determine the production of free radicals, the fluorescent probe 2″-7″-dichlorodihydrofluorescein diacetate (DCFDA) was used, which is sensitive to the presence of free radicals, such that when the latter are intracellularly generated there is an increase of fluorescence.
When the fluorescent probe passes into the cell, intracellular esterases hydrolyze the probe, transforming it into DCFH 2 . Peroxidases, cytochrome C and Fe 2+ can oxidize the probe to DCF in the presence of hydrogen peroxide, and the accumulation of DCF in the cell can be measured as an increase of fluorescence at 530 nm when it is excited at 485 nm.
Materials and Methods
SH-SY5Y human neuroblastoma cells were cultured following the procedure described in Example 3.
For the fluorescence assays, the cells were seeded in 96-well plates with opaque walls at a density of 10,000 cells/well. The experiments were performed 24-48 hours after the seeding.
To evaluate the effects of compound Ic on the generation of ROS, the cells were incubated with increasing concentrations of compound Ic (0.01 and 0.1 μM) for 24 hours and then they were preincubated with the fluorescent probe DCFDA for 45 minutes. Subsequently, the baseline fluorescence of each well, both of the wells containing cells and compound Ic and of those containing only the cells, was quantified. Then, hydrogen peroxide was added at the concentration of 50 μM, both to the wells containing cells and compound Ic and to those containing only the cells, and the fluorescence of DCFDA was assessed as an indicator of the generation of ROS at 30 and 60 minutes after the addition of hydrogen peroxide. The baseline fluorescence of each well containing compound Ic was subtracted from it in order to obtain the net fluorescence. The fluorescence values were standardized with respect to the fluorescence caused by hydrogen peroxide at 30 minutes (this value was considered to be 1).
The baseline of the assay (cells in the absence of compound and of toxic stimulus) and the control (cells in the absence of compound and in the presence of hydrogen peroxide) were also included in the study.
Results
FIG. 3 shows that the addition of hydrogen peroxide to the SH-SY5Y cells tripled the production of ROS at 30 and 60 minutes of incubation (Control bars of the Figure).
When the cells were treated for 24 hours with compound Ic, before the exposure to hydrogen peroxide, the ROS generated by hydrogen peroxide at 30 and 60 minutes were significantly reduced. When compound Ic was present in the cells at the concentration of 0.1 μM, a statistically significant reduction of 40% in the formation of free radicals induced by hydrogen peroxide was observed.
These results indicate that the compounds of the present invention are capable of reducing the formation of radical species, with the consequent neuroprotective and antioxidant effect, which makes the compounds of the present invention potential drugs for the treatment of diseases associated with oxidative stress, such as neurodegenerative and neurovascular diseases.
Example 5
Neuroprotective Effect of the Compounds of Formula (I) in Hippocampal Slices Subjected to Oxygen and Glucose Deprivation (OGD)
A known in vitro brain ischemia model consists of oxygen and glucose deprivation in rat hippocampal slices ( Galantamine and memantine produce different degrees of neuroprotection in rat hippocampal slices subjected to oxygen - glucose deprivation , M. Sobrado et al., Neurosci. Lett. 365, 132-136 (2004); Neuroprotective effects of the new thiadiazolidone NP 00111 against oxygen and glucose deprivation in rat hippocampal slices: implication of Erk 1/2 and PPARy receptors , A O. Rosa et al., Experimental Neurology 212, 93-99 (2008)).
The objective of the assay was to determine the neuroprotective effect of the compounds of formula (I) against the lesion caused by OGD in rat hippocampal slices. The lesion was evaluated by measuring the release of LDH into the extracellular medium as an indicator of cell death or by determining cell viability by means of the reduction of the tetrazolium salt MTT to formazan.
Materials and Methods
Male Spague Dawley strain rats (250-325 g) were used. After anaesthesia by means of an intraperitoneal injection of 60 mg/Kg sodium pentobarbital (Euta-Lender®), they were decapitated with a guillotine and the brain was extracted after a craniotomy. The brain was immediately submersed in a dissection solution, a cold (4° C.) modified Krebs-Henseleit solution at pH 7.4, the composition of which is: 120 mM NaCl, 2 mM KCl, 0.5 mM CaCl 2 , 26 mM NaHCO 3 , 10 mM MgSO 4 , 1.18 mM KH 2 PO 4 , 11 mM glucose and 200 mM sucrose, bubbled with 95% O 2 -5% CO 2 . The hippocampi were isolated, embedded in 2% low melting point agarose (Sigma-Aldrich), and cut into 350 μm transverse slices in a vibratome (Leica VT1000S).
After the cutting in the vibratome, the slices were transferred to a vial with sucrose-free dissection Krebs solution, bubbled with 95% O 2 -5% CO 2 for 60 minutes (equilibrium period).
After the equilibrating period, the medium was removed and an oxygenated solution (normal Krebs solution (120 mM NaCl, 2 mM KCl, 2 mM CaCl 2 , 26 mM NaHCO 3 , 1.19 mM MgSO 4 , 1.18 mM KH 2 PO 4 and 11 mM glucose), bubbled with 5% CO 2 and 95% O 2 for 30 minutes (preincubation period), was introduced. The baseline slices were maintained in this oxygenated solution throughout the entire experiment. To induce OGD, the oxygenated solution was replaced with another one which lacked glucose and was bubbled with a mixture of gases of 5% CO 2 and 95% N 2 (anoxic solution). The slices were in a bath at 37° C. After inducing OGD, the anoxic medium was replaced with another one which contained the oxygenated solution (reoxygenation period).
To evaluate the effect of the compounds, they were incubated for the 30 minutes of the preincubation and throughout the OGD and during the reoxygenation. Two OGD-reoxygenation protocols were used: (i) 1 hour of OGD and 2 hours of reoxygenation and (ii) 15 minutes of OGD followed by 2 hours of reoxygenation.
When the OGD-reoxygenation protocol (i): 1 hour of OGD and 2 hours of reoxygenation was used, the slices were incubated with increasing concentrations of compound Ic (1 and 10 μM). The baseline (slices without compound Ic and without OGD) and the control (slices in the absence of compound Ic and with OGD) were also included in the same study.
When the OGD-reoxygenation protocol (ii): 15 minutes of OGD followed by 2 hours of reoxygenation was used, the slices were incubated with increasing concentrations of compound Ic (0.3 and 1 μM) or with increasing concentrations of compound Ib (1 and 3 μM). In the same study these two compounds of the invention were compared with N-acetylcysteine (NAC) at 10 mM. The baseline (slices in the absence of compound Ic or Ib and of OGD) and the control (slices in the absence of compound Ic or Ib and with OGD) were also included.
For the protocol of 1 hour of OGD followed by 2 hours of reoxygenation, the viability was determined by measuring the release of LDH into the extracellular medium according to the method described in Example 3. The quantification of LDH was performed in samples taken (i) after the preincubation period, (ii) after the hour of OGD and (iii) after each hour of reoxygenation (1 hour and 2 hours).
For the protocol of 15 minutes of OGD followed by 2 hours of reoxygenation, the cell viability was evaluated by means of the tetrazolium salt MTT, which is internalized in those cells which are viable and are therefore capable of reducing the tetrazolium to formazan which is an insoluble and coloured product which is deposited in the cell exterior. To that end, after the experiment had ended, the hippocampal slices were incubated with MTT at a final concentration of 0.5 mg/mL in a Krebs-HEPES solution (in mM: NaCl, 144; KCl, 5.9; MgCl 2 , 1.2; CaCl 2 , 2; HEPES, 10; glucose, 11; at pH 7.3) at 37° C. After 3 hours, the medium was removed and the formazan precipitated in the solution was dissolved in dimethylsulfoxide. Then, the absorbance was measured in a plate reader (Labsystems iEMS Reader MF), at 500 nm. The data were represented taking the result of the baseline slices, i.e., those not subjected to OGD, as 100% viability.
Results
FIG. 4 shows that compound Ic reduced cell death in a concentration-dependent after one hour of OGD followed by 2 hours of reoxygenation. Although a protective effect of compound Ic against OGD was observed, the protective effect was greater during the reoxygenation stage. At 2 hours of reoxygenation and at the concentration of 1 μM, compound Ic presented a statistically significant protective effect of 40%.
FIGS. 5 and 6 show that in the protocol of 15 minutes of OGD followed by 2 hours of reoxygenation, the OGD-reoxygenation reduced cell viability from 100% (Baseline) to 67% (Control) and that the two compounds Ic and Ib were capable of offering protection.
Compound Ib showed the maximum statistically significant protection (85%) at the concentration of 3 μM, whereas compound Ic was more potent, showing the maximum statistically significant protection (93%) at a concentration of 1 μM.
FIGS. 5 and 6 also show the higher efficacy of compounds Ic and Ib in comparison with N-acetylcysteine, which presented the maximum statistically significant protection (83%) at a millimolar range concentration (10 mM).
Example 6
Anti-Inflammatory Effect of the Compounds of Formula (I) in Lipopolysaccharide (LPS)-Activated Rat Cerebral Cortex Astrocytes
Inflammation in the nervous system, known as neuroinflammation, has a different behaviour from that which is manifested in the rest of the organism, mainly due to the presence of inflammatory cells typical of brain tissue.
A neuroinflammatory component is found in some neurodegenerative and neurovascular diseases, so the objective of the present study was to determine if the compounds of the present invention were capable of reducing the release of inflammatory markers by the astroglia.
Materials and Methods
Newborn male rats aged 2-3 days were used. After a craniotomy, both cortices were extracted and deposited in a Petri dish with cold PBS. Under a microscope magnifying lens, the meninges of each cortex were extracted. Once clean, they were submersed in cold DMEM and a mechanical dissection was performed with a pipette. Then, the sample was centrifuged at 1,000 rpm for 5 minutes and the supernatant was decanted. The precipitate was resuspended in DMEM with 20% FBS and a mixture of antibiotics (penicillin/streptomycin). Finally, it was passed through a 70 μm filter and seeded in a 75 cm 2 flask with an aerated filter stopper. The calculation for the seeding of the cells was one flask (15 mL of medium) for every newborn used.
The culture medium was replaced after 3 days with a DMEM with 10% serum and the same antibiotics. After one week, 4 μM of ARAC (cytosine arabinoside) was added to each flask to remove the microglia in the culture.
After 3 days of incubation with this cell growth inhibitor, the flasks were stirred at a speed of 250 rpm in a horizontal stirrer inside an oven at 37° C. After 3 hours, the medium was removed from them and it was replaced with a 1:5 mixture of trypsin (0.25% EDTA) PBS. When the medium was removed, the microglia detached with the stirring were removed.
Then, they were left for a few minutes at 37° C. for the trypsin to act. During this time, the astrocytes were observed under the microscope and when they adopted a round shape, or were detached, a 1:5 mixture of FBS/PBS was added to them to block the enzymatic effects of the trypsin.
Subsequently, the medium of each flask was collected and taken to 50 mL Falcon tubes, they were centrifuged for 5 minutes at 1,000 rpm and the supernatant was decanted. The precipitate was resuspended in DMEM with 10% FBS and antibiotics and the cells were counted for their subsequent seeding.
The induction of inflammation in the astrocytes was performed by means of adding 10 μg/mL lipopolysaccharide together with the compounds to be studied (compound Ic at 0.03 μM and chondroitin sulphate at 10 μM) for 2 hours. Then, the RNA of the astrocytes was extracted by the phenol method, with the entire material free of RNAse. The quantification was performed by the direct measurement of absorbance at 260/280 nm in a Nanodrop® spectrophotometer. The amplification of 500 ng of RNA was performed by reverse transcription (5 minutes at 65° C., reverse transcriptase was added to it, 10 minutes at 25° C., 50 minutes at 50° C. and 5 minutes at 85° C.), taking it to a final volume of 15.20 μL.
To conduct the RT-PCR (Reverse Transcription Polymerase Chain Reaction) analysis, an MyiQ5 iCycler system (Bio-Rad Laboratories, Inc., Hercules, Calif.) was used. The thermal annealing conditions were as follows: the initial denaturation at 95° C. for 3 minutes, followed by 40 cycles of 95° C. for 15 seconds and 60° C. for 1 minute. Fluorescence measurements were taken for each annealing step. At the end of each PCR, the data were automatically analyzed by the system and amplification graphs were obtained. For each PCR, 3 μL of template cDNA were added, which was added to 12 μL of IQ™ SYBR-Green Supermix 2×(Bio-Rad) and to which there were added the F and R oligomers for TNF-alpha, IP-10, SOCS, and actin, which was used to prepare the RT-PCR standard curves. All the amplification reactions were carried out in duplicate, and the number of duplicates of the mean threshold cycle (C t ) was used to calculate the expression level (number of copies) of the cytokines, using the curve generated by actin as the standard.
The activity of compound Ic was compared with chondroitin sulphate in the same study. The baseline (in the absence of compound and of LPS) and the control (in the absence of compound and with LPS) were also included.
Results
FIG. 7 shows the anti-inflammatory effect of compound Ic and of chondroitin sulphate in LPS-activated rat astrocytes.
When the rat astrocytes were activated with LPS for 2 hours, there was an increase in the production of TNFα of almost ten times with respect to the baseline (Control bar).
The treatment of the astrocytes, in a simultaneous manner, with LPS and with chondroitin sulphate (10 μM) or with compound Ic (0.03 μM) significantly reduced the production of TNFα, the reduction being greater in the astrocytes treated with Ic (75%) than with chondroitin sulphate (31%).
Example 7
Neuroprotective Effect of the Compounds of Formula (I) in an Experimental Thrombotic Stroke Model in Mice
Neuronal death occurs during brain ischemia or stroke; therefore a medicament with a neuroprotective profile can have a therapeutic potential in patients who have suffered from a cerebral infarction or stroke. To explore if the compounds of formula (I) can offer neuroprotection in vivo, the experimental photothrombotic stroke model was used. In the photothrombosis model a focal cerebral infarction is induced in the area of the cortex illuminated by means of a cold light source in mice previously treated with the Rose Bengal stain; this stain is photosensitive and produces free radicals when it is stimulated with light, causing lesions in the surrounding vascular endothelium, which causes platelet aggregation and the formation of thrombi in the microvessels of the cerebral cortex ( Non - invasive induction of focal cerebral ischemia in mice by photothrombosis of cortical microvessels: characterization of inflammatory responses , M. Schroeter et al., J Neurosci Methods. 117(1), 43-49. (2002); Melatonin reduces infarction volume in a photothrombotic stroke model in the wild - type but not cyclooxygenase -1- gene knockout mice , L Y. Zhou et al., J Pineal Res. 41(2), 150-156. (2006)).
Materials and Methods
Adult male Swiss breed mice from Harlan laboratories (Barcelona), with a weight of about 30 g, were used. Once anaesthetised with isoflurane, the mice were placed in a stereotaxic frame, maintaining their rectal temperature at 37±0.5° C. during the entire procedure. Subsequently, the cranium was exposed by means of a dorsomedial incision in the skin and the periosteum was removed. By means of the use of a micromanipulator, a fibre-optic cable was placed to emit a beam of light of 1.9 mm in diameter and 3000° K, connected to a cold light source (Zeiss KL 1500), in 2.0 mm posterior and 3.0 mm lateral to Bregma on the right side. According to the mouse brain atlas (Franklin and Paxinos, 1986), the sensitive-motor cortex, the putamen caudate and the hippocampus are right below this stereotaxic position. Then, the mice were injected with 1 mg of the Rose Bengal photosensitive probe and the brain was illuminated through the intact cranium for 30 minutes. Finally, the skin was sutured and the animals were left in a cage until their recovery under observation.
The animals were sacrificed by decapitation 72 hours after the ischemia. Then, the brains were extracted, cut into 1 mm thick slices (Brain matrix, Stoelting, Wood Dale, Ill., USA), stained with the tetrazolium salt TTC at 2% and fixed by immersion in 4% paraformaldehyde.
To quantify the cortical cerebral infarction volume, the sections stained with TTC were scanned on both their rostral and caudal part and by means of the image analysis programme ImageJ 1.41 (National Institutes of Health, Bethesda, Md., USA) the area of the ipsi-, contralateral cortex and the cerebral infarction of each of the sections scanned, both in the caudal and rostral part, was quantified. Subsequently, the cerebral infarction volume was calculated.
Protocol of Administration of Compound Ic
A dose of 10 mg/kg of compound Ic was used and melatonin at a concentration of 15 mg/kg was used as a positive control as described by L Y. Zhou et al. ( J Pineal Res. 41(2), 150-156. (2006)). The controls were treated with saline. The different treatments were administered by intraperitoneal (i.p.) route. Compound Ic was administered 24 hours and 1 hour before inducing the brain ischemia. After the induction of the ischemia, the animals were treated by i.p. route twice a day until their sacrifice, 72 hours after the ischemia.
Results
As can be observed in FIG. 8 , in the animals treated with saline, the cortical infarction volume induced by photothrombosis was 6.1±2.18%; said cerebral infarction was significantly reduced in the animals treated with 10 mg/kg of compound Ic (2.8±1.95%). Melatonin, which was used as a positive control, caused a significant reduction of the infarction volume (4.3±1.63%). With the expression of these data in terms of protection, compound Ic at the dose of 10 mg/kg provided a 53% protection (p<0.001), whereas melatonin, at the dose of 15 mg/kg, provided a 29% protection (p<0.05).
These results indicate that the compounds of the present invention can be useful in the treatment of cerebral infarction or stroke. | The present invention relates to the use of a series of sulphated disaccharides for the preparation of a medicament for the treatment or prevention of a neurodegenerative and/or neurovascular disease, of a traumatic brain injury or of a traumatic spinal cord injury. The present invention also relates to the use of said sulphated disaccharides for the preparation of a neuroprotective medicament or of an antioxidant medicament. The neurodegenerative and/or neurovascular diseases are preferably: Alzheimer's disease, Parkinson's disease, amyotrophic lateral sclerosis and stroke. | 0 |
The application is a continuation application of Ser. No. 555,421, filed Nov. 23, 1983 now abandoned, which in turn is a continuation application of Ser. No. 394,225, filed July 1, 1982, now abandoned.
FIELD OF THE INVENTION
The invention relates to laboratory apparatus useful in the assay of biological and biochemical reactants and is particularly concerned with multiwell filtration devices able to retain fluids for substantial periods of time before filtration is performed.
BACKGROUND OF THE INVENTION
Test plates for in vitro analysis which contain a multiplicity of individual wells or reaction chambers are commonly known laboratory tools. Such devices have been employed for a broad variety of purposes and assays as are exemplified by U.S. Pat. Nos. 3,649,464; 4,304,865; 4,276,048; 4,154,795; and U.S. Pat. No. Re. 30,562. Microporous membrane filters and filtration devices containing such microporous membranes have become especially useful with many of the recently developed cell and tissue culture techniques and assays - particularly those in the fields of virology and immunology.
Typically, a 96-well filtration plate is used to conduct multiple assays simultaneously some of which last several hours before filtration is actually performed. With such filtration plates, especially those containing microporous membranes, there is a well recognized and recurrent problem in that fluids in the wells tend to pass through the membrane by capillary action and gravity flow thereby causing a loss of contents from within the reaction well before the desired stage in the experimental design. Prevention of fluid loss by capillary action and gravity flow becomes especially important when living cells or tissues are being maintained or grown within the reaction wells. Under these circumstances, favorable media conditions for the cells or tissue must be maintained for hours or even days and any loss of fluid from the wells, however small, will affect the condition of the cells and influence the results of the assay. Prevention of fluid loss through the membrane in this manner is also vitally important when the assay utilizes very small sample volumes as reactants, such test samples often being less than 100 microliters in volume. The pendant drop that invariably forms on the underside of the microporous membrane due to such capillary action and gravity flow is typically about 50 microliters in volume and it is apparent that a fluid loss of such proportions must drastically affect the assay.
Nevertheless, insofar as is presently known, no filtration apparatus has been able to prevent this loss of fluid from the reaction well, particularly under small sample volume assay conditions.
SUMMARY OF THE INVENTION
A filtration apparatus for the assay of microliter quantities of biological and biochemical reactants is provided comprising a plate having a plurality of apertures open at each end, filtration means disposed across and sealed about one end of each aperture thereby forming a well with a discrete filtering area and a hydrophobic fabric disposed across and bonded adjacent to the filtering area bounded by each well. The hydrophobic fabric prevents a loss of fluid by capillary action and gravity flow from within the well in the absence of an applied differential pressure. Additionally provided are fluid collection means and a guiding projection which directs such fluid as passes through the filtration means to a predetermined location within the fluid collection means.
DESCRIPTION OF THE FIGURES
The present invention may be best understood when taken in conjunction with the accompanying drawing, in which:
FIG. 1 is an expanded view of a vacuum assembly useful with the invention;
FIG. 2 is an overhead view of a filtration apparatus comprising one embodiment of the present invention;
FIG. 3 is a cross-sectional view of the preferred filtration apparatus comprising the present invention;
FIG. 4 is one embodiment of fluid collections means useful with the preferred embodiment illustrated in FIG. 3; and
FIG. 5 is another preferred embodiment of the invention illustrated in FIG. 3.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The invention is an improvement in filtration apparatus having at least one reaction well which typically contains a microporous membrane for the separation and retention of matter from fluids. Attached adjacent to the microporous membrane is a porous hydrophobic fabric which is situated either above or preferably below the filtering microporous membrane. This hydrophobic fabric prevents fluid loss by capillary action and gravity flow through the membrane in the absence of a vacuum force but will still allow diffusion of gases into or out the interior of each well on the plate.
Embodiments of the invention are most useful with the vacuum assembly shown in FIG. 1 which is capable of simultaneously processing 96 individual test samples of up to 440 microliters (ul) each. The vacuum assembly comprises a base 2 which acts as a vacuum chamber and contains a hose barb for connection to a regulated external vacuum source. Housed within the base 2 are fluid collection means 4 which include a collection tray 6 and/or a receiving plate 8 having up to 96 individual chambers for the collection of filtrate. A filter support 10 holding a 96-well filtration plate 12 lies above the fluid collection means 4 separated by gaskets 14 and 16 which form an airtight seal in the presence of a vacuum force.
Detailed views of the filtration plate utilizing the preferred embodiment of the present invention are shown in FIGS. 2 and 3. It will be appreciated that the number of wells found in the filtration plate are simply a matter of convenience for the investigator. The plate 20 may contain as few as one well or as many wells as are functionally permissible given the actual dimensions of the plate. The filtration plate may be formed of any resilient and nonreactive material commonly available, the composition of choice being a matter of convenience or economics only. Each well 22 comprises an aperture 24 through the entire depth of the plate, the thickness of the plate determining the volume of fluid to be retained within the well. The diameter of the aperture will vary to meet the user's needs but typically will range from 3 to 25 millimeters in diameter. The filtration means 26, typically a microporous membrane filter, is disposed across and sealed about the aperature 24 in the plate 20 such that the area across each well will serve as a filtering area 28. Methods of bonding the microporous membrane to the plate and sealing it about the perimeter of the aperature 24 are well known in the art and need not be described in detail here. The composition and flow characteristics of the filtration means 26 forming the filtering area 28 across each aperature 24 is also a matter of choice. Typically nitrocellulose membranes cellulose acetate, polycarbonate and polyvinylidene fluoride microporous membranes are selected because of their proven characteristics in aqueous solutions and tissue culture media. The porosity of the membrane will be selected with a view to the chosen application. Although 0.025 to 10.0 micrometer porosity membranes of 150 micrometers thickness are favored, the filtration means 26 are not limited to microporous membranes as such. Rather, ultrafiltration media can be utilized in lieu of microporous membrane. By the term ultrafiltration media is meant a material capable of retaining a molecule in solution. Such ultrafiltration media are useful for retaining molecules as small as about 100 daltons and generally molecules as large as about two million daltons. Examples of such ultrafiltration media are well known in the art and include polysulfone and other polymeric materials available from Millipore Corporatin under the registered trademark, PELLICON®. Similarly, macrofiltration media such as glass fiber for retention of gross particles may be used. It will be appreciated by those ordinarily skilled in the art that the individual filtering areas 28 bounded by each well 22 can be removed via a filter punch after filtration for further processing if necessary.
As can be seen in FIG. 3, a hydrophobic fabric 30 is disposed across and bonded adjacent to the filtering areas 28 of the well 22. Preferably, the hydrophobic fabric is bonded to the filtration means abutting the well perimeter 32 such that a minute space 34 is created and maintained between the fabric 30 and the filtering area 28. The fabric 30 may be heat bondable or utilize and adhesive for attachment to the filtration means 26. In addition, the fabric 30 may be formed of woven or a nonwoven materials and be composed any of hydrophobic polyester, polyolefin, polytetrafluoroethylene or other polymer--many suitable varieties being commercially available.
It is preferred that attachment of the filtration means 26 and the hydrophobic fabric 30 to the plate 20 be performed as separate steps to insure their proper positioning and the formation of the minute space 34. Nevertheless, it is possible to attach both the filtrations means and the hydrophobic fabric simultaneously, particularly if a heat bondable hydrophobic material is used as the fabric layer.
Affixation of a porous hydrophobic fabric in this manner permits the use of small sample volumes, often less than 100 microliter (hereinafter ul), to be used as reactants. Without the fabric layer, a drop of fluid approximately 50 ul in volume will collect below the filtration means as a pendant drop and become lost. With the hydrophobic fabric in place, the pendant drop that forms below the filtering area 28 as a result of capillary action and gravity flow will be substantially retained within minute space 34 and the tendency for liquid to pass through the filtering area is subtantially reduced or entirely eliminated. As a result, assays during which the well contents require a fluid media incubation phase or a bathing of the reactants in fluid can be performed without errors or inconvenience.
Another aspect of the present invention is the pendant drop release fixture illustrated in FIGS. 3 and 5. This fixture is intended to be used with the multichambered fluid collection means shown in FIGS. 1 and 4 which is designed to receive filtrate from the interior of the well aligned directly above it via a plurality of individual receiving chambers 50. In this manner, the filtrate from each well will be retained separately. This compartmentalization feature alone, however, may not correct for the problem of comingling of filtrates deriving from different wells as the fluid is pulled through the hydrophobic fabric by an applied differential pressure. Similary, in those situations where the hydrophobic fabric is not present or is not necessary for the purposes of the assay, pendant drops will form and routinely collect on the underside of each filtering area. In small volume assays, the worker cannot afford to lose the 50 ul hanging as a drop from the membrane. Even in larger volume assays, an accidental movement or subsequent manipulations of the filter plate will dislodge the pendant drop and cause it to fall into the wrong receiving chamber causing cross-contamination of filtrates and erroneous test results.
Both these kinds of problems are corrected by placement of a pendant drop release fixture--in the form of a guiding projection 60--between the filtering area 28 and the fluid collection means 4 beneath the plate 20. The preferred embodiment of this guiding projection 60 appears in FIGS. 3 and 5 as a series of spikes 61 molded in a pattern corresponding to the individual filtering areas 28 in the plate 20. Each spike 60 serves a dual function: first, as a surface upon which the small volumes of fluid which would otherwise be lost as a pendant drop are collected and removed from the filtering area 28; second, as a guide by which the fluids forming a pendant drop are directed to the appropriate chamber 50 in the fluid collection means 4. The projections 61 can be injection molded or a die cut assembly. Any molding polymer material such as nylon, polystyrene, polycarbonate and polyethylene may be used for making the guiding projections; however, a hydrophilic material is preferred because it promotes interception and guidance of the pendant drop.
It is expected that the hydrophobic fabric and the fluid guiding projection will be used in tandem in the majority of assays. Nevertheless, where retention of fluid within the well is not necessary, the pendant drop release fixture may be used alone to advantage. | A multiwell filtration apparatus for the assay of microliter quantities is provided which prevents fluid loss by capillary action and gravity flow through a microporous membrane or ultrafilter. The filtration apparatus is particularly advantageous in assays requiring maintenance of fluid within the reaction wells for substantial time periods and in small sample volume assays in the range of 100 microliter volumes. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Continuation In Part of U.S. patent application Ser. No. 12/567,679 filed Sep. 25, 2009, which application is incorporated in its entirety herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to supercharger cooling and in particular to cooling a hotter end of a supercharger including two or more rotating rotors.
[0003] Modern roots supercharger have improved efficiency by having an axial inlet at an inlet end and timing gears at an opposite end. Unfortunately, the opposite end is hotter than the inlet end exposing the timing gears to such heat reduced gear and lubricant life.
[0004] Twin screw type superchargers draw air into the rear of the supercharger and compress the air as it travels from the rear to the front of the supercharger between supercharger rotors. According to the ideal gas law, the air traveling through the supercharger is heated proportional to the compression of the air inside the supercharger and is thus hotter at the front of the supercharger then at the rear of the supercharger. Further, no supercharger is 100 percent efficient, and although screw type superchargers are more efficient than roots-type superchargers, they remain approximately 70 to 80 percent efficient, which means that if the ideal temperature increase is 100 degrees, the actual temperature increase in 20 to 30 percent greater (in terms of absolute temperature). This temperature variation from the front and the rear of the supercharger results in a corresponding unequal heating of supercharger components, and as a result, unequal expansion of the supercharger components and an accompanying variation in clearances (for example, rotors, cases, front plate, gears, bearings, and the like) between supercharger components. The rotor bearing are interference fit, and when the end cover becomes hot enough, the bearing may rotate in the bearing seats, damaging the seats, and causing the rotors to contact and destroy the supercharger.
[0005] When the front plate expands from heat, gears positioned by the front plate experiences an increased gear clearance. Correct gear positions are critical in a twin screw supercharger because the gear positions determine the location of the male and female rotors and their separation. Excessive gear clearance may also result in rotor contact, and proper operation of the supercharger requires that the rotors remain in phase with each other throughout the operating temperature range of the supercharger, which is between 100° F. and 450° F.
[0006] A possible solution to the variation of clearances with temperature is to increase rotor to rotor clearance to compensate for the temperature variation over the entire temperature range of supercharger operation. Unfortunately increasing the clearances in a twin screw type supercharger reduces supercharger efficiency. Further, increasing gear clearance results in noisy supercharger operation which is often objectionable to a driver, and accelerates wear of the gears.
[0007] Further, the rotors of twins screw type superchargers are generally made from aluminum. The aluminum rotors generally have 0.003 inches to 0.004 inches of clearance and thus controlling the expansion of the rotors, regardless of the clearances between gears, has been an issue with the twin screw type superchargers for decades. Greater than ideal clearances have been incorporated into the supercharger designed to deal with rotor expansion. Unfortunately these large clearances reduce supercharger efficiency resulting in hotter air charges, lower output, and higher power requirement for operating the supercharger. Further, should the rotors contact each other due to excessive expansion, the supercharger is generally destroyed.
[0008] The front (output) or discharge side of the supercharger is the hottest and rotor contact always occurs towards the front of the supercharger. The rear (inlet) or intake is ingesting cooler ambient air so there is generally no rotor contact at the rear end of the supercharger. And, the higher the temperatures inside the supercharger, the more severe the rotor contact and the farther the contact reaches from the rear to the front of the supercharger.
[0009] The rotors fore and aft shafts and bearings support and stabilize the positions of the rotors. Unfortunately, the front plate having a higher temperature expands more than the rear plate which is closer to ambient air temperature. This temperature imbalance accompanied by the expansion imbalance causes the front of the rotors to separate more than the rear of the rotors. The rotor gears are attached to the front of the rotors and as a result experienced increased gear lash as the fronts of the rotors separate. Both the gear lash and the rotor expansion move the rotors outward closer to the supercharger case and the timing change from the excess gear lash results in circumferentially excess movement of one rotor or in relation to the other.
[0010] In addition to loss of efficiency and damage to the supercharger, the increased temperatures shorten the life of supercharger seals.
[0011] The front case of the supercharger contains the oil used to lubricate the gears and bearings. Friction from the rotating gears, bearings, and seals heat the oil, and higher supercharger rpm, greater boost, and higher air temperature at the front of the supercharger, further contribute to higher oil temperature. These effects combine to make controlling the temperature of the twin screw supercharger extremely difficult.
[0012] A possible solution to cooling the supercharger is to provide a pressurized flow of engine oil to the supercharger gears. Unfortunately, this approach requires external lines to provide a source of pressurized oil to the supercharger, and external drain lines from the supercharger to the engine oil pan to drain the oil from the supercharger, which create potential oil leaks. Further, additional heating of engine oil raises oil temperature and affects oil flow reducing the cooling affect of the oil.
[0013] Thus, a need remains for cooling the front (output) end of a screw type supercharger.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention addresses the above and other needs by providing a supercharger cooling system which provides a path for coolant from an air/coolant heat exchanger to a supercharger intercooler and then loops around the supercharger housing proximal to a hot outlet end of the supercharger and back to the heat exchanger. The heat exchanger may be a dedicated air/coolant heat exchanger or be a vehicle radiator. The intercooler is sandwiched between the supercharger and intake manifold and cools the flow of hot compressed air from the supercharger into the intake manifold. The supercharger cooling loop cools the bearings and seals, the forward ends of the male and female rotors, and the male and female rotor gears. The cooling loop is preferably located between the supercharger rotors and the rotor drive gears to form a barrier to heat. A dedicated pump cycles the coolant flow and restrictions control the flow of coolant to the supercharger.
[0015] In accordance with one aspect of the invention, there is provided a system for circulating engine coolant generally at 160 degrees Fahrenheit to 200 degrees Fahrenheit to the hot front (outlet end) of the supercharger. The cooling provided reduces the temperatures of the rotor bearings, seals, and gears. Providing the coolant flow to the outlet end wall of the supercharger provides a barrier to heat thereby improving performance and reduces wear and failures.
[0016] In accordance with another aspect of the invention, there is provided a system for circulating engine coolant through the outlet end wall of the supercharger. The outlet end wall includes seats for the outlet end rotor bearings and separates the rotor drive gears from the hot compressed air in the outlet end of the supercharger. Preventing overheating of the outlet end wall maintains proper rotor centerdistance thereby improving performance and reduces wear and failures.
[0017] In accordance with yet another aspect of the invention, there is provided the a system for circulating engine coolant through the outlet end wall of the supercharger. The outlet end wall separates the outlet end wall from the hot compressed air in the outlet end of the supercharger. Cooling the outlet end wall provides a barrier to heat reaching the rotor drive gears and lubricating oil inside the discharge side cover which lubricates the rotor drive gears. Such cooling improves lubrication and extends the life of the lubricating oil.
[0018] In accordance with still another aspect of the invention, there is provided the a system for circulating engine coolant through a supercharger housing proximal to the outlet end wall of the supercharger. Cooling the housing proximal to the outlet end wall provides a barrier to heat reaching the rotor drive gears and lubricating oil inside the discharge side cover which lubricates the rotor drive gears. Such cooling improves lubrication and extends the life of the lubricating oil.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0019] The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0020] FIG. 1A is a side view of a supercharged engine according to the present invention.
[0021] FIG. 1B is a top view of the supercharged engine according to the present invention.
[0022] FIG. 1C is a front view of the supercharged engine according to the present invention.
[0023] FIG. 2A is a side view of a supercharger, intercooler, and intake manifold according to the present invention.
[0024] FIG. 2B is a top view of the supercharger, intercooler, and intake manifold according to the present invention.
[0025] FIG. 3 is a cross-sectional view of the supercharger, intercooler, and intake manifold according to the present invention taken along line 3 - 3 of FIG. 2B .
[0026] FIG. 4 shows the supercharged engine, a heat exchanger, and coolant lines according to the present invention.
[0027] FIG. 5 is a front view of a supercharger outlet end wall and intercooler coolant flow according to the present invention.
[0028] FIG. 6 is a cross-sectional view of the supercharger outlet end wall taken along line 6 - 6 of FIG. 5 .
[0029] FIG. 7A is a front view of a coolant channel cover according to the present invention.
[0030] FIG. 7B is an edge view of the coolant channel cover according to the present invention.
[0031] FIG. 8 shows the supercharged engine, a heat exchanger, and coolant lines according to the present invention.
[0032] FIG. 9 shows a cutaway view of the supercharger housing proximal to the outlet end wall showing a coolant path according to the present invention.
[0033] FIG. 10 shows a cross-sectional view of the supercharger housing proximal to the outlet end wall taken along line 10 - 10 of FIG. 9 showing a coolant path according to the present invention.
[0034] FIG. 11 shows a cross-sectional view of a single piece supercharger housing and outlet end wall proximal to the outlet end wall taken along line 6 - 6 of FIG. 5 showing a coolant path according to the present invention.
[0035] Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
[0037] A side view of a supercharged engine 10 according to the present invention is shown in FIG. 1A and a top view of the supercharged engine 10 is shown in FIG. 1B . The supercharged engine 10 includes a screw compressor type supercharger 12 attached to an intake manifold 20 through an intercooler 22 . The screw compressor type supercharger 12 compresses air received through a throttle body 16 and provides the compressed air to the supercharged engine 10 through the intercooler 22 and intake manifold 20 . The screw compressor type supercharger 12 is driven by a belt 14 connecting a crankshaft pulley to a supercharger pulley.
[0038] A side view of the screw compressor type supercharger 12 according to the present invention is shown in FIG. 2A and a top view of the screw compressor type supercharger 12 is shown in FIG. 2B . A supercharger pulley 18 is attached to the screw compressor type supercharger 12 at a front (outlet) end 12 a of the supercharger and the throttle body 16 is attached at a rearward end 12 b . While the supercharger is shown as having the outlet end to the front, belt drives may also be provided to position the inlet end of the supercharger to the front and the supercharger driven from the rear, and such variations are intended to come within the scope of the present invention. The supercharger includes a housing 13 having a length L, an inlet end wall 51 behind the housing 13 , and the outlet end wall 47 ahead of the housing 13 .
[0039] A cross-sectional view of the screw compressor type supercharger 12 taken along line 3 - 3 of FIG. 2B is shown in FIG. 3 . A first rotor 24 and a second rotor 26 are rotatably housed in a housing 13 of the screw compressor type supercharger 12 . The rotors 24 and 26 are turned by the pulley 18 and draw ambient air 28 through the throttle body 16 and through the rear (inlet) end 12 b and into the screw compressor type supercharger 12 . The ambient air is compressed as it passes through the screw compressor type supercharger 12 by the rotors 24 and 26 . The compressed air 29 is pumped through compressed air passage 30 and through the intercooler 22 and the intake manifold 20 into the engine 10 .
[0040] The power produced by a supercharging internal combustion engine 10 is generally increased by increasing the supercharger 12 boost pressure. Increasing the boost pressure necessarily results in increased temperature of the compressed air 29 being pumped into the engine 10 . Such temperature increase is proportional to the absolute pressure increase (the Ideal Gas Law) and further increased by less than 100 percent supercharger efficiency. The hot air flowing through the supercharger further heats mechanical components and lubrication oil of the supercharger. The air flow is heated as it passes from the inlet end 12 b to the outlet end 12 a , and as a result, the components near the front 12 a of the supercharger 12 experience significantly greater temperature rise than near the rear 12 b . Such heating of elements near the front 12 a of the supercharger 12 has resulted in reduced performance, wear to components, and mechanical failures.
[0041] The supercharged engine 12 , a heat exchanger 45 , and coolant lines 40 a , 40 b , and 40 c according to the present invention are shown in FIG. 4 . Increased pressure (i.e., boost) often requires intercooling to prevent detonation. The air to liquid coolant intercooler 22 is popular for many installations because of the compact size and the elimination of a cooling air flow through the intercooler required by air to air intercoolers. The intercooler 22 is conveniently mounted between the supercharger 12 and the intake manifold 20 . The circulating liquid coolant is cooled by air 43 in a radiator 45 which is generally mounted in the front of the car. The line 40 a carries the coolant 41 from a heat exchanger coolant outlet 45 b on the heat exchanger 45 to an intercooler coolant inlet 22 a on the intercooler 22 through a pump 44 . The line 40 b carries the coolant 41 from an intercooler coolant outlet 22 b on the intercooler 22 to a supercharger coolant inlet 12 a on the supercharger 12 . The line 40 c carries the coolant 41 from a supercharger coolant outlet 12 b on the supercharger 12 back to a heat exchanger coolant inlet 45 a on the heat exchanger 45 to complete the cycle.
[0042] The pump 44 may be a mechanical pump or an electric pump. When an electric pump is used the pump may be controlled, for example using a pulse width modulated power signal, to provide the required coolant flow 41 to the supercharger 12 .
[0043] Two restricted flows 41 a and 41 b connect the line 40 b to the line 40 c . The restricted flow 41 a passed through a fixed restriction 48 and the flow 41 b passes through a variable restriction 49 to control the amount of coolant 41 flowing through the supercharger 12 . The variable restriction 49 may be thermostatically controlled and is preferably controlled based on supercharger 12 temperature.
[0044] A front view of a supercharger outlet end wall 47 and coolant flow 41 according to the present invention is shown in FIG. 5 and a cross-sectional view of the supercharger outlet end wall 47 and discharge end cover 59 taken along line 6 - 6 of FIG. 5 is shown in FIG. 6 . As the boost is increased, the temperature of the compressed air 30 pumped into the engine 10 also increases, particularly at the outlet end 12 a of the supercharger (see FIG. 2A ). The outlet end wall 47 is in contact with the hot compressed air 30 causing the temperature of the outlet end wall 47 , the bearings 52 and 53 , the shaft seals 54 and 55 , the rotor drive gears 50 a and 50 b , and lubricating oil inside the discharge end cover 59 to increase under high boost, reducing performance and increases wear and failures.
[0045] The outlet end wall 47 is generally made of aluminium and includes seats 52 a and 53 a for the bearings 52 and 53 . Because of the high thermal expansion of aluminum, outlet end wall 47 does not maintain the centerdistance of the gears 50 a and 50 b and the rotors 24 and 26 when the hot compressed air 30 heats the outlet end wall 47 to high operating temperatures. The gears 50 a and 50 b are made of steel having a coefficient of thermal expansion different from the outlet end wall 47 and as a result the gear mesh of the gears 50 a and 50 b is affected by the expansion of the outlet end wall 47 . The supercharger inlet end wall is also made of aluminium but is continuously cooled by the inlet air 28 at ambient temperature, and as a result, the outlet ends 24 a and 26 a of the rotors 24 and 26 do not maintain the same rotor centerdistance as the inlet ends. Heat is also generated by the rotor drive gears 50 a and 50 b , the pulley 18 , the bearings 52 and 53 and the seals 54 and 55 .
[0046] Some of the heat is further transferred to oil in the space 57 between the discharge end cover 59 and the outlet end wall 47 . The oil is continuously thrown against neighbouring walls, and additionally, a number of mounting bosses spaced around the interior of the discharge end cover 59 tend to collect the oil in the top half of the discharge end cover 59 delaying the oil from running down into the oil sump, resulting in the hot oil heating the discharge end cover 59 . The lubricating quality of the oil may be reduced when the oil is heated excessively resulting in wear to the gears 50 a and 50 b.
[0047] The supercharger cooling system according to the present invention cools the outlet end wall 47 thereby effectively cooling the bearing seats 52 a and 53 a , the bearings 52 and 53 , and the seals 54 and 55 , and creating a barrier to heat from the hot compressed air 30 reaching the gears 50 a and 50 b . As a result, the rotor centerdistance in the outlet end 12 a remains very close to the rotor centerdistance in the inlet end 12 b , and proper gear mesh is maintained, thereby improving performance and reducing wear and failures. Additionally, reducing expansion allows the rotor to rotor centerdistance to be kept small for optimum performance and safe operation.
[0048] More preferably, the flow 41 through the liquid coolant channel 46 circles around the outside radii of the seats 52 a and 53 a of the two bearings 52 and 53 to cool the seats 52 a and 53 a , the bearings 52 and 53 , and the outlet end wall 47 . Cooling the outlet end wall 47 contributes to maintaining the centerdistance between the rotors and the gears, even under high boost conditions. Cooling the bearing seats 52 a and 53 a also helps to maintain an interference fit of the bearings 52 and 53 to the bearing seats 52 a and 53 a . Cooling the outlet end wall 47 also provides a barrier to heat flowing from the hot compressed air flow 30 through the outlet end wall 47 and into the space 57 inside the discharge end cover 59 , thereby preventing or reducing heating of the gears 50 a and 50 b and the oil residing in the space 57 .
[0049] A front view of a coolant channel cover 56 is shown in FIG. 7A and an edge view of the coolant channel cover 56 is shown in FIG. 7B . The coolant channel cover 56 includes an O-ring 56 a circling it's outside edge for sealing outside the coolant flow 41 against a recess edge of the outlet end wall 47 . O-rings 46 a (see FIG. 6 ) provide a second seal between the outlet end wall 47 and the coolant channel cover 56 for sealing inside the coolant flow 41 .
[0050] The present invention reduces heating of the discharge end cover 59 because a rear face of the cooling channel cover 56 is directly cooled by the liquid coolant 41 in channel 46 . The oil in the space 57 is exposed to a front face of the cooling channel cover 56 and is cooled as the oil runs down the front face of the cooling channel cover 56 .
[0051] A supercharged engine 10 ′, the heat exchanger 24 , and coolant lines are shown in FIG. 8 . The supercharged engine 10 ′ is similar to the supercharged engine 10 but does not include an intercooler. The heat exchanger coolant outlet 45 b is connected to the supercharger coolant inlet 12 a.
[0052] In another embodiment, a liquid coolant channel between forward edges 24 ′ and 26 ′ of the rotors 24 and 26 respectively and the bearings 52 and 53 creates a barrier to heat from the hot compressed air 30 reaching the gears 50 a and 50 b improving performance and reducing wear and failures. A cutaway view of a second supercharger housing 13 a proximal to the outlet end wall 47 showing a coolant path 60 through the housing 13 a is shown in FIG. 9 and a cross-sectional view of the supercharger housing 13 a proximal to the outlet end wall 47 taken along line 10 - 10 of FIG. 9 showing the coolant path 60 is shown in FIG. 10 . The rotors include rotor shaft 24 ′ and 26 ′ connecting the rotors to the gears 50 a and 50 b and the coolant path 60 circles the rotor shafts. The coolant path 60 is centered a distance D from the outlet end wall 47 . The distance D is preferably less than three inches and more preferably less than two inches.
[0053] A cross-sectional view of a single piece supercharger housing and outlet end wall 13 ′ taken along line 6 - 6 of FIG. 5 showing the coolant channel 46 is shown in FIG. 11 . The single piece supercharger housing and outlet end wall 13 ′ is a single piece, and is otherwise similar to the supercharger housing and the outlet end wall 47 .
[0054] Space in the engine compartment is often limited and an embodiment of the supercharger cooling system according to the present invention described below uses an existing engine cooling system to provide the desired cooling without adding significant additional parts. The existing engine cooling system includes a radiator mounted in the front of the car and a water pump. The water pump circulates the existing liquid coolant through the radiator and the engine. The water pump may also be used to circulate a part of the total coolant flow to the cooling channel 46 in the outlet end wall 47 to cool the supercharger. A parallel circuit comprising the lines 40 a , and 40 c is connected to the existing vehicle cooling system with the line 40 a connected to a higher pressure point and the line 40 c to a lower pressure point. The amount of liquid coolant cycled through the cooling channel 46 is controlled by the two restrictions 48 and 49 . By altering the size of the two restrictions 8 and 9 each flow can be determined for optimum cooling performance.
[0055] While the above description focuses on a screw type supercharger, those skilled in the art will recognize that the present invention is equally applicable to a roots type supercharger and such cooling for a roots type supercharger is intended to come within the scope of the present invention.
[0056] The liquid coolant is often a water based coolant but may also be a Propylene glycol coolant or any other liquid coolant.
[0057] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | A supercharger cooling system provides a path for coolant from an air/coolant heat exchanger to a supercharger intercooler and then loops around the supercharger housing proximal to a hot outlet end of the supercharger and back to the heat exchanger. The heat exchanger may be a dedicated air/coolant heat exchanger or be a vehicle radiator. The intercooler is sandwiched between the supercharger and intake manifold and cools the flow of hot compressed air from the supercharger into the intake manifold. The supercharger cooling loop cools the bearings and seals, the forward ends of the male and female rotors, and the male and female rotor gears. The cooling loop is preferably located between the supercharger rotors and the rotor drive gears to form a barrier to heat. A dedicated pump cycles the coolant flow and restrictions control the flow of coolant to the supercharger. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of testing a semiconductor storage device.
[0003] 2. Background Art
[0004] [0004]FIG. 3 is a schematic diagram for illustrating a related-art method of testing a semiconductor storage device. In the drawing, reference numeral 1 designates a semiconductor storage device under test. As is well known, a plurality of semiconductor memory cells 2 are arranged along bit lines and column lines.
[0005] Reference numerals 3 and 4 designate redundant lines provided in suitable number to the bit and column lines. Reference numeral 5 designates a terminal for receiving power, a signal, and a test pattern at the time of test operation and for transmitting a test result. Reference numeral 6 designates a tester f or testing the semiconductor storage device 1 . The tester 6 has a power terminal 7 f or supplying power to the semiconductor storage device 1 ; a signal terminal 8 f or supplying a test signal and a test pattern; and a result output terminal 9 for receiving the test result output from the semiconductor storage device 1 .
[0006] [0006]FIG. 4 is a flowchart showing the related-art test method, wherein a nonvolatile storage device is to be tested. In step S 41 , a test is commenced. In step S 42 , an erasure test is performed. The test is performed by means of subjecting all semiconductor storage devices under test connected to the tester 6 to identical voltages for identical periods of time. Further detailed explanations of the test will be provided later. In step S 43 , a writing test is performed.
[0007] The test is identical with an erasure test (step S 42 ), except for a difference between an erasure operation and a writing operation. Through the erasure test (step S 42 ) and the write test (step S 43 ), testing is completed in step S 44 .
[0008] [0008]FIG. 5 is a flowchart showing test procedures of the erasure test (step S 42 ) shown in FIG. 4. In step S 51 , a test is commenced. In step S 52 , a predetermined voltage pulse and a signal are applied to all the semiconductor storage devices (memory cells) for a predetermined period of time, thereby effecting collective writing operation.
[0009] [0009]FIG. 6 shows the distribution of a threshold value (Vth) of the semiconductor storage device under test after writing, and the distribution of the threshold value of the semiconductor storage device after erasure. The vertical axis represents the number of memory cells, and the horizontal axis represents Vth.
[0010] Reference numeral 61 designates a distribution of the threshold value after step S 52 .
[0011] In step S 53 , a pulse which differs in voltage level from that used for writing is applied to the semiconductor storage devices for a predetermined period of time, thereby collectively erasing all the memory cells. At this time, the threshold value Vth also changes. Hence, as indicated by arrow 62 shown in FIG. 6, the distribution of the threshold value Vth after erasure shifts leftward.
[0012] In step S 54 , a lead test is performed, thereby checking threshold values Vth of individual semiconductor storage devices under test. Then, the distribution of Vth after erasure operation is ascertained.
[0013] The threshold values Vth shift in the direction designated by arrow 62 shown in FIG. 6 during the course of progress from a writing phase to an erasure phase. However, the speed of change in the threshold values Vth differs from one semiconductor storage device to another. The distribution of the threshold values Vth after erasure phase varies, as designated by 63 , 64 , and 65 shown in FIG. 6.
[0014] Reference numeral 66 designates a tolerance of high level; and 67 designates a tolerance of low level.
[0015] The distribution 63 corresponds to a center characteristic falling within the tolerance. In this case, a defective bit 68 and a defective line 69 of an anomalous distribution fall outside the tolerance. Reference numerals 64 and 65 designate characteristics that go outside the tolerance.
[0016] In step S 55 shown in FIG. 5, redundancy analysis is performed. By means of a contrast between the distribution of the threshold values Vth after the erasure phase and tolerances 66 and 67 , the number of defective bit and column lines is checked. A determination is made as to whether or not the defective bit and column lines are greater in number than redundant lines ( 3 and 4 shown in FIG. 3). When the defective bit and column lines are lesser in number than the redundant lines, there is made a determination on restoring all the defective bit and column lines by replacing the bit and column lines with the redundant lines 3 and 4 . In a case where the defective bit and column lines are greater in number than the redundant lines, the defective bit and column lines equal in number to the redundant lines 3 and 4 are restored by being replaced with the redundant lines 3 and 4 .
[0017] In the case shown in FIG. 6, a small number of defective bit lines show an anomalous distribution 68 , and a small number of defective column lines show an anomalous distribution 69 . Hence, the distribution 63 enables restoration of the defective bit and column lines by means of replacing the bit and column lines with redundant lines. However, in relation to the distribution 64 , a large number of defective bit and column lines exist outside the tolerance of high level 66 . In relation to the distribution 65 , a large number of defective bit and column lines fall outside the tolerance of low level 67 . Hence, restoration of all the defective bit and column lines by replacement of the bit and column lines with redundant lines is impossible.
[0018] In step S 56 , the semiconductor storage devices under test having the defective bit and column lines, which could not have been restored by the redundant lines, are determined to be defective. In step S 57 , the test is completed.
[0019] The method of testing related-art semiconductor storage devices is implemented in the manner as mentioned above. All semiconductor storage devices are tested under the same conditions; that is, at a given voltage and a given period of time. A voltage level is changed once during the course of progress from collective writing operation to collective erasure operation and vice versa. A lead test is performed in accordance with the distribution of the threshold values Vth determined by the thus-changed voltage level. Hence, there arises a problem of a characteristic of a semiconductor storage device being likely to go out of tolerance as a result of, e.g., an increase in the width of distribution of threshold values Vth or a distribution which has a narrow width but whose position varies greatly.
[0020] Further, the width of a distribution recently tends to become smaller, because of miniaturization. In addition to a tendency toward a smaller tolerance, the number of memory cells is increased in association with an increase in storage capacity, thereby resulting in a wider distribution. Hence, there also arises a problem of a characteristic of a semiconductor storage device becoming likely to go out of tolerance.
SUMMARY OF THE INVENTION
[0021] The present invention has been conceived to solve the problem set forth. The present invention is aimed at providing a method of testing a semiconductor storage device which subjects a plurality of semiconductor storage devices to an optimized test, thereby restoring a considerable number of semiconductor storage devices, which would otherwise been determined to be defective under the related-art test method.
[0022] According to one aspect of the present invention, a method of testing a semiconductor storage device comprises the following steps. Firstly a plurality of test patterns are set in a tester for testing semiconductor storage devices. Secondly different test patterns are applied to respective semiconductor storage devices connected to said tester. Thirdly it is determined whether or not results of the tested semiconductor storage devices fall within a predetermined tolerance.
[0023] Hence, from among semiconductor storage devices which have been determined to be unrestorable under the related-art test method, a considerable number of semiconductor storage devices can be restored.
[0024] Other and further objects, features and advantages of the invention will appear more fully from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a flowchart showing a test method according to the first embodiment.
[0026] [0026]FIG. 2 is a flowchart showing a test method according to the second embodiment.
[0027] [0027]FIG. 3 is a schematic diagram for illustrating a related-art method of testing a semiconductor storage device.
[0028] [0028]FIG. 4 is a flowchart showing the related-art test method, wherein a nonvolatile storage device is to be tested.
[0029] [0029]FIG. 5 is a flowchart showing test procedures of the erasure test (step S 42 ) shown in FIG. 4.
[0030] [0030]FIG. 6 shows the distribution of a threshold value (Vth) of the semiconductor storage device under test after writing, and the distribution of the threshold value of the semiconductor storage device after erasure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] First Embodiment
[0032] A first embodiment of the present invention will now be described hereinbelow by reference to FIG. 1.
[0033] [0033]FIG. 1 is a flowchart showing a test method according to the first embodiment. In step S 11 , a test is commenced. In step S 12 , a plurality of test patterns are set for a tester. Tests are performed by means of applying different test patterns to a plurality of semiconductor storage devices under test connected to the tester.
[0034] In some cases, different test patterns are applied to respective semiconductor storage devices. However, in another case, identical test patterns are applied to a limited number of semiconductor storage devices.
[0035] In this respect, the test method according to the present invention differs from the related-art test method which performs a test under the same conditions by means of applying a single test pattern to all semiconductor storage devices under test.
[0036] The method of the present invention is identical with the related-art method in terms of the manner of checking threshold values Vth of the semiconductor storage devices through a lead test, and of analyzing redundancy and determining whether or not the semiconductor storage devices are defective on the basis of the thus-checked threshold values. Hence, its repeated explanation is omitted, and the test is completed in step S 13 .
[0037] In the embodiment, different test patterns are applied to respective semiconductor storage devices, thereby optimizing test conditions. As a result, from among semiconductor storage devices which have been determined to be unrestorable by the related-art test method, a considerable number of semiconductor storage devices can be restored.
[0038] Second Embodiment
[0039] A second embodiment of the present invention will now be described by reference to the accompanying drawings.
[0040] [0040]FIG. 2 is a flowchart showing a test method according to the second embodiment. More specifically, in the second embodiment, a plurality of tests are set, and semiconductor storage device—which have been determined to be effective through all the tests and by virtue of restoration using redundant bit and column lines—are determined to be non-defective.
[0041] In FIG. 2, for example, a test is performed twice.
[0042] More specifically, in step S 21 a test is commenced. In step S 22 , a plurality of test patterns are set for a tester, as in the case of the first embodiment. Different test patterns are applied to respective semiconductor storage devices connected to the tester, thereby performing a first test.
[0043] In some cases, different test patterns are applied to respective semiconductor storage devices. However, there may be a case where identical test patterns are applied to a limited number of semiconductor storage devices.
[0044] Even this test is identical with the related-art test method in terms of the manner of checking threshold values Vth of the semiconductor storage devices through a lead test, and of analyzing redundancy and determining whether or not the semiconductor storage devices are defective on the basis of the thus-checked threshold values. Hence, its repeated explanation is omitted. In step S 23 , a plurality of semiconductor storage devices determined to be effective in the first test, including semiconductor storage devices that have been restored in the first test, are subjected to a second test through use of the result of the first test and a test pattern differing from that employed in the first test. The second test is identical with the first test in terms of procedures and a determination method.
[0045] The semiconductor storage devices that have been determined to be effective even in the second test are determined to be non-defective, and the test is completed in step S 24 .
[0046] Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may by practiced otherwise than as specifically described.
[0047] The entire disclosure of a Japanese Patent Application No. 2001-149214, filed on May 18, 2001 including specification, claims, drawings and summary, on which the Convention priority of the present application is based, are incorporated herein by reference in its entirety. | A plurality of test patterns are set in a tester for testing semiconductor storage devices. Different test patterns are applied to respective semiconductor storage devices connected to the tester. A determination is made as to whether or not results of the tested semiconductor storage devices fall within a predetermined tolerance. | 6 |
This application is a continuation of application Ser. No. 337,745, filed Apr. 13, 1989 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a container for a roll of a light-sensitive strip material such as a photographic roll film or a roll of photographic paper. More particularly, this invention relates to a lightproof container having an opening for drawing out the light-sensitive strip material where teremp cloth is provided.
2. Description of Prior Art
As the container for a roll of a light-sensitive strip material, various types have been disclosed in U.S. Pat. No. 4,148,395, U.S. Pat. No. 4,179,028, U.S. Pat. No. 4,239,164, U.S. Pat. No. 4,272,035, U.S. Pat. No. 4,291,802, U.S. Pat. No. 4,398,814, U.S. Pat. No. 4,403,845, Japanese Patent KOKAI No. 60-156058, Japanese Patent KOKOKU No. 59-36736 and Japanese Utility Model KOKOKU No. 56-16608.
Generally, a light-shielding member is provided at the drawing out part of a container for a light-sensitive strip material in order to prevent the inner light-sensitive strip material from being exposed to the light leaked from the drawing out part. Various light-shielding members are known, and among these, the light-shielding members mainly composed of cloth are called teremp cloth.
An example of conventional teremp cloth disclosed in Japanese Utility Model KOKOKU No. 46-20539 is shown in FIG. 19. This teremp cloth was composed of a woven ground fabric 1 and coreless pile yarn 4 woven thereinto. The ground fabric 1 was formed by weaving the warp 2 and the woof 3 like shown in FIG. 20. The above coreless pile yarn was formed from a soft raw yarn such as viscose yarn or acetate yarn by crimp processing, and the ground fabric 1 was impregnated with an adhesive material 5 for filling in order to fix the pile yarn 4. Generally, such a teremp cloth was manufactured first by weaving the warp 2 and the woof 3 together with entangling pile warp yarn 4 therein to form double velvet and then by cutting the loop.
However, in the case of the conventional teremp cloth as shown in FIG. 19, fraying or falling out of pile yarn occurs during the manufacture of the teremp cloth and drawing out or in the light-sensitive strip material. Dust from the pile yarn adheres to the surface of the light-sensitive material, and causes trouble in exposure and development. In addition, it is necessary to arrange the orientation of pile yarn so as to prevent meander movement of the light-sensitive material during its drawing out. It is also a problem that its manufacture process is complicated and manufacturing cost is expensive. Particularly, in the case of the container for a roll of photographic color printing paper capable of loading in a light room, adhesion of pile yarn dust is a serious problem under high temperature and high humidity conditions because of increasing adhesion of the gelatin layer.
A filling material solution was impregnated into the ground fabric 1, and dried to form a filling layer 5 which fixed the pile yarn 4 to the ground fabric 1. A heat-sealable adhesive layer 6 was coated on the filling layer 5, and the teremp cloth was stuck on the drawing out opening of container body 7.
In such a conventional teremp cloth, the weaving yarn of ground fabric must be thickened in order not to impregnate the filling material solution deeply into the pile yarn in the coating process of the filling material solution. As a result, a velvet cloth made of a large quantity of yarn was employed as the teremp cloth, though it was expensive. Besides, the thickness of the adhesive layer 6 varied according to the irregularity of the ground fabric, impregnation rate of adhesive, ununiformity in weaving yarn arrangement of the ground fabric or the like, and various problems occurred caused by the variation of the adhesive layer thickness, such as unstable adhesive strength to container body 7, significant non-uniformity in light-shielding in the case of an adhesive containing a light-shielding material, generation of furrows on ground fabric 1, wrinkling and the like. In the case of coating a hot-melt adhesive layer, similar problems occurred.
SUMMARY OF THE INVENTION
An object of the invention is to provide a container for a roll of a light-sensitive strip material wherein the pile yarn of teremp cloth is not so deeply impregnated with a filling material solution, even though the ground fabric is not so dense.
Another object of the invention is to provide a container for a roll of a light-sensitive strip material not giving rise to troubles in exposure and development caused by adhesion of pile yarn dust.
Another object of the invention is to provide a container for a roll of a light-sensitive strip material using a teremp cloth wherein the thickness of the adhesive layer for fixing teremp cloth on the container body is made uniform and various problems caused by non-uniformity in the thickness of the adhesive layer are solved.
Such objects can be achieved by coating the molten resin of polyolefin copolymer on the ground fabric of teremp cloth to form a filling layer usable as the adhesive layer to attach the teremp cloth to the container body and/or by laminating a multilayer coextruded film comprising an ethylene copolymer resin adhesive layer for fixing the teremp cloth on the container body and a thermoplastic resin base layer. The multilayer coextruded film greatly contributes to the improvement in the uniformity of the adhesive layer.
Thus, the present invention provides a container for a roll of a light-sensitive strip material having a core on which said light-sensitive strip material is coiled to form a roll, an opening for drawing out said light-sensitive strip material and a teremp cloth provided on said opening for shielding the light-sensitive material from light, wherein a filling layer formed of polyolefin copolymer resin usable as the adhesive layer for fixing said teremp cloth on the container body is provided at the ground fabric of said teremp cloth.
The present invention also provides a container for a roll of a light-sensitive strip material having a core on which said light-sensitive strip material is coiled to form a roll, on opening for drawing out said light-sensitive strip material and a teremp cloth provided on said opening for shielding from light, wherein a multilayer coextruded film is laminated under the ground fabric of said teremp cloth, and said multilayer coextruded film has a tensile strength of more than 500 g/15 mm width and comprises an adhesive layer of an ethylene copolymer resin having a comonomer content of 5 to 36% for fixing said teremp cloth on the container body and a thermoplastic resin base layer having a melting point higher than said ethylene copolymer resin adhesive layer by 10° C. or more and a Young's modulus of more than 15 kg/mm 2 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 14 are schematically illustrated sectional views of teremp cloths attached to the container body according to the invention.
FIGS. 15 to 18 are perspective views of containers embodying the invention.
FIG. 19 is a schematically illustrated sectional view of a conventional teremp cloth stuck on a container body.
FIG. 20 is a schematic plan view illustrating a woven structure.
DETAILED DESCRIPTION OF THE INVENTION
The polyolefin copolymer resin for the filling layer has a strong adhesive force to a ground fabric and it can fix pile yarns to the ground fabric. It can adhere teremp cloth on the drawing out opening of a container body by reactivating the resin by means of a heat-sealing method or an ultrasonic heating method, and it has a viscosity so as not to impregnate into pile yarns up to the vicinity of their tips at the time of coating. It is also necessary for the polyolefin copolymer resin not to adversely affect the light-sensitive material. Such a polyolefin copolymer resin may be selected from various thermoplastic polyolefin copolymer resins, and a particularly preferable resin is ethylene-ethylacrylate (EEA) resin having an ethylacrylate content of more than 6% by weight measured by NUC test method. This EEA resin is excellent in coloring, heat stability, melt extrusion coating, adhesion to paper, metal and thermoplastic resin, and homogeneous blending with carbon black and other thermoplastic resins. Representative manufacturers of the EEA resin are UNION CARBIDE, NIPPON UNICAR, MITSUBISHI PETROCHEMICAL, SUMITOMO CHEMICAL, MITSUI POLYCHEMICALS, etc.
Light-shielding material such as carbon black, metal powder or aluminum paste may be blended with the polyolefin copolymer resin in order to prevent entry of light through the filling layer. Antistatic agent may also be blended in order to prevent static electrification caused by the friction between the light-sensitive strip material and the teremp cloth.
The thickness of the filling layer is usually 15 to 150 μm, preferably 20 to 100 μm.
The filling layer may be formed by various coating methods, however, extrusion coating is preferable because of small neck-in, strong adhesive force to ground fabric, good separability from the chill roll and easy and inexpensive production.
The teremp cloth may directly be attached to the drawing out opening of the container body using the filling layer as the adhesive layer. However, it is preferably attached through the multilayer coextruded film. In the latter case, the filling layer may also be a conventional one.
The ethylene copolymer resin adhesive layer is incorporated in order to adhere the ground fabric of teremp cloth to the container body made of paper, plastic, metal or the like. In view of a balance between heat-sealability and blocking, preferable resins for this layer are EEA resin, ethylene-methylacrylate copolymer (EMA) resin, ethylene-vinylacetate copolymer (EVA) resin, ethylene-acrylic acid copolymer (EAA) resin and ethylene methacrylic acid copolymer (EMAA) resin. The comonomer content of the copolymer resin is 5 to 36%. When the comonomer content is less than 5%, heat sealing to the container body made of paper, plastic or metal becomes difficult. While, when the comonomer content is beyond 36%, blocking occurs.
In order to secure light-shielding or antistatic property, light-shielding material or conductive light-shielding material is preferably blended into the copolymer resin layer. For example, blending 0.1 to 20% by weight of carbon black is particularly preferable.
The thickness of the ethylene copolymer resin layer is usually 5 to 145 μm, and 15 to 80 μm is preferable.
The thermoplastic resin base layer is incorporated in order to prevent wrinkling or furrowing, to secure tensile strength, to prevent curling, to prevent unevenness in thickness and the like, at the molding of the multilayer coextruded film and at the laminating on the ground fabric. The melting point of the thermoplastic resin base layer is higher than the foregoing ethylene copolymer resin layer by 10° C. or more. The multilayer coextruded film is first laminated under the teremp cloth, and cut into a prescribed size. This teremp cloth is heat-sealed on the drawing out opening of the container body. At that time, if the melting point is not higher the copolymer resin layer by 10° C., the teremp cloth is separated by layer separation. Additionally, Young's modulus of the thermoplastic resin layer is more than 15 kg/mm 2 . In the cast that the Young's modulus is less than 15 kg/mm 2 , wrinkling, furrowing and elongation occur caused by tension added during laminating the multilayer coextruded film on the teremp cloth, and thereby film thickness and light-shielding of the multilayer coextruded film become uneven. Examples of the thermoplastic resins suitable for such a base layer are various polyolefin resins, particularly polyethylenes such as low-density polyethylene (LDPE), low-pressure linear low-density polyethylene (L-LDPE), medium-density polyethylene (MDPE) and high-density polyethylene (HDPE), polypropylenes, and blended resins containing more than 50% by weight of the above polyethylene or polypropylene. 0.3 to 15% by weight of carbon black is preferably blended into the thermoplastic resin. The above polyethylenes and polypropylenes containing the above amount of carbon black are excellent in film moldability, prevention of blocking, Young's modulus of film, prevention of winkling at lamination, less deterioration of film surface, and the like. The thickness of the thermoplastic resin base layer is usually 5 to 145 μm, preferably 15 to 80 μm.
The multilayer coextruded film may be composed of three or more layers. In this case, the extra layer may be the same or a different ethylene copolymer resin layer, the same or a different ethylene copolymer resin layer, the same or a different thermoplastic resin base layer, or another intermediate layer capable of being coextruded. The total thickness of the multilayer coextruded film is usually 30 to 150 μm, and the total content of light-shielding material is preferably 0.3 to 30 g/m 2 . The tensile strength of this multilayer coextruded film is more than 500 g/15 mm width. When the tensile strength is less than 500 g/15 mm width, this film becomes liable to be broken, winkled or furrowed at the time of laminating on the teremp cloth.
Adhesion of the multilayer coextruded film on the ground fabric or teremp cloth may be carried out by any known method, however, wet lamination, dry lamination and extrusion laminating are preferable in view of securing the softness of teremp cloth and efficient production.
The fiber forming the teremp cloth is not limited, however, polyester fiber and polyamide fiber are preferable because of low hygroscopicity and good restoration. Moreover, they can be cut by fuging such as heat-slitting or supersonic-slitting without forming fray at the cut position. Heat setting after raising is acceptable, and their physical strengths are large. The teremp cloth is preferably knitted fabric because of less falling out of yarns. Examples of preferred teremp cloth are raising knit (pile knit), wet knitted fabrics, such as tubular knitted fabric and plain stitch fabric, raised to form looped piles, warp knitted fabrics, such as tricot fabric, raschel fabric including double raschel fabric and milanese fabric, raised to form looped piles, and sinker pile fabric having looped piles manufactured by using a circular knitting machine.
In the case of utilizing the foregoing filling layer as the adhesive layer, the filling layer is reactivated (melted) by known method such as using supersonic waves or high-frequency waves, and the teremp cloth is then stuck on the container body. An adhesive layer may be coated on the filling layer, and teremp cloth is stuck on the container body through this adhesive layer. In the case that the foregoing multilayer coextruded film is laminated, the ethylene copolymer resin adhesive layer is utilized as the adhesive layer. This adhesive layer is reactivated in a similar manner as above, and then stuck on the container body.
The light-sensitive strip material placed in the container of the invention is not limited, and includes color photographic printing paper, printing paper for computerized type-setting system, photoresist, microfilm for computer and JIS 135-type photographic film. The container to which the present invention can be applied is any of known container admitting a roll of the above light-sensitive strip materials coiled around a core and a drawing out the light-sensitive strip material from drawing out opening. Examples of such a container are various light-shielding containers for microfilm for computer, for printing paper for computerized type-setting system, and for color photographic printing paper, and JIS 135-type photographic film cartridge.
EXAMPLES
EXAMPLES 1 to 6
Examples of the container provided with the filling layer are illustrated in FIGS. 1 to 6.
The light-shielding teremp cloth 19a shown in FIG. 1 is composed of a ground knitted fabric 1 and long fluffed pile yarns 8al and short fluffed pile yarns 8as alternately wound around warp yarns 2 of the ground fabric 1. The light-shielding filling layer 16a is composed of EEA resin and light-shielding material blended thereinto, and formed by melt coating on the ground fabric 1. The teremp cloth 19a is directly attached to on the container body 7 using the filling layer 16a as the adhesive layer.
In the light-shielding teremp cloth 19a shown in FIG. 2, long fluffed piles 8al, short fluffed piles 8as, long looped piles 9al and short looped piles 9as are formed. The filling layer 16a is the same as employed in the example of FIG. 1.
The light-shielding teremp cloth 19a of FIG. 3 is the same as the teremp cloth 19a of FIG. 1, except that long looped piles 9al are formed instead of short fluffed piles 8as. The filling layer 16a is the same as employed in FIG. 1.
Piles of the light-shielding teremp cloth 19a of FIG. 4 are all long looped piles 9al. The filling layer 16a is the same as employed in FIG. 1.
Piles of the light-shielding teremp cloth 19a of FIG. 5 are all long fluffed piles 8al. The filling layer 16a is the same as employed in FIG. 1.
In the light-shielding teremp cloth 19a of FIG. 6, long looped piles 9al and short looped piles 9as are alternately formed. A light-shielding filling layer 16b and an adhesive layer 10 are coextruded on the ground fabric 1, and the ground fabric 1 is stuck on the container body 7 through the adhesive layer 10 of coextruded layer 17a. The filling layer 16a is composed of thermoplastic resin and light-shielding material blended thereinto, and the adhesive layer 10 is composed of EEA resin.
FIGS. 15 to 18 show the examples of the containers into which any of the above teremp cloth structure is incorporated.
The light-shielding container of FIG. 15 is used for a photographic color printing paper or a printing paper for computerized type-setting system. The container body 7 is box-shaped, and made of metal, plastic resin or paper. A drawing out opening (port) 18 is provided at one corner side, and the teremp cloth 19 was stuck on both inner faces being opposite to each other. Core 21 of the roll of the light-sensitive strip material 20 is provided at the center of the container.
Another example of the container is shown in FIG. 16. This container is a modification of the above container, and protection of the light-sensitive material and moisture-proofness (and light-shielding) are improved by wrapping with a moistureproof film 22 to seal it. 23 indicates its heat-sealing portion. This moistureproof film is a laminated film composed of an aluminum-metallized thermoplastic resin film layer and a heat-sealing layer or an inflation film of a thermoplastic resin. The moistureproof film may be imparted with light-shielding property.
Another example of the container is shown in FIG. 17. This container is JIS 135-type film cartridge. A drawing out opening 25 is provided at the cylindrical face of the cartridge body 24 in its longitudinal direction, and the teremp cloth 19 was stuck on both inner faces being opposite to each other. 27 indicates core (spool) of JIS 135-type film 26.
Still another example of the container is shown in FIG. 18. This container is a simplified light-shielding container, and it is composed of a container body 7 and two side panels 29. A short axis 30 projects from slightly upper position of the center of each panel 29, and it supports the core 21 of light-sensitive strip material 20. The side panels 29 are fixed by sealing tape 31 as shown on the left side of the assembled box (b) or on the right side thereof.
Various properties of the containers of the invention were measured and compared with those of a comparative container and a conventional container. The results are shown in Table 1.
TABLE 1______________________________________Invention Compar- Conven- Testing1 2 ative tional Method______________________________________Structure Tricot Double Tricot Velvetof Teremp Knitting Pile Knitting WeavingCloth KnittingGround 50 50 50 150Fabric Deniers Deniers Deniers DeniersYarn Polyester Nylon Polyester Rayon Yarn Yarn Yarn YarnPile Yarn 50 75 50 75 Deniers Deniers Deniers Deniers Polyester Nylon Polyester Rayon Yarn Yarn Yarn YarnForm 35% 100% 35% 100%Fluffedof Pile 65% 0% 65% 0%LoopedPile Length 1.1 1.1 1.1 1.1(mm)Filling Melt Melt Solution SolutionLayer Coating Coating Coating Coating(Thickness) of EEA of EEA resin *1 resin *2 30 um 30 umAdhesive -- -- Solution SolutionLayer Coating CoatingFray at Cut A A B D IPositionPile Cut- A B B C Iting DustFalling Out A A B D Iof PilesExudation B B E C IIof FillingMaterialCost Ratio 28 30 56 100 III______________________________________ *1 Ethylacrylate Content 18% "NUC6170" (NIPPON UNICAR) *2 Ethylacrylate Content 22% "MB830" (NIPPON UNICAR) Evaluations are as follows: A: very excellent B: excellent C: practical D: having a problem E: impractical
Testing methods are as follows:
I: A photographic color printing paper was placed in each exemplified container, and the container was allowed to stand at 30° C. under 80% RH for 12 hours. Then, the color printing paper was drawn out, and a fray at the cut position, pile cutting dust and falling out of piles were estimated by adhered dusts on the face of the color printing paper.
II. Each filling layer was coated of the ground fabric of each teremp cloth, and after 24 hours, exudation of the filling material was estimated by touch sense and observation of the pile portion.
III: Cost of the conventional teremp cloth was set as 100.
EXAMPLES 7 to 14
Examples of the container provided with the multilayer coextruded film are illustrated in FIGS. 7 to 14.
In the light-shielding teremp cloth of FIG. 7, long fluffed piles 8al and short looped piles 9as are randomly formed on the ground fabric 1a of knitting structure, and a multilayer coextruded film 11a is laminated on the ground fabric 1a through an adhesive layer 10. This multilayer coextruded film 11a is composed of an ethylene copolymer resin adhesive layer 12a containing light-shielding material and a thermoplastic resin base layer 13a containing light-shielding material.
The structure of teremp cloth portion illustrated in FIG. 8 is the same as illustrated in FIG. 7, except that the ethylene copolymer resin adhesive layer 12 does not contain light-shielding material.
The structure of teremp cloth portion illustrated in FIG. 9 is the same as illustrated in FIG. 7, except that the thermoplastic resin base layer 13 does not contain light-shielding material.
The structure of teremp cloth portion illustrated in FIG. 10 is the same as illustrated in FIG. 7, except that both of the ethylene copolymer resin adhesive layer 12 and the thermoplastic resin base layer 13 do not contain light-shielding material.
The structure of teremp cloth portion illustrated in FIG. 11 is the same as illustrated in FIG. 7, except that the multilayer coextruded film 11a is directly laminated on the ground fabric 1a through a boundary layer 14 formed by heating.
The structure of teremp cloth portion illustrated in FIG. 12 is the same as illustrated in FIG. 7, except that the multilayer coextruded film 11a is composed of a central thermoplastic resin base layer 13a and two ethylene copolymer resin adhesive layers 12a, as a located on both sides thereof.
The structure of teremp cloth portion illustrated in FIG. 13 is the same as illustrated in FIG. 7, except that an intermediate layer 15 is incorporated into the multilayer coextruded film 11a.
The structure of teremp cloth portion illustrated in FIG. 14 is the same as illustrated in FIG. 8, except that one more thermoplastic resin base layer 13a is incorporated into the multilayer coextruded film 11a.
Various properties of the containers of the invention were measured and compared with those of a comparative container and a conventional container.
In the container I of the invention, the configuration shown in FIG. 7 was employed. The ground fabric 1a was tricot knitting structure, and its yarn was 50 deniers polyester yarn. The pile yarn was also 50 deniers polyester yarn, and the piles was composed of 30% of fluffed piles and 70% of looped piles. The adhesive layer 10 was composed of EEA resin ("NUC-6170", NIPPON UNICAR), and its thickness was 20 μm. The thermoplastic resin base layer 13a was composed of HDPE resin ("HIZEX 3300F", MITSUI PETROCHEMICAL INDUSTRIES) and 3% of carbon black was blended thereinto, and its thickness was 30 μm. Melting point of the HDPE resin was 131° C., and its Young's modulus was 125 kg/mm 2 . The ethylene copolymer resin adhesive layer 12a was composed of EEA resin ("DPDJ-8026", NIPPON UNICAR) and 3% of carbon black was blended thereinto, and its thickness was 20 μm. The ethylacrylate comonomer content of the EEA resin was 8%, and its melting point was 85° C. The total thickness of such a multilayer coextruded film 11a was accordingly 50 μm, and its tensile strength was 1530 g/15 mm width.
The configuration of the container II of the invention, was similar to that shown in FIG. 7. The ground fabric 1a was double raschel knitting structure, and its yarn was 50 deniers nylon yarn. The pile yarn was 75 deniers nylon yarn, and all piles were fluffed. The adhesive layer 10 was formed by coating vinyl acetate emulsion. The thermoplastic resin base layer 13a was composed of HDPE resin ("HIZEX 5300S", MITSUI PETROCHEMICAL INDUSTRIES) and 3% of carbon black blended thereinto, and its thickness was 30 μm. The melting point of the HDPE resin was 134° C., and its Young's modulus was 163 kg/mm 2 . The ethylene copolymer resin adhesive layer 12a was composed of EEA resin ("DPDJ-6169", NIPPON UNICAR) and 3% of carbon black blended thereinto, and its thickness was 20 μm. The ethylacrylate comonomer content of the EEA resin was 18%, and its melting point was 67° C. The total thickness of the multilayer coextruded film 11a was 50 μm, and its tensile strength was 2250 g/15 mm width.
The configuration of the comparative container was similar to that shown in FIG. 19. The ground fabric 1 was tricot knitting structure, and its yarn was 50 deniers polyester yarn. The pile yarn was also 50 deniers polyester yarn, and the piles were composed of 30% of fluffed piles and 70% of looped piles. The filling layer 5 and the adhesive layer 6 were formed by solution coating.
The configuration of the conventional container was shown in FIG. 19. The ground fabric 1 was velvet weaving structure, and its yarn was 150 deniers rayon yarn. The pile yarn was 75 deniers rayon yarn, and the piles were all fluffed. The filling layer 5 and the adhesive layer 6 were formed by solution coating.
The results are shown in Table 2.
TABLE 2______________________________________Invention Compar- Conven- Test1 2 ative tional Method______________________________________Configura- FIG. 7 FIG. 7 FIG. 19 FIG. 19tionStructure Tricot Double Tricot Velvetof Teremp Knitting Raschel Knitting WeavingCloth KnittingGround 50 50 50 50Fabric Deniers Deniers Deniers DeniersYarn Polyester Nylon Polyester Rayon Yarn Yarn Yarn YarnPile Yarn 50 75 50 75 Deniers Deniers Deniers Deniers Polyester Nylon Polyester Rayon Yarn Yarn Yarn YarnForm 30% 100% 30% 100%Fluffedof Pile 70% 0% 70% 0%LoopedFilling Solution SolutionLayer Coating CoatingAdhesive EEA VA Solution SolutionLayer Coating CoatingThermo- HDPE HDPE -- --plastic with CB with CBResin BaseLayerEthylene EEA EEA -- --Copolymer with CB with CBResinAdhesiveLayerFray at Cut A A B D IPositionFalling out A A B D Iof PilesExudation A A E D IIof FillingMaterialSoftness A A D D-E IICost Ratio 22 27 31 100 IIIEvenness A A D D IVof Adhe-sive LayerDeforma- A A D D Vtion ofGroundFabric______________________________________
Evaluations and testing methods are the same as described previously. The remaining testing methods are as follows.
IV: Evenness of each adhesive layer was judged by measuring a perpendicular cut face of this layer.
V: Deformation such as wrinkle, furrow and curl was judged by observation of the ground fabric after coating the adhesive layers. | In a container for a roll of a light-sensitive strip material having a core on which the light-sensitive strip material is coiled to form a roll, an opening for drawing out the light-sensitive strip material and a teremp cloth provided on the above opening for shielding from light, wherein a filling layer formed of polyolefin copolymer resin usable as the adhesive layer for fixing the teremp cloth on the container body is provided at the ground fabric of the teremp cloth, and/or a multilayer coextruded film is laminated under the ground fabric of the teremp cloth, and the multilayer coextruded film has a tensile strength of more than 500 g/15 mm width and comprises an adhesive layer of an ethylene copolymer resin having a comonomer content of 5 to 36 % for fixing said teremp cloth on the container body and a thermoplastic resin base layer having a melting point of higher than the ethylene copolymer resin adhesive layer by 10° C. or more and a Young's modulus of more than 15 kg/mm 2 .
In this container, the filling material does not so deeply permeate into pile yarns, even though the ground fabric is not so dense. Adhesion of pile yarn dust hardly occurs, and troubles in exposure and development caused by the pile yarn dust are solved. By incorporating the multilayer coextruded film, the thickness of the adhesive layer for fixing teremp cloth on the container body is made uniform and various problems caused by non-uniformity in the thickness of the adhesive layer are solved. | 6 |
PRIORITY CLAIM
The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/228,057, filed Jul. 23, 2009, which application is incorporated herein by reference in its entirety.
BACKGROUND
The present invention generally relates to therapies for patients with heart dysfunction, such as congestive heart failure and other dysfunctions after a heart attack. The present invention more specifically relates to catheter-based therapies for heart dysfunction. The present invention also relates specifically to cell-based therapies for heart dysfunction.
In the United States, there are an estimated 7,750,000 adults that have survived a heart attack, or myocardial infarction. These myocardial infarctions often lead to congestive heart failure and potentially life threatening heart rhythm disorders. Cell-based therapy has emerged as an encouraging approach to rebuilding such damaged hearts. In particular, catheter-based transendocardial injection is considered a promising delivery mode. Examples of therapeutic agents comprise mesenchymal stem cells and skeletal myoblasts.
Effective catheter-based delivery of a therapeutic agent requires knowledge of the internal architecture of the left ventricle and the ability to position and orient the catheter in the left ventricular chamber. Furthermore, the ability to penetrate and inject a therapeutic agent into the myocardium is required, typically by means of an injection needle. It would be advantageous if an endoventricular injection catheter comprised integrated echocardiographic capabilities that enabled real-time image guidance to control depth of needle injection into left ventricular wall and prevent myocardial perforation. It would be further advantageous if the same catheter could be used to identify infarcted regions in order to indicate suitable injection sites. It would be still further advantageous if leakage of the therapeutic agent could be prevented following removal of the injection needle. It would be yet still further advantageous if the therapeutic agent could be delivered from a distal reservoir to minimize trauma to the therapeutic cells during delivery.
SUMMARY OF THE INVENTION
The invention provides an endoventricular injection catheter with integrated echocardiographic capability. The catheter comprises an elongated body having a distal end and an imaging core arranged to be inserted into a heart. The imaging core is arranged to transmit ultrasonic energy and to receive reflected ultrasonic energy at the distal end to provide electrical signals representing echocardiographic images to enable cardiac visualization. The catheter further includes an injector carried on the elongated body with the imaging core. The injector is arranged to inject a therapeutic agent into tissue of the heart visualized by the imaging core.
The elongated body may include a telescoping section to permit longitudinal positioning of the imaging core. The imaging core may be a mechanically rotating imaging core.
The catheter may further include a deflection system that causes the elongated body distal end to deflect in a desired direction. The deflection system may include a steerable guide sheath. The deflection system may alternatively include a deflection section sheath, a steering ring, at least one steering wire, and a deflection control knob.
The elongated body of the catheter may include a guide wire lumen for receiving a guide wire. The guide wire lumen may be at the distal end of the elongated body of the catheter. Alternatively, the guide wire lumen may extend along the elongated body of the catheter proximal to the distal end.
The elongated body may include an imaging core lumen and an outer circumferential surface. The imaging core lumen and the outer surface may define a substantially uniform wall thickness of the elongated body over a portion of the elongated body circumference.
The imaging core comprises a plurality of transducers. The catheter may further include a cannula lumen and the injector may include a cannula received by the cannula lumen and an injection needle within the cannula. The cannula may be formed of a super-elastic material.
The catheter may further include an injection system including the injector. The injection system may include a proximal handle. The injection handle may include injection controls for extending the cannula, advancing the injection needle, limiting advancement of the injection needle beyond the cannula, and torquing the cannula. The injection needle may include an end stop that limits advancement of the injection needle within the cannula. The injection system may further include a reservoir within the cannula and a plunger that forces therapeutic agent into the needle.
The injector may include a pair of injection needles. The injector may further comprise a fiber optic bundle and an ultraviolet light source for photocrosslinking an injected bioabsorbable polymer solution.
The invention further provides a method of providing image-guided transendocardial injection of a therapeutic agent into a left ventricular wall of a heart. The method includes the steps of providing an endoventricular injection catheter having integrated echocardiographic capability. The catheter may include an elongated body having a distal end and an imaging core arranged to be inserted into a heart. The imaging core may be arranged to transmit ultrasonic energy and to receive reflected ultrasonic energy at the distal end to provide electrical signals representing echocardiographic images to enable cardiac visualization. The catheter may further include an injector carried on the elongated body with the imaging core. The injector is arranged to inject a therapeutic agent into tissue of the heart visualized by the imaging core. The method further includes the steps of delivering the endoventricular injection catheter into the left ventricle of the heart, visualizing the left ventricular wall of the heart using the imaging core, identifying infarct regions of the left ventricle, and injecting a therapeutic agent into the visualized infarcted regions of the left ventricle using the injector. The method may include the further step of injecting a bioabsorbable agent with the injector to prevent back flow of the therapeutic agent.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with further features and advantages thereof, may best be understood by making reference to the following descriptions taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify identical elements, and wherein:
FIG. 1 illustrates use of catheter;
FIG. 2 shows a block diagram of an endoventricular injection catheter system with integrated echocardiographic capabilities;
FIG. 3 is a partial sectional view of a catheter embodying the invention;
FIG. 3A is a sectional view taken along lines A-A of FIG. 3 ;
FIG. 4 is a partial sectional view of the catheter of FIG. 3 shown partially extended;
FIG. 5 is a partial sectional view of the distal end of the catheter of FIG. 3 having an injection cannula and needle according to an aspect of the present invention;
FIG. 6 is a partial sectional view of another catheter embodying the present;
FIG. 7 is a partial sectional view of another catheter embodying the invention;
FIG. 7A is a sectional view taken along lines A-A of FIG. 7 ;
FIG. 7B is a sectional view taken along lines B-B of FIG. 7 ;
FIG. 7C is a sectional view taken along lines C-C of FIG. 7 ;
FIG. 8 is a partial sectional view of another catheter embodying the invention shown deflected;
FIG. 9 is a sectional view of still another catheter embodying the invention;
FIG. 10 is a sectional view of still another catheter embodying the invention;
FIG. 11 is a sectional view of still another catheter embodying the invention;
FIG. 12 is a partial sectional view of the distal end of another catheter embodying the invention;
FIG. 13 is a partial sectional view of the distal end of another catheter embodying the invention;
FIG. 14 is a side view of an imaging core of another catheter having multiple transducers according to further aspects of the invention;
FIG. 15A is a top view of an injection system embodying the invention;
FIG. 15B is a side view of the injection system of FIG. 15A ;
FIG. 16A is another top partial sectional view of injection system FIG. 15A showing the internal elements thereof in greater detail;
FIG. 16B is a partial sectional side view of the injection system of FIG. 16A ;
FIG. 17 is a sectional view of the distal tip of an injection cannula and an injection needle with side ports and a closed end according to further aspects of the invention;
FIG. 18A is a sectional view of the distal tip of another injection needle with side ports and an opened end according to further aspects of the invention;
FIG. 18B is a perspective view of the distal tip of an injection needle with an opened end according to further aspects of the invention;
FIG. 19 is a sectional view of the distal tip of an injection cannula and an injection needle with an end stop according to aspects of the invention;
FIG. 20 is a perspective view of the distal tip of an injection needle having a dual injection needle according to further aspects of the invention;
FIG. 21 is a perspective view of the distal tip of a dual injection needle with a fiber optic bundle according to further aspects of the invention;
FIG. 21A is a sectional view taken along lines A-A of FIG. 21 ;
FIG. 22 is a partial sectional view of still another catheter embodying the invention;
FIG. 23A is a top view of another injection system proximal handle embodying the invention;
FIG. 23B is a side view of the injection system of FIG. 23A ;
FIG. 24A is another partial sectional top view of the injection system of FIG. 23A showing the internal elements thereof in greater detail;
FIG. 24B is a partial sectional side view of the injection system of FIG. 24A ;
FIG. 25 is a flow diagram illustrating processing stages for image guidance of transendocardial injections according to aspects of the invention;
FIG. 26 is a flow diagram illustrating processing stages for identifying an infarct region; and
FIG. 27 is a flow diagram illustrating processing stages for calculating tissue classifiers according to further aspects of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a cut-away illustration of a heart having therein an endoventricular injection catheter 2 having integrated echocardiographic capabilities delivered via a steerable guide sheath 4 . The steerable guide sheath 4 is delivered percutaneously from a femoral arterial site to the aorta 6 and through the aortic valve 8 into the left ventricle 10 . The catheter 2 comprises a mechanically rotating imaging core 12 , an injection cannula 402 , and an injection needle 404 . FIG. 1 illustrates how the steerable guide sheath 4 and endoventricular injection catheter 2 can be used to inject a needle into a region of interest 14 in the left ventricular wall under echocardiographic guidance.
FIG. 2 shows a high-level block diagram of the endoventricular injection catheter system comprising the endoventricular injection catheter 2 with integrated echocardiographic capabilities, an injection control system 20 , a patient interface module 22 , and console 24 . The injection control system 20 is mechanically coupled to the catheter 2 . The patient interface module is electrically and mechanically coupled to the catheter. The patient interface module 22 further provides electrical isolation of the patient from the system. The patient interface module 22 may take the form as described for example in additional detail in U.S. patent application Ser. No. 12/633,278 by Moore et al., the complete disclosure of which is hereby incorporated herein by reference. The patient interface module 22 and console 24 are coupled by analog and digital signal lines. The console 24 controls operation of the patient interface module 22 and the imaging aspect of the catheter 2 . The console 24 may further display images. The endoventricular injection catheter system may be employed to advantage to provide, for example, image guidance of transendocardial injection of therapeutic agents such as cell-based solutions to heart attack victims.
Referring to FIG. 3 , it shows an endoventricular injection catheter with integrated echocardiographic capability 2 embodying aspects of the present invention. The catheter 2 comprises a first proximal housing 30 , a telescoping section 32 , a second proximal housing 33 , a proximal section 34 , a distal section 36 , an imaging core 12 , and an injection system 400 . The endoventricular injection catheter 2 may be used in combination with a steerable guide sheath 4 ( FIG. 1 ) wherein the catheter 2 is disposed within the steerable guide sheath 4 as illustrated in FIG. 1 . The catheter length may be generally between 100 cm and 150 cm, more particularly, for example, between 110 cm and 120 cm. The diameter of the catheter proximal section 34 may generally be between 8 F and 18 F, as for example approximately 10 F. The diameter of the catheter distal section 36 may be between 6 F and 10 F, as for example about 8 F.
The first proximal housing 30 mates to the patient interface module (not shown) via engagement pins 41 and couples mechanical energy to the drive cable 40 and electrical energy into a transmission line 42 disposed within the drive cable 40 that is electrically connected to the ultrasonic transducer 44 . A saline flush port 43 enables acoustic coupling from the ultrasonic transducer 44 to the exterior of the distal section 36 . For additional description of the first proximal housing 30 , reference may be had for example, to U.S. patent application Ser. No. 12/336,441 by Moore the complete disclosure of which is hereby incorporated herein by reference.
The telescoping section 32 enables longitudinal translation of the imaging core 12 with respect to the catheter sheaths. The telescoping section 32 includes an outer supporting member 46 , an inner tubular member 48 , and a primary inner member 50 that slides into the inner tubular member 48 . The telescoping section further includes an end cap 52 and an end stop 54 that is bonded to the distal end of the inner tubular member 48 . The inner tubular member 48 is bonded to the proximal housing 30 . The supporting member 46 and the primary inner member 50 are bonded to the second proximal housing 33 . The end cap 52 includes a groove 53 that provides a connection point for controlled movement of the telescoping section 32 . The end stop 54 prevents the supporting member 46 and primary inner member 50 from disengaging the inner tubular member 48 when the telescoping section is fully extended. The telescoping section length is generally between 1 cm and 5 cm, more particularly between 2 cm and 3 cm. The primary inner member 50 is formed of a biocompatible material such as polyetheretherketone (PEEK) or stainless steel. The primary inner member 50 has an inner diameter typically between 0.075″ and 0.100″. The supporting member 46 is also formed of a biocompatible material such as PEEK or stainless steel. Further description of such a telescoping section may be found, for example, in U.S. patent application Ser. No. 12/336,441 by Moore, the complete disclosure of which is hereby incorporated herein by reference.
The proximal section 34 includes a secondary member 58 , an imaging core lumen 60 , and an injection cannula lumen 62 . A cross-sectional view of the proximal section 34 is illustrated in FIG. 3A . The proximal section 34 further includes an exit port 64 for the injection cannula. The secondary member 58 is formed of a biocompatible flexible material such as PEEK and has an outer diameter generally between 8 F and 18 F, more particularly approximately 10 F. The imaging core lumen 60 diameter may be between 0.075″ and 0.100″. The injection cannula lumen 62 diameter may be between 0.030″ and 0.037″, sufficient to pass an injection cannula of size typically between 20 gauge to 22 gauge.
The distal section 36 includes a distal sheath 66 , a flushing exit port 68 , an atraumatic tip 70 , and an imaging core lumen 61 . The distal sheath 66 is formed of a biocompatible flexible material such as polyethylene or other thermoplastic polymer that minimizes acoustic loss. The atraumatic tip 70 is formed of a low durometer material such as polyether block amide (Pebax®) or blend of Pebax grades such as Pebax 63D and 40D. The imaging core lumen 60 diameter may be between 0.075″ and 0.100″.
The imaging core 12 includes a drive cable 40 , a transducer housing 72 , an ultrasonic transducer 44 , and a transmission line 42 disposed within the drive cable 40 . The imaging core is electrically and mechanically coupled by a connector 74 to the patient interface module. The electrical coupling enables sending and receiving of electrical signals along the transmission line 42 to the ultrasonic transducer 44 . The mechanical coupling enables rotation of the imaging core 12 . The drive cable 40 may be formed of a stainless steel round-wire coil with a coil outer diameter in the range 0.070″ to 0.180″, more particularly approximately 0.105″ for a 10 F distal sheath profile. The elongation and compression of the drive cable during acceleration must be minimized to insure accurate positioning. The drive cable should also minimize non-uniform rotation of the imaging core. The transducer housing 72 is described in additional detail in U.S. patent application Ser. No. 12/330,308 by Zelenka and Moore, the complete disclosure of which is hereby incorporated herein by reference.
The ultrasonic transducer 44 includes at least a piezoelectric layer and may further include conductive layers, at least one matching layer, and a backing layer. The ultrasonic transducer 44 may further include a lens. Design and fabrication of ultrasonic transducers for imaging catheters are known to those skilled in the art. The ultrasonic transducer generally operates over frequency ranges of 5 MHz to 60 MHz, more particularly between 10 MHz to 30 MHz.
The injection system 400 comprises an injection cannula 402 and an injection needle (not shown) disposed within the injection cannula 402 . The injection cannula 402 may be formed of a biocompatible superelastic material such as a nickel-titanium (or Nitinol) alloy that can take a curved shape. The cannula size is generally between 20 gauge and 24 gauge, more particularly approximately 22 gauge. The distal tip of the injection cannula 402 can be treated to be echogenic to facilitate ultrasound image guidance.
FIG. 4 illustrates the endoventricular injection catheter 2 of FIG. 3 with the telescoping section 32 in a partially extended position. The first proximal housing 30 and imaging core 12 which are fixedly attached to each other are shown translated relative to the telescoping section 32 , the second proximal housing 33 , and the proximal sheath 34 . Telescoping imaging catheters enable the imaging core 12 to translate longitudinally through the imaging core lumen 60 while the proximal sheath 34 and distal sheath (not shown) remain fixed in position. As described herein, the imaging core 12 can translate longitudinally through the imaging core lumen 60 . The position of the imaging core 12 when the telescoping catheter 32 is in an un-extended state is as shown in FIG. 3 . The distance of travel of the imaging core 12 between the un-extended position and the fully-extended position within the length of the inner tubular member is limited by end stop 54 . As mentioned elsewhere herein, the end cap 52 facilitates controlled movement of the telescoping section 32 and the end stop 54 prevents the supporting member 46 and primary inner member 50 from disengaging the inner tubular member 48 when the telescoping section is fully extended.
FIG. 5 illustrates the distal end of the embodiment of FIG. 3 for echocardiographic guidance of the injection cannula 402 and an injection needle 404 . The injection cannula 402 is shaped to facilitate image-guided delivery of the injection needle 404 to a specific site of interest. The optimal bend angle for image guidance of transendocardial injections can be determined empirically. An endoventricular injection catheter with integrated echocardiographic capabilities provides real-time image guidance during needle injection into the left ventricular wall and facilitates prevention of myocardial perforation.
Referring now to FIG. 6 , another endoventricular injection catheter 102 with integrated echocardiographic capabilities embodying the invention is shown. The endoventricular injection catheter 102 comprises a proximal housing 132 , a proximal member 134 , a distal sheath 136 and an injection system 138 . The longitudinal position of the imaging core 112 remains fixed relative to the catheter sheaths 134 , 136 because no telescoping section is included. A non-telescoping catheter may be advantageous because of reduced complexity and manufacturing cost in applications wherein longitudinal positioning of the imaging core 112 is not critical.
Referring to FIG. 7 , another alternative embodiment of an endoventricular injection catheter 202 with integrated echocardiographic and deflection capabilities embodying the invention is shown. The endoventricular injection catheter 202 includes the first proximal housing 30 , the telescoping section 32 , a second proximal housing 233 , a proximal section 234 , a deflection section 235 , a distal section 236 , the imaging core 12 , the injection system 400 , and a deflection control system 239 . An advantage of an endoventricular injection catheter with a deflection capability is a steerable guide sheath is not required for delivery and positioning of the catheter. The catheter length may be generally between 100 cm and 150 cm, more particularly between 110 cm and, for example 120 cm. The diameter of the proximal section 234 may be generally between 8 F and 18 F, more particularly, for example, approximately 10 F. The diameter of the distal section 236 may be generally between 6 F and 10 F, more particularly, for example, approximately 8 F.
The first proximal housing 30 mates to the patient interface module (not shown) via engagement pins 41 . It couples mechanical energy to the drive cable 40 and electrical energy into a transmission line 42 disposed within the drive cable 40 that is electrically connected to the ultrasonic transducer 44 .
The telescoping section 32 , as previously described enables longitudinal translation of the imaging core 12 with respect to the catheter sheaths. The telescoping section 32 includes the outer supporting member 46 , the inner tubular member 48 , and the primary inner member 50 that slides into the inner tubular member 48 . The telescoping section further includes the end cap 52 and an end stop 54 that is bonded to the distal end of the inner tubular member 48 . The inner tubular member 48 is bonded to the proximal housing 30 . The supporting member 46 and the primary inner member 50 are bonded to the second proximal housing 33 . The end cap 52 includes a groove 53 that provides a connection point for controlled movement of the telescoping section 32 . The end stop 54 prevents the supporting member 46 and primary inner member 50 from disengaging the inner tubular member 48 when the telescoping section is fully extended. The telescoping section length may be generally between 1 cm and 5 cm, more typically between 2 cm and 3 cm. The primary inner member 50 may be formed of a biocompatible material such as polyetheretherketone (PEEK) or stainless steel. The primary inner member 50 an inner diameter typically between 0.075″ and 0.100″, for example. The supporting member 46 may also be formed of a biocompatible material such as PEEK or stainless steel.
The second proximal housing 233 includes a guide wire lumen 263 , an imaging core lumen 265 , and an injection cannula lumen 267 . The second proximal housing 233 further includes a deflection control knob 278 that is bonded to steering wires 280 , 282 , as by welding, brazing, or soldering, for example. The second proximal housing 233 may be formed of a biocompatible rigid material. The guide wire lumen 263 diameter may be between 0.015″ and 0.037″, sufficient, for example, to pass 0.014″, 0.018″ and 0.035″ guide wires. The imaging core lumen 265 diameter may be between 0.075″ and 0.100″. The injection cannula lumen 267 diameter may be between 0.030″ and 0.037″, sufficient, for example, to pass an injection cannula of size generally between 20 gauge to 22 gauge. The second proximal housing 233 is bonded to the primary inner member 50 and a secondary member 258 of the proximal section 234 .
Referring now to FIG. 7A along with FIG. 7 , the proximal section 234 includes the secondary member 258 and multiple lumens. The multiple lumens include an imaging core lumen 260 , a guide wire lumen 261 , an injection cannula lumen 262 , and two steering wire lumens 284 , 286 . The proximal section further includes an exit port 264 for the injection cannula. The secondary member 258 may be formed of a biocompatible flexible material such as PEEK and may have an outer diameter generally between 8 F and 18 F, more particularly approximately 10 F, for example. The diameter of the imaging core lumen 260 may be between 0.075″ and 0.100″. The diameter of the guide wire lumen 261 may be between 0.015″ and 0.037″, sufficient, for example, to pass 0.014″, 0.018″ and 0.035″ guide wires. The diameter of the steering wire lumen 284 , 286 may be between 0.008″ and 0.014″, sufficient, for example, to pass a steering wire having a diameter of between 0.006″ and 0.012″, for example. The diameter of the injection cannula lumen 262 may be between 0.030″ and 0.037″, sufficient, for example, to pass an injection cannula of size between 20 gauge to 22 gauge, for example.
Referring now to FIG. 7B along with FIG. 7 , the deflection section 235 includes a deflection section sheath 288 , reinforcement coil 290 , a steering ring 292 , and multiple lumens. The deflection section sheath 288 may be formed of a low durometer material such as an olefin. Olefins facilitate bonding to the proximal section 234 and distal section 236 . The use of a low durometer material further insures that the catheter bends in the deflection section 235 . The multiple lumens include an imaging core lumen 294 , a guide wire lumen 291 , and two steering wire lumens 296 , 298 . The diameter of the imaging core lumen 294 may be between 0.075″ and 0.100″. The diameter of the guide wire lumen 291 may be between 0.015″ and 0.037″, sufficient, for example, to pass 0.014″, 0.018″ and 0.035″ guide wires. The diameter of the two steering wire lumens 296 , 298 may be between 0.008″ and 0.014″, sufficient, for example, to pass a steering wire having a diameter between 0.006″ and 0.012″, for example.
Referring now to FIG. 7C along with FIG. 7 , the distal section 236 includes a distal sheath 266 , a flushing exit port 268 , an atraumatic tip 270 , an imaging core lumen 293 , and a guide wire lumen 295 . The distal section further includes an exit port 297 for the guide wire. The distal sheath 266 may be formed of a biocompatible flexible material such as polyethylene or other thermoplastic polymer that minimizes acoustic loss. The atraumatic tip may be formed of a low durometer material such as polyether block amide (Pebax®) or blend of Pebax grades such as Pebax 63D and 40D. The diameter of the imaging core lumen 293 may be between 0.075″ and 0.100″. The diameter of the guide wire lumen 295 may be between 0.015″ and 0.037″, sufficient, for example, to pass 0.014″, 0.018″ and 0.035″ guide wires.
The imaging core 12 includes a drive cable 40 , a transducer housing 72 , an ultrasonic transducer 44 , and the transmission line 42 disposed within the drive cable 40 . The imaging core is electrically and mechanically coupled by a connector 74 to the patient interface module. The electrical coupling enables sending and receiving of electrical signals along the transmission line 42 to the ultrasonic transducer 44 . The mechanical coupling enables rotation of the imaging core 12 . The drive cable 40 may be formed of a stainless steel round-wire coil having a coil outer diameter in the range 0.070″ to 0.180″, for example, approximately 0.105″ for a 10 F distal sheath profile. The elongation and compression of the drive cable during acceleration must be minimized to insure accurate positioning. The drive cable should also minimize non-uniform rotation of the imaging core. The transducer housing 72 is described in additional detail in U.S. patent application Ser. No. 12/330,308 by Zelenka and Moore the complete disclosure of which is hereby incorporated herein by reference.
The ultrasonic transducer 44 may include at least a piezoelectric layer and typically further comprises conductive layers, at least one matching layer, and a backing layer. The ultrasonic transducer 44 may further comprise a lens. Design and fabrication of ultrasonic transducers for imaging catheters are known to those skilled in the art. The ultrasonic transducer generally operates over frequency ranges of 5 MHz to 60 MHz, more typically between 10 MHz to 30 MHz.
The injection system 400 includes an injection cannula 402 and an injection needle (not shown) disposed within the injection cannula 402 . The injection cannula 402 may be formed of a biocompatible superelastic material such as a nickel-titanium (or Nitinol) alloy that can take a curved shape. The cannula size may be between 20 gauge and 24 gauge, more particularly approximately 22 gauge, for example. The distal tip of the injection cannula 402 can be treated to be echogenic to facilitate ultrasound image guidance.
The deflection system 239 generally includes deflection control means, at least one steering wire, and a steering ring. In accordance with this embodiment, the deflection system 239 includes a deflection control knob 278 , two steering wires 280 , 282 , and a steering ring 292 . The steering wires may be formed of polytetrafluoroethylene (PTFE) coated stainless steel. The diameter of the steering wires 280 , 282 may be between 0.006″ and 0.012″. The steering wires 280 , 282 may be welded, brazed, or soldered to the steering ring 292 . The steering ring 292 may be formed of stainless steel and located toward the distal end of the deflection section 235 . The reinforcement coil 290 of the deflection section 235 prevents pinching of the imaging core lumen 294 . Alternatively, a reinforcement braid could be used in place of the reinforcement coil. The location of the injection cannula exit port 264 proximal to the deflection section 235 insures that the injection cannula 402 does not prevent deflection of the catheter. FIG. 8 illustrates deflection of the distal end of the endoventricular injection catheter 202 when the deflection control knob 278 is rotated.
An over-the-wire imaging catheter sheath having variable thickness between the outer diameter and the imaging core lumen can lead to imaging artifacts. A distal section sheath 300 having an alternative imaging core lumen 302 as illustrated in FIG. 9 provides a more uniform sheath thickness in the lower portion of the sheath which is relevant to the imaging direction. Another alternative embodiment of the distal section has an elliptical-shaped sheath 310 as illustrated in FIG. 10 with an alternative imaging core lumen 312 . It also provides a more uniform sheath thickness in the lower portion of the sheath. Still another embodiment of the distal section is shown in FIG. 11 wherein the distal sheath 320 provides for a still larger range of directions having a uniform sheath thickness. FIG. 11 shows an alternate embodiment of the imaging core lumen 322 .
Short monorail tip catheter designs provide an alternative to over-the-wire catheter designs wherein a short monorail tip enables rapid exchange of the catheter in comparison to the over-the-wire design shown in FIG. 7 . An advantage of rapid exchange catheters is that they typically have smaller overall profiles compared to over-the-wire catheters. Catheters having smaller profiles require smaller access sites, such as the femoral artery, which may in turn reduce bleeding complications. With a monorail design it is not necessary to have a guide wire lumen in the deflection control section, proximal section, deflection section, or distal sheath. The reduction in material can reduce the cost of manufacturing.
FIG. 12 illustrates an alternative embodiment of the distal section including a distal sheath 330 having an imaging core lumen 331 , a short monorail tip 332 , a flushing exit port 334 , and a guidewire lumen 336 for guidewire GW. The short monorail tip 332 is bonded to the distal sheath 330 wherein the imaging core lumen 331 is parallel to the guide wire lumen 336 . The wall thickness in the distal sheath 330 is uniform around the imaging core lumen 331 . Such a distal section including a monorail design is described, for example, in additional detail in U.S. patent application Ser. No. 12/547,972 by Zelenka the complete disclosure of which is hereby incorporated by reference.
FIG. 13 illustrates another alternative distal section embodiment including a distal sheath 340 having an imaging core lumen 341 , a short monorail tip 342 , a flushing exit port 344 , a guidewire lumen 346 for guidewire GW, and a support bar 348 . The support bar 348 can prevent collapse of the imaging core lumen 341 in cases of large deflections of the catheter. The support bar 348 is formed of a suitably rigid material such as stainless steel or PEEK.
An advantage of an imaging catheter with a mechanically rotating and translating imaging core is the ability to image a volume of interest without repositioning the catheter sheath. The imaging core can be longitudinally translated within the catheter sheath by means of an external translation device. A disadvantage of an imaging catheter with a mechanically rotating and translating imaging core for imaging moving structures such as the heart is that the rate at which a volume can be swept is relatively slow compared to cardiac motion velocities. Imaging cores comprising multiple transducer elements can reduce the time to image a volume of interest.
FIG. 14 illustrates an alternative embodiment of an imaging core 350 including a drive cable 352 , a first transducer housing 354 , a first ultrasonic transducer 356 , a first transmission line 358 , a second transducer housing 360 , a second ultrasonic transducer 362 , a second transmission line 364 , and a transducer housing coupling 366 . The first ultrasonic transducer 356 is seated in the first transducer housing 354 and is connected to the first transmission line 358 . The second ultrasonic transducer 362 is seated in the second transducer housing 360 and is connected to the second transmission line 364 . The facing direction of the second transducer housing 360 and second ultrasonic transducer 362 is 180° relative to the facing direction from the facing direction of the first transducer housing 354 and first ultrasonic transducer 356 . The first transducer housing 354 and second transducer housing 360 are mechanically connected by the transducer housing coupling 366 , generally a flexible coil.
The use of multiple transducers reduces the amount of time required to ultrasonically scan a volume. In an exemplary design, the first and second transducer housings 354 , 360 and transducer housing coupling 366 can be fabricated from a single stainless steel hypotube. The first and second transducer housings 354 , 360 provide rigid support to the first and second ultrasonic transducers 356 , 362 by means of a fitted slot. The transducer housing coupling 366 is a spiral-cut section of the hypotube and balances axial rigidity to the first and second transducer assemblies with bending flexibility. The pitch of the spiral cut can be constant or can be varied depending upon the target stiffness characteristics. For example, the pitch may be decreased for more flexibility or increased for less flexibility. In an exemplary design, the first and second transducer housings 354 , 360 may be approximately 0.155″ in length, the transducer housing coupling 366 may be approximately 0.235″ in length, and the transducer diameters may be 0.100″, for example. The pitch of spiral-cut coupling may be 0.040″ having 0.004″ kerfs. The alternative embodiment of an imaging core comprising multiple transducers is described in additional detail in U.S. patent application Ser. No. 12/633,278 by Moore et al. the complete disclosure of which is hereby incorporated by reference.
Referring now to FIGS. 15A and 15B , the injection system 400 thereshown include an injection cannula 402 , an injection needle 404 disposed within the cannula 402 , and a proximal handle 410 . The injection system further includes a female Luer lock 412 and a connection tube 414 . The proximal handle 410 includes a cannula extension controller 416 , a maximum needle depth controller 420 , a needle injection controller 422 , and a torque device 426 . As described further above, the proximal handle can be adapted to extend the cannula, advance the injection needle, limit advancement of the injection needle beyond the cannula, and torque the cannula. The use of the maximum needle depth controller 420 and needle injection controller 422 in combination can further prevent perforation of the left ventricular wall and pericardial sac during injection. Mechanical design safeguards operate in combination with real-time echocardiographic guidance to prevent myocardial perforation.
The injection cannula 402 may be formed of a biocompatible superelastic material such as a nickel-titanium (or Nitinol) alloy that can take a curved shape. The cannula size may be between 20 gauge and 24 gauge, more particularly approximately 22 gauge, for example. The distal tip of the cannula can be treated to be echogenic to facilitate ultrasound image guidance. The needle 404 may be formed of stainless steel or a nickel-titanium alloy and may be between 24 gauge and 26 gauge in size. The needle 404 can be treated to be echogenic to facilitate ultrasound image guidance. A multiport manifold (not shown) can be connected to the female Luer lock 412 for delivery of therapeutic solutions, crosslinkable polymer solutions, and other fluids through the injection needle 404 .
Referring now to FIGS. 16A and 16B along with FIG. 3 , an embodiment of the proximal handle 410 and the internal control mechanisms are illustrated. The segment of the cannula 402 inside the proximal handle 410 is slotted 403 . The cannula extension controller 416 is coupled to the cannula 402 by a first rigid member 428 . The cannula 402 can be extended beyond the exit port 64 of the injection cannula lumen 62 of the endoventricular injection catheter 2 by sliding the cannula extension controller 416 toward the torque device 426 . The maximum needle depth controller 420 is coupled to a stop plate 431 by a second rigid member 430 . The needle injection controller 422 is coupled to a needle injection support member 436 by a third rigid member 432 . The second and third rigid members 430 , 432 extend through the slot 403 of the cannula 402 . The needle injection support member 436 extends the length of the cannula and is bonded to the injection needle 404 , as for example by welding or brazing. The stop plate 431 is disposed inside the slotted cannula 402 and outside the needle injection support member 436 . The maximum length that the injection needle 404 can extend beyond the distal end of the cannula 402 can be limited by the maximum needle depth controller 420 . The maximum needle depth controller 420 is used to adjust the distance between the stop plate 431 and the third rigid member 432 that is attached to the needle injection controller 422 . The injection needle 404 can be extended beyond the distal end of the injection cannula 402 by sliding the needle injection controller 422 toward the torque device 426 . The control mechanisms of the injection system 400 , including the cannula extension controller 416 , the maximum needle depth controller 420 , the needle injection controller 422 , and the torque device 426 , may be used in combination with real-time echocardiographic guidance to safely inject the needle at a site of interest. Real-time echocardiographic guidance provides visual feedback for primary prevention of myocardial perforation. The maximum needle depth controller 420 provides a proximal mechanical control as a secondary prevention to myocardial perforation. A syringe (not shown) that is filled with a therapeutic agent can be connected to the female Luer lock 412 and used for delivery of the therapeutic agent. The therapeutic agent passes through the connector tube 414 , a flexible tube 434 , and the injection needle 404 into the myocardium. The profile of the flexible tube 434 tapers from a size comparable to the connector tube 414 down to a size comparable to the injection needle 404 .
Referring now to FIG. 17 , the distal tip of the injection cannula 402 and an embodiment of an injection needle 404 are shown. The needle 404 includes a closed, non-coring tip 405 with a primary bevel 470 and secondary bevel 472 . The needle further includes side flush ports 474 to distribute the therapeutic agent. An alternative embodiment of an injection needle 407 is shown in FIGS. 18A and 18B wherein the distal tip 408 of the needle is open.
Still another alternative embodiment of the injection needle is shown in FIG. 19 wherein an injection needle 471 comprises an end stop 482 . The end stop 482 can be formed by several different methods including swaging or laser welding. The end stop 482 insures that the injection needle does not extend beyond a pre-determined maximum length beyond the cannula, as for example, approximately 6 mm. A maximum depth limiter at the proximal handle of the injection control system may not be sufficient, because the relative longitudinal position of the distal cannula tip and the distal needle tip can shift when traversing a curved path such as the aortic arch. The end stop 482 provides a safeguard in addition to safeguards provided by real-time echocardiographic guidance and a maximum depth limit controller that further mitigates accidental myocardial perforation by the injection needle.
Back leakage of the injected therapeutic agent can reduce the efficacy of the agent. Back leakage can be prevented by injection of a bioabsorbable polymer solution such as a poloxamer that gels as it reaches body temperature. The polymer solution can be administered simultaneously with the injection of the therapeutic solution. Alternatively, the polymer solution can be injected after the injection of the therapeutic agent. The same injection needle can be used for injection of the therapeutic agent and polymer solution. An alternative embodiment of the injection needle may take the form of a dual injection needle 484 as shown in FIG. 20 . The first and second needles 486 , 492 of the dual injection needle 484 are bonded along a line, as for example by laser welding. The therapeutic agent can be injected using needle 486 while the polymer solution can be injected using needle 492 for example. The dual injection needle 484 may be used in combination with a second connection tube and female Luer lock (not shown) at the injection system proximal handle connected to the second needle.
An alternative approach to prevent back leakage of the therapeutic agent is by use of a bioabsorbable photocrosslinkable hydrogel such as poly(ethylene glycol) (or PEG). The photocrosslinkable hydrogel may be administered simultaneously with or secondary to the therapeutic agent. Ultraviolet illumination of the hydrogel at the injection site initiates photocrosslinking and can be performed using a fiber optic bundle 464 as shown in FIGS. 21 and 21A . The fiber optic bundle 464 runs the length of the injection needle and can be disposed above the bond line 466 . The proximal end of the fiber optic bundle may be coupled to an ultraviolet light source (not shown) including a lamp providing light having a long wavelength of, for example, 365 nm.
Still another concern regarding delivery of the therapeutic agent to a region of interest is potential trauma to the therapeutic cells during delivery through the injection needle from the proximal end to the distal end such that viability of the therapeutic agent is degraded. An alternative embodiment of an injection system 500 is shown in FIG. 22 wherein the therapeutic agent can be loaded into a distal reservoir chamber 506 to minimize the length of the delivery path. The distal reservoir chamber 506 can be of sufficient volume for multiple injections. The size of a cannula lumen 662 can be increased by reducing the size of the drive cable 640 and imaging core lumen 660 . The size of a cannula lumen 662 can be further increased by increasing the catheter profile.
The proximal end of an injection needle 504 is bonded to the reservoir chamber 506 . The reservoir chamber can be loaded with the therapeutic agent by retracting the needle to its most proximal position that is determined by a proximal end stop 508 of the cannula 502 . When the reservoir chamber is at this loading position a reservoir chamber loading window 510 , cannula loading window 512 , and a proximal sheath loading window 664 can be aligned to enable loading of the therapeutic agent. The windows 510 , 512 , 664 may be pass-through holes or holes filled with a self-closing material such as silicone. A plunger 514 and plunger head 516 are advanced distal of the windows to further prevent any leakage of the therapeutic agent outside the reservoir chamber 506 .
The cannula 502 comprises a tapered distal section 520 with a flared tip 522 . The shoulder 524 of the tapered distal section 520 further prevents the injection needle 504 from extending beyond a pre-determined length, as for example, approximately 6 mm. A distal means to limit extension of the needle beyond the cannula may be necessary in situations wherein the relative longitudinal position of the distal cannula tip and the distal needle tip can shift when traversing a curved path such as the aortic arch. The flared tip 522 provides a blunt surface 523 to help stabilize the cannula against the left ventricular wall and prevent penetration of the cannula into the tissue.
Referring now to FIGS. 23A and 23B , a still further injection system 500 includes the injection cannula 502 , the injection needle 504 disposed within the injection cannula 502 , and a proximal handle 530 . The proximal handle 530 comprises a cannula extension controller 536 , a maximum needle depth controller 540 , a needle injection depth controller 542 , a torque device 546 , and a distal reservoir plunger controller 548 . The maximum needle depth controller 540 is a proximal control to restrict the depth to which the needle 504 can extend beyond the distal tip of the cannula 502 . The needle injection depth controller 542 is arranged to vary the position of the needle distal tip relative to the cannula distal tip. The distal reservoir plunger controller 548 is used to dispense the therapeutic agent.
Referring to FIGS. 24A and 24B along with FIG. 22 , the internal control mechanisms of proximal handle 530 are illustrated. The segment of the cannula 502 inside the proximal handle 530 has a slot 503 . The cannula extension controller 536 is coupled to the cannula 502 by a first rigid member 550 . The cannula 502 can be extended beyond the exit port 674 of the injection cannula lumen 662 of the endoventricular injection catheter 602 by sliding the cannula extension controller 536 toward the torque device 546 . The maximum needle depth controller 540 is coupled to a stop plate 554 by a second rigid member 552 . The needle injection controller 542 is coupled to a needle injection support member 558 by a third rigid member 556 . The distal reservoir plunger controller 548 is coupled to the distal reservoir plunger 514 by a fourth rigid member 550 . The second rigid member 552 , third rigid member 556 , and fourth rigid member 550 extend through the slot 503 of the cannula 502 . The needle injection support member 558 extends the length of the cannula 502 and is bonded to the injection needle 504 , by welding or brazing, for example. The stop plate 554 is disposed inside the slotted cannula 502 and outside the needle injection support member 558 .
The maximum length that the injection needle 504 can extend beyond the distal end of the cannula 502 can be limited by the maximum needle depth controller 540 . The maximum needle depth controller 540 is used to adjust the distance between the stop plate 554 and the third rigid member 556 that is attached to the needle injection controller 542 . The injection needle 504 can be extended beyond the distal end of the injection cannula 502 by sliding the needle injection controller 542 toward the torque device 546 .
The control mechanisms of the injection system 500 , including the cannula extension controller 536 , the maximum needle depth controller 540 , the needle injection controller 542 , and the torque device 546 may be used in combination with real-time echocardiographic guidance to safely inject the needle at a site of interest. Real-time echocardiographic guidance provides visual feedback for primary prevention of myocardial perforation. The maximum needle depth controller 540 provides a proximal mechanical control as a secondary prevention to myocardial perforation. The tapered distal section 520 of the cannula 502 provides a distal mechanical control as a tertiary prevention to myocardial perforation. The therapeutic agent can be delivered from the distal reservoir 506 through the needle 504 to the site of interest by use of the distal reservoir plunger controller 548 .
FIGS. 25 , 26 and 27 are flow diagrams illustrating sets of processing stages for image guidance of transendocardial injections according to aspects of the invention. FIG. 25 shows an exemplary set of processing stages for transendocardial injection of a therapeutic agent to an infarcted region in a left ventricular wall. The catheter is delivered to the left ventricular chamber in step 700 via a retrograde approach. The catheter is oriented to enable imaging of a region with a suspected infarct in step 702 . A set of baseline images are then acquired in step 704 .
The region of infarct is identified in step 706 . Referring now to FIG. 26 , an exemplary set of processing stages to identify an infarct region is illustrated. Image data is first acquired in step 730 . Identification of the infarct region includes image segmentation in step 732 into blood and non-blood tissues, compensation of image data for imaging system and ultrasound transducer effects in step 734 , calculation of tissue classifiers in step 736 , and finally identification of infarct region in step 738 . Compensation of system and transducer effects mitigates range-dependent amplitude and frequency variations in the ultrasound signals that can degrade accuracy of tissue classification. FIG. 27 shows an exemplary set of processing stages for calculation of tissue classifiers. The image data of interest are selected 750 . The integrated backscatter and slope-of-attenuation tissue parameters are calculated in steps 752 and 754 , respectively. Calculation of such tissue classifiers are known to those skilled in the art of ultrasound tissue classification. The process is repeated for all image data of interest as indicated by decision block 756 . Referring now to FIG. 26 , the calculated tissue classifiers are used to identify the infarct region in step 738 . Infarcted tissue is known to have higher values of integrated backscatter and slope-of-attenuation. The ranges of tissue classifiers corresponding to infarcted tissue are determined empirically.
Referring back now to FIG. 25 , the injection cannula is deployed and stabilized at the site of infarction in step 708 . The maximum depth limit for the injection needle is set in step 710 . The needle is then injected into the myocardium in step 712 . The therapeutic agent is injected into the myocardium in step 714 . The needle is removed from the injection site in step 716 and repositioned at a next injection site following decision block 718 as necessary.
While particular embodiments of the present invention have been shown and described, modifications may be made, and it is therefore intended to cover in the appended claims, all such changes and modifications which fall within the true spirit and scope of the invention as defined by those claims. | An endoventricular injection catheter with integrated echocardiographic capability enables injections into heart tissue under visualization. The catheter includes an elongated body having a distal end and an imaging core arranged to be inserted into a heart. The imaging core is arranged to transmit ultrasonic energy and to receive reflected ultrasonic energy at the distal end to provide electrical signals representing echocardiographic images to enable cardiac visualization. The catheter further includes an injector carried on the elongated body with the imaging core. The injector is arranged to inject a therapeutic agent into tissue of the heart visualized by the imaging core. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to an escutcheon. In particular, the invention is directed to a reversible decorative escutcheon for a ceiling fixture.
BACKGROUND OF THE INVENTION
Escutcheons provide a decorative surface to cover a portion of a wall or to cover the opening in a ceiling through which the support of a ceiling fixture extends. Escutcheons are used to avoid an unpleasant and disagreeable appearance and to maintain the architectural appearance of the building interior by hiding the interface between the ceiling fixture support and the ceiling. Installation of fixtures is speeded up, as escutcheons cover up imprecise holes, irregular holes, and broken out portions of ceilings, for example.
Conventional escutcheons are known to come in a variety of shapes and designs, and are used with a variety of ceiling fixtures, such as ceiling fans, sprinklers, chandeliers, and other types of hanging lights. Because escutcheons are used in a variety of ceiling fixtures, manufacturers and retailers must make available a large variety of shapes and designs in order to meet consumer needs.
However, companies today are now focusing more and more on becoming more efficient, productive and profitable. Therefore, the need to reduce manufacturing and retail cost and to increase sales is a high priority.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a reversible escutcheon which will reduce manufacturing and retail cost.
It is a further object of the invention to provide a reversible escutcheon which can be applied to any flat surface.
It is another object of the present invention to provide a reversible escutcheon which can be readily and securely installed during the installation of a ceiling fixture.
It is another object of the present invention to provide a reversible escutcheon configured with different types of indicia.
It is yet another object of the present invention to provide a reversible escutcheon which can be easily repainted to match the color of an existing ceiling.
It is still another object of the present invention to provide a reversible escutcheon which can be readily and inexpensively manufactured.
It is yet another object of the present invention to provide a reversible escutcheon which can be installed to cover a ceiling fixture hole without replastering the ceiling.
It is an object of the present invention to provide a reversible escutcheon which mounts flush with the ceiling without any modifications to the ceiling.
It is another object of the invention to provide a reversible escutcheon which will reduce inventory costs by at least half; e.g. by effectively providing two escutcheons in one.
It is a still further object of the invention to provide a multipurpose escutcheon engineered as a single component.
It is a further object of the invention to provide a reversible escutcheon which can be secured to a flat surface without the use of fasteners and tools.
In summary, the present invention is directed to a reversible escutcheon for a ceiling fixture which mounts flush with the ceiling.
BRIEF DESCRIPTIONS OF THE DRAWINGS
These and other objects, advantages and novel features of the present invention will become apparent from the following detailed description taken in consideration of the accompanying drawings, in which:
FIG. 1 is a plan view of an escutcheon according to the present invention;
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a perspective view of an escutcheon shown installed with a ceiling light fixture;
FIG. 4 is an elevational view similar to FIG. 3, with a partial sectional view of the escutcheon and a ceiling;
FIG. 5 is a plan view of another preferred embodiment of an escutcheon having a rectangular shape;
FIG. 6 is a plan view of still another preferred embodiment of an escutcheon having an octagonal shape;
FIG. 7 is a plan view of yet another preferred embodiment of an escutcheon having a hexagonal shape; and
FIG. 8 is a partial sectional view illustrating embossed patterns on both sides of an escutcheon.
FIGS. 9A-9B, 10A-10B, and 11A-11B are further preferred embodiments of escutcheons according to the invention, respectively, showing respective paired front and rear sides.
DETAILED DESCRIPTION OF THE INVENTION
In the accompanying drawings, FIGS. 1-4 disclose a preferred embodiment of a reversible escutcheon A of the present invention.
Referring now to FIGS. 1 and 2, escutcheon A includes a base 10 having two opposing surfaces or escutcheon faces 12 and 14. A hole 16 extends from surface 12 toward surface 14, through base 10. Hole 16 is for receiving a support portion S of a ceiling fixture F (See FIG. 4) and can be configured to accommodate a variety of support shapes and sizes.
Escutcheon A further includes a raised edge 18 which extends around the perimeter of base 10 and projects from surface 12. Escutcheon A also includes a raised edge 20 which extends around the perimeter of base 10 and projects from surface 14.
It is further contemplated that one or both of raised edges 18 and 20 extend around only a portion of the perimeter of base 10.
As shown in FIGS. 1 and 3, surfaces or escutcheon faces 12 and 14 are provided with patterns or indicia 22 which may be decorations. While the indicia 22 are shown to be print designs, it is contemplated to be within the scope of the invention that a variety of types of indicia 22 can be used. For example, surfaces 12 and 14 can be provided with raised and/or embossed patterns or designs (see FIG. 8), wood grain patterns, or even just a solid color.
It is also contemplated to be within the scope of the invention that surfaces 12 and 14 could each be provided with a different type of indicia, such as an embossed design on one surface and a wood grain design on the other surface.
As shown in FIGS. 2, and 4, raised edges 18 and 20 are preferably greater in height than respective surfaces 12 and 14. This permits escutcheon A to be installed with either edge 18 or 20 substantially flush with the ceiling, allowing either surface 14 or 12 to be exposed, respectively, thereby making escutcheon A reversible without any additional modifications to the ceiling (See FIG. 4).
FIGS. 5-7 illustrate other preferred embodiments of escutcheon A.
FIG. 5 shows an escutcheon B as having a generally rectangular shape.
FIG. 6 shows an escutcheon C as having a generally octagonal shape.
FIG. 7 shows an escutcheon D as having a hexagonal shape.
As further shown in FIG. 8, escutcheon A can be provided with embossed or raised patterns or indicia 24 and 26 on surfaces 12 and 14, respectively. To permit the flush installation of escutcheon A, it is preferred that the height H1 of raised edge 18 be greater that the height J1 of embossed indicia 24, and it is also preferred that the height H2 of raised edge 20 be greater that the height J2 of embossed indicia 26.
One advantage of raised edge 18 having a height H1 greater than height J1 of embossed indicia 24 is that raised edge 18 can be used as a glue edge. In use, adhesive or glue may be applied to raised edge 18. When glue is used to attach the escutcheon to a surface, no fasteners need be used.
While edges 18 and 20 are shown to extend generally perpendicular to surfaces 12 and 14 (See FIGS. 2 and 8), it is contemplated to be within the scope of the invention that edges 18 and 20 can extend at angles greater or less than 90 degrees.
FIGS. 9A and 9B illustrate first and second faces, respectively, of a further embodiment of an escutcheon K according to the invention. As in the other preferred embodiments, FIG. 9A can be referred to as the "front" and FIG. 9B can be referred to as the "rear" it being appreciated that one or both faces will be displayed according to the user. As with the other preferred embodiments of the invention, escutcheon K will typically be glued or otherwise attached to a wall or ceiling, in which case one side would be visible, when installed. When escutcheon K is glued to a clear surface, such as a sliding glass door or window pane, both sides would be visible.
Escutcheon K includes a hole 30 configured to surround the support of a ceiling fixture, for example, and one or more raised portions which have decorative as well as functional uses. For example, portions 34 and 38 are configured to function as elements, conveniently referred to as glue edges, on which an adhesive will be placed for securing the front face of FIG. 9A to a wall. The front face is attached to a wall when the rear face shown in FIG. 9B is to be displayed. It will be appreciated that the extent, configuration, and texture of glue edge 38, for example, will be sized and selected as a function of the size and weight of escutcheon K, the intended use thereof, the surface to which escutcheon K is to be attached, the adhesive to be used, and the like.
The rear face shown in FIG. 9B illustrates additional glue edges 42 and 46, one or both of which may be used when installing escutcheon K on a ceiling, when the front face shown in FIG. 9A is to be visible.
FIGS. 10A and 10B illustrate the front and rear faces, respectively, of an escutcheon L according to another preferred embodiment of the invention. Indicia 50 is surrounded by a raised portion 52, which may likewise serve as a glue edge as in the other embodiments. A hole 56 is provided when an object such as the support for a chandelier is to be surrounded by escutcheon L. The rear side shown in FIG. 10B will have one or more glue edges 58. Hole 56 will be either pre-formed or pre-cut, or will be manufactured so that the user may readily remove a functional and decorative plug, depending on the intended use.
An escutcheon M according to a still further preferred embodiment of the invention is shown in FIGS. 11A and 11B. Escutcheon M has decorative raised portions serving as glue edges 64 and 68, as well as a center 70. In this embodiment the center 70 will typically be formed as a solid portion integral with the remainder of escutcheon M. Escutcheon M is particularly suited for attaching to walls and for applications where nothing extends through the center thereof. The rear face shown in FIG. 11B likewise has glue edges 74 and 78.
It is also contemplated to be within the scope of the invention that each of the embodiments of the escutcheon according to the invention can be secured in place using conventional anchoring devices, such as adhesives, screws, and nails.
While this invention has been described as having a preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims. | A reversible escutcheon for a ceiling fixture having a base with first and second opposed surfaces. The base also defines a hole extending from the first surface to the second surface. A first raised edge extends around at least a portion of the perimeter of the base and projects from the first surface. A second raised edge extends around at least a portion of the perimeter of the base and projects from the second surface. The first and second edges are selectively mountable adjacent to a ceiling wherein one of the second and first surfaces is exposed, respectively. | 4 |
BACKGROUND OF THE INVENTION
(i) Field of the Invention
This invention relates to asphalt production and particularly but not exclusively to production of asphalt used in road making.
(ii) Prior Art
Asphalt making apparatus usually includes a conveyor system, transporting mineral ore aggregate from cold feed bins to a dryer, where it is preheated. The dryer is usually of the rotatable drum type fitted with lifters to ensure good contact with the burner combustion gases. A conveyor system transports the preheated mineral ore aggregate from the dryer to a vibrating screen, which screen separates the preheated aggregate into various fractions and deposits the different fractions into hot bins. A mineral filler system discharges specified weights of mineral ore aggregate from the hot bins into a pug-mill mixer or similar mixing device, and after a specified dry mixing time, a predetermined weight or volume of bitumen is discharged into the pug-mill, the added bitumen being held in electrically heated storage bins prior to discharge into the pug-mill. The pug-mill then wet mixes preheated mineral ore aggregate and bitumen until a uniform mixture is obtained, and the resultant asphalt is then discharged into trucks and transported to the road-making site. Asphalt produced in this way is known as "hot mix".
One reason for producing "hot mix" in factories remote from the road-making site is that bitumen is an inflammable material and careful control must be maintained over heating of the bitumen to maintain the bitumen in a stable state. The required control would be more difficult to achieve if the "hot mix" was produced on site. Also, the equipment needed to produce the "hot mix" is not easily transportable and therefore moving the equipment from site to site is difficult and inefficient.
The burners used in the described drum type dryers usually operate on diesel fuel oil, or in some cases on heavy furnace oil, and are fitted with an exhaust fan to remove combustion gases and provide suction for secondary air to the burner. A duct positioned prior to the fan is fitted with a separator to effect dust removal, the dust being discharged as waste. Where the factory is located in built-up areas, pollution controls are necessary to limit the amount of dust discharged into the atmosphere to within "clean air" regulations.
SUMMARY OF THE INVENTION
In accordance with the invention asphalt is produced by a process including heating the aggregate in a microwave heater. More particularly, the invention envisages a process comprising heating the aggregate in a microwave heater, and then mixing the so heated aggregate with heated bitumen to produce asphalt. It would, however, also be possible to produce asphalt by heating aggregate and bitumen together. The invention also provides asphalt production apparatus comprising means for heating aggregate and bitumen, and means operable to mix the aggregate and bitumen the means for heating at least the aggregate including a microwave heater.
Aside from reducing the difficulties associated with the use of the customary drum type dryers, the microwave heaters render practical the production of hot mix asphalt on site, since the microwave heaters are relatively compact and relatively easily transportable. In such as case, much of the wastage presently associated with asphalt road making may be avoided.
Also, it is envisaged that "hot mix" asphalt produced using conventional processes or by a process according to the invention may be poured and sealed into containers of suitable shape and construction. When asphalt is required, the containers may be transported to the road-making site, whereat subsequent reheating of the containers in microwave heaters will render the asphalt suitable for use in road making. An advantage of this process is that "hot mix" asphalt may be stored in a solid state and reheated in microwave heaters positioned on-site.
In another aspect the invention provides a method of making asphalt wherein aggregate and bitumen are heated in one or more substantially closed vessels separately prior to mixing and/or together during mixing. In a still further aspect the invention provides a method of making asphalt in which aggregate is heated in a substantially closed vessels and then mixed with heated bitumen. The invention makes possible the re-cycling of used asphalt by simply re-heating such used asphalt in a closed vessel using a microwave heater. In the past, the heating has not been possible using conventional techniques.
Dielectric heating is the term applied to the generation of heat in non-conducting materials by their energy losses when subjected to an alternating high frequency electric field. The basic principle is that the material to be heated is placed between two capacitor plates across which a high frequency alternating voltage is impressed.
The term microwave heater conventionally refers to directly heating non-conducting materials using dielectric heating; however, the term has also come to include heaters which operate as a combination of both dielectric and induction heaters and it is in this extended sense that the term is used in the present specification.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The invention is further described with reference to the accompanying drawing in which:
FIG. 1 is a block layout of an asphalt factory incorporating the present invention.
DETAILED DESCRIPTION
In the factory represented by FIG. 1 mineral ore aggregate is transported on conveyor belts from feed bins 4 to a microwave heater 6. When the temperature of the aggregate in the heater reaches the temperature range 300°-400° F., the heated mineral ore aggregate is discharged into a vertical elevator which conveys the aggregate to a vibrating screen 8, which separates the aggregate into various size functions and deposits these into hot bins 10. The exact temperature the aggregate is heated to in the microwave heater 6 is dependent on the mix type and the factory temperature loss during transport from the microwave heater outlet to a plug-mill mixer referred to later, the pug-mill mixer 14.
After leaving the heater, dry mixing is carried out. This comprises weighing out the appropriate quantity of mineral ore aggregate from each hot bin 10, (specified for a particular mix) cumulatively into a weighing hopper 12. The batch of mineral ore aggregate so weighed out is then discharged into pug-mill mixer 14 and dry mixed for a specified time. Pug-mill mixer 14 may be of conventional form being twin shafted and fitted with replaceable mixing tips and liner plates to ensure close tolerances between mixer tips and the body of the mill. Bitumen is stored in heated storage bins 18, in the conventional manner being, for example, electrically heated or, where high asphalt throughput justifies higher initial capital outlay, by use of hot oil heating. Bitumen is pumped from the heated storage bins 18 to a mixing platform 16 and a specified weight or volume is introduced from the mixing platform 16 into pug-mill 14 after completion of the mineral ore aggregate dry mixing. After introduction of bitumen into pug-mill mixer 14, wet mixing begins and continues until a uniform mixture of asphalt is obtained--the wet mixing cycle taking normally 45-80 seconds. The asphalt is then discharged into trucks at a discharge point 20 and transported to the road-making site.
Aside from manufacture of asphalt by the described process already processed asphalt may be re-processed by heating it in a substantially closed vessel by using a microwave heater. Samples of asphalt that have been layed for some time and dug up and recycled in this manner may well be quite satisfactory when so re-used.
It will be appreciated that heating by microwave apparatus will result in consumption of a considerable quantity of electricity in the production of the asphalt. However, additional running costs incurred this way can to some measure be offset by the substantial decrease in electric power consumed by ancillary equipment normally used in an asphalt plant. More particularly, conventional plants making use of drum dryers for heating the aggregate will normally require a substantial electric motor to rotate the drum in which the aggregate is heated, an additional motor to provide an air blast for operation of the oil burner used in the drum dryer as well as a substantial motor to operate cyclone and other separators and dust extractors needed to remove dust generated because of the necessary agitation of the aggregate during heating. In a medium sized plant, motors operating these apparatuses may have a total power consumption of the order of 350 kilowatts. Aside from this, the conventional dryers together with dust extractors occupy a substantial area of plant which need not be provided by use of the invention. These apparatuses are also costly and even with proper dust and combustion products extraction, conventional plants still create very substantial environmental problems.
As well as the use of a microwave heater to heat the aggregate and/or mixed bitumen, a microwave heater could be employed to maintain the bitumen in the heated condition prior to mixing. This heating is customarily effected with a heater which heats a suitable heat exchange fluid such as oil which is circulated around a tank containing bitumen. The use of a microwave heater either to heat the bitumen directly or indirectly by such a heat exchange fluid would result in substantial advantages, particularly, the heating could be effected in a substantially closed vessel so that generation of fumes would be minimized.
Whilst in the described plant, heating of the aggregate is effected directly by a microwave heater, the aggregate could be heated by a heat exchanger having fluid therein heated by a microwave heater.
The described construction has been advanced merely by way of explanation and many modifications may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims. | Methods of manufacturing and re-processing asphalt in which bitumen for the asphalt is heated by use of a microwave oven. Re-processed asphalt is recycled in a microwave oven in a closed vessel. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the formation of flat fabric for the molding of items such as gaskets which have a reinforcement inlay of textile. In such fabric a textile panel is produced from which the inlaid areas (corresponding to the desired items) are separated either before or after the provision of an embedding material (e.g. a material covering or saturating the inlays to achieve the desired properties of the finished product).
2. Discussion of the Relevant Art
Heretofore, it has been known to produce articles of the foregoing type from a woven fabric panel. This approach involves regularly laid weft and warp threads. The items in question are then stamped out of the textile pattern either before or after application of the embedding material. There is thus produced by this known method a very substantial waste of the panel material. The costs for the thread utilized in this waste must, of course, be taken into account in calculating the entire cost of the items. There is an additional problem in that the reinforcement threads utilized for the strenghtening inlays, depending on the ultimate use, must have certain mechanical, thermal, chemical, or other particular properties and the price would correspond thereto.
One of the objects of the present invention is to provide a process of the heretofore described type in which the amount of material and the cost is substantially reduced.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating principles, features and advantages of the present invention, there is provided a process for the formation and molding of articles such as gaskets from embedding material and a flat textile panel. The panel is divisible into useful areas corresponding to the articles and areas outside the useful areas. The method includes the step of locating the reinforcement threads in the areas corresponding to the useful areas, in greater thickness and density than in the majority of the areas of the panel remaining outside the useful areas. Another step is producing the textile panel from a ground pattern with the reinforcement threads inlaid thereinto. The method also includes the step of separating the useful areas from the textile panel and embedding the embedding material onto the appropriate useful areas corresponding to the articles before or after the separation of the articles.
By providing the foregoing method an improved gasket or other useful article is achieved. A fabric or textile panel is produced from a ground stitch pattern having reinforcement threads laid thereinto in such a manner that the reinforcement threads are present in the useful sectors in greater density. These useful areas of greater density correspond to areas where the inlays are placed with a greater density than in most of the remaining material, which lies outside the useful segment and is separated from the useful segments distinguished by the dense inlays. Under the term "density" there is included the total of reinforcement threads.
In this procedure, the reinforcing threads are substantially only used where they will later be needed, that is to say, in the useful sectors which will be cut out. Accordingly, the cost of reinforcement thread material is also substantially lower than before. The threads of the ground stitch pattern can be slightly or significantly less expensive than the material for the reinforcement threads.
Since the reinforcement threads are not laid-in in a regular manner, it is possible to provide, within the useful segment itself, zones of different density of reinforcement threads if it is desired to obtain, within the finished item, zones of different solidity.
A further cost saving is obtained by the fact that the reinforcement threads are not, as is the case in weaving, deformed into a sinuous shape, but rather can be laid into the ground stitch pattern in substantially straight form. In order to cover a predetermined surface with reinforcement threads therefore, a lesser length of reinforcement thread is required.
In a preferred modification of the invention the reinforcement threads are provided as fully running-through weft threads, partial weft threads, warp inlays or combinations thereof in order to provide useful sectors which have a greater thread density than the remaining areas. Full weft threads can, for example, be provided by the conventional magazine arrangement. Partial weft threads can be provided from guide bars. Warp inlay threads can be provided with simple thread guides. All of these arrangements are well known in warp knitting machines. It is thus possible to carry out the process of the present invention on entirely conventional warp knitting machines.
It will be noted, of course, that when both of the foregoing modes are utilized there is provided a crossing zone of very high thread density.
In a further embodiment of the invention, the reinforcement threads are laid in the form of a plurality of partial weft threads which complement each other in the wider sections (of larger width) of the useful sector; and weft thread segments are provided in the sectors of lesser width of the useful area. This is valuable for the formation of annular-shaped portions.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more fully understood, the invention will now be described in greater detail with reference to the appended drawings showing the preferred embodiments of the invention; wherein:
FIG. 1 is a plan view of a fabric having full, reinforcing, warp and weft threads, grouped to intersect at useful circular areas;
FIG. 2 is a plan view of a fabric having full, reinforcing, warp threads (at the useful areas) and other, reinforcing threads laid as partial weft threads;
FIG. 3 is a plan view of a fabric having four reinforcing threads laid as partial weft threads to form an annular pattern; and
FIG. 4 is a plan view of a fabric having reinforcing, partial weft threads laid along a curved channel together with reinforcing warp threads laid to follow the same channel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The figures each illustrate a sector to be cut out of a fabric pattern. However, each have different laying patterns and reinforcement threads and different forms of the useful sectors.
FIG. 1 illustrates a fabric panel 1 which shows a ground work pattern 2 indicated at the lower left as a tricot stitch. This tricot stitch may be provided by a conventional warp knitting machine having the usual guide bars needles etc (not shown). In this ground pattern there are provided warp threads 3 and full weft threads 4 which serve as reinforcement threads. These weft threads may be laid by the usual weft thread magazine (not shown) by transversely laying weft thread into the stitching area of the knitting machine just upstream of the needles. Subsequent formation of the tricot stitch captures the weft thread in the resulting fabric. These reinforcement threads 3, 4 do not have to contribute much to the solidity of the reinforcement inlay. In an extreme circumstance, the ground pattern only serves to hold the reinforcement threads in their predetermined position until the embedding material is applied thereto. Four warp threads 3 are provided adjacent to each other in sector 5 whereby the sector 6 is left free in the panel direction.
These reinforcing warp threads 3 are laid into the fabric in the usual fashion so that they are stitched into the fabric.
Four weft threads 4 are placed next to each other in sector 7 whereby the segment 8, running perpendicular to the panel direction, is left free. The interrupted pattern is achieved by, for example, threading less than all of the positions in the weft thread magazine.
As reinforcement thread materials, it is desirable to utilize technical threads such as carbon, glass, quartz, fluoro-containing polymers such as "TEFLON" (trademark) or particular purpose polyamides such as "KEVLAR" (trademark) or metallic threads such as steel, silver, or gold. Such technical threads and metallic threads are expensive and in some cases extraordinarily expensive. Thus, it is possible to provide substantial savings by the concentration of the reinforcement threads in the useful areas where they are required. It is further to be noted that the material utilized for the reinforcement threads, as opposed to the thread material used for the ground stitch pattern can be provided of more rigid and/or more breakable material. In this group there may be considered, for example, glass, quartz, or carbon threads. Such materials either cannot be woven or can only be woven with substantial difficulty since in the weaving process each single thread must be forced into a wave-like pattern. However, when such reinforcement threads are laid into the ground stitch pattern they may be provided in a substantially linear manner and thus the bending influence thereof is considerably reduced.
The orthogonal dotted lines 9 and 10 indicate the boundaries of each quadrant 11 within which the reinforcement threads show the same pattern. In each of these quadrants 11 there is provided one useful sector 12 in which the reinforcement threads 3 and 4 cross each other and therefore have a particularly high density. The cut to separate the strenghtened inlays will be led around the edge 13 of the useful sector.
The sectors lying outside the useful sector 12, namely area 14, is waste. This sector 14 comprises the inexpensive thread material of the ground stitch 2 and contains only the straight reinforcement thread portions 3, 4 which are necessary for the reinforcement threads (which are laid across the entire panel) to span across a plurality of neighboring useful sectors 12. The best results are obtained when the proportion of reinforcement thread in the remaining (to be discarded) sector is less than 10%, suitably 5%, of the total consumption of reinforcement thread material. This means that the reinforcement thread, during the transition from one useful sector to the adjacent useful sector is practically linear, that is to say, it is led either in the direction of the panel or perpendicular thereto.
The reinforced inlay, which is later formed by the cutting out, stamping out or using other separating means, along line dotted line 13, has the shape of the desired item; here a circular disk. While in an ordinary fabric pattern it does not matter at which point the reinforcement inlay corresponding to the molding item is separated out, in this case care must be taken that only the useful segment to be utilized as inlay is separated out. This can be done without causing any substantial difficulties. For example, in the cutting or stamping, the work tool must grasp the edge of the useful segment, a requirement which, in the automatic application of the process can be readily controlled by optical or other sensors. Another possibility exists therein in providing separating threads at the edge of the useful segment which can be dissolved either by chemical means or by the influence of elevated temperatures.
In the embodiment of FIG. 2 the fabric panel comprises a ground stitch 22 in the form of a tricot stitch. The reinforcement threads comprise warp threads 23, full weft threads 24 and partial weft inlay threads 25. In the rectangularly shaped sector 26 which is delineated by dotted lines 27 and 28, there is found a useful sector 31 having an outside boundary formed by dotted (later separation) line 29 and an inside boundary formed by dotted (later separation) line 30. The warp inlay threads 23 are laid down the entire length of useful sector 31, that is to say, across the entire segment 34, while intermediate segment 35 is free thereof. The weft inlaid threads 24 are laid across the entire panel width during the working of the first sector 36 of the usage sector 31 and in the working of the last segment 37 of usage sector 31. These threads are inserted by a magazine as described previously. The intermediate segment 38 and the subsequent sector 39 have no full weft threads. In the intermediate sector 38 however, partial weft threads 25 are so laid that they cover the area from the cut-out edge 29 to the cut-out edge 30. These partial weft threads are laid in the panel travel direction in the other sectors 36, 37 and 39. The thus produced reinforcement inlay thus has the form of a rectangular, annular plate. The partial weft threads 25 are laid across the relevant width of the fabric panel in a similar manner by means of a single guide bar (not shown) used for these partial weft threads.
In the fabric panel of FIG. 3 the ground stitch 42 can be of any desired form, that is to say, in place of the indicated tricot stitch 42, there may equally be used a pillar stitch, a two and one stitch or the like. The reinforcement threads comprise only partial weft inlay threads 43, 44 and 45, 46, which are laid by different guide bars. The dotted lines 47 and 48 designate the edges of the rectangular surfaces 49 and 50 which provide, in the panel direction, two differentiatiable useful sectors 51 and 52. In consequence thereof there are also four differentiable waste sectors 53, 54, 55 and 56, which are shown in diagonal shading. Later the unshaded usage sectors 51 and 52 are stamped out. The separation line is not indicated in this embodiment but will be understood to run around the inside and outside periphery of the useful sectors.
In the first worked sector 57, all four partial weft threads 43 thru 46 are in operation. They are shogged transversely in alternate directions from stitch to stitch. This may be accomplished with four separate guide bars, if desired. The locus of the shogging for threads 44 and 45 remains the same throughout section 57, but threads 43 and 46 vary. These threads reciprocate over an ever increasing span, the outward reach increasing while the inner reach begins to migrate outwardly. In the next sector 58 only the outer threads 43 and 46 are laid as partial weft threads while the corresponding threads 44 and 45 are led down the corresponding inner edge of usage area 51. Threads 43 and 46 are shogged over a channel that moves outwardly, reaches a midpoint where their lateral motions are invariant, and enter a trailing section where the lateral motions reverse and tend toward convergence. There follows segment 59 in which all of the four partial weft threads 43 thru 46 are in operation. In this section the threads perform the same operations as in section 57 but in reverse order. In the next sector 60 all of the partial weft threads are led in panel direction without shogging.
In subsequent sector 61 all four threads 43, 44, 45 and 46 are in operation, again. This operation is the same as was performed in section 57. Subsequently in sector 62, only the two outer threads 43 and 46 are laid as weft threads. The operations in this section are similar to that of section 58 except that the operations of section 62 terminate early. In sector 63 all four threads are operational and shog with approximately equal displacements. In sector 64 all of the threads are led in the panel direction. In order to obtain a desired carved form the subsequent weft thread inserts are displaced sidewards mutually with respect to each other.
When the desired molded item has a curved shape, it is recommended that the reinforcement threads be laid into the useful area as partial weft threads during the working thereof; whereby at least some of the mutually succeeding partial weft thread inlays are displaced laterally with respect to each other. Thus, warp inlays can be laid in the shifting motion corresponding to the displacement of the partial weft threads so that the reinforcement threads cross in the entire channeled area.
In the embodiment shown in FIG. 4 there is provided a fabric panel 61 with a ground stitch 62 in the form of a pillar stitch. Within the dotted lines 63 and 64, designating a rectangle 65, there is provided a use area 66 and two waste areas 67 and 68 shown in diagonal shading. The later separation cut to remove the reinforcement inlay runs substantially between the useful sector 66 and the remaining sectors 67 and 68.
In this embodiment the reinforcement threads are provided by four warp inlay threads 69, 70, 71 and 72 as well as partial weft thread inlays 73. The partial weft thread 73 is so led that succeeding segments are displaced laterally from each other so that in the final result a carved form is provided to the ultimately obtained inlay. The warp inlay thread 69 to 72 are subjected to deflecting motion in such a manner that they follow the displacement of partial weft thread 73. The tension which operates upon the warp threads 69-72 in the goods themselves ensures that they are not as sinuous as shown in the drawing but less sinuous. Also in this embodiment different types of ground stitch may be utilized.
A finished product will have been saturated or covered with an embedding material or other further treatment such as pressing, polishing, or the like of the thus provided product. The finished product may be used as a gasket material, such as gasket rings, head gaskets or the like and other items.
It is to be appreciated that various modifications may be implemented with respect to the above described preferred embodiments. It is possible to provide different thread densities. This may be achieved where the useful segments are formed next to each other in the textile panel, the reinforcement threads being provided as full weft inlays only during the working of the useful sectors. Another possibility exists therein in providing the reinforcement threads as warp threads only across the breadth of the useful sector, where the useful sectors follow each other in the fabric panel.
Yet another possibility exists whereby the useful sectors are provided both adjacent to each other and following each other in the textile. In this situation, panel reinforcement threads in the form of partial weft threads, can be laid into the useful sectors during the working thereof; but between the useful sectors the reinforcement threads are led in the direction of the travel of the panel. This possibility can also be combined with other measures. For example, during the working of the first and last useful subsectors, reinforcement threads are provided as full weft inlays and in between the subsectors are laid-in as partial weft threads. In this manner it is possible to provide rectangular useful sectors with a surrounding rectangular waste area.
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. | An article and process for the formation and molding of articles such as gaskets from useful areas of a flat textile panel. This panel is divisible into useful areas possessing textile reinforcement inlay threads in greater thickness and density than in the majority of the areas of the panel remaining outside the useful areas. The textile panel is produced from a ground pattern with the reinforcement threads inlaid thereinto. The useful areas are separated from the textile panel and embedding material is embedded onto the appropriate useful areas corresponding to the articles before or after the separation of the articles. | 3 |
This application is a is a continuation-in-part of application Ser. No. 07/409,457, filed Sept. 19, 1989, the subject matter of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a downhill or cross-country ski shoe or boot equipped with an energy source supplying an energy consuming device, such as a heating device.
2. Description of Background Information
Ski shoes or boots are known which are intended to improve the comfort of the wearer by means of the incorporation of heating devices. These devices include the electrical type, which use a heating resistance, and the liquid or gaseous fuel type which use a fuel reservoir or tank for a burner positioned in the shoe or boot. Liquid or gaseous fuel heating devices are advantageous, compared to electric devices, in making it possible to obtain a greater autonomy, making them more convenient, and to ensure the temperature and desired comfort within the shoe or boot during a relatively long period of time.
Heating devices using liquid fuel, such as described, for example, in Italian Patent No. 1,136,269 and French Patent No. 2,080,146, generally comprise a rechargeable liquid fuel burner, which is positioned under a heat diffusion plate incorporated in the sole of the shoe or boot so as to be as close as possible to the foot of the wearer of the shoe or boot. Other heating devices which use gaseous fuel include a gas reservoir or tank, supplying fuel through a valve to a catalytic burner, all these elements being totally positioned in the sole of the shoe or boot.
Such heating devices with gaseous fuel are described, for example, in Italian Design Model No. 196,850 and in International Patent Application WO 86/05663. These gaseous fuel heating devices are of the rechargeable gas tank type and it is consequently necessary to provide, in the sole of the shoe or boot which contains the tank, an orifice through which the internal gas tank can be connected to an external gas recharging source.
The known heating devices, either of the elastic type or the liquid or gaseous fuel type, have the disadvantage that once the heating is started, this heating can only be stopped by manual intervention of the wearer of the shoe or boot. That is, the wearer must think of shutting off the heating when he takes off the shoe or boot, which can obviously be forgotten. Therefore, the removed boot is still heated, causing rapid exhaustion of the energy source used and a waste of this energy.
SUMMARY OF THE INVENTION
It is an object of the present invention to improve upon known apparatus. To this end, the present invention is directed to an item of wearing apparel which includes means for receiving an extremity and means for selectively tightening and loosening a portion of said item of wearing apparel about said extremity, the item of wearing apparel further including:
(a) an energy source;
(b) an energy consuming device; and
(c) means for controlling the supply of energy from the energy source to the energy consuming device including means for preventing the supply of energy from the energy source to the energy consuming device in response to loosening the portion of the item of wearing apparel about the extremity by the means for selectively tightening and loosening a portion of the item of wearing apparel about the extremity.
According to a specific aspect of the invention, the energy consuming device includes a heating device of either an electric or gaseous type. Specifically, the heating device could be an interchangeable gas fuel cartridge.
According to a further specific aspect of the invention, the item of wearing apparel is a boot, such as an alpine or cross-country ski shoe or boot.
More specifically, the boot includes an upper and the energy source and the means for controlling the supply of energy from the energy source to the energy consuming device is supported by the upper.
Still further according to the invention, the energy for preventing the supply of energy from the energy source to the energy consuming device includes means for detecting the loosening of the portion of the item of wearing apparel, wherein the supply of energy is prevented upon the detection of loosening of the portion of the item of wearing apparel.
In a still further specific aspect of the invention, the means for controlling the supply of energy from the energy source to the energy consuming device includes a manually actuated energy supply switch movable at least between an ON position, in which the supply of energy is permitted between the energy source and the energy consuming device, and an OFF position, in which the supply of energy is prevented from the energy source, wherein the means for controlling the supply of energy from the energy source to the energy consuming device includes means for linking the means for detecting the loosening of the portion of the item of wearing apparel to the energy switch, wherein upon the detection of the loosening of the portion of the item of wearing apparel, the energy switch is permitted to move to the OFF position.
Further according to the invention, the item of wearing apparel includes means for biasing the energy switch toward the OFF position and means for maintaining the energy switch in the ON position against the force of the means for biasing in response to a failure of the means for detecting the loosening of the portion of the item of wearing apparel to detect the loosening of the portion of the item of wearing apparel.
As applied to a boot, the means for detecting the loosening of a portion of the boot comprises a member located proximate the upper of the boot which is moved by means for selectively tightening and loosening the portion of the boot.
It is an additional object of the present invention to provide a ski boot or shoe comprising an upper provided with means for tightening the upper. The boot includes an energy source for supplying an energy consuming device. A device for controlling a supply element of the energy consuming device is connected between the energy source and the energy consuming device, and further includes means actuated by the means for tightening the upper so as to allow the opening of the energy supply element when the upper is tightened and to automatically cause the closing of this supply element in response to the loosening of the upper.
The means actuated by the tightening means includes an element forming a retractable abutment, which is movable between an operative abutment position and an inoperative position, and a pawl for contacting the abutment when it is the operative position to open the energy supply element. A spring biases the retractable element to the inoperative position.
According to one embodiment, the retractable abutment includes a portion of the upper which is cut so as to form a movable flap. The flap is defined by a U-shaped cutout which is joined to an upper portion of the rear wall of the upper and which is detached from the rest of the rear wall of the upper along its two lateral and vertical edges and its lower horizontal and transverse edge. The lower edge is adapted to form the abutment for the pawl. The means for tightening includes at least one tightening cable which surrounds the upper part of the upper where the flap is formed and the cable passes behind the flap. The flap includes a thickness which increases downwardly so that the flap has substantially, in the vertical and longitudinal cross-section, the shape of a trapezoid whose large base constitutes a lower edge which forms the abutment. The flap is biased by the spring towards the exterior of the boot. The spring includes a curved blade which is affixed at its upper end to an upper part of the upper and whose lower curved part rests against an internal surface the flap.
In another embodiment in which the boot is of the front entry type, the tightening of the upper is achieved by means of a cable surrounding the front of the upper, wherein the cable is connected to a tightening lever. The tightening lever is journalled about an axis on an exterior clevis which can slide horizontally with respect the upper. The clevis is connected to a front end of a support strap which extends along the internal surface of the upper. The support strap includes a rear part which extends above the pawl. An internal groove in the rear wall of the upper is adapted to receive the support strap. The support strap is normally biased towards the rear by a spring. The clevis includes a rivet which extends through a horizontal slot provided in the wall of the upper, wherein the rivet is affixed to the front end of the support strap. A spring is positioned in a horizontal slot provided in the front part of the support strap. A wall including a shoulder projects through the slot in the support strap, with the spring resting at one end against the shoulder and at the other end against an edge of the slot.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are described below, by way of non-limiting examples, in which further objects, features, and advantages of the present invention will become apparent, with reference to the annexed drawings in which:
FIG. 1 is a vertical and longitudinal sectional view of a boot with an upper having a single portion provided with a gas heating device according to the invention in the position wherein the gas supply is turned on;
FIGS. 2 and 3 are partial vertical and longitudinal sectional views on an enlarged scale, illustrating the operation of the device for control of the gas supply;
FIG. 4 is a vertical and longitudinal sectional view of an alternative embodiment of the invention; and
FIG. 5 is a horizontal sectional view taken along line V--V of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As mentioned above, an object of the present invention is to overcome the disadvantages of the above-mentioned known devices by providing a shoe or boot provided with means to automatically turn off the energy supply as soon as the wearer of the shoe or boot loosens the upper thereof.
The downhill or cross-country ski shoe or boot comprises an upper provided with means for tightening. The boot is equipped with an energy source supplying an energy consuming device, such as a heating device, and a device for controlling an element for supplying the energy consuming device connected between the energy source and the consuming device. It includes means activated by the tightening means of the upper of the boot so as to allow the opening of the energy supply element alone when the upper of the boot is tightened and to automatically cause the closing of the supply element as soon as the skier loosens the upper.
The energy consuming device which is incorporated in the boot can be a heating device of the electric type, and in this case, the means activated by the tightening means of the upper of the boot acts on an electric switch which is connected between an electric energy source and a heat-resistance assembly. Alternatively a liquid or gaseous fuel type may be used, in which the means activated by the tightening means of the upper of the boot acts on a device for controlling a valve connected between a tank of gas or liquid fuel and a heating assembly.
The boot with an upper shown in FIGS. 1-3, which can be a downhill or cross-country ski boot, is of the rear entry type. It is provided with a heating device which in this embodiment is of the gas fuel type. However, the invention also applies in the same way to a boot provided with an electric or liquid fuel heating device or to any other energy consuming device. The heating device includes heating assembly 1 which is positioned in an opening with an appropriate shape provided in the upper part of sole 2 of the boot. Heating assembly includes burner 3 which is affixed, for example, by welding, under heat diffusion plate 4, which is itself placed under internal sole 5 of the boot so as to be able to heat the skier's foot in extreme cold weather. Burner 3 is connected to gas supply tube 7 and electrode 8, which is part of an ignition device, for example of the piezoelectric type to which conductor wires 9 are connected.
Heating assembly is supplied with gas from an interchangeable gas fuel cartridge 11 which is positioned in a housing provided in the rear part of upper 12 of the boot. Gas cartridge 11 is vertically positioned with its gas outlet orifice directed downwardly. In the description which follows, it is understood that the "vertical" direction is the direction in which the upper 12 extends when in fact the rear wall of the upper is slightly inclined towards the front. Gas cartridge 11 is connected at its lower end to supply element 13 which is constituted by an assembly forming a pressure-reducing valve having a control element for opening and closing which includes pin 14 projecting outside the body of valve 13 and which is movable in a vertical slot in the body. Pin 14 is biased downwardly in the direction of its open position by return spring 14a which is positioned within pressure-reducing valve 13. Pin 14 is actuated by lug 15 which is part of a control device 16 for the gas supply. Control device 16 acts on pusher 17 of ignitor 18 (of the piezoelectric type, for example) which is connected by electric conductor 9 to electrode 8 so as to produce an ignition spark.
Control device 16 includes two substantially vertical plates which are adjacent to one another, in the vertical and longitudinal planes, that is, a manual control plate 19 of relatively short height and an actuation plate 21 of greater height for actuation of valve 13, which extends both above and below plate 19. Plate 21 for actuation of valve 13 has a generally rectangular shape, and includes on its lower part, lug 15 which extends under pin 14 and is in contact therewith. Manual control plate 19 is substantially C-shaped and is open towards the rear. It includes vertically member 19a, lower wing 19b, and upper wing 19c. Lower wing 19b actuates pusher 17 of the piezoelectric ignitor 18 and is located between the upper surface of pusher 17 and internal projection 22 of the rear wall of upper 12 of the boot. Upper wing 19c of manual control plate 19 extends outside the rear wall of the upper 12, by passing through vertically elongated slot 23. Control knob 24 is fixed to the external end of wing 19c. The two plates 19, 21 are constantly biased upwardly by compression spring 25 which rests on the upper surface of internal projection 22.
The two plates 19 and 21 are coupled to one another by means permitting relative vertical movement of manual control plate 19 with respect to actuation plate 21. In particular, member 19a of manual control plate 19 includes two lugs 26 which are vertically aligned and are respectively engaged in vertically aligned slots 27 which are provided in actuation plate 21.
Manual control plate 19 also includes at its upper part a lug 19d which extends upwardly and acts on pawl 28 which is journalled about a horizontal and transverse axis 29 on the upper part of the actuation plate 21. Pawl 28 is in the form of a lever with two arms extending in the direction of the rear wall of upper 12. The end of lower arm 28a of pawl 28 is in contact with the upper end of actuation lug 19d and the upper arm 28b of the pawl extends upwardly as far as the rear wall of upper 12. Pawl 28 is biased in a clockwise direction by spring 31 so that its upper arm 28b is constantly pushed in the direction of the rear wall of upper 12.
The ski boot shown in FIG. 1 is provided with means for tightening upper 12 around the lower leg of the skier. In this embodiment, the tightening means include cables 32 surrounding the upper portion of the upper and which are connected to a tightening device of any known manually maneuverable type. Cables 32 extend behind one part of the rear wall of upper 12 which is cut to provide a movable flap 33. More particularly, flap 33 is defined by a U-shaped cutout that remains adjacent to the upper portion of the rear wall of upper 12 and it is detached from the rest of the wall of upper 12 along its two lateral and vertical edges and its lower horizontal and transverse edge 33a. Lower edge 33a is adapted to form an abutment for the end of upper arm 28b of pawl 28. Flap 33 has on its part where cables 32 rest, a thickness which increases towards the bottom so that the flap 33 has substantially the shape of a trapezoid in vertical and longitudinal section, whose large base constitutes lower edge 33a which forms an abutment on flap 33. Moreover, flap 33 is biased by spring 34, which tends to push it towards the outside of the boot. In the rest position, i.e., when the upper 12 is not tightened around the skier's lower leg, flap 33 is in the position shown in FIG. 3 where its internal surface 33b is substantially even with the internal surface of the rear wall of upper 12 while its external surface 33c projects downwardly towards the exterior. Return spring 34 of flap 33 is preferably a spring with a curved blade which is affixed at its upper end, for example by rivet 35, to the upper part of the rear wall of upper 12 and whose lower curved part which is concave facing the flap 33, rests against the internal surface 33b of flap 33.
When the skier, after having put on his boot, tightens the upper 12 around the lower leg by cables 32, the force exerted by cables 32 on external surface 33c of flap 33 causes the retraction of flap 33 within the upper as shown in FIG. 2. In this position, upper arm 28b of pawl 28, which rests against the lower part of internal surface 33b of flap 33, is pushed slightly towards the interior and the device 16 for control of the gas supply is normally in the closed position. Manual control plate 19 is in effect pushed into its extreme upper position by spring 25, with lower wing 19b being in contact with projection 22. Moreover, actuation plate 21 is also pushed by spring 25 into the extreme upper position and its lower lug 15 holds the pin 14 in its extreme upper position which corresponds to the closing of the valve.
If the skier wishes to turn on the heating device, he pushes downwardly on control knob 24, which has the effect of lowering the two plates 19 and 21 against the force of return spring 25. The lowering of lug 15 frees the pin 14 which is then pushed into the lower open position by spring 14a so that valve 13 opens and the gas can flow to burner 3. Since plate 19 follows the lowering movement of control knob 24 beyond the intermediate open position, it pushes, by its lower wing 19b, pusher 17 of the piezoelectric ignitor 18, which then causes the production of a spark in electrode 8 to ignite the gas. After release, control knob 24 automatically returns, under the action of return spring 25 to the intermediate open position which is shown in FIG. 1. It is retained in this position because the pawl 28 is then latched as is shown in FIG. 1. In effect, in the course of the lowering movement of actuation plate 21, upper arm 28a of pawl 28 slides on internal surface 33b of the flap 33 and when it arrives just underneath lower edge 33a of the flap, pawl 28 pivots in a clockwise direction about its axis 29 under the bias of spring 31. The upper end of upper arm 28a of pawl 28 engages under lower edge 33a of flap 33 and is immobilized by the lower edge. Pawl 28 being thus latched, its lower arm 28a constitutes a fixed abutment for upper lug 19d of plate 19, which prevents the automatic return of the two plates 19 and 21 into the closed position. However, the skier may turn off the heating at any time, by pulling the control knob 24 upwardly. In this case, lug 19d presses on the pawl 28 and causes it to pivot in a counterclockwise edge 33a of flap 33. Then, the two plates 19, 21 can automatically slide upwardly under the action of return spring 25 to pass into the closed gas supply position.
According to the preceding description, it can be seen that for the pawl 28 to be locked in position and to constitute an abutment to hold the plates 19 and 21 in the open gas position, it is necessary that the flap 33 be pushed into upper 12; that is, cables 32 must be tightened around upper 12. Consequently, if the skier forgets to turn off the heat before he opens the upper of the boot, the turning off of the gas supply of burner 3 automatically occurs. In effect, flap 33 is then pushed towards the exterior of the boot as soon as cables 32 are loosened under the action of return spring 34 to move to the position shown in FIG. 3 in which its internal surface 33b is substantially even with the internal surface of the rear wall of upper 12. Consequently, if device 16 for control of the gas supply is in the open position in which it was retained by pawl 28 in abutment against lower edge 33a of flap 33, the pawl 28 then escapes the abutment, which permits the two plates 19, 21 to automatically slide upwardly under the action of the return spring 25 to pass into the closed gas supply position.
In the alternative embodiment shown in FIGS. 4 and 5, the boot is of the front entry type and the tightening of upper 12 of the boot is achieved by means of cable 36 which surrounds the front of the upper and which is hooked to pivoting lever 37 which is provided with several hooking notches 38 to obtain various degrees of tightening. Tightening lever 37 is journalled about axis 39 on exterior clevis 41 which can slide horizontally with respect to the wall of upper 12. Clevis 41 includes rivet 42 which extends through horizontal slot 43 which is provided in the wall of upper 12. Rivet 42 is affixed within upper 12 to a front end of support strap 44 which extends along the internal surface of upper 12. Support strap 44 includes rear part 44a which extends above pawl 28 of control device 16 of the gas supply. At this location, the rear wall of upper 12 includes a portion 45 which projects towards the exterior of the boot and includes an internal groove 46 whose transverse cross-section corresponds to that of support strap 44, so that rear part 44a of strap 44 can be retracted into groove 46. Support strap 44 is normally biased towards the rear by compression spring 47. Spring 47 is positioned in horizontal slot 48 which is provided in the front part of support strap 44 and it rests at its front end on a shoulder 49, which projects in slot 48 in the wall of upper 12. Spring 47 rests at its rear end on the rear edge of slot 48.
When upper 12 of the boot is tightened on the skier's lower leg, tightening lever 37 is pressed against upper 12, as shown in FIG. 5, and in this position clevis 41 is moved towards the front. The frontward movement of clevis 31 is transmitted by rivet 42 to the extreme front part of support strap 44 which is pulled towards the front against the action of spring 47 which is compressed further on shoulder 49. Rear part 44a of support strap 44 is then out of the groove 46 and in this out position, it is located just above the end of upper arm 28b of pawl 28 to form an abutment permitting the locking of the gas supply control device 16 in the open position, such as previously described in reference to FIGS. 1-3.
If the heating device is in operation and the skier loosens upper 12 while forgetting to turn off the gas supply, the loosening of upper 12 causes movement of lever 37 into the position indicated in dotted lines in FIG. 5, and the consequent loosening of support strap 44. Strap 44 is thus pushed towards the rear under the action of spring 47. This movement is made possible by the sliding of rivet 42 in slot 43. Because of this rearward movement, rear part 44a of support strap 44 is retracted into groove 46 which is in the wall of upper 12, and therefore removes the abutment that it formed. The pawl 28 thus is freed and plate 21 can then slide upwardly to close supply valve 13 by its lug 15.
Although the invention has been described with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to the particulars disclosed and extends to all equivalents within the scope of the claims. For example, although the preceding description is directed to an alpine ski boot comprising, as an energy consuming device, a heating device, it is contemplated that the invention could apply likewise to any energy consuming device adapted, for example, to exert an automatic mechanical action.
Further, in the embodiment in which the heating assembly is of the electric type, in which case, a replaceable and/or rechargeable battery supply could be housed adjacent an upper of the boot which is connected to a resistance element or elements located proximate the internal sole of the boot. An electric switch could be provided in a location to be activated by the means for detecting the loosening of a portion of the boot to disconnect the battery supply to the resistance element or elements. For example, consistent with any of the disclosed embodiments, the control knob 24 located for convenient access for the wearer of the boot on the rear of the boot, e.g., could be used to act on the aforementioned switch, in which case, maintaining the actuation plate in the lower position would be effective to maintain the switch in the activated position for heating the boot. The activation and deactivation of the switch would be analogous to the opening and closing of the valve 13 by means of the lug 15 of actuation plate 21 acting on the pin 14, as shown in FIG. 1. | An item of wearing apparel, such as a shoe or boot, particularly for downhill or cross-country skiing, having a foot support zone, a sole, and an upper which may be tightened, in which the shoe or boot has a heating assembly located proximate the sole. The heating assembly includes a heating device such as a burner for producing heat, a plate for diffusion of the heat, the plate being located proximate the foot support zone, a source of fuel, a supply circuit for feeding fuel to the heating device, and a valve for regulating the feeding of fuel to the heating device. The energy supply is automatically turned off when the upper of the shoe or boot is loosened. | 0 |
BACKGROUND OF THE INVENTION
Various knock-down and reusable containers are known in the prior art, and the objective of the present invention is to improve on the prior art by the provision of a more economical reusable shipping container which is extremely rugged and durable and requires minimum labor and the mere use of a screwdriver or equivalent prying implement to assemble and disassemble. The fastener components of the reusable container are economical to manufacture from sheet metal and are very rugged and durable and are applicable to various types of container panels.
Other features and advantages of the invention will become apparent during the course of the following description.
BRIEF DESCRIPTION OF DRAWING FIGURES
FIG. 1 is a perspective view of a typical reusable shipping container embodying the invention, partly schematic.
FIG. 2 is a fragmentary perspective view of a container and one and two way fastener assemblies employed thereon.
FIG. 3 is a fragmentary horizontal cross sectional view taken on line 3--3 of FIG. 1.
FIG. 4 is a fragmentary vertical section taken on line 4--4 of FIG. 1.
FIG. 5 is a perspective view of a one way fastener assembly reinforcing plate.
FIG. 6 is a perspective view of a two way fastener assembly reinforcing plate.
FIG. 7 is a vertical section taken on line 7--7 of FIG. 6.
FIG. 8 is a perspective view of a fastener assembly spring clip employed in both the one and two way fastener assemblies of the invention.
DETAILED DESCRIPTION
Referring to the drawings in detail, wherein like numerals designate like parts, and referring first to FIG. 1, the numeral 20 designates a knock-down reusable shipping container embodying the invention and being formed of plywood or the like and being of rectangular form when erected. The container 20 includes a top wall 21, identical side walls 22 and end walls 23 and a base or bottom wall 24 which may have attached skids 25, if desired, adjacent the side walls 22. The details of construction of the plywood panels or walls forming the container 20 may be varied, and the shape and size of the container may be varied, without departing from the invention.
Fastener assembly means, now to be described, are employed at a plurality of points on the corners of the container 20 to secure it in assembled relationship and to render it quickly separable when desired by the mere use of a screwdriver or equivalent instrument. The fastener assembly means comprises plural identical one way fastener assemblies 26 and plural identical two way fastener assemblies 27 as depicted in FIG. 1. The one way fastener assemblies 26 are employed at strategic points along the vertical and horizontal corners of the container 20 while the two way fastener assemblies 27 are utilized at the eight compound or cubic corners of the container.
FIG. 2 depicts one of the one way fastener assemblies 26 and one of the two way fastener assemblies 27 in detail. A single description of each type of fastener assembly 26 and 27 will serve to describe them all.
Each one way corner fastener assembly 26 comprises a pair of identical reinforcing metal plates 28 each having a single end right angular flange 29 to lap one vertical or horizontal edge 30 or 31 of the particular container wall carrying the plate 28. Each plate 28 is externally ribbed at 32 for added rigidity and has preferably four corner openings 33 for the reception of rivets 34 which serve to rigidly connect the plates 28 to their respective container panels. FIG. 3 shows the right angular relationship of a pair of the plates 28 in one of the one way fastener assemblies 26 on a vertical corner of the container 20. This is the same construction employed in the fastener assembly 26 for the horizontal corner illustrated in FIG. 2. In that figure, the right angular flange 29 of the vertically disposed plate 28 is concealed beneath the container top wall 21 and projects inwardly from the visible flange 29.
As shown in FIG. 2, each plate 28 has a generally central rectangular opening 35 formed therethrough to receive one end terminal 36 of a right angular symmetrically formed spring steel clip 37 having equal length arms. The clip terminals 36 at the ends of its arms are reversely bent as shown in FIG. 8 to snap over one straight edge 38, FIG. 5, of the rectangular opening 35 receiving it. The underlying container walls or panels are recessed at 39 to accommodate the clip terminals 36. The spring clips 37 are omitted in FIGS. 3 and 4 for clarity and details of the fastener assemblies 26 and 27 are omitted in FIG. 1 for the same reason. As shown in FIG. 2, the spring clip 37 lies flat against the right angular faces of the two reinforcing plates 28 and no parts of the assembly 26 project above the ribs 32 which serve to protect the clip from contact with exterior objects. The spring clip may be tapped into place manually as with the handle of a screwdriver and the terminals 26 may be separated from the openings 35 by insertion therethrough of the blade or tip of the screwdriver which can then lift the terminals 36 free from the adjacent edge 38 with which they are interlocked. The connection formed between the adjacent container walls by the one way assembly 26 is extremely strong and secure. At the same time it is quickly releasable and easy to re-establish at any time.
The two way fastener assembly 27 at each cubic corner of the container comprises one pair of the described reinforcing plates 28 on adjacent right angular container walls such as the walls 22 and 23 and a third coacting substantially square reinforcing plate 40 on a third wall of the container forming a cubic corner, such as the top wall 21 or the bottom wall 24. The application of the two plates 28 to the walls 22 and 23 is as previously described in FIGS. 2 and 5 for the one way assembly 26. The right angular flanges 29 lap the upper edges of the walls 22 and 23, as described.
Additionally, the two way plate 40 has a pair of right angular flanges 41 which lap the adjacent edges of the wall or panel 21 and lie adjacent to the two plates 28, see FIG. 4. The two way plate 40 is externally ribbed at 42 and 43 near its margins for rigidity and to protect the two spring clips 37 that are employed at right angles to each other, FIG. 2, in the two way assembly 27. The ribs 42 and 43 are interrupted to accommodate the clips 37 whose legs or right angular portions lie flush against the plates 28 and 40. The plate 40 has a single generally central square opening 44 formed therethrough, and two adjacent right angular edges of this opening receive a pair of the spring clip terminals 36 in interlocking releasable relationship as described in connection with the one way assembly 26. The other two corresponding terminals 36 of clips 37 interlock with edges of the openings 35 in the pair of plates 28 used in the two-way assembly 27. It should be apparent from an inspection of FIG. 2 that the two way fastener assembly 27 rigidly and releasably interconnects three adjacent walls or panels of the rectangular container 20 at each compound or cubic corner thereof. It should be mentioned that the plate 40 also has apertures 33 to receive rivets 34 used to attach the plate 40 to its associated container wall.
By placing the two way fastener assemblies 27 at the eight cubic corners of the container 20 and arranging the one way fastener assemblies 26 at spaced intervals along all of the horizontal and vertical corners of the shipping container, the separable walls of the latter are secured in assembly with great strength to resist bursting. At the same time, with a very minimum effort, all container walls can be knocked down flat and the only tool required for this is a screwdriver to remove the several clips 37.
The advantages of the invention should be readily apparent to those skilled in the art without the necessity for further description herein.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims. | A knock-down reusable shipping container includes completely separable top, base, end and side walls and fastener means whereby adjoining corners of the separable walls may be securely fastened in assembled relationship and quickly separated. Spring clip fasteners cooperate with reinforcing plates on the respective container walls to produce one way and two way corner connections. Economy of manufacture and minimized labor in the use of the invention are featured. | 1 |
FIELD OF THE INVENTION
The present invention relates to ice makers. More particularly, but not exclusively, the present invention relates to cooling an ice maker on a door of a refrigerator.
BACKGROUND OF THE INVENTION
Refrigerators have long provided for making ice. Some refrigerators include ice makers on a door of the fresh food compartment. Yet, problems remain with cooling the ice makers and or ice storage bins. What is needed is a refrigerator which provides for on the door ice maker cooling.
SUMMARY
Therefore, it is a primary object, feature, or advantage of the present invention to improve over the state of the art.
It is a further object, feature, or advantage of the present invention to provide a refrigerator which provides for on the door cooling.
Yet another object, feature, or advantage of the present invention is to provide a refrigerator which may make clear ice.
One or more of these and/or other objects, features, or advantages of the present invention will become apparent from the specification and claims that follow. No single embodiment need meet or provide each and every object, feature, or advantage. Different embodiments may have different objects, features, or advantages. The present invention is not to be limited by or to these objects, features, or advantages.
According to one aspect, a refrigerator is provided. The refrigerator includes a refrigerator cabinet, a refrigerator compartment disposed within the refrigerator cabinet, a refrigerator compartment door for providing access to the refrigerator compartment, an ice maker on the refrigerator compartment door, a thermoelectric cooler associated with the ice maker and operatively connected to the refrigerator compartment door, the thermoelectric cooler having a first side and an opposite second side, and a cooling loop operatively connected to the refrigerator compartment door and configured for cooling the thermoelectric cooler. The refrigerator may further include a heat sink thermally coupled with one of the first side and the opposite second side. There may be cooling media within the cooling loop such as glycol and/or water. The cooling loop may further provide for heating water to provide heated water. The refrigerator may further include a dispenser on the refrigerator compartment door and adapted to dispense the heated water.
According to another aspect, a method of making ice on a door of a refrigerator is provided. The method includes providing a refrigerator, the refrigerator having a refrigerator cabinet, a refrigerator compartment disposed within the refrigerator cabinet, a refrigerator compartment door for providing access to the refrigerator compartment, an ice maker on the refrigerator compartment door, a thermoelectric cooler associated with the ice maker and operatively connected to the refrigerator compartment door, the thermoelectric cooler having a first side and an opposite second side, and a cooling loop operatively connected to the refrigerator compartment door. The method further provides for cooling a surface associated with the ice maker using the first side of the thermoelectric cooler. The method further provides for circulating cooling media through the cooling loop to cool the second side of the thermoelectric cooler. The method may further include cooling water by circulating the cooling media through the cooling loop. The method may further include heating water or ice by circulating the cooling media through the cooling loop. The refrigerator may further include a fan associated with the refrigerator compartment door and further comprising altering temperature in the refrigerator compartment door using the fan.
According to another aspect, a refrigerator is provided. The refrigerator may include a refrigerator cabinet, a refrigerator compartment disposed within the refrigerator cabinet, a refrigerator compartment door for providing access to the refrigerator compartment, an ice maker on the refrigerator compartment door, and a fluid cooled thermoelectric cooler associated with the ice maker and operatively connected to the refrigerator compartment door.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one example of a refrigerator of the present invention.
FIG. 2 is a perspective view of the refrigerator of FIG. 1 with the French doors in an open position.
FIG. 3 is a perspective view of one example of an ice maker of the present invention.
FIG. 4 is a cross-sectional view of the ice maker of FIG. 3 taken along section line 4 - 4 .
FIG. 5 is a cross-sectional view of the ice maker of FIG. 3 taken along section line 5 - 5 .
FIG. 6 is an end view of the ice maker showing an inlet and outlet for the fluid loop.
FIG. 7 is an exploded view of the ice maker.
FIG. 8 is a diagram illustrating one example of a fluid loop.
FIG. 9 is a diagram illustrating another example of a fluid loop.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates one embodiment of a refrigerator of the present invention. In FIG. 1 a refrigerator 10 has a bottom mount freezer with French doors. It is should be understood that the present invention may be used in other configurations including side-by-side refrigerator configurations and other types of configurations, especially where an ice maker and/or ice storage is on a door providing access to a fresh food compartment. The refrigerator 10 has a refrigerator cabinet 12 . One or more compartments are disposed within the refrigerator cabinet 12 . As shown in FIG. 1 , a fresh food compartment 14 is shown with French doors 16 , 18 providing access to the fresh food compartment 14 . Mounted on the door 16 is a water and ice dispenser 20 . Below the fresh food compartment 14 is a freezer compartment 22 which may be accessed by pulling drawer 24 outwardly.
FIG. 2 illustrates the refrigerator 10 of FIG. 1 with French doors 16 , 18 in an open position. Mounted on the French door 16 is an ice making compartment 30 in which an ice maker 32 and an ice storage bucket 34 may be disposed. Note the ice making compartment as shown in FIG. 2 is within the refrigeration or fresh food compartment 14 .
FIG. 3 illustrates one example of an ice maker 32 where a liquid cooled system is used for freezing water into ice. An ice mold 40 is positioned above a thermoelectric cooler (TEC). The ice mold 40 is preferably fixed in place during harvesting of the ice. FIG. 4 illustrates an end view of the ice maker showing the thermoelectric cooler 46 with electrical inputs 42 , 44 shown. Fluid is shown in fluid line 48 which is in contact with a bottom side 50 of the thermoelectric cooler 46 . The fluid line 48 comprises a plurality of channels 51 at least partially separated by a plurality of fins 53 . Thus, in operation fluid within the fluid line 48 can remove heat from the thermoelectric cooler 46 . FIG. 5 provides another illustration where one or more thermoelectric coolers 46 are used to remove heat from an ice maker using liquid cooling. During harvest, heat may be provided to the ice mold. The heat may be provided through the thermoelectric cooler or through warm fluid through the fluid line 48 .
FIG. 6 is an end view of the ice maker 32 . The ice maker 32 has a fluid inlet 60 and a fluid outlet 62 for the fluid loop.
FIG. 7 is an exploded view of the ice maker 32 . The ice maker 32 has a flex grid 70 which sits inside a molded tray wall 72 . A tray cold plate 40 is also shown along with a gasket 74 with openings for thermoelectric devices 46 . A transfer plate 76 is also provided as is a transfer cover 78 and a seal 80 for sealing the transfer cover 78 to the transfer plate 76 . A harvest assembly 82 is shown which may be used for harvesting ice from the ice maker 32 .
FIG. 8 is a diagram illustrating one example of a fluid loop 88 through the ice maker 32 with thermo electric coolers 46 . Fluid is received through the fluid inlet 60 for cooling the thermo electric coolers 46 . As a result of the cooling process the temperature of the fluid increases so that fluid leaving the ice maker 32 at the fluid outlet 62 may be warm. A pump 90 may be placed within the fluid loop 88 to pump the fluid through the fluid loop 88 . A heat exchanger 92 is provided which provides for removing heat from the fluid in the fluid loop 88 . Heat may be removed in any number of ways. For example, a fan may be used to drive cooling air from any number of sources to cool fluid within the fluid loop 88 , although any number of types and configurations of heat exchangers may be used.
FIG. 9 is a diagram illustrating another example of a fluid loop 88 through the ice maker 32 with thermo electric coolers 46 . Fluid such as water is received through the fluid inlet 60 for cooling the thermo electric coolers 46 . As a result of the cooling process the temperature of the fluid increases so that fluid leaving the ice maker 32 at the fluid outlet 62 may be warm. A valve 94 is shown which allows for the warm fluid to be released to a water dispenser or otherwise. It is to be understood that the warm fluid is not necessarily hot but may be, for example, room temperature. Thus, room temperature water may be dispensed for drinking or other purposes without needing to provide additional heating or else the warm water may be further heated using only a limited amount of additional energy to provide an even higher temperature. Thus, energy savings can be achieved in this way as well. The valve 94 which may be electronically controlled allows a portion of the warm water to be directed to the water dispenser or otherwise and a remaining portion of the water to be circulated to the heat exchanger 92 . Because water may be removed from the fluid loop 88 at the valve 94 , another valve 96 is provided which allows for additional fluid to be added to the system. The valve 96 as shown is positioned after the heat exchanger 92 , although depending upon temperature of fluid being added, fluid could be added elsewhere in the loop 88 .
Thus, the present invention provides for using a thermoelectric cooler to be used in making ice. The ice maker may reside in the refrigerator compartment at above freezing temperature, particularly where clear ice is desired. Alternatively, the ice maker may reside in the freezer compartment.
Therefore, a refrigerator which provides for on the door cooling has been provided. The present invention contemplates numerous variations including the number and placement of thermoelectric coolers where used, the manner in which fluid cooling is used, the type of cooling fluid, the placement of the ice maker, and other options, variations, and alternatives. In general, the present invention is only intended to be limited by the scope of the following claims. | A refrigerator includes a refrigerator cabinet, a refrigerator compartment disposed within the refrigerator cabinet, a refrigerator compartment door for providing access to the refrigerator compartment, an ice maker on the refrigerator compartment door, a thermoelectric cooler associated with the ice maker and operatively connected to the refrigerator compartment door, the thermoelectric cooler having a first side and an opposite second side, and a cooling loop operatively connected to the refrigerator compartment door and configured for cooling the thermoelectric cooler. | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to a method for removing and recoating of diamond-like carbon films and its products thereof. The method is to immerse the units that are coated with diamond-like carbon films into a hydrogen chloride solution to come off the coating. The method without damaging the surfaces of the units can effectively get off diamond-like carbon films. The novel method is of great value to relative industry and reduces the production cost.
BACKGROUND OF THE INVENTION
[0002] To modify the properties of the surfaces of the units, we use functional coatings of techniques of surface treatments. The method is extensively applied to semiconductor industry, photoelectric industry, mold industry, machining industry, machine tool industry, sports and recreation industry, construction, kitchen and plumbing industry, etc.
[0003] Diamond is the hardest in the Nature, and it covers the surfaces of the units by ion plating techniques to form diamond films or diamond-like carbon films. Diamond-like carbon films have sp 3 bonding and sp 2 one of carbon. Therefore, they contain many properties that include high hardness, low friction coefficient, low chemical activity, high heat conductivity, low electric conductivity, etc. Due to the combination of superior properties, the ion plating techniques of diamond-like carbon films have many uses.
[0004] The structures of diamond-like carbon films are non-crystalline and they have carbon films of sp 3 bonding and sp 2 one. Diamond-like carbon films are divided into hydrogen-containing diamond-like carbon films (a-c:H) and hydrogen-free diamond-like carbon films (a-c). Hydrogen-containing diamond-like carbon films are usually synthesized by the dissociation of hydro-carbon gases. The methods include Plasma Enhanced Chemical Vapor Deposition (PECVD), Hot-Filament Chemical Vapor Deposition (Hot-Filament CVD), etc. Hydrogen-free diamond-like carbon films (a-c) are made by the methods that include Magnetron Sputtering, Electron Beam Evaporation, Pulsed Laser Ablation (PLA), Cathodic Arc Evaporation, etc.
[0005] At present, the diamond-like carbon films suffered from frequent localized spalling due to the inherent high residual stress, incomplete pre-treatment, and other operating defects. An effective method for removing and recoating diamond-like carbon films is urgently needed.
[0006] By using dry sandblasting or wet sandblasting methods, diamond-like carbon films on the surfaces of bad units have been removed by means of mechanical erosion. Sandblasting method can peel off diamond-like carbon films and damages the surfaces of the units simultaneously; it is not fit for the units that are high precision, low surface roughness and sharp angles. And this method tends to damage the business prestige.
[0007] This invention can effectively remove the surface treatment without damaging the units. So far similar inventions have not appeared yet.
SUMMARY OF THE INVENTION
[0008] This invention is to immerse the units that are coated with diamond-like carbon films into a chemical solution over a span. It can completely remove diamond-like carbon films on the surfaces of the units.
[0009] The chemical solution is a hydrogen chloride solution. Moreover, we can use a catalyst to control the chemical reaction rate. The catalyst is a nitric acid. By the experiments the inventors find the fact that adding a nitric acid in the chemical solution can accelerate effectively the rate of diamond-like carbon film removing.
[0010] The benefits of this invention are as follows: (1) the time of film removing is short; the relative production cost is lower and many good applications on industries. (2) The precision of the dimensions of the original units is intact. (3) The units that have diamond-like carbon films removed will retain the fine luster after polishing the surfaces again and recoating diamond-like carbon films.
[0011] Compare this invention with sandblasting, we can see the apparent advantage. The units that have diamond-like carbon films removed will have a lower roughness and fine luster of the surface, shown in FIG. 3 and FIG. 4 respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing aspects and many of the attendant advantages of this invention will be more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0013] FIG. 1 depicts the procedure diagram concerning the removing steps according to a preferred embodiment of this invention.
[0014] FIG. 2 depicts the procedure diagram concerning the successive steps of removing and recoating according to a preferred embodiment of this invention.
[0015] FIG. 3 depicts the roughness of the surfaces of the units of this invention.
[0016] FIG. 4 depicts the luster of the surfaces of the units of this invention.
[0017] FIG. 5 depicts the beginning photo and end one of the surfaces of the units for removing diamond-like carbon films.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] For achieving the foregoing purposes and virtues, the invention relates to a method for removing and recoating of diamond-like carbon films and its products thereof are to immerse a unit into a chemical solution and remove diamond-like carbon films on the surfaces of the unit. And then the same unit that has diamond-like carbon films removed can be recoated after polishing. This invention uses a hydrogen chloride solution that is common and easily obtainable.
[0019] The removing steps are as follows, shown in FIG. 1 .
[0020] a. Preparing a solution: a chemical solution is a hydrogen chloride solution whose concentration is ranged from 1% to 37%.
[0021] b. Immersing a unit: immersing a unit that is coated with diamond-like carbon films into the hydrogen chloride solution.
[0022] c. Film removing: in due time taking out the unit whose diamond-like carbon films have been completely removed according to the thickness of the films.
[0023] By using the method we can remove diamond-like carbon films without damaging the surfaces of the units.
[0024] The recoating steps are as follows, shown in FIG. 2 .
[0025] a. Preparing a solution: a chemical solution is a hydrogen chloride solution whose concentration is ranged from 1% to 37%.
[0026] b. Immersing a unit: immersing a unit that is coated with diamond-like carbon films into the hydrogen chloride solution.
[0027] c. Film removing: in due time taking out the unit whose diamond-like carbon films have been completely removed according to the thickness of the films.
[0028] d. Polishing the unit: polishing the unit whose diamond-like carbon films have been removed.
[0029] e. Recoating films: recoating diamond-like carbon films onto the unit that has been polished as required.
[0030] The units whose diamond-like carbon films have been removed will become new products after polishing again and recoating the films. The surfaces of the new units whose diamond-like carbon films have been removed will have a lower roughness and a fine luster. The method can improve the quality of the new units.
[0031] The conditions of implementation and relative information and data of an example of this invention are as follows:
[0032] (1) The material of this unit: SUS304 stainless steel.
[0033] (2) The test area of the foregoing unit: 3 cm×2 cm.
[0034] (3) The film type: diamond-like carbon films.
[0035] (4) The film thickness: 2 μm.
[0036] (5) The aqueous solution: a hydrogen chloride solution whose concentration is 15%.
[0037] (6) The capacity of the aqueous solution: 500 ml.
[0038] (7) The temperature range of aqueous solution: 0° C.-100° C.
[0039] (8) The container: strong acids resistance.
[0040] The ways of implementation:
[0041] Immersing a unit that is coated with diamond-like carbon films into a hydrogen chloride solution whose capacity is 500 ml and concentration is from 1% to 37%.
[0042] The effect of implementation:
[0043] Through the immersing for a period of one minute to four hours, the surfaces of the unit have diamond-like carbon films has been removed completely, as shown in FIG. 5 . The temperature of aqueous solution will affect the rate of film removing. At the same concentration, for example, 15%, the rate of film removing is 0.5 μm per hour at 25° C. and 0.5 μm per minute at 100° C. At room temperature (about 25° C. ) the best range of concentration is from 12% to 18%. Immersing a unit at this range of temperature and concentration until the film removing process is finished.
[0044] This invention has many benefits, for example, a hydrogen chloride solution is easy to acquire. For instance, if the concentration of aqueous solution has been adjusted to match the certain condition, the aqueous solution can be used at room temperature. Furthermore, the aqueous solution does not need to be heated or undergone other complicated procedures. This invention can avoid many problems associated with environmental safety.
[0045] Moreover, if the units have to have diamond-like carbon films removed, we do not need to worry about the fact that the original precision of the dimensions of the units will be affected. This invention is very convenient for units that have complex profiles. And it can reduce the expenses for preparing other manufacturing procedures such as grinding, milling, etc. This invention can remove directly diamond-like carbon films on the surfaces of the units. Because machining methods have not been used, the residual stress will not been produced in the units. The residual stress deforms the products and affects the precision and strength of the products and produces worse influence on the follow-up machining. The residual stress also makes light scatter from transparent optics products, and affects the optical properties of the products.
[0046] Besides, if we want to remove the coating, we can adjust the rate of film removing as required. The method is very economical and practical. Polish the units after diamond-like carbon films being removed, and then recoating new diamond-like carbon films. The surfaces of the new units will have a lower roughness and fine luster. The method can effectively improve the quality of the new units.
[0047] This invention is also added an adequate catalyst to control the reaction rate except the above-mentioned steps. The catalyst can use a nitric acid (HNO 3 ). By the inventors' experimental effect for tests, the fact is found that adding a nitric acid (HNO 3 ) to a chemical solution will effectively increase the rate of film removing. The relative information is as follows:
Hydrogen chloride aqueous Nitric acid Time The rate of film solution (HCl) aq (HNO 3 ) (minute) removing (μm/hr) 15% None 240 0.5 15% Add 1 ml of 1% 125 0.96 15% Add 1 ml of 70% 50 2.4
1. The range of concentration of nitric acid is from 1% to 70% to be effective. 2. For the above rate of film removing adding a nitric acid (HNO 3 ) whose concentration is from 1% to 70% will effectively improve the reaction rate.
[0050] As is understood by a person skilled in the art, the foregoing preferred embodiments of the present invention are illustrated of the present invention rather than limiting of the present invention. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded with the broadest interpretation so as to encompass all such modifications and similar structure. | The invention relates to a method for removing and recoating of diamond-like carbon films and its products thereof. The method is to immerse the units that are coated with diamond-like carbon films into the hydrogen chloride solution to come off the coating, which was located on the units' surface. In addition, the method can effectively improve the past fault of poor adhesion, resulting from excessive residual stress and damaged unit surface due to the conventional sandblasting film removing process. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German Patent Application 10 2010 028 660.5, filed on May 6, 2010, and International Patent Application PCT/EP2011/057091, filed on May 4, 2011, both of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to a stacked plate heat exchanger having a plurality of elongated plates which are stacked on top of each other and connected to one another, and which have a cavity through which a medium to be cooled is conducted in the longitudinal direction of the plates, and which plates delimit a further cavity for conducting a coolant therethrough, wherein approximately in the two end regions of each elongated plate, a through hole is arranged for supplying the medium to be cooled, which through hole is at least partially surrounded at its boundary by a dome.
BACKGROUND
[0003] Stacked plate heat exchangers which cool air fed to an internal combustion engine by means of oil-coolant or air cooling are well known in the cooler industry. FIG. 1 shows an elongated plate of a stacked plate heat exchanger which is cooled with oil. In the perspective view of FIG. 1 a , the elongated plate 1 has a plate rim 2 and a plurality of circular-segment-shaped, stamped through holes 3 . At least 2 of the circular-segment-shaped stamped through holes 3 are surrounded by a dome 4 ( FIG. 1 b ). As can be seen from the cross-section in FIG. 1 c , each through hole 3 has a distance 5 from the edge of the plate. This results in that the effectiveness of the heat exchanger is limited because not all regions of the elongated plate are utilized for heat transfer.
[0004] A similar arrangement is given in the case of a stacked plate heat exchanger which is cooled with air and which is illustrated in FIG. 2 . Here too, the stacked plate heat exchanger consists in particular of a plurality of elongated plates 6 of which only one is shown in FIG. 2 . This elongated plate 6 is completely surrounded by a plate rim 7 . Each plate 6 has two through holes 8 for the medium to be cooled and, furthermore, two through holes 9 for the coolant. As is shown in FIG. 2 b , the through hole 8 as well as the through hole 9 is surrounded by a dome 10 , 11 . Such a dome 10 , 11 in the plates 6 is necessary so as to separate the coolant from the medium to be cooled in the heat exchanger. The described arrangement of the through holes 8 and 9 in the plate 6 results in increased material requirements and a more complex plate geometry due to a higher degree of forming with regard to the through holes 8 and 9 . Also, a disadvantage here is that for the available volume to be installed only limited power for heat exchange is available.
SUMMARY
[0005] It is therefore an object of the present invention to provide a stacked plate heat exchanger with which, while maintaining a simple plate geometry, a maximum power-to-volume ratio during the heat transfer is achieved.
[0006] According to the invention, the object is achieved in that the through hole is arranged approximately at the edge of the elongated plate, wherein the dome and/or the through hole is integrated in the edge of the elongated plate. This has the advantage that no thermotechnically ineffective regions are present in the heat exchanger when using the elongated plate. Thus, the entire elongated plate is utilized for the heat exchange, which results in a compact design. Said compact design enables saving material cost and allows a simpler plate geometry.
[0007] Advantageously, the dome is arranged adjacent to a rim delimiting a base plate of the elongated plate. Thus, the available installation space is fully utilized because the heat exchange takes place over the entire surface of the elongated plate.
[0008] In one configuration, the dome is arranged in a different plane than the rim of the elongated plate, wherein said dome is preferably embossed into the base plate or is raised and protrudes from the base plate. This arrangement results in an improved stackability of the individual plates of the heat exchanger.
[0009] Advantageously, in another embodiment, the dome can completely fill a space between a rim delimiting a base plate of the plate and the respective through hole. Through this, the available installation space is optimally utilized without creating dead spaces for the medium to be cooled.
[0010] In a refinement, the through hole is arranged in a different plane than the elongated plate. This configuration too improves stackability of the elongated plates.
[0011] In one variant, the dome has a plurality of elongated holes feeding the coolant. This increases the compactness of the component because the dome is used as a spacer to the elongated plate arranged thereabove and also receives on the same surface the elongated holes for conducting the coolant therethrough.
[0012] Furthermore, the through hole is approximately circular-segment-shaped, wherein the elongated holes surrounding the through hole are curved in a circular-arc-shaped manner. Through this configuration, consumption of material is reduced and an optimal plate geometry is achieved.
[0013] In one refinement, the dome of a first elongated plate together with a further elongated plate arranged therebelow or thereabove forms an annular channel which is interrupted by the elongated holes. By using the dome for the annular channel in which the coolant is transported, material requirements for the heat exchanger can be further reduced and the design can be configured in a particularly compact manner
[0014] In another advantageous embodiment, the base plate can lie in a first plane which lies between a second plane, in which the respective through hole lies, and a third plane in which the elongated holes lie. Thus, within a small area, a multi-step structure is obtained which is characterized by a high stiffness.
[0015] According to another advantageous embodiment, the dome can at least partially be integrated in a rim delimiting a base plate of the elongated plate. In this case, rim and dome quasi transition into each other and enable dual use of the respective wall section. This results in a particularly compact structure.
[0016] Particularly advantageous is a refinement in which an outer dome wall running along the edge of the plate is integrated in the rim. In other words, said outer wall of the dome forms an integral part of the rim when dome and rim are arranged on the same side of the plate, or forms an integral extension of the rim when dome and rim are arranged on opposite sides of the plate. This too results in a particularly compact design.
[0017] Advantageously, the dome is formed with a predetermined inclination angle which is in particular directed inward toward the through hole. Through this, stackability of the elongated plates is further improved because gaps which can occur in the solder joint of the plates lying on top of one another are prevented.
[0018] Furthermore, between a closure region of the dome and the rim, a segment is formed, the further inclination angle of which is larger than the predetermined inclination angle of the dome, wherein the deviation of the predetermined inclination angle of the dome from the further angle of the segment is approximately 5°. Through this geometry, the rim of the elongated plate has clearance in the region of the dome resulting in a circumferential soldering joint lying in one plane. Leakages within the heat exchanger are reliably prevented.
[0019] In particular, the segment is arranged at the height of the dome and ends flush with the elongated plate. This embodiment requires only a minor change in the degree of forming during the fabrication of the dome.
[0020] In another embodiment, a cam is formed on the dome at least in one closure region of the dome, which cam has approximately the predetermined inclination angle of the rim and preferably extends parallel to the dome. This cam seals a channel which is formed by using the different angles of the dome and the segment when stacking two elongated plates on top of one another.
[0021] Advantageously, the closure region of circular-arc-shaped dome is configured in a semicircular manner. Through the configuration of the closure region of the dome, said cam forms a kind of a closure in order to limit any liquid that penetrates through this channel into the heat exchanger. The cam can be kept very small in terms of its dimensions. In a refinement, said cam has an extension of less than 6 mm.
[0022] In one refinement, the dome and at least one cam are integrally formed from the elongated plate. These parts can easily be manufactured as stampings. Manufacturing is carried out in a single work step which requires only simple tools. This reduces manufacturing costs significantly.
[0023] Advantageously, the elongated plate is formed from solderable aluminum. By using this easily-formable material, manufacturing the stacked plate heat exchanger is simplified and material costs are reduced.
[0024] The invention allows different embodiments. Some of them shall be explained in more detail by means of the figures illustrated in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In the figures:
[0026] FIG. 1 shows an elongated plate of a stacked plate heat exchanger with oil cooling according to the prior art
[0027] FIG. 2 shows an elongated plate of a stacked plate heat exchanger with air cooling according to the prior art
[0028] FIG. 3 shows the configuration of the dome of a heat exchanger which is cooled with air
[0029] FIG. 4 shows an elongated plate of the heat exchanger according to FIG. 3 with an inwardly curved dome
[0030] FIG. 5 shows an elongated plate of a heat exchanger with oil cooling with an outwardly curved dome
[0031] FIG. 6 shows an elongated plate of a heat exchanger with oil cooling with inwardly inclined dome
[0032] FIG. 7 shows a cut-out from the end region of an elongated plate with a step on the rim of the plate
[0033] FIG. 8 shows a detailed illustration of the step according to FIG. 7
[0034] FIG. 9 shows an illustration of a segment arranged on the dome
[0035] FIG. 10 shows a cross-section through a heat exchanger with the step according to FIG. 9
[0036] FIG. 11 shows an illustration of a cam in the radius region of the dome
[0037] FIG. 12 shows a cross-section through the heat exchanger with the cam according to FIG. 11 .
DETAILED DESCRIPTION
[0038] Identical features are designated with identical reference numbers.
[0039] FIG. 3 shows an elongated plate 6 of a stacked plate heat exchanger for air cooling, wherein the said plate is oval. This elongated plate 6 consists of a base plate 12 around the edge of which a boundary 7 is attached. This boundary 7 is at an angle of approximately 90° to the base plate 12 and serves for a better stacking of the different plates 6 on top of one another. On the opposite ends of the plate 6 , in each case one through hole 8 is arranged which is machined out of the plate 6 . Each through hole 8 is positioned so close to the edge of the boundary 7 that between the through hole 8 and the boundary 7 only a dome 10 is arranged, which is also designated as passage. Thus, this passage 10 completely fills the space between the boundary 7 and the through hole 8 . The through hole 8 has a semicircular shape, wherein the radius of the semicircle is completely surrounded by the passage 10 .
[0040] FIG. 3 b shows a closer view of a through hole 8 a with the passage 10 surrounding said hole. The passage 10 has a plurality of elongated holes 13 which fill the entire surface of the passage 10 and which face away from the base plate 12 of the elongated plate 6 . Said passage is raised above the plane predetermined by the base plate 12 so that the elongated holes 13 are positioned in a plane above the plane spanned by the base plate 12 .
[0041] The medium to be cooled is fed through the through hole 8 a to the heat exchanger and is discharged again from the heat exchanger through the additional through hole 8 b which is illustrated in FIG. 3 a . The elongated holes 13 serve for feeding the cooling medium, in this case air, to the heat exchanger. Between the two through holes 8 a, 8 b, turbulence inserts are arranged which are not illustrated here and which are used for generating turbulences with the objective that the medium to be cooled flows over the entire surface of the base plate 12 and thus achieves a large heat contact with the cooling medium.
[0042] As can be seen from FIG. 3 b , said passage 10 is stamped out from the material of the base plate 12 of the elongated plate 6 in the outward direction using a stamping process.
[0043] In the embodiment shown in the FIGS. 3 a and 3 b , the dome 10 or the passage 10 is at least partially integrated in the rim 7 of the plate 6 , namely in the region of an outer wall of the dome 10 or the passage 10 , which outer wall is not described in detail here and which extends along the edge of the plate 6 . In the example of FIG. 3 , the rim 7 and the outer wall of the passage 10 project from different sides of the plate 6 so that the passage 10 , in the region of its outer wall, forms an integral extension of the rim 7 .
[0044] FIG. 4 shows a similar arrangement of the elongated plate 6 which is used for a stacked plate heat exchanger with air cooling. The elongated plate 6 likewise consists of a base plate 12 which has an oval shape and is surrounded by a boundary 7 . The two through holes 8 a, 8 b extending at the ends of the elongated plate 6 are in each case surrounded along their semicircle radius by a passage 10 a, 10 b. Here too, the passages 10 a, 10 b have elongated holes 13 for transporting the coolant. In contrast to FIG. 3 , the passage 10 a, 10 b is formed inward, which means that the base plate 12 of the elongated plate 6 is formed in a higher plane than the elongated holes 13 of the passage 10 a, 10 b. As can be seen from FIG. 4 b , thus, there is a step 15 between the base plate 12 and the outer edge of the surface of the passage 8 a, 8 b.
[0045] FIGS. 4 a and 4 b show in particular an embodiment in which the base plate 12 of the plate 6 lies in a first plane which is not described in detail here and which, viewed in the stacking direction, lies between a second plane, which is not described in detail here and in which the respective through hole 8 a or 8 b lies, and a third plane which is not described in detail here and in which the elongated holes 13 lie. This results in an extremely rigid, multi-stepped structure for the plate 6 in the region of the elongated holes 13 .
[0046] FIGS. 5 and 6 illustrate a comparable arrangement for a stacked plate heat exchanger which is cooled with oil. The elongated plate 1 is formed in a rectangle-like manner and has rounded corners, wherein this base plate 14 too is completely surrounded by a boundary 2 . In the corners of the base plate 14 , four through holes 3 a - 3 d are arranged, two opposing through holes 3 b, 3 c of which are arranged along a longitudinal side of the base plate 14 and have in each case one passage 4 a, 4 b (FIG. 5 a and 5 c ). As shown in FIG. 5 b , there is a step 15 in that the base plate 14 leaves the normal plane and transitions with the passage 4 a into a plane thereabove. In this embodiment, each through hole 3 a to 3 d extends completely into the edge region of the base plate 14 and is directly enclosed there by the boundary 2 . The passage 4 a, 4 b completely encloses the through holes 3 b, 3 c, wherein a part of the passage 4 a, 4 b is integrated in the boundary 2 .
[0047] FIG. 6 illustrates a plate 1 for the stacked plate heat exchanger with oil cooling, wherein the passage 4 a, 4 b is directed inward. The two passages 4 a, 4 b are arranged opposing each other toward the inside of the base plate 14 . As illustrated in the FIGS. 6 b and 6 c , the plane spanned by the base plate 14 is higher than the plane in which the through hole 3 b, 3 c lies.
[0048] FIG. 7 illustrates cut-outs from the elongated plate 6 of the stacked plate heat exchanger which is cooled with air. FIG. 7 a shows an inwardly embossed passage 10 while FIG. 7 b illustrates an outwardly extending passage 10 . It is apparent from the marked regions that a step 15 between the boundary 7 of the base plate 12 and the passage 10 occurs in each case at the point where the base plate 12 transitions into the passage 8 . As illustrated in FIG. 8 , such a step 15 involves the problem that a gap 16 occurs when soldering a plurality of plates 6 lying on top of one another. This gap 16 is clearly visible in particular in FIG. 8 b . In order to prevent such a gap 16 in the soldering joint and to configure the stacked plate heat exchanger in a particularly tightly sealed manner, a segment 17 with an angle which is approximately 5° steeper than the angle at which the passage 10 is inclined toward the elongated holes 13 is inserted at the height of the transition of the passage 10 into the base plate 12 . Through this clearance of the surface in the inward direction to the base plate 12 , optimal soldering of two plates 6 lying on top of one another is achieved because in this manner, a circumferential contact between the soldering surface and the plate 6 is obtained. The direct contact is uniform everywhere ( FIG. 9 ).
[0049] The circumferential direct contact of the plate 6 with the soldering surface is illustrated again in FIG. 10 for a stacked plate heat exchanger with a plurality of plates 6 lying on top of one another. Here, a circumferential channel 18 is created between two plates 6 lying on top of one another. In order to seal this circumferential channel 18 and to prevent coolant from leaking from said channel 18 , a cam 19 is placed in the radius region of the semicircular passage 10 , in particular near the two ends of a passage 10 . Said cam 19 is located at the outer edge of the last elongated hole 13 of the passage 10 , wherein the cam 19 is at an angle perpendicular to the base plate 12 , which angle is larger than the angle of the outside of passage 10 to the base plate 12 . Said cam 19 is approximately 5 mm wide and is arranged approximately at the radial end of the wall of the passage 10 near the segment 17 (see FIGS. 11 a and b ).
[0050] FIGS. 11 c and 11 d show the arrangement of the cam 19 in a section through a plurality of plates 6 of the stacked plate heat exchanger stacked on top of one another. The cam 19 is positioned in the region of the boundary 7 of the elongated plate 6 and is at an obtuse angle thereto. When placing the plates 6 on top of one another, said plates are positioned such that the passages 10 of in each case two adjoining plates 6 lie on top of one another.
[0051] FIG. 12 also illustrates plates 6 of the stacked plate heat exchanger stacked on top of one another in a cross-section. The second angle of 5°, which is determined by the segment 17 , leads to a circumferential channel 18 ( FIG. 12 b ) which is completely sealed by the cam 19 ( FIG. 12 a ).
[0052] The individual elongated plates 1 , 6 of the stacked plate heat exchanger are made from a solderable aluminum and form with the described embodiments a compact heat exchanger which has a high power-to-volume ratio resulting in a maximum degree of heat transfer between the medium to be cooled and the coolant. The compact configuration of the heat exchanger results in a reduction of material consumption during the production. Moreover, a lower forming degree is required which leads to a cost-effective solution. A reliable soldering process due to a circumferential soldering surface is possible without steps so that a tightly sealed heat exchanger is generated. | A stacked plate heat exchanger may include a plurality of elongated plates on top of and connected to one another. The elongated plates may define a first cavity in the longitudinal direction of the plates and be configured to cool a medium. The elongated plates may define a second cavity for conducting a coolant therethrough, wherein in two end regions of each elongated plate, a through hole may be arranged for supplying the medium to be cooled. The through hole may be at least partially surrounded at its boundary by a dome and arranged approximately at the edge of the elongated plates. At least one of the dome and the through hole may be integrated in the edge of the elongated plate. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a shellfish and algae inhibiting composition which is coated on a ship bottom, a fishing net, apparatus, in sea such as a buoy for wave generator, a construction in water such as a dam apparatus, a waterway for cooling water used in a condenser of a heat power plant or in a heat-exchanger for petrochemical plants.
It has been known that various shellfish and algae such as Balanus, Ostrea, Mytilus, Hydrozoa, Styela, Bugula, Ulva, Enteromorpha, Ectocarpus, etc.. have been bred on the surfaces in water such as the ship bottom, the apparatus in water, the construction in water, the waterway for cooling water and the like.
These shellfish and algae cause the increase of flow resistance and the decrease of heat conductivity to disadvantageously decrease the functions of the apparatus.
For example, taking the ship, the decrease of the speed and the excess consumption of the fuel are caused. Moreover, in order to clean the ship bottom, the loss for the suspension of the ship service is caused and the cost for the cleaning is needed. These are remarkable economical loss.
In the constractions in water, the handling trouble is caused.
In the waterway for cooling water used in the condenser or the heat exchanger, the rate of water supply is decreased to decrease the cooling coefficient, and the function of the condenser or the heat exchanger is damaged by shellfish or algae mass which are peeled off from the wall of the waterway. These are also remarkable economical loss.
In order to prevent such trouble caused by the breeding and the adhesion of shellfish and algae in sea water or fresh water, it has been proposed to use paints containing a heavy metal compound such as copper oxides, mercury oxides; an organo-tin oxide; an organic chlorine-containing compound and an organic sulfur-containing compound, or an arsenic compound such as phenarsazine chloride etc..
In the waterway for the cooling water, chlorine or formaline is directly added in the water to prevent the breeding and the adhesion of shellfish and algae.
However, the inhibiting compositions containing the heavy metal compound such as copper oxides and mercury oxides have low stability in a storage because the heavy metal compound is reactive to the resin component in the composition.
In the polluted sea such as harbor to which industrial discharged water is flowed, hydrogen sulfide is generated by microorganism in the polluted sea and the heavy metal compound is discolored and deteriorated to lose the effect.
The copper compounds and the mercury compounds are effective against shellfish such as Balanus, Ostrea, Mytilus, Hydrozoa, Styela, Bugula, etc., however, they are not effective against algae.
When the inhibiting composition is coated on a substrate made of light metal such as aluminum and aluminum-magnesium, the heavy metal such as copper and mercury is deposited on the substrate to electrochemically accelerate the corrosion of the substrate. This is the other disadvantage.
The inhibiting compositions containing the organo-tin compound such as tributyl tin oxide have inferior effect to those of the inhibiting compositions containing the copper compound or the mercury compound, and also they are expensive. When a large amount of the organo-tin compound is mixed, the characteristics of the coated film is deteriorated and bad smell is caused in the handling.
The inhibiting compositions containing the organic chlorine-containing compound or the organic sulfur-containing compound have inferior effects comparing with the other inhibiting compositions. For example, even though they are effective for Bugula, they are not effective for Balanus. They are only effective for certain shellfish or algae whereby it is difficult to use them in practical applications.
The inhibiting composition containing phenarsazine chloride has been used. However phenarsazine chloride is toxic to human body, and stimulates mucous membrane whereby the preparation of the composition and the coating operation are not easy. When chlorine or formaline is added to water in the waterway for the cooling water, the cooling apparatus is corroded and the effect for inhibiting the adhesion of shellfish and algae is not remarkable.
These conventional active ingredients are toxic to human body and fish, whereby the application is limited.
In the specification, the composition for inhibiting an adhesion of shellfish and algae is referred as the shellfish-algae inhibiting composition.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the disadvantages of the conventional composition for inhibiting an adhesion of shellfish and algae, and to provide a shellfish algae inhibiting composition which has low toxicity to fish and no toxicity to animals and which imparts excellent effect for inhibiting the adhesion of shellfish and algae for a long term even in a polluted sea.
Another object of the invention is to provide a shellfish-algae inhibiting composition which does not electrochemically corrode light metal substrate such as aluminum and magnesium and which does not corrode a cooling apparatus in a waterway, and which inhibit an adhesion and a breeding of shellfish and algae.
These objects of the invention have been attained by providing a composition for inhibiting an adhesion of shellfish and algae which comprises a resin, a medium and a N-arylmaleimide having the formula ##STR2## Wherein X represents hydrogen or halogen atom; Y 1 represents hydrogen, or halogen atom or alkyl, lower alkoxy, nitro, hydroxyl, alkoxycarbonyl, carboxyl, phenyl, phenylamino, alkenyl, thiocyano, sulfone, acetylamino or sulfamoyl group; Y 2 represents hydrogen, or halogen atom or alkyl, lower alkoxy, nitro or hydroxyl group and Y 3 represents hydrogen or halogen atom or dialkylamino group.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The N-arylmaleimide can be produced by reacting a maleic anhydride having the formula ##STR3## wherein X represents hydrogen or halogen atom; with an arylamine having the formula ##STR4## wherein Y 1 , Y 2 and Y 3 are defined above, and then dehydrating the resulting N-arylmaleamide for a cyclization in the presence of an acid catalyst, without separating the N-arylmaleamide from the reaction mixture.
Suitable N-arylmaleimides having the formula [I] which are used as effective shellfish and algae inhibiting agent in the invention are shown in Table 1, wherein the substituents X, Y 1 , Y 2 and Y 3 are shown. The compound numbers are referred in the following examples. ##STR5##
__________________________________________________________________________Com- Meltingpound N-aryl maleimide Substituent pointNo. [I] X Y.sub.1 Y.sub.2 Y.sub.3 (° C)__________________________________________________________________________1 N-phenylmaleimide H H H H 88 - 902 N-(2-chlorophenyl) maleimide H 2 - Cl H H 72 - 74.53 N-(3-chlorophenyl) maleimide H 3 - Cl H H 90 - 924 N-(4-chlorophenyl) maleimide H 4 - Cl H H 109 - 1105 N-(3-bromophenyl) maleimide H 3 - Br H H 127 - 1306 N-(4-iodophenyl) maleimide H 4 - I H H 157 - 1617 N-(4-fluorophenyl) maleimide H 4 - F H H 151 - 1538 N-(o-tolyl) maleimide H 2 - CH.sub.3 H H 74 - 769 N-(p-tolyl) maleimide H 4 - CH.sub.3 H H 164 - 16510 N-(4-n-butylphenyl) maleimide H 4 - C.sub.4 H.sub.9 H H 168 - 17011 N-(4-dodecylphenyl) maleimide H 4 - C.sub.12 H.sub.25 H H 67 - 6812 N-(3-methoxyphenyl) maleimide H 3 - CH.sub.3 O H H 62 - 6413 N-(4-ethoxyphenyl) maleimide H 4 - C.sub.2 H.sub.5 O H H 135 - 13714 N-(3-isopropoxyphenyl) maleimide H H H b.p. 179- 180/3 mmHg15 N-(2-nitrophenyl) maleimide H 2 - NO.sub.2 H H 120 - 12216 N-(3-nitrophenyl) maleimide H 3 - NO.sub.2 H H 126 - 12817 N-(4-nitrophenyl) maleimide H 4 - NO.sub.2 H H 164.5 - 16618 N-(4-hydroxyphenyl) maleimide H 4 - OH H H 187 - 18919 N-(2-carboxyphenyl) maleimide H 2 - COOH H H 147 - 15520 N-(o-biphenylyl) maleimide H ##STR6## H H 139 - 14021 N-(p-biphenylyl) maleimide H ##STR7## H H 139 - 14122 N-(anilinophenyl) maleimide H ##STR8## H H 130 - 13123 N-(3-vinylphenyl) maleimide H 3 CH CH.sub.2 H H 100 - 10224 N-(4-vinylphenyl) maleimide H 4 CH CH.sub.2 H H 118 - 12025 N-(4-thiocyanophenyl) maleimide H 4 - SCN H H 79 - 8026 N-(4-sulfophenyl) maleimide H 4 - SO.sub.3 H H H 11227 N-(4-acetylaminophenyl) maleimide H 4-NHCOCH.sub.3 H H 217 - 21828 N-(2,3-dichlorophenyl) maleimide H 2 - Cl 3 - Cl H 97 - 9829 N-(2,5-dichlorophenyl) maleimide H 2 - Cl 5 - Cl H 122 - 12330 N-(3,4-dichlorophe- nyl) maleimide H 3 - Cl 4 - Cl H 171 - 17231 N-(3,5-dichlorophenyl) maleimide H 3 - Cl 5 - Cl H 136 - 13732 N-(2-chloro-4-nitro- phenyl) maleimide H 4 - NO.sub.2 2 - Cl H 141 - 14233 N-(4-chloro-2-nitro- phenyl) maleimide H 2 - NO.sub.2 4 - Cl H 16934 N-(4-chloro-2-hydroxy phenyl) maleimide H 2 - OH 4 - Cl H 172 - 17535 N-(2,3-xylyl) maleimide H 2 - CH.sub.3 3 - CH.sub.3 H 118 - 12036 N-(2,4-xylyl) maleimide H 2 - CH.sub.3 4 - CH.sub.3 H 106 - 10737 N-(2,5-xylyl) maleimide H 2 - CH.sub.3 5 - CH.sub.3 H 82 - 8338 N-(3,5 xylyl) maleimide H 3 - CH.sub.3 5 - CH.sub.3 H 85 - 86.539 N-(4-methyl-3- nitrophenyl maleimide H 3 - NO.sub.2 4 - CH.sub.3 H 10240 N-(2-methyl-3-nitro- phenyl) maleimide H 3 - NO.sub.2 2 - CH.sub.3 H 167 - 16841 N-(2,5-dimethoxy- phenyl) maleimide H 2 - CH.sub.3 O 5 - CH.sub.3 O H 12242 N-(4-ethoxy-2- nitrophenyl) maleimide H 2 - NO.sub.2 4 - C.sub.2 H.sub.5 O H 8343 N-(3-carboxy-4-hydro- xyphenyl) maleimide H 3 - COOH 4 - OH H 214 - 22244 N-(4-carboxy-3-hyd- roxyphenyl) maleimide H 4 - COOH 3 - OH H 239 - 24345 N-(2,4,6-trichloro- phenyl) maleimide H 2 - Cl 4 - Cl 6 - Cl 130 - 13246 N-(4-dimethylamino- 3,5-dinitrophenyl) maleimide H 3 - NO.sub.2 4 - NO.sub.2 4-N(CH.sub.3).sub.247 N-phenyl-2,3-dich- loromaleimide Cl H H H 208 - 21048 N-phenyl-2,3-dibromo- maleimide Br H H H 16549 N-phenyl-2,3-difluoro- maleide F H H H 88 - 9050 N-(2-chlorophenyl)2,3-dichloro maleimide Cl 2 - Cl H H 13251 N-(3-chlorophenyl)- 2,3-dichloro maleimide Cl 3 - Cl H H 18352 N-(4-chlorophenyl)- 2,3-dichloromaleimide Cl 4 - Cl H H 210 - 21653 N-(4-iodophenyl)-2,3 dichloromaleimide Cl 4 - I H H 251 - 25454 N-(4-chlorophenyl)-2,3- difluoromaleimide F 4 - Cl H H 74 - 7655 N-(p-tolyl)-2,3-di- bromomaleimide Br 4 - CH.sub.3 " " 17456 N-(4-methoxyphenyl)- 2,3-dichloromaleimide Cl 4 - CH.sub.3 O " " 209 - 21057 N-(4-nitrophenyl)-2,3- dibromomaleimide Br 4 - NO.sub.2 " " 207 - 20858 N-(4-ethoxycarbonyl- phenyl)-2,3-dichloro- maleimide Cl 4 - COOC.sub.2 H.sub.5 " " 30559 N-(2-carboxyphenyl)-2,3- dichloromaleimide Cl 2 - COOH " " 327 - 32960 N-(3-carboxyphenyl)- 2,3-dichloromaleimide Cl 3 - COOH " " 238 - 24061 N-(4-carboxyphenyl)- 2,3-dichloromaleimide Cl 4 - COOH " " 30562 N-(4-thiocyanophenyl)- 2,3-dichloromaleimide Cl 4 - SCN " " 205 - 20863 N-(4-sulfamoylphenyl)- 2,3-dichloromaleimide Cl 4 - SO.sub.2 NH.sub.2 " " 30064 N-(3,4-dichlorophenyl)- 2,3-dichloromaleimide Cl 3 - Cl 4 - Cl " 206 - 20865 N-(2-chloro-4-meth- oxycarbonylphenyl)- Cl 4 - COOCH.sub.3 2 - Cl H 156 - 157 2,3-dichloromaleimide66 N-(2,5-xylyl)-2,3- dichloromaleimide Cl 2 - CH.sub.3 5 - CH.sub.3 H 127 - 12967 N-(2-methyl-6-metho- oxycarbonylphenyl)- 2,3-dichloromaleimide Cl 6 - COOCH.sub.3 2 - CH.sub.3 H 121 - 122__________________________________________________________________________
The N-arylmaleimides having the formula [I] which is used as an active ingredient for shellfish and algae inhibiting composition in the invention can be produced by reacting an maleic anhydride having the formula [II] with an arylamine having the formula [III] with or without a solvent at 20° to 100° C. for 0.5 to 2 hours and then, dehydrating the resulting N-arylmaleamide [IV] for a cyclization in the presence of an acid catalyst at 80° to 200° C. for 1 to 10 hours, without separating the N-arylmaleamide [IV] from the reaction mixture, as shown in the following reaction formula.
Reaction formula 1 ##STR9## In the formula, X, Y 1 , and Y 2 , and Y 3 are defined above.
When the reaction is carried out in a solvent, an inert solvent is used.
Suitable solvents include aliphatic hydrocarbons such as octane, decane, ligroin and cyclohexane; aromatic hydrocarbons such as benzene, toluene, xylene, ethyl benzene, diisopropyl benzene, solvent naptha; haloaromatic hydrocarbons such as chlorobenzene, dichlorobenzene, chlorotoluene and chloroisopropyl benzene; ethers such as n-butyl ether, dissoamyl ether and dioxane; nitriles such as acetonitrile, propionitrile, and benzonitrile; and ketones such as methylethyl ketone and methyl isobutyl ketone.
The acid catalyst can be conventional dehydrating agents.
Suitable acid catalysts include hydrochloric acid, sulfuric acid, sulfur trioxide, trifluoroacetic acid, trifluoromethanesulfonic acid, phosphoric acid, acetic anhydride, thionyl chloride, phosphorus oxychloride and toluenesulfonic acid.
The amount of the acid catalyst is in a range of 0.01 to 0.3 mole per 1 mole of the maleic anhydride [II].
Suitable maleic anhydride having the formula [II] used as the starting material, include maleic anhydride, 2,3-difluoromaleic anhydride, 2,3-dichloromaleic anhydride, and 2,3-dibromomaleic anhydride.
Suitable aromatic amines used as the other starting material include aniline, haloanilines, alkylanilines, lower alkoxyanilines, nitroanilines, hydroxyanilines, alkoxycarbonylanilines, carboxyanilines, phenylanilines, phenylaminoanilines, alkenylanilines, thiocyanoanilines, sulfoneanilines, acetylaminoanilines, sulfamoylanilines, dihaloanilines, dialkylanilines, di(lower alkoxy) anilines, halo-nitroanilines, halo-hydroxyanilines, alkyl-nitroanilines, alkyl-alkoxycarbonylanilines, nitro-lower alkoxyanilines, carboxyl-hydroxyanilines, trihaloanilines and N,N-dialkylaminodinitroanilines.
The amount of the aromatic amine III is usually equimole to the maleic anhydride II and can be more than equimole to it.
The preparation of the N-arylmaleimides of the invention will be illustrated by certain examples.
Preparation 1
In a 500 ml four necked flask equipped with a thermometer, a condenser having a water separator, a dropping funnel and a stirrer, 150 ml of xylene was charged and 19.6 g (0.2 mole) of maleic anhydride was dissolved.
Then a solution of 25.5 g (0.2 mole) of 4-chloroaniline in 100 ml of xylene was added dropwise to the solution at room temperature with stirring. The exothermic reaction was caused. The reaction was carried out with stirring at 60° to 68° C. for 2 hours after the addition.
Then, 1.0 g (0.0097 mole) of sulfuric acid was added to the former reaction mixture. The reaction was carried out with stirring at 135° to 138° C. for 4 hours under the azeotropical distillation.
After the reaction, xylene was distilled off, and the reaction mixture was poured into 500 ml of water and the precipitate was separated by a filtration. The product was recrystallized from ethanol to obtain 36.5 g of N-(4-chlorophenyl)maleimide having a melting point of 109° to 110° C. (yield 88.1%).
Preparations 2 to 8
In accordance with the process of Preparation 1, various N-arylmaleimides were produced by reacting various maleic anhydride with various aromatic amines in various solvents, and then dehydrating the products for the cyclization.
The results are shown in Table 2.
Table 2__________________________________________________________________________ ##STR10## Cyclization inStarting Materials Additional reaction dehydrationPrep. Maleic an- Aromatic amines Reaction Acid catalyst Temp. Time Temp. TimeNo. hydrides (g) (g) Solvent (ml) (g) (° C) (hr.) (° C) (hr.)__________________________________________________________________________2 X = H (19.6) Y.sub.1 = 4 - NO.sub.2 xylene (300) sulfuric acid 65 - 70 2 137 4 140 Y.sub.2 = H (1) Y.sub.3 = H (27.6)3 X = H (19.6) Y.sub.1 = 3-Cl ethylbenzene sulfuric acid 60 - 65 2 135 5 137 Y.sub.2 = 5 - Cl (300) (1) Y.sub.3 = H (32.4)4 X = H (19.6) Y.sub.1 = 4 - OH dioxane trifluoroacetic 50 - 55 2 98 6 101 Y.sub.2 = H (300) acid Y.sub.3 = H (21.8) (0.5)5 X = H (19.6) ##STR11## toluene (300) sulfuric acid (1.0) 55 - 60 2 50 5 100 Y.sub.2 = H Y.sub.3 = H (36.8)6 X = H (19.6) Y.sub.1 = H chlorobenzene hydrochloric 50 - 55 2 130 6 132 Y.sub.2 = H (300) acid (2.0) Y.sub.3 = H (18.6)7 X = H (19.6) Y.sub.1 = 2 - CH.sub.3 benzonitrile thionyl chloride 60 - 65 2 190 3 Y.sub.2 = H (300) (0.5) Y.sub.3 = H (21.4)8 X = H (19.6) Y.sub.1 = 3-CH.sub.3 xylene (300) sulfuric acid) 70 - 75 2 137 3.540 Y.sub.2 = 5-CH.sub.3 (1.0) Y.sub.3 = H (24.2)9 X = H (19.6) Y.sub.1 = 3-CHCH.sub.2 xylene (300) phosphorus 35 - 42 2 137 4 140 Y.sub.2 = H oxychloride Y.sub.3 = H (23.8) (1.0)10 X = H (19.6) Y.sub.1 = 2-COOH 1,2-diethoxy- hydrochloric 50 - 53 2 123 7 125 Y.sub.2 = H ethane (300) acid (2.0) Y.sub.3 = H11 X = H (19.6) ##STR12## dichloroben- zene (300) sulfur tri- oxide (0.5) 60 - 65 2 174 3 175 Y.sub.2 = H Y.sub.3 = H (33.8)12 X = H (19.6) Y.sub.1 = 2-CH.sub.3 O toluene(300) hydrochloric 54 - 58 2 108 4 110 Y.sub.2 = 5-CH.sub.3 O acid (2.0) Y.sub.3 = H (30.6)13 X = Cl (33.4) Y.sub.1 = 4-Cl solvent sulfuric acid 40 - 48 2 130 5 135 Y.sub.2 = H naphtha (300) (1.0) Y.sub.3 = H (25.5)14 X = F (26.8) Y.sub.1 = H xylene (300) p-toluene- 50 - 255 137 3 140 Y.sub.2 = H sulfonic acid Y.sub.3 = H (18.6) (0.5)15 X = Cl (33.4) Y.sub.1 = 2-CH.sub.3 xylene (300) thionyl chloride 60 - 63 2 138 3.540 Y.sub.2 = 5-CH.sub.3 (0.5) Y.sub.3 = H (24.2)16 X = Cl (33.4) Y.sub.1 = 4-SCN xylene (300) sulfuric acid 50 - 56 2 137 3 140 Y.sub.2 = H (1.0) Y.sub.3 = H (30.0)17 X = Cl (33.4) Y.sub.1 = 4 - COOC.sub.2 H.sub.5 methylethyl sulfuric acid 58 - 62 2 80 5 Y.sub.2 = H ketone (300) (1.0) Y.sub.3 = H18 X = Br (25.6) Y.sub.1 = 4 - NO.sub.2 xylene (300) trifluoro- 50 - 55 2 137 4 140 Y.sub.2 = H methane Y.sub.3 = H sulfone (1.0)__________________________________________________________________________Reaction products Prep. No.##STR13## Amount (g) Yield (%) Melting point (° C)__________________________________________________________________________2 X=H, Y.sub.1 =4-NO.sub.2, Y.sub.2 =H, Y.sub.3 =H N-(4-nitrophenyl)maleimide 37.1 85.0 164.5 - 166.03 X=H, Y.sub.1 =3-Cl, Y.sub.2 =5Cl, Y.sub.3 =H, N-(3,5-dichlorophenyl)maleimide 43.1 89.2 136 - 1374 X=H, Y.sub.1 =4-OH, Y.sub.2 =H, Y.sub.3 =H N-(4-anilinophenyl) maleimide 31.8 84.0 187 - 189##STR14## Y.sub.3 =H N-(4-anilinophenyl)maleimide 45.3 85.3 130 - 1316 X=H, Y.sub.1 =H, Y.sub.2 =H, Y.sub.3 =H N-phenyl maleimide 28.8 83.2 88 - 907 X=H, Y.sub.1 =2-CH.sub.3, Y.sub.2 =H, Y.sub.3 =H N-o-tolyl)maleimide 30.3 80.9 74 - 768 X=H, Y.sub.1 =3-CH.sub.3, Y.sub.2 =5-C.sub.3, Y.sub.3 =H N-(3,5-xylyl)maleimide 33.2 82.6 85 - 86.59 X=H, Y.sub.1 =3-CHCH.sub.2, Y.sub.2 H, Y.sub.3 H N-(3-vinylphenyl)maleimide 31.6 79.5 100 - 10210 X=H, Y.sub.1 =2-COOH, Y.sub.2 =H, Y.sub.3 =H N-(2-carboxyphenyl)maleimide 35.0 80.5 147 - 15511##STR15## Y.sub.3 =H N-(p-biphenylyl)-maleimide 41.7 83.7 139 - 14112 X=H, Y.sub.1 =2-CH.sub.3 O, Y.sub.2 =5-CH.sub.3 O Y.sub.3 =H N-(2,5-dimethoxyphenyl)maleimide 38.2 81.6 12213 X=Cl, Y.sub.1 =4-Cl, Y.sub.2 =H, Y.sub.3 =H N-(4-chlorophenyl)-2,3-chloro maleimide 45.0 81.5 210 - 21614 X=F, Y.sub.1 =H, - N-phenyl-2,3-difluoromaleimide 34.3 82.0 88 - 9015 X=Cl, Y.sub.1 =2-CH.sub.3, Y.sub.2 =5-CH.sub.3, Y.sub.3 =H, 46.5 86.0 127 - 12916 X=Cl, Y.sub.1 =4-SCN, Y.sub.2 =H, Y.sub.3 =H N-(4-thiocyanophenyl)-2,3- dichloromaleimide 48.9 81.8 205-20817 X=Cl, Y.sub.1 =4-COOC.sub.2 H.sub.5, Y.sub.2 =H. Y.sub.3 =H, N-(4-ethoxycarbonylphenyl)- 2,3-dichloromaleimide 52.1 83.0 197 - 20018 X-Br, Y.sub.1 =4-NO.sub.2, Y.sub.2 =H, Y.sub.3 =H. N-(4-nitrophenyl)-2,3-dibromo- phenylmaleimide 30.0 80.2 207 - 208__________________________________________________________________________
The shellfish-algae inhibiting agents of the invention can be used in a form of a coating compositions such as varnishes, paints, solutions and emulsions.
One or more N-arylmaleimides [I] are mixed with suitable film forming composition to prepare a shellfish-algae adhesion inhibiting paint. The paint is coated on the ship bottom or the construction in water or the inner wall of an apparatus for passing a cooling water, whereby the adhesion of shellfish or algae on the coated surface can be prevented.
The film forming compositions used in the purposes can be oil varnishes, synthetic resins, and synthetic rubbers. It is possible to blend suitable pigment and filler if desired, in the shellfish-algae inhibiting composition.
The N-arylmaleimide [I] is usually incorporated at a ratio of 5 to 80 wt.%, preferably 10 to 50 wt.% to the film forming composition.
In order to inhibit the adhesion and growth of shellfish and algae in the passage for the cooling water, it is possible to add the N-arylmaleimide in a form of emulsion, however, in order to maintain the effect for inhibiting the adhesion for a long time, it is necessary to coat a paint or varnish on the inner wall.
When the N-arylmaleimide of the invention is applied on the fishing net, the N-arylmaleimide and a resin are dissolved in an organic solvent to prepare a resin solution and a fishing net is immersed into the resin solution and the treated fishing net is dried.
In the preparation of the resin solution, the N-arylmaleimide [I] is incorporated at a ratio of 1 to 10 wt.%, preferably 1 to 6 wt.% and the resin is incorporated at a ratio of 5 to 15 wt.% preferably 7 to 12 wt.% in the organic solvent.
The effect is not substantially different, in the range of the concentration of the N-arylmaleimide [I].
The resins used in the preparation of the resin solution can be vinylchloride resins, phenol resins, alkyd resins, chlorinated rubber and the like.
The organic solvents can be benzene, toluene, xylene, chloroform and the like. When the resin is not easily soluble, 5 to 15 vol.% of dimethylformamide, dimethyl acetamide, dimethyl sulfoxide and the like is blended in the organic solvent.
The materials for the fishing nets for treating with the shellfish-algae inhibiting composition is not restricted, and the composition can be applied for the fishing net made of natural fibers, polyvinyl chloride, polyvinylalcohol, polyvinylidene chloride, polyfluoroethylene, polyamide, polyethylene, polypropylene, polystyrene, polyacrylonitrile and the like.
The effects of the N-arylmaleimides [I] of the invention for inhibiting the adhesion of shellfish and algae will be illustrated by certain inhibiting tests of the coated products coated with the compositions containing the N-arylmaleimides [I].
Composition 1
The compound No. 1 of N-phenyl-maleimide was mixed in the following components and the mixture was pulverized and blended by a pocket mill to prepare shellfish-algae adhesion inhibiting composition.
______________________________________Compound No. 1 20.0 wt.%Red oxide 10.0 wt.%Talc 15.0 wt.%Barium sulfate 20.0 wt.%vinyl resin 5.5 wt.%Rosin 5.5 wt.%Tricresylphosphate 2.0 wt.%Methyl isobutyl ketone 11.0 wt.%Xylene 11.0 wt.%Total 100.0 wt.%______________________________________
Composition 2
The compound No. 2 of N-(2-chlorophenyl)maleimide was mixed in the following components, and the mixture was pulverized and blended by a pocket mill to prepare shellfish-algae adhesion inhibiting composition.
______________________________________Compound No. 2 15.0 wt.%Red oxide 18.0 wt.%Talc 10.0 wt.%Aluminum stearate 0.5 wt.%Graphite 0.5 wt.%Rosin 26.0 wt.%Boiled oil 12.0 wt.%Solvent naphtha 18.0 wt.%Total 100.0 wt.%______________________________________
Test 1
Shellfish-Algae Inhibiting Test
(1) Preparation of sample plate and Test method.
Each steel plate (300 × 100 × 1mm) was precoated with a wash primer for one time and further coated with a ship bottom coating for two times. and further coated with a ship bottom coating for two times. Each plate was further coated with each composition (Paint composition 1 using various N-arylmaleimides shown by Compound No.) by a brush for two times to prepare the sample.
Each sample was fitted in a wooden frame and was dipped into sea from a raft for dipping at a depth of 1.5 m.
(2) Result
The samples dipped in sea were pulled up for each specific terms of 2, 4, 6, 8, 10 amd 12 months. The ratio of a shellfish-algae adhered area to the total area of the sample was shown by percentage.
The ratio of shellfish adhered area to the area of the sample and the ratio of algae adhered area to the total area of the sample were shown by percentage.
The results are shown in Table 3.
Table 3__________________________________________________________________________Term for dipping 2 months 4 months 6 months 8 months 10 months 12 monthsAdheredshellfishand algaeCompoundNo. S A T S A T S A T S A T S A T S A T__________________________________________________________________________1 0 0 0 0 0 0 5 0 5 15 0 15 30 0 30 40 10 502 0 0 0 0 0 0 0 0 0 10 0 10 20 0 20 30 10 403 0 0 0 0 0 0 0 0 0 0 0 0 6 0 6 12 1 134 0 0 0 0 0 0 2 0 2 10 0 10 25 0 25 35 10 455 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 10 1 116 0 0 0 0 0 0 0 0 0 6 0 6 15 0 15 20 10 307 0 0 0 0 0 0 0 0 0 0 0 0 6 0 6 25 5 308 0 0 0 0 0 0 0 0 0 4 0 4 15 0 15 25 6 319 0 0 0 0 0 0 0 0 0 4 0 4 20 0 20 30 10 4010 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 15 6 2111 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 15 4 1912 0 0 0 0 0 0 0 0 0 1 0 1 10 0 10 15 1 1613 0 0 0 0 0 0 0 0 0 4 0 4 15 0 15 25 10 3514 0 0 0 0 0 0 0 0 0 4 0 4 15 0 15 20 6 2615 0 0 0 0 0 0 0 0 0 0 0 0 8 0 8 15 0 1516 0 0 0 0 0 0 0 0 0 4 0 4 15 0 15 25 6 3117 0 0 0 0 0 0 0 0 0 0 0 0 10 0 10 15 6 2118 0 0 0 0 0 0 0 0 0 10 0 10 20 0 20 30 10 4019 0 0 0 0 0 0 2 0 2 8 0 8 20 0 20 35 8 4320 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 15 6 2121 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 15 4 1922 0 0 0 0 0 0 0 0 0 0 0 0 8 0 8 15 6 2121 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 15 4 1922 0 0 0 0 0 0 0 0 0 0 0 0 8 0 8 15 6 2123 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 15 4 1924 0 0 0 0 0 0 0 0 0 1 0 1 8 0 8 20 10 3025 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 8 10 826 0 0 0 0 0 0 4 0 4 10 0 10 30 1 31 50 5 5527 0 0 0 0 0 0 0 0 0 8 0 8 15 0 15 30 2 3228 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 10 10 2029 0 0 0 0 0 0 0 0 0 6 0 6 20 0 20 25 10 3530 0 0 0 0 0 0 0 0 0 4 0 4 15 0 15 20 6 2631 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 10 1 1132 0 0 0 0 0 0 1 0 1 8 0 8 15 0 15 25 8 3333 0 0 0 0 0 0 0 0 0 8 0 8 20 3 23 25 10 3534 0 0 0 0 0 0 1 0 1 8 0 8 20 0 20 30 10 4035 0 0 0 0 0 0 0 0 0 0 0 0 10 0 10 10 10 2036 0 0 0 0 0 0 0 0 0 4 0 4 20 1 21 30 15 4537 0 0 0 0 0 0 0 0 0 1 0 1 15 0 15 20 6 2638 0 0 0 0 0 0 0 0 0 1 0 1 6 0 6 10 10 2039 0 0 0 0 0 0 0 0 0 6 0 6 15 0 15 25 12 3740 0 0 0 0 0 0 0 0 0 0 0 0 8 0 8 20 5 2541 0 0 0 0 0 0 0 0 0 4 0 4 8 0 8 20 6 2642 0 0 0 0 0 0 1 0 1 8 0 8 15 0.1 15.1 20 8 2843 0 0 0 0 0 0 0 0 0 0 0 0 6 0 6 10 8 1844 0 0 0 0 0 0 2 0 2 10 0 10 30 2 32 40 20 6045 0 0 0 0 0 0 0 0 0 0 0 0 8 0 8 15 1 1646 0 0 0 0 0 0 0.2 0 0.2 8 0 8 20 0 20 40 15 5547 0 0 0 0 0 0 0 0 0 8 0 8 20 0 20 30 8 3848 0 0 0 0 0 0 0 0 0 4 0 4 10 0 10 15 8 2349 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 20 8 2850 0 0 0 0 0 0 0 0 0 4 0 4 8 0 8 15 10 2551 0 0 0 0 0 0 0 0 0 4 0 4 8 0 8 15 10 2552 0 0 0 0 0 0 0 0 0 6 0 6 15 0 15 20 20 4053 0 0 0 0 0 0 0 0 0 4 0 4 12 0 12 20 10 3054 0 0 0 0 0 0 0 0 0 1 0 1 10 0 10 20 8 2855 0 0 0 0 0 0 0.2 0 0.2 8 0 8 15 0 15 25 10 3556 0 0 0 0 0 0 0 0 0 4 0 4 15 0 15 25 10 3557 0 0 0 0 0 0 0 0 0 1 0 1 8 0 8 15 8 2358 0 0 0 0 0 0 0 0 0 8 0 8 15 0 15 30 10 4059 0 0 0 0 0 0 0.2 0 0.2 10 0 10 40 0 40 50 6 5660 0 0 0 0 0 0 0 0 0 4 0 4 10 0 10 25 8 3361 0 0 0 0 0 0 1 0 1 15 0 15 40 0 40 55 3 5862 0 0 0 0 0 0 0 0 0 0 0 0 2 0 2 10 8 1863 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 12 8 2064 0 0 0 0 0 0 0 0 0 0 0 0 8 0 8 20 10 3065 0 0 0 0 0 0 0 0 0 0 0 0 6 0 6 20 4 2466 0 0 0 0 0 0 0 0 0 4 0 4 15 0 15 25 6 3167 0 0 0 0 0 0 0 0 0 1 0 1 12 0 12 35 4 39non-treated 20 35 55 30 55 85 55 45 100 65 35 100 80 20 100 80 20 100__________________________________________________________________________ S : Shellfish A : Algae T : Total
Shellfish-Algae Inhibiting Test for Fishing Net 1
(1) Preparation of composition
The compound No. 1 of N-phenylmaleimide was uniformly mixed with the following components to prepare a resin solution.
______________________________________Compound No. 1 8 wt. %Chlorinated rubber 5 wt. %Rosin 2 wt. %Toluene 85 wt. %Total 100 wt. %______________________________________
(2) Treatment of Fishing net
A fishing net having 11 knots (stitch of 3.03 cm) prepared by using polyamide filaments (manufactured by Toray Co. Ltd.), was immersed into the resin solution (1) and was dried for 12 hours in air.
Shellfish-Algae Inhibiting Test for Fishing Net 2
(1) Preparation of Composition
The Compound No. 3 of N-(3-chlorophenyl)maleimide was uniformly mixed with the following components to prepare a resin solution.
______________________________________Compound No.3 5 wt. %Vinyl resin 5 wt. %Rosin 5 wt. %Xylene 85 wt. %Total 100 wt. %______________________________________
(2) Treatment of Fishing Net
In accordance with the treatment of fishing net 1-(2), the fishing net was treated with the resin solution 2-(1).
Test for Treated Fishing Net 3
The shellfish-algae inhibiting tests were carried out by using various treated fishing nets treated with resin solutions containing various N-arylmaleimides is accordance with the test for treatment of fishing net 1.
(1) Test Method
Each sample having a size of 50 × 50 cm cut from the treated fishing nets, and was supported by each steel frame having a size of 60 × 60 cm and was dipped into sea from a raft by dipping at a depth of 1.5 m.
(2) Results
The samples dipped in sea were pulled up for each specific terms of 1, 2, 3, 4, 5 and 6 months.
The conditions adhereing of shellfish and algae such as Hydrozoa, Styela, Bugula, Ulva, Enteromorpha, Ectocarpus, etc.. were observed and the ratio of the weight increases of the nets were measured.
The results are shown in Table 4. The ratings are given as follows.
- no adhesion
± spots
+ small amount in adhesion for the whole surface
++ large amount in adhesion for whole surface
+++ large amount for clogging whole meshes.
The ratio of weight increase of the net is shown by percent of each weight increase to the original weight of the net. The weights were measured at 1 hour after pulling up the net from the sea.
Table 4__________________________________________________________________________Com- Adhesion of algae Ratio of weight increase of net (%)pound (Month) (Month)No. 1 2 3 4 5 6 1 2 3 4 5 6__________________________________________________________________________1 - - - ± + ++ 5 9 6 13 24 502 - - - ± + ++ 3 4 9 10 25 693 - - - - - ± 3 3 4 3 6 154 - - - + ± + 4 4 5 20 15 425 - - - - - - 3 5 5 3 6 96 - - - ± ± ± 3 9 8 12 19 227 - - - - - - 10 8 10 9 15 98 - - - - - - 3 9 15 5 15 139 - - - - - ± 4 10 9 8 13 2510 - - - - - ± 8 8 8 16 10 1611 - - - - - - 3 4 15 8 8 812 - - - - - - 4 3 5 2 6 913 - - - - - - 3 5 10 9 13 1514 - - - - - - 3 9 15 11 13 1015 - - - - - - 7 15 15 6 9 1516 - - - - - - 6 10 10 21 9 917 - - - - - ± 3 4 4 6 6 1518 - - - ± ± + 3 6 10 10 15 3319 - - - + ++ ++ 3 9 6 18 29 9120 - - - - - - 7 7 17 22 10 1021 - - - - - - 3 3 15 12 12 922 - - - - - - 4 3 5 4 6 1023 - - - - - - 4 3 5 4 9 1024 - - - - - ± 4 3 5 10 9 1825 - - - - - - 5 10 13 8 20 1326 - - ± + ± ++ 3 9 16 28 69 12027 - - - - ± + 5 5 6 5 17 4028 - - - - ± - 6 10 15 8 25 8291 - - - - ± + 3 9 6 13 22 4430 - - - - ± + 4 5 13 6 25 5031 - - - - - - 3 3 3 4 9 632 - - - ± + ++ 3 9 13 13 30 7133 - - - ± + ++ 3 4 4 15 29 5134 - - - + ++ ++ 3 3 3 14 40 9535 - - - ± + ++ 3 3 4 16 20 5036 - - ± ± + ++ 3 8 7 24 31 6237 - - - ± + ++ 5 4 10 13 25 6538 - - - - ± + 7 10 18 13 25 4039 - - - ± + ++ 9 15 18 19 40 7340 - - - ± + ++ 6 3 8 19 42 5941 - - - ± ± + 3 10 14 14 14 4942 - - ± - ± + 7 8 15 8 21 4843 - - - + +30 ++ 3 4 3 20 45 9844 - - ± ± + ++ 9 15 15 15 25 6945 - - - - - - 3 6 7 9 6 946 - - ± + ++ ++ 3 9 15 23 51 11047 - - ± ± ± + 5 8 15 20 15 5048 - - - ± ± + 5 8 16 16 19 3949 - - - - - + 9 8 15 14 10 2650 - - ± + + ++ 5 4 18 25 24 2951 - - - - ± + 4 6 13 12 21 5052 - - - ± + ++ 5 8 12 15 28 7953 - - ± ± + ++ 5 8 15 19 35 8554 - - - - - - 5 8 8 11 9 1855 - - - ± - + 4 8 7 15 10 5556 - - ± + + ++ 6 7 16 28 24 6057 - - - ± ± ++ 4 5 9 24 51 12058 - - - - + ++ 5 8 13 12 25 11659 - - ± + ++ ++ 7 9 15 25 63 16160 - - ± + ++ ++ 4 4 9 15 45 12961 - - ± + ++ ++ 4 5 10 23 45 13162 - - - - - - 3 6 3 15 8 963 - - - - ± + 3 3 4 3 18 4064 - - ± + ++ ++ 3 9 19 31 70 14565 - - ± + ++ ++ 3 3 16 25 44 12166 31 - + + + ++ 9 8 21 28 46 13067 - - - ± + ++ 6 6 11 19 31 82Non- - ± + ++ +++ +++ 3 11 44 51 161 395treated__________________________________________________________________________ | A composition for inhibiting an adhesion of shellfish and algae comprises a resin, a medium and a N-arylmaleimide having the formula ##STR1## wherein X represents hydrogen or halogen atom; Y 1 represents hydrogen, or halogen atom or alkyl, lower alkoxy, nitro, hydroxyl, alkoxycarbonyl, carboxyl, phenyl, phenylamino, alkenyl, thiocyano, sulfone, acetylamino, or sulfamoyl group; Y 2 represents hydrogen or halogen atom or alkyl, lower alkoxy, nitro or hydroxyl group and Y 3 represents hydrogen or halogen atom or dialkylamino group.
The inhibiting composition is coated on a fishing net, a ship bottom or other apparatus in water. | 2 |
FIELD OF THE INVENTION
This invention relates to a burner tip which is to be used for boilers, heating furnaces, melting furnaces and other burning apparatus to promote the mixing of a liquid fuel with such spraying medium as air or steam, and provides the fine granulation of the liquid fuel and the perfect combustion of the fuel which is effective and economical in saving energy and preventing pollution.
BACKGROUND OF THE INVENTION
The fuel necessary to operate boilers, heating furnaces, melting furnaces and other burning apparatus under today's circumstances, tends to rise in price and lower in quality, making it desirable, therefore, to save energy and to prevent the effects of pollution. For this purpose, the fuel should burn well, that is, be low in the contents of O 2 , soot and NO x . It is known that these functions depend usually on the spraying characteristics of the fuel and its mixing characteristics with air.
In the conventional burning apparatus, not only is fuel used, but also a spraying medium such as air or steam is used to propel the fuel in a jet into the burner. When the spraying medium is jetted out of a nozzle, that is, jetted from the high pressure side to the low pressure side, it will mix with and finely granulate the fuel by the energy of the expanding spray.
However, since liquid fuel is an imcompressible fluid and has little dispersibility in itself, it is necessary to increase the degree of mixing of the spraying medium with it in order to promote the fine granulation of the liquid fuel. Generally, the amount of mixing of the spraying medium must be increased. Thus, this has been a defect in that any saving of fuel energy is lost in the mixing.
Further, particles in the spray fluctuate so much in their granularity as to be different in the rate of mixing with air for combustion and a favorable combustion is hard to attain. Therefore, the modification of the wind box and blower around the conventional burner has been costly.
Further, in order to attain low NO x , apparatus has been proposed for slow combustion (such as exhaust gas recirculation, two-step combustion or divided flame combustion), water injection (reduction of efficiency by the evaporation of the latent heat of water) or de-nitrification. These steps also have the defect that the saving of energy is lost.
The burner tip of the present invention is made to eliminate such defects as are mentioned above. It changes the jet manner, promotes the mixing of a liquid fuel with such spraying medium as air or steam and produces the fine granulation of the liquid fuel and enables the combustion to be effective and economical to thereby save energy and prevent pollution.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show an embodiment of the present invention. In the Drawings:
FIG. 1 is a side elevational view of a burner tip according to the present invention;
FIG. 2 is a vertically sectioned view of the same;
FIG. 3 is a plan view of the burner tip body;
FIG. 4 is a partly sectioned elevation of the same;
FIG. 5 is a bottom view of the same;
FIG. 6 is a plan view of a flow divider;
FIG. 7 is a partly sectioned elevation of the body shown in FIG. 6;
FIG. 8 is a bottom view of the same;
FIG. 9 is a plan view showing a plate for feeding a liquid fuel and spraying medium;
FIG. 10 is a partly sectioned elevation of the same;
FIG. 11 is a plan view of the feeding plate;
FIG. 12 is a magnified view of the inner end of a jet port of the burner tip body.
DETAILED DESCRIPTION OF THE INVENTION
In the drawings, a burner tip body generally depicted by the numeral 1 is formed to be tapered and conically hollow and is provided with a recess 2 in the center of the interior of the tip. An annular recessed groove 3 is formed in the interior of the body at a proper spacing outside the recess 2, and a plurality of jet ports 4 opening on the tapered outer peripheral surface between the above mentioned recess 2 and annular recessed groove 3. Furthermore, on the inner surface of the tip body, communicating slots 5 are provided between the sides of the inner ends of the jet ports 4 and the above mentioned recess 2 and communicating slots 6 between the other sides of the inner ends of the above mentioned jet ports 4 and the circular recessed groove 3.
The arrangement of the communicating slots 5 and 6 at the inner ends of the respective jet ports 4 is such that the gaseous mixture enters tangentially to rotate in the port 4 whereby gaseous mixing is jetted out of the jet ports 4 as shown in detail in FIG. 12.
A flow divider 7, as is shown in detail in FIGS. 6, 7 and 8 is located in the burner tip body 1. As shown in FIG. 2, the flow divider 7 is shaped to be tapered to fit conformingly in the conical hollow interior with the recess 2, circular recessed groove 3, jet ports 4 and communicating slots 5 and 6 and is provided in its central part with a hole 8 communicating with the recess 2. The outer periphery of the flow divider 7 is provided with a proper number of holes 9 communicating respectively at their outer ends with the circular recessed groove 7 and at their inner ends with the central hole 8.
In the illustrated embodiment, the interior of the flow divider 7 is enlarged to provide a cylindrical mixing chamber 10 communicating with the hole 8. A feeding plate 11, for feeding liquid fuel and spraying medium is abutted against the end of flow divider 7 enclosing the chamber 10. As shown in FIGS. 9, 10 and 11, the feeding plate 11 is provided with a recess 13 fitting the cylindrical chamber 10 of the flow divider 7 to form, therewith, the complete mixing chamber generally defined by the numeral 12. A plurality, or selected number of holes 14 for feeding a liquid fuel into the above mentioned mixing chamber 12 pass axially through plate 11. Outside and concentric to the periphery of the recess 13, there is provided a selected number of holes 15 for feeding a spraying medium such as air or steam. The plate 11 is provided on the interior frontal surface facing the flow divider 7, with a corresponding number of radial passages 16, communicating in a spiral direction between the holes 15, and the recess 13. By the way, holes 15 and communicating passages 16 are closed on the flow divider 7 side by the flow divider 7, itself.
A hollow conduit defining a liquid fuel feeding passage and a concentric 17 spraying medium feeding passage 18 are connected to the liquid fuel and spraying medium feeding plate 11 so that liquid fuel may be fed to the holes 14 and such spraying medium as air or steam may be fed to the surrounding holes 15.
As a result, as shown in FIG. 2, the liquid fuel will be fed vertically into the mixing chamber 12 from the holes 14, while the spraying medium will be fed horizontally and rotated into the mixing chamber 12 through the communicating grooves 16 from the holes 15 to form a gaseous mixture within the mixing chamber 12.
Incidentally, in the present invention, a gaseous mixture of liquid fuel and spraying medium may be fed directly into the chamber 10 on the interior surface of the flow divider 7. Therefore, the plate 11 for feeding the liquid fuel and spraying medium need not always be provided on the back surface of the flow divider 7 as shown in the drawings.
Nevertheless, in the above described embodiment and as ilustrated in the drawings, the liquid fuel and spraying medium feeding plate 11 is provided to jet the fuel and spraying medium through the co-axial conduits 17 and 18 respectively in streams which intersect substantially at right angles with each other and particularly to rotate the spraying medium via passage 16 entering the chamber 12 to thereby promote the mixing of the liquid fuel with the spraying medium.
The burner tip body 1, the flow divider 7, and the liquid fuel and spraying medium feeding plate 11 may be connected together by screw-threading or by welding selected parts together.
A gaseous mixture in which the liquid fuel is made into fine grains or mist will be formed by the expansion energy of the spraying medium and the rotation of the spraying medium itself caused by providing the communicating grooves 16 spirally with respect to the recess 13. The gaseous mixture will be divided by the flow divider 7 into two streams, one stream leading from the mixing chamber 12 to the central recess 2 of the burner tip body 1 through the hole 8; the other stream leading from the chamber 12 to the circular recessed groove 3 through the holes 9.
The gaseous mixture stream fed to the central recess 2 will then be fed to the side of the inner ends of the respective jet ports 4 through the respective communication groove 5, while the gaseous mixture stream fed to the circular recessed groove 3 of the burner tip body 1 will be fed to the other side of the inner ends of the respective jet ports 4 through the respective communicating grooves 6. The two streams recombine and mix further, in a spiral swirl and will be jetted of the jet ports 4 while being rotated as shown in FIG. 12.
As a result, the mixing and the fine granulation or misting of the liquid fuel will be further promoted and the gaseous mixture will be uniformly diffused over a wide range.
Therefore, a perfect combustion will be approached and a favorable combustion will be attained. Production of soot will be reduced, as will the O 2 content, and reduce the thermal loss of the exhaust gas. Thus, by the reduced O 2 content, the thermal efficiency will improve, the thermal NO x will be reduced to be as a whole low, and the rate of conversion from SO 2 to SO 3 will reduce to prevent corrosion at a low temperature.
As in the above, the present invention is effective and economical to save energy and prevent pollution.
Examples of the results of burning tests on the burner tip device of the present invention are shown in the following data which are comparisons of the same level of the smoke concentration (combustibility).
______________________________________Data 1: Data in a boiler of a maximum evaporationof 200 t./hr. (which could evaporate amaximum of 200 tons of water per hour). Burner of Conventional present burner invention Effects______________________________________Burner 2.5 dia × 6 2.5 dia × 6dimensions holes × 80 holes × 80 deg. deg.Burner type Divided Rotating flame low flow jetting NO.sub.xNumber of 6 6burners usedFuel oil Heavy oil C Heavy oil CkindCombustion 6,950 kg./hr. 7,500 kg./hr.amountSmoke 2.3 deg. 2.3 deg.concentrationExhaust gas 1.7% 0.7% ReductionO.sub.2 % by 59%NO.sub.x concen- 142 ppm. 133 ppm. Reductiontration of 9 ppm.Economizer 299 deg. C. 292 deg. C. Reductionoutlet gas of 7 deg. C.temperatureEvaporation 13.3 13.45 Rise bymultiplica- 1.1%tion______________________________________
As is seen from the above data, NO x is lower with the burner tip of the present invention, the energy saving effect is higher by 1.1 percent in efficiency and the saving of the cost in a large boiler is much larger than with the conventional low NO x burner.
Further, with the conventional burner, auxilliary steam was used under a pressure of 11.5 kg./cm 2 . G for the spraying medium, but with the burner tip of the present invention, the combustion state was kept sufficiently favorable enough under a pressure of 9.0 kg./cm. 2 G.
______________________________________Data 2: Data in a boiler of a maximum evaporationof 30 t./hr. (which could evaporate amaximum of 30 tons of water per hour). Burner of Conventional present burner invention Effects______________________________________Burner 4.2 dia × 18 4.2 dia × 16dimensions holes × 90 holes × 90 deg. deg.Burner type Normal Rotating flow internal jetting mixingNumber of 1 1burners usedFuel oil Heavy oil C Heavy oil CkindCombustion 1,480 lit./hr. 1,580 lit./hr.amountSmoke 2.5 deg. 2.6 deg.concentrationExhaust gas 6.4% 4.1% ReductionO.sub.2 % by 36%NO.sub.x concentra- Not Nottion measured measuredAir heater 184 deg. C. 176 deg. C. Reductionoutlet gas of 8 deg. C.temperatureThermal About 88% About 89.2% Rise of 1.2%efficiency______________________________________
As shown by the numerical value of a furnace load of 1,260,000 kcal./m. 3 , the combustion chamber of the boiler was so narrow as to be very difficult to improve combustion by prior art methods. However, with the burner tip of the present invention, combustion was improved and the effect of saving energy was attained.
______________________________________Data 3: Data in a boiler of a maximum evaporationof 12 t./hr. (which could evaporate amaximum of 12 tons of water per hour). Burner of Conventional present burner invention Effects______________________________________Burner 4.4 dia × 7 4.4 dia × 7dimensions holes × 65 holes × 60 deg. deg.Burner type Normal Rotating flow internal jetting mixingNumber of 1 1burnersusedFuel oil Heavy oil C Heavy oil CkindCombustion 800 lit./hr. 800 lit./hr.amountSmoke 2.0 deg. 2.0 deg.concentrationExhaust gas 7.5% 4.7% ReductionO.sub.2 % by 37%NO.sub.x concen- 236 ppm. 199 ppm. Reductiontration of 37 ppm.Furnace 295 deg. C. 262 deg. C. Reductionoutlet gas of 33 deg. C.temperatureThermal About 80% About 83.6% Rise ofefficiency 3.6%______________________________________
As seen from the above, as compared with the conventional normal burner, the burner tip of the present invention is high, effectively reducing NO x . When the burner tip of the present invention is used in a small boiler, the flames will be so short that the high temperature part of the flame will move readily from the boiler outlet to the furnace interior surface, therefore, the exhaust gas temperature will be very low and the efficiency will be very high.
Three examples of the test data have been shown in the above. In the light of the average with other data, the effect of reducing the O 2 rate is shown to be about 40 percent. Thus, the burner tip of the present invention requires no modification of the boiler, is cheap and contributes much to the industry by saving energy and preventing pollution. | A tapered body having a hollow conical interior is provided with a central recess and an annular groove spaced outside the recess. The body has a number of jet ports opening on the tapered outer peripheral surface between the central recess and the annular groove. A first set of slots extending respectively between the jet ports and the central recess is provided as is a second set of grooves extending between said jet ports and said annular groove. A tapered flow divider is adapted to fit within said body to define therewith a mixing chamber. The flow divider has means for supplying fuel and a gaseous media to the mixing chamber and holes for feeding the mixture of fuel and gaseous media to the jet ports via the central recess and the annular groove and the first and second grooves. | 5 |
TECHNICAL FIELD
[0001] This disclosure relates to a treated fabric that is comprised of splittable conjugate yarns and to a process for modifying such a fabric to enhance its water absorbency. Specifically, the present invention relates to a consolidated nonwoven fabric containing continuous filaments comprised of polyester and polyamide components, in which portions of at least one of the components have been removed. The process used to remove portions of the polyamide component involves treating the fabric with acid. A basic solution is used to remove portions of the polyester component of the fabric. The result, using either or preferably both treatments, is a nonwoven fabric with a much greater ability to absorb water. Contemplated end uses of such a treated fabric are also provided.
BACKGROUND
[0002] As will be discussed herein, the present process is applicable to any conjugate yarn that includes a polyamide as one of its components. The present process improves the absorption characteristics of fabrics of any construction (woven, knit, or nonwoven) that are comprised of microdenier yarns that result from splitting conjugate multi-component yarns. Microdenier fabrics are traditionally created by mechanically or chemically splitting a conjugate yarn into its elementary filaments. Although the benefits of this process are readily apparent on a specific nonwoven fabric that will be discussed in detail herein, it should be understood that it is equally applicable to woven or knitted microdenier fabrics created from splittable yarns.
[0003] Nonwovens are known in the industry as an alternative to traditional woven or knit fabrics. To create a nonwoven fabric, a fibrous web must be created and then consolidated. Staple fibers are formed into a web through the carding process, which can occur in either wet or dry conditions. Alternatively, continuous filaments, which are formed by extrusion, may be used in the formation of a web. The web is then consolidated and bonded by means of needle-punching, point-bonding, chemical bonding, or hydroentangling. A second bonding technique may also be employed.
[0004] A preferred substrate for the present disclosure is a nonwoven formed of continuous splittable filaments that are extruded as a web and then consolidated. The continuous conjugate filaments are obtained by means of a controlled spinning process. The continuous filaments have the following characteristics: (1) the continuous filaments are comprised of at least two elementary filaments and at least two different fiber types; (2) the continuous filaments are splittable along at least a plane of separation between elementary filaments of different fiber types; (3) the continuous filaments have a filament number (that is, titer or yarn count) of between 0.3 dTex and 10 dTex; and (4) the elementary filaments of the continuous filament have a filament number between 0.005 dTex and 2 dTex. Simply put, the nonwoven fabric can be described as a nonwoven fabric made from conjugate filaments. Such a fabric is described in U.S. Pat. Nos. 5,899,785 and 5,970,583, both to Groten et al., each of which is incorporated herein by reference.
[0005] A wide range of synthetic materials may be utilized to create the elementary filaments of the continuous conjugate filaments. The conjugate filaments used the present process differ from those common in the art in that they are comprised of elementary filaments of different polymer types. Such polymer types may include polyesters, polyamides, polyolefins, polyurethanes, and the like.
[0006] However, the present invention is intended to improve the characteristics of fabrics that contain polyesters or polyamides as part of the conjugate yarns. As such, the group of polymer materials forming the elementary filaments is selected from among the following groups: polyester and polyamide; polyolefin and polyamide; polyurethane and polyamide; polylactic acid and polyamide; polyester, polyolefin, and polyamide; and polyester, polyolefin, polyurethane, and polyamide; or any other combination as may be known in the art.
[0007] It is desirable in the nonwoven fabrics described above to fully split, or separate, the elementary filaments of the continuous filaments from one another. The same goal applies to woven or knitted fabrics as well. The resultant microdenier strands contribute to the textile quality of the nonwoven fabric. The microdenier yarns contribute to the softness and hand of woven or knitted fabrics.
[0008] However, the fabric described in the above-referenced patents is not as absorbent as many other synthetic fabrics that may be used in the drying or wiping cloth market and that may have a similar composition but different construction. The nonwoven of the present disclosure is more absorbent after being subjected to the present process.
SUMMARY
[0009] In a preferred embodiment, the present process involves subjecting a fabric having splittable conjugate yarns both to an acidic treatment and to a basic treatment, each of which erodes a portion of the components of the conjugate yarns. The acid treatment, given certain reaction kinetics, removes a portion of the polyamide element of the conjugate filament. The basic treatment has a similar effect on the polyester element of the conjugate filament, making it more hydrophilic. The at least partial removal of the polyamide component, coupled with the increased hydrophilicity of the polyester component, results in a fabric having enhanced absorptive properties. In an alternate embodiment, treatments with only acid or only basic solution may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The following photographs were taken with a Hitachi Camera, Model VK-C350, after having been magnified through an Olympus BH2 optical microscope. The following photographs are of various fabric cross-sections.
[0011] [0011]FIG. 1 is a photograph, taken by an optical microscope at a magnification of 1060×, of a nonwoven fabric that has been dyed but not subjected to the present process;
[0012] [0012]FIG. 2 is a photograph, taken by an optical microscope at a magnification of 1060×, of a nonwoven fabric that has been subjected only to the acid treatment of the present process;
[0013] [0013]FIG. 3 is a photograph, taken by an optical microscope at a magnification of 1060×, of a nonwoven fabric that has been subjected only to the basic treatment of the present process;
[0014] [0014]FIG. 4 is a photograph, taken by an optical microscope at a magnification of 1060×, of a nonwoven fabric that has been subjected to a 0.25% acidic treatment and a basic treatment; and
[0015] [0015]FIG. 5 is a photograph, taken by an optical microscope at a magnification of 1060×, of a nonwoven fabric that has been subjected to a 2.0% acidic treatment and a basic treatment.
DETAILED DESCRIPTION
[0016] The present product is created by subjecting a fabric comprised of splittable continuous conjugate filaments to successive treatments with acid and base. The resultant treated fabric has enhanced ability to absorb water, as compared with the untreated fabric and other drying cloths made of similar synthetic materials.
[0017] The present process includes the steps of: (a) treating the fabric with acid and rinsing; and (b) treating the fabric with base and rinsing. In one preferred embodiment, before treatment with acid or base, the fabric is subjected to high pressure hydroentanglement, as described in U.S. patent application Ser. No. 09/344,596, filed Jun. 25, 1999, which is commonly owned and is hereby incorporated by reference.
[0018] The term “polyamide” is intended to describe any long-chain polymer having recurring amide groups (—NH—CO—) as an integral part of the polymer chain. Examples of polyamides include nylon 6, nylon 6 6, nylon 1 1, and nylon 610.
[0019] The term “polyester” is intended to describe any long-chain polymer having recurring ester groups (—C(O)—O—). Examples of polyesters include aromatic polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polytrimethylene terephthalate (PTT) and aliphatic polyesters such as polylactic acid (PLA).
[0020] In one embodiment, the conjugate filaments present, in cross-section, a configuration of zones representing the cross-sections of the different elementary filaments in the form of wedges or triangular sections. Such a shape is clearly identifiable in the central area of FIG. 1, which shows a circular cross-section having narrow, dark wedges between wider wedges. The dark wedges represent the polyamide component of the conjugate filament, while the wider, lightly colored wedges represent the polyester component of the conjugate filament. As may be realized, the percentage of polyester in the conjugate filament is larger than the percentage of polyamide. Distributions of polyester to polyamide range from 95-5 to 5-95, with 65-35 being a typical distribution by weight.
[0021] A review of FIG. 1 shows a plurality of polyester wedges that have been dislodged from their multi-component “packages.” Slightly above and to the left of the central circular package is a cross-section in which some polyester wedges have been dislodged, but the polyamide skeleton remains largely intact. A similar structure, but with more polyester wedges removed, is visible in the lower left corner of the photograph.
[0022] Several items should be noted, upon review of a representative photograph of the nonwoven's composition. First, while the core portions of the conjugate filaments are shown as polyamides, no core portion is required. In fact, hollow core conjugate filaments are also suitable for use in the present process, particularly since such hollow filaments are more likely to fully split. Furthermore, cores made of polyester or fibers without a recognizable “core” would be suitable as well.
[0023] Second, it should be noted that FIG. 1 is a photograph of a piece of untreated nonwoven fabric. The fabric shown in FIG. 1 was processed as described above, by extruding a web and then consolidating the filaments of the web. The fabric was then subjected to the conditions of the present process, but without the addition of the acid or the basic treatment. That is, the fabric was tumbled in a jet dye machine for 90 minutes at 130° C., cooled, rinsed, tumbled in a jet dye machine for 30 minutes at 130° C., cooled, rinsed, and then dyed. From the photograph, it is clear that merely tumbling the fabric during processing does not affect the desired filament splitting.
[0024] The object of the consolidation process is to fully split the different elementary filaments from one another. It is clear from the photograph that some multiple-component filaments remain. The fact that hydroentanglement alone is insufficient to separate the elementary filaments points to a need for additional processing, as is described herein.
[0025] Finally, the photograph shows a symmetrical cross-section of the conjugate filament, having a central median axis. In fact, the median axis of the conjugate filament can be positioned at a point other than the central line of the filament. The conjugate filament can be unsymmetrical, having elementary filaments with non-uniform cross-sections. The cross-section of the conjugate filaments can be substantially circular in shape or can be comprised of multiple lobes that are joined at a central region. Another variation of the construction of splittable conjugate filaments are those having a cross-section in which ribbons, or fingers, of one component are positioned between ribbons, or fingers, of a second different component. Yet another variation includes either one or a plurality of elementary filaments of one material that are integrated in a surrounding matrix of a second different material.
[0026] It is understood in the art that polyamides, such as nylon, can be etched—that is, partially eroded—by subjecting such fibers to acidic solutions. One example of an etching treatment is found in U.S. Pat. No. 4,353,706 to Burns, Jr. et al., which is commonly owned and is hereby incorporated by reference. The objective of the present process, unlike that of Burns, Jr. et al., is not to produce a sculptured pile fabric, but to produce a fabric more capable of absorbing water.
[0027] Both strong and weak acids are useful in the present process. Examples of common strong acids include sulfuric, phosphoric, nitric, and hydrochloric acids. Weak acids may also be employed in the present process including organic acids, such as formic acid, and sulfonic acids, such as benzene sulfonic acid; naphthalene sulfonic acid; ortho-, meta-, and para-toluene sulfonic acids; and alkylated aromatic sulfonic acids wherein the alkyl group may be straight chain or branched chain and may contain from one to about 20 carbon atoms. Preferably, the weak acids useful in the present process have a pK A value of from about 0.1 to about 2.0, preferably from about 0.4 to about 1.0. More preferably, paratoluene sulfonic acid (PTSA) is often used for the present process, because of the relative ease with which its corrosive properties may be controlled.
[0028] To determine the necessary reaction conditions, one must consider the kinetics and diffusion processes involved in the reaction. In general, the mass transport rate of the acid or base reactant to the polymer, the reaction rate of the reactant with the polymer, and the mass transport rate of the degraded polymer out of the fiber matrix are factors which affect the rate of reaction. The mass transport rate of the reactants is largely affected by the concentration of the reactant, the temperature, and the rate of liquid movement during the reaction process. The introduction of phase transfer catalysts, which transfer reactants from the liquid interface into the polymer, can also affect the reaction rate. The reaction rate is generally proportional to the concentration of acid or base reactant, the concentration of the polymer reactant, the temperature during the reaction, and the presence of any catalyst. The rate of mass transport of degraded polymer is affected by the concentration of degraded polymer, temperature, rate of liquid movement during the reaction process.
[0029] It has been found that subjecting the fabric to either an acidic solution or a basic solution increase the treated fabric's ability to absorb water. However, subjecting the fabric to both an acidic solution and a basic solution results in a fabric having greatly enhanced absorption capacity.
[0030] A particularly effective range of concentrations, when using PTSA, are concentrations greater than about 1% of the weight of the bath (owb), though improvements in water absorbency have been realized with concentrations as low as about 0.25% owb. More preferably, when using PTSA, the range is from about 1% to about 3%, based on the weight of the bath. Most preferably, when using PTSA, the acid concentration is about 2%, based on the weight of the bath. Obviously, different concentrations may be desirable for different acid types, such as organic or strong.
[0031] Exposure times, again using PTSA, can range upwards from about 30 minutes to about 120 minutes. The preferred exposure time is about 90 minutes, when a 2% concentration of PTSA is used. Strong acids or higher acid concentrations would likely require a shorter exposure time, while organic acids might need longer periods over which to effect the desired fiber modifications.
[0032] The acid selectively targets the polyamide components of the nonwoven fabric. Where the conjugate filaments have been at least partially split during hydroentanglement, the acid tends to further split the filaments into their elementary components and to erode the polyamide components. This result is due to the acid's preferential affinity for polyamides. Where conjugate filaments are not split, there is a tendency for the polyamide components to be dissolved or eroded by the acid, while the relative grouping of the components may remain largely unchanged (see FIG. 2).
[0033] [0033]FIG. 2 is a photograph of a nonwoven fabric that has been subjected only to an acidic solution (where the acid concentration was about 2% owb). In the central area of the photograph, a composite structure is visible in which most of the polyamide components of the conjugate filament have been removed. Only three dark-colored polyamide components remain between the polyester components. Below and to the left of the central circular structure are individual polyester wedges that have been separated from neighboring polyamide wedges. Because of the concentration level used, there appear to be no individual polyamide wedges. The polyamide portions appear to have been completely eroded.
[0034] Due to the dissolution of at least some of the polyamide components of the fabric, the resulting fabric has a decreased weight, typically on the order of about 2 to about 25%. The resulting fabric also has improved water absorption characteristics, although those characteristics are further enhanced by a subsequent basic treatment as described below.
[0035] Following acid treatment, the fabric is then subjected to a basic treatment. The basic solution reacts with the polyester component of the conjugate filament, making it more hydrophilic. The term “basic” is intended to describe the hydroxides of any alkali or alkaline earth metal and amines. The preferred basic solutions are sodium hydroxide (NaOH) and potassium hydroxide (KOH), with sodium hydroxide being more preferred because of cost. Amines are less preferred because of their tendency to react with the entire fiber rather than the surface of the fiber.
[0036] Additionally, a phase transfer catalyst may be used to affect the reaction rate. Commonly, alkyl quaternary salts are used. Such salts often have a carbon chain length of about 16.
[0037] The preferred concentration for the basic solution is significantly less than that of the acidic solution. In fact, a concentration range from about 0.025% to about 0.10% (based on the weight of the bath) is sufficient to create the desired modifications in the polyester components. Preferably, the concentration of the basic solution is about 0.050% based on the weight of the bath. It has been found that higher concentration levels of the basic solution may be used. Such concentrations may result in a weakened fabric, loss of textile quality, and resemblance to a paper-type product.
[0038] Exposure times, using sodium hydroxide, can range from about 15 minutes to about 90 minutes. The preferred exposure time is about 30 minutes, when a 0.050% owb concentration of sodium hydroxide is used. The base selectively targets the polyester components of the fabric and, specifically, the ester groups. The base hydrolizes the ester bonds in the polyester, creating hydrophilic cites. These cites make the polyester more hydrophilic and the surface of the polyester becomes more water-loving.
[0039] Again, the fabric that has been treated only with base has improved water absorption characteristics as compared with the untreated fabric, although the improvements are not as significant as those realized with a combination of acid and basic treatments. FIG. 3 is a photograph of a nonwoven fabric, as described herein, in which the fabric has been subjected only to a basic solution. In this photograph, a number of joined polyamide clusters are visible. Individual polyester wedges seen in earlier photographs are also present and separate from the polyamide skeletons. As compared with FIG. 2, there appears to be little, if any, degradation in the polyamide component. This is expected because the basic solution targets only the polyester component.
[0040] It has been found that the combination of successive acid and basic treatments imparts the most desired characteristics to the treated fabric. Functionally, the nonwoven fabric, having been treated with both acid and base, is significantly better at absorbing water than (a) the untreated fabric, (b) the fabric treated only with acid, and (c) the fabric treated only with base. Structurally, the treated fabric contains a plurality of fully split conjugate yarns, having individualized polyester components and degraded individualized polyamide components, and a plurality of polyamide “skeletons.” The term “polyamide skeletons” is intended to describe a structure comprised of polyamide components that are joined to one another. In some yarn configurations, when treated, these polyamide skeletons tend to fold over onto themselves.
[0041] [0041]FIG. 4 is a photograph of a cross-section of nonwoven fabric that has been subjected to a 0.25% owb acid solution and a 0.050% owb basic solution. The photograph shows a plurality of individual polyester wedges, some of which are slightly squared off on the sides that were arc-shaped. Slightly to the left of the center of the photograph, a polyamide skeleton is visible. Some parts of the polyamide skeleton appear to be degraded, not having the full width and shape of their original form. The polyamide skeletons experience reconfiguration due to the present process. Reconfiguration may be interpreted to mean (a) separation of the skeleton into at least two parts; (b) separation of the skeleton into at least two parts, in which at least one part has been dissolved; and (c) removal of at least a portion of the skeleton, particularly in which removal is at least partially due to dissolution.
[0042] [0042]FIG. 5 is a photograph of a cross-section of nonwoven fabric that has been subjected to a 2.0% owb acid solution and a 0.050% owb basic solution. The photograph shows a plurality of polyester wedges and only a small polyamide cluster in the central area of the photograph. As compared with that of FIG. 4, the fabric of FIG. 5 has much less polyamide remaining. The polyamide components have been removed by the higher concentration of acid. For example, in a fabric having a 65-35% polyester-polyamide composition, removal levels of polyamide vary upwards from 50%. For best results, in terms of water absorption, at least 75% of the polyamide should be removed.
[0043] After treating with acid and base, the nonwoven fabric may be dyed using conventional dyeing techniques. Other finishing chemicals may be added, for example, to improve the hand or soil release characteristics of the fabric.
[0044] The process steps will now be discussed in more detail. In a preferred embodiment, the acid treatment step is conducted in a jet-dyeing machine, into which the fabric is fed, along with an acid solution containing about 2.0% PTSA (based on the weight of the bath). The temperature of the bath is raised to approximately 130° C. and held for an exposure time of about 90 minutes. It is believed that temperatures as high as 150° C. would also be acceptable. After the necessary time, the fabric is cooled, preferably to at least 60° C. It is then rinsed, preferably twice, with water to prevent reaction between the acid and the base, which will be used in the next step.
[0045] The fabric, having been treated with acid, may then be treated with base. The fabric is fed into a jet-dyeing machine along with a basic solution containing about 0.050% sodium hydroxide (based on the weight on the bath). The temperature of the bath is raised to approximately 130° C. After an exposure time of about 30 minutes, the fabric is then cooled to about 50° C. and rinsed, preferably twice, with water.
[0046] Other finishing chemicals can be applied to the treated fabric, including soil release agents, wetting agents, and hand-building agents. One particularly preferred additive is a high molecular weight ethoxylated polyester, sold under the trade name Lubril QCX, by Rhone Poulenc, which improves both the hand and the soil release characteristics of the fabric. Such chemicals are effectively applied in a padding operation, although other application techniques may be employed. By way of example only, a 3% concentration of Lubril QCX was found to improve the hand and soil release characteristics of the fabric, without negatively impacting the fabric's ability to absorb water.
[0047] The phrase “absorption capacity” is intended to describe the capacity of the fabric to absorb water. The capacity is measured as milliliters of water per gram of fabric. The untreated nonwoven fabric described herein has an absorption capacity of about 3.5 ml/g. The nonwoven fabric of the present product, having been subjected to acidic and basic treatments, has an absorption capacity of about 7.0 ml/g, an improvement of about 200%. The nonwoven fabric of the present product, having been subjected to high pressure hydroentanglement, acidic treatment, and basic treatment, has an absorption capacity of about 6.2 ml/g.
[0048] TABLE 1 shows the results of several trials, conducted according to the process steps described herein.
TABLE 1 Absorption Capacity Testing with Various Treatments Acid Acid Exposure Base Absorption % Concentration Time Concentration Capacity Improvement Treatment (% owb) (minutes) (% owb) (ml/g) (vs. untreated) None 0 0 0 3.52 n/a Dyed 0 0 0 3.82 109 NaOH only 0 0 0.050 4.38 124 PTSA/NaOH 0.25 30 0.050 4.30 122 PTSA/NaOH 0.50 30 0.050 4.43 126 PTSA/NaOH 1.0 60 0.050 4.58 130 PTSA/NaOH 1.0 90 0.050 5.07 144 PTSA/NaOH 2.0 30 0.050 4.82 137 PTSA/NaOH 2.0 60 0.050 5.11 145 PTSA/NaOH 2.0 90 0.050 6.31 179 PTSA/NaOH 2.5 90 0.050 6.76 192 PTSA/NaOH 2.5 120 0.050 7.04 200 PTSA/NaOH 3.0 120 0.050 6.71 191
[0049] The absorbent fabric described herein can be utilized for a variety of purposes. By way of example only, the absorbent fabric may be used as a drying cloth, as a wiping cloth, as part of a filtration system, or as any other product in which the fabric's absorbent characteristics may be beneficial. | In a preferred embodiment, the present process involves subjecting the nonwoven fabric both to an acidic treatment and to a caustic treatment, each of which erodes a portion of the components of the conjugate yarns. The acid treatment, given certain reaction kinetics, removes a portion of the polyamide element of the conjugate filament. The caustic treatment has a similar effect on the polyester element of the conjugate filament, making it more hydrophilic. The at least partial removal of the polyamide component, coupled with the increased hydrophilicity of the polyester component, results in a fabric having enhanced absorptive properties. In an alternate embodiment, treatments with only acid or only caustic solution may be employed. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to an effluent container. More particularly, the present invention relates to a disposable bag configured to contain effluent generated during the cleaning of a fin fan cooler.
BACKGROUND OF THE INVENTION
[0002] From time to time coolers, such as fin fan coolers, are in need of cleaning. One way of cleaning a fin fan cooler is to flow cleaning fluid (which is often water) through the fin fan cooler. As the cleaning fluid moves through the fin fan cooler, the cleaning fluid may pick up contaminates from the cooler. The contaminates may have leaked from the cooler or may be present due to other sources. One tool that may be used in the cleaning process is a hydroblaster. The hydroblaster may discharge cleaning fluid through a fin fan cooler causing the cleaning fluid to flow through the fin fan cooler and out the other side of the cooler.
[0003] In view of current environmental concerns, it may be desirable to recapture the cleaning fluid once it has flowed through the fin fan cooler. Recapture of the cleaning fluid may be desirable because the cleaning fluid itself may need proper disposal or that the cleaning fluid, once it has been contaminated by being flushed through the cooler becomes an effluent that now contains contaminates that need to be properly disposed of.
[0004] Further, it is possible that a fin fan cooler may leak causing an effluent to flow out of the cooler.
[0005] Accordingly, it is desirable to provide an apparatus that allows an effluent flowing out of a structure such as a fin fan cooler to captured for proper disposal.
SUMMARY OF THE INVENTION
[0006] The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus is provided that in some embodiments provide an apparatus that allows an effluent flowing out of a structure such as a fin fan cooler to captured for proper disposal.
[0007] In accordance with one embodiment of the present invention, an effluent container is provided. The container may include: a first sheet of material having at least four sides; a second sheet of material also having at least four sides attached to the first sheet of material on at least three sides such that a fourth side of both the first and second sheets are not attached and form an open end to the container, the container having an interior; a first liner attached to the first sheet of material; a second liner attached to the second sheet of material; closure structure located on the fourth side of both the first and second sheets and configured to allow the container to be closed onto a structure; attaching structure attached to the fourth side of both the first and second sheets and configured to provide attaching points for attaching the container to a structure; and a drain located on one of the sheets at an end opposite the open end, the drain configured to provide selective fluid communication between the interior of the container and an outside of the container.
[0008] In accordance with another embodiment of the present invention, an effluent container may be provided. The container may include: a first sheet of material having at least four sides; a second sheet of material also having at least four sides attached to the first sheet of material on at least three sides such that a fourth side of both the first and second sheets are not attached and form an open end to the container the container having an interior; a first liner attached to the first sheet of material; a second liner attached to the second sheet of material; a closure structure located on the fourth side of both the first and second sheets and configured to allow the container to be closed onto a structure, wherein the closure structure is a strap that can be shortened to attach the container to a structure; and a drain located on one of the sheets at an end opposite the open end, the drain configured to provide selective fluid communication between the interior of the container and an outside of the container.
[0009] In accordance with yet another embodiment of the present invention, an effluent container is provided. The container may include: a first sheet of material; a second sheet of material having a corresponding shape to the first sheet of material, the first sheet and second sheet of material being attached to each other around the perimeter of the first and second sheets so as to form a container having an open end, such that the container has an interior; a first liner attached to the first sheet of material; a second liner attached to the second sheet of material, wherein the first and second liners are secured to the respective first and second sheets with securing sheets trapping the first and second liners between the securing sheet and the respective first and second sheets; at least one of either: attaching structure located on the container configured to allow the container to be attached to a structure and closure structure located on the both the first and second sheets of material at the open end, the closure structure configured to allow the container to be closed onto a structure; and a drain located on one of the sheets at an end opposite the open end, the drain configured to provide selective fluid communication between the interior of the container and an outside of the container.
[0010] There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
[0011] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
[0012] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view illustrating a containment bag attached to a structure according to this disclosure.
[0014] FIG. 2 is a front, perspective view of a containment bag in accordance with this disclosure.
[0015] FIG. 3 is a bottom view of a containment bag in accordance with this disclosure.
[0016] FIG. 4 is a cross-sectional view taken along the lines 4-4 in FIG. 3 .
[0017] FIG. 5 is a top view of one example of a latched buckle that may be used in accordance with this disclosure.
[0018] FIG. 6 is a top view of a non-latched buckle that may be used in accordance with this disclosure.
[0019] FIG. 7 is a top view of a sample of the fabric that may be used in the containment bag in accordance with this disclosure.
[0020] FIG. 8 is a cross-sectional view taken along the line 8-8 in FIG. 2 .
DETAILED DESCRIPTION
[0021] The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides a container that may be easily attached to a structure that may be a source of an effluent. The container will allow the effluent to be recaptured for proper recycling, reclamation, or disposal. In some embodiments, the container will be inexpensive and easy to dispose of so that the container itself does not require cleaning or create a problem for disposal.
[0022] FIG. 1 is a perspective view of a container 10 in accordance with the present disclosure. The container 10 is attached to a source 12 . The source 12 is a structure upon which the container 10 is attached. The source 12 may contain or be a fin fan cooler. At side opposite of the source 12 , (not shown) a hydroblaster may be cleaning the fin fan cooler causing a cleaning fluid to flow through the fin fan cooler. The cleaning fluid may pick up contaminants in the fin fan cooler creating an effluent. The effluent is captured by the container 10 when the effluent flows out of the fin fan cooler.
[0023] The container 10 has an open end 14 . The open end 14 exposes the interior 15 of the container 10 . The container 10 is secured to the source 12 by closing structure 16 such as straps 16 . Although straps 16 are illustrated in the accompanying figures, other closing structure 16 may be used in accordance of the present disclosure. Closing structure 16 that may be used in accordance with the present disclosure may gather the open end 14 around the source 12 so as to close gaps between the container 10 , and the source 12 and secure the container 10 to the structure defining the source 12 .
[0024] FIG. 2 is a perspective top and front end view of the container 10 . The container 10 is made primarily of material 18 . The material 18 may be polyethylene in a sheet form. In some embodiments, the polyethylene is low density polyethylene (LDPE) and may be reinforced with fibers such as, for example, but not limited to, nylon. Several layers of material 18 are used in the construction of the container 10 . For example, as shown in FIG. 2 , a top sheet of material 20 is located above the bottom sheet of material 22 . The top material 20 and the bottom material 22 are connected at seams 24 . In some embodiments, the seams 24 are located around the outer edges of the top material 20 and the bottom material 22 with the exception of one edge. This one edge where the top material 20 is not connected to the bottom material 22 defines the open end 14 .
[0025] In some embodiments, the top material 20 and the bottom material 22 may be constructed in a multiple plies. In other words, the top material 20 may be actually two or more sheets. In some embodiments, the top material 20 and the bottom material 22 are two ply sheets. The top material 20 and the bottom material 22 may be attached in a variety of ways to form the seams 24 . For example, the seams 24 may be formed by sewing, heat welding, sonic welding, impulse welding, epoxies, adhesives, or any other suitable way of attaching sheets together.
[0026] The straps 16 may be equipped with multiple buckles 26 as shown. The buckles 26 may assist a user in tightening the open end 14 around a source or other structure 12 to which it is desired to attach the container 10 .
[0027] In some embodiments, the open end 14 of the container 10 may be equipped with attaching structure 28 . In the embodiment shown in the figures, the attaching structure 28 may be in the form of loops 28 . The loops 28 may be made of the material folded back over itself and attached to the container 10 at various seams 24 . The attaching structure 28 may provide another way for the container 10 to be attached to a structure 12 or otherwise provide a structure to move or secure the container 10 .
[0028] In addition to having an open end 14 , the container 10 has a closed end 30 . The closed end 30 is surrounded by the seams 24 . In some embodiments, the container 10 may have a generally rectangular shape, however, as shown in FIG. 2 , the closed end 30 may be formed of two seams 24 that are at an obtuse angle to each other. In instances where the container 10 is rectangular in shape, the container 10 may have three long seams 24 which attach the top material 20 to the bottom material 22 . In embodiments having more than four sides, as shown in FIG. 2 , there will generally be more than three seams 24 attach the top material 22 the bottom material 22 .
[0029] FIG. 3 is a bottom view of the container 10 in accordance with an embodiment of this disclosure. The bottom material 22 or sheet 22 is seen attached by various seams 24 to the top material 20 or sheet 20 (not shown in FIG. 3 but is a readily seen in FIG. 2 ). The straps 16 along with the buckles 26 are readily visible. The straps 16 may be attached to each other serially to form a single long strap or belt. The strap 16 may reside in a strap loop 32 . The strap loop 32 may be comprised of the material 18 folded back on itself to form a loop and is attached to the container 10 by a seam 24 . The strap loop 32 may have various breaks or openings 31 or windows 31 in order to allow a user access to the strap 16 and, in some embodiments, the buckles 26 .
[0030] Portions of the strap 16 and the buckles 26 are illustrated in FIG. 3 to reside in the strap loop windows 31 . The portions of the strap 16 that are located in the strap loop 32 are shown in broken lines FIG. 3 .
[0031] FIG. 3 illustrates a liner 34 in broken lines. In some embodiments, the liner 34 is made of high density polyethylene (HDPE). The liner 34 helps to reinforce the container 10 . In some embodiments, the liner 34 is located in the interior 15 of the container 10 . The liner 34 may be attached to top material 20 and the bottom material 22 shown in FIG. 3 .
[0032] In some embodiments, the liner 34 is attached to top material 24 the bottom material 22 by a retaining flap 36 . The retaining flap 36 may be made of the same material 18 as the top material 20 or sheet 20 and the bottom material 22 or sheet 22 . The retaining material or flap 36 may extend beyond the liner 34 toward the closed end 30 to form a loose end 38 as shown. The retaining flap 36 may be attached to the top material 24 the bottom material 22 by retaining seams 40 .
[0033] The container 10 is equipped with a drain 42 . The drain 42 is useful in allowing effluent accumulating in the container 10 be drained into an appropriate container or disposal system. In the embodiment shown in FIG. 3 , the drain 42 is located in the bottom sheet 22 at the closed end 30 near a junction between two seams 24 that form an obtuse angle.
[0034] FIG. 4 is a cross-sectional view of the container 10 shown in FIG. 3 . Starting toward the top of FIG. 4 , the seam 24 at the closed end 30 connecting the top material 20 and the bottom material 22 is shown. The drain 42 located in the bottom sheet 22 is illustrated. Both the cap 46 and the spigot 48 are shown. In some embodiments, the cap 46 attaches to the spigot 48 by threads. If needed, a gasket may be used to help seal the cap 46 to the spigot 48 . When the container 10 is in use, the cap 46 may be removed and replaced by a hose or other conduit.
[0035] The loose ends 38 for each of the retained flaps 36 can be seen. The loose ends 38 may provide reinforcement to the container 10 . The retaining flaps 36 are attached by retaining seams 40 located both before and after the liner 34 thereby trapping the liner 34 between the retaining seams 40 , the retaining flaps 36 and the top 20 and bottom 22 sheets.
[0036] The strap loop retaining seams 44 are shown attaching strap loop 32 to the container 10 . The strap 16 residing in the strap loop 32 is also shown. The strap loop retaining seams 44 are formed of material 18 folded back on itself. The loops 28 are also shown. The loops 28 are formed of material 18 looped back on itself, and attached to the container 10 by retaining seam 50 .
[0037] FIG. 5 is a top view of a buckle 26 in a closed position in accordance with an embodiment. FIG. 6 is a top view of the buckle 26 in an open position. With reference to both FIGS. 5 and 6 , the straps 16 are shown attached to the buckle 26 and the strap ends 54 are shown. In some embodiments, the strap 16 may be tightened by pulling on the strap ends 54 . The buckle 26 may be of a common snapping type buckle 26 . The buckle 26 may include an interior buckle 56 that fits with an exterior buckle 58 to snap in place. The interior buckle 56 may include flexing fingers 60 that are compressed together when entering the compression end of the exterior buckle 58 .
[0038] Once the flex fingers 60 have moved beyond the compressing end 62 to the locking cutouts 64 , the flex fingers 60 may move outwardly thereby locking the interior buckle 56 to the exterior buckle 58 . To unlock and remove the interior buckle 56 from the exterior buckle 58 , a user may compress the flex fingers 60 towards each other, and then simply slide the interior buckle 56 out of the exterior buckle 58 as shown in FIG. 6 . The particular buckles 26 shown are meant to be examples only. Other types of buckles or fasteners may be used in accordance with this disclosure.
[0039] FIG. 7 is a close-up view of the material 18 out of which various portions of the container 10 may be made. In some embodiments, the material 18 is used to form the top sheet 20 the bottom sheet 22 , strap loop 52 , the retaining lap 36 , and the strap loop 32 . Other features may also be formed of the material 18 . In the embodiment shown in the figures, the material 18 is formed of low density polyethylene (LDPE) reinforced by nylon fibers 66 and 68 . Fibers 66 run in a longitudinal direction and fibers 68 run in a latitudinal direction thereby forming a grid-like structure. In some embodiments, the longitudinal fibers 66 may be interwoven with the latitudinal fibers 68 .
[0040] In some embodiments, the fabric 18 may be translucent or even transparent. These features will allow a user to monitor the amount of effluent contained within the container 10 . In some embodiments, symbols, logos, trademarks or other writing such as instructions or other useful information may be printed on the material 18 . As mentioned above, some embodiments the material 18 made of multiple plies. In some embodiments the material 18 may withstand temperatures up to 172° F.
[0041] The container 10 may be constructed of material 18 configured to withstand fluid pressured to 40,000 PSI. Fluids at such pressure may originate from a hydroblaster. The container 10 may come in a variety of sizes such as 4, 6, 8, 10, 12, 14, 16, 18, 20 foot lengths and 12, 18 and 30 inch widths. Other sizes larger, smaller and in between those mentioned may also be used.
[0042] FIG. 8 illustrates a cross-sectional view of the loops 28 . The loops 28 may be useful in securing or moving the container 10 with respect to the structure 12 (as shown in FIG. 2 ). The loops 28 may be made of the material 18 folded back on itself trapping an interior portion 70 . The loops 28 may be attached to the container 10 by the loop retaining seam 50 .
[0043] Although an example of the container 10 is shown being used with a fin fan cooler, it will be appreciated that container 10 may be used with other structures that may have effluent flowing out. The fin fan cooler is merely a non-limiting example of a structure for which the container 10 of this disclosure may be useful.
[0044] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An effluent container may include: a first sheet of material; a second sheet of material being attached to the first sheet of material so as to form a container, first and second liners are secured to the respective first and second sheets with securing sheets; at least one of either attaching structure located on the container configured to allow the container to be attached to a structure and closure structure located on the both the first and second sheets of material at the open end, the closure structure configured to allow the container to be closed onto a structure; and a drain located on one of the sheets at an end opposite the open end, the drain configured to provide selective fluid communication between the interior of the container and an outside of the container. | 8 |
INFORMATION DISCLOSURE STATEMENT
The game of crisscross, or tick-tack-toe, has been the basis for numerous forms of apparatus to play tick-tack-toe or some variation of that game. The usual form of the game requires that players successively place game pieces into predetermined locations in an effort to place, usually, three pieces in a line. The player who succeeds in this is the winner.
One problem with the tick-tack-toe games is that pieces are placed, and the game is over very quickly. Also, with two reasonably sophisticated players, each player is so successful at blocking the other that it is very difficult for either player to win a game.
Previous efforts to devise a game based on tick-tack-toe have resulted in elaborate apparatus with complex rules, or simple apparatus that retains the shortcomings of the basic game.
SUMMARY OF THE INVENTION
This invention relates generally to a game apparatus, and is more specifically concerned with a game derived from the game of tick-tack-toe, for two or more players.
The present invention provides a gameboard having a plurality of predetermined locations arranged in a grid. Each player has a plurality of game pieces that are unique to that player, all game pieces being receivable within each of the predetermined locations in either a first position or a second position. The two positions of the game pieces determine the two possibilities for subsequent movement of the game piece within the grid.
In playing the game of the present invention, the players successively place one of their game pieces in a location. Each player attempts to place (for example) three pieces in a line, while other players attempt to block such efforts. When all players have placed all their pieces, if no player has won the game, the game continues with the players successively moving their pieces in an effort to achieve the winning line. The game pieces contain indicia for indicating the position of the piece, and the position determines the allowed direction of motion of the piece within the grid. The position of the piece, hence the allowed direction of motion, can be changed by a player during that player's turn, or as a player's turn.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will becomes apparent from consideration of the following specification when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a game apparatus made in accordance with the present invention, showing one game piece exploded therefrom;
FIG. 2 is a top plan view of a gameboard, or grid, for use by two players, and showing some game pieces in conjunction therewith;
FIG. 3 is a view similar to FIG. 2, but showing a gameboard for use by 3 or 4 players; and,
FIG. 4 is a view similar to FIG. 3, but showing game pieces for four players, and illustrating the continuation of the game after all pieces have been laid.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring now more particularly to the drawings, and to those embodiments of the invention here presented by way of illustration, FIG. 1 shows the preferred arrangement for apparatus made in accordance with the present invention. In FIG. 1 it will be seen that there is a gameboard generally designated at 10 having a grid 11 on the gameboard defining a plurality of locations, or squares, within the grid 11.
The gameboard is provided with a pair of cover members, one cover member 12 being hinged along an edge 14 for pivotal motion with respect to the gameboard 10. It will be seen that the cover member 12 is L-shaped, and is of such size as to cover a row of squares and a column of squares of the grid 11. As shown in FIG. 1, the grid 11 includes four rows and four columns of squares for a total of sixteen squares. As a result, when the cover member 12 is pivoted to cover a portion of the grid 11, the portion of the grid 11 remaining uncovered will comprise nine squares.
It will be seen that the cover member 12 is provided with a lip 15 along the inner edges. This lip 15 cooperates with a mating lip 16 on the cover member 18. It will be seen that the cover member 18 is hinged at an edge 19 to the gameboard 10; therefore, the cover member 18 can be pivoted with respect to the gameboard 10 and cover the remaining nine squares of the grid.
From the foregoing description, it will be understood that the cover members 12 and 18 can be placed over the grid 11 to completely enclose the grid 11. The cover member 18 can be opened to expose nine squares to allow two players to play a game, and the remaining cover portion 12 can be pivoted to uncover the remaining seven squares to allow three or four players to play the game.
It will be seen that there is a game piece shown at 20, the game piece 20 being such as to be received within any one of the squares of the grid 11. It will therefore be understood that, for transporting the game, a required number of game pieces 20 can be received within the squares of the grid 11, the cover members 12 and 18 can be placed over the grid, and the entire game is unitized for easy transport.
Looking now at FIG. 2 of the drawings, there is a gameboard designated at 10A. While the gameboard 10A is substantially the same as the gameboard 10, the entire gameboard includes only the nine squares, and the covers have been omitted. The game as shown in FIG. 2 is a very simple version of the same game, but lacking the versatility in that only two players can reasonably play the game. The gameboard 10A includes a grid 11A defining nine squares. The game pieces are designated at 20A and 20B, the pieces 20A being unique to one player while the pieces 20B are unique to the other player.
The game pieces 20A and 20B are designed so that any game piece 20A or 20B can be received within any one of the squares defined by the grid 11A. Furthermore, any game piece 20A or 20B can be received within any square in either of two different rotational positions. It will be noted that each of the game pieces includes position indicating means designated at 21, the indicating means 21 being here shown as crossed arrows.
While those skilled in the art will devise numerous forms of game pieces, the game pieces here illustrated are regular octagons, the arrows of the indicating means 21 being perpendicular to opposite, parallel sides of the octagon. Also, while many variations may be devised for rendering game pieces 20A and 20B unique, the means here indicated is by coloring the different game pieces individually. As here illustrated, the game pieces 20A are red and the game pieces 20B are yellow. Apart from the color, the game pieces 20A and 20B are precisely alike so any game piece can be received within any square of the grid 11A.
The game as illustrated in FIG. 2 of the drawings, having nine squares, is substantially equivalent to the conventional game tick-tack-toe, and the beginning of the present game is played by substantially the same rules. Rather than having two different shapes of game piece, or markers, each player has a different color of game piece. The players take turns laying a game piece 20A or 20B into a square of the grid 11A, each player attempting to place three game pieces in a contiguous line. Of course, the opposite player attempts to block the first player, so it is possible that neither player will achieve a contiguous line of three game pieces. After all game pieces are laid, if there is no winner the game pieces are moved within the grid in accordance with rules to be discussed hereinafter.
Looking now at FIG. 3 of the drawings, it will be seen that there is a gameboard indicated at 10, it being understood that the gameboard shown in FIG. 3 is the same as the gameboard shown in FIG. 1 except that the cover pieces 12 and 18 are omitted. The gameboard 10 also includes the grid 11 which defines sixteen squares.
Since the gameboard 10 is useable by four players, there are four unique game pieces indicated at 20, 20A, 20B and 20C. The game piece 20 shown in FIG. 1 is uncolored, or white, so the game pieces 20 in FIG. 3 are also white. The game pieces 20A and 20B are the red and yellow pieces as were discussed in conjunction with FIG. 2; and, an additional game piece 20C is indicated as colored blue.
With this description, it will be understood that the game shown in FIG. 3 is played in the same manner as has been previously discussed, the players successively placing one game piece into a selected square of the grid 11. It is the object for a player to place three of his game pieces in a contiguous line while the other players attempt to block a player to prevent that player from winning.
With the above in mind, attention is directed to FIG. 4 of the drawings which shows the gameboard 10 with grid 11, and having three game pieces of each of four players placed within the grid 11, but with no game piece achieving a contiguous line of three game pieces. It will be understood that, in the conventional tick-tack-toe game, the game would end at this point and no player would be declared the winner. In the present game however the game continues, each player continuing to try to become a winner.
Since all of the game pieces 20, 20A, 20B and 20C are placed within a square on the gameboard 10, the game pieces can be moved only from one location to another in an effort to win the game. Furthermore, since the game pieces of the present invention are placed both as to location within the grid 11 and with respect to the rotational position of the game piece, either aspect of positioning a game piece may be important.
In FIG. 4 of the drawings, it will be seen that the white game piece 25 is on the gameboard with the indicating means 21 pointing diagonally. This means that the game piece 25 can be moved only diagonally of the gameboard 10. If the player having the white game pieces wishes to move the game piece 25, the piece 25 must be moved to the square designated at 26. The red game piece 28 also has the indicating means 21 pointing diagonally, so this game piece can be moved only diagonally; however, it will be noted that there is no vacant space in the diagonal of the gameboard. As an alternative, the player having the red pieces may elect to take his turn by removing the game piece 28, rotating the game piece so that the indicating means 21 points along the grid, and replace the game piece 28 into the square 29. Thus, the player has had his turn, and has varied his position in the game, but has left the game piece 28 in the same square 29 as before his turn. While the player makes little progress on this turn, the player can make a physical move along the grid 11 on his next turn at the game.
Following these simple rules, it will be understood that the players can move the various game pieces within the grid 11 until one player achieves a contiguous line of three of his unique game pieces. It is contemplated that any straight line of three contiguous squares will constitute a win.
In beginning a game of the present invention, it is contemplated that some chance means will be used to determine which player begins, and successive players will take their turns in rotational order following the player who is first. The chance means might well take the form of a die, though other well known devices may be used. It will also be understood that, when four players are playing the game, the players may be divided into teams so that two players cooperate to achieve one winning line of one color game piece, while blocking the other two players and the other two colors of game pieces.
It will therefore be understood that the present invention provides a game apparatus that is simple and easy to learn, being based on the familiar game of tick-tack-toe, but the game adds several extra dimensions to appeal to more sophisticated players. The game has the very familiar aspect of simply placing the game pieces in the grid, but then continues in the aspect of shifting the game pieces in a further effort for one player to win. The tension of the first aspect of the game is increased because the placement of the game pieces during the first aspect of the game has a great effect on the second aspect of the game. As a result, long term strategy is beneficial and renders the game more exciting.
While regular octagonal game pieces have been disclosed, it will be readily understood that other shapes that allow the variation in rotational position will function as well. Other changes will suggest themselves to those skilled in the art, so it will be understood by those skilled in the art that the particular embodiments of the invention here presented are by way of illustration only, and are meant to be in no way restrictive; therefore, numerous changes and modifications may be made, and the full use of equivalents resorted to, without departing from the spirit or scope of the invention as defined in the appended claims. | A game derived from tick-tack-toe, and a gameboard and game pieces for playing the game. The gameboard is square, with a grid of sixteen square locations to receive game pieces. For two players, a cover is placed over seven of the locations to leave a grid of nine, and for three or four players all sixteen locations are used. The game pieces are octagonal and are placed for movement along the grid or diagonally to the grid. Pieces are placed in turn to attempt to place three in a contiguous line. When all pieces have been placed and no player has won, the pieces are moved within the grid in an effort to win. A piece must be moved in the direction set when the piece was placed, but the piece can be changed during a move, or the direction can be changed as one player's turn. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a bumper reinforcement constructed for a part of a bumper of a vehicle.
[0003] 2. Description of the Related Art
[0004] For protection of a vehicle body, a driver and other people in a vehicle such as a motorcar, a bumper is mounted on each of front and rear sides of a vehicle frame. The bumper comprises of a bumper reinforcement, as a strength member, supported by the vehicle frame, and a bumper cover, as a face member, contiguous with a vehicle exterior panel and covering the bumper reinforcement. An impact force F exerted on the bumper is absorbed substantially solely by the bumper reinforcement when the vehicle strikes another vehicle or other object. Possible impacts are grouped into light impacts and heavy impacts depending on the magnitude of the impact force F, and horizontal impacts and local impacts depending on the nature of the impact force F. The bumper reinforcement, which should protect the vehicle, driver and other people in the vehicle irrespective of the magnitude or nature of the impact force, has to be exchanged with a new one with increased frequency if it is intended to effectively absorb an impact force by deformation of the bumper reinforcement for every kind of impact. To this end, an improved bumper reinforcement has been proposed which is comprised of a bumper beam and a reinforcement member. The reinforcement member serves to absorb the impact force F in a light impact or a local impact while the bumper beam serves to absorb the impact force F in a heavy impact or a horizontal impact. This conventional art is exemplified by Japanese Patent Laid-Open Publication No. Hei 06-328988.
[0005] Specifically, according to the conventional bumper reinforcement, the reinforcement member deforms to absorb the impact force F at the beginning of exertion of the impact force or if the impact force F is small, and the bumper beam absorbs the impact force F with continued exertion of the impact force F or if the impact force F is large. This two-piece bumper reinforcement structure can achieve an increased degree of impact absorption performance compared to the conventional single-piece structure. Japanese Patent Laid-Open Publication No. 2001-322517 and U.S. Pat. No. 4,998,761 also disclose a similar two-piece bumper reinforcement.
[0006] In the bumper reinforcement of Japanese Patent Laid-Open Publication No. 2001 - 322517 , a reinforcement member, which is to be mounted on a bumper beam at a forward surface remote from a vehicle frame, is provided with a substantially central portion that varies in cross-sectional shape so as to have a higher degree of rigidity with respect to a compressive load exerted in the front-to-rear direction compared to the remaining portions. This reinforcement member can easily absorb the impact force F as it has a slightly decreased strength tending to deform to a suitable extent. The bumper reinforcement of U.S. Pat. No. 4,998,761 is comprised of a bumper beam with a longitudinal rib, and a reinforcement member concealing the rib.
[0007] The ordinary conventional bumper reinforcement is comprised of a reinforcement member having a substantially convex cross section, and a bumper beam having a closed cross section (box type), as shown in FIG. 10 of the accompanying drawings. When a large impact force F is exerted on the bumper reinforcement, first the reinforcement member plastically deforms and then the bumper beam plastically deforms under the impact force F transmitted from the reinforcement member, thereby absorbing the impact force (FIG. 11 or 12 ). The transition of this impact absorption is illustrated in FIG. 13, which is a graph showing a relationship between the amount of displacement of the bumper beam at the forward surface and the load (impact force F) necessary to cause displacement by such an mount. This graph indicates that the load has a peak with respect to the amount of displacement and the displacement of the bumper beam progresses with respect to the low load decreasing from the peak. For this reduction of amount of impact absorption, the impact force F is absorbed not by continuous plastic deformation of the bumper beam, but the forward surface of the bumper beam is bent about the portion on which a local impact force F is exerted.
[0008] According to the bumper reinforcement of U.S. Pat. No. 4,998,761, in the presence of the rib on the forward surface of the bumper beam, the local bending of the bumper beam can be retarded with plastic deformation across a wide area, thus realizing an increased amount of impact absorption compared to the conventional bumper reinforcement described in the preceding paragraph. However, in many cases, the reinforcement member extends along only a part of the entire length of the bumper beam, and in such an event, the impact force F is exerted on the rib of the bumper beam at the portion devoid of the reinforcement member so that an effective load receiving area of the forward surface of the bumper beam is reduced to cause plastic deformation only with the low load. Consequently, the present inventors have conducted studies in an effort to realize an improved bumper reinforcement in which ( 1 ) local bending of the bumper beam is retarded with plastic deformation allowed in a wider area to increase the amount of impact absorption, and ( 2 ) plastic deformation of the bumper beam does not occur at the portion devoid of the reinforcement member.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing problems, it is an object of the present invention to provide a bumper reinforcement in which (1) local bending of a bumper beam is retarded with plastic deformation allowed in a wider area to increase the amount of impact absorption, and (2) plastic deformation of the bumper beam does not occur at the portion devoid of a reinforcement member.
[0010] To attain the above-described object, according to the present invention, there is provided a bumper reinforcement for being attached to a front side or a rear side of a vehicle frame as a strength member, comprising a bumper beam to be supported on the vehicle frame, and a reinforcement member attached to the bumper beam on a forward side thereof which is upstream with respect to an impact exertion direction, wherein the reinforcement member has a concave portion of a substantially C-shaped cross section projecting in a downward direction reverse to the impact exertion direction, the bumper beam has, on the forward surface to which the reinforcement member is attached, a groove portion extending longitudinally of the reinforcement member, and bottom surface of the concave portion of the reinforcement member engages with a surface of the groove portion of the bumper beam.
[0011] The term “the impact exertion direction” is a direction in which the impact force F is exerted on the vehicle, namely, a direction from the front side of the vehicle toward the rear side of the vehicle in the front bumper, for example, of the ordinary vehicle, identical to the forward-to-backward direction of the vehicle. Accordingly, the position where the reinforcement member is attached to the bumper beam is the forward surface of the bumper beam in accordance with the forward-to-backward direction of an ordinary vehicle. However, if the impact force F is exerted on the vehicle from the upper side or lower side depending on the type of the vehicle, the position where the reinforcement member is attached to the bumper beam may be varied in accordance with the impact exertion direction. In the following illustrative examples, with the impact exertion direction being defined as a direction from the front surface of the bumper beam toward the rear surface of the bumper beam, the reinforcement member is attached to the front surface of the bumper beam.
[0012] Because the substantially concave portion of the reinforcement member projects in the impact exertion direction, it is possible to concentrate the impact force F transmitted to the bumper beam at the bottom surface of the concave portion. Because of a groove portion extending longitudinally of the reinforcement member, the bumper beam has an increased rigidity on its front surface so that possible plastic deformation due to exertion of a local impact force F expands across a wide area (deformation enhancing effect). Since the groove portion of the bumper beam projects in an upward direction reverse to the impact exertion direction, the remaining flat or curved portion of the forward surface of the bumper beam can serve as a wide region for receiving load.
[0013] Alternatively, the bumper beam may have a plurality of groove portions. In such an alternative case, a single reinforcement member may have the same number of concave portions or the same number of reinforcement members may each have a single concave portion so that the bottom surface of each concave portion engages with a surface of one of the plurality of groove portions. The increase of rigidity of the forward surface of the bumper beam can be achieved basically by extending the groove portions substantially parallel (perfectly parallel and/or slightly aslant) to the longitudinal direction of the bumper beam. Although it is preferable for the bottom surface of each concave portion to engage with the surface of the respective groove portion over the entire area, they may be locally spaced from each other by, for example, a member separate from the bumper beam.
[0014] The required width (perpendicular to the longitudinal direction) of the groove portion is such that the bottom surface of the concave portion can engage with the surface of the groove portion and the remaining forward surface of the bumper beam and the groove surface can be a flat or curved surface. The inventor's experiments indicate that for forming a single groove portion in the flat forward surface of the bumper beam, the groove width is within a range of ⅛-{fraction (4/8)}, preferably {fraction (1/7)}-{fraction (3/7)}, of the width (perpendicular to the longitudinal direction) of the bumper beam. For forming a plurality of groove portions in the flat forward surface of the bumper beam, the total width of all the groove portions is within the above-described range of the width of the bumper beam. The formation of these groove portions are such that the surface of the groove portion is retracted from the forward surface of the bumper beam or the remaining forward surface of the bumper beam is relatively projected, the surface of the groove portion and the remaining forward surface of the bumper beam being parallel to each other and being connected to each other by slant side walls of the groove portion. The angle of inclination of each slant side wall in free form is preferably as small as possible because, when an impact force F is exerted on the bumper beam, the slant side walls plastically deform so as to be substantially perpendicularly to the remaining forward surface of the bumper beam, as they are pulled by the remaining forward surface of the bumper beam pushed backward by the backward surface of the concave portion of the reinforcement member.
[0015] According to the bumper reinforcement of the present invention, the above-described deformation enhancing effect can be realized reliably because the bottom surface of the concave portion of the reinforcement member engages with the surface of the groove portion of the bumper beam to transmit the impact force F from the reinforcement member to the groove portion of the bumper beam. This face-to-face engagement may be accomplished by merely pressing the bottom surface of the concave portion of the reinforcement member against the surface of the groove portion of the bumper beam. However, these two surfaces are preferably joined with one another to improve the aforementioned transmission of the impact force F and the deformation enhancing effect. As another preferable feature, the reinforcement member has a pair of support legs extending from symmetrical side edges of the concave portion to the bumper beam in parallel to the impact exertion direction so as to be joined with, by overlapping, two corresponding side surfaces of the bumper beam which surfaces are parallel to the impact exertion direction. Because of these support legs, it is possible to attach the reinforcement member to the bumper beam in a stable posture and to facilitate the transmission of the impact force F and the deformation enhancing effect as plastic deformation of the bumper beam is caused chiefly by the transmission of the impact force F from the concave portion of the reinforcement member to the groove portion of the bumper beam.
[0016] Basically the bumper beam has a structure of any cross-sectional shape such that the groove portion is normally formed on the forward surface of the bumper beam, the side where a reinforcement member is attached. Preferably the structure of the bumper beam may have (a) a closed cross-sectional shape provided by bending a single blank plate in such a manner that symmetrical side edges of the plate connect to each other, or (b) an open cross-sectional shape provided by bending a single blank plate in such a manner that symmetrical side edges of the plate extend toward and terminate short of each other. As another preferable feature, in the structure of the closed cross-sectional shape (a), (c) one of the side edges of the blank plate may be folded inwardly with the other side edge of the blank plate connecting to the folded edge portion, the folded side edge of the blank plate terminating in a reinforcing rib connecting to an inside surface of the bent plate diametrically.
[0017] The above and other objects, features and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a perspective view of a bumper reinforcement of the present invention, showing a reinforcement member of a substantially C-shaped cross section attached to a bumper beam 1 having a structure of a closed cross section;
[0019] [0019]FIG. 2 is a vertical end elevation of the bumper reinforcement of FIG. 1;
[0020] [0020]FIG. 3 is a horizontal sectional view of the bumper reinforcement of FIG. 1;
[0021] [0021]FIG. 4 is an end elevation of a bumper reinforcement of an alternate embodiment of the present invention, showing a reinforcement member having a plurality of concave portions;
[0022] [0022]FIG. 5 is a vertical end elevation of the bumper reinforcement of FIG. 1, illustrating how the reinforcement member and the bumper beam deform when an impact force F is exerted on the bumper reinforcement;
[0023] [0023]FIG. 6 is a horizontal sectional view corresponding to FIG. 5;
[0024] [0024]FIG. 7 is a graph showing a relationship between the amount of displacement of the bumper beam and the load necessary to displace the bumper beam by such an amount, in the bumper reinforcement according to the present invention;
[0025] [0025]FIG. 8 is a vertical end elevation of a bumper reinforcement of a further alternate embodiment of the present invention;
[0026] [0026]FIG. 9 is a vertical end elevation of a bumper reinforcement of a furthermore alternate embodiment of the present invention;
[0027] [0027]FIG. 10 is a vertical end elevation of a conventional bumper reinforcement;
[0028] [0028]FIG. 11 is a vertical end elevation of the conventional bumper reinforcement, showing how a reinforcement member and a bumper beam deform when an impact force F is exerted on the reinforcing member;
[0029] [0029]FIG. 12 is a horizontal sectional view corresponding to FIG. 11; and
[0030] [0030]FIG. 13 is a graph showing a relationship between the amount of displacement of the bumper beam and the load necessary to displace the bumper beam to such an amount, in the conventional bumper reinforcement.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Various preferred embodiments of the present invention will now be described with reference to the accompanying drawings.
[0032] [0032]FIG. 1 is a perspective view of a bumper reinforcement 4 in which a reinforcement member 3 having a concave portion 2 of substantially C-shaped cross section is attached to a bumper beam 1 of a closed cross-sectional shape. FIG. 2 is a vertical end elevation of the bumper reinforcement 4 , and FIG. 3 is a horizontal sectional view corresponding to FIG. 2. Although the bumper reinforcement 4 of this embodiment is actually curved as seen in FIG. 1, it is shown as a straight part in FIG. 3 for convenience. In this and other embodiments described later, the bumper reinforcement is for a bumper attached to a front side of a vehicle. The reinforcement member 3 is attached to the bumper beam 1 within a predetermined range equidistantly extending in opposite directions from a substantially central point of the bumper beam 1 . Alternatively, the reinforcement member may extend over the entire length of the bumper beam. In another alternative form, a plurality of reinforcement member segments may be attached continuously or partially to the bumper beam.
[0033] In the bumper reinforcement 4 as shown in FIGS. 1 and 2, a rear (backward) surface 6 of the bumper beam 1 , having a structure of a closed cross section provided with a single groove portion 5 integrally by bending a single blank, is connected to a vehicle frame 7 (indicated by dash-and-two-dot lines in FIG. 1). The reinforcement member 3 is attached to the bumper reinforcement 4 on a forward surface 8 thereof remotely from the vehicle frame 7 . The bumper is comprised of the bumper reinforcement 4 and a bumper cover 9 concealing the bumper reinforcement 4 , and absorbs an impact force F, which is exerted toward the vehicle beyond the bumper cover 9 , by plastic deformation of the reinforcement member 3 or the bumper beam 1 .
[0034] The reinforcement member 3 has a concave portion 2 of a substantially C-shaped cross section projecting from a flat forward surface 10 in an impact exertion direction (toward the forward surface 8 of the bumper beam 1 ), and a pair of support legs 13 , 13 extending from symmetrical side edges of the forward surface 10 toward upper and lower surfaces 11 , 12 of the bumper beam 1 in parallel to the impact exertion direction so as to be joined with, by overlapping, the upper and lower surfaces 11 , 12 of the bumper beam 1 , these surfaces being parallel to the impact exertion direction. The bumper beam 1 has a structure of a closed cross section provided by bending a single blank plate so as to connect the symmetrical side edges to each other on the forward side of the bumper beam 1 . This closed structure is provided with a groove portion 5 having a surface 14 at a portion where the symmetrical side edges connect to each other, the surface 14 of the groove portion 5 being integrally joined with the forward surface 8 by slant side walls 15 , 15 of the groove portion 5 . The reinforcement member 3 is attached to the bumper beam 1 by pressing and joining (e.g., spot-welding) the bottom surface 16 of the concave portion 2 of the substantially C-shaped cross section against and to the surface 14 of the groove portion 5 . Alternatively, the reinforcement member 3 may have a plurality of concave portions 2 , 2 as shown in FIG. 4. In this case, the bumper beam 1 preferably has a plurality of groove portions 5 , 5 equal to or more than the number of concave portions 2 , 2 of the reinforcement member 3 (may include one or more groove portions not corresponding to the concave portions).
[0035] In the bumper reinforcement 4 of the present invention, as shown in FIGS. 2 and 3, the forward surface 10 of the reinforcement member, the bottom surface 16 of the concave portion, the groove surface 14 of the bumper beam, and the front or forward surface 8 of the bumper beam are substantially parallel to one another. The impact force F exerted on the bumper reinforcement 4 at the forward side thereof, as shown in FIG. 5 (the bumper cover is not shown in the figure), first compresses a pair of convex (in cross section) portions 17 , 17 of the reinforcement member 3 sandwiching the concave portion 2 toward the forward surface 8 of the bumper beam, and then pushes the bottom surface 16 of the concave portion 2 connected to the portion in which the impact force F is exerted, toward the bumper beam 1 , thereby causing the forward surface 8 of the bumper beam to plastically deform in accordance with the amount of displacement of the bottom surface 16 of the concave portion of the reinforcement member 3 .
[0036] During this plastic deformation, as shown in FIG. 6, the forward surface 8 of the bumper beam bends over a wide range extending longitudinally of the bumper beam 1 . Specifically, because the forward surface 8 of the bumper beam is increased in rigidity by the groove portion 5 , the forward surface 8 of the bumper beam undergoes not only local deformation (bending) but also plastic deformation over a wide range as portions around the forward surface 8 are pulled by the portion pushed by the bottom surface 16 of the concave portion of the reinforcement member. When substantially convex sectional portions 17 of the reinforcement member 3 are compressed, the upper and lower surfaces 11 , 12 of the bumper beam 1 are curved inwardly as if pulled by the support legs 13 , 13 of the reinforcement member, and angle of inclination of the slant side walls 15 , 15 partly defining the groove portion 5 of the bumper beam 1 become steep with respect to the vertical line while being pressed by the bottom surface 16 of the concave portion of the reinforcement member. These displacements as plastic deformation in various portions around the forward surface 8 of the bumper beam also contribute to impact absorption.
[0037] In accordance with enlarging the area of deformation in the forward surface 8 of the bumper beam as described above, a graph in FIG. 7, representing the relationship between the amount of displacement of the front surface 8 and the load (=impact force F) necessary to cause displacement by such an amount, shows that the load necessary to cause displacement of the bottom surface 16 of the concave portion of the reinforcement member, which is equal to the displacement of the forward surface 8 of the bumper beam, becomes substantially constant. An equal of displacements between the bottom surface 16 and the front surface 8 is caused by the structure joining the bottom surface 16 of the concave portion with the surface 14 of the groove portion extending contiguously to the front surface 8 of the bumper beam. Since the amount of impact absorption is equal to the area of the hatched region in the graph of FIG. 7, the bumper reinforcement 4 of the present invention can be achieved to improve absorption of the impact force F, apparently from comparison to the hatched area in a graph of FIG. 13 describing absorption of the conventional bumper reinforcement as well as the area indicated by a broken line in FIG. 7.
[0038] The impact absorption performance of the bumper reinforcement 4 can be easily adjusted by changing the structure of the reinforcement member 3 and/or the structure of the bumper beam 1 . For example, by using a modified bumper beam 18 having a structure of an open cross-sectional shape, as shown in FIG. 8, provided by bending symmetrical side edges of a single blank plate so as to extend toward and terminating short of each other with a gap therebetween, the upper and lower surfaces 11 , 12 of the modified bumper beam 18 is allowed to displace with an increased degree of freedom compared to the bumper beam 1 in FIG. 2 so that plastic deformation of the forward surface 8 can easily occur with the compression of the reinforcement member 3 , thereby reducing the amount of impact absorption of the bumper reinforcement 4 . In another alternative form, by using a modified bumper beam 21 having a structure of an closed cross-sectional shape, as shown in FIG. 9, provided by folding one side edge of a single blank plate inwardly with the other side edge connecting to the folded-in edge portion 19 with the one side edge terminating in a reinforcing rib 20 connecting to an inside surface of the bent plate diametrically, the reinforcing rib 20 restricts an amount of plastic deformation of the front surface 8 of the bumper beam with compression of the reinforcement member 3 , thereby increasing the amount of impact absorption of the bumper reinforcement 4 .
[0039] According to the present invention, as described herein above, it is to provide a bumper reinforcement that has excellent impact absorption performance with the reliability as a security device. Further, according to easy manufacturing without special members, the bumper reinforcement of the present invention can also provide a high cost performance for production without changing the materials and/or factory facilities. | A bumper reinforcement attached to a front or a rear side of a vehicle frame as a strength member comprising: a bumper beam to be supported on the vehicle frame, and a reinforcement member attached to the bumper beam on a forward surface thereof which is upstream with respect to an impact exertion direction, wherein: the reinforcement member has a concave portion of a substantially C-shaped cross section projecting in a downstream direction reverse to the impact exertion direction, the bumper beam has a groove portion extending longitudinally of the reinforcement member on the forward surface to which the reinforcement member is attached, and the reinforcement member and the bumper beam are engaged by joining a bottom surface of the concave portion and a surface of the groove portion. | 1 |
RELATED APPLICATIONS
[0001] This is a divisional of co-pending U.S. patent application Ser. No. 11/757,160 filed Jun. 1, 2007.
BACKGROUND
[0002] Sealing members are used in a variety of applications to establish fluid seals, such as in valves in a pressurized fluid system. Generally, it is desirable that a sealing member retain its sealing capability over a wide range of operational conditions. It is further generally desirable that a sealing member remain in place when subjected to significant pressurized fluid flow, such as when the sealing member is disposed on a piston member moving from a closed position to an open position.
[0003] This phenomena is illustrated in FIGS. 1A-1B , wherein shown a prior art valve assembly 10 that includes a piston 12 , the piston selectively regulating pressurized fluid flow from an inlet port 14 . The piston 12 is depicted in its closed position in FIG. 1A , thereby sealing the inlet port 14 . In FIG. 1B , the piston 12 is depicted as it transits from the valve closed position to the valve open position.
[0004] The fluid flow is sealed in the piston closed position ( FIG. 1A ) by a conventional O-ring sealing member 16 that presses against the inner wall of the port 14 . The sealing member 16 has a circular cross-sectional shape, and is retained on the piston 12 within an annular recess 18 . The outer radial surface of the sealing member 16 forms a fluid seal against interior annular sidewall 20 of a housing 22 , and an opposing inner radial surface of the sealing member 16 forms a fluid seal against the surface of the annular recess 18 .
[0005] As the piston 12 moves initially to the piston open position of FIG. 1B , significant fluid flow (arrows 24 ) can pass adjacent the sealing member 16 . Particularly in higher pressure fluid environments, a portion of the fluid can pass between the inner radial surface of the sealing member 16 and the recess 18 , exerting an outwardly (or radially) directed force on the sealing member 16 . If the hoop strength (the ability to retain its initial hoop shape) of the sealing member 16 is insufficient to resist this outwardly directed force, the sealing member 16 can be deformed and dislocated (blown out) from the annular recess 18 , as depicted in FIG. 1B .
SUMMARY
[0006] Accordingly, various embodiments of the present invention are generally directed to an apparatus for controlling a pressurized fluid.
[0007] In accordance with some embodiments, a valve assembly is provided in which a piston is moved from a closed position in which a pressurized fluid flow is inhibited to an open position in which a pressurized fluid flow is established. A sealing member is disposed within an annular recess of the piston and characterized as an endless annular ring extending about a central axis of the piston. The sealing member has an elongated circle cross-sectional shape when the sealing member is in an uncompressed state prior to installation in said recess, the cross-sectional shape defined by parallel top and bottom surfaces having a length L in a direction perpendicular to and intersecting the central axis, and having opposing inner and outer surfaces of a radius R, the inner and outer surfaces respectively facing toward and facing away from the central axis, and wherein the dimensional value of L is at least five times greater than the dimensional value of R.
[0008] Further advantages and features of various embodiments of the present invention will be apparent from the following description when read in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1A and 1B generally illustrate a prior art valve assembly in which a conventional O-ring having a circular cross-sectional shape provides a fluid seal.
[0010] FIGS. 2A and 2B show an exemplary valve assembly incorporating a sealing member constructed in accordance with embodiments of the present invention.
[0011] FIG. 3 is a top plan view of the sealing member of FIGS. 2A-2B .
[0012] FIG. 4 is a cross-sectional representation of the sealing member along line 4 - 4 in FIG. 3 , illustrating an exemplary elongated circle cross-sectional shape of the sealing member.
[0013] FIG. 5 is an enlarged view of a portion of FIG. 4 showing the exemplary length and radial dimensions of the elongated circle cross-sectional shape.
[0014] FIG. 6 illustrates an alternative construction for the sealing member which utilizes an embedded stiffening material.
[0015] FIG. 7 illustrates a preferred manner in which the elastomeric material of the sealing member is extruded.
[0016] FIG. 8 shows a top plan view of the extruded material after processing in accordance with FIG. 7 .
[0017] FIG. 9 shows an alternative extrusion process that provides sealing members with other cross-sectional shapes.
[0018] FIG. 10 is a cross-sectional elevational view of an alternative sealing member configuration formed by the process of FIG. 9 .
[0019] FIG. 11 is a cross-sectional elevational view of another alternative sealing member formed by the process of FIG. 9 .
[0020] FIG. 12 is a side elevational, cross-sectional depiction of the extrusion mechanisms generally depicted in FIGS. 7 and 9 .
[0021] FIG. 13 is an end elevational, cross-sectional depiction of the extrusion mechanism of FIG. 12 .
[0022] FIG. 14 provides a flow chart for an exemplary sealing member processing routine, generally illustrative of steps carried out in accordance with various embodiments of the present invention.
DETAILED DESCRIPTION
[0023] FIGS. 2A and 2B show relevant portions of a valve assembly 100 to generally illustrate an exemplary environment in which various embodiments of the present invention can be advantageously practiced. The valve assembly 100 is contemplated as being of the type configured to selectively alter the flow of a pressurized fluid in a pressurized fluid system, although such is not limiting.
[0024] The valve assembly 100 comprises a housing 102 with an upstream inlet port 104 and a downstream outlet port 106 . A piston 108 selectively moves between a closed position ( FIG. 2A ) and an open position ( FIG. 2B ) to selectively inhibit or permit fluid flow of the pressurized fluid from the inlet port 104 to the outlet port 106 . A biasing member 110 , such as a spring, biases the piston 108 to the closed position. Other biasing arrangements can readily be used, however, or omitted entirely, as applicable for a particular application.
[0025] An annular sealing member 112 is supported in a corresponding annular groove 114 of the piston 108 by a pressure washer member 108 A that is attached to the body of the piston 108 via a bolt 108 B secured in a threaded bore (not separately numbered). The sealing member 112 contactingly engages the sidewall 116 of the inlet port 104 in the housing 102 to establish a fluid-tight seal while the valve assembly 100 remains in the closed position.
[0026] When the pressure of the pressurized fluid is sufficient to overcome the biasing force supplied by biasing member 110 , the piston 108 advances upwardly as depicted in FIG. 2B . As the piston 108 moves to the open position, the sealing member 112 disengages the sidewall 116 , and as this occurs, the sealing member 112 is subjected to the pressurized fluid as the fluid passes from the inlet port 104 to the outlet port 106 . As explained more fully below, the sealing member 112 is advantageously configured to provide effective steady-state sealing in conditions such as depicted in FIG. 1 , as well as to resist mechanical deformation and dislocation (blowout) while being subjected to substantial amounts of fluid flow pressure as depicted in FIG. 2 .
[0027] As depicted in FIGS. 3 and 4 , the sealing member 112 is generally characterized as an endless annular ring, that is, an O-ring, which extends about a central axis 118 . The sealing member 112 is preferably formed of an elastomeric material and has a cross-sectional shape characterized as a radially elongated circle.
[0028] As further depicted in FIG. 5 , the elongated circle cross-sectional shape of the sealing member 112 is generally defined by opposing, parallel top and bottom flat surfaces, that is, linear segments 120 , 122 , and opposing inner and outer radiused surfaces, that is, semicircular end segments) 124 , 126 ; that is, the inner radiused surface is numbered 124 , and the outer radiused surface is numbered 126 . Each of the flat surfaces 120 , 122 has a length L in a direction perpendicular to, and which intersects, the central axis 118 . That is, each of the flat surfaces 120 , 122 lays in a plane that is normal to the central axis 118 . Each of the radiused surfaces 124 , 126 has a radius R that is numbered 130 .
[0029] The cross-sectional shape represented in FIG. 5 is a steady-state configuration for the sealing member 112 ; that is, the sealing member 112 maintains the elongated circle cross-sectional shape while in an uncompressed state (i.e., in the absence of any externally applied support or compression force acting upon the member). For purposes of clarity, it will be noted that the cross-sections of FIGS. 4 and 5 are taken along a plane that includes the central axis 118 of the sealing member 112 .
[0030] The dimensional values of L and R can vary depending on the requirements of a given application, with the dimensional value of the length L being greater than the dimensional value of the radius R; that is, L>R. Preferably, the dimensional value of the length L is greater than five times the dimensional value of the radius R, that is, L>5·R. As noted, the flat surfaces 120 , 122 lay along respective planes normal to the central axis 118 , and the radiused surfaces 124 , 126 are disposed to compressingly engage corresponding sidewalls to effect fluid sealing at the innermost diameter (ID) and outermost diameter (OD) extents of the sealing member 112 , that is, respectively, the inner radiused surface 124 and the outer radiused surface 126 . Exemplary values for the radiuses R for different industry standard classes of circular cross-sectional shaped O-rings are set forth in Table 1:
[0000]
TABLE 1
Class
Radius R (inches)
2-0
0.0350
2-1
0.0515
2-2
0.0695
2-3
0.1050
2-4
0.1375
[0031] The sealing member 112 can be adapted to have inner and outer radii R that correspond to any of the above classes, and used in an associated application provided that the corresponding retention groove (e.g., 114 in FIGS. 2A-2B ) is extended (deepened) by a sufficient distance to accommodate the length dimension L of the sealing member 112 . It will be noted that the multiple-piece configuration (pressure washer 108 A, bolt 108 B and body portion) is preferably set forth for the piston 108 in FIGS. 2A-2B to facilitate installation of the sealing member 112 .
[0032] The sealing member 112 of FIGS. 2-4 is contemplated as comprising an equivalent class 2-3 member, with R being nominally 0.1050 inches, in (±0.0060 in). The corresponding length value L of the sealing member 112 is nominally 0.5400 in (±0.0060 in). The OD of the sealing member 112 is nominally 3.2700 in (±0.0200 in), and the ID is nominally 1.9800 in (±0.0160 in). The same L and R values can be used with different respective ID and OD values, and vice versa, as desired.
[0033] The elongated circle cross-sectional shape has been found by the present inventor to provide unexpected operational improvements over conventional configurations, such as the conventional circular O-ring depicted in FIGS. 1A-1B . The elongated circle cross-sectional shape of the sealing member of the present invention significantly enhances the hoop strength of the sealing member 112 , and the length dimension L reduces the exposure of the inner radiused surface 124 to fluid pressure, that is, to pressured exerted behind the sealing member 112 within the annular groove 114 when the sealing member 112 is initially exposed to high pressure fluid as when the valve assembly 100 actuates to move from the closed position of FIG. 2A to the open position of FIG. 2B .
[0034] With the hoop strength of the sealing member 112 retaining the sealing member appropriately seated in the annular groove 114 , the sealing member 112 is maintains a fluid-tight fluid seal in the captured sealing environment of FIG. 2A , provides low-frictional sliding contact against the annular wall 116 , and resists damage or dislocation of the sealing member 112 in the high pressure environment of FIG. 2B .
[0035] A suitable material from which the sealing member 112 can be advantageously formed is a fluoroelastomer such as is commercially available under the registered trademark Viton® by E. I. du Pont de Nemours & Company, Wilmington, Del., USA. Other suitable materials can include any number of natural or synthetic rubbers, urethanes, plastics, etc. A suitable durometer (hardness) of the sealing member 112 may be in the order of 70-80, depending on the requirements of a given application, although both harder and softer materials can be used as desired.
[0036] Further, the seal member 112 can be stiffened with a suitable filler such as glass fibers, carbon filaments, nanotubes, etc., such as depicted in FIG. 6 in which an alternative sealing member 132 retains the afore described elongated circle cross-sectional shape of the sealing member 112 , but additionally incorporates an internal stiffening core 134 . The core 134 generally serves to further strengthen the sealing member 132 against damage or removal during operation, that is, to enable the sealing member 132 to resist removal from the groove 114 upon application of compressive and pressure forces.
[0037] The sealing members 112 , 132 can be formed in a number of ways. Taylor U.S. Pat. No. 6,315,299, assigned to the assignee of the present invention, generally discloses a compression molding process whereby a reinforcing member is placed into an annular molding cavity. Sealing material is injected into the cavity, such as a suitable elastomer, and the combination is cured to form a reinforced sealing member. While generally operable, one difficulty associated with molding processes, such as that taught by the '299 patent process is consistently maintaining a ring member in a centrally disposed orientation. Injected material often deflects the ring and pushes it to one side of the annular cavity, resulting in non-uniform thicknesses of elastomeric material.
[0038] The various embodiments presented herein are preferably formed using an extrusion process, such as set forth in FIG. 7 . An extrusion mechanism 142 extrudes uncured seal material 144 so that the extruded material remains in a soft, malleable state. A guide 146 at the exit portion of the mechanism 142 preferably induces a desired amount of curvilinearity to the extruded material 144 along a longitudinal length of the extruded material exiting the mechanism 142 to provide a substantially circular shape.
[0039] As depicted in FIG. 8 , this advantageously forms an orthogonal mating seam 148 between the leading and trailing edges of the extruded material 144 ; that is, the leading and trailing edges nominally align at the junction or seam 148 , ensuring substantially uniform thickness and eliminating voids or other discontinuities in the sealing material. It is contemplated that the seam 148 can remain visible in the sealing member at the conclusion of the subsequent curing process without affecting the operation thereof, and will enhance the hoop strength at the seam by facilitating improved joining of the leading and trailing edges. The extruded material 144 is thereafter cured in a suitable curing operation to form the sealing member.
[0040] When internal stiffening material is to be incorporated into the sealing member, the extruded material 144 can be formed hollow; that is, as shown in FIG. 7 , a central channel or interior cavity 150 extends through the extruded material 144 as it exits the extrusion mechanism 142 . A slit can be subsequently formed in the extruded material 144 along the internal cavity to facilitate placement of the stiffening material 134 therein.
[0041] Alternatively, as depicted in FIG. 10 , an extruded slit 152 can be formed in the extruded material 144 during the extrusion process, facilitating subsequent insertion of the stiffening material 134 . In either case, the extruded material 144 is thereafter cured in a suitable curing operation to form the sealing member.
[0042] While various embodiments presented above provide a sealing member with enhanced hoop strength in conjunction with the provision of an elongated circle cross-sectional shape, other embodiments disclosed herein are provided with alternative cross-sectional shapes. FIG. 9 , illustrating an alternative extrusion process similar to that set forth in FIG. 7 , depicts the use of an extrusion mechanism 166 and guide 168 to provide curvilinearly extending, uncured extruded material 170 that mates at an orthogonal seam, like the seam 148 of FIG. 8 . However, the extruded material 170 in FIG. 9 is provided with a substantially circular cross-sectional shape, unlike the elongated circle shape formed in FIG. 7 .
[0043] An interior cavity 172 is formed to extend the length of the material 170 to accommodate the placement of a suitable internal stiffening material 174 , and the formation of the interior cavity 172 during the extrusion process substantially ensures that the extruded material 170 will have a uniform thickness.
[0044] As desired, a slit can be cut at the internal diameter (ID) of the material 170 to facilitate placement of the stiffening material, or an extruded slit 178 can be formed during the extrusion process. Because the extrusion process precisely locates the centrally disposed cavity 172 , the cross-sectional shape of the material 170 can be varied as desired, such as that of an exemplary rounded rectangle cross-sectional shape as depicted in FIG. 11 .
[0045] FIGS. 12 and 13 further illustrate preferred aspects of the various extrusion processes disclosed herein. For clarity, FIGS. 12 and 13 are illustrated with respect to the extrusion process of FIG. 7 , although it will be understood that these figures can readily be adapted to the process of FIG. 9 .
[0046] In FIG. 12 , a housing 180 defines an interior sidewall 180 with a shape nominally conforming to the desired cross-sectional shape of the extruded material ( 144 in FIG. 7 ). A cantilevered, centrally disposed barrier 182 is supported by a support arm 184 to form the interior cavity 150 in the extruded material. As desired, the interior sidewall 180 can include a curvilinearly shaped exit portion 186 to initiate the desired curvilinearity along the longitudinal length of the extruded material 144 , with or without the further use of the external guide 146 .
[0047] FIG. 13 generally provides an end view of the arrangement of FIG. 12 . A diverting flange 188 extends from the barrier portion 182 in a direction substantially orthogonal to the support arm 184 ( FIG. 12 ). The flange 188 further interrupts the flow of the extruded material 144 to form the aforementioned slit 152 ( FIG. 7 ).
[0048] FIG. 14 provides a flow chart for a sealing member processing routine 200 , generally illustrative of preferred steps carried out in accordance with the foregoing discussion.
[0049] At extruding step 202 , a suitable sealing material is initially extruded from a suitable extrusion process such as depicted in FIGS. 7 , 9 and 12 - 13 . The extruded material (such as 144 ) will normally be in an uncured state such as an uncured elastomeric material. The extrusion process further imparts a desired level of curvilinearity to the extruded material 144 as it exits the extrusion process, assuring an orthogonal mating seam ( 148 , FIG. 8 ).
[0050] When an interior stiffening material is desired, the extruded material is supplied with an extruded central cavity, such as 150 in FIG. 7 or 172 in FIG. 9 . In such case a slit can be formed at slitting step 204 in the extruded material. This can be carried out by a separate slitting operation, or by extruding the slit into the extruded material 144 ( FIG. 13 ). Where employed, stiffening material can be inserted at a curing step 206 or at a stiffening step 208 described hereafter.
[0051] The extruded material is cured in a suitable curing operation at curing step 206 , which preferably involves placing the material in a molding cavity and subjecting the material to appropriate pressure and temperature conditions for a suitable dwell time associated with the material to effect the appropriate curing. Other arrangements, such as curing ovens, can also be used, as desired.
[0052] When an internal stiffening material is desired, the stiffening step 208 following curing will involve filling the internal cavity ( 150 or 172 ) with the selected material, and curing same as required. At application step 210 , the cured sealing member, following completion of the molding operation, can be used in an appropriate application to effect a fluid seal, such as in the valve member 100 depicted in FIGS. 2A and 2B . The process is completed at an end step 212 .
[0053] For purposes of the appended claims, the recited first means will be understood to correspond to the afore described sealing members that achieve enhanced hoop strength, namely the elongated circle cross-sectional shaped sealing member 112 of FIGS. 2A-2B and 3 - 5 ; the elongated circle cross-sectional shaped sealing member 132 with an associated internally disposed stiffening material core 134 of FIG. 6 ; and the extruded sealing members with respective circular and rounded rectangle cross-sectional shapes and interiorly placed stiffening material of FIGS. 10-11 . Prior art conventional O-rings as discussed in FIGS. 1A-1B , and prior art reinforced O-rings with molded in place reinforcement rings as disclosed by the aforementioned '299 patent process, are not included within the scope of the recited first means and are explicitly excluded from the definition of an equivalent.
[0054] Moreover, for purposes of the appended claims the term “elongated circle” will be understood to correspond to the shape as set forth in FIG. 5 in which a circle is linearly extended in a single direction (i.e., opposing 180 degree semicircular segments separated by linear line segments), and will thus exclude continuously curvilinear shapes such as ellipses and ovals, as well as segmented shapes such as a rounded rectangle.
[0055] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | Apparatus for controlling a pressurized fluid. In accordance with some embodiments, a valve assembly includes a piston moved between closed and open positions. A sealing member is disposed within an annular recess of the piston and characterized as an endless annular ring extending about a central axis of the piston. The sealing member has an elongated circle cross-sectional shape when the sealing member is in an uncompressed state prior to installation in said recess. The cross-sectional shape is defined by parallel top and bottom surfaces having a length L in a direction perpendicular to and intersecting the central axis, and having opposing inner and outer surfaces of a radius R, the inner and outer surfaces respectively facing toward and facing away from the central axis, and wherein the dimensional value of L is at least five times greater than the dimensional value of R. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. 119(e) to U.S. Provisional Application No. 61/238,195 filed Aug. 30, 2009, which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to apparatus and methods for assembling pipes, and more particularly to methods and systems for joining tubes for solar receivers.
[0004] 2. Discussion of the Background
[0005] Solar thermal power plants may be used to obtain electric power from the sun. In such plants, the solar flux impinges on tubes through which a heat exchange medium flows. In some solar thermal power plants, tubes are situated in a solar collector, such as along the axis of a parabolic trough. The heated heat exchange medium from the tubes may be used in a thermodynamic cycle to generate electric power.
[0006] FIG. 1A is a perspective view of a portion of a typical prior art concentrating solar power plant 100 comprising one or more solar energy collectors 110 arranged in a field. Each collector 110 includes one or more trough-shaped structures 113 having a reflective surface 119 , two or more ground supports 111 , an absorber tube 115 that extends the length of the collector, and tube supports 117 that couple the reflector to the absorber tube. It is not uncommon for each collector 110 to have a length A of approximately 380 feet (116 meters), a width B of approximately 20 feet (6 meters), and a height off the ground H greater than 10 feet (3 meters).
[0007] Typically, surfaces 119 have a longitudinal axis along length A and a parabolic shape in a plane perpendicular to the longitudinal axis, and absorber tube 115 is supported along the axis, such that light normally impinging on the reflector is focused (or concentrated) on the absorber tube. A mechanism (not shown) is provided to so rotate reflective surface 119 during the day to direct incident sunlight on absorber tube 115 and thus optimize the collection of solar energy on the tube.
[0008] Absorber tube 115 is generally hollow to permit the flow of a heat transfer medium, such as water, salt, or some other liquid or gas, along the absorber tube, thus collecting the concentrated solar energy. The exiting heat transfer medium may then, for example, be used to drive a turbine or heat engine (not shown) to generate electricity.
[0009] The construction of certain solar power plants 100 generally involves the following steps: 1) placing ground supports 111 in the field, 2) attaching trough-shaped structures 113 to the ground supports, and 3) joining absorber tube 115 to tube supports 117 . To facilitate construction, absorber tube 115 may be formed by joining many smaller tubes that are joined together. The smaller tubes are sometimes referred to as “solar receiver tubes” or “heat collection elements (HCE).”
[0010] FIG. 2 is a partial sectional side view of a prior art HCE 200 , FIG. 3 is an end view of the HCE, and FIG. 4 is a sectional end view of the HCE. HCE 200 may be, for example and without limitation, a SCHOTT solar receiver tube model PTR 70 (SCHOTT Solar, Inc., Albuquerque N. Mex.).
[0011] Typically, HCE 200 includes an outer tube 210 having a diameter D that is capped at each end by a metal flange 215 , an inner tube 211 and that is coaxial with the outer tube, and a metal bellows 213 that connects the flange and inner tube. Tube 210 is preferably optically transparent and is made, for example of a glass. Flange 215 is attached to a bellows 213 that extends to tube 211 . Tube 211 is thermally conductive, and may be formed from a metal, and has a length L and an inner diameter d, through which a heat transfer medium may flow. Tube 210 is generally transparent to sunlight to facilitate the solar heating of a heat exchange medium that may flow through glass tube 211 , as indicated by arrows in FIG. 2 . Tubes 210 and 211 , bellows 213 and flange 215 are sealed to form a volume 212 , which is evacuated to provide a high thermal insulation between tubes 210 and 211 .
[0012] In general, the length L is from 5 feet (1.5 m) to 20 feet (6 m), the diameter D is from 2 inches (50 mm) to 7 inches (0.18 m), and the diameter d is from 1 inch (25 mm) to 4 inches (0.1 m).
[0013] For certain HCEs 200 , tube 211 protrudes longitudinally beyond the end of each flange 215 by a distance S, which it typically from 0.375 inches (10 mm) to 4 inches (0.1 m). The portion of tube 211 that so protrudes is referred to as a collar 214 . Forming an absorber tube 115 requires joining collars 214 of adjacent absorber tubes. In certain other HCEs 200 , the free ends of flange 215 may also have a radial protrusion at the end.
[0014] FIG. 1B is a perspective view illustrating details of a prior art solar energy collector 110 . Absorber tube 115 is formed from a plurality of HCEs 200 , denoted 200 a , 200 b , and 200 c . The ends of each pair of HCEs are support by one tube support 117 .
[0015] One method for joining HCEs 200 is by orbital welding. One example of such a welder system is an Arc Machines model 207 power supply controller (Arc Machines, Inc., Pacoima, Calif.) with its mating 207-CW cooling package may be used with an Arc Machine 9-7500 welder.
[0016] Due their length, L, and glass components, solar receiver tubes tend to be fragile, and difficult to join, typically by welding, since the collars 214 protrude beyond the ends of the glass outer tube 210 by a relatively small distance from each end. Further, collars 214 are adjacent to bellows 213 , on whose integrity the vacuum of volume 212 depends. In addition, the height C may make it very difficult to place and manipulate a welder. Solar receiver tube are thus difficult to join, especially in the field, without damaging the more fragile glass outer tube 210 or the bellows 213 joining tubes 210 and 211 . There is a need in the art for methods and apparatus that permit the easy and rapid joining of such tubes to facilitate more efficient assembly of solar energy systems.
BRIEF SUMMARY OF THE INVENTION
[0017] In certain embodiments, an apparatus for welding the ends of a first and a second HCE is provided, where each HCE includes an outer collar and a concentric and inner tube. The apparatus includes: a first mechanism for accepting the first outer collar; a second mechanism for accepting the second outer collar; and a weld head. The first mechanism and second mechanism are attached to the weld head, and where at least one of the first mechanism and the second mechanism is adjustable to translate the accepted HCE in a longitudinal HCE direction.
[0018] In certain other embodiments, an apparatus for welding the ends of a first and a second HCE using a weld head is provided, where each HCE includes an outer collar and a concentric and inner tube. The apparatus includes: a first mechanism for accepting the first outer collar and adapted for attachment to the weld head; and a second mechanism for accepting the second outer collar and adapted for attachment to the weld head. When the first mechanism and the second mechanism are attached to the weld head, at least one of the first mechanism and the second mechanism is adjustable to translate the accepted HCE in a longitudinal HCE direction.
[0019] In certain embodiments, an apparatus for welding the ends of a first and a second HCE is provided. Each HCE includes an outer collar and a concentric and inner tube. The apparatus includes a weld head, a first means for clamping the first collar and longitudinally positioning the ends of an accepted first HCE; and a second means for clamping the second collar and longitudinally positioning the ends of an accepted second HCE. The first and second means permit locating the ends of the first HCE and second HCE for welding by the weld head.
[0020] In yet certain other embodiments, an apparatus for welding the ends of a first and a second HCE in a solar energy system at a height above the ground is provided, where each HCE includes an outer collar and a concentric and inner tube. The apparatus includes: a vehicle having a weld head, a welding power supply, and a platform to enable a user to reach the HCEs for welding.
[0021] In certain embodiments, a method of assembling a solar energy system is provided, where the solar energy system includes an absorber tube formed from a plurality of joined HCEs. The method includes: placing the plurality of HCEs in the solar energy system; moving a vehicle having a weld head, a welding power supply, and a platform to enable a user to reach the HCEs along the HCEs; and welding adjacent HCEs.
[0022] These features together with the various ancillary provisions and features which will become apparent to those skilled in the art from the following detailed description, are attained by the tube joining apparatus and method of the present invention, preferred embodiments thereof being shown with reference to the accompanying drawings, by way of example only, wherein:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0023] FIG. 1A is a perspective view of a portion of a typical prior art concentrating solar power plant;
[0024] FIG. 1B is a perspective view illustrating details of a prior art solar energy collector;
[0025] FIG. 2 is a partial sectional side view of a prior art heat collection element (HCE);
[0026] FIG. 3 is an end view of 2 - 2 of FIG. 2 ;
[0027] FIG. 4 is a sectional end view 3 - 3 of FIG. 2 ;
[0028] FIG. 5 is side view of a triple-joined HCE;
[0029] FIG. 6A is a side view of a field welding vehicle;
[0030] FIG. 6B is a top view of the field welding vehicle of FIG. 6A ;
[0031] FIG. 7A is a view of the back of the vehicle of FIG. 6A during a welding operation;
[0032] FIG. 7B is a cross-sectional view of HCEs near a weld location, illustrating the use of a traveling purge dam to isolate the region being welded;
[0033] FIG. 8A is a perspective view of an embodiment of a joining apparatus;
[0034] FIG. 8B is an exploded perspective view of an embodiment of a joining apparatus;
[0035] FIG. 9A is an end view of the apparatus of FIG. 8 illustrating the use of an adjustable FIG. in an open configuration;
[0036] FIG. 9B is an end view of the apparatus of FIG. 8 illustrating the use of an adjustable clamp in a closed configuration;
[0037] FIG. 10A as an exploded view of an adjustable clamping mechanism portion;
[0038] FIG. 10B as an assembled view of the adjustable clamping mechanism;
[0039] FIG. 11 is a top view 11 - 11 of FIG. 9A showing adjacent HCEs prior to welding within the lower part of a welding apparatus;
[0040] FIGS. 12A , 12 B, 12 C, and 12 D, which are sequential sectional side views 12 - 12 from FIG. 11 illustrating one embodiment of a method of joining HCEs; and
[0041] FIGS. 13A and 13B are side views different HCEs illustrating variations in HCE dimensions.
[0042] Reference symbols are used in the Figures to indicate certain components, aspects or features shown therein, with reference symbols common to more than one Figure indicating like components, aspects or features shown therein.
DETAILED DESCRIPTION OF THE INVENTION
[0043] In general, embodiments are provided that permit the field welding of tubes (HCEs) to form absorber tubes of solar energy systems. One embodiment of an apparatus for field welding tubes is illustrated in FIGS. 6A , 6 B, and 7 A, where FIG. 6A is a side view of a field welding vehicle 600 , FIG. 6B is a top view of the field welding vehicle, and FIG. 7A is a view of the back of the vehicle during a welding operation. Field welding vehicle 600 may be used, for example and without limitation to field weld a plurality of HCEs 200 to form an absorber tube 115 .
[0044] Field welding vehicle 600 includes and/or may supply all of the electricity and gases needed to operate welder 620 . Vehicle 600 may be, for example and without limitation a modified vehicle such as a cargo van or box truck. Thus, for example and without limitation, field welding vehicle 600 may include, but it not limited to, one or all of the following: a roof air-conditioning 601 for environmental control; a generator 603 within the vehicle for onboard operations; automatic self-leveling outriggers 605 to stabilize vehicle in work mode; and a slide out work platform 610 .
[0045] Platform 610 may include one or more of the following: a safety railing 611 , a safety rigging belt; a weld head holder bracket for welder 620 ; and auxiliary lighting for night work. Platform 610 may also include support arms 613 a and 613 b for alignment and support of adjacent HCEs 200 relative to welder 620 during welding, and power actuation of support arm, by electric, pneumatic, hydraulic means.
[0046] Prior to welding, the HCEs 200 for collector 110 are placed and secured by tube supports 117 in the approximate location where they will reside as absorber tube 115 . Thus, for example and without limitation, HCEs 200 are positioned in tube supports 117 . Structure 113 is rotated to a service position to provide access to HCEs 200 , as illustrated in FIG. 7A .
[0047] Alternatively, several HCEs 200 may be joined prior to being placed in collector 110 . Thus, two or more tubes may be pre-joined, as illustrated, without limitation in FIG. 5 as a side view of a triple-joined HCE 500 in FIG. 5 , having an end 501 and an end 503 . HCE 500 is formed by welding three HCE 200 ( 200 - 1 , 200 - 2 , and 200 - 3 ). Specifically, welds 505 are formed at end 203 of HCE 200 - 1 and end 201 of HCE 200 - 2 , and at end 203 of HCEs 200 - 2 and end 203 of HCE 200 - 3 . In general, the procedure for welding HCE 200 and 500 into collector 110 are the same.
[0048] Vehicle 600 , as shown in FIG. 7A , preferably starts at one end of collector 110 , joins collars 214 of a first set of adjacent ends 201 , 203 , 501 , or 503 (referred to in general as ends 201 or 203 ), then drives to the next set of ends for joining and stabilizes the vehicle with automatic self-leveling outriggers 605 .
[0049] As illustrated in FIG. 7A , the height H of absorber tube 115 off the ground is generally too high above ground level to be easily worked on. Thus field welding vehicle 600 may include a movable platform 610 to permit a worker to easily access to HCEs 200 .
[0050] A purge gas may be provided to the interior of the HCEs 200 by flowing the gas through the aligned HCEs. Alternative, as shown in FIG. 7B as a cross-sectional view of HCEs 200 near a weld location, a traveling purge dam 700 may be used to isolate regions of collars 214 a and 214 b being welded. After one weld is completed, dam 700 is pulled through HCEs 200 to the next weld location.
[0051] FIGS. 6B and 7A illustrate support arms 613 a and 613 b positioned off of platform 610 such that a worker may support ends 201 , 203 to facilitate joining the HCEs. Support arms 613 a and 612 b may include a cradle, or alternatively clamps, to restrain HCEs 200 near where welding is to occur, with sufficient spacing to permit access to welding equipment.
[0052] In one embodiment, a worker places adjacent HCEs in support arms 613 a and 613 b , and then positions welder 620 for welding. In another embodiment, welder 620 is manually placed by a worker. In another embodiment, welder 620 is supported by a “skyhook” or other devices on vehicle 600 .
[0053] In many instances, variations between different HCEs 200 or the placement in supports 117 requires that adjustments be made to adjacent tubes prior to welding. Thus, for example, slight longitudinal adjustments to the position of ends 201 , 203 (or 501 and 503 ) of adjacent HCEs 200 (or 500 ) may be required for welding. Longitudinal adjustments are provided by welder 620 .
[0054] In certain embodiments, welder 620 is a welding device that includes means for clamping the collar and longitudinally positioning the ends of accepted HCEs for proper welding. Welder 620 may thus include longitudinally adjustable clamps to accurately position collars 214 of adjacent HCEs 200 or 500 . As one embodiment, which is not meant to limit the scope of the present invention, FIG. 8A is a perspective views of an embodiment of a joining apparatus 800 , and FIG. 8B is an exploded perspective view of the joining apparatus. Apparatus 800 includes an adjustable left clamp 810 and an adjustable right clamp 820 , which are both means for clamping the collar and longitudinally positioning the ends of accepted HCEs
[0055] Joining apparatus 800 may be generally similar to welder 620 , and may include a joining device, such as an orbital welder 801 , an adjustable left clamp 810 and an adjustable right clamp 820 . Thus, for example, adjustable left clamp 810 may be used to restrain one HCE 200 , adjustable right clamp 820 may be used to restrain an adjacent HCE, and one or more of the left and right clamps may be used to position the HCEs respective collars for welding in welder 801 .
[0056] In one embodiment, orbital welder 801 may have an electrode 802 that moves along a circular path during welding to weld collars 214 of ends 201 , 203 . Clamps 810 and 820 are adapted to restrain a pair of adjacent HCEs 200 and provide for longitudinal alignment of the HCEs for proper welding in orbital welder 801 .
[0057] In another embodiment, orbital welder 801 includes a left clamp 803 , a left clasp 804 , and a left hinge 805 , and a right clamp 807 , a right clasp 808 , and a right hinge 809 . Adjustable left clamp 810 includes the left clamp 803 , clasp 804 , and hinge 805 , a bottom adjustable clamping portion 812 and a top adjustable clamping portion 815 . Bottom adjustable clamping portion 812 further includes a portion 812 a that is attached to welder 801 and a portion 812 b that moves longitudinally within portion 812 a according to the action of a lead screw 813 . Portion 812 b presents a bottom clamping surface 814 having a seating surface 811 . Top adjustable clamping portion 815 further includes a portion 815 a that is attached to left clamp 803 and a portion 815 b that moves longitudinally within portion 815 a according to the action of a top lead screw 816 . Portion 815 b presents a top clamping surface 817 having a seating surface 818 .
[0058] Adjustable right clamp 820 , which is similar to clamp 810 , includes the right clamp 807 , clasp 808 , and hinge 809 , a bottom adjustable clamping portion 822 , and a top adjustable clamping portion 825 . Bottom adjustable clamping portion 822 further includes a portion 822 a that is attached to welder 801 and a portion 822 b that moves longitudinally within portion 822 a according to the action of a lead screw 823 (which is shown FIG. 12A ). Portion 822 b presents a bottom clamping surface 824 having a seating surface 821 . Top adjustable clamping portion 825 further includes a portion 825 a that is attached to right clamp 807 and a portion 825 b that moves longitudinally within portion 825 a according to the action of a top lead screw 826 (shown in FIG. 12B ). Portion 825 b presents a top clamping surface 827 having a seating surface 828 .
[0059] Bottom adjustable clamping portions 812 and 822 are thus fixed to opposite sides of welder 801 , and top adjustable clamping portion 814 and 824 are affixed to clamps 803 and 807 , respectively. Clamp 810 and 820 and may be held in a partially locked or fully locked position by clasp 804 and 808 , respectively.
[0060] As discussed subsequently, lead screws 813 , 816 , 823 , and 826 may turned to longitudinally move seating surfaces 811 , 818 , 821 , and 828 . Thus when left clamping surfaces 814 and 817 are closed to restrain flange 215 of one HCE 200 , and right clamping surfaces 824 and 827 are closed to restrain the flange of an adjacent HCE, lead screws 813 , 816 , 823 , and 826 may be used to adjust the location of a welding electrode 802 relative to the ends of the HCEs
[0061] In certain embodiments, welder 801 and clamps 810 and 820 , when closed about HCEs 200 a and 200 b , for an enclosure about the welding location. The enclosure may be used, for example, to provide a purge gas to the outer portion of collars 214 during welding. In one embodiment, clamps 810 and/or 820 have components that cooperate to form an enclosure when clasps 804 and 808 are secured. FIGS. 8A and 8B show an enclosure portion 831 , which is attached to right clamp 810 , and enclosure portion 833 , which is attached to clamp 820 . Enclosure portions 831 and 833 permit clamps 810 and 820 to move separately, and to form an enclosure when securing HCEs 200 a and 200 b . In one embodiment, portion 833 may include a transparent material, such as a glass or plastic, to permit a user to inspect the placement and/or adjustment of electrode 802 relative to ends 201 and 203 prior to welding.
[0062] FIGS. 9A and 9B is an end view of apparatus 800 illustrating the use of adjustable clamp 810 . FIG. 9A is an open configuration, in which HCE 200 may be inserted or removed from apparatus 800 . FIG. 9B is a closed configuration, in which top portion is rotated and clasped. As shown in FIG. 9B , clamping surfaces 814 and 817 form a circular clamping surface that may be used to retain a flange 215 . Likewise, clamp 820 has a similar open configuration and a closed configuration in which clamping surfaces 824 and 827 may also be used to retain a flange 215 . Surfaces 814 , 817 , 824 , and 827 may be used to electrically collars 214 with respect to welder 801 .
[0063] Adjustable clamping portions 812 , 815 , 822 , and 815 are independently adjustable in a longitudinal direction (along the axis of an accepted HCE 200 or 500 ). Adjustable clamping portions 812 , 815 , 822 , and 815 are also identical, and are illustrated in FIG. 10A as an exploded view of an adjustable clamping mechanism adjustable clamping mechanism portion 1000 and in FIG. 10B as an assembled view of the adjustable clamping mechanism.
[0064] Adjustable clamping mechanism portion 1000 includes a welder mounting plate 1010 a slidable sleeve 1020 , and a lead screw 1030 . Mounting plate 1010 has a welder mounting surface 1017 , a sleeve guide 1015 , several guide pins 1011 surrounded by springs 1013 , and a treaded hole 1019 . Slideable sleeve 1020 has a semicircular portion 1023 with a clamping surface 1025 having an innermost edge 1026 , holes 1012 and 1028 , and a surface 1027 . Lead screw 1030 , which may have a knurled head, passes through hole 1028 and into treaded hole 1019 .
[0065] When mounting plate 1010 and sleeve 1020 are assembled, portion 1023 passes through sleeve guide 1015 , pins 1011 pass through holes 1012 and springs 1013 push against mounting plate 1010 and surface 1027 . As shown in FIG. 10B , the longitudinal distance between innermost edge 1026 and mounting surface 1017 , Z, is adjustable by turning lead screw 1030 .
[0066] With reference to FIGS. 8A , 8 B, 9 A 9 B, 10 A and 10 B, adjustable clamping mechanism portion 1000 corresponds to adjustable clamping portions 812 , 815 , 822 , and 825 ; mounting plate 1010 corresponds to portions 812 a , 815 a , 822 a , and 825 a , sleeve 1020 corresponds to portions 812 b , 815 b , 822 b , and 825 b , clamping surface 1025 corresponds to clamping surfaces 814 , 817 , 824 ; and 827 ; innermost edge 1026 , corresponds to seating surfaces 811 , 818 , 821 , and 828 ; lead screw 1030 corresponds to lead screws 813 , 816 , 823 , and 826 . Mounting plate 1010 may be either fixedly or removably attached to welder 801 , left clamp 803 and right clamp 807 for example and without limitation, by screws, clamps, slots, pins, adhesives, welding, or any other joining method.
[0067] FIG. 11 is a top view 11 - 11 of FIG. 9A showing adjacent HCEs 200 prior to welding within the lower part of apparatus 800 . As shown in FIG. 11 , a first HCE 200 a is resting in and/or supported by support arm 613 a and a second HCE 200 b is resting in and/or supported by support arm 613 b . Flange 215 a and 215 b are resting against clamp surface 824 and 814 , respectively, with ends 201 a and 203 b aligned along the centerlines of HCEs 200 a and 200 b , and positioned end-to-end near electrode 802 of welder 801 .
[0068] A method of aligning and welding HCEs 200 a and 200 b is illustrated in FIGS. 12A , 12 B, 12 C, and 12 D, which are sequential sectional side views 12 - 12 from FIG. 11 illustrating one embodiment of a method of joining HCEs. As shown in FIG. 12A , HCE 200 a is positioned with flange 215 a on clamping surface 824 and HCE 200 b is positioned with flange 215 b on clamping surface 814 .
[0069] As is also shown, each flange 215 has a lip 216 that slightly protrudes radially outwards from the flange. Although not a necessary part of HCE 200 , lip 216 may provide a convenient feature for locating the HCE. Other techniques for locating HCE 200 within apparatus 800 may be used, including visual inspection. With electrode 802 located near ends 201 a , 203 b , lead screws 813 and 823 are adjusted such that lip 216 a seats against seating surface 821 and lip 216 b seats against seating surface 811 .
[0070] FIG. 12A also illustrates the rotation of lead screws 813 and 823 to longitudinally translate portions 812 b and 822 b , respectively, relative to HCEs 200 a and 200 b . Lead screws 813 and 823 may be adjusted so that seating surfaces 811 and 821 , respectively, are brought in contact with lips 216 a and 216 b . In addition, lead screws 813 and 823 may be adjusted to bring the tip of electrode 802 in alignment with ends 201 a and 203 a.
[0071] Next, as shown in FIG. 12B , the top right clamp 820 is closed by rotating right clamp 807 over flange 215 a . With clasp 808 loosely tightened, lead screw 825 is adjusted such that lip 216 a seats against surface 828 .
[0072] As shown in FIG. 12C , the top left clamp 810 is closed by rotating left clamp 803 over flange 215 b . With clasp 804 loosely tightened, lead screw 813 is adjusted such that lip 216 b seats against surface 818 .
[0073] A final adjustment may now be made, as indicated in FIG. 12D . Specifically, it is important that lip 216 a seats against surfaces 821 and 828 , that lip 216 b seats against surface 811 and 818 , and that ends 201 a and 203 b align with the orbital motion of electrode 802 . Lead screws 813 , 816 , 823 , and 826 are rotated to achieve alignment. In one embodiment, a portion of enclosure portion 833 is a window 1200 , as shown in FIG. 12D , which allows a user to view the location of electrode 802 during this adjustment. Clasps 804 and 808 are then tightened to lock apparatus 880 onto HCEs 200 between seating surfaces 814 , 817 , 824 , and 827 .
[0074] At this point, the user initiates the welding sequence, which may include providing an external purge gas within welder 801 and initiating the movement of electrode 802 about ends 201 / 203 . When the weld in complete, the external purge gas flow is stopped, clasp 804 is released, clamp 803 is opened, and then clasp 808 is released and clamp 807 is opened, and apparatus 800 may be moved to the next weld location. In certain embodiments, portions 815 b and 825 b must be moved longitudinally away from each other to clear weld head 801 and permit clamps 803 and 807 to be opened.
[0075] The importance of being able to make fine adjustments is highlighted in FIGS. 13A and 13B , which are side views different HCEs illustrating variations in HCE dimensions. The dimension S is the distance from an edge of flange 215 , which may be lip 216 , to end 201 or 203 . FIG. 13A illustrates the case where the ends of adjacent HCE 200 a and 200 b have the same dimensions. Thus, the distance S=S 1 is the same for each, and the distance between adjacent lips 216 is G 1 =2 S 1 , and the weld occurs at the midpoint of G 1 . Importantly, G 1 is the space which a welder must fit to reach collars 214 .
[0076] FIG. 13B illustrates another case, were each distance S is different (one is S 1 , and the other S 2 ), the total distance between adjacent lips is G 2 =S 2 +S 3 , and the weld does not occurs at the midpoint, since S 2 does not equal S 3 . Since it is important that the tip of the weld electrode be in the vicinity of end 201 a / 203 b , and since flange 205 must be clamped for welding, it is important that both the spacing and the relative position of the HCEs and electrode be adjustable, as provided by apparatus 800 .
[0077] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.
[0078] Similarly, it should be appreciated that in the above description of embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention. | Apparatus and methods for assembling solar receiving tubes in the field are described. In one embodiment, a welder is provided having longitudinally adjustable clamps that permit the easy restraining and adjustment of tube position for welding. In another embodiment, a system for moving along the length of a solar collector and sequentially welding tubes is described. | 1 |
DESCRIPTION
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to rotary engines.
[0003] 2. Description of the Prior Art
[0004] Since the invention of the rotary pump in 1588 by Ramelli, the concept of a properly functioning internal combustion rotary engine has been the “Holy Grail” of engine design. The only rotary engine to be mass-produced was the Wankel Rotary Engine. Even since its first mass production in the 1970's, the rotary engine has not enjoyed widespread production or success.
[0005] The main advantage of the rotary engine is, as its name implies, is rotational energy. Unlike the piston engine, a crankshaft and complex set of connecting rods are not needed to convert the up and down motion of a piston into rotational energy. This conserves energy, weight and manufacturing costs. Rotary engines also are known for their small size and high power to weight ratio.
[0006] Historically, rotary engines have been plagued by several problems. Leakage under pressure has been a problem with designs since Ramelli first invented the rotary pump. Later internal combustion designs all had overheating as a common design fault. In the 1970's, General Motors abandoned an ambitious rotary engine project due to strict new environmental regulations on vehicle emissions. Additionally, rotary engines have had gas mileage far below the industry standard and are notorious for needing major engine seal repairs.
[0007] Several improvements to the Wankel design have been implemented One such improvement is the apex seal which serves to reduce friction and fuel loss through leakage under pressure. Significant problems with the design still exist:
[0008] (a) There are engine vibration problems. The rotor chums in such a way as to cause it to vibrate. A balance weight must be added to decrease these vibrations. Even with this added weight there are still noticeable vibrations. The weight, of course, reduces overall efficiency.
[0009] (b) There are friction problems. Indeed all engines have friction problems. Rotary engine designs however, have considerable friction. In the Wankel design, the rotor must make three rotations inside the engine chamber for the drive shaft to rotate once. This 3:1 rotor to drive shaft causes friction and heat problems.
[0010] (c) There is difficulty manufacturing the engine. To date only the Mazda RX-7 uses a rotary engine design. Other companies have constructed test engines, but have not mass-produced them.
[0011] (d) There is a waste problem with the fuel/air mixture leaking under pressure. In most designs, including the Wankel, a small amount of the fuel/air mixture used for combustion is lost during the engine rotation process. This is a design flaw. In the Wankel design's case, as the rotor rotates, there is also a point where some of the fuel/air mixture escapes via the exhaust port.
[0012] (e) There is difficulty in repairing the engine. Problems inside the rotor chamber are very difficult to get to.
SUMMARY OF THE INVENTION
[0013] Accordingly, the previous disadvantages are remedied in our invention. Several objects and advantages of the invention are:
[0014] (a) to provide an engine that has a low level of vibration without the use of balancing weights thus allowing for a lighter engine;
[0015] (b) to provide an engine with greatly reduced engine friction;
[0016] (c) to provide an engine that is relatively easy to manufacture;
[0017] (d) to provide an engine that comprises few parts;
[0018] (e) to provide an engine that is smaller and more compact than existing ones;
[0019] (f) to provide an engine that conserves the fuel/air mixture.
[0020] Further objects and advantages are to provide an engine that because of the above listed objects and advantages will allow for superior gas mileage and performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 shows an end view of an engine design incorporating an eccentric shaft with 6 chambers. Swivel-type separating vanes are attached to the rotor. This design incorporates a timing belt/chain to activate the valves.
[0022] [0022]FIG. 2 shows an end view of a four-chamber design attached directly to the main drive shaft with spring-loaded vanes, one of the possible embodiments of the design. This design incorporates a stationary gear to manipulate the timing gears and activate the valves.
[0023] [0023]FIG. 3 shows a simplified side view of the same four-chamber style engine as in FIG. 2.
[0024] [0024]FIG. 4 shows an end view of a four-chamber engine design with an eccentric shaft.
[0025] [0025]FIG. 5 shows a side view of the same four-chamber style engine as in FIG. 4.
[0026] [0026]FIG. 6 shows an end view of a variation of the design with sparkplugs and ports contained within the rotor. The rotor in this case, is stationary and the outer casing rotates.
[0027] [0027]FIG. 7 shows a side view of FIG. 6.
[0028] [0028]FIG. 8 show an end view of an engine design with an eccentric shaft with 4 chambers. Swivel vanes are attached to the engine casing in this embodiment
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] The engine has a casing ( 1 ), which can be of various shapes. The rotor ( 2 ), which also can be of various shapes, is contained inside casing ( 1 ) and sits slightly off center of the drive shaft. Separating vanes ( 3 ), create separate chamber rooms within the engine. Each engine chamber contains the means to intake, compress, combust, and expel a fuel mixture. This process enables the engine to create rotational energy.
[0030] An embodiment of the present invention is illustrated in FIG. 1.
[0031] The engine has a casing ( 1 ), which in this case, is a hexagon shape. The rotor ( 2 ), which is also a hexagon shape, is contained inside casing ( 1 ). Swivel-type separating vanes ( 3 ), create separate chambers ( 23 ) within the engine. Fuel/air mixture enters each engine chamber through an in-take port ( 17 ), and intake valve ( 4 ). Valve spring ( 26 ) applies constant pressure on the valve to keep it closed. The motion of rotor ( 2 ) then compresses the fuel/air mixture and combusts it using sparkplug ( 8 ) Expended gas is then expelled through exhaust valve ( 5 ) and exhaust port ( 18 ). Combustion causes rotor ( 2 ) to move about the chamber.
[0032] This motion is converted to rotational energy with eccentric shaft ( 21 ) causing drive shaft ( 7 ) to rotate as the action is repeated in another chamber.
[0033] For every two rotations of rotor ( 2 ) camshaft ( 9 ) rotates once. As camshaft ( 9 ) rotates, it moves cam ( 6 ), which in turn acts to manipulate rocker arm ( 25 ). It is this manipulation of rocker arm ( 25 ) which causes intake valves ( 4 ) and exhaust valves ( 5 ) to open and close in each chamber room ( 23 ).
[0034] The opening and dosing of the aforementioned valves accomplish replenishment of the fuel air mixture inside each separate chamber room ( 23 ). In this embodiment, the fuel/air mixture travels through the intake port ( 17 ) and then travels through intake valve ( 4 ) and is sucked into the airtight chamber room ( 23 ) created by rotor ( 2 ) and separating vanes ( 3 ). After combustion, the spent gas leaves the chamber through exhaust valve ( 5 ) into the exhaust port ( 18 ). From there the spent gas exits the engine.
[0035] Instead of using gears in this process other possible variations of this design include; using belts, chains, or nuts to rotate camshaft ( 9 ). There are also various possibilities envisioned for the separating vane system. An embodiment of one such possibility can be seen in FIG. 1 where swivel vanes are attached to the rotor and slide freely in and out of vane hole ( 34 ) and vane slot ( 31 ). FIG. 8 depicts a design with swivel vanes attached to engine casing ( 1 ) and sliding freely in and out of vane hole ( 34 ) and vane slot ( 31 ) located in the rotor in this embodiment. Sliding vanes which move through the rotor are another possibility for the separating vane system.
[0036] Any number of separating vanes ( 3 ) can be incorporated to allow for any number of chamber rooms ( 23 ). Any number of intake valves ( 4 ) and exhaust valves ( 5 ) may also be used. To prevent friction a ball bearing ( 16 ) or similar system can easily be installed for the separating vanes ( 3 ) Furthermore, a crank and cam shaft can accomplish the same vane manipulation. It should also be noted that variations of the design with or without an eccentric shaft are possible as represented in FIG. 4 and FIG. 2 respectively.
[0037] Given that the area where the rotor comes closest to the chamber wall in FIG. 1 with the spark plug being located at 0 degrees., 180 degrees marks the area where the rotor is furthest from the chamber wall. From 0 degrees to 180 degrees the intake valve is open. As the intake valve opens, the fuel air mixture enters the engine chamber.
[0038] From 180 degree to 360 degrees the intake valve is dosed and no l air mixture enters the chamber. At this time the fuel air mixture in the chamber is compressed. As the rotor nears a complete 360-degree cycle and the fuel air mixture is at its highest point of compression the spark plugs ignite. This combustion causes a rapid increase in chamber pressure causing the rotor to rotate. This occurs from 360 degrees to 540 degrees. After this point the exhaust valve opens and the spent gas is purged through the rotor and out the timing side exhaust hole. This purging process occurs from 540 degrees to 720 degrees.
[0039] Explanation of Four Engine Cycles:
[0040] Cycle one-intake process 0-180 degrees
[0041] Cycle two-compression press 180-360 degrees=one rotation
[0042] Cycle three-combustion process 360-540 degrees
[0043] Cycle four-purge process 540-720 degrees=two rotations
[0044] This invention achieves the same results in two rotations as does a conventional for-stroke internal combustion engine.
[0045] Accordingly, the reader will see that the invention described here has numerous advantages over existing designs. This invention is smaller and lighter than existing designs. Additionally, the advantages described will allow for superior gas mileage and performance in that this invention; solves vibration problems; eliminates the need for balance weights; has greatly reduced engine friction compared to the piston engine and existing rotor engine models; is easy to manufacture; solves existing rotary engine fuel/air mixture waste problems and is easy to maintain and repair because of its simplicity.
[0046] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of the engine. For example the engine can have any number of separating vanes or a slightly different shaped engine casing, etc.
[0047] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
[0048] Parts List
[0049] 1) Casing 17) Intake port
[0050] 2) Rotor 18) Exhaust port
[0051] 3) Separating vanes 21) Eccentric shaft
[0052] 4) Intake valve 22) Side seal
[0053] 5) Exhaust valve 23) Chamber room
[0054] 6) Cam 24) Vane spring
[0055] 7) Drive shaft 25) Rocker arm
[0056] 8) Spark plug or injector 26) Valve spring
[0057] 9) Cam shaft 31) Separating vane slot
[0058] 10) Timing gear 33) Timing belt
[0059] 11) Stationary gear 34) Separating vane hole
[0060] 12) Side casing 35) Separating vane swivel
[0061] 16) Shaft support bearings | An internal combustion rotary engine consisting of casing ( 1 ) housing a rotor positioned slightly off-center of drive shaft ( 7 ) allowing A to displace the fuel/air mixture about the engine chamber. ( 2 ) Separating vanes ( 3 ) create separate chamber rooms ( 23 ) within the engine. Each separate chamber room ( 23 ) has its own capability to accomplish the four Otto cycles; intake, compression, combustion and exhaust in a 720-degree rotation of rotor ( 2 ). Each chamber room ( 23 ) also has its own method for combustion ( 8 ) as well as a set of intake valves ( 4 ) and exhaust valves ( 5 ) which draw in and expel the fuel/air mixture, respectively. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application 60/607,975, filed Sep. 8, 2004, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to an electrically variable transmission having two motor/generators, two planetary gear sets, and five torque transfer devices arranged to provide improved launch, performance and gradeability.
BACKGROUND OF THE INVENTION
[0003] Internal combustion engines, particularly those of the reciprocating piston type, currently propel most vehicles. Such engines are relatively efficient, compact, lightweight, and inexpensive mechanisms by which to convert highly concentrated energy in the form of fuel into useful mechanical power. A novel transmission system, which can be used with internal combustion engines and which can reduce fuel consumption and emissions, may be of great benefit to the public.
[0004] Typically, a vehicle is propelled by such an engine, which is started from a cold state by a small electric motor and relatively small electric storage batteries, then quickly placed under the loads from propulsion and accessory equipment. Such an engine is also operated through a wide range of speeds and a wide range of loads and typically at an average of approximately a fifth of its maximum power.
[0005] A vehicle transmission typically delivers mechanical power from an engine to the remainder of a drive system, such as fixed final drive gearing, axles and wheels. A typical mechanical transmission allows some freedom in engine operation, usually through alternate selection of five or six different drive ratios, a neutral selection that allows the engine to operate accessories with the vehicle stationary, and clutches or a torque converter for smooth transitions between driving ratios and to start the vehicle from rest with the engine turning. Transmission gear selection typically allows power from the engine to be delivered to the rest of the drive system with a ratio of torque multiplication and speed reduction, with a ratio of torque reduction and speed multiplication known as overdrive, or with a reverse ratio.
[0006] An electric generator can transform mechanical power from the engine into electrical power, and an electric motor can transform that electric power back into mechanical power at different torques and speeds for the remainder of the vehicle drive system. This arrangement allows a continuous variation in the ratio of torque and speed between the engine and the remainder of the drive system, within the limits of the electric machinery. An electric storage battery used as a source of power for propulsion may be added to this arrangement, forming a series hybrid electric drive system.
[0007] The series hybrid system allows the engine to operate with some independence from the torque, speed and power required to propel a vehicle, so the engine may be controlled for improved emissions and efficiency. This system allows the electric machine attached to the engine to act as a motor to start the engine. This system also allows the electric machine attached to the remainder of the drive train to act as a generator, recovering energy from slowing the vehicle into the battery by regenerative braking. A series electric drive suffers from the weight and cost of sufficient electric machinery to transform all of the engine power from mechanical to electrical in the generator and from electrical to mechanical in the drive motor, and from the useful energy lost in these conversions.
[0008] A power-split transmission can use what is commonly understood to be “differential gearing” to achieve a continuously variable torque and speed ratio between input and output. An electrically variable transmission can use differential gearing to send a fraction of its transmitted power through a pair of electric motor/generators. The remainder of its power flows through another, parallel path that is all mechanical and direct, of fixed ratio, or alternatively selectable.
[0009] One form of differential gearing is a planetary gear set. Planetary gearing is usually the preferred embodiment employed in differentially geared inventions, with the advantages of compactness and different torque and speed ratios among all members of the planetary gear set. However, it is possible to construct this invention without planetary gears, as by using bevel gears or other gears in an arrangement where the rotational speed of at least one element of a gear set is always a weighted average of speeds of two other elements.
[0010] A hybrid electric vehicle transmission system also includes one or more electric energy storage devices. The typical device is a chemical electric storage battery, but capacitive or mechanical devices, such as an electrically driven flywheel, may also be included. Electric energy storage allows the mechanical output power from the transmission system to the vehicle to vary from the mechanical input power from the engine to the transmission system. The battery or other device also allows for engine starting with the transmission system and for regenerative vehicle braking.
[0011] An electrically variable transmission in a vehicle can simply transmit mechanical power from an engine input to a final drive output. To do so, the electric power produced by one motor/generator balances the electrical losses and the electric power consumed by the other motor/generator. A hybrid electrically variable transmission system in a vehicle includes an electrical storage battery, so the electric power generated by one motor/generator can be greater than or less than the electric power consumed by the other. Electric power from the battery can sometimes allow both motor/generators to act as motors, especially to assist the engine with vehicle acceleration. Both motors can sometimes act as generators to recharge the battery, especially in regenerative vehicle braking.
[0012] A successful substitute for the series hybrid transmission is the two-range, input-split and compound-split electrically variable transmission now produced for transit buses, as described in U.S. Pat. No 5,931,757, issued Aug. 3, 1999 to Michael R. Schmidt, and commonly assigned with the present application. Such a transmission utilizes an input means to receive power from the vehicle engine and a power output means to deliver power to drive the vehicle. First and second motor/generators are connected to an energy storage device, such as a battery, so that the energy storage device can accept power from, and supply power to, the first and second motor/generators. A control unit regulates power flow among the energy storage device and the motor/generators as well as between the first and second motor/generators.
[0013] Operation in first or second variable-speed-ratio modes of operation may be selectively achieved by using clutches in the nature of first and second torque transfer devices. In the first mode, an input-power-split speed ratio range is formed by the application of the first clutch, and the output speed of the transmission is proportional to the speed of one motor/generator. In the second mode, a compound-power-split speed ratio range is formed by the application of the second clutch, and the output speed of the transmission is not proportional to the speeds of either of the motor/generators, but is an algebraic linear combination of the speeds of the two motor/generators. Operation at a fixed transmission speed ratio may be selectively achieved by the application of both of the clutches. Operation of the transmission in a neutral mode may be selectively achieved by releasing both clutches, decoupling the engine and both electric motor/generators from the transmission output.
[0014] The two-range, input-split and compound-split electrically variable transmission may be constructed with two sets of planetary gearing or with three sets of planetary gearing. In addition, some embodiments may utilize three torque transfer devices—two to select the operational mode desired of the transmission and the third selectively to disconnect the transmission from the engine. In other embodiments, all three torque transfer devices may be utilized to select the desired operational mode.
[0015] U.S. Pat. No. 6,527,658, issued Mar. 4, 2003 to Holmes et al and commonly assigned with the present application, discloses an electrically variable transmission utilizing two planetary gear sets, two motor/generators and two clutches to provide input split, compound split, neutral and reverse modes of operation. Both planetary gear sets may be simple, or one may be individually compounded. An electrical control member regulates power flow among an energy storage device and the two motor/generators. This transmission provides two ranges or modes of electrically variable transmission (EVT) operation, selectively providing an input-power-split speed ratio range and a compound-power-split speed ratio range. One fixed speed ratio can also be selectively achieved.
SUMMARY OF THE INVENTION
[0016] The present invention provides an electrically variable transmission having two motor/generators, two differential gear sets such as planetary gear sets, and five torque transfer devices arranged to provide improved launch, performance and gradeability, and enabling five fixed speed ratios. “Gradeability” is a vehicle's ability to climb a grade at a given speed.
[0017] A fixed speed ratio is an operating condition in which the mechanical power input to the transmission is transmitted mechanically to output, and no power flow is necessary through the motor/generators. An electrically variable transmission that may selectively achieve several fixed speed ratios for operation near full engine power can be smaller and lighter for a given maximum capacity. Fixed ratio operation may also result in lower fuel consumption when operating under conditions where engine speed can approach its optimum without using the motor/generators.
[0018] The invention also provides a new and novel electrically variable transmission, as above, that can be manufactured at a significant cost reduction relative to prior known electrically variable transmissions. The present invention may achieve this through the use of additional clutches to provide fixed speed ratios and therefore allow smaller electrical components, and the use of only two planetary gear sets, the minimum for a compound power split arrangement.
[0019] These and other aspects of the invention, as well as the advantages thereof over existing and prior art forms, which will be apparent in view of the following detailed specification, are accomplished by means hereinafter described and claimed.
[0020] By way of a general introductory description, an electrically variable transmission embodying the concepts of the present invention has an input member to receive power from an engine and an output member to deliver power to the drive members that propel the vehicle. There are first and second motor/generators as well as first and second planetary gear sets. Each planetary gear set has an inner gear member and an outer gear member that meshingly engages a plurality of planet gear members rotatably mounted on a carrier. The input member is continuously connected to one member (preferably a ring gear) of the first planetary gear set, and the output member is continuously connected to one member (preferably a carrier) of the second planetary gear set. One motor/generator is continuously connected to another member (preferably a sun gear) in the first planetary gear set as well as being selectively connected to a member (preferably a ring gear) of the second planetary gear set. The second motor/generator is continuously connected to the remaining member (preferably a sun gear) of the second planetary gear set, and is selectively connected to the remaining member (preferably a carrier) of the first planetary gear set.
[0021] Preferably, the first planetary gear set is a compound planetary gear set, and the second planetary gear set is a simple planetary gear set.
[0022] A first torque transfer device (CB 12 R) selectively grounds the ring gear of the second planetary gear set, and a second torque transfer device (C 234 ) selectively connects the ring gear of the second planetary gear set to the sun gear of the first planetary gear set as well as to the rotor of one motor/generator.
[0023] A third torque transfer device (CA) selectively connects the carrier of the first planetary gear set to ground.
[0024] A fourth torque transfer device (CB) selectively connects the carrier of the first planetary gear set to the sun gear of the second planetary gear set.
[0025] A fifth torque transfer device (C 13 ) selectively connects the ring gear of the first planetary gear set with the sun gear of the second planetary gear set.
[0026] Preferably, the first, third and fifth torque transfer devices are engaged during launch so that the first and second planetary gear sets operate in underdrive to increase torque output to the output member.
[0027] The above features and advantages, and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a schematic lever diagram representing one preferred form of an electrically variable transmission embodying the concepts of the present invention;
[0029] FIG. 2 is a partial schematic lever diagram illustrating only those torque transmitting mechanisms which are engaged during battery-only launch in the lever diagram of FIG. 1 to illustrate torque multiplication; and
[0030] FIG. 3 is a chart illustrating clutching engagements for fixed speed ratio operation of the transmission represented by the lever diagram of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] An electromechanical transmission is described in commonly assigned U.S. Provisional Ser. No. 60/590,427, entitled “Electrically Variable Transmission with Selective Fixed Ratio Operation,” by Holmes et al., filed Jul. 22, 2004, and hereby incorporated by reference in its entirety.
[0032] With reference to the lever diagram of FIG. 1 , a preferred embodiment of the improved electrically variable transmission is designated generally by the numeral 10 . Transmission 10 is designed to receive at least a portion of its driving power from an engine 12 . The engine 12 has an output shaft that may also serve as the forward input member of a transient torque damper (not shown). Transient torque dampers are well known in this art, but irrespective of the particular transient torque damper employed, the output member thereof serves as the input member 18 of the transmission 10 .
[0033] In the embodiment depicted, the engine 12 may be a fossil fuel engine, such as a diesel engine which is readily adapted to provide its available power output typically delivered at a constant number of revolutions per minute (RPM).
[0034] Irrespective of the means by which the engine 12 is connected to the transmission input member 18 , the transmission input member 18 is operatively connected to a compound planetary gear set 20 in the transmission 10 .
[0035] The transmission 10 utilizes two differential gear sets, preferably in the nature of planetary gear sets. The first planetary gear set 20 is a planetary gear set. It employs an outer gear member 22 , typically designated as the ring gear, which circumscribes an inner gear member 24 , typically designated as the sun gear. A carrier 26 rotatably supports a plurality of planet gears such that one set of planet gears meshingly engages the outer, ring gear member 22 and another set of planet gears meshingly engages the inner, sun gear member 24 of the first planetary gear set 20 . The input member 18 is secured to the ring gear member 22 of the first planetary gear set 20 .
[0036] The second planetary gear set 32 is a simple planetary gear set, and also has an outer gear member 34 , often also designated as the ring gear, that circumscribes an inner gear member 36 , also often designated as the sun gear. A plurality of planet gears are also rotatably mounted in a carrier 40 such that each planet gear member simultaneously, and meshingly, engages both the outer, ring gear member 34 and the inner, sun gear member 36 of the second planetary gear set 32 .
[0037] The preferred embodiment 10 also incorporates first and second motor/generators 46 and 48 , respectively. The stator of the first motor/generator 46 is secured to the transmission housing 54 . The rotor of the first motor/generator 46 is secured the inner, sun gear 24 of the first planetary gear set 20 .
[0038] The stator of the second motor/generator 48 is also secured to the transmission housing 54 . The rotor of them second motor/generator 48 is secured to the sun gear 36 of the second planetary gear set 32 .
[0039] The two planetary gear sets 20 and 32 as well as the two motor/generators 46 and 48 may be coaxially oriented. This configuration assures that the overall envelope—i.e., the circumferential dimension—of the transmission 10 may be minimized.
[0040] The ring gear 34 of the second planetary gear set 32 is selectively grounded to the housing 54 , as by a first clutch means in the nature of a torque transfer device 62 (CB 12 R). That is, the grounded ring gear 34 is selectively secured against rotation by an operative connection to the non-rotatable housing 54 . The ring gear 34 of the second planetary gear set 32 is also selectively connected to the sun gear 24 of the first planetary gear set 20 , as by a second clutch means in the nature of a torque transfer device 64 (C 234 ). The first and second torque transfer devices 62 and 64 are employed to assist in the selection of the operational modes of the hybrid transmission 10 .
[0041] A third torque transfer device 65 (CA) selectively connects the carrier 26 with the transmission housing 54 .
[0042] A fourth torque transfer device 67 (CB) selectively connects the carrier 26 to the sun gear 36 . A fifth torque transfer device 68 (C 13 ) selectively connects the ring gear 22 with the sun gear 36 .
[0043] The output drive member 70 of the transmission 10 is secured to the carrier 40 of the second planetary gear set 32 , for transmitting power to the final drive 72 .
[0044] Returning now to the description of the power sources, it should be apparent from the foregoing description, and with particular reference to FIG. 1 , that the transmission 10 selectively receives power from the engine 12 . As described in the above-referenced U.S. Provisional Ser. No. 60/590,427, the hybrid transmission also receives power from an electric power source. The electric power source may be one or more batteries. Other electric power sources, such as fuel cells, that have the ability to provide, or store, and dispense electric power may be used in place of batteries without altering the concepts of the present invention.
[0045] The electric power source communicates with an electrical control unit (ECU) by electrical transfer conductors. The ECU communicates with the first motor/generator 46 and the second motor/generator 48 via electrical transfer conductors.
[0046] FIG. 2 is a partial lever diagram illustrating only those torque transfer devices which are engaged during battery-only launch (in forward or reverse) for the transmission 10 of FIG. 1 in order to illustrate torque multiplication. Lever diagrams are commonly used to represent planetary gear arrangements, as described in SAE paper 810102, “The Lever Analogy: A New Tool in Transmission Analysis”, Feb. 23, 1981.
[0047] As shown in FIG. 2 , in battery-only launch, the torque transfer devices 62 , 65 and 68 are engaged. In this configuration the lever associated with the first planetary gear set 20 operates in underdrive mode and multiples the torque of motor/generator 46 . This torque is represented by the following formula: T(R)=T(A)*(R 1 /S 1 ), where T(R 1 ) is the torque at ring gear 22 , T(A) is the torque of motor/generator 56 , and R 1 /S 1 is the ring gear/sun gear tooth ratio of the planetary gear set 20 . This torque T(A) is transmitted to the sun gear 36 via the torque transfer device 68 . Hence, the total torque at the sun gear 36 is T(S 2 )=(T(A)*(R 1 /S 1 )+T(B)), where T(A) is the torque of motor/generator 56 , R 1 /S 1 is the ring gear/sun gear tooth ratio of the planetary gear set 20 , and T(B) is the torque of motor/generator 48 .
[0048] The lever associated with the second planetary gear set 32 multiplies the torque of the sun gear 36 because it is operating in underdrive. The output torque is therefore: T(OUT)=(T(A)*(R 1 /S 1 )+T(B))*(1+R 2 /S 2 ), where T(A) is the torque of motor/generator 56 , R 1 /S 1 is the ring gear/sun gear tooth ratio of the planetary gear set 20 , T(B) is the torque of motor/generator 48 , and R 2 /S 2 is the ring gear/sun gear tooth ratio of the planetary gear set 32 .
[0049] Therefore, both levers work in underdrive mode, and hence deliver a higher value of output torque than the total torque input by the motor/generators 46 and 48 . This higher value of output torque results in improved launch, performance and gradeability. The launch direction can be switched from reverse to forward, and vice versa, by simply reversing the motor direction.
[0050] FIG. 3 shows a chart illustrating clutching engagements for fixed speed ratio operation of the transmission represented by the lever diagram of FIG. 1 . For example, in the first fixed speed ratio the torque transfer devices 68 and 62 are engaged, and in the fifth fixed forward speed ratio the torque transfer devices 65 , 64 and 67 are engaged.
[0051] While only the preferred embodiment of the present invention is disclosed, it is to be understood that the concepts of the present invention are susceptible to numerous changes apparent to one skilled in the art. Therefore, the scope of the present invention is not to be limited to the details shown and described but is intended to include all variations and modifications which come within the scope of the appended claims. | The present invention provides an electrically variable transmission having two motor/generators, two differential gear sets such as planetary gear sets, and five torque transfer devices arranged to provide improved launch, performance and gradeability, and enabling five fixed speed ratios. An input member is continuously connected to one member (preferably a ring gear) of the first planetary gear set, and an output member is continuously connected to one member (preferably a carrier) of the second planetary gear set. One motor/generator is continuously connected to another member (preferably a sun gear) in the first planetary gear set as well as being selectively connected to a member (preferably a ring gear) of the second planetary gear set. The second motor/generator is continuously connected to the remaining member (preferably a sun gear) of the second planetary gear set, and is selectively connected to the remaining member (preferably a carrier) of the first planetary gear set. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a laser drive circuit for controlling a laser beam such as a magneto-optical disk drive, and more particularly to a laser drive circuit for precisely controlling a laser beam intensity.
2. Related Background Art
In a prior art magneto-optical disk drive, a laser beam is irradiated to a recording medium having a magnetic film having a vertical magnetic anisotropy to locally raise a temperature while an external magnetic field is applied to orient the magnetization at the local point along a direction of the magnetic field.
In the magneto-optical recording, since the light beam and the magnetic field are used, a magnetic field modulation system in which a signal is converted to a magnetic field for recording, or a light modulation system in which the signal is converted to the turn-on and the turn-off of a laser beam for recording may be used. In the light modulation system, a magnetic field is applied along a direction of record and the signal is recorded by turning on and off the laser beam.
In the light modulation system, since the laser beam is turned on and off, a laser drive circuit for modulating a laser beam power between a maximum power and a minimum power in accordance with the values (binary values) of the record signal is required.
FIG. 1 shows a configuration of a prior art laser drive circuit disclosed in Japanese Laid-Open Patent Application No. 2-166636. A portion of a laser beam L1 emitted from a semiconductor laser LD is detected by a photo-detector PD. The detection output is amplified by an amplifier 1 which produces a detection signal S PDIO , which is applied to two sample-and-hold circuits 2 and 3 which sample and hold the detection signal. A timing of the sampling and the holding is controlled by a pulse generator 4 which receives a record signal S REC and generates a sampling pulse S PH at the rise of the record signal S REC and generates a sampling pulse S PL at the fall of the record signal S REC . The timing of the sampling and the holding is determined in accordance with the condition of the record signal. When the record signal S REC is at an H-level, a laser beam intensity from the semiconductor laser LD is maximum, and when it is at an L-level, the laser beam intensity from the semiconductor laser LD is minimum. The control to modulate the laser beam intensity in this manner is conducted by a laser drive amplifier 5.
When the record signal S REC is at the H-level, the detection signal S PDIO is sampled and held by the sample and hold circuit 2, and when the record signal S REC is at the L-level, the detection signal S PDIO is sampled and held by the sample and hold circuit 3. The timing of the sampling and the holding is controlled by the pulse generator 4, which receives the record signal S REC and generates the sampling pulse S PH at the rise of the record signal S REC and generates the sampling pulse S PL at the fall of the record signal S REC .
The hold voltages V HH and V HL produced by sampling and holding by the two sample and hold circuits 2 and 3 are applied to differential amplifiers 6 and 7, respectively. The differential amplifier 6 produces a maximum error voltage V ERH which is a difference between the hold voltage V HH and a maximum reference voltage V RH , and the differential amplifier 7 produces a minimum error voltage V ERL which is a difference between the hold voltage V HL and a minimum reference voltage V RL . The maximum error voltage V ERH and the minimum error voltage V ERL are applied to the laser drive amplifier 5 so that a maximum power and a minimum power of the laser beam L1 of the semiconductor laser LD are feedback-controlled.
FIG. 2 shows a configuration of the laser drive amplifier 5 disclosed in the above-mentioned Japanese Laid-Open Patent Application No. 2-166636. In the laser drive amplifier 5, the record signal S REC and an inverted record signal are applied to first and second input terminals a and b, and the maximum error voltage V ERH and the minimum error voltage V ERL are applied to third and fourth input terminals c and d.
The laser drive amplifier 5 controls the laser drive current Id in accordance with the level of the input record signal S REC so that the laser beam at the minimum power or the maximum power is emitted from the semiconductor laser LD.
In this manner, the laser beam emitted from the semiconductor laser is modulated between the maximum power and the minimum power, and the maximum power and the minimum power are separately feedbackcontrolled.
By the above configuration, the laser beam intensity is controlled to the predetermined maximum power or minimum power.
The prior art laser drive circuit of the magneto-optical disk drive has the following disadvantages.
An operational characteristic of the sample and hold circuit in the prior art laser drive circuit generally includes a linearity error and a gain error.
The linearity error and the gain error are further explained. An input voltage and a hold voltage of the sample and hold circuit have a relationship as shown in FIG. 3. A characteristic between the input voltage and the hold voltage generally includes the linearity error and the gain error.
Theoretically, the input voltage and the hold voltage are in a proportional relationship, but in actual a graph showing the relationship therebetween is not linear as shown in FIG. 3 in which the increase of the hold voltage decreases as the input voltage becomes higher. An error caused by this characteristic is called the linearity error. Thus, the linearity error is larger as the input voltage becomes higher.
Theoretically, a gain of the hold voltage to the input voltage is unity (that is, a graph of the input voltage versus the hold voltage is a straight line with a unity gradient), but in actual it is smaller than unity. An error caused by this characteristic is called the gain error.
The hold voltage produced by the sample and hold circuit includes the errors due to the linearity error and the gain error. When such a hold voltage is fed back to the semiconductor laser to control the laser beam intensity, it is not possible to exactly control the laser beam intensity to the predetermined level.
When a sample and hold circuit with a small error is to be designed, a construction is complex and a cost is high.
Further, it is required that the modulation of the laser beam power between the maximum power and the minimum power is done at a high speed. This requirement is further emphasized when a higher recording density of the optical recording medium is desired. In order to modulate the laser beam at the high speed, it is necessary that the sample and hold circuit operates at the high speed, but the above error is larger in a high speed sample and hold circuit. To reduce the error, the cost is higher.
The above problems occur in the record mode as well as in the reproduction and erase modes. In the prior art laser drive circuit, since the detection signal from the photo-detector is applied to the sample and hold circuit even in the reproduction and erase modes, it is affected by the linearity error and the gain error so that the laser beam intensity cannot be exactly controlled to the predetermined level.
In the prior art laser drive circuit, when the minimum reference voltage is varied in the differential amplifier 6 to vary the minimum error voltage applied to the input terminal d (see FIG. 3) of the laser drive amplifier 7, a current I1 which flows in a transistor Q4 also varies. As a result, when a transistor Q3 is activated, the maximum power of the laser beam varies with the change of the current. In order to prevent the change of the maximum power, the maximum error voltage must be set in accordance with the change of the minimum error voltage, and the control is complex.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a laser drive circuit which does not cause the deterioration of the controllability of a laser beam intensity by the affect of a linearity error and a gain error of a sample and hold circuit.
It is another object of the present invention to provide a laser drive circuit which can maintain a maximum or minimum power of a laser beam when the other power is varied.
In order to achieve the above objects, the present invention provides a laser drive circuit for modulating a laser beam intensity emitted from a laser device to a maximum power and a minimum power in accordance with a first and second values of a binary signal, comprising: a photo-detector for detecting the laser beam emitted from the laser device to produce a detection output signal; a first differential amplifier for producing a maximum error detection signal representing a difference between the detection output signal applied thereto and a maximum reference; a second differential amplifier for producing a minimum error detection signal representing a difference between the detection output signal applied thereto and a minimum reference; a first sample and hold circuit for sampling and holding the maximum error detection signal at a timing of the first value of the binary signal and outputting the same as a maximum error signal; a second sample and hold circuit for sampling and holding the minimum error detection signal at a timing of the second value of the binary signal and outputting the same as a minimum error signal; and a laser drive amplifier for controlling the maximum power and the minimum power of the laser beam emitted from the laser device in accordance with the maximum error signal and the minimum error signal.
In the above construction, the detection output signal from the photo-detector for detecting the laser beam is applied to the first and second differential amplifiers. The first differential amplifiers produces the maximum error detection signal, which is held by the first sample and hold circuit. The second differential amplifier produces the minimum error detection signal, which is held by the second sample and hold circuit. The timing of holding by those two sample and hold circuits is such that the first sample and hold circuit holds it when the record signal is of the first value, and the second sample and hold circuit holds it when the record signal is of the second value. The signals held by the two sample and hold circuits represent the errors to the maximum power and the minimum power, respectively, of the laser beam emitted. Accordingly, by feeding back the outputs of the two sample and hold circuits to the laser drive amplifier, the laser beam intensity emitted from the laser device may be controlled to the predetermined maximum power or minimum power.
In accordance with another aspect of the present invention, there is provided a laser drive circuit comprising: a monitor for monitoring a laser beam; a sample and hold circuit for sampling and holding an output of the monitor; a differential amplifier for producing a first error signal representing a difference between a level of a hold signal sampled and held by the sample and hold circuit and a predetermined first reference; an error detection circuit for producing a second error signal representing a difference between an output level of the monitor and a predetermined second reference, a laser driver for controlling a laser beam intensity in accordance with the first error signal or the second error signal; and a switch for selectively applying to the laser driver the first error signal when the laser beam is modulated and the second error signal when the laser beam is not modulated.
In accordance with other aspect of the present invention, there is provided a laser drive circuit comprising: a monitor for monitoring a laser beam; a differential amplifier for producing a first error signal representing a difference between an output from the monitor and a predetermined first reference; a sample and hold circuit for sampling and holding the first error signal; an error detection circuit for producing a second error signal representing a difference between the output level of the monitor and a predetermined second reference; a laser driver for controlling a laser beam intensity in accordance with a hold signal sampled and held by the sample and hold circuit and the second error signal; and a switch for selectively supplying to the laser driver the hold signal when the laser beam is modulated and the second error signal when the laser beam is not modulated.
In the above construction, when the laser beam is not modulated, the output from the monitor for monitoring the laser beam is applied to the laser driver through the error detection circuit so that it is not affected by the sample and hold circuit.
When the laser beam is modulated, the first error signal which represents the difference between the output from the monitor and the first reference is produced by the differential amplifier and it is supplied to the sample and hold circuit so that the affect of the linearity error and the gain error of the sample and hold circuit is eliminated.
In accordance with a further aspect of the present invention, there is provided a laser drive circuit comprising: a first output setting circuit for setting a first setting corresponding to a minimum power of a laser beam emitted from a laser drive; a second output setting circuit for setting a second setting corresponding to a maximum power of the laser beam; a subtractor for producing a difference between the second setting and the first setting; and a laser drive amplifier for superimposing a signal corresponding to the output of the subtractor onto a signal representing the first setting and supplying the superimposed signal to the laser device.
In the above construction, the first output setting circuit sets the first setting corresponding to the minimum power of the laser beam of the laser device and supplies it to the subtractor and the laser drive amplifier, and the second output setting circuit sets the second setting corresponding to the maximum power of the laser beam and supplies it to the subtractor, which subtracts the first setting from the second setting and supplies the resulting output to the laser drive amplifier, which in turn superimposes a pulsive signal having an amplitude corresponding to the output of the subtractor to the signal representing the first setting of the first output setting circuit at a predetermined interval and supplies the superimposed signal to the laser device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a configuration of a prior art laser drive circuit,
FIG. 2 shows a configuration of a laser drive amplifier in FIG. 1.
FIG. 3 shows a relationship between an input voltage and a hold voltage of a sample and hold circuit,
FIG. 4 shows a block diagram of a configuration of a laser drive circuit in accordance with a first embodiment of the present invention,
FIGS. 5A to 5F show timing charts of an operation of the laser drive circuit in the first embodiment of the present invention,
FIG. 6 shows a configuration of a laser drive circuit in accordance with a second embodiment of the present invention,
FIG. 7 shows a configuration of a laser drive circuit in accordance with a third embodiment of the present invention,
FIG. 8 shows a configuration of a laser drive circuit in accordance with a fourth embodiment of the present invention, and
FIGS. 9A to 9D show waveforms for explaining an operation of the laser drive circuit in the fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 4 shows a block diagram of a configuration of a laser drive circuit in accordance with a first embodiment of the present invention, and FIGS. 5A to 5F show timing charts for explaining an operation of the laser drive circuit.
In FIG. 4, a portion of a laser beam L1 emitted from a semiconductor laser LD is detected by a photo-detector PD, and a detection output is applied to an amplifier 1 where it is amplified. An amplified detection output signal S PD (FIG. 5B) from the amplifier 11 is applied to a first differential amplifier 12 and a second differential amplifier 13.
The detection output signal S PD applied to the first differential amplifier 12 is compared with a maximum reference voltage V RH (which is applied to the first differential amplifier 12) to determine a difference between S PD and V RH to produce a maximum error detection signal S EH (see FIG. 5C), which is applied to a first sample and hold circuit 14.
The detection output signal S PD applied to the second differential amplifier 13 is compared with a minimum reference voltage V RL (which is applied to the second differential amplifier 13) to determine a difference between S PD and V RL to produce a minimum error detection signal S EL (FIG. 5D), which is applied to a second sample and hold circuit 15.
The first sample and hold circuit 14 and the second sample and hold circuit 15 sample and hold the maximum error detection signal S EH and the minimum error detection S EL applied thereto, respectively, at a timing of a first sampling pulse S SH and a second sampling pulse S SL , respectively, applied from a pulse generator 16.
A first hold voltage (an output of the first sample and hold circuit 14) and a second hold voltage (an output of the second sample and hold circuit 15) produced by the sampling and the holding are applied to a laser drive amplifier 5 as the maximum error voltage V EH and the minimum error voltage V EL , respectively.
A record signal S WR (see FIG. 5A) is applied to the pulse generator 16. The detection output from the photo-detector PD has a waveform which depends on the record signal S WR . Accordingly, the detection output signal S PD (which is the amplified version of the detection output) from the amplifier 11 has a waveform which depends on the record signal S WR (see FIG. 5B). The pulse generator 16 generates a first sampling pulse S SH (see FIG. 5E) which rises at a rise timing of the record signal S WR and a second sampling pulse S SL (see FIG. 5F) which rises at a fall timing of the record signal S WR . The first sampling pulse S SH is applied to the first sample and hold circuit 14 and the second sampling pulse S SL is applied to the second sample and hold circuit, and they are sampled and held by the sample and hold circuits, respectively.
In the laser drive amplifier 5, the record signal S WR and the inverted record signal are applied to first and second input terminals a and b, respectively, and the maximum error voltage V EH and the minimum error voltage V EL are applied to third and fourth input terminals c and d, respectively.
In the laser drive amplifier 5, the laser drive current I LD is switched in accordance with the level of the input record signal S WR so that the laser beam of the minimum power or the maximum power is emitted from the semiconductor laser LD.
In the present laser drive circuit, a separate feedback loop is configured for each of the maximum power and the minimum power of the laser beam L1 as a whole laser drive circuit.
In the laser drive circuit, the feedback loop functions to keep the hold voltages of the first sample and hold circuit 14 and the second sample and hold circuit 15 at zero volt, because the feedback loop acts to keep the maximum error detection signal S EH and the minimum error detection signal S EL produced by the differential amplifiers 12 and 13 at zero level.
In the present laser drive circuit, the first and second sample and hold circuits operate around zero hold voltage when the feedback loop is relatively stable. As a result, the sample and hold circuits operate in a range in which the absolute values of the linearity error and the gain error in FIG. 3 are small.
In accordance with the present invention, even if the input level versus hold level characteristic of the sample and hold circuit includes the linearity error and the gain error, those errors hardly appear in the output of the sample and hold circuit and the desired laser beam intensity is attained with a high precision.
FIG. 6 shows a configuration of a laser drive circuit in accordance with a second embodiment of the present invention. Numerals 1 to 7 designate the same elements as those shown in FIG. 1. A reproduction reference voltage V RR which is a reference voltage in a reproduction mode and an erase reference voltage V RE which is a reference voltage in an erase mode are supplied to a switch 21. An erase status signal is applied to the switch 21. The erase status signal is generated when a magneto-optical disk drive erases a signal from a recording medium. When the erase status signal is generated, the switch 21 selects the erase reference voltage V RE , and when the erase status signal is not generated, it selects the reproduction reference voltage V RR .
An error detection circuit 22 compares the level of the detection output S PDIO from the amplifier 1 and the reference voltage (the reproduction reference voltage V RR or the erase reference voltage V RE ) from the switch 21 to produce an error detection signal V EC representing a difference therebetween.
The error detection signal V EC from the error detection circuit 22, and the maximum error voltage V ERH and the minimum error voltage V ERL from the differential amplifiers 6 and 7 are applied to a switch 23. A write status signal and the erase status signal are applied to the switch 23. The write status signal is generated when the magnetooptical disk drive records a signal to the recording medium. The write status signal and the erase status signal are produced by a control CPU which is external to the present circuit. When the write status signal is generated, the switch 23 selects the maximum error voltage V ERH and the minimum error voltage V ERL , and when the erase status signal is generated or when more of the write status signal and the erase status signal is not generated, it selects the error detection signal V EC . The output of the switch 23 is applied to the laser drive amplifier 5.
An operation of the present laser drive amplifier is explained below. An operation in the record mode is first explained. In the record mode is first explained. In the record mode, the write status signal is generated. The switch 23 selects the maximum error voltage V ERH and the minimum error voltage V ERL and applies them to the laser drive amplifier 5. As a result, the laser beam which is modulated between the maximum power and the minimum power can be feedback-controlled as it is in the prior art.
An operation in the erase mode is now explained. In the erase mode, the erase status signal is generated. The switch 21 selects the erase reference voltage V RE and applies it to the error detection circuit 22. The switch 23 selects the error detection signal V EC from the error detection circuit 22 and applies it to the laser drive amplifier 5. In the erase mode, the laser beam is not modulated. Accordingly, a control to keep the laser beam intensity at a constant level is conducted. The laser drive amplifier 5 controls to keep the laser beam intensity at the constant level in accordance with the error detection signal V EC .
An operation in the reproduction mode is now explained. In the present embodiment, the reproduction mode is enabled when none of the write status signal and the erase status signal is generated. The switch 21 selects the reproduction reference voltage V RR and applies it to the error detection circuit 22. The switch 23 selects the error detection signal V EC from the error detection circuit 22 and applies it to the laser drive amplifier 5. In the reproduction mode, the laser beam is not modulated like in the erase mode. Accordingly, a control is conducted to keep the laser beam intensity at the constant level. The laser drive amplifier 5 controls to keep the laser light beam at the constant level in accordance with the error detection signal V EC . The laser beam intensity in the reproduction mode is lower than those in the record mode and the erase mode.
In the erase mode and the reproduction mode in which the laser beam is not modulated, the error detection signal V EC applied to the laser drive amplifier 5 does not pass through the sample and hold circuit so that it is not affected by the gain error or the linearity error of the sample and hold circuit.
A third embodiment of the present invention is now explained. In the embodiment of FIG. 6, the affect of the linearity error and the gain error of the sample and hold circuit is eliminated in the reproduction mode and the erase mode, but the affect of the linearity error and the gain error is not eliminated in the record mode in which the laser beam is modulated. In the present embodiment, the affect of the linearity error and the gain error of the sample and hold circuit in the record mode can be reduced.
FIG. 7 shows a configuration of a laser drive circuit in accordance with the third embodiment of the present invention. It differs from the configuration of FIG. 6 in that the positions of the sample and hold circuits and the differential amplifiers are exchanged. In FIG. 7, the operation in the reproduction mode and the erase mode is identical to that of the embodiment of FIG. 6 and the explanation thereof is omitted.
An operation in the record mode is now explained. The detection signal S PDIO is applied to the differential amplifiers 6 and 7. The differential amplifier 6 compares the level of the detection signal S PDIO with the maximum reference voltage V HH to produce an error voltage representing a difference therebetween. The differential amplifier 7 compares the level of the detection signal S PDIO with the minimum reference voltage V HL to produce an error voltage representing a difference therebetween. Those error voltages are applied to the sample and hold circuits 2 and 3, respectively.
The sample and hold circuits 2 and 3 sample and hold the input error voltages at the timing of the sampling pulse from the pulse generator 4 as they do in the prior art. They produce the hold voltages as the maximum error voltage V ERH and the minimum error voltage V ERL , respectively, which are applied to the laser drive amplifier 5 through the switch 23. The operations of the switch 23 and the laser drive amplifier 5 are same as those of the embodiment in FIG. 6.
In the embodiment of FIG. 6, the detection signal S PDIO is applied to the sample and hold circuit. In the present embodiment, the error voltage produced by the differential amplifier is applied to the sample and hold circuit. Since the feedback loop formed by the laser drive circuit controls the maximum power and the minimum power of the modulated laser beam in the record mode to the predetermined levels, it functions to keep the error voltage produced by the differential amplifier at zero level. Accordingly, the sample and hold circuit operates around the zero hold voltage in a relatively stable state of the feedback loop. As a result, the sample and hold circuit operates in a range in which the absolute values of the linearity error and the gain error in FIG. 2 are relatively small.
In the laser drive circuit of the embodiment of FIG. 7, the affect of the linearity error and the gain error of the sample and hold circuit is reduced in the feedback control of the laser beam intensity in the record mode in which the laser beam is modulated.
In the embodiments of FIGS. 6 and 7, when the magneto-optical disk drive is not in the record mode, the erase mode or the reproduction mode, the operation in the reproduction mode described above is varied out, and this does not raise a problem. In the embodiments of FIGS. 6 and 7, the write status signal and the erase status signal are externally applied although they may be other signals. For example, the write status signal, the erase status signal and a read status signal (which is generated in the reproduction mode) may be applied. Alternatively, a signal identifying the record mode or the erase mode and the write status signal may be applied.
In the embodiments of FIGS. 6 and 7, the maximum power and the minimum power are feedbackcontrolled in the record mode in which the laser beam is modulated although only one of them may be controlled. For example, where exact control is desired only for the maximum power, the feedback control may be conducted for only the maximum power. In this case, one sample and hold circuit and one differential amplifier are sufficient.
In the embodiments of FIGS. 6 and 7, the switch 23 is connected to the outputs of the error detection circuit 22 and the differential amplifiers 6 and 7 although it may be connected to the inputs of the error detection circuit 22 and the sample and hold circuits 2 and 3.
In the present invention, the laser beam intensity can be controlled with a high precision without being affected by the linearity error and the gain error of the sample and hold circuit.
FIG. 8 shows a block diagram of a laser drive circuit in accordance with a fourth embodiment of the present invention, and FIGS. 9A-9D show waveforms for explaining an operation thereof.
A first output setting circuit 31 sets a first voltage V1 corresponding to the minimum power of the laser beam L1 of the semiconductor laser LD and supplies the set voltage to a negative input terminal of a subtractor 33 and the input terminal d of the laser drive amplifier 5. A second output setting circuit 32 sets a second voltage V2 corresponding to the maximum power of the laser beam L1 of the semiconductor laser LD and supplies the set voltage to a positive input terminal of the subtractor 33.
The first voltage V1 which is the output from the first output setting circuit 31 in FIG. 8 is equivalent to the output V ERL from the differential amplifier 7 in FIG. 1 or the output V EL from the sample and hold circuit 15 in FIG. 4. The first output setting circuit 31 may be the circuit comprising the differential amplifier 7 and the preceding stage thereof in FIG. 1, or the circuit comprising the sample and hold circuit 15 and the preceding stage thereof in FIG. 4.
The second voltage V2 which is the output from the second output setting circuit 32 in FIG. 8 is equivalent to the output V ERH from the differential amplifier 6 in FIG. 1 or the output V EH from the sample and hold circuit 14 in FIG. 4. The second output setting circuit 22 may be the circuit comprising the differential amplifier 6 and the preceding stage thereof in FIG. 1 or the circuit comprising the sample and hold circuit 14 and the preceding circuit thereof in FIG. 4.
Similarly, since the first voltage V1 and the second voltage V2 are equivalent to V ERL and V ERH in FIGS. 6 and 7, the circuits for outputting V ERL and V ERH in FIGS. 6 and 7 may be used as the first output setting circuit 31 and the second output setting circuit 32.
The voltage levels outputted by the first output setting circuit 31 and the second output setting circuit 32 may be set to any desired values, and those circuits output the voltages V1 and V2 of the predetermined magnitude of the predetermined polarity, as shown in FIGS. 9A and 9B.
As shown in FIG. 9C, the subtractor 33 subtracts the first voltage V1 from the second voltage V2 to produce a voltage V2-V1, which is applied to the input terminal c of the laser drive amplifier 5, which is identical to that shown in FIG. 4. The record signal is applied to the input terminal a and the inverted record signal from the inverter 14 is applied to the input terminal b. The first voltage V1 from the first output setting circuit 31 is applied to the input terminal d.
An operation of the present laser drive circuit is now explained. The first output setting circuit 31 sets the first voltage V1 corresponding to the minimum power of the laser beam L1 of the semiconductor laser LD and supplies it to the subtractor 13 and the laser drive circuit 5. The second output setting circuit 32 sets the second voltage V2 corresponding to the maximum power of the laser beam L1 of the semiconductor laser LD and supplies it to the subtractor 13, which subtracts the first voltage V1 from the second voltage V2 and supplies the resulting voltage V2-V1 to the laser drive amplifier 5.
In the laser drive amplifier 5, a transistor Q1 is turned off and a transistor Q2 is turned on when the input record signal is at a low level so that a current I1 caused by the first voltage V1 applied to a transistor Q4 is supplied to the semiconductor laser LD. On the other hand, when the record signal is at a high level, the transistor Q1 is turned on and the transistor Q2 is turned off. As a result, a current Id which is a sum of the current I1 due to the first voltage V1 and a current I0 due to the output voltage V2-V1 of the subtractor 13 applied to the transistor Q3 is supplied to the semiconductor laser LD. In the laser drive amplifier 5, the control is made such that the current to be supplied to the semiconductor laser LD is switched in accordance with the level of the input record signal as shown in FIG. 9D.
In the present invention, the powers corresponding to the minimum power and the maximum power of the laser beam can be independently set by using the first output setting circuit, the second output setting circuit and the subtractor. Thus, even if one of the minimum power and the maximum power of the laser beam is varied, the other power does not follow it and the control of the power may be simply done. PG,29 | A laser drive circuit for modulating a laser beam intensity emitted from a laser device to a maximum power and a minimum power in accordance with a first and second values of a binary signal comprises: a photo-detector for detecting the laser beam emitted from the laser device to produce a detection output signal; a first differential amplifier for producing a maximum error detection signal representing a difference between the detection output signal applied thereto and a maximum reference; a second differential amplifier for producing a minimum error detection signal representing a difference between the detection output signal applied thereto and a minimum reference, a first sample and hold circuit for sampling and holding the maximum error detection signal at a timing of the first value of the binary signal and outputting the same as a maximum error signal; a second sample and hold circuit for sampling and holding the minimum error detection signal at a timing of the second value of the binary signal and outputting the same as a minimum error signal; and a laser drive amplifier for controlling the maximum power and the minimum power of the laser beam emitted from the laser device in accordance with the maximum error signal and the minimum error signal. | 6 |
FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to a process cartridge, and an image forming apparatus which employs a process cartridge.
[0002] Here, an “electrophotographic image forming apparatus” means an apparatus, such as an electrophotographic copying machine, an electrophotographic printer (laser beam printer, LED printer, etc.), or the like, which forms an image on recording medium, with the use of an electrophotographic image forming method.
[0003] A “process cartridge” means a cartridge in which an electrophotographic photosensitive drum, and one or more process means, that is, a charging means, and a developing means or a cleaning means, for processing the electrophotographic photosensitive drum, are integrally disposed so that they can be removably mountable in the main assembly of the image forming apparatus. More specifically, a process cartridge is a cartridge in which an electrophotographic photosensitive drum, and at least one among the abovementioned processing means, such as a developing means, a charging means, and a cleaning means, are integrally disposed. It also means a cartridge in which at least a developing means as a processing means, and an electrophotographic photosensitive drum, are integrally disposed so that they can be removably mountable in the main assembly of an electrophotographic image forming apparatus.
[0004] In the field of an electrophotographic image forming apparatus which employs one of the electrophotographic image formation processes, a process cartridge system has long been employed, according to which an electrophotographic photosensitive drum, and a single or plurality of processing means which act on the electrophotographic photosensitive drum, are integrally disposed in a cartridge to make it possible for them to be removably mountable in the main assembly of the image forming apparatus. Also according to this process cartridge system, an image forming apparatus can be maintained by a user himself, without relying on a service person, drastically improving the image forming apparatus in operability. Thus, a process cartridge system is widely in use in the field of image forming apparatus.
[0005] The image forming operation of an electrophotographic image forming apparatus is as follows: First, the electrophotographic photosensitive drum is exposed to a beam of light projected from a laser, an LED, an ordinary electric light, or the like, while being modulated with pictorial information, forming thereby an electrostatic latent image on the photosensitive drum. The electrostatic latent image is developed by the developing apparatus. Then, the developed image on the photosensitive drum is transferred onto recording medium; an image is formed on the recording medium.
[0006] As regards the structure for positioning the process cartridge in the main assembly of the image forming apparatus, the following structure is known. A supporting member for supporting the process cartridge is pushed into the main assembly of the apparatus. Then, the process cartridge is raised by the engagement between the cartridge side positioning portion and the main assembly side positioning portion. Thereafter, the process cartridge is separated from the supporting member. In this manner, the process cartridge is positioned to the main assembly without interference from the supporting member. (Japanese Laid-open Patent Application Hei 6-29998). It is desirable that the mounting and the mounting operation of the process cartridge relative to the main assembly of the apparatus is simple and easy.
[0007] The present invention is one of the further developments of the above described prior art.
SUMMARY OF THE INVENTION
[0008] Thus, the primary object of the present invention is to provide a process cartridge and an electrophotographic image forming apparatus in which when the process cartridge is mounted to the main assembly of the apparatus, a first cartridge side portion to be positioned and a second cartridge side portion to be positioned are less frictioned relative to a member or members of the main assembly.
[0009] It is another object of the present invention to provide a process cartridge and an electrophotographic image forming apparatus in which when the process cartridge is mounted to the main assembly of the apparatus, a first cartridge side portion to be positioned and a second cartridge side portion to be positioned are less contacted to a member or members of the main assembly.
[0010] It is a further object of the present invention to provide a process cartridge and an electrophotographic image forming apparatus in which the mounting operativity of the process cartridge relative to the main assembly of the apparatus is improved.
[0011] It is a further object of the present invention to provide a process cartridge and an electrophotographic image forming apparatus in which the process cartridge can be mounted to the main assembly of the apparatus with the stability.
[0012] It is a further object of the present invention to provide a process cartridge and an electrophotographic image forming apparatus in which the positioning accuracy of the process cartridge in the main assembly is improved.
[0013] It is a further object of the present invention to provide a process cartridge and an electrophotographic image forming apparatus in which the positioning accuracy of the process cartridge in the main assembly is stably high.
[0014] According to an aspect of the present invention, there is provided a process cartridge detachably mountable to a main assembly of an electrophotographic image forming apparatus, wherein said apparatus includes a first main assembly side positioning portion, a second main assembly side positioning portion, a first main assembly side guide, a second main assembly side guide, a first main assembly side regulating portion, a second main assembly side regulating portion, an urging member for urging process cartridge to the main assembly side positioning portion by an urging force, said process cartridge comprising an electrophotographic photosensitive drum; process means actable on said electrophotographic photosensitive drum; a first cartridge side portion-to-be-guided to be guided by the first main assembly side guide when said process cartridge enters the main assembly along an axial direction of said electrophotographic photosensitive drum; a second cartridge side portion-to-be-guided to be guided by the second main assembly side guide when said process cartridge advances in the main assembly along the axial direction of the electrophotographic photosensitive drum in mounting it to the main assembly; a first cartridge side portion-to-be-regulated, provided at a leading side with respect to the advancing direction, for being regulated by the first main assembly side regulating portion in upward movement thereof when said process cartridge advancing in the main assembly while being guided by the first main assembly side guide and the second main assembly side guide is urged upwardly by the urging force of said urging member; a second cartridge side portion-to-be-regulated, provided at a trailing side with respect to the advancing direction, for being regulated by the first main assembly side regulating portion in upward movement thereof when said process cartridge advancing in the main assembly while being guided by the first main assembly side guide and the second main assembly side guide is urged upwardly by the urging force of said urging member; a first cartridge side portion to be positioned to be positioned at the first main assembly side positioning portion by the urging force of said urging member after said first cartridge side portion-to-be-regulated advancing in the main assembly while being regulated in the upward movement by said first main assembly side regulating portion passes the first main assembly side regulating portion; and a second cartridge side portion to be positioned to be positioned at the second main assembly side positioning portion by the urging force of said urging member after said second cartridge side portion-to-be-regulated advancing in the main assembly while being regulated in the upward movement by said second main assembly side regulating portion passes the second main assembly side regulating portion, wherein said process cartridge is mounted to the main assembly with said first cartridge side portion to be positioned at the first main assembly side positioning portion by the urging force of said urging member and with said second cartridge side portion to be positioned at the second main assembly side positioning portion by the urging force of said urging member.
[0015] According to the present invention, a process cartridge and an electrophotographic image forming apparatus in which when the process cartridge is mounted to the main assembly of the apparatus, a first cartridge side portion to be positioned and a second cartridge side portion to be positioned are less frictioned relative to a member or members of the main assembly, can be provided.
[0016] According to the present invention, a process cartridge and an electrophotographic image forming apparatus in which when the process cartridge is mounted to the main assembly of the apparatus, a first cartridge side portion to be positioned and a second cartridge side portion to be positioned are less contacted to a member or members of the main assembly, can be provided.
[0017] According to the present invention, a process cartridge and an electrophotographic image forming apparatus in which the mounting operativity of the process cartridge relative to the main assembly of the apparatus is improved, can be provided.
[0018] According to the present invention, a process cartridge and an electrophotographic image forming apparatus in which the process cartridge can be mounted to the main assembly of the apparatus with the stability, can be provided.
[0019] According to the present invention, a process cartridge and an electrophotographic image forming apparatus in which the positioning accuracy of the process cartridge in the main assembly is improved, can be provided.
[0020] According to the present invention, a process cartridge and an electrophotographic image forming apparatus in which the positioning accuracy of the process cartridge in the main assembly is stably high, can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic sectional view of the electrophotographic color image forming apparatus in the first of the preferred embodiments of the present invention, showing the general structure of the apparatus.
[0022] FIG. 2 is a cross-sectional view of the cartridge, showing the general structure of the cartridge.
[0023] FIG. 3 is a perspective view of the cartridge and image forming apparatus when the former is in the position from which it is mounted into the latter.
[0024] FIG. 4 is an external perspective view of the process cartridge.
[0025] FIG. 5 is a schematic drawing of the cartridge positioning portion of the main assembly of the image forming apparatus, and the cartridge pressing portion of the main assembly of the image forming, showing their structures.
[0026] FIG. 6 is a detailed view of the cartridge positioning mechanism and cartridge pressing mechanism, on the rear side, of the main assembly of the image forming apparatus, showing their structures.
[0027] FIG. 7 is a detailed view of the cartridge positioning mechanism and cartridge pressing mechanism, on the front side, of the main assembly of the image forming apparatus, showing their structures.
[0028] FIG. 8 is a plan view of the cartridge pressing rear mechanism of the main assembly of the image forming apparatus, as seen from the right-hand side (as seen from front side of main assembly), showing the operation of the cartridge pressing mechanism.
[0029] FIG. 9 is a plan view of the cartridge pressing rear mechanism of the main assembly of the image forming apparatus, as seen from the leading end side of the cartridge in terms of the direction in which the cartridge is mounted, showing the operation of the cartridge pressing mechanism.
[0030] FIG. 10 is a plan view of the cartridge pressing front mechanism of the main assembly of the image forming apparatus, as seen from the left-hand side (as seen from front side of main assembly), showing the operation of the cartridge pressing mechanism.
[0031] FIG. 11 is a plan view of the cartridge pressing front mechanism of the main assembly of the image forming apparatus, as seen from the trailing end side of the cartridge in terms of the direction in which the cartridge is mounted, showing the operation of the cartridge pressing mechanism.
[0032] FIG. 12 is a schematic drawing which shows the directions in which force is applied during the mounting or removal of the cartridge.
[0033] FIG. 13 is an external perspective view of the cartridge in the second embodiment of the present invention.
[0034] FIG. 14 is a schematic drawing which depicts the cartridge positioning mechanism and cartridge pressing mechanism of the main assembly of the image forming apparatus in the second embodiment of the present invention.
[0035] FIG. 15 is a sectional view of the cartridge, at a horizontal plane which coincides with the axial line of the photosensitive drum, as seen from above.
[0036] FIG. 16 is a plan view of the cartridge pressing rear mechanism of the main assembly of the image forming apparatus in the second embodiment, as seen from the right-hand side (as seen from front side of main assembly), showing the operation of the cartridge pressing mechanism.
[0037] FIG. 17 is a plan view of the cartridge pressing rear mechanism of the main assembly of the image forming apparatus in the second embodiment, as seen from the leading end side of the cartridge in terms of the direction in which the cartridge is mounted, showing the operation of the cartridge pressing mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
[0038] Hereafter, the process cartridge (which hereafter will be referred to as “cartridge” and electrophotographic color image forming apparatus (which hereafter will be referred to as “image forming apparatus”) in the first of the preferred embodiments of the present invention will be described with reference to the appended drawings.
(General Structure of Image Forming Apparatus)
[0039] First, referring to FIG. 1 , the image forming apparatus in this embodiment will be described regarding its general structure. An image forming apparatus 100 shown in FIG. 1 has four cartridge bays 22 ( 22 a - 22 d ), that is, the spaces into which four cartridges are mountable one for one ( FIG. 3 ). The four cartridge bays 22 are juxtaposed side by side (in parallel), in a single straight row angled relative to the horizontal direction. The cartridge 7 in each cartridge bay 22 ( 22 a - 22 d ) has one electrophotographic photosensitive drum 1 ( 1 a - 1 d ).
[0040] The electrophotographic photosensitive drum 1 (which hereafter may be referred to as “photosensitive drum”) is rotationally driven in the clockwise direction of the drawing, by a driving member (unshown). Each cartridge 7 also has the following processing means, which are disposed in the adjacencies of the peripheral surface of the photosensitive drum 1 in a manner to surround the photosensitive drum 1 , in the order in which they will be listed next. They are a cleaning means 6 ( 6 a - 6 d ), which removes the developer (which hereafter may be referred to as “toner”) remaining on the peripheral surface of the photosensitive drum 1 after the transfer, a charge roller 2 ( 2 a - 2 d ) which uniformly charges the peripheral surface of the photosensitive drum 1 , a scanner unit 3 which forms an electrostatic latent image on the peripheral surface of the photosensitive drum 1 , by emitting a beam of laser light while modulating the beam of laser light with pictorial information, a development unit 4 ( 4 a - 4 d ) which develops the electrostatic latent image on the peripheral surface of the photosensitive drum 1 with the use of toner, and an intermediary transfer belt 5 onto which the four toner images on the photosensitive drums, one for one, which are different in color, are sequentially transferred. The photosensitive drum 1 , cleaning member 6 , charge roller 2 , and development unit 4 are integrated in the form of a cartridge (process cartridge), that is, the cartridge 7 , which is removably mountable in the main assembly 100 a of the image forming apparatus 100 by a user.
[0041] The intermediary transfer belt 5 is stretched around a driver roller 10 and a tension roller 11 , being thereby supported by them. The main assembly 100 a of the image forming apparatus 100 is provided with first transfer rollers 12 ( 12 a - 12 d ), which are on the inward side of the loop which the intermediary transfer belt 5 forms. The first transfer rollers 12 are positioned so that they oppose the photosensitive drums 1 ( 1 a - 1 d ), one for one. To the transfer belt 5 , transfer bias is applied from a bias applying means (unshown).
[0042] After the formation of a toner image on the photosensitive drum 1 , the toner image is transferred onto the intermediary transfer belt 5 . More specifically, four toner images are formed on the four photosensitive drums 1 , one for one. Then, as the four photosensitive drums 1 are further rotated in the direction indicated by an arrow mark Q, and the intermediary transfer belt 5 is rotated in the direction indicated by an arrow mark R, the four toner images are sequentially transferred (first transfer) in layers onto the intermediary transfer belt 5 , by the positive bias applied to the first transfer rollers 12 . Then, the four layers of toner images on the intermediary transfer belt 5 , which are different in color, are conveyed to a second transferring portion 15 .
[0043] Meanwhile, in synchronism with the progression of the abovementioned image forming operation, a sheet S of recording medium is conveyed by a sheet conveying means made up of a sheet feeding-and-conveying apparatus 13 , a pair of registration rollers 17 , etc. The sheet feeding-and-conveying apparatus 13 has a sheet feeder cassette 24 in which multiple sheets S are storable, a sheet feeder roller 8 which conveys the sheet S, and a pair of sheet conveying rollers 16 which conveys further the sheet S after the feeding of the sheet S into the main assembly 100 a of the image forming apparatus 100 . The main assembly 100 a is structured so that the sheet feeder cassette 24 can be pulled out of the main assembly 100 a in the frontward direction of the main assembly 100 a , in FIG. 1 . The sheets S in the sheet feeder cassette 24 are kept pressed by the sheet feeder roller 8 , and fed into the main assembly 100 a by the sheet feeder roller 8 , while being separated one by one by a sheet separator pad 9 (friction-based sheet separating method).
[0044] After being fed into the main assembly 100 a from the sheet feeding apparatus 13 , the sheet S is conveyed to the second transfer portion 15 by the pair of registration rollers 17 . In the second transfer portion 15 , positive bias is applied to the second transfer roller 18 , whereby the four toner image on the intermediary transfer belt 5 , which are different in color, are transferred (second transfer) onto the sheet S as the sheet S is conveyed through the second transfer portion 15 .
[0045] A fixing portion 14 as a fixing means is a portion of the image forming apparatus, which fixes the toner images on the sheet S by applying heat and pressure. A fixation belt 14 a is cylindrical, and is guided by a belt guiding member (unshown) having a heat generating means, such as a heater, bonded to the belt guiding member. The fixation belt 14 a and a pressure application roller 14 b are kept pressed against with each other by the application of a preset amount of pressure thereto, forming thereby the fixation nip.
[0046] After the transfer of the toner images (unfixed toner images) onto the sheet S from the image forming portion, the sheet S is conveyed to the fixing portion 14 , and then, is conveyed through the fixation nip between the fixation belt 14 a and pressure application roller 14 b in the fixing portion 14 . As the sheet S is conveyed through the fixation nip, the sheet S and the toner images thereon are subjected to heat and pressure. As a result, the unfixed toner images on the sheet S become fixed to the sheet S. Thereafter, the sheet S having the fixed toner images is discharged into a delivery tray 20 by a pair of sheet discharging rollers 19 .
[0047] Meanwhile, the toner remaining on the peripheral surface of the photosensitive drum 1 after the toner image transfer is removed by the cleaning member 6 . Then, the removed toner is recovered into a chamber for the recovered toner, which is in the photosensitive member unit 26 ( 26 a - 26 d ).
[0048] As for the toner remaining on the intermediary transfer belt 5 after the transfer (second transfer) of the toner images onto the sheet S, it is removed by a transfer belt cleaning apparatus 23 . The removed toner is recovered into a waste toner container (unshown) located in the rear portion of the image forming apparatus, through the waste toner passage (unshown).
(Cartridge)
[0049] Next, referring to FIG. 2 , the cartridge in this embodiment will be described. FIG. 2 is a cross-sectional view of the cartridge 7 , in which a substantial amount of toner t is present. Incidentally, a cartridge 7 a , that is, a cartridge in which the toner t of yellow color is present, a cartridge 7 b , that is, a cartridge in which the toner t of magenta color is present, a cartridge 7 c , that is, a cartridge in which the toner t of cyan color is present, and a cartridge 7 d , that is, a cartridge in which the toner t of black color is present, are the same in structure.
[0050] Each cartridge 7 is made up of a photosensitive member unit 26 and a development unit 4 . The photosensitive member unit 26 is provided with the photosensitive drum 1 , charge roller 2 (charging means), and cleaning member 6 (cleaning means). The development unit 4 has a development roller 25 .
[0051] The photosensitive drum 1 is rotatably supported by the cleaning means frame 27 of the photosensitive member unit 26 , with the interposition of a pair of bearings which will be described later. In an image forming operation, the photosensitive drum 1 is rotationally driven, by transmitting to the photosensitive member unit 26 the driving force from a motor (unshown). There are the charge roller 2 and cleaning member 6 in the adjacencies of the peripheral surface of the photosensitive drum 1 as described above. As the above described transfer residual toner is removed from the peripheral surface of the photosensitive drum 1 by the cleaning member 6 , the removed toner falls into a chamber 27 a for the removed toner. The cleaning means frame 27 is also provided with a pair of charge roller bearings 28 , which are attached to the cleaning means frame 27 in such a manner that the charge roller bearings 28 are movable in the direction indicated by a double-headed arrow mark D, which connects the centers of the charge roller 2 and photosensitive drum 1 . The shaft 2 j of the charge roller 2 is rotatably supported by the charge roller bearings 28 , and the bearings 28 are kept pressured toward the photosensitive drum 1 by a pair of charge roller pressing members 46 .
[0052] The development unit 4 has the development roller 25 and a developing means frame 31 . The development roller 25 rotates in contact with the photosensitive drum 1 in the direction indicated by the arrow mark B. The development roller 25 is rotatably supported by a developing means frame 31 . More specifically, the development roller 25 is supported by a pair of bearing members 32 ( 32 R and 32 L) attached to the lengthwise ends of the developing means frame 31 . The development unit 4 is provided with a toner supply roller 34 and a development blade 35 . The toner supply roller 34 rotates in contact with the development roller 25 in the direction indicated by an arrow mark C. The development blade 35 is for regulating in thickness the toner layer on the peripheral surface of the development roller 25 . Further, the development unit 4 has a toner conveying member 36 for conveying the toner in the toner storage portion 31 a of the development unit 4 to the toner supply roller 34 while stirring the toner. The toner conveying member 36 is in the toner storage portion 31 a.
[0053] The development unit 4 is connected to the photosensitive member unit 26 . More specifically, a pair of pins 37 ( 37 R and 37 L) are put through, one for one, the holes 32 Rb and 32 Lb of the bearing members 32 R and 32 L, respectively, so that the development unit 4 is pivotally movable relative to the photosensitive member unit 26 about the pins 37 ( 37 R and 37 L). The development unit 4 is under the pressure from pressure application springs 38 . Therefore, when the cartridge 7 is used for image formation in the main assembly of the image forming apparatus, the development unit 4 rotates about the pins 37 in the direction indicated by an arrow mark A, placing thereby the development roller 25 in contact with the photosensitive drum 1 .
[0000] (Structure of Means for Mounting Cartridge into Main Assembly of Image Forming Apparatus)
[0054] Next, referring to FIG. 3 , the portion of the cartridge, which allows the cartridge to be removably mounted into the main assembly of the image forming apparatus, and the portion of the main assembly of the image forming apparatus, which allows the cartridge to be removably mounted into the main assembly of the image forming apparatus, will be described regarding their structures.
[0055] FIG. 3 is a perspective view of the cartridge and image forming apparatus when the former is in the position from which it is mounted into the latter. Incidentally, in this embodiment, the cartridge and the main assembly 100 a of the image forming apparatus 100 are structured so that the former is inserted into the latter, in the front-to-rear direction, that is, the direction indicated by an arrow mark F, which is parallel to the axial line of the photosensitive drum 1 , so that the cartridge 7 can be removably mounted into the main assembly 100 a.
[0056] Referring to FIG. 3 , the main assembly 100 a is provided with a cover 21 (front cover), which is on the front side of the main assembly 100 a . The front cover 21 can be opened or closed. Opening the front cover 21 exposes the four cartridge bays 22 ( 22 a - 22 d ), which are for the cartridges 7 ( 7 a - 7 d ), one for one. The four cartridge bays 22 are juxtaposed side by side (in parallel), in a singe straight row angled relative to the horizontal direction. The main assembly 100 a is provided with top cartridge guides 80 ( 80 a - 80 d ) as first cartridge guides of the main assembly 100 a , and bottom cartridge guides 81 ( 81 a - 80 d ) as second cartridge guides of the main assembly 100 a . The top and bottom cartridge guides 80 and 81 are located at the top and bottom of the four cartridge bays 22 , one for one, and extend from the front to rear of the main assembly 100 a . The photosensitive member unit 26 of each cartridge 7 is provided with a projection 29 (first portion by which cartridge is guided), and a tongue-like portion 30 (second portion by which cartridge guided) by which the cartridge 7 is guided when the cartridge 7 is mounted into, or removed from, the corresponding cartridge bay 22 . More specifically, in order to mount the cartridge 7 into the corresponding cartridge bay 22 , the projection 29 and tongue-like portion 30 of the photosensitive member unit 26 are to be fitted in the cartridge guides 80 and 81 of the main assembly 100 a , respectively, and then, the cartridge 7 is to be pushed into the cartridge bay in the direction indicated by an arrow mark F in the drawing.
[0057] Incidentally, the abovementioned projection 29 (first portion of cartridge 7 , by which cartridge 7 is guided) is located at the top of the leading end of the cartridge 7 , in terms of the direction in which the cartridge 7 is inserted into the main assembly 100 a , whereas the tongue-like portion 30 (second portion of cartridge 7 , by which cartridge 7 is guided) is on the bottom surface of the cartridge 7 , and extends from the leading end to the trailing end.
[0058] Each cartridge 7 is also provided with a pair of cartridge positioning portions 40 a and 50 a (by which cartridge 7 is positioned relative to main assembly 100 a ), which are located at the leading and trailing ends of the cartridge 7 , in terms of the abovementioned cartridge insertion direction. The operation to mount the cartridge 7 into the main assembly 100 a concludes as the cartridge 7 becomes correctly positioned in the main assembly 100 a . Incidentally, for the purpose of controlling the rotation of the cartridge 7 , which occurs as driving force is transmitted to the cartridge 7 , the leading end of the cartridge 7 is provided with a shaft 27 b ( FIG. 4 ), which protrudes in the direction parallel to the cartridge mounting direction (cartridge insertion direction), whereas the trailing end of the cartridge 7 is provided with a groove 27 c , which is U-shaped in cross section. As the cartridge 7 becomes correctly positioned in the main assembly 100 a , the shaft 27 b fits into a hole 82 b ( FIG. 5 ) of the main assembly 100 a , which is elongated in cross section, and the shaft 92 c ( FIG. 5 ) of the main assembly 100 a fits into the groove 27 c of the cartridge 7 .
[0059] In terms of the direction in which the cartridge 7 advances as it is inserted into the main assembly 100 a , the projection 29 (by which cartridge 7 is guided) of the cartridge 7 is located at the top of the leading end of the cartridge 7 , as described above. The tongue-like portion 30 of the cartridge 7 is on the bottom surface of the cartridge 7 , extending from the leading end of the cartridge 7 to the trailing end of the cartridge 7 . Further, in terms of the direction perpendicular to the axial line of the photosensitive drum 1 , the tongue-like portions 29 and 30 are on the same side of the photosensitive drum 1 .
[0060] Therefore, it is ensured that the cartridge 7 reliably advances into the main assembly 100 a.
[0061] As for the structural arrangement for correctly positioning the cartridge 7 in the main assembly 100 a , it will be described later in detail.
(Structure for Correctly Positioning Cartridge, and Structure for Pressing Cartridge)
[0062] Next, referring to FIGS. 4-7 , the structural arrangement, in this embodiment, for correctly positioning the cartridge relative to the main assembly 100 a , and the structural arrangement for pressing the cartridge to correctly positioning the cartridge, will be described.
[0063] FIG. 4 is an external perspective view of the cartridge in this embodiment. The photosensitive drum 1 , which the cartridge 7 has, is rotatably supported, by the lengthwise end portions of its shaft (unshown), by a pair of bearings 40 and 50 , one for one, which are solidly attached to the cleaning means frame 27 .
[0064] The bearing 40 (first bearing which supports one of lengthwise ends of shaft of photosensitive drum 1 ) is the bearing on the rear side, that is, the leading end side in terms the direction in which the cartridge 7 is made to advance in the main assembly 100 a when it is mounted into the main assembly 100 a . It is provided with a cartridge positioning first portions 40 a ( 40 a 1 , 40 a 2 ), which are two portions of the top side of the peripheral surface of the bearing 40 a . More specifically, the cartridge positioning first portion 40 a (which is made up of portions 40 a 1 and 40 a 2 ) is for correctly positioning the leading end of the cartridge 7 relative to the main assembly 100 a , in terms of the direction vertical to the abovementioned cartridge advancement direction. It is arcuate in cross section. Incidentally, in terms of the cartridge advancement direction, the bearing 40 , that is, the bearing which will be at the deepest end of the cartridge bay, is located at the downstream end of the cartridge 7 ( FIG. 4 ). The cartridge 7 is also provided with a pressure catching portion 40 b , which catches the pressure applied to the cartridge 7 by the cartridge pressing member 83 (which may be referred to as pressure applying member, or upwardly pushing member), which is a portion of the bottom side of the peripheral surface of the cartridge positioning first portion 40 a . Incidentally, the above-mentioned cartridge advancement direction is the direction in which the cartridge 7 is advanced into the main assembly 100 a when a user mounts the cartridge 7 into the main assembly 100 a.
[0065] Further, the abovementioned cartridge positioning portions 40 a ( 40 a 1 and 40 a 2 ) is positioned so that it straddles the axial line I of the photosensitive drum 1 ( FIG. 15 ). That is, the cartridge 7 has the cartridge positioning first portion 40 a 1 , which is on one side of the axial line I of the photosensitive drum 1 , and the cartridge positioning second portion 40 a 2 , which is on the other side of the axial line I of the photosensitive drum 1 . The cartridge positioning first portion 40 a 1 (positioning portion on leading end side) is on the opposite side of the abovementioned axial line I from the cartridge positioning second portion 40 a 2 (positioning portion on trailing end side) ( FIG. 15 ). As for the abovementioned pressure catching portion 40 b , it is on the downstream side of the photosensitive drum 1 in terms of the cartridge advancement direction. As seen from the direction J ( FIG. 9( c )) in which upward pressure is applied by the abovementioned pressing member 83 (pressure applying member, upwardly pushing member), the pressure catching portion 40 b is (roughly at the mid point) between the cartridge positioning first and second portions 40 a 1 and 40 a 2 . Therefore, as the pressure catching portion 40 b is pressed, the cartridge positioning portion 40 a is reliably pressed upon the cartridge catching portion 82 a (cartridge positioning first portion on main assembly side), being thereby correctly positioned relative to the main assembly 100 a . Incidentally, in this embodiment, the cartridge 7 is provided with the cartridge positioning first and second portions 40 a 1 and 40 a 2 as the cartridge positioning portions on the leading end side. Therefore, it is ensured that the cartridge 7 is more reliably pressed upon the cartridge catching (pressure catching) portion 82 a of the main assembly 100 a . However, the number of the cartridge positioning portions with which the leading end of the cartridge 7 is provided may be only one, as long as it is properly positioned.
[0066] Further, the cartridge 7 is provided with a pushing member 40 c , which is the first pushing member for moving the pressing member 83 into its retreat. With reference to the center of the cartridge 7 , in terms of the horizontal direction perpendicular to the abovementioned cartridge advancement direction, the pushing portion 40 c is located closer to the lengthwise end wall of the cartridge 7 than the pressure catching portion 40 b . The pushing portion 40 c is protruding downstream from the downstream end wall of the cartridge 7 in terms of the cartridge advancement direction, and its end portion is provided with a projection 40 d which is projecting downward. More specifically, the projection 40 d of the pushing portion 40 c is tapered, providing thereby gently slanted surfaces 40 e and 40 f , that is, the slanted surfaces on the downstream and upstream sides, respectively, which are slanted so that their intersection is the peak of the projection 40 d (projection 40 d ).
[0067] Further, the bearing 40 , that is, the bearing on the rear side, is provided with a first contact portion 40 h (cartridge movement regulating first portion of cartridge), which protrudes further upward than the cartridge positioning portion 40 a . The first contact portion 40 h is flat across the top surface (end surface), and is between one end of the cartridge positioning first portion 40 a 1 and the other end of the cartridge positioning second portion 40 a 2 . That is, the first contact surface 40 h is between the cartridge positioning first and second portions 40 a 1 and 40 a 2 ; the cartridge positioning first portion 40 a 1 is located next to one end of the first contact surface 40 h , and the cartridge positioning second portion 40 a 2 is located next to the other end of the first contact surface 40 h . Located on the upstream of the first contact surface 40 h in terms of the cartridge mounting direction is a surface 40 g , which is closer to the axial line of the photosensitive drum 1 than the top surface of the first contact surface 40 h . Further, the bearing 40 , that is, the bearing on the rear end, is provided with a contact surface 40 i , which is the surface for correctly positioning the cartridge 7 in terms of the lengthwise direction of the cartridge 7 . Incidentally, as the cartridge 7 is mounted into the main assembly 100 a , the contact surface 40 i comes into contact with the inward surface of the rear lateral panel of the main assembly 100 a , ensuring that the cartridge 7 is correctly position in terms of the lengthwise direction of the cartridge 7 .
[0068] Next, the bearing 50 (second bearing, that is, bearing which supports other end of photosensitive drum 1 in terms of direction parallel to axial line of photosensitive drum 1 ) will be described. The bearing 50 is the bearing on the front side, that is, the trailing side in terms of the abovementioned cartridge advancement direction. The bearing 50 , that is, the bearing on the front side, is provided with cartridge positioning second portions 50 a ( 50 a 1 and 50 a 2 ), which are two portions of the top side of the peripheral surface of the bearing 50 . More specifically, the cartridge positioning second portions 50 a (portions 50 a 1 and 50 a 2 ) are for correctly positioning the front end of the cartridge 7 relative to the main assembly 100 a , in terms of the direction perpendicular to the abovementioned cartridge advancement direction. They are arcuate in cross section. The cartridge 7 is also provided with an upward pressure catching portion 50 b , which catches the pressure applied to the cartridge 7 by an upwardly pulling member 93 ( FIG. 5 ). The pressure catching portion 50 b is located farther from the axial line of the bearing 50 a than the cartridge positioning first portion 50 a.
[0069] As described above, the cartridge 7 has the first bearing 40 , which supports one of the lengthwise end portions of the photosensitive drum 1 in terms of the direction parallel to the axial line of the photosensitive drum 1 . The contact surface 40 h and cartridge positioning first portions 40 a ( 40 a 1 and 40 a 2 ) are portions of the peripheral surface of the first bearing 40 . Further, the cartridge 7 has the second bearing 50 which supports the other lengthwise end of the photosensitive drum 1 in terms of the direction parallel to the axial line of the photosensitive drum 1 . The contact portion 50 h (contact surface) and cartridge positioning second portions 50 a are portions of the peripheral surface of the second bearing 50 .
[0070] Therefore, it is ensured that the cartridge 7 is precisely positioned relative to the main assembly 100 a.
[0071] Incidentally, like the cartridge positioning portion 40 a , that is, the cartridge positioning portion on the rear side, the cartridge positioning portion 50 a has a cartridge positioning portion (cartridge positioning third portion 50 a 1 ), which is on one side of the axial line of the photosensitive drum 1 , and a cartridge positioning portion (cartridge positioning fourth portion 50 a 2 ), which is on the other side of the axial line of the photosensitive drum 1 . The cartridge positioning third portion 50 a 1 (positioning portion on leading end side) is on the opposite side of the abovementioned axial line I from the cartridge positioning fourth portion 50 a 2 (positioning portion on trailing end side) ( FIG. 15 ). As for the abovementioned pressure catching portion 50 b , it is on the downstream side of the photosensitive drum 1 in terms of the cartridge advancement direction. As seen from the direction K ( FIG. 11( c )) in which upward pressure is applied by the abovementioned upwardly pulling member 93 (pressure applying member, upwardly pushing member), the pressure catching member 50 b is (roughly at the mid point) between the cartridge positioning third and fourth portions 50 a 1 and 50 a 2 . Therefore, as the pressure catching portion 50 b is pressed, the cartridge positioning portions 50 a are reliably pressed upon the pressure catching portion 92 a , being thereby correctly positioned relative to the main assembly 100 a.
[0072] Incidentally, in this embodiment, the cartridge 7 is provided with the cartridge positioning third and fourth portions 50 a 1 a 50 a 2 as the cartridge positioning portions on the trailing end side. Therefore, it is ensured that the cartridge 7 is more reliably pressed upon the pressure catching portions 92 a of the main assembly 100 a . However, the number of the cartridge positioning portions which the trailing end of the cartridge 7 is provided may be only one, as long as it is properly positioned.
[0073] Further, the cartridge 7 is provided with a pushing member 50 c , which is the second pushing member for moving the upwardly pulling member 93 into its retreat. With reference to the center of the cartridge 7 , in terms of the direction which is horizontal and perpendicular to the abovementioned cartridge advancement direction, the pushing portion 50 c is located closer to the lengthwise end wall of the cartridge 7 than the pressure catching portion 50 b . The pushing portion 50 c is protruding downstream from the main portion of the bearing 50 in terms of the cartridge advancement direction, and its end portion is provided with a projection 50 d which is projecting downward. More specifically, the projection 50 d is tapered, providing thereby gently slanted surfaces 50 e and 50 f , that is, the slanted surfaces on the downstream and upstream sides, respectively, which are slanted in such a manner that their intersection is the peak of the projection 50 d (projection 50 d ). Further, the bearing 50 , that is, the bearing on the front side, is provided with a second contact portion 50 h (contact surface, which serves as cartridge movement regulating portion), which protrudes further upward than the cartridge positioning portion 50 a . The second contact portion 50 h is flat across the top surface (second contact surface), and is between one end of the cartridge positioning third portion 50 a 1 and the other end of the cartridge positioning fourth portion 50 a 2 . That is, the second contact surface 50 h is between the cartridge positioning third and fourth portions 50 a 1 and 50 a 2 ; the cartridge positioning third portion 50 a 1 is located next to one end of the second contact surface 50 h , and the cartridge positioning fourth portion 50 a 2 is located next to the other end of the second contact surface 50 h . Located on the upstream of the contact surface 50 h in terms of the cartridge mounting direction is a surface 50 g , which is closer to the axial line of the photosensitive drum 1 than the top surface of the first contact portion 50 h.
[0074] Further, in terms of the direction perpendicular to the axial line of the photosensitive drum 1 , the top surface (area of first contact) of the contact portion 40 h is different in position from the cartridge positioning first portions 40 a ( 40 a 1 and 40 a 2 ). Also in terms of the direction perpendicular to the axial line of the photosensitive drum 1 , the top surface (area of second contact) is different in position from the cartridge positioning second portions 50 a ( 50 a 1 and 50 a 2 ).
[0075] Further, in terms of the above-mentioned cartridge advancement direction, the top surface (area of first contact) of the first contact portion 40 h is on the leading end side, and the top surface (area of second contact) of the second contact portion 50 h is on the trailing end side.
[0076] Therefore, it is ensured that the cartridge 7 is precisely positioned relative to the main assembly 100 a.
[0077] Further in terms of the direction perpendicular to the axial line of the photosensitive drum 1 , the top surface of the contact surface 40 h is between one end of the cartridge positioning portions 40 a ( 40 a 1 and 40 a 2 ) and the other end of the cartridge positioning portions 40 a ( 40 a 1 and 40 a 2 ). Also in terms of the direction perpendicular to the axial line of the photosensitive drum 1 , the top surface (area of contact) of the second contact portion 50 h is between one end of the cartridge positioning second portions 50 a ( 50 a 1 and 50 a 2 ) and the other.
[0078] Therefore, it is ensured that the cartridge 7 is precisely positioned relative to the apparatus main assembly 100 a.
[0079] Next, the structure of the cartridge positioning portion of the main assembly 100 a , and the cartridge pressing mechanism of the main assembly 100 a , will be described. FIG. 5 is a schematic drawing for describing the structure of the cartridge positioning portion of the main assembly 100 a of the image forming apparatus 100 , and the cartridge pressing mechanism of the main assembly 100 a , and show the structures thereof. FIG. 6 is a detailed drawing of the cartridge positioning portion and cartridge pressing mechanism, on the rear side, and shows the structures thereof. FIG. 7 is a detailed drawing of the cartridge positioning portion and cartridge pressing mechanism, on the front side, and shows the structures thereof.
[0080] Referring to FIG. 5 , the main assembly 100 a is provided with a rear lateral panel 82 , which is on the leading end side, in terms of the cartridge mounting direction, and a front lateral panel 92 , which is on the trailing end side. The lateral panel 92 is provided with a hole through which the cartridge 7 is removably mountable in the cartridge bay 22 . The cartridge 7 is inserted into the main assembly 100 a through this hole. Further, the cartridge 7 is inserted into the cartridge bay 22 in the direction of the arrow mark F, along the above described cartridge guiding top guide 80 and cartridge guiding bottom guide 81 ( FIG. 3 ).
[0081] The lateral plate 82 is provided with two cartridge catching portions 82 a ( 82 a 1 and 82 a 2 ), that is, the first portions of the main assembly, which are for correctly positioning the cartridge 7 relative to the main assembly in terms of the direction perpendicular to the direction (advancement direction) in which the cartridge 7 is mounted. The lateral plate 82 is also provided with the pressing member 83 , which is for pressing the cartridge 7 toward the cartridge catching portion 82 a by being under the pressure applied thereto by the resiliency (elastic force) of a compression spring 85 . This pressing member 83 functions as an upwardly pushing member which keeps the cartridge 7 pressed upward by being pressed upward by the pressure applied by the compression spring 85 .
[0082] The pressing member 83 is located under the cartridge catching portion 82 a . It is attached to the lateral plate 82 . More specifically, a shaft 84 solidly fixed to the lateral plate 82 , that is, the lateral plate on the rear side, of the main assembly, is put through the through hole 83 a , the axial line of which coincides with the pivotal axis of the pressing member 83 , so that the pressing member 83 is enabled to take the cartridge pressing position in which it keeps the cartridge 7 pressed on the cartridge catching portions 82 a , position in its retreat in which it does not press on the cartridge 7 , and the standby position in which it remains in the path of the cartridge 7 .
[0083] Further, the pressing member 83 is provided with a cartridge pushing portion 83 b , by which the pressing member 83 pushes the cartridge when the pressing member 83 is in the cartridge pressing position. The cartridge pushing portion 83 b corresponds in position to the pressure catching portion 40 b of the cartridge 7 . The pressing member 83 is also provided with a pressure catching first portion 83 c for moving the pressing member 83 into the retreat. The pressure catching first portion 83 c corresponds in position to the pushing portion 40 c of the cartridge 7 . The pressure catching first portion 83 c is provided with an upward projection 83 d . The upward projection 83 d is provided with gently slanted surfaces 83 e and 83 f , which are the upstream and downstream surfaces of the projection 83 d , respectively, in terms of the cartridge mounting direction. The surfaces 83 e and 83 f are slanted so that the joint between the two surfaces is the peak of the projection 83 d . Further, in terms of the direction perpendicular to the cartridge mounting direction, the pressure catching portion 83 c is located further outward (in terms of the radium direction of hole 83 a ) from the axial line of the hole 83 a than the cartridge pushing portion 83 b . That is, in terms of the lengthwise direction of the pressing member 83 , the abovementioned axial line of the hole 83 a , cartridge pressing portion 83 b , and pressure catching portion 83 c , are positioned in the listed order.
[0084] The lateral plate 82 is provided with a cartridge movement regulating first portion 86 (cartridge movement regulating first portion of main assembly) which prevents the cartridge 7 from moving upward by the reactive force generated as the cartridge pushes the pressing member 83 into its retreat. The cartridge movement regulating first portion 86 is formed of resin, and is located between the two cartridge catching portions 82 a ( 82 a 1 and 82 a 2 ) of the lateral plate 82 .
[0085] Referring to FIG. 7 , the lateral plate 92 is provided with the cartridge insertion hole 92 b , and two cartridge catching portions 92 a ( 92 a 1 and 92 a 2 ), which function as the cartridge positioning second portions of the main assembly. The cartridge catching portions 92 a are two portions of the top portion of the inward surface of the hole 92 b , and are for correctly positioning the cartridge 7 in terms of the direction perpendicular to the cartridge mounting direction. Further, the lateral plate 92 , that is, the frontal lateral plate of the main assembly, is provided with a cartridge pulling member 93 for upwardly pulling the cartridge 7 toward the cartridge catching portions 92 a , by being under the tensional force generated by a pressure application spring 95 , which is a tension spring. The cartridge pulling member 93 is located upward of the cartridge catching portions 92 a . It is pivotally supported by the lateral plate 92 ; a shaft 94 solidly attached to the lateral plate 92 is put though a hole 93 a (whose axial line is rotational axis) of the cartridge pulling member 93 . The cartridge pulling member 93 is attached to (supported by) the lateral plate 92 so that it is enabled to take the position in which it keeps the cartridge 7 pressed upon the cartridge catching portions 92 a , position in its retreat in which it is free from the force from the spring 95 , and standby position in which it is in the path of the cartridge 7 .
[0086] Further, the cartridge pulling member 93 is provided with a cartridge pulling portion 93 b for pulling the cartridge upward when the cartridge pulling member 93 is in the cartridge pulling position. The cartridge pulling portion 93 b corresponds in position to the cartridge pulling force catching portion 50 b of the cartridge 7 . The cartridge pulling member 93 is also provided with a cartridge catching second portion 93 c for moving the cartridge pulling member 93 into its retreat. The cartridge catching second portion 93 c corresponds in position to the pushing portion 50 c of the cartridge 7 . It is provided with an upward projection 93 d , which has gently slanted surfaces 93 e and 93 f ( FIG. 10 ) slanted so that their intersection is the peak of the upward projection 93 d.
[0087] Further, in terms of the direction perpendicular to the cartridge mounting direction, the cartridge catching portion 93 c is located further outward from the axial line of the hole 93 a than the cartridge pulling portion 93 b . That is, in terms of the lengthwise direction of the cartridge pulling member 93 , the hole 93 a , cartridge pulling portion 93 b , and cartridge catching portion 93 c are positioned in the listed order. Further, the lateral plate 92 , that is, the frontal lateral plate of the main assembly, is provided a cartridge movement regulating second portion 96 , which is for preventing the cartridge 7 from being moved upward by the reactive force which occurs as the cartridge pulling member 93 is pushed into its retreat. The cartridge movement regulating portion 96 is between the abovementioned two cartridge catching portions 92 a ( 92 a 1 and 92 a 2 ).
[0088] Incidentally, in this embodiment, on the leading end side of the cartridge 7 in terms of the cartridge mounting direction, the pressure applying member 83 (pressing member, upwardly pushing member) is located below the cartridge catching portion 83 a to press the cartridge upward from below to cause the cartridge 7 to bump into the cartridge catching portions 82 a , whereas on the trailing side of the cartridge 7 in terms of the cartridge mounting direction, the cartridge pulling member 93 (cartridge pressing member) is positioned above the cartridge catching portions 92 a to pull the cartridge 7 upward from above to cause the cartridge to bump into the cartridge catching portions 92 a which are positioned above the cartridge. That is, as the cartridge 7 is moved into its image forming position in the main assembly 100 a , the cartridge catching portion 82 a (portion to be pressed) is pressed by the upward force from the cartridge pushing member 83 . Thus, the cartridge positioning first and second portions 40 a 1 and 40 a 2 (cartridge positioning portions of cartridge, on leading end side) are correctly positioned by the cartridge catching portions 82 a (cartridge positioning first portion of main assembly). Further, the upwardly pulling force catching portion 50 b is pushed by the upwardly pulling force from the upwardly pulling member 93 . Therefore, the cartridge positioning third and fourth portions 50 a 1 and 50 a 2 (cartridge positioning portions of cartridge, on trailing end side) are correctly positioned by the cartridge catching portions 92 a ( 92 a 1 and 92 a 2 ) (cartridge positioning second portions of main assembly). Thus, the employment of this structural arrangement makes it possible to provide the lateral plate 92 , that is, the frontal lateral plate of the main assembly, with the hole through which the cartridge 7 can be mounted into the cartridge bay 22 . Therefore, the bearing 50 , that is, one of the bearings in the adjacencies of the cartridge positioning portion, can be directly pressed. Therefore, the pressure applied to the bearing 50 remains stable. Therefore, the cartridge 7 is precisely positioned and remains precisely positioned. Therefore, the photosensitive drum 1 is precisely placed in contact with the intermediary transfer belt 5 , and remains precisely in contact with the belt 5 .
[0089] Incidentally, this embodiment is not intended to limit the present invention in structural arrangement. That is, the cartridge pressing member 83 and cartridge pulling member 93 may be positioned on the leading and trailing end sides, respectively, as elastically pressing members, in terms of the cartridge mounting direction, or vice versa. In either case, the above described effects can be obtained.
(Operation of Cartridge Pressing Mechanism During Mounting and Removal of Cartridge)
[0090] Next, referring to FIGS. 8-11 , the operations of the cartridge pressing mechanism during the mounting of the cartridge 7 into the image forming apparatus, and the removal of the cartridge 7 from the image forming apparatus, will be described.
(a) Leading End Side: Operations of Cartridge Pressing Mechanism During Mounting and Removal of Cartridge
[0091] FIG. 8 is a plan view of the right-hand side (as seen from front side) of the cartridge pressing rear mechanism of the main assembly. FIG. 9 is a plan view of the rear side of the cartridge pressing rear mechanism (leading end side in terms of cartridge mounting direction) of the main assembly.
[0092] The cartridge 7 is to be mounted in the direction indicated by the arrow mark F as described before. Referring to FIGS. 8( a ) and 9 ( a ), as the cartridge 7 is inserted, the slanted surface 40 e of the pushing portion 40 c of the bearing 40 , that is, the rear bearing of the cartridge 7 , comes into contact with the slanted surface 83 e of the cartridge catching portion 83 c (standby position). Then, as the cartridge 7 is inserted further, the pressing member 83 is gradually pushed down, causing the projection 40 d of the pushing portion 40 c to come into contact with the projection 83 d of the cartridge catching portion 83 c , as shown in FIG. 8( b ). Consequently, the pressing member 83 retreats in the direction indicated by an arrow mark X (position in retreat).
[0093] More specifically, the pressing member 83 moves into the position in its retreat, in which its pressing portion 83 b does not contact the pressure catching portion 40 b of the cartridge 7 , as shown in FIG. 9( b ). Therefore, while the cartridge 7 is mounted, the pressure catching portion 40 b is not subjected to any pressure. The pressure which the cartridge 7 receives from the pressing member 83 when it is mounted is removed by the pushing portion 40 c , which is located further from the hole 83 a . That is, the amount of force necessary to push down the pressing member 83 against the force which acts to upwardly push the cartridge 7 is reduced by the ratio between the distance from the axial line of the hole 83 a to the pressure catching portion 40 b (pushing portion 83 b ) and the distance from the axial line of the hole 83 a to the pushing portion 40 c (pressure catching portion 83 c ). Therefore, the amount of load to which the cartridge 7 is subjected when it is mounted is substantially smaller than the amount of pressure which the cartridge 7 receives from the pressing member 83 ; the amount of force required to mount the cartridge 7 is substantially smaller than the amount of the pressure which the cartridge 7 receives from the pressing member 83 .
[0094] Further, when the cartridge 7 is mounted, the cartridge 7 is subjected to upward force, that is, the reactive force generated as the pressing member 83 is pushed down into its retreat. However, the contacting surface 40 h comes into contact with the cartridge movement regulating portion 86 , that is, the cartridge contacting first portion of the main assembly. Therefore, the cartridge 7 is prevented from moving upward. Here, the cartridge movement regulating portion 86 of the main assembly and the main assembly contacting surface 40 h are positioned so that they remain in contact with each other until immediately before the cartridge positioning portion 40 a is correctly positioned by coming into contact with the cartridge catching portion 83 . Therefore, while the cartridge 7 is mounted, more specifically, from the moment the cartridge 7 begins to receive the upward pressure from the pressing member 83 until immediately before the cartridge 7 is correctly positioned, the cartridge movement regulating portion 86 , that is, the cartridge regulating portion of the main assembly, which is formed of resin, and the contacting surface 40 h , slide on each other, and therefore, the cartridge positioning portion 40 a does not rub against the cartridge catching portion 82 a of the main assembly, which is formed of a thin sheet of steel or the like. Therefore, the problem that the cartridge positioning portion 40 a is shaved by the cartridge catching portion 82 a is prevented.
[0095] As the cartridge 7 is inserted even further, the cartridge catching portion 83 c is disengaged from the pushing portion 40 c , and therefore, the pressing member 83 gradually returns to its pressing position from the retreat. Then, the cartridge 7 is inserted far enough for the contacting surface 40 i , which is for correctly positioning the cartridge 7 in terms of the lengthwise direction of the cartridge 7 , to come into contact with the lateral plate 82 , that is, the rear lateral plate of the main assembly, the pressing portion 83 b comes into contact with the pressure catching portion 40 b , as shown in FIGS. 8( c ) and 9 ( c ), causing the cartridge 7 to be pressed (pressing position) in the direction indicated by an arrow mark J (pressing direction in FIG. 9) . During this process, the cartridge positioning portion 40 a of the cartridge 7 bumps into the cartridge catching portion 82 a of the rear lateral plate 82 of the main assembly, correctly positioning thereby the cartridge 7 in terms of the direction perpendicular to the cartridge mounting direction. Also during this process, the cartridge movement regulating portion 86 of the main assembly becomes disengaged from the contacting surface 40 h ; a preset amount of gap is created between the cartridge movement regulating portion 86 and the surface 40 g (recessed surface). At the same time, the cartridge catching portion 83 c moves past the pushing portion 40 c ; a preset amount of gap is created between the cartridge catching portion 83 c and the recessed surface 40 j.
[0096] As described above, the cartridge pressing mechanism is structured so that the pressing member 83 can be in the standby position, pressing position, and retreat. More specifically, in terms of the top to bottom direction, the standby position, pressing position, and retreat are located in the listed order. Therefore, the pressing member 83 applies a sufficient amount of pressure to the cartridge 7 .
[0097] When removing the cartridge 7 from the main assembly 100 a , the cartridge mounting operation described above is to be carried out in reverse. The pressure which the cartridge 7 receives from the pressing member 83 is removed by the pushing portion 40 c , which is more distant from the axial line of the hole 83 a (rotational axis) than the pressure catching portion 40 b , as it is during the mounting of the cartridge 7 . Therefore, the amount of force necessary for the operation to remove the cartridge 7 in this embodiment is smaller than the amount of force necessary for the operation to remove a cartridge 7 in accordance with the prior art, as it is during the mounting of the cartridge 7 .
[0098] Incidentally, whether mounting the cartridge 7 into the main assembly 100 a , or removing the cartridge 7 from the main assembly 100 a , it is necessary to move the pressing member 83 in the direction perpendicular to the cartridge mounting direction. In this embodiment, however, the projection 83 d of the pressure catching portion 83 c is provided with the gently slanted surfaces on the upstream and downstream sides, one for one, in terms of the cartridge mounting direction. Further, the projection 40 d of the pushing portion 40 c is provided with gently slanted surfaces on the upstream and downstream, one for one, in terms of the cartridge mounting direction. Further, when the cartridge 7 is mounted, the slanted surface 40 e of the pushing portion 40 c comes into contact with the slanted surface 83 e of the pressure catching portion 83 c , whereas when the cartridge 7 is removed, the slanted surface 40 f of the pushing portion 40 c comes into contact with the slanted surface 83 f of the pressure catching portion 83 c . The movement of the pressing member 83 in the direction of the arrow mark X begins under the above described condition. In other words, the cartridge pressing mechanism in this embodiment is structured so that the slanted surfaces of the cartridge 7 remain in contact with the slanted surfaces of the main assembly 100 a while the pressing member 83 moves. Therefore, the cartridge 7 smoothly moves into the main assembly when the cartridge is mounted, and also, smoothly comes out of the main assembly when the cartridge 7 is removed.
(b) Trailing End Side: Operations of Cartridge Pressing Mechanism During Mounting and Removal of Cartridge
[0099] FIG. 10 is a plan view of the left-hand side (as seen from front side) of the cartridge pressing front mechanism of the main assembly. FIG. 11 is a plan view of the front side of the cartridge pressing front (trailing end side in terms of cartridge mounting direction) mechanism of the main assembly.
[0100] As the cartridge 7 is inserted, the slanted surface 50 e of the pushing portion 50 c of the bearing 50 , that is, the front bearing of the cartridge 7 , comes into contact with the slanted surface 93 e of the cartridge catching portion 93 c (standby position), as shown in FIGS. 10( a ) and 11 ( a ). Then, as the cartridge 7 is inserted further, the upwardly pulling member 93 is gradually pushed down, causing the projection 50 d of the pushing portion 50 c to come into contact with the projection 93 d of the cartridge catching portion 93 c , as shown in FIG. 10( b ). Consequently, the upwardly pulling member 93 retreats in the direction indicated by an arrow mark Y (position in retreat). More specifically, the upwardly pulling member 93 retreats into a position in which its upward force applying portion 93 b does not contact the upward force catching portion 50 b of the cartridge 7 , as shown in FIG. 11( b ). Therefore, while the cartridge 7 is mounted, the upward force catching portion 50 b is not subjected to the upward pressure.
[0101] The pressure which the cartridge 7 receives from the upwardly pulling member 93 when it is mounted is removed by the pushing portion 50 c , which is located further from the axial line of the hole 93 a than the upward force catching portion 50 b . That is, the amount of force necessary to push down the upwardly pulling member 93 against the force which acts to upwardly push the cartridge 7 is reduced by an amount equivalent to the ratio between the distance from the axial line of the hole 93 a to the upward force catching portion 50 b (upwardly pulling force applying portion 93 b ) and the distance from the axial line of the hole 93 a to the pushing portion 50 c (upwardly pulling member 93 ). Therefore, the amount of load to which the cartridge 7 is subjected when it is mounted is substantially smaller than the amount of pressure which the cartridge 7 receives from the upwardly pulling member 93 ; the amount of force required to mount the cartridge 7 is substantially smaller than the amount of force which the cartridge 7 receives from the upwardly pulling member 93 .
[0102] Further, when the cartridge 7 is mounted, the cartridge 7 is subjected to upward force, that is, the reactive force generated as the upwardly pulling member 93 is pushed down into its retreat. However, the contacting surface 50 h comes into contact with the cartridge movement regulating portion 96 , that is, the cartridge contacting second portion of the main assembly. Therefore, the cartridge 7 is prevented from moving upward. Here, the cartridge movement regulating portion 96 of the main assembly and the main assembly contacting surface 50 h are positioned so that they remain in contact with each other until immediately before the cartridge positioning portion 50 a is correctly positioned by coming into contact with the cartridge catching portion 92 a . Therefore, while the cartridge 7 is mounted, more specifically, from the moment the cartridge 7 begins to receive the upward force from the upwardly pulling member 93 until immediately before the cartridge 7 is correctly positioned, the cartridge movement regulating portion 96 , that is, the cartridge regulating portion of the main assembly, which is formed of resin, and the cartridge contacting surface 50 h , slide on each other, and therefore, the cartridge positioning portion 50 a does not rub against the cartridge catching portion 92 a of the main assembly, which is formed of a thin sheet of steel or the like. Therefore, the problem that the cartridge positioning portion 50 a is shaved by the cartridge catching portion 92 a is prevented.
[0103] As the cartridge 7 is inserted even further, the cartridge catching portion 93 c is disengaged from the pushing portion 50 c , and therefore, the upwardly pulling portion 93 gradually returns to the upwardly pulling position from the retreat. Then, the cartridge 7 is inserted far enough for the contacting surface 50 i , which is for correctly positioning the cartridge 7 in terms of the lengthwise direction of the cartridge 7 , to come into contact with the lateral plate 82 , that is, the rear lateral plate of the main assembly, the upwardly pulling portion 93 b comes into contact with the cartridge catching portion 50 b , as shown in FIGS. 10( c ) and 11 ( c ), causing the cartridge 7 to be pressed (pressing position) in the direction indicated by an arrow mark K (upwardly pulling direction in FIG. 11) . During this process, the cartridge positioning portion 50 a of the cartridge 7 bumps into the cartridge catching portion 92 a of the frontal lateral plate 92 of the main assembly, correctly positioning thereby the cartridge 7 in terms of the direction perpendicular to the cartridge mounting direction. Also during this process, the cartridge movement regulating portion 96 of the main assembly becomes disengaged from the contacting surface 50 h ; a preset amount of gap is created between the cartridge movement regulating portion 96 and the recessed surface 50 g . At the same time, the cartridge catching portion 93 c moves past the pushing portion 50 c ; a preset amount of gap is created between the cartridge catching portion 93 c and the recessed surface 50 j.
[0104] As described above, the cartridge pressing mechanism is structured so that the upwardly pulling member 93 is enabled to move into the standby position, upwardly pulling (pressing) position, and retreat. More specifically, in terms of the top to bottom direction, the standby position, upwardly pulling (pressing) position, and retreat are located in the listed order. Therefore, the upwardly pulling member 93 applies to the cartridge 7 a sufficient amount of pressure for pulling up the cartridge 7 .
[0105] When removing the cartridge 7 from the main assembly 100 a , the cartridge mounting operation described above is to be carried out in reverse. The upward force which the cartridge 7 receives from the upwardly pulling member 93 is removed by the pushing portion 50 c , which is more distant from the axial line of the hole 93 a (rotational axis of pulling member 93 ) than the upward force catching portion 50 b , as it is during the mounting of the cartridge 7 . Therefore, the amount of force necessary for the operation to remove the cartridge 7 in this embodiment is significantly smaller than the amount of force necessary for the operation to remove a cartridge 7 in accordance with the prior art, as the amount of the force necessary for the operation to mount the cartridge 7 in this embodiment is significantly smaller than the amount of force necessary for the operation to mount a cartridge in accordance with the prior art.
[0106] Incidentally, whether mounting the cartridge 7 into the main assembly 100 a , or removing the cartridge 7 from the main assembly 100 a , it is necessary to move the upwardly pulling member 93 in the direction perpendicular to the cartridge mounting direction. In this embodiment, however, the projection 93 d of the pressure catching portion 93 c is provided with the gently slanted surfaces, which are on the upstream and downstream sides, one for one, in terms of the cartridge mounting direction. Further, the projection 50 d of the pushing portion 50 c is provided with gently slanted surfaces, which are on the upstream and downstream, one for one, in terms of the cartridge mounting direction. Thus, when the cartridge 7 is mounted, the slanted surface 50 e of the pushing portion 50 c comes into contact with the slanted surface 93 e of the pressure catching portion 93 c , whereas when the cartridge 7 is removed, the slanted surface 50 f of the pushing portion 50 c comes into contact with the slanted surface 93 f of the pressure catching portion 93 c . It is under this condition that the movement of the upwardly pulling member 93 in the direction of the arrow mark Y begins. In other words, the cartridge pressing mechanism in this embodiment is structured so that the slanted surfaces of the cartridge 7 remain in contact with the slanted surfaces of the main assembly 100 a while the upwardly pulling member 93 moves. Therefore, the cartridge 7 smoothly moves into the main assembly when the cartridge is mounted, and also, smoothly comes out of the main assembly when the cartridge 7 is removed.
[0107] Incidentally, when the cartridge 7 is mounted or removed, the operation of the cartridge pressing mechanism in this embodiment occurs on the leading and trailing end sides, in terms of the cartridge mounting direction, roughly at the same time. Further, the direction in which the pressing member 83 , that is, the rear pressing member, is rotated is opposite from the direction in which the pressing member 93 (upwardly pulling member), that is, the front pressing member, is rotated.
[0108] To describe in more detail, referring to FIGS. 12( a ) and 12 ( b ), on the leading end side in terms of the direction perpendicular to the cartridge mounting direction, the axial line of the hole 83 a is on the left side of Line L, which coincides with the axial line of the photosensitive drum 1 and extends in the direction parallel to the direction in which the cartridge 7 is moved to be correctly positioned, and the pressure catching portion 83 c is on the right side of Line L. On the other hand, on the trailing end side, the axial line of the hole 93 a is on the right-hand side of the abovementioned Line L, and the pressure catching portion 93 c is on the left-hand side of Line L; the positional relationship between the hole and pressure catching portion of the pressing portion on the leading end side is opposite to that on the trailing end side.
[0109] That is, the pressing member 83 , which is on the rear side of the main assembly, is rotated in the direction indicated by an arrow mark M when it is moved into the retreat, whereas the upwardly pulling member 93 , which is on the front side of the main assembly, is rotated in the direction indicated by an arrow mark N when it is moved into the retreat. Therefore, the loads from the pressing members 83 and 93 , that is, the pressing members on the rear and front sides of the main assembly, to which the pushing portions 40 c and 50 c are subjected when the cartridge 7 is mounted or removed, act in the directions indicated by arrow marks P 1 and P 2 , respectively, in FIGS. 12( a ) and 12 ( c ). The angles of the directions P 1 and P 2 of these loads are preset relative to Line L, which extends in the direction in which the cartridge is pushed up. Further, the abovementioned angles are roughly symmetrical with reference to Line L, which extends in the direction parallel to the directions P 1 and P 2 of the load, that is, the direction in which the cartridge 7 is upwardly pushed, as shown in FIG. 12( c 0 . Therefore, when the cartridge 7 is mounted or removed, its remains stable in attitude, being therefore significantly better in operability than a cartridge in accordance with the prior art.
(Structural Arrangement for Preventing Shaving of Cartridge Positioning Portion of Cartridge)
[0110] The cartridge 7 in this embodiment is prevented from being shaved across its cartridge positioning portion when it is mounted into, or removed from, the main assembly 100 a . This embodiment can reduce the problem that when the cartridge 7 is mounted into the main assembly 100 a , the cartridge positioning first and second portions (portions 40 a and 50 a ) of the cartridge 7 rub against the corresponding portions (members) of the main assembly 100 a . Further, this embodiment can reduce the problem that when the cartridge 7 is mounted into the main assembly 100 a , the abovementioned cartridge positioning first and second portions are placed in contact with the corresponding portions (members) of the main assembly 100 a.
[0111] That is, as described above, the bearings 40 and 50 , that is, the bearings on the leading and trailing end sides, in terms of the cartridge mounting direction, are provided with the contacting portions 40 h and 50 h , which protrude upward beyond the cartridge positioning portions 40 a and 50 a , which also are the portions of their peripheral surfaces. These contacting portions 40 h and 50 h are flat across the top surface, and positioned on one side of the cartridge positioning portion of the cartridge 7 , and the other, respectively.
[0112] As the cartridge 7 is inserted into the main assembly 100 a structured as described above, the cartridge 7 is subjected to the upward force, that is, the reactive force generated as the pressing member 83 , that is, the cartridge pressing rear member, and the upwardly pulling member 93 , that is, the cartridge pressing front member, are pushed downward into their retreats. During this process, the contacting portion 40 h (surface) comes into contact with the cartridge movement regulating portion 86 , that is, the cartridge contacting first portion of the main assembly, and the contacting portion 50 h (surface) comes into contact with the cartridge movement regulating portion 96 , that is, the cartridge contacting second portion of the main assembly. Therefore, the cartridge 7 is prevented from moving upward.
[0113] Here, the cartridge pressing mechanism is structured so that the cartridge movement regulating portion 86 , that is, the cartridge movement regulating portion of the main assembly, which is on the rear side of the main assembly, and the contacting portion 40 h (surface) remain in contact with each other until immediately before the cartridge positioning portion 40 a is correctly positioned by coming into contact with the cartridge catching portion 82 a . Similarly, the cartridge movement regulating portion 96 , that is, the cartridge movement regulating portion of the main assembly, which is on the front side of the main assembly, and the contacting portion 50 h (surface) remain in contact with each other until immediately before the cartridge positioning portion 50 a is correctly positioned by coming into contact with the cartridge catching portion 92 a.
[0114] Therefore, while the cartridge 7 is mounted, more specifically, from the moment the cartridge 7 begins to receive the upward force from the pressing member 83 and upwardly pulling member 93 until immediately before the cartridge 7 is correctly positioned, the cartridge movement regulating portions 86 and 96 , that is, the cartridge regulating portions of the main assembly, which is formed of resin, and the cartridge contacting surfaces 40 h and 50 h , slide on the cartridge movement regulating portions 86 and 96 , respectively, and therefore, the cartridge positioning portions 40 a and 50 a , which are on the rear and front sides, do not rub against the cartridge catching portions 82 a and 92 a of the main assembly, which are formed of a thin sheet of steel or the like. Therefore, the problem that the cartridge positioning portions 40 a and 50 a are shaved by the cartridge catching portions 82 a and 92 a is prevented.
[0115] As described above, the cartridge pressing mechanism is structured so that the cartridge 7 is mounted or removed while cancelling the cartridge pressing force by the pressure applied to the point of the pressing member, which is farther from the portion of the pressing member, by which the pressing member presses on the cartridge 7 . Therefore, the amount of force necessary to mount or remove the cartridge 7 is sufficiently small relative to the amount of force (pressure) which the cartridge 7 receives from the pressing member. Thus, the amount of force required to mount the cartridge 7 , that is, the cartridge in this embodiment, into the main assembly of the image forming apparatus in this embodiment, or remove the cartridge 7 from the image forming apparatus in this embodiment, is significantly smaller than that required to mount a cartridge in accordance with the prior art into the main assembly of an image forming apparatus in accordance with the prior art, or removing the cartridge in accordance with the prior art from the main assembly of the image forming apparatus in accordance with the prior art. In other words, the present invention can provide a cartridge and an image forming apparatus, which are significantly better in operability in terms of the mounting of the cartridge.
[0116] Further, when mounting the cartridge 7 into the main assembly 100 a , or removing the cartridge 7 from the main assembly 100 a , the cartridge positioning members are prevented from being shaved. Therefore, it is ensured that the cartridge 7 is correctly positioned.
[0117] Incidentally, the structure of the image forming apparatus in this embodiment is such that the cartridges are juxtaposed side by side (in parallel) in a horizontal straight row, and also, that the intermediary transfer unit is disposed on the top side of the cartridges so that the cartridges can be pressed upward from below by the pressing members. However, this embodiment is not intended to limit the present invention in terms of image forming apparatus structure. For example, the present invention is also applicable to an image forming apparatus structured so that its intermediary transfer unit is on the under side of the cartridges, and the cartridges are pressed downward from above by the pressing member (pressuring member). In the case of such a structural arrangement, the photosensitive drum 1 is placed in contact with the intermediary transfer belt 5 by applying downward pressure to the cartridge 7 .
[0118] In the case of an image forming apparatus, such as the one in this embodiment, which is structured so that the cartridges are pressed from below, the amount of force necessary to press a cartridge to correctly position the cartridge needs to be set in consideration of the weight of the cartridge itself. Therefore, it must be greater than the amount of force necessary to press a cartridge in an image forming apparatus structured so that the cartridge is pressed from above, and so is the amount of force necessary to push down the pressing member. Thus, the effects of the present invention can be further enhanced by structuring the image forming apparatus so that the cartridge can be mounted or removed while cancelling the pressure applied to the cartridge by the cartridge pressing portion of the cartridge pressing member, by the portion of the cartridge pressing member, which is farther from the rotational axis of the cartridge pressing member than the cartridge pressing portion of the cartridge pressing member.
[0119] Also in this embodiment, it is on both the leading and trailing end sides of the cartridge, in terms of the cartridge mounting direction, that the force from the cartridge pressing member (inclusive of upwardly pulling member) is cancelled by the portion of the cartridge pressing member, which is farther from the axial line the pressing member than the cartridge pressing portion of the pressing member while the cartridge is mounted or removed. However, this embodiment is not intended to limit the present invention in scope in terms of the structure of an image forming apparatus. For example, an image forming apparatus may be structured so that only one end of the image forming apparatus, that is, either the leading or trailing end in terms of the cartridge mounting direction, is provided with the cartridge pressing member. However, an image forming apparatus having the pressing member on both the leading and trailing end in terms of the cartridge mounting direction is smaller in the total amount of force necessary to mount or remove the cartridge than an image forming apparatus having the cartridge pressing member on only the leading or trailing end in terms of the cartridge mounting direction. Also as described above, by structuring an image forming apparatus so that the cartridge pressing member on the rear side, and the cartridge pressing member (cartridge pulling member) on the front side, are symmetrical with respect to the direction in which the load from the pressing member is pushed up, it is possible to keep the cartridge 7 stable in attitude when mounting or removing the cartridge 7 , enhancing further the effects of this embodiment of the present invention.
Embodiment 2
[0120] Next, referring to FIGS. 13 and 14 , the second embodiment of the present invention will be described. By the way, this embodiment is the same in the basic structure of an image forming apparatus as the first embodiment described above. Therefore, this embodiment will be described regarding only the structural features different from those in the first embodiment to avoid the repetition of the same description. Further, the members, portions, etc., of the image forming apparatus in this embodiment, which are the same in function as those in the first embodiment described above, are given the same referential symbols.
[0121] FIG. 13 is an external perspective view of the cartridge in this embodiment. FIG. 14 is a schematic perspective view of the cartridge positioning member and cartridge pressing member on the rear side of the main assembly of the image forming apparatus, showing their structures.
[0122] The image forming apparatus in the first embodiment was structured so that the bearing of the cartridge 7 , which is on the leading end, in terms of the direction in which the cartridge 7 is mounted into the main assembly of the image forming apparatus, is provided with the pressing member 83 having the pushing portion 83 c for pushing down the cartridge 7 . In this embodiment, the image forming apparatus structured so that the pushing portion for pushing down the pressing member is a part of the development unit, will be described.
[0123] Referring to FIG. 12 , it is the development unit 4 that is provided with a pressing member pushing portion 140 c , which is for moving the pressing member into its retreat. The pushing portion 140 c protrudes downstream from the downstream end of the cartridge 7 in terms of the cartridge mounting direction. The end portion of the pushing portion 140 c is provided with a projection 140 d , which projects downward. The projection 140 d is provided with two surfaces 140 e and 140 f , which are gently slanted so that the intersection of the two surfaces is the peak of the projection 140 d . In terms of the direction perpendicular to the cartridge mounting direction, the pushing portion 140 c is on the opposite side of the pressure catching portion 40 b from the axial line of the hole 183 a ( FIG. 14 ) of the cartridge pressing member 183 (pressure applying member), which will be described later. Further, the pushing portion 140 c is located farther from the axial line of the hole 183 a than the pressure catching portion 40 b.
[0124] Referring to FIG. 14 , as for the main assembly 100 a , it is provided with the cartridge pressing member 183 , which is for pressing the cartridge 7 toward the cartridge catching portion 82 a (pressure catching portion). The pressing member 183 is located below the cartridge catching portion 82 a . The pressing member 183 is attached to the lateral plate 82 , that is, the lateral plate of the main assembly on the rear side; the shaft 84 solid attached to the lateral plate 82 is put through the hole 183 a of the pressing member 183 so that the pivotal axis of the pressing member 183 coincides with the axial line of the hole 183 a . Further, the pressing member 183 is rotatably attached to the lateral plate 82 so that it is rotatably movable to the cartridge pressing position, in which it presses the cartridge 7 upon the cartridge catching portion 82 a , and the retreat into which it is moved to remove the pressure which it applies to the cartridge 7 .
[0125] Further, the pressing member 183 is provided with a pressing portion 183 b , which presses on the cartridge 7 when the pressing member 183 is in the pressing position. The pressing portion 183 b corresponds in position to the pressure catching portion 40 b of the cartridge 7 . The pressing member 183 is also provided with a pressure catching portion 183 c , which is for moving the pressing member 183 into the retreat. The pressure catching portion 183 c corresponds in position to the pushing portion 140 c of the cartridge 7 .
[0126] The pressure catching portion 183 c is provided with an upward projection 183 d , which has two surfaces 183 e and 183 f . The surfaces 183 e and 183 f are on the downstream and upstream sides, respectively, in terms of the cartridge mounting direction, and are gently slanted so that their intersection is the peak of the projection 183 d.
[0127] In terms of the direction perpendicular to the cartridge mounting direction, the pressure catching portion 183 c is on the opposite side of the pressing portion 183 b from the axial line of the hole 183 a . Further, the pressure catching portion 183 c is located farther from the axial line of the hole 183 a than the pressing portion 183 b.
[0128] Next, the movement of the components of the cartridge pressing mechanism in this embodiment, which occur when the cartridge 7 is mounted into the image forming apparatus 100 , will be described. FIG. 16 is a plan view of the cartridge pressing rear mechanism, as seen from the left side (as seen from front side of image forming apparatus) of the main assembly of the image forming apparatus, and shows the operation of the cartridge pressing member, which occurs when the cartridge 7 is mounted into the main assembly 100 . FIG. 17 is a plan view of the cartridge pressing rear mechanism, as seen from the leading end side of the cartridge 7 in terms of the cartridge mounting direction, and shows the operation of the pressing member.
[0129] The cartridge 7 is mounted in the direction indicated by an arrow mark F shown in FIG. 16( a ). Referring to FIGS. 16( a ) and 17 ( a ), as the cartridge 7 is inserted, the slanted surface 140 e of the pushing portion 140 c of the development unit 4 comes into contact with the slanted surface 183 e of the cartridge catching portion 183 c (standby position). Then, as the cartridge 7 is inserted further, the pressing member 183 is gradually pushed down, causing the projection 140 d of the pushing portion 140 c to come into contact with the projection 183 d of the cartridge catching portion 183 c , as shown in FIG. 16( b ). Consequently, the pressing member 183 retreats in the direction indicated by an arrow mark T (position in retreat). More specifically, the pressing member 183 retreats into the position (position in retreat) in which its pressing portion 183 b does not contact the pressure catching portion 140 b of the cartridge 7 , as shown in FIG. 17( b ). Therefore, while the cartridge 7 is mounted, the pressure catching portion 140 b is not subjected to any pressure. The pressure which the cartridge 7 receives from the pressing member 183 when it is mounted is cancelled by the pushing portion 140 c , which is located further from the rotational axis of the pressing member 183 , which coincides with the axial line of the hole 183 a . That is, the amount of force necessary to push down the pressing member 183 against the force which acts to upwardly pushing the cartridge 7 is reduced by the ratio between the distance from the axial line of the hole 183 a to the pressure catching portion 140 b (pushing portion 183 b ) and the distance from the axial line of the hole 183 a to the pushing portion 140 c (pressure catching portion 183 c ). Therefore, the amount of load to which the cartridge 7 is subjected when it is mounted is substantially smaller than the amount of pressure which the cartridge 7 receives from the pressing member 183 ; the amount of force required to mount the cartridge 7 is substantially smaller than the amount of the pressure required to mount a cartridge ( 7 ) in accordance with the prior art.
[0130] Further, when the cartridge 7 is mounted, the cartridge 7 is subjected to upward force, that is, the reactive force generated as the pressing member 183 is pushed down into its retreat. However, the contacting surface 40 h comes into contact with the cartridge movement regulating portion 86 , that is, the cartridge contacting first portion of the main assembly. Therefore, the cartridge 7 is prevented from being moved upward. Here, the cartridge movement regulating portion 86 of the main assembly and the main assembly contacting second surface 40 h of the cartridge 7 are positioned so that they remain in contact with each other until immediately before the cartridge positioning portion 40 (a pressure catching portion) is correctly positioned by coming into contact with the cartridge catching portion 82 a . Therefore, while the cartridge 7 is mounted, more specifically, from the moment the cartridge 7 begins to receive the upward pressure from the pressing member 183 until immediately before the cartridge 7 is correctly positioned, the cartridge movement regulating portion 86 , that is, the cartridge movement regulating portion of the main assembly, which is formed of resin, and the contacting surface 40 h , slide on each other, and the pressure catching portion 40 a (cartridge positioning portion of cartridge) does not rub against the cartridge catching portion 82 a of the main assembly, which is formed of a thin sheet of steel or the like. Therefore, the problem that the cartridge positioning portion 40 a is shaved by the cartridge catching portion 82 a is prevented.
[0131] As the cartridge is inserted even further, the cartridge catching portion 183 c is disengaged from the pushing portion 140 c , and therefore, the pressing member 183 gradually returns to the pressing position from the retreat. Then, the cartridge 7 is inserted far enough for the contacting surface 40 i , which is for correctly positioning the cartridge 7 in terms of the lengthwise direction of the cartridge 7 , to come into contact with the lateral plate 82 , that is, the rear lateral plate of the main assembly, the pressing portion 183 b comes into contact with the pressure catching portion 40 b , as shown in FIGS. 16( c ) and 17 ( c ), causing the cartridge 7 to be pressed (pressing position) in the direction indicated by an arrow mark S (pressing direction). During this process, the cartridge positioning portion 40 a of the cartridge 7 bumps into the cartridge catching portion 82 a of the rear lateral plate 82 of the main assembly, correctly positioning thereby the cartridge 7 in terms of the direction perpendicular to the cartridge mounting direction. Also during this process, the cartridge movement regulating portion 86 of the main assembly becomes disengaged from the second contacting surface 40 h ; a preset amount of gap is provided between the cartridge movement regulating portion 86 and the surface 40 g (recessed surface). At the same time, the cartridge catching portion 183 c moves past the pushing portion 140 c ; a preset amount of gap is provided between the cartridge catching portion 183 c and the recessed surface 140 j.
[0132] Also in this embodiment, the pressing member 183 is enabled to apply a sufficient amount of pressure to the cartridge 7 .
[0133] When removing the cartridge 7 from the main assembly 100 a , the cartridge mounting operation described above is to be carried out in reverse. The upward force which the cartridge 7 receives from the pressing member 183 is cancelled by the pushing portion 140 c , which is located farther from the axial line of the hole 183 a , as it is during the mounting of the cartridge 7 . Therefore, the amount of force necessary for the operation to remove the cartridge 7 in this embodiment is significantly smaller than the amount of force necessary for the operation to remove a cartridge 7 in accordance with the prior art, as the amount of the force necessary for the operation to mount the cartridge 7 in this embodiment is significantly smaller than the amount of force necessary for the operation to mount a cartridge in accordance with the prior art.
[0134] Further, as the cartridge catching portion 82 a of the main assembly becomes disengaged from the pressure catching portion 40 a (cartridge positioning portion of cartridge), the cartridge movement regulating portion 86 of the main assembly comes into contact with the second contacting surface 40 h . Further, even during the removal of the cartridge 7 , the cartridge movement regulating portion 86 of the main assembly, which is formed of resin, and the second contacting surface 40 h , slide against each other, preventing thereby the pressure catching portion 40 a from rubbing against the cartridge catching portion 82 a of the lateral plate of the main assembly, as long as the cartridge 7 is under the upward force applied by the pressing member 183 . Therefore, the problem that the pressure catching portion 40 a (cartridge positioning portion of cartridge) is shaved by the cartridge catching portion 82 a as it rubs against the cartridge catching portion 82 a is prevented.
[0135] In this embodiment, only the portion of the development unit 4 , which corresponds in position to the rear end side of the main assembly of the image forming apparatus, is provided with the pushing portion. However, it may be only the front end of the development unit that is provided with the pushing portion. The effects of providing only the front end of the development unit with the pushing portion are the same as that achievable by providing only the rear end of the development unit with the pushing portion.
[0136] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
[0137] This application claims priority from Japanese Patent Applications Nos. 331309/2006 filed Dec. 8, 2006, and 266399/2007 filed Oct. 12, 2007, which are hereby incorporated by reference. | A process cartridge is detachably mountable to a main assembly of an electrophotographic image forming apparatus. The cartridge includes a drum, first and second guidable portions guidable by first and second guides when the cartridge enters or advances in the main assembly, first and second regulatable portions provided at leading and trailing sides of the cartridge with respect to the advancing direction and regulated by a first main assembly regulator when the process is advancing in the main assembly, and first and second positionable portions to be positioned at first and main assembly second positioners, respectively, by the urging force of a main assembly urging member after the first and second regulatable portions pass the first and second regulators, respectively. The cartridge is mounted to the main assembly with the first and second positionable portions at the first and second positioners, respectively, by the urging force of the urging member. | 6 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method and a system for prediction and treatment of hydrodynamic and terrain-induced slugs being transported in a multi-phase flow line.
The method and the system according to the present invention can be adapted to any production system, e.g. flow line system or wellbore tubing, transporting a multiphase fluid towards a downstream process including a separator (two- or three-phase) or a slug catcher at the inlet, in which there is regulation of both pressure and liquid level(s). The multiphase fluid normally consists of a mixture of an oil (or a condensate) phase, gas and water.
2. Description of Related Art
A typical production system where the present invention could be implemented includes multiphase transport from platform wells, from subsea wells towards a subsea separator, from a subsea production template towards an offshore platform including a riser, between offshore platforms, from a subsea production system towards an onshore process facility or between onshore process facilities.
Depending on fluid properties, flow line characteristics and superficial velocities of the different fluid phases, a multiphase production system might give what is known as slug flow, experienced as fluctuating mass flow and pressure at the production system outlet. Further, if these slugs are “large” compared to the design of the downstream equipment, the fluctuations could propagate into the process and reach a level untenable to the operators. As a consequence, and as a precaution to avoid a process trip, there are numerous examples where multiphase production lines have been choked down due to incoming slugs.
Slugs are normally initiated in two ways that are fundamentally different. Terrain-induced slugs are caused by gravity effects when the velocity differences, and thus the interfacial friction, between the separate fluid phases is too small to allow the lightest fluid(s) to counteract the effect of gravity on the heavier fluid(s) in upward inclinations. Hydrodynamic slugs (identified in a flow regime envelope as a function of the pipe angle and the superficial fluid velocities for a given fluid) are formed by waves growing on the liquid surface to a height sufficient to completely fill the pipe. Because of differences in the velocities of the various fluid phases up- and downstream of this hydrodynamic slug, an accumulation of liquid and thus a dynamic slug growth can occur.
Hydrodynamic slugs too are affected by the flow line elevation profile, since their formation and growth depend on the pipe angles. Note, however, that an obvious way to prove the distinction between terrain-induced and hydrodynamic slugs is that hydrodynamic slugs could be formed in 100% horizontal flow lines (sometimes even in downwards inclination), whereas terrain-induced slugs somehow need an up-wards inclination.
Slugging is by definition a transient phenomenon, and steady state conditions are hard to achieve in a slugging flow line system. In such a system, hydrocarbon liquid (alternatively water or a hydrocarbon/water mixture) accumulates along the production system and the slugs will at some point reach the flow line exit. Between these slugs, there will be periods where small amounts of liquid exiting the system and the process will more or less receive a single gas phase, also described as gas slugs.
In order to overcome process disturbances due to slugging (terrain-induced or hydrodynamic), three methods have traditionally been used in multiphase transportation systems:
Reduce the flow rate and thereby the slug volumes within the limits of the downstream process, by throttling the inlet choke or by selecting a smaller flow line diameter in the design phase Prolong start-up time or ramp up time when changing flow rates Increase if possible the dimensions of the downstream process (i.e. slug catcher, alternatively the 1 st stage separator)
These “traditional” methods will either reduce production from the flow line systems in question or increase the costs and dimensions of the downstream process. Additionally, even if accounted for, slugs might grow larger than expected or could occur at unfortunate moments compared to actual process capabilities. As a consequence, the pressure and flow fluctuations could result in process shut-downs, which might have significant financial impacts.
Since every gas and oil producer wants to optimize the operating conditions of their process plants, there have been several attempts to find improved solutions to overcome process perturbations caused by slugging in the upstream production system.
U.S. Pat. No. 5,544,672 describes a system for mitigation of slug flow. It detects incoming slugs upstream of the separator and performs a rough calculation of their respective volumes. These slug volumes are thereafter compared with the liquid handling capacity of the separator. If the estimated volume of the incoming slugs exceeds the liquid slug handling capacity of the separator, a throttling valve located upstream of the separator is choked.
This solution has the advantage that it is simple and could be used for both hydrodynamic as well as terrain-induced slugs, since it is located downstream of the point where slugs are generated. However, the system entails some major disadvantages:
Since the flow rate is being throttled down, it has a negative impact on the production and thereby the field economics. It does not take into account the slug handling capacity in the downstream process. It does not describe how gas slugs are identified and treated. As a consequence pressure fluctuations in the separator due to incoming gas slugs must still be solved by gas flaring. The system does not separate water slugs from hydrocarbon (HC) liquid slugs which could give process perturbations downstream of a three-phase separator. It prolongs the start-up time after system shut-down, since the production is being throttled down every time a liquid slug is present.
International Patent Application WO 01/34940 describes a small (mini-) separator located at the top of the riser just upstream of the 1 st stage separator. Slugs are either suppressed by volumetric flow controller or liquid flow controller mode, depending on the slug characteristics. Regulation is achieved by two fast acting valves on the gas and liquid outlet streams downstream of the mini-separator, based on pressure and liquid level data from the mini-separator as well as flow rate measurements of its outlet streams.
Moreover, the International Patent Application WO 02/46577 describes a model-based feedback control system for stabilization of slug flow in multiphase flow lines and risers. The system consists of a single fast acting valve located at the outlet of the transport system, i.e. upstream of the separator. The opening of this valve is adjusted by a single output control signal from the feedback controller that uses continuous monitoring of pressure upstream of the point where slugs are generated as the main input parameter. This control system is specially suited for terrain-induced slugs since any liquid accumulation is detected by pressure increase upstream of the slug (due to static pressure across the liquid column). However, the system does not show the same performance for slugs which are hydrodynamic by nature since these slugs could be formed in perfectly horizontal flow lines, and thereby not cause a build-up of pressure upstream of the slug.
Briefly, for the two latter slug control systems, fast acting equipment located at the outlet of the transportation system, in combination with quick response time of the control loops are used to suppress development of slugs, by immediately counteracting the forces contributing to slug growth.
However, these solutions also entail several disadvantages:
As for the slug mitigation system they do not take into account the slug handling capacity in the downstream process. The control system described in WO 02/46577 does not cater to hydro-dynamic slugs, while the system described in WO 01/34940 handles slugs which are terrain-induced by nature far better than hydrodynamic slugs. They are normally not self-regulating for any operational range in the transport system, and the systems require manual input from an operator or must be de-activated during some of the normal production scenarios. They both require fast acting valve(s) in combination with quick response time of the control loops. They generalize on flow line systems including vertical piping (i.e. risers or tubing) at the outlet of the transport system. The system described in WO 01/34940 requires topside equipment and could be costly, especially in the case of weight being an issue.
Generally speaking, none of the existing systems fully integrates the transport system and the downstream process. Hence, they do not cover the full range of incoming slugs including hydrodynamic slugs as well as gas and water slugs. Finally, their application is limited to a narrow operating range and they require manual input or de-activation at some time.
SUMMARY OF THE INVENTION
In light of the shortcomings mentioned above, the inventors have found that there is a need for a more efficient method and system for prediction and treatment of slugs. The present invention describes a method and a system applicable in connection with a downstream process in which the disadvantages of former systems have been eliminated. The basic idea is to fully integrate the production system and the downstream process. The main advantages of the invention is that it utilizes the whole downstream process for slug treatment and it applies to any kind of slug normally present in a multiphase flow line system independent of the type or nature of the slug. It will also cover any operating range if it is properly designed.
In accordance with the present invention, this objective is accomplished in a method of the above kind in that said method comprises the following steps: detecting said slug downstream of the point for slug initiation and upstream of said process by means of a slug detector, determining and measuring all main characteristics of said slug by means of a computer unit that receives all signals from said slug detector. The computer unit receives signals from all instruments needed for regulation of pressure and liquid levels from every separator or slug catcher in the liquid trains of the entire downstream process. The computer unit determines the nature of every incoming slug and predicts its arrival time to said separator or slug catcher and corresponding volume and compares it with the actual slug handling capability of said process. The computer unit processes all of the incoming data in order to find an optimum regulation of said downstream process so that process perturbations due to incoming slugs are reduced to a minimum throughout the entire process. The regulation of said process is achieved by means of choke adjustments or by adjusting the speed of compressors or pumps connected to each separator.
Furthermore, in accordance with the present invention, this objective is accomplished in a system of the above kind in that the system comprises a slug detector located downstream of the point for slug initiation and upstream of said process inlet including instruments dedicated to determine and measure the main slug characteristics of every incoming slug, a computer unit integrated into said flow line system and said downstream process including software which determines the type of the slug, its volume and predicts its arrival time into said downstream process.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in further detail in connection with the following figures, where:
FIG. 1 shows a process diagram of the present invention in its simplest form implemented in an offshore production system producing towards an onshore process including a vertical two-phase slug catcher at the inlet of the process;
FIG. 2 shows a simplified process diagram of the present invention implemented in an offshore production system including a riser producing towards a horizontal three-phase separator; and
FIG. 3 shows a simplified process diagram of the present invention implemented in an offshore production system including a riser and a horizontal three-phase separator at the process inlet.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a process diagram of the present invention in its simplest form implemented in an offshore production system producing towards an onshore process including a vertical two-phase slug catcher 8 at the inlet of the process. It is further seen that the slug catcher pressure 3 is controlled by adjustment of a gas outlet valve 6 . Correspondingly, its liquid level 9 is controlled by adjustment of a liquid outlet valve 7 .
A simple description of the invention is as follows: The distance 2 between the slug detector 1 and the process has been optimized with respect to the process and its parameters for regulation. When the slug detector 1 detects a liquid slug, the computer unit 4 determines its nature and calculates its arrival time and volume. Based on this information and the current liquid level 9 in slug catcher 8 , the computer unit immediately sends a signal to the liquid valve 7 to start liquid draining of the slug catcher 8 , prior to slug arrival. When the liquid slug finally arrives at the slug catcher, the liquid level will already be adjusted to near low alarm, and the liquid outlet valve 7 will be nearly fully opened. Moreover, when the slug tail is detected, the liquid valve 7 starts closing before the slug tail enters the separator. Correspondingly, when a gas slug is detected, measures are taken to reduce slug catcher pressure 3 by opening the gas outlet valve 6 . Thus, the forces that contribute to slug growth will be counteracted and at the same time the process will take care of the incoming slug. Hence, the invention optimizes the slug handling capacity of the process, and the operator will see reduced perturbations in the process. Depending on which option is used for determination of the fluid velocities, a multiphase meter or flow transmitter 5 is included upstream of the topside choke 19 .
FIG. 2 shows a simplified process diagram of the present invention implemented in an offshore production system including a riser 13 , producing towards a horizontal three-phase separator 8 , not including the hydrocarbon liquid train downstream of the separator. As in FIG. 1 the distance 2 between the slug detector 1 and the process has been optimized with respect to the process and its parameters for regulation. An alternative location 10 of the slug detector as part of the riser is also indicated for deep-water developments. In this example it is seen that the separator pressure 3 is regulated by adjustments of the gas compressor speed 14 . Moreover, the hydrocarbon liquid level 9 is regulated by speed control of the downstream pump 15 . Regulation of the water level 11 is achieved by means of an outlet valve 12 . Basically, the regulation of the system is performed very similar to the example given in FIG. 1 , but instead of using outlet valves for regulation of the pressure 3 and liquid level 9 , the computer unit 4 gives input to the gas compressor 14 and oil pump 15 speed controls, respectively. In this production system, water slugs are detected because they are denser than oil/condensate slugs besides having a lower content of gas. Depending on which option is used for determination of the fluid velocities, a multiphase meter or flow transmitter 5 is included upstream of the topside choke 19 .
FIG. 3 shows a simplified process diagram of the present invention implemented in an offshore production system including a riser 13 and a horizontal three-phase separator 8 at the process inlet. As opposed to the first two figures, the downstream liquid train is included, and it includes a second separator 21 in addition to the first separator 8 . It is seen that the computer unit 4 is used for regulation of pressure and liquid level in the entire hydrocarbon liquid train, and hence the entire process takes part in the slug treatment. The separator pressures 3 and 16 are both regulated by means of valves on the gas outlets 6 and 17 . The liquid levels 9 and 18 are controlled by means of a valve on the liquid outlet 7 of the first separator 8 and a pump 15 on the liquid outlet of the second separator 9 . Regulation of the water level 11 is achieved by means of an outlet valve 12 . As in the other two figures, the distance 2 between the slug detector 1 and the process has been optimized with respect to the process and its parameters for regulation.
Depending on which option is used for determination of the fluid velocities, a multiphase meter or flow transmitter 5 is included upstream of the topside choke 19 .
It is important that the computer unit 4 also includes normal (traditional) pressure and level regulation of each separator unit in the process in case the pressure or liquid level(s) pass their alarm levels, approaching their trip levels. During such circumstances, there might be a need to de-activate the regulation.
When utilizing the present invention the incoming slugs (terrain-induced or hydro-dynamic by nature) are detected at an early stage by instrumentation (slug detector 1 ) dedicated to define the slug characteristics. While e.g. WO 02/46577 bases its control on measurements of pressure and temperature upstream of the point where slugs are generated (in order to suppress slug formation if any pressure build-up is recorded), it is essential for the present invention that the instrumentation is located downstream of the point of slug formation, since its intention is to describe the slug characteristics. The simplest way to define the slug characteristics is by use of a densitometer as described in U.S. Pat. No. 5,544,672, but the instrumentation could easily be extended for more sophisticated information. Online information of the fluid mixture density is used for determination of:
Liquid slug front Liquid slug tail Nature of slug:
A very high density gives indication of a water slug. A high density gives indication of a HC liquid slug. A low density gives indication of a gas slug.
In addition to a densitometer, the basic instrumentation according to the present invention includes registration of the differential pressure (dP) between the slug detector and the process arrival as a precaution if slugs should be formed downstream of the slug detector. Including more complex instrumentation will further optimize the detector, as long as the production system remains pigable. In particular, additional information on the on-line water cut in combination with the local hold-up or void fraction as well as fluid velocities of the different phases would be valuable input to the computer unit 4 , and so is a multiphase meter 5 at the flow line outlet.
The location 2 of the slug detector must be sufficient for the downstream process to respond adequately prior to slug arrival. Hence, this location 2 needs to be optimized for every new implementation, since it very much depends on the actual production system. It is believed that an optimum location will be within 3 km from the process inlet, giving the computer unit sufficient time to react to incoming slugs. One exception applies to large gas, condensate systems producing towards an onshore installation where the volume of the slug catchers sometimes is very significant. Note also that for extreme deep-water developments, the optimum location could be somewhere inside the riser itself as seen in FIG. 2 (at 10 ) and not necessarily in the subsea flow line or at the riser bottom.
In short, the basic principle of the present slug detector is quite similar to the one described in U.S. Pat. No. 5,544,672. The main improvements are as follows:
In order to optimize the performance of the computer unit, the location of the slug detector must be adapted to the slug handling capabilities of the downstream process. The detector must make the distinction between hydrocarbon liquid slugs and water slugs. Therefore, in addition to the densitometer, the slug detector includes a measurement of one of the following parameters: Gas void fraction, local liquid hold-up or water cut.
The slug detector sends its signals to the computer unit 4 , which constitutes the main component of the present invention. It collects all incoming information from the slug detector as well as the main process parameters of the downstream liquid train. Its overall purpose is to calculate (for every incoming slug):
a) The estimated arrival time for the incoming slug. b) The slug volume. c) The nature of the slug (i.e. water slug, hydrocarbon liquid slug or gas slug) and thereafter optimize the regulation of the downstream process.
The computer unit, which preferably includes an on-line transient thermohydraulic simulator, includes three options to define the fluid velocity(ies) and thereby the estimated slug arrival time. Firstly, it could be estimated by manual input, but then some operating scenarios would require de-activation of the system and thereby use of traditional (i.e. manual) methods for slug control. The second alternative is to calculate the fluid velocity(ies) by use of the thermohydraulic flow simulator, where a multiphase meter at the flow line outlet 5 will improve the performance of the computer calculations. Finally, the velocities of the different fluid phases could be determined based on on-line ultrasonic measurements, located somewhere between the slug detector and the process arrival.
The prediction of reliable slug volumes is obtained through an integral module. Based on information of the slug front, slug tail, mixture density, the fluid velocities defined above and one of the following: water cut, gas void fraction or local hold-up, the computer unit will give accurate estimates of the slug arrival times and their corresponding volumes.
When all of the slug characteristics have been described, the output signals from the computer unit will be optimized and adjusted to reduce the process perturbations in the downstream HC liquid train to a minimum.
The present invention describes a solution for slug treatment that has a number of advantages compared to already known solutions:
Since the main slug characteristics of all incoming slugs are known before they enter downstream equipment, it is easy to take corrective measures to reduce fluctuations and perturbations in the entire process. It applies to any type of slug independent of whether it is hydrodynamic by nature or terrain-induced and regardless of whether it is a liquid, water or a gas slug. It links the transport system and the downstream process and thereby makes use of all the slug handling capacity in the entire downstream process. It applies to any production system of multiphase transport, regardless of whether it is a well or if it is a subsea, topside or onshore installation. Basically, a single computer unit is sufficient for control of a production facility receiving incoming slug flow from different sources. It will shorten the start-up time after shut-down or for variations of flow rate. There is no need for fast acting valves. If properly designed it will reduce the risk of process shut-downs due to slug flow. | A system and a method for prediction and treatment of all kinds of slugs being formed in a flow line system or wellbore tubing transporting a multiphase fluid towards a downstream process including a separator or a slug catcher at the process inlet. The system includes a slug detector ( 1 ) located downstream of the point for slug initiation and upstream of the process and a computer unit ( 4 ) integrating the flow line system and the downstream process including software which determines the type of the slug, its volume and predicts its arrival time into the downstream process. The computer unit processes all its incoming data to obtain an optimum regulation of the process so that process perturbations due to incoming slugs are reduced to a minimum through the process. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to thermoplastic, moldable, non-exuding phase change materials and method of making same.
Phase change materials may be repeatedly converted between solid and liquid phases and utilize their latent heat of fusion to absorb, store and release heat or cool during such phase conversions.
These latent heats of fusion are greater than the sensible heat capacities of the materials. For example, in phase change materials, the amount of energy absorbed upon melting or released upon freezing is much greater than the amount of energy absorbed or released upon increasing or decreasing the temperature of the material over an increment of 10° C.
Upon melting and freezing, per unit weight, a phase change material absorbs and releases substantially more energy than a sensible heat storage material that is heated or cooled over the same temperature range. In contrast to a sensible heat storage material that absorbs and releases energy essentially uniformly over a broad temperature range, a phase change material absorbs and releases a large quantity of energy in the vicinity of its melting/freezing point.
The problem with such phase change materials is in containing them in an appropriate matrix. In my U.S. Pat. No. 5,053,446, there is disclosed a polyolefin matrix containment system; in my U.S. Pat. No. 4,797,160, there is disclosed use of a cementitious matrix containing alkyl hydrocarbon phase change materials neat or in pellets or granules formed by incorporating the alkyl hydrocarbon phase change material in polymers or rubbers, and in my U.S. Pat. No. 5,106,520 and 5,282,994, there is disclosed a free flowing, conformable powder-like mix of silica particles and a phase change material.
Each of these containment means have properties and utilities for specific applications, but none is universally best for all applications. For example, pellets of a phase change material, such as a crystalline alkyl hydrocarbon, and a polyolefin, such as cross-linked high density polyethylene (HDPE), have been used in floor panels and elsewhere for moderating room temperatures and for energy efficiency. But, such pellets are expensive and have a problem with some "oozing" (exuding) of the low melting point phase change material during thermocycling of the pellets above and below the melting temperature of the phase change material.
Accordingly, it would be desirable to have ways to contain alkyl hydrocarbon phase change materials that might be lower in cost and eliminate oozing and/or provide properties that would enable the phase change material to be more effectively utilized.
SUMMARY OF THE INVENTION
That need is met by the present invention which provides a multi-component composite that is potentially low in cost, can be formed into a variety of configurations (pellets, sheets, rods, tubes, plugs for hollow core cement blocks, films and fibers), shows no oozing of the phase change material when thermocycled, has an apparent density of about 1, and can be modified with an additional component to provide microwave heating capability. In addition, the thermoplastic, moldable, non-exuding phase change material of the present invention, after formed into pellets, for example, can be repeatedly thermocycled above the melting point of the phase change material without undergoing melt flow, and there is little apparent change in volume during melting and freezing.
The composite of the present invention is a solidified melt mixture of an alkyl hydrocarbon phase change material, a polyolefin resin, an ethylene copolymer, and silica particles. When a microwave heating capability is desired, a microwave absorbing additive can be added as a fifth major ingredient.
The polyolefin resin is preferably an uncrosslinked high density polyethylene; although, a higher melting polypropylene may also be used. The ethylene copolymer is preferably an ethylene-vinyl acetate copolymer containing approximately 10-20% by weight vinyl acetate, but may also be an ethylene-methyl acrylate copolymer, an ethylene-ethyl acrylate copolymer, or equivalent molar copolymer. The silica particles are preferably precipitated silica particles having a surface area of from 50 to 500 square meters per gram and primary particle sizes of from 0.005 to 0.025 microns; although, fumed silicas can also be used. The alkyl hydrocarbon phase change material is preferably a crystalline alkyl hydrocarbon having a heat of fusion of greater than about 30 cal/g. When the composite is to be used for thermal energy storage in building structures, a paraffin having a C-18 or C-19 chain length and a melting and freezing point of about 75° F. and thermal energy storage of about 30 cal/g is preferred. When the composite is to be used for thermal energy storage in food and beverage containers, such as by placing the composite, molded and shaped to fit into the space between the walls of a dual walled food or beverage container, such as cups, bowls, plates, trays, etc., a paraffin having a melting and freezing point of about 147° F. is preferred. The microwave absorbing additive is preferably a glycerine or a carbon black.
In one embodiment, the preferred weight percentage of each ingredient based on the total weight of the composite is about 60% phase change material, about 16-22% polyolefin, about 8-12% ethylene copolymer, and about 8-16% silica particles. A small amount, i.e. 0.1 to 8.0% of carbon black may be added to render the composite microwaveable. In the microwaveable embodiment when glycerine is used as the microwave absorbing additive, the preferred weight percentages are about 55% phase change material, about 15-21% polyolefin, about 7-11% ethylene copolymer, about 7-15% silica particles, and about 7.5% microwave absorbing additive.
The method of preparing the composite involves melting an alkyl hydrocarbon phase change material, stirring silica particles into that melted material until a stiff gel is formed, to the stiff gel a mixture of polyolefin resin and ethylene copolymer, heating to melt the polyolefin resin and ethylene copolymer, mixing vigorously to form a uniform viscous gel, cooling the viscous gel to solidify it into a moldable composite, and forming the moldable composite into a shape useful for thermal energy storage. When a microwaveable composite is desired, the microwave absorbing additive is added either early into the melted phase change material or last after the other four ingredients have already been incorporated, but in any event, prior to the cooling step.
As mentioned previously, the composite can be formed into a variety of shapes. For example, it can be formed into pellets which can be used in all of the manners in which the pellets of U.S. Pat. No. 5,053,446 are used. It can also be molded into a plug form sized to fit into the hollow core(s) of a hollow core cementitious building block as disclosed in my pending application Ser. No. 08/468,441, filed on an even date herewith. Likewise the composite of the present invention can be molded and shaped to fit into the space between the walls of a dual walled food or beverage container, such as cups, bowls, plates, trays, etc. Numerous other forms and thermal energy storage uses are possible.
The composite of the present invention has the advantage of lower cost, thermoplastic processability, adaptability for forming into pellets, sheets, rods, films, fibers and moldings, and higher apparent density (when compared with phase change material/silica dry powders), and microwave heating capability and elimination of oozing (when compared with phase change material/cross-linked HDPE pellets). This combination of properties and performance characteristics makes the phase change material of the present invention suitable for a wide variety of applications for which previous phase change materials have not been universally adapted.
Accordingly, it is an object of the present invention to provide an improved phase change material in the form of a composite which is thermoplastic, moldable, and non-exuding and to provide a method for making such a composite. These, and other objects and advantages of the present invention, will become apparent from the following detailed description and the accompanying claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The composite of the present invention, in its most basic form is a solidified melt mixture of a polyolefin resin, an ethylene copolymer, silica particles, and an alkyl hydrocarbon phase change material. When it is desired to have a composite that can be heated by microwave energy, then a fifth major ingredient, namely, a microwave absorbing additive is added.
The polyolefin is preferably a high-density polyethylene (HDPE) having a molecular weight or melt index in the range of 0.5 to 5 decigrams/minute. Examples of such materials are Marlex 6006 and Alathon 6210 from Phillips Chemical Co., Bartlesville, Okla. and Occidental Chemical Company, Niagara Falls, NY, respectively. The HDPE when it cools from the melt establishes a matrix within which the lower melting phase change material can melt and freeze without changing the volume of the composite significantly. Thus, the melting temperature must be well above the highest temperature that will be encountered in use. For this reason, commercial low-density polyethylenes would be less desirable though not without some utility. It also is possible to substitute a higher melting polypropylene for HDPE, which may be a decided advantage in some applications, although, processing is more difficult.
The ethylene copolymer serves a compatibilizing bridge between the very low molecular weight phase change material and the high molecular weight, high melting HDPE. A series of ethylene-vinyl acetate (EVA) copolymers containing from 5 to 28% wt. of vinyl acetate were tested for compatibility and oozing reduction. As a result, copolymers in the range of 10-20% wt. of vinyl acetate are preferred and those containing about 15-17% wt. acetate most preferred. Comparable compatibility and non-oozing could be obtained in melt-mixed blends wherein equivalent quantities of ethylene/methyl acrylate (EMA), or ethylene/ethyl acrylate (EEMA) are substituted for EVA.
The silica in the composite is added to tie up the low-melting phase change material in a stable gel--thereby to prevent oozing. The amount of silica is, therefore, directly related to the amount of the phase change material and should be about 7-16% of composite weight. Preferred is ABS precipitated silica from PPG Industries Inc., of Pittsburgh, Pa., which is a normal, hydrophilic silica with a surface area of 150 m 2 /gram and a particle size of about 0.022 microns. However, other precipitated silica having a comparable particle size and surface area would work equally as well. Fumed silicas of comparable or smaller particle size and equal or greater surface should also be satisfactory, but are much more expensive. Accordingly, the preferred silica is a precipitated hydrophilic silica having a particle size of 0.005 to 0.025 microns and a surface area of 50 to 500 square meters per gram.
Substantially any phase change material can be used which is compatible with the polyolefin. In most cases, compatible phase change materials will be characterized by a long alkyl hydrocarbon chain within their molecular structure. Preferred phase change materials are crystalline organic compounds such as crystalline alkyl hydrocarbons, crystalline fatty acids, crystalline fatty acid esters, crystalline 1-olefins, crystalline primary alcohols, crystalline alicyclic hydrocarbons, and crystalline aromatic hydrocarbons which melt and freeze within the desired thermal transfer temperature range (e.g., 0° to 80° C.).
A number of commercially available waxes are useful as phase change materials in the present invention including Shellwax 100 (MP 42°-44° C.), Shellwax 120 (MP 44°-47° C.), Shellwax 200 (MP 52°-55° C.), Shellwax 300 (MP 60°-65° C.) all of which are products of Shell Oil Co., Houston, Tex.; Boron R-152 (MP 65° C.) a product of BP America, Cleveland, Ohio; Union SR-143 (MP about 61° C.) a product of Union Oil Co., Los Angeles, Calif.; Witco 128 (MP about 53° C.), Witco LLN, Witco 45A, Witco K-18, Witco K-19, Witco K-61, Witco K-51, and Witco 85010-1 all products of Witco Corp., New York, N.Y.; Aristowax 143 (MP 34°-61° C.) from Unocal Corp., Los Angeles, Calif., and Paraffin 150 (MP about 61° C.). These waxes have heats of fusion greater than 30 cal/g and by comparison to other phase change materials, they are inexpensive. Many of them cost as little as $.15 (U.S.) per pound when purchased in a tank car quantity.
The phase change material is selected to have a melting temperature in the range desired for the intended application. For heating and cooling of residential buildings, a paraffin of about C-18 or C-19 chain length (e.g., K-18 or K-19 from Witco) that melts and freezes near room temperature (˜75° F.) would be selected. For food serving and other higher temperature uses, a phase change material that melts in the region of 147° F. (e.g., Parvan 147 from Exxon) would be selected.
In prior research, glycerine at about 10% wt. has been found to be an effective microwave absorbing additive in phase change material/silica dry powders for hot medical therapy and warm clothing applications. In the current melt-mixed composite, a somewhat lower concentration in the amount of about 7-8% wt. appears to heat effectively in about 4 minutes to a temperature well above the melting point of the phase change material component.
A somewhat more effective alternate to the glycerine as a microwave heating additive is the special grade of Cabot Conducting Carbon Black XC-72-R from Cabot Corp., Boston, Mass. This black will heat effectively at lower concentrations than glycerine. A further advantage of the carbon black as a microwave heating additive is that since it is not a liquid that has to be taken up by the silica (gelled), a formulation with somewhat higher concentration of phase change material could be used. The major disadvantage of carbon black is that even in low concentrations the color of the composite will be changed to a dark gray to black depending on the exact concentration.
Thus, when the composite is without a microwave absorbing additive or when carbon black is used as that additive in small amounts (i.e., about 0.1-8 weight percent), then the composite will preferably contain about 60% phase change material, about 16-22% polyolefin, about 8-12% ethylene copolymer and about 8-16% silica particles, all based on the total weight of the composite. When glycerine is added as a microwave absorbing additive, the preferred percentages are about 55% phase change material, about 15-21% polyolefin, about 7-11% ethylene copolymer, about 7-15% silica particles, and about 7-8% microwave absorbing additive.
EXAMPLE 1
Illustrative Example of Laboratory Manufacture of K-18/HDPE/E-VA/Silica (60/16/8/16) Composite
1. Obtain supplies of Witco K-18 phase change material from Witco Corp., Santowhite Powder antioxidant from Monsanto Chemical, Co., HDPE (Marlex 6006 or Alathon 6210 from Phillips Chemical Co. and Occidental Chemical Co., respectively), EVA Copolymer (17% VA copolymer) from Quantum Chemical Co. and Silica (ABS) from PPG Industries Inc.
2. Select a small 60 gram batch size of K-18 for ease of manual mixing. Weigh this amount of K-18 into a small stainless steel mixing bowl of proper size, add 1 part of Santowhite Powder antioxidant (based on the K-18)., and heat to 150° C. with stirring.
3. Incrementally, add with stirring 16 grams of ABS silica to form a rather stiff gel.
4. To the gel, add together 16 grams of Alathon 6210 and 8 grams of EVA. Heat to melt the two polymers, then mix vigorously with a putty knife or spatula to a uniform viscous gel with no visible lumps of HDPE or EVA pellets.
5. Pour or trowel the viscous gel in a flat 12"×12" polished steel mold, place a polished metal sheet on top of the melt, and press manually to form a flattened disc of about 1/8" thickness.
6. While the disc is still hot, remove the top cover plate and use a sharp knife to slice the molded disc into pellets. The pellets may be used "as is," extruded to form strands, fibers, films, etc., or molded into shapes. EXAMPLE 2.
Illustrative Example of Laboratory Manufacture of PCM/HDPE/E- VA/Silica/Glycerine (55/16/8/14/7) Composite with Microwave Heating Capability
1. The raw materials are the same as in the above example, except that a higher melting phase change material (e.g., Parvan 147 from Exxon) is substituted for K-18, and there is an added microwave heating component (Glycerine or Carbon Black).
2. The other steps in the laboratory process are identical to the above example except for the added microwave heating component. If glycerine is used, it may be added early into the PCM component or added last after the other four components have already been incorporated.
3. The mixed melt can be pressed to form a sheet disc or processed into pellets, sheets, films, fibers, or molded objects.
4. As previously noted, if carbon black is used as the microwave absorbing additive, the amount of phase change material can be increased to ˜60% wt.
EXAMPLE 3
Composites No. 1-8, were prepared as set forth in Table I below, with the physical evaluation made, as also noted in Table I:
TABLE I______________________________________ PER- SURFACE CENT OILNO. COMPOSITE VA RATING COMMENT______________________________________1 K-18/Marlex 6006/E- 3 strong, veryVA/ABS 65/25/10/5 brittle, very little oil2 K-18/Marlex 6006/E- 19 4 oil onVA/ABS 65/20/10/5 squeezing, brittle but strong3 K-18/Marlex 6006/E- 28 3 brittle, notVA/ABS 65/20/10/5 too strong, very little oil4 K-18/Alathon 6210/E- 17 2 strong, tough,VA/ABS almost no oil60/21.5/10.5/85 K-18/Alathon 6210/E- 17 2 strong, tough,VA/ABS 60/20/10/10 almost no oil6 K-18/Alathon 6210/E- 17 1 strong, tough,VA/ABS 60/19/9/12 dry surface7 K-18/Alathon 6210/E- 17 1 strong, tough,VA/ABS 60/18/8/14 dry surface8 K-18/Alathon 6210/E- 17 1 strong, tough,VA/ABS 60/16/8/16 dry surface______________________________________
As can be seen, the optimum composite is No. 8. That composite is moldable, non-oozing, and tough enough to withstand further processing. However, composites 4-7 are also acceptable for most purposes.
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the compositions and methods disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims. | A thermoplastic, moldable, non-exuding phase change material in the form of a composite useful for thermal energy storage. The composite is preferably a solidified melt mixture of a polyolefin resin, and ethylene copolymer, silica particles and a fatty acid, fatty acid ester, primary alcohol or hydrocarbon phase change material. For a microwave heating capability, a microwave absorbing additive may be added as a fifth major ingredient. The composite can be formed into a variety of configurations such as pellets, sheets, rods, tubes, plugs for hollow core cement blocks, films, and fibers, all for thermal energy storage uses. | 3 |
FIELD OF THE INVENTION
[0001] This invention relates to new cosmetic compositions containing certain poly-α-olefins and to the use of these poly-α-olefins as oil components in cosmetic and pharmaceutical preparations. The cosmetic or pharmaceutical preparations show good dermatological compatibility and impart a particularly light feeling on the skin.
PRIOR ART
[0002] Consumers expect cosmetic skin- and hair-care emulsions to satisfy a range of requirements. Apart from the cleaning and skin-/hair-care effects which determine the intended application, value is placed on such diverse parameters as very high dermatological compatibility, good lipid-layer-enhancing properties, elegant appearance, optimal sensory impression and stability in storage.
[0003] Besides a number of surfactants, preparations used to clean and care for the human skin and hair contain, above all, oil components and water. The oil components/emollients used include, for example, hydrocarbons, ester oils and vegetable and animal oils/fats/waxes. In order to meet stringent commercial requirements in regard to sensory properties and optimal dermatological compatibility, new oil components and emulsifier mixtures are continually being developed and tested. A large number of natural and synthetic oils, for example almond or avocado oil, ester oils, ethers, alkyl carbonates, hydrocarbons and silicone oils, are used in the production of cosmetic or pharmaceutical preparations. A key function of the oil components—besides their care effect which is directly related to lipid layer enhancement of the skin—is to provide the skin of consumers with a non-sticky, almost instantaneous and long-lasting feeling of smoothness and suppleness.
[0004] The subjective feeling on the skin can be correlated and objectivized with the physicochemical parameters of the spreading of the oil components on the skin, as illustrated by U. Zeidler in the journal Fette, Seifen, Anstrichmittel 87, 403 (1985). According to this reference, cosmetic oil components can be classified as low-spreading (<300 mm 2 /10 mins.), medium-spreading (>/=300 to 1000 mm 2 /10 mins.) and high-spreading oils (>/=1000 mm 2 /10 mins.). If a high-spreading oil is used as the oil component in a predetermined formulation, the required feeling of smoothness of the skin is achieved very quickly and, where cyclomethicones, for example Dow Corning 245 fluid (Dow Corning Corporation) or Abil® B 8839 (Goldschmidt Chemical Corporation), are used, a velvety feeling desirable to the consumer is also obtained. Unfortunately, the experience does not last long because the high volatility of the last-mentioned structures means that the pronounced feeling of smoothness and hence the velvety feel disappear very quickly, leaving the skin with an unpleasant, dull feeling.
[0005] However, cyclomethicones have the advantage over other hydrocarbon-based emollients, such as very light mineral oils, polybutylenes (for example Arlamol® HD, ICI), ethyl hexyl cyclohexane (Cetiol® S, Cognis Deutschland GmbH & Co. KG), that they have a very light feeling on the skin. Accordingly, there is a need for hydrocarbon-based oil components/emollients which combine the advantages of the cyclomethicones, such as a light feeling on the skin and good spreading properties, without having any of their disadvantages.
[0006] The problem addressed by the present invention was to provide improved, high-spreading oil components and preparations containing them which would impart an almost instantaneous and relatively long-lasting feeling of smoothness to the skin and which would show good dermatological compatibility. In addition, the oil components would lend themselves to simple and stable incorporation in emulsions, would be hydrolysis-stable in the event of pH variations and would lead to low-viscosity compositions imparting a very light feeling on the skin.
DESCRIPTION OF THE INVENTION
[0007] The present invention relates to a cosmetic composition containing at least one poly-α-olefin obtainable by subjecting at least one primary alcohol to dehydrating polymerization at 60 to 340° C. in the presence of acidic alumino layer silicate, the primary alcohol being selected from the group consisting of
[0000] a) unsaturated monofunctional alcohols,
b) branched monofunctional alcohols and
c) difunctional alcohols.
[0008] The poly-α-olefins used in the cosmetic composition according to the invention have already been described. They are mentioned in applicants' German patent application DE 10152267 and in International patent application PCT/EP02/11392. Besides describing the compounds themselves, the documents in question also contain detailed information on their production. Reference is made here to the corresponding applications.
[0009] Purely by way of a brief summary, it is pointed out that the reaction of the primary alcohol is preferably carried out in an inert gas atmosphere with continuous removal of the water formed. The acidic alumino layer silicate used as catalyst preferably has an acid charge of 3 to 300 mval/100 g. Examples of alumino layer silicates are talcum and clays with a sheet structure, such as kaolinite, montmorillonite, bentonites and hectorites. It is appropriate to carry out the reaction with removal of water until no more water is eliminated. The reaction times are normally in the range from 2 to 48 hours. The catalyst is then removed, for example by filtration. The degree of oligomerization of the poly-α-olefins is in the range from 1 to 10. The adjustment of a particular degree of oligomerization can be achieved by returning the olefin entrained during the continuous removal of water to the reaction mixture, which leads to relatively high degrees of oligomerization. The poly-α-olefins obtained are odorless, colorless or yellowish products which may be liquid or solid. There is no exact structural formula for the poly-α-olefins obtained because, under the dehydrating polymerization conditions, the primary alcohols in question are isomerized into various unsaturated monomers which then polymerize with one another.
[0010] The primary alcohols mentioned may be used individually or in admixture with one another. Whereas the alkyl chain of the group b) alcohols is branched, the alkyl chains of the primary alcohols of groups a) and c) may be either linear or branched. The unsaturated alcohols may be mono- or polyunsaturated, more particularly olefinically unsaturated.
[0011] Preferred cosmetic compositions are those in which the primary alcohol contains 6 to 72 carbon atoms and more particularly 6 to 24 carbon atoms.
[0012] The group a) alcohol is preferably a linear alcohol. Examples of unsaturated monofunctional alcohols of group a) are 10-undecen-1-ol, coleyl alcohol, elaidyl alcohol, ricinolyl alcohol, linoleyl alcohol, linolenyl alcohol, gadoleyl alcohol, erucyl alcohol and brassidyl alcohol.
[0013] The group b) alcohol is preferably an alcohol selected from the group of branched alcohols having b1) at least one methyl group and, more particularly, 1 to 6 methyl branches in the alkyl chain, b2) a C 2-18 branch in the alkyl chain and b3) a C 2-18 branch in the α-position to the terminal CH 2 OH group.
[0014] In the case of group b1) with at least one methyl branch in the alkyl chain, the methyl group may be positioned anywhere in the alkyl chain. Suitable examples are isooctyl alcohol, isononyl alcohol, isostearyl alcohol or isotridecyl alcohol. Of these, isononyl alcohol is particularly preferred. Where there are several methyl groups, they preferably number 2 to 6 in any distribution over the alkyl chain of the alcohol. In the case of group b2) alcohols branched by a C 2-18 alkyl group, there are preferably no other branches in the alkyl chain of the alcohol.
[0015] Other suitable primary monofunctional branched alcohols are the Guerbet alcohols known to the expert which are obtainable by dimerization of fatty alcohols and which, structurally, are distinguished by the presence of a relatively long alkyl chain, preferably with 2 to 18 carbon atoms, in the α-position to the terminal CH 2 OH group. Suitable Guerbet alcohols are 2-hexyl decanol, 2-butyl octanol, 2-octyl dodecanol and 2-hexyldecyl palmitate/stearate, 2-ethyl hexanol and 2-propyl heptanol. 2-Ethyl hexyl alcohol is preferred.
[0016] Suitable group c) alcohols, i.e. difunctional alcohols (with 2 hydroxyl groups), are saturated or unsaturated diols, such as pentane-1,5-diol, octane-1,8-diol, hexane-1,6-diol, decane-1,10-diol, dodecane-1,12-diol, octadecane-1,12-diol or the dimer diols known to the expert.
[0017] The poly-α-olefins may be used in unsaturated form in the cosmetic composition according to the invention. In the interests of greater oxidation stability, however, the poly-α-olefins are preferably hydrogenated after the dehydrating polymerization and used in the hydrogenated (hardened) form in the compositions according to the invention.
[0018] The hydrogenation is described in the above-cited International patent application PCT/EP02/11392 and may be carried out in known manner at temperatures in the range from 150° C. to 250° C. and preferably at temperatures in the range from 190 to 210° C. and under pressures of 20 to 150 bar (low-pressure process) or 150 to 350 bar (high-pressure process). Suitable catalysts are the hydrogenation catalysts known from the prior art, such as nickel or the noble metal catalysts, more particularly based on palladium or platinum. Particularly suitable noble metal catalysts are palladium catalysts, more particularly palladium on coal. The catalyst may be added to the poly-α-olefins in typical quantities either in the form of a suspension or in solid form. For the preferred palladium on coal, the quantities used are in the range from 0.001 to 5% by weight, expressed as palladium. However, the catalyst may also be applied to a solid carrier material, such as active charcoal, graphite, kieselguhr, silica gel, spinets, aluminium oxide or ceramic materials. Other suitable catalysts are nickel catalysts, for example suspended nickel, such as Nysofact 101 I a (Engelhard), which is preferably used in quantities of 0.01 to 5% by weight, based on nickel.
[0019] As already mentioned, the described poly-α-olefins are colorless to pale yellowish, substantially odorless compounds with high spreading values, typically above 1,000 mm 2 /10 minutes and preferably above 1,600 mm 2 /10 minutes (Zeidler's definition). Accordingly, they are eminently suitable for use as oil components in cosmetic or pharmaceutical preparations. Wherever poly-α-olefins in general are mentioned in the following, both the hydrogenated and the non-hydrogenated compounds are included.
Cosmetic Preparations
[0020] The compound according to the invention allows the production of stable cosmetic emulsions. These cosmetic emulsions are preferably body care formulations, for example in the form of creams, milks, lotions, sprayable emulsions, products for eliminating body odor, etc. The compound according to the invention may also be used in surfactant-containing formulations such as, for example, foam and shower baths, hair shampoos and care rinses.
[0021] The cosmetic preparations may be formulated as emulsions or dispersions which contain water and the oil phase alongside one another. Preferred cosmetic compositions are those in the form of a w/o or o/w emulsion with the usual concentrations—known to the expert—of oils/fats/waxes, emulsifiers, water and the other auxiliaries and additives typically used in cosmetic preparations.
[0022] The cosmetic composition according to the invention contains 1 to 50% by weight, preferably 5 to 40% by weight and more particularly 5 to 25% by weight oil of components which, together for example with oil-soluble surfactants/emulsifiers and oil-soluble active components, form part of the so-called oil or fatty phase. In the context of the invention, the oil components include fatty compounds, waxes and liquid oils, but not emulsifiers/surfactants. The poly-α-olefins may be present as sole oil component or in combination with other oils/fats/waxes. The percentage content of the at least one poly-α-olefin, based on the total quantity of oil components, is 0.1 to 100% by weight and preferably 1 to 50% by weight. Quantities of 1 to 20% by weight and more especially 3 to 20% by weight are particularly preferred.
[0023] Depending on the particular application envisaged, the cosmetic formulations contain a number of other auxiliaries and additives, such as, for example, surface-active substances (surfactants, emulsifiers), other oil components, pearlizing waxes, consistency factors, thickeners, superfatting agents, stabilizers, polymers, silicone compounds, fats, waxes, lecithins, phospholipids, biogenic agents, UV protection factors, antioxidants, deodorants, antiperspirants, antidandruff agents, film formers, swelling agents, insect repellents, self-tanning agents, tyrosinase inhibitors (depigmenting agents), hydrotropes, solubilizers, preservatives, perfume oils, dyes, etc. which are listed by way of example in the following.
[0024] The quantities of the particular additives are governed by the particular application envisaged. In another preferred embodiment, the cosmetic composition contains 0.1 to 20% by weight, preferably 1 to 15% by weight and more particularly 1 to 10% by weight of a surface-active substance or a mixture of surface-active substances.
Surface-Active Substances
[0025] The surface-active substances present may be anionic, nonionic, cationic and/or amphoteric or zwitterionic surfactants or emulsifiers or a mixture thereof. In surfactant-containing cosmetic preparations such as, for example, shower gels, foam baths, shampoos, etc., at least one anionic surfactant is preferably present. Body-care creams and lotions preferably contain nonionic surfactants/emulsifiers.
[0026] Typical examples of anionic surfactants are soaps, alkyl benzene-sulfonates, alkanesulfonates, olefin sulfonates, alkylether sulfonates, glycerol ether sulfates, α-methyl ester sulfonates, sulfofatty acids, alkyl sulfates, fatty alcohol ether sulfates, glycerol ether sulfates, fatty acid ether sulfates, hydroxy mixed ether sulfates, monoglyceride (ether) sulfates, fatty acid amide (ether) sulfates, mono- and dialkyl sulfosuccinates, mono- and dialkyl sulfosuccinamates, sulfotriglycerides, amide soaps, ether carboxylic acids and salts thereof, fatty acid isethionates, fatty acid sarcosinates, fatty acid taurides, N-acylamino acids such as, for example, acyl lactylates, acyl tartrates, acyl glutamates and acyl aspartates, alkyl oligoglucoside sulfates, protein fatty acid condensates (particularly wheat-based vegetable products) and alkyl (ether) phosphates. If the anionic surfactants contain polyglycol ether chains, they may have a conventional homolog distribution although they preferably have a narrow-range homolog distribution. Typical examples of nonionic surfactants are fatty alcohol polyglycol ethers, polyglycerol esters, alkylphenol polyglycol ethers, fatty acid polyglycol esters, fatty acid amide polyglycol ethers, fatty amine polyglycol ethers, alkoxylated triglycerides, mixed ethers and mixed formals, optionally partly oxidized alk(en)yl oligoglycosides or glucuronic acid derivatives, fatty acid-N-alkyl glucamides, protein hydrolyzates (particularly wheat-based vegetable products), polyol fatty acid esters, sugar esters, sorbitan esters, polysorbates and amine oxides. If the nonionic surfactants contain polyglycol ether chains, they may have a conventional homolog distribution, although they preferably have a narrow-range homolog distribution. Typical examples of cationic surfactants are quaternary ammonium compounds, for example dimethyl distearyl ammonium chloride, and esterquats, more particularly quaternized fatty acid trialkanolamine ester salts. Typical examples of amphoteric or zwitterionic surfactants are alkylbetaines, alkylamidobetaines, amino-propionates, aminoglycinates, imidazolinium betaines and sulfobetaines. The surfactants mentioned are all known compounds. Information on their structure and production can be found in relevant synoptic works in this field. Typical examples of particularly suitable mild, i.e. particularly dermatologically compatible, surfactants are fatty alcohol polyglycol ether sulfates, monoglyceride sulfates, mono- and/or dialkyl sulfosuccinates, fatty acid isethionates, fatty acid sarcosinates, fatty acid taurides, fatty acid glutamates, α-olefin sulfonates, ether carboxylic acids, alkyl oligo-glucosides, fatty acid glucamides, alkylamidobetaines, amphoacetals and/or protein fatty acid condensates, preferably based on wheat proteins.
Oil Components
[0027] Body care preparations, such as creams, lotions and milks, normally contain a number of other oil components and emollients which contribute towards further optimizing their sensory properties. Suitable oil components are, for example, Guerbet alcohols based on fatty alcohols containing 6 to 18 and preferably 8 to 10 carbon atoms, esters of linear C 6-22 fatty acids with linear or branched C 6-22 fatty alcohols or esters of branched C 6-13 carboxylic acids with linear or branched C 6-22 fatty alcohols such as, for example, myristyl myristate, myristyl palmitate, myristyl stearate, myristyl isostearate, myristyl oleate, myristyl behenate, myristyl erucate, cetyl myristate, cetyl palmitate, cetyl stearate, cetyl isostearate, cetyl oleate, cetyl behenate, cetyl erucate, stearyl myristate, stearyl palmitate, stearyl stearate, stearyl isostearate, stearyl oleate, stearyl behenate, stearyl erucate, isostearyl myristate, isostearyl palmitate, isostearyl stearate, isostearyl isostearate, isostearyl oleate, isostearyl behenate, isostearyl oleate, oleyl myristate, oleyl palmitate, oleyl stearate, oleyl isostearate, oleyl oleate, oleyl behenate, oleyl erucate, behenyl myristate, behenyl palmitate, behenyl stearate, behenyl isostearate, behenyl oleate, behenyl behenate, behenyl erucate, erucyl myristate, erucyl palmitate, erucyl stearate, erucyl isostearate, erucyl oleate, erucyl behenate and erucyl erucate. Also suitable are esters of linear C 6-22 fatty acids with branched alcohols, more particularly 2-ethyl hexanol and isopropanol, esters of C 18-38 alkylhydroxycarboxylic acids with linear or branched C 6-22 fatty alcohols, more especially Dioctyl Malate, esters of linear and/or branched fatty acids with polyhydric alcohols (for example propylene glycol, dimer diol or trimer triol) and/or Guerbet alcohols, triglycerides based on C 6-10 fatty acids, liquid mono-, di- and triglyceride mixtures based on C 6-18 fatty acids, esters of C 6-22 fatty alcohols and/or Guerbet alcohols with aromatic carboxylic acids, more particularly benzoic acid, esters of C 2-12 dicarboxylic acids with linear or branched alcohols containing 1 to 22 carbon atoms or polyols containing 2 to 10 carbon atoms and 2 to 6 hydroxyl groups, vegetable oils, branched primary alcohols, substituted cyclohexanes, linear and branched C 6-22 fatty alcohol carbonates, such as Dicaprylyl Carbonate (Cetiol® CC) for example, Guer-bet carbonates based on C 6-18 and preferably C 8-10 fatty alcohols, esters of benzoic acid with linear and/or branched C 6-22 alcohols (for example Finsolv® TN), linear or branched, symmetrical or nonsymmetrical dialkyl ethers containing 6 to 22 carbon atoms per alkyl group, such as Dicaprylyl Ether (Cetiol® OE) for example, ring opening products of epoxidized fatty acid esters with polyols, silicone oils (cyclomethicone, silicon methicone types, etc.) and/or aliphatic or naphthenic hydrocarbons such as, for example, mineral oil, Vaseline, petrolatum, isohexadecanes, squalane, squalene or dialkyl cyclohexanes.
Fats and Waxes
[0028] Fats and waxes are added to the body care products both as care components and to increase the consistency of the cosmetic preparations. Typical examples of fats are glycerides, i.e. solid or liquid, vegetable or animal products which consist essentially of mixed glycerol esters of higher fatty acids. Fatty acid partial glycerides, i.e. technical mono- and/or di-esters of glycerol with C 12-18 fatty acids, such as for example glycerol mono/dilaurate, palmitate or stearate, may also be used for this purpose. Suitable waxes are inter alia natural waxes such as, for example, candelilla wax, carnauba wax, Japan wax, espartograss wax, cork wax, guaruma wax, rice oil wax, sugar cane wax, ouricury wax, montan wax, beeswax, shellac wax, spermaceti, lanolin (wool wax), uropygial fat, ceresine, ozocerite (earth wax), petrolatum, paraffin waxes and microwaxes; chemically modified waxes (hard waxes) such as, for example, montan ester waxes, sasol waxes, hydrogenated jojoba waxes and synthetic waxes such as, for example, polyalkylene waxes and polyethylene glycol waxes.
[0029] Suitable pearlizing waxes are, for example, alkylene glycol esters, especially ethylene glycol distearate; fatty acid alkanolamides, especially cocofatty acid diethanolamide; partial glycerides, especially stearic acid monoglyceride; esters of polybasic, optionally hydroxysubstituted carboxylic acids with fatty alcohols containing 6 to 22 carbon atoms, especially long-chain esters of tartaric acid; fatty compounds, such as for example fatty alcohols, fatty ketones, fatty aldehydes, fatty ethers and fatty carbonates which contain in all at least 24 carbon atoms, especially laurone and distearylether; fatty acids, such as stearic acid, hydroxystearic acid or behenic acid, ring opening products of olefin epoxides containing 12 to 22 carbon atoms with fatty alcohols containing 12 to 22 carbon atoms and/or polyols containing 2 to 15 carbon atoms and 2 to 10 hydroxyl groups and mixtures thereof.
Thickeners
[0030] Suitable thickeners are, for example, Aerosil® types (hydrophilic silicas), polysaccharides, more especially xanthan gum, guar-guar, agar-agar, alginates and tyloses, carboxymethyl cellulose and hydroxyethyl and hydroxypropyl cellulose, polyacrylates (for example Carbopols® and Pemulen types [Goodrich]; Synthalens® [Sigma]; Keltrol types [Kelco]; Sepigel types [Seppic]; Salcare types [Allied Colloids]), polyacrylamides, polymers, polyvinyl alcohol and polyvinyl pyrrolidone. Other consistency factors which have proved to be particularly effective are bentonites, for example Bentone® Gel VS-5PC (Rheox) which is a mixture of cyclopentasiloxane, Disteardimonium Hectorite and propylene carbonate, and a sodium polyacrylate known as Cosmedia® SP. Other suitable consistency factors are electrolytes, such as sodium chloride and ammonium chloride.
Stabilizers
[0031] Metal salts of fatty acids such as, for example, magnesium, aluminium and/or zinc stearate or ricinoleate may be used as stabilizers.
UV Protection Factors and Antioxidants
[0032] UV protection factors in the context of the invention are, for example, organic substances (light filters) which are liquid or crystalline at room temperature and which are capable of absorbing ultraviolet radiation and of releasing the energy absorbed in the form of longer-wave radiation, for example heat. UV-B filters can be oil-soluble or water-soluble. The following are examples of oil-soluble substances:
3-benzylidene camphor or 3-benzylidene norcamphor and derivatives thereof, for example 3-(4-methylbenzylidene)-camphor; 4-aminobenzoic acid derivatives, preferably 4-(dimethylamino)-benzoic acid-2-ethylhexyl ester, 4-(dimethylamino)-benzoic acid-2-octyl ester and 4-(dimethylamino)-benzoic acid amyl ester; esters of cinnamic acid, preferably 4-methoxycinnamic acid-2-ethylhexyl ester, 4-methoxycinnamic acid propyl ester, 4-methoxycinnamic acid isoamyl ester, 2-cyano-3,3-phenylcinnamic acid-2-ethylhexyl ester (Octocrylene); esters of salicylic acid, preferably salicylic acid-2-ethylhexyl ester, salicylic acid-4-isopropylbenzyl ester, salicylic acid homomethyl ester; derivatives of benzophenone, preferably 2-hydroxy-4-methoxybenzo-phenone, 2-hydroxy-4-methoxy-4′-methylbenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone; esters of benzalmalonic acid, preferably 4-methoxybenzalmalonic acid di-2-ethylhexyl ester; triazine derivatives such as, for example, 2,4,6-trianilino-(p-carbo-2′-ethyl-1′-hexyloxy)-1,3,5-triazine and Octyl Triazone or Dioctyl Butamido Triazone (Uvasorb® HEB); propane-1,3-diones such as, for example, 1-(4-tert.butylphenyl)-3-(4′-methoxyphenyl)-propane-1,3-dione; ketotricyclo(5.2.1.0)decane derivatives.
[0042] Suitable water-soluble substances are
2-phenylbenzimidazole-5-sulfonic acid and alkali metal, alkaline earth metal, ammonium, alkylammonium, alkanolammonium and glucammonium salts thereof and 2,2-(1,4-phenylene)-bis-1H-benzimidazole-4,6-disulfonic acid and salts thereof, more particularly the sodium salt; sulfonic acid derivatives of benzophenones, preferably 2-hydroxy-4-methoxybenzophenone-5-sulfonic acid and salts thereof; sulfonic acid derivatives of 3-benzylidene camphor such as, for example, 4-(2-oxo-3-bornylidenemethyl)-benzene sulfonic acid and 2-methyl-5-(2-oxo-3-bornylidene)-sulfonic acid and salts thereof.
[0046] Typical UV-A filters are, in particular, derivatives of benzoyl methane such as, for example, 1-(4′-tert.butylphenyl)-3-(4′-methoxyphenyl)-propane-1,3-dione, 4-tert.butyl-4′-methoxydibenzoyl methane (Parsol® 1789) or 1-phenyl-3-(4′-isopropylphenyl)-propane-1,3-dione and enamine compounds. The UV-A and UV-B filters may of course also be used in the form of mixtures. Particularly favorable combinations consist of the derivatives of benzoyl methane, for example 4-tert.butyl-4′-methoxydibenzoylmethane (Parsol® 1789) and 2-cyano-3,3-phenylcinnamic acid-2-ethyl hexyl ester (Octocrylene) in combination with esters of cinnamic acid, preferably 4-methoxycinnamic acid-2-ethyl hexyl ester and/or 4-methoxycinnamic acid propyl ester and/or 4-methoxycinnamic acid isoamyl ester. Combinations such as these are advantageously combined with water-soluble filters such as, for example, 2-phenylbenzimidazole-5-sulfonic acid and alkali metal, alkaline earth metal, ammonium, alkylammonium, alkanolammonium and glucammonium salts thereof.
[0047] Besides the soluble substances mentioned, insoluble light-blocking pigments, i.e. finely dispersed metal oxides or salts, may also be used for this purpose. Examples of suitable metal oxides are, in particular, zinc oxide and titanium dioxide. Silicates (talcum), barium sulfate and zinc stearate may be used as salts. The oxides and salts are used in the form of the pigments for skin-care and skin-protecting emulsions.
[0048] Besides the two groups of primary sun protection factors mentioned above, secondary sun protection factors of the antioxidant type may also be used. Secondary sun protection factors of the antioxidant type interrupt the photochemical reaction chain which is initiated when UV rays penetrate into the skin.
Biogenic Agents
[0049] In the context of the invention, biogenic agents are, for example, tocopherol, tocopherol acetate, tocopherol palmitate, ascorbic acid, (deoxy)ribonucleic acid and fragmentation products thereof, f3-glucans, retinol, bisabolol, allantoin, phytantriol, panthenol, AHA acids, amino acids, ceramides, pseudoceramides, essential oils, plant extracts, for example prunus extract, bambara nut extract, and vitamin complexes.
Deodorants
[0050] Deodorants counteract, mask or eliminate body odors. Body odors are formed through the action of skin bacteria on apocrine perspiration which results in the formation of unpleasant-smelling degradation products. Accordingly, deodorants contain active principles which act as germ inhibitors, enzyme inhibitors, odor absorbers or odor maskers.
[0051] Germ Inhibitors
Basically, suitable germ inhibitors are any substances which act against gram-positive bacteria such as, for example, 4-hydroxybenzoic acid and salts and esters thereof, N-(4-chloro-phenyl)-N′-(3,4-dichlorophenyl)-urea, 2,4,4′-trichloro-2′-hydroxy-diphenylether (triclosan), 4-chloro-3,5-dimethylphenol, 2,2′-methylene-bis-(6-bromo-4-chlorophenol), 3-methyl-4-(1-methyl-ethyl)-phenol, 2-benzyl-4-chlorophenol, 3-(4-chlorophenoxy)-propane-1,2-diol, 3-iodo-2-propinyl butyl carbamate, chlorhexidine, 3,4,4′-trichlorocarbanilide (TTC), antibacterial perfumes, thymol, thyme oil, eugenol, clove oil, menthol, mint oil, farnesol, phenoxyethanol, glycerol monocaprate, glycerol monocaprylate, glycerol monolaurate (GML), diglycerol monocaprate (DMC), salicylic acid-N-alkylamides such as, for example, salicylic acid-n-octyl amide or salicylic acid-n-decyl amide.
[0053] Enzyme Inhibitors
Suitable enzyme inhibitors are, for example, esterase inhibitors. Esterase inhibitors are preferably trialkyl citrates, such as trimethyl citrate, tripropyl citrate, triisopropyl citrate, tributyl citrate and, in particular, triethyl citrate (Hydagen® CAT). Esterase inhibitors inhibit enzyme activity and thus reduce odor formation. Other esterase inhibitors are sterol sulfates or phosphates such as, for example, lanosterol, cholesterol, campesterol, stigmasterol and sitosterol sulfate or phosphate, dicarboxylic acids and esters thereof, for example glutaric acid, glutaric acid monoethyl ester, glutaric acid diethyl ester, adipic acid, adipic acid monoethyl ester, adipic acid diethyl ester, malonic acid and malonic acid diethyl ester, hydroxycarboxylic acids and esters thereof, for example citric acid, malic acid, tartaric acid or tartaric acid diethyl ester, and zinc glycinate.
[0055] Odor Absorbers
Suitable odor absorbers are substances which are capable of absorbing and largely retaining the odor-forming compounds. They reduce the partial pressure of the individual components and thus also reduce the rate at which they spread. An important requirement in this regard is that perfumes must remain unimpaired. Odor absorbers are not active against bacteria. They contain, for example, a complex zinc salt of ricinoleic acid or special perfumes of largely neutral odor known to the expert as “fixateurs” such as, for example, extracts of ladanum or styrax or certain abietic acid derivatives as their principal component. Odor maskers are perfumes or perfume oils which, besides their odor-masking function, impart their particular perfume note to the deodorants.
Antiperspirants
[0057] Antiperspirants reduce perspiration and thus counteract underarm wetness and body odor by influencing the activity of the eccrine sweat glands.
[0058] Suitable astringent active principles of antiperspirants are, above all, salts of aluminium, zirconium or zinc. Suitable antihydrotic agents of this type are, for example, aluminium chloride, aluminium chlorohydrate, aluminium dichlorohydrate, aluminium sesquichlorohydrate and complex compounds thereof, for example with 1,2-propylene glycol, aluminium hydroxyallantoinate, aluminium chloride tartrate, aluminium zirconium trichlorohydrate, aluminium zirconium tetrachlorohydrate, aluminium zirconium pentachlorohydrate and complex compounds thereof, for example with amino acids, such as glycine.
Antidandruff Agents
[0059] Suitable antidandruff agents are piroctone olamine (1-hydroxy-4-methyl-6-(2,4,4-trimethylpentyl)-2-(1H)-pyridinone monoethanolamine salt), Baypival® (Climbazole), Ketoconazol® (4-acetyl-1-{4-[2-(2,4-dichlorophenyl) r-2-(1H-imidazol-1-ylmethyl)-1,3-dioxylan-c-4-ylmethoxy-phenyl}-piperazine, ketoconazole, elubiol, selenium disulfide, colloidal sulfur, sulfur polyethylene glycol sorbitan monooleate, sulfur ricinol polyethoxylate, sulfur tar distillate, salicylic acid (or in combination with hexachlorophene), undecylenic acid, monoethanolamide sulfosuccinate Na salt, Lamepon® UD (protein/undecylenic acid condensate), zinc pyrithione, aluminium pyrithione and magnesium pyrithione/dipyrithione magnesium sulfate.
Insect Repellents
[0060] Suitable insect repellents are N,N-diethyl-m-toluamide, pentane-1,2-diol or 3-(N-n-butyl-N-acetylamino)-propionic acid ethyl ester), which is marketed under the name of Insect Repellent® 3535 by Merck KGaA, and butyl acetylaminopropionate.
Self-Tanning Agents and Depigmenting Agents
[0061] A suitable self-tanning agent is dihydroxyacetone. Suitable tyrosine inhibitors which prevent the formation of melanin and are used in depigmenting agents are, for example, arbutin, ferulic acid, koji acid, coumaric acid and ascorbic acid (vitamin C).
Hydrotropes
[0062] In addition, hydrotropes, for example ethanol, isopropyl alcohol or polyols, may be used to improve flow behavior. Suitable polyols preferably contain 2 to 15 carbon atoms and at least two hydroxyl groups.
Preservatives
[0063] Suitable preservatives are, for example, phenoxyethanol, formal-dehyde solution, parabens, pentanediol or sorbic acid and the silver complexes known under the name of Surfacine® and the other classes of compounds listed in Appendix 6, Parts A and B of the Kosmetikverordnung (“Cosmetics Directive”).
Perfume Oils and Aromas
[0064] Suitable perfume oils are mixtures of natural and synthetic perfumes. Natural perfumes include the extracts of blossoms, stems and leaves, fruits, fruit peel, roots, woods, herbs and grasses, needles and branches, resins and balsams. Animal raw materials, for example civet and beaver, and synthetic perfume compounds of the ester, ether, aldehyde, ketone, alcohol and hydrocarbon type may also be used.
Dyes
[0065] Suitable dyes are any of the substances suitable and approved for cosmetic purposes. Examples include cochineal red A (C.I. 16255), patent blue V (C.I. 42051), indigotin (C.I. 73015), chlorophyllin (C.I. 75810), quino-line yellow (C.I. 47005), titanium dioxide (C.I. 77891), indanthrene blue RS (C.I. 69800) and madder lake (C.I. 58000). These dyes are normally used in concentrations of 0.001 to 0.1% by weight, based on the mixture as a whole.
EXAMPLES
[0066] In the following Examples, AV stands for acid value, IV for iodine value and OHV for hydroxyl value.
Example 1
[0067] 2,700 g isononyl alcohol were heated under nitrogen in the presence of 5% by weight of the catalyst K5 until the separation of water was observed. The reaction mixture was kept at that temperature until there was no further elimination of water. The still hot reaction mixture was removed from the catalyst by filtration and gave a clear colorless product. Analysis: AV=0.1, IV=167, OHV=0.7.
Example 2
[0068] 1,200 g 2-ethyl hexanol were heated under nitrogen in the presence of 5% by weight of the catalyst K5 until the separation of water was observed. The reaction mixture was kept at that temperature until there was no further elimination of water. The still hot reaction mixture was removed from the catalyst by filtration and gave a clear, colorless product. Analysis: AV=0.2, IV=217, OHV=0.4.
Example 3
[0069] 1,030 g poly-α-olefin based on isononyl alcohol (obtained from Example 1) and 0.05% by weight palladium on coal were treated with 100 bar hydrogen for 5 hours at 200° C. The catalyst was filtered off and the product deodorized. Analysis: OHV=0.9, AV=1.6, IV=0.1.
Example 4
[0070] 560 g poly-α-olefin based on 2-ethylhexanol (obtained from Example 2) and 0.05% by weight palladium on coal were treated with 100 bar hydrogen for 5 hours at 200° C. The catalyst was filtered off and the product deodorized. Analysis: OHV=0.1, IV=1.1, AV=0.1.
Cosmetic Compositions
Example 5
[0071] The following o/w emulsion was prepared using the poly-α-olefin of Example 3 as oil component:
[0000]
Eumulgin ® B2
2%
by weight
Lanette ® O
5%
by weight
Oil component
16%
by weight
Glycerol
3%
by weight
Water
73.85%
by weight
Formalin (37%)
0.15%
by weight
Example 6
[0072] The following o/w emulsion was prepared using the poly-α-olefin of Example 3 as oil component:
[0000]
Eumulgin ® VL 75
4.5%
by weight
Oil component
16%
by weight
Carbopol ®
0.3%
by weight
KOH (20%)
0.7%
by weight
Glycerol
3%
by weight
Water
75.35%
by weight
Formalin (37%)
0.15%
by weight
Example 7
[0073] The following o/w emulsion was prepared using the poly-α-olefin of Example 3 as oil component:
[0000]
Dehymuls ® PGPH
5%
by weight
Oil component
20%
by weight
Glycerol
5%
by weight
Mg sulfate•7H 2 O
1%
by weight
Water
68.85%
by weight
Formalin (37%)
0.15%
by weight
[0074] The isononyl oligomer poly-α-olefin had a constant viscosity (ca. 5,000 mPas) over the storage period of 12 weeks at room temperature. The emulsions containing Carbopol® were stable over 4 weeks both at minus 5° C. and at 40, 45 and 50° C.
[0075] Table 1 below shows the viscosity and storage stability tests for the emulsion of Example 6 by comparison with emulsions containing Nexbase® 2006 FG or thinly liquid paraffin oil as the oil component. In contrast to the emulsion according to the invention, the comparison emulsions had separated after about 1 week under these conditions.
[0000]
TABLE 1
Isononyl
oligomer
Paraffin oil.
Nexbase ®
hydrogenated
thinly liquid
2006FG
Eumulgin ® VL 75
4.50
4.50
4.50
Isononyl oligom.
16.00
—
—
hydrogenated
Paraffin oil, thinly
—
16.00
—
liquid
Nexbase ® 2006FG
—
—
16.00
Carbopol ®
0.30
0.30
0.30
KOH, 20%
0.70
0.70
0.70
Glycerol, 86%
3.00
3.00
3.00
Water, deionized
75.35
75.35
75.35
Formalin, 37%
0.15
0.15
0.15
Viscosity in mPas
Day 1
4000
4800
4800
1 Weeks
4000
6400
6000
4 Weeks
4800
—
—
8 Weeks
5200
—
—
12 Weeks
4800
—
—
Stabilities *
1 Week RT/−5° C./
1/1/1/1/1
1/1/1/5/5
1/1/1/1/1
40° C./45° C./50° C.
4 Weeks RT/−5° C./
1/1/1/1/1
5/1/5/—/—
5/5/5/5/5
40° C./45° C./50° C.
8 Weeks RT/−5° C./
1/1/1/1/1
—/1/—/—/—
—/—/—/—/—
40° C./45° C./50° C.
12 Weeks RT/−5° C./
1/1/1/1/1
—/—/—/—/—
40° C./45° C./50° C.
In Table 1, “1” = stable emulsion, “5” = non-stable emulsions and “—” = emulsions which were clearly unstable, i.e. had separated, RT = room temperature.
[0076] Examples of formulations which demonstrate the various potential applications of the cosmetic compositions according to the invention are presented in the following Tables. All quantities represent percentages by weight of the commercially available substances in the composition as a whole.
[0000]
TABLE 2
O/W sun protection emulsions
Component
1
2
3
4
5
6
7
8
9
10
11
L = Lotion, C = Cream
L
C
S
L
C
L
L
C
L
C
L
Eumulgin ® VL 75
4
4
2
Eumulgin ® B2
2
Tween ® 60
1
Myrj ® 51
3
2
Cutina ® E 24
1
1
Hostaphat ® KL 340 N
2
Lanette ® E
0.5
0.5
Amphisol ® K
1
1
0.5
1
Sodium stearate
1
2
Emulgade ® PL 68/50
1
5
4
Tego ® Care 450
3
Cutina ® MD
2
6
4
6
Lanette ® 14
1
1
2
4
Lanette ®O
1
6
5
2
2
Antaron V 216
1
2
2
1
Emery ® 1780
0.5
0.5
Lanolin, anhydrous, USP
5
Poly-α-olefin (Example 4)
2
2
4
1
2
2
2
1
2
2
1
Myritol ® PC
5
Myritol ® 331
5
8
6
10
2
Finsolv ® TN
1
1
8
Cetiol ® CC
2
5
4
4
2
2
Cetiol ® OE
3
2
3
Dow Corning DC ® 244
4
1
5
2
2
Dow Corning DC ® 2502
1
2
Squatol ® S
4
Silikonöl Wacker AK ® 350
2
Cetiol ® 868
2
4
7
Cetiol ® J 600
3
2
5
Mineral oil
9
Cetiol ® B
1
2
Eutanol ® G
Eutanol ® G 16
Cetiol ® PGL
5
5
Almond oil
2
1
Photonyl ® LS
2
2
Panthenol
1
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1
Photonyl ® LS
Neo Heliopan ® Hydro (Na salt)
2
2.2
3
3
2
Neo Heliopan AP (Na salt)
2
1.5
2
2
1
1
Neo Heliopan ® 303
3
5
9
4
Neo Heliopan ® BB
1
2
Neo Heliopan ® MBC
2
3
2
2
2
1
Neo Heliopan ® OS
10
7
Neo Heliopan ® E 1000
7.5
6
6
Neo Heliopan ® AV
7.5
7.5
4
5
Uvinul ® T 150
2
2.5
1
Parsol ® 1789
1
1
2
2
2
Zinc oxide NDM
10
5
10
3
5
4
Eusolex ® T 2000
5
3
3
4
Veegum ® Ultra
0.7
1
1
Keltrol ® T
0.2
0.5
0.5
Carbopol ® 980
0.5
0.2
0.2
0.2
0.5
0.1
0.3
0.2
Ethanol
10
Butylene glycol
2
4
3
2
5
2
2
Glycerin
5
5
5
3
3
2
4
3
Preservative, NaOH Water
q.s. to 100
[0000]
TABLE 3
O/W sun protection emulsions
Component
12
13
14
15
16
17
18
19
20
21
22
L = Lotion, C = Cream
L
L
L
C
L
C
S
C
C
L
L
Eumulgin ® VL 75
4
3
4.5
3
4
Eumulgin ® B2
1
Tween ® 60
1
Myrj ® 51
Cutina ® E 24
2
Hostaphat ® KL 340 N
0.5
Lanette ® E
0.5
0.5
0.5
0.1
0.5
Amphisol ® K
0.5
1
1
1
Sodium stearate
1
Emulgade ® PL 68/50
6
4.5
1
5
Tego ® Care 450
1
4
Cutina ® MD
1
8
6
1
4
1
Lanette ® 14
2
2
1
Lanette ® O
2
1
1
Antaron V 220
1
2
0.5
2
0.5
Poly-α-olefin (Example 4)
4
2
4
6
10
4
2
8
2
1
3
Myritol ® PC
5
Myritol ® 331
12
12
8
8
10
8
Finsolv ® TN
5
3
3
Cetiol ® CC
6
6
5
5
Cetiol ® OE
2
2
Dow Corning DC ® 244
2
1
Dow Corning DC ® 2502
1
1
Ceraphyl ® 45
2
2
Silikonöl Wacker AK ® 350
1
Cetiol ® 868
2
Cetiol ® J 600
2
Mineral oil
10
Cetiol ® B
4
4
4
Eutanol ® G
3
3
Eutanol ® G 16 S
10
Cetiol ® PGL
2
Photonyl ® LS
2
Panthenol
1
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1
Neo Heliopan ® Hydro (Na salt)
3
Neo Heliopan AP (Na salt)
2
2
2
1
Eusolex ® OCR
6
9
5
7
9
4
7
Neo Heliopan ® BB
1
1
1
Neo Heliopan ® MBC
2
1
3
1
3
Neo Heliopan ® OS
2
7
Neo Heliopan ® E1000
4
5
Neo Heliopan ® AV
4
7.5
5
5
4
7.5
Uvinul ® T 150
1
1.3
1
1
Parsol ® 1789
1
2
1
Z-Cote ® HP 1
7
2
5
7
5
6
2
Eusolex ® T 2000
5
2
10
10
2
Veegum ® Ultra
1.5
1.5
1.5
1.2
1
Keltrol ® T
0.5
0.5
0.5
0.4
0.5
Pemulen ® TR 2
0.3
0.3
0.1
0.2
0.3
Ethanol
5
8
Butylene glycol
1
3
3
8
1
Glycerin
2
4
3
3
3
3
3
5
3
Water/preservative/NaOH
to 100/q.s./q.s
[0000]
TABLE 4
W/O sun protection emulsions
Component
23
24
25
26
27
28
29
30
31
32
33
L = Lotion; C = Cream
C
L
C
L
C
L
L
L
L
C
C
Dehymuls ® PGPH
4
2
1
3
3
1
1
2
2
4
1
Monomuls ® 90-O18
2
Lameform ® TGI
2
4
3
1
3
Abil ® EM 90
4
Glucate ® DO
3
Isolan ® PDI
4
2
Arlacel ® 83
2
Elfacos ® ST9
2
Elfacos ® ST37
Arlacel ® P 135
2
Dehymuls ® HRE 7
Zinc stearate
1
1
1
1
1
Microcrystalline wax
5
2
5
Beeswax
1
1
5
7
Tego ® Care CG
1
.5
Prisorine ® 3505
1
1
1
1
1
1
Emery ® 1780
5
4
Wool wax alcohol, anhydrous, USP
1
Antaron V 216
2
Poly-α-olefin (Example 4)
3
4
2
1
10
2
2
6
3
12
1
Myritol ® PC
3
4
Myritol ® 331
10
3
6
8
Finsolv ® TN
5
5
Cetiol ® CC
12
22
2
2
5
Cetiol ® OE
4
5
4
2
Dow Corning DC ® 244
2
Dow Corning DC ® 2502
1
2
Prisorine ® 3758
2
Silikonöl Wacker AK ® 350
4
3
Cetiol ® 868
2
Eutanol ® G 16
3
Eutanol ® G 16S
Cetiol ® J 600
4
2
Ceraphyl ® 45
2
2
6
Mineral oil
4
Cetiol ® B
2
4
3
Eutanol ® G
3
8
Cetiol ® PGL
11
4
9
Almond oil
1
5
Photonyl ® LS
2
1
4
Panthenol
1.0
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1.0
Magnesium sulfate x 7 water
1
Neo Heliopan ® Hydro (Na salt)
2
3
2
Neo Heliopan AP (Na salt)
2
1
2
1
2
1
Neo Heliopan ® 303
4
6
Neo Heliopan ® BB
4
2
2
Neo Heliopan ® MBC
4
3
Neo Heliopan ® OS
Neo Heliopan ® E 1000
5
Neo Heliopan ® AV
3
6
6
7.5
7.5
5
7.5
Uvinul ® T 150
2.5
1
2
Parsol ® 1789
2
1
2
Zinc oxide NDM
6
Eusolex ® T 2000
15
10
5
4
4
Ethanol
8
Butylene glycol
2
6
2
5
2
Glycerin
5
3
3
5
3
2
10
4
Water, preservative
to 100, q.s.
[0000]
TABLE 5
W/O sun protection emulsions
Component
34
35
36
37
38
39
40
41
42
43
44
L = Lotion; C = Cream
L
C
L
L
C
L
L
L
L
C
C
Dehymuls ® PGPH
3
1
5
1
1
3
2
4
0.5
1
4
Monomuls ® 90-O18
1
Lameform ® TGI
4
1
3
1
Abil ® EM 90
1
2
Glucate ® DO
3
2
Isolan ® PDI
3
4
Arlacel ® 83
3
Elfacos ® ST9
2
Elfacos ® ST37
2
Arlacel ® P 135
3
Dehymuls ® HRE 7
4
Zinc stearate
2
2
1
1
1
1
Microcrystalline wax
4
1
4
Beeswax
4
2
1
2
1
Tego ® Care CG
Isostearic acid
1
1
1
1
1
1
Emery ® 1780
7
3
Wool wax alcohol, anhydrous, USP
Antaron V 220
0.5
2
1
1
1
Poly-α-olefin (Example 4)
2
4
3
3
2
2
1
3
3
1
4
Myritol ® PC
Myritol ® 331
4
2
3
5
8
5
4
Finsolv ® TN
5
5
7
Cetiol ® CC
3
1
3
16
12
Cetiol ® OE
3
2
3
Dow Corning DC ® 244
4
2
Dow Corning DC ® 2502
1
Prisorine ® 3578
1
Silikonöl Wacker AK ® 350
1
Cetiol ® 868
Eutanol ® G 16
3
Eutanol ® G 16S
7
Cetiol ® J 600
3
Ceraphyl ® 45
1
5
4
Mineral oil
9
Cetiol ® B
3
3
2
2
Eutanol ® G
2
5
Cetiol ® PGL
2
Almond oil
2
Photonyl ® LS
3
2
Panthenol
1.0
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1.0
Magnesium sulfate x 7 water
1
Neo Heliopan ® Hydro (Na salt)
4
4
Neo Heliopan AP (Na salt)
2
1
2
1
Neo Heliopan ® 303
6
2
6
Neo Heliopan ® BB
2
2
2
Neo Heliopan ® MBC
2
3
4
2
Neo Heliopan ® OS
10
8
Neo Heliopan ® E 1000
5
6
5
Neo Heliopan ® AV
5
5
7.5
5
Uvinul ® T 150
1
2
2
3
2
Parsol ® 1789
1
1
1
0.5
Z-Cote ® HP 1
4
10
5
5
Titanium dioxide T 805
2
3
7
4
7
Ethanol
8
10
Butylene glycol
5
1
3
3
8
2
Glycerin
6
2
5
5
3
5
Water, preservative
to 100, q.s.
[0000]
TABLE 6
W/O care emulsions
Component
45
46
47
48
49
50
51
52
53
54
55
L = Lotion, C = Cream
C
L
C
L
C
L
L
L
C
C
C
Dehymuls ® PGPH
1
3
1
2
3
1
1
2
1
1
1
Monomuls ® 90-O18
2
2
2
Lameform ® TGI
4
1
3
1
4
3
3
Abil ® EM 90
4
Isolan ® PDI
4
Glucate ® DO
5
Arlacel ® 83
5
Dehymuls ® FCE
Dehymuls ® HRE 7
4
1
Zinc stearate
2
1
1
1
1
1
1
Microcrystalline wax
5
2
5
Beeswax
4
1
1
4
7
Tego Care ® CG
1
0.5
Prisorine ® 3505
1
1
1
1
1
Dry Flo ® Plus
SFE 839
3
Emery ® 1780
1
1
Lanolin; anhydrous USP
5
4
Poly-α-olefin (Example 4)
3
4
2
12
10
2
2
6
3
12
1
Cegesoft ® C 17
3
1
Myritol ® PC
2
4
Myritol ® 331
6
2
6
2
8
Finsolv ® TN
5
2
5
Cetiol ® A
6
4
Cetiol ® CC
8
2
2
2
5
Cetiol ® SN
5
3
Cetiol ® OE
3
4
2
4
2
Dow Corning DC ® 244
1
2
Dow Corning DC ® 2502
1
2
Prisorine ® 3758
3
Silikonöl Wacker AK ® 350
4
3
Cetiol ® 868
2
7
Cetiol ® J 600
4
2
Ceraphyl ® 45
2
2
6
Mineral oil
4
Cetiol ® B
2
4
3
Eutanol ® G 16
1
3
Eutanol ® G
3
8
Cetiol ® PGL
4
9
Almond oil
1
5
Insect Repellent ® 3535
2
N,N-Diethyl-m-toluamide
3
5
Photonyl ® LS
2
2
Panthenol
1.0
Bisabolol
0.2
Tocopherol/Tocopheryl Acetate
1.0
Magnesium sulfate x 7 water
1
Bentone ® 38
1
Propylene carbonate
0.5
Ethanol
8
Butylene Glycol
2
6
2
5
2
Glycerin
5
3
3
5
3
2
10
4
Water, preservative
to 100, q.s.
[0000]
TABLE 7
W/O care emulsions
Component
56
57
58
59
60
61
62
63
64
65
66
L = Lotion, C = Cream
L
C
L
L
C
L
L
L
L
C
C
Dehymuls ® PGPH
3
1
5
1
1
3
3
4
1
1
1
Monomuls ® 90-O18
1
1
Lameform ® TGI
4
1
3
Abil ® EM 90
3
2
Isolan ® PDI
3
4
Glucate ® DO
1
Arlacel ® 83
3
Dehymuls ® FCE
4
1
Dehymuls ® HRE 7
7
Zinc stearate
2
2
1
1
1
1
1
1
Microcrystalline wax
4
1
4
Beeswax
4
2
2
1
1
2
5
Tego ® Care CG
Prisorine ® 3505
1
1
1
1
1
1
Dry Flo ® Plus
1
SFE ® 839
5
4
Emery ® 1780
Lanolin anhydrous USP
7
3
Poly-α-olefin (Example 4)
3
4
4
8
10
2
8
6
3
12
7
Cegesoft ® C 17
2
Myritol ® PC
8
Myritol ® 331
4
3
5
3
5
4
Finsolv ® TN
5
7
Cetiol ® A
6
Cetiol ® CC
3
6
3
3
8
Cetiol ® SN
5
Cetiol ® OE
3
2
3
8
Dow Corning ® DC 244
4
2
2
Dow Corning ® DC 2502
1
Prisorine ® 3758
1
Silikonöl Wacker AK ® 350
1
1
4
Cetiol ® 868
10
Cetiol ® J 600
4
3
Ceraphyl ® 45
1
5
4
Mineral oil
9
Cetiol ® B
3
3
2
2
Eutanol ® G 16
1
Eutanol ® G
2
5
Cetiol ® PGL
10
6
3
Almond oil
2
5
2
Photonyl ® LS
2
2
Panthenol
1.0
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1.0
Magnesium sulfate x 7 water
1
Bentone ® 38
1
Propylene carbonate
0.5
Ethanol
8
10
Butylene glycol
5
1
3
3
8
2
1
Glycerin
6
2
5
5
3
5
Water, preservative
to 100, q.s.
[0000]
TABLE 8
O/W care emulsions
Component
67
68
69
70
71
72
73
74
75
76
77
L = Lotion, C = Cream
C
C
C
L
C
L
L
C
L
C
C
Eumulgin ® VL 75
4
Dehymuls ® PGPH
2
Generol ® R
1
Eumulgin ® B2
0.8
Tween ® 60
1
Cutina ® E 24
0.6
2
Hostaphat ® KL 340 N
2
Lanette ® E
1
Amphisol ® K
0.5
1
1
0.5
Sodium stearate
0.5
Emulgade ® PL 68/50
2.5
4
Tego ® Care CG
2
Tego ® Care 450
5
Cutina ® MD
1
6
5
4
6
Lanette ® 14
1
2
4
Lanette ® O
4.5
4
1
2
2
Novata ® AB
1
1
Emery ® 1780
0.5
0.5
Lanolin, anhydrous, USP
5
Cetiol ® SB 45
1.5
2
Poly-α-olefin (Example 4}
3
4
2
1
10
2
2
6
3
12
1
Cegesoft ® C 17
Myritol ® PC
5
Myritol ® 331
2
5
5
6
12
Finsolv ® TN
2
2
8
Cetiol ® CC
4
6
4
4
5
Cetiol ® OE
4
3
Dow Corning DC ® 245
2
5
1
Dow Corning DC ® 2502
2
1
Prisorine ® 3758
1
Silikonöl Wacker AK ® 350
0.5
0.5
0.5
1
4
Cetiol ® 868
2
4
Cetiol ® J 600
2
3
3
2
5
Ceraphyl ® 45
3
Mineral oil
9
Cetiol ® SN
5
Cetiol ® B
2
Eutanol ® G
2
3
Cetiol ® PGL
5
5
Dry Flo ® Plus
5
1
SFE 839
5
2
Almond oil
1
Insect Repellent ® 3535
2
4
2
3
N,N-Diethyl-m-toluamide
2
3
Photonyl ® LS
2
2
2
Panthenol
1
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1
Veegum ® ultra
1
Keltrol ® T
0.4
0.5
Pemulen ® TR 2
0.3
0.3
Carbopol ® Ultrez 10
0.3
0.3
0.2
0.2
0.2
0.1
0.3
0.2
Ethanol
10
Butylene glycol
4
3
2
5
2
Glycerin
2
5
5
3
3
2
4
3
Water, preservative, NaOH
to 100, q.s., pH 6.5-7.5
[0000]
TABLE 9
O/W care emulsions
Component
78
79
80
81
82
83
84
85
86
87
88
L = Lotion, C = Cream
C
C
L
C
L
C
L
L
L
L
C
Eumulgin ® VL 75
4
3
1
2
Generol ® R
2
Eumulgin ® B2
2
1
Tween ® 60
1
Cutina ® E 24
2
Hostaphat ® KL 340 N
Lanette ® E
0.5
1
Amphisol ® K
0.5
1
1
1
Sodium stearate
1
Emulgade ® PL 68/50
6
5
4
Tego ® Care CG
Tego ® Care 450
4
Cutina ® MD
3
3
8
6
8
4
Lanette ® 14
2
2
1
Lanette ® O
2
2
3
1
1
1
6
Novata ® AB
Emery ® 1780
Lanolin, anhydrous, USP
4
Cetiol ® SB 45
2
Poly-α-olefin (Example 4)
3
4
2
1
10
2
2
6
3
12
1
Cegesoft ® C 17
4
Myritol ® PC
6
5
5
Myritol ® 331
5
5
7
10
3
Finsolv ® TN
5
5
3
3
1
Cetiol ® CC
2
Cetiol ® OE
2
2
5
Dow Corning DC ® 245
2
1
8
2
Dow Corning DC ® 2502
1
1
3
Prisorine ® 3758
3
2
Silikonöl Wacker AK ® 350
1
1
Cetiol ® 868
2
Cetiol ® J 600
2
Ceraphyl ® 45
3
Cetiol ® SN
Cetiol ® B
5
5
4
3
Eutanol ® G
3
5
5
Cetiol ® PGL
5
2
Dry Flo ® Plus
1
1
SFE 839
1
1
Almond oil
2
Photonyl ® LS
2
Panthenol
1
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1
Veegum ® Ultra
1
Keltrol ® T
0.5
Carbopol ® ETD 2001
0.3
0.3
0.5
0.2
0.2
Pemulen ® TR 2
0.3
0.3
0.5
Ethanol
5
8
10
Butylene glycol
5
2
3
3
8
Glycerin
2
4
3
3
7
5
3
5
Water, preservative, NaOH
to 100, q.s. (pH 6.5-7.5)
[0000]
TABLE 10
Spray formulations
Component
89
90
91
92
93
94
95
96
97
98
99
S = Body spray, S* = Sun
S
S
S
S
S
S*
S*
S*
S*
S*
S*
protection spray
Emulgade ® SE-PF
8.9
7.5
7.5
4.3
9.8
8.2
9.9
Eumulgin ® B2
3.1
3
4.2
Eumulgin ® B3
4.2
3.3
Eumulgin ® HRE 40
4.7
Cutina ® E 24
5.9
4
Amphisol ® K
1
1
1
Eumulgin ® VL 75
2
Emulgade ® PL 68/50
0.5
2.5
1
Cutina ® MD
3.1
Antaron V 220
1
1
1
1
1
Poly-α-olefin (Example 4)
11
5
7
7
7
5
4
5
5
4
6
Myritol ® PC
Myritol ® 331
3
4
3
3
3
3
Finsolv ® TN
4
8
Cetiol ® CC
6
5
5
2
2
4
Cetiol ® OE
5
5
2
Dow Corning DC ® 244
4
4
5
Cetiol ® 868
3
Cetiol ® J 600
2
2
Mineral oil
2
Cetiol ® B
2
Eutanol ® G
2
1
Photonyl ® LS
2
2
2
2
Panthenol
1
Bisabolol
0.2
Tocopherol/Tocopherylacetate
1
Neo Heliopan ® Hydro (Na salt)
2
3
Neo Heliopan AP (Na salt)
2
2
2
1
Eusolex ® OCR
2
3
Neo Heliopan ® BB
1
Neo Heliopan ® MBC
2
2
2
1
1
Neo Heliopan ® OS
5
Neo Heliopan ® AV
6
6
2
7.5
2
Uvinul ® T 150
1
1
1
1
Parsol ® 1789
1
1
1
Z-Cote ® HP 1
2
2
Eusolex ® T 2000
2
2
Veegum ® Ultra
1.5
Laponite ®XLG
1.5
Keltrol ® T
0.5
Pemulen ® TR 2
0.2
Insect Repellent ® 3535
1
N,N-Diethyl-m-toluamide
1
Ethanol
Butylene glycol
1
2
1
Glycerin
3
2
3
2
3
Water/preservative/NaOH
to 100/q.s./q.s
[0000]
APPENDIX
1)
Abil ® EM 90
INCI: Cetyl Dimethicone Copolyol
Manufacturer: Tego Cosmetics
(Goldschmidt)
2)
Amphisol ® K
INCI: Potassium Cetyl Phosphate
Manufacturer: Hoffmann La Roche
3)
Antaron ® V 220
INCI: PVP/Eicosene Copolymer
Manufacturer: GAF General Aniline
Firm Corp. (IPS-Global)
4)
Antaron ® V 216
INCI: PVP/Hexadecene Copolymer
Manufacturer: GAF General Aniline
Firm Corp. (IPS-Global)
5)
Arlacel ® 83
INCI: Sorbitan Sesquioleate
Manufacturer: Uniqema (ICI
Surfacants)
6)
Arlacel ® P 135
INCI: PEG-30 Dipolyhydroxystearate
Manufacturer: Uniqema (ICI
Surfacants)
7)
Bentone ® 38
INCI: Quaternium-18 Hectorite
Manufacturer: Rheox (Elementis
Specialties)
8)
Carbopol ® 980
INCI: Carbomer
Manufacturer: Goodrich
9)
Carbopol ® 2984
INCI: Carbomer
Manufacturer: Goodrich
10)
Carbopol ® ETD 2001
INCI: Carbomer
Manufacturer: BF Goodrich
11)
Carbopol ® Ultrez 10
INCI: Carbomer
Manufacturer: Goodrich
12)
Cegesoft ® C 17
INCI: Myristyl Lactate
Manufacturer: Cognis Deutschland GmbH,
Grunau
13)
Ceraphyl ® 45
INCI: Diethylhexyl Malate
Manufacturer: International Specialty Products
14)
Cetiol ® 868
INCI: Ethylhexyl Stearate
Manufacturer: Cognis Deutschland GmbH
15)
Cetiol ® A
INCI: Hexyl Laurate
Manufacturer: Cognis Deutschland GmbH
16)
Cetiol ® B
INCI: Butyl Adipate
Manufacturer: Cognis Deutschland GmbH
(Henkel)
17)
Cetiol ® J 600
INCI: Oleyl Erucate
Manufacturer: Cognis Deutschland GmbH
18)
Cetiol ® OE
INCI: Dicaprylyl Ether
Manufacturer: Cognis Deutschland GmbH
19)
Cetiol ® PGL
INCI: Hexyldecanol, Hexyldecyl Laurate
Manufacturer: Cognis Deutschland GmbH
20)
Cetiol ® CC
INCI: Dicaprylyl Carbonate
Manufacturer: Cognis Deutschland
GmbH
21)
Cetiol ® SB 45
INCI: Shea Butter Butyrospermum
Parkii (Linne)
Manufacturer: Cognis Deutschland
GmbH
22)
Cetiol ® SN
INCI: Cetearyl Isononanoate
Manufacturer: Cognis Deutschland
GmbH (Henkel)
23)
Cutina ® E 24
INCI: PEG-20 Glyceryl Stearate
Manufacturer: Cognis Deutschland
GmbH
24)
Cutins ® MD
INCI: Glyceryl Stearate
Manufacturer: Cognis Deutschland
GmbH
25)
Dehymuls ® FCE
INCI: Dicocoyl Pentaerythrityl
Distearyl Citrate
Manufacturer: Cognis Deutschland
GmbH
26)
Dehymuls ® HRE 7
INCI: PEG-7 Hydrogenated Castor
Oil
Manufacturer: Cognis Deutschland
GmbH
27)
Dehymuls ® PGPH
INCI: Polyglyceryl-2
Dipolyhydroxystearate
Manufacturer: Cognis Deutschland
GmbH
28)
Dow Corning ® 244 Fluid
INCI: Cyclomethicone
Manufacturer: Dow Corning
29)
Dow Corning ® 245 Fluid
INCI: Cyclopentasiloxane
Cyclomethicone
Manufacturer: Dow Corning
30)
Dow Corning ® 2502
INCI: Cetyl Dimethicone
Manufacturer: Dow Corning
31)
Dry ® Flo Plus
INCI: Aluminium Starch Octenylsuccinate
Manufacturer: National Starch
32)
Elfacos ® ST 37
INCI: PEG-22 Dodecyl Glycol Copolymer
Manufacturer: Akzo-Nobel
33)
Elfacos ® ST 9
INCI: PEG-45 Dodecyl Glycol Copolymer
Manufacturer: Akzo-Nobel
34)
Emery ® 1780
INCI: Lanolin Alcohol
Manufacturer: Cognis Corporation (Emery)
35)
Emulgade ® PL 68/50
INCI: Cetearyl Glucoside, Ceteayl Alcohol
Manufacturer: Cognis Deutschland GmbH
36)
Emulgade ® SE-PF
INCI: Glyceryl Stearate, Ceteareth-20,
Ceteareth-12, Cetearyl Alcohol, Cetyl
Palmitate
Manufacturer: Cognis Deutschland GmbH
37)
Eumulgin ® B 2
INCI: Ceteareth-20
Manufacturer: Cognis Deutschland GmbH
38)
Eumulgin ® VL 75
INCI: Lauryl Glucoside (and) Polyglyceryl-2
Dipolyhydroxystearate (and) Glycerin
Manufacturer: Cognis Deutschland
GmbH
39)
Eusolex ® OCR
INCI: Octocrylene
Manufacturer: Merck
40)
Eusolex ® T 2000
INCI: Titanium Dioxide, Alumina,
Simethicone
Manufacturer: Rona (Merck)
41)
Eutanol ® G
INCI: Octyldodecanol
Manufacturer: Cognis Deutschland
GmbH
42)
Eutanol ® G 16
INCI: Hexyldecanol
Manufacturer: Cognis Deutschland
GmbH
43)
Eutanol ® G 16 S
INCI: Hexyldecyl Stearate
Manufacturer: Cognis Deutschland
GmbH
44)
Finsolv ® TN
INCI: C 12/15 Alkyl Benzoate
Manufacturer: Findex
(Nordmann/Rassmann)
45)
Generol ® R
INCI: Brassica Campestris
(Rapseed) Sterols
Manufacturer: Cognis Deutschland
GmbH
46)
Glucate ® DO
INCI: Methyl Glucose Dioleate
Manufacturer: NRC
Nordmann/Rassmann
47)
Hostaphat ® KL 340 N
INCI: Trilaureth-4 Phosphate
Manufacturer: Clariant
48)
Isolan ® PDI
INCI: Diisostearoyl Polyglyceryl-3
Diisostearate
Manufacturer: Goldschmidt AG
49)
Keltrol ® T
INCI: Xanthan Gum
Manufacturer: CP Kelco
50)
Lameform ® TGI
INCI: Polyglyceryl-3 Diisostearate
Manufacturer: Cognis Deutschland GmbH
50)
Lanette ® 14
INCI: Myristyl Alcohol
Manufacturer: Cognis Deutschland GmbH
51)
Lanette ® E
INCI: Sodium Cetearyl Sulfate
Manufacturer: Cognis Deutschland GmbH
52)
Lanette ® O
INCI: Cetearyl Alcohol
Manufacturer: Cognis Deutschland GmbH
53)
Monomuls ® 90-0-18
INCI: Glyceryl Oleate
Manufacturer: Cognis Deutschland GmbH
54)
Myrj ® 51
INCI: PEG-30-Sterate
Manufacturer: Uniqema
55)
Myritol ® 331
INCI: Cocoglycerides
Manufacturer: Cognis Deutschland GmbH
56)
Myritol ® PC
INCI: Propylene Glycol
Dicaprylate/Dicaprate
Manufacturer: Cognis Deutschland GmbH
57)
Neo Heliopan ® 303
INCI: Octocrylene
Manufacturer: Haarmann & Reimer
58)
Neo Heliopan ® AP
INCI: Disodium Phenyl
Dibenzimidazole Tetrasulfonate
Manufacturer: Haarmann & Reimer
59)
Neo Heliopan ® AV
INCI: Ethylhexyl Methoxycinnamate
Manufacturer: Haarmann & Reimer
60)
Neo Heliopan ® BB
INCI: Benzophenone-3
Manufacturer: Haarmann & Reimer
61)
Neo Heliopan ® E 1000
INCI: Isoamyl-p-Methoxycinnamate
Manufacturer: Haarmann & Reimer
62)
Neo Heliopan ® Hydro (Na-Salz)
INCI: Phenylbenzimidazole Sulfonic
Acid
Manufacturer: Haarmann & Reimer
63)
Neo Heliopan ® MBC
INCI: 4-Methylbenzylidene Camphor
Manufacturer: Haarmann & Reimer
64)
Neo Heliopan ® OS
INCI: Ethylhexyl Salicylate
Manufacturer: Haarmann & Reimer
65)
Novata ® AB
INCI: Cocoglycerides
Manufacturer: Cognis Deutschland
GmbH
66)
Parsol ® 1789
INCI: Butyl
Methoxydibenzoylmethane
Manufacturer: Hoffmann-La Roche
(Givaudan)
67)
Pemulen ® TR-2
INCI: Acrylates/C10-30 Alkylacrylate
Crosspolymer
Manufacturer: Goodrich
68)
Photonyl ® LS
INCI: Arginine, Disodium Adenosine
Triphosphate, Mannitol, Pyridoxine HCL,
Phenylalanine, Tyrosine
Manufacturer: Laboratoires Serobiologiques
(Cognis)
69)
Prisorine ® ISAC 3505
INCI: Isostearic Acid
Manufacturer: Uniqema
70)
Prisorine ® 3758
INCI: Hydrogenated Polyisobutene
Manufacturer: Uniqema
71)
Ravecarb ® 106
Polycarbonatdiol
Manufacturer: Enichem
73)
SFE ® 839
INCI: Cyclopentasiloxane and
Dimethicone/Vinyl Dimethicone
Crosspolymer
Manufacturer: GE Silicones
74)
Silikonöl Wacker AK ® 350
INCI: Dimethicone
Manufacturer: Wacker
75)
Squatol ® S
INCI: Hydrogenated Polyisobutene
Manufacturer: LCW (7-9 rue de I'Industrie
95310 St-Ouen I'Aumone France)
76)
Tego ® Care 450
INCI: Polyglyceryl-3 Methylglucose
Distearate
Manufacturer: Tego Cosmetics
(Goldschmidt)
77)
Tego ® Care CG 90
INCI: Cetearyl Glucoside
Manufacturer: Goldschmidt
78)
Tween ® 60
INCI: Polysorbate 60
Manufacturer: Uniqema (ICI
Surfactants)
79)
Uvinul ® T 150
INCI: Octyl Triazone
Manufacturer: BASF
80)
Veegum ® Ultra
INCI: Magnesium Aluminium Silicate
Manufacturer: Vanderbilt
81)
Z-Cote ® HP 1
INCI: Zinc Oxide, Dimethicone
Manufacturer: BASF | The invention is directed to a cosmetic composition which contains at least one poly-α-olefin produced by subjecting at least one primary alcohol to dehydrating polymerization at a temperature of 60° C. to 340° C. in the presence of acidic alumino layer silicates. The primary alcohol is an alcohol from the group of unsaturated monofunctional alcohols, branched monofunctional alcohols and difunctional alcohols. The poly-α-olefin is a high-spreading oil component which imparts an almost instantaneous and relatively long-lasting feeling of smoothness to the skin and has good dermatological compatibility. | 0 |
BACKGROUND OF INVENTION
The present invention relates generally to vehicular sliding doors in which the rearward side of the sliding door is supported by a roller bracket that traverses a roller track mounted along the exterior side of the vehicle.
A typical sliding door for a passenger vehicle such as a van, minivan, or a crossover vehicle is supported and guided by upper and lower roller bracket assemblies at the front edge of the sliding door and a center roller bracket assembly attached to the rear edge of the door. The size of the door opening that may be uncovered when the sliding door opens is limited in the prior art to the available distance of rearward travel for the door. A large door opening is desired for ease of ingress/egress and for maximizing the size of loads that may pass through the door opening. However, door travel is typically limited by the length of the tracks in which the roller bracket assemblies traverse during opening of the sliding door. The center track which receives a roller bracket mounted to the rearward edge of the sliding door has not been able to extend beyond the back edge of the vehicle body. Therefore, the open door space for ingress/egress in prior art vehicles has been undesirably limited.
SUMMARY OF INVENTION
By extending the length of the rear roller track supporting a sliding door to beyond the rear end of the vehicle when the sliding door itself is opened beyond a particular location, a larger door and door opening are possible for any particular vehicle size. This provides better occupant access to rear seats and increases the maximum cargo size that can be loaded through the door opening.
In one preferred aspect of the invention, a sliding door system for a vehicle has a sliding door that slides from a door opening toward a rear end of the vehicle. A roller bracket has a hinged connection at one end for coupling to the sliding door and has orthogonal rollers at the other end. A fixed primary track mounts to a side of the vehicle and extends away from the door opening to a terminus. The primary track has a generally C-shaped cross section with a first vertical load portion and a first horizontal load portion. The first load portions receive the orthogonal rollers. A concentric track bracket mounts to the side of the vehicle and has at least a portion disposed between the terminus of the primary track and the rear end of the vehicle. The concentric track bracket has a generally C-shaped cross section greater than and substantially coaxial with the primary track. A track extension has a first end and an interlock end, the track extension being slidably received in the concentric track bracket between a retracted position and an extended position. The track extension is locked in coaxial abutment with the terminus when in the retracted position. The interlock end extends past the rear end of the vehicle when in the extended position. The track extension has a generally C-shaped cross section with a second vertical load portion and a second horizontal load portion, the second load portions aligned with the first load portions, respectively, for receiving the orthogonal rollers when the roller bracket moves from the primary track to the track extension. When the roller bracket moves in an opening direction from the primary track into the track extension and then to the interlock end, the track extension remains in the retracted position. When the orthogonal rollers enter the interlock end then they are captured and the track extension is released to slide within the concentric track to the extended position. When the track extension returns from the extended position to the retracted position then the orthogonal rollers are released from the interlock end, thereby enabling the roller bracket to slide through the track extension and back into the primary track.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view showing a vehicle with a sliding door in the closed position.
FIG. 2 is a diagram showing the relationship between door opening size and sliding door travel for a vehicle body having a particular length.
FIG. 3 is an end view of a track system with a roller bracket received in the track extension.
FIG. 4 is a front plan view showing a track extension in the retracted position.
FIG. 5 is a front plan view of a track extension in an extended position.
FIGS. 6-10 are front plan views showing a roller interacting with an interlock on the track extension.
FIG. 11 is an end view showing the embodiment of FIGS. 6-10 .
FIG. 12 is a top view showing the interlock system of FIG. 11 .
DETAILED DESCRIPTION
Referring now to FIG. 1 , a vehicle 10 has a sliding door 11 supported along an upper roller track 12 , a lower roller track 13 , and a center roller track 14 . Respective roller brackets (not shown) slidable in each track are joined to respective door brackets (not shown) on the interior side of sliding door 11 . In a conventional system, a pair of brackets at the top and bottom of the forward edge of sliding door 11 is joined to the roller brackets sliding in tracks 12 and 13 , respectively. A door bracket attached at the center rear edge of sliding door 11 is coupled to a roller bracket slidably received in track 14 . The tracks have initial portions which move radially outward so that the door first moves outward from the vehicle body in order to clear the vehicle body and then slides toward the rear of vehicle 10 . Because of this compound movement, each roller bracket is pivotally connected to its respective door bracket.
Sliding door 11 and the opening in vehicle 10 which receives sliding door 11 each have a front-to-back width designated D 1 . For conventional sliding doors, the rearward movement of sliding door 11 has a maximum distance designated D 2 which is the length of center track 14 from the edge of the door opening to the end of track 14 . The space available for track 14 is limited by the overall length of vehicle 10 . If distance D 2 is less than distance D 1 , then when a conventional sliding door 11 is at its maximum rearward travel position it continues to block a portion of the door opening. It would be desirable to obtain an extension of the sliding door travel.
As shown in FIG. 2 , vehicle 10 may have a side passenger opening 16 allowing ingress to and egress from seats 17 . In the upper half of FIG. 2 , opening 16 is sufficiently small compared to the length of the vehicle behind opening 16 that a center track 18 can be accommodated on vehicle 10 to allow opening of the sliding door to a position 19 using conventional door sliders. In the lower half of FIG. 2 , a larger (i.e., wider) opening 16 ′ allows easier ingress and egress to rear seat 17 . However, the remaining length of the vehicle for accommodating a longer track is insufficient. Therefore, the sliding door cannot be moved to a desired position 19 ′ using the conventional sliding door support apparatus. Therefore, in addition to a primary track 20 , the present invention employs a track extension 21 that slides rearward beyond the rear end of the vehicle at the appropriate times so that the door is supported over a greater range of movement.
FIG. 3 shows the main elements of the invention including a track extension 21 slidably retained inside a concentric track bracket 22 by means of sliders 23 and 24 . A roller bracket 25 is attached to a sliding door 26 via a door bracket 27 and hinge pin 28 . Roller bracket 25 has orthogonal rollers 30 and 31 as is known in the art. Track extension 21 has a generally C-shaped cross section with a horizontal load portion 32 for containing roller 30 and a vertical load portion 33 for supporting roller 31 . Concentric track bracket 22 has a similar but slightly larger C-shaped cross section for nestingly receiving track extension 21 . Concentric track bracket 22 is fixedly mounted to the side of the vehicle 34 .
The tracks and track bracket are shown in greater detail in FIGS. 4 and 5 . Concentric track bracket 22 preferably nestingly receives both primary track 20 and track extension 21 . Primary track 20 is also fixedly mounted to the side of the vehicle and extends away from the door opening to a terminus 36 . Primary track 20 has the same generally C-shaped cross section with a vertical load portion and horizontal load portion as discussed for track extension 21 . When track extension 21 is in its retracted position as shown in FIG. 4 , it is locked in coaxial abutment with terminus 36 so that the orthogonal rollers can freely move between primary track 20 and track extension 21 . Track extension 21 has a first end 37 and an interlock end 38 to receive an interlock (described below) that prevents the roller bracket from sliding off the end of track extension 21 . In order to prevent track extension 21 from sliding off the end of concentric track bracket 22 , a stop feature 40 is provided on track extension 21 and a stop feature 41 is provided on concentric track bracket 22 for interfering with one another when track extension 21 reaches its maximum extended position, thereby preventing further movement in the rearward direction of track extension 21 . Stops 40 and 41 may preferably comprise an indent and an outdent which are stamped into the respective sheet metal components. A shock absorbing rubber bumper may be provided on the stop features to prevent the user from experience shock or noise at the end of the door travel.
FIGS. 6-10 show the detailed functioning of the present invention. During the door opening process, roller bracket 25 first traverses primary track 20 beginning at the door opening. Roller bracket 25 moves in the opening direction from primary track 20 into track extension 21 and to interlock end 38 while extension track 21 remains locked in the retracted position. When the orthogonal rollers (or, alternatively, some other activating portion of roller bracket 25 ) enters interlock end 38 then the rollers or other feature are captured at the interlock end and track extension 21 is released within concentric track bracket 22 to slide to the extended position. During the door closing process, an occupant pulls the door in the closing direction so that track extension 21 returns from the extended position to the retracted position. Then the orthogonal rollers are released from the interlock end and track extension 21 is again locked in the retracted position enabling roller bracket 25 to slide through track extension 21 back into primary track 20 for normal closing of the sliding door.
A preferred interlock mechanism of the present invention is also shown in FIGS. 6-10 . A lever 45 is mounted by a hinge pin 46 onto track extension 21 . Lever 45 has a roller recess 47 adapted to capture a roller 30 . Lever 45 also has a capture slot 48 for receiving a fulcrum pin 50 which is mounted on concentric track bracket 22 . In the normal locked position shown in FIG. 6 , lever 45 is rotated to the maximum extent in the counter clockwise direction with fulcrum pin 50 captured at the end of slot 48 . Lever 45 is preferably held in place by a detent mechanism (not shown). In this position, roller 30 clears the leading edge of recess 47 so that it can freely move into or away from recess 47 . As shown in FIGS. 7-9 , movement of roller 30 toward the left causes clockwise rotation of lever 45 until fulcrum pin 50 escapes slot 48 . In the normal unlocked position, roller 30 is fully captured in recess 47 and track extension 21 is released and free to move rearward as shown in FIG. 10 by forces transmitted through roller 30 . During the door closing process, the sequence of FIGS. 6-10 is reversed whereby track extension 21 retracts within concentric track bracket 22 causing slot 48 to approach fulcrum pin 50 . Because of the sloped surface of slot 48 , the action of fulcrum pin 50 against slot 48 causes lever 45 to rotate in the counter clockwise direction until roller 30 is released from recess 47 , whereupon track extension 21 becomes locked in the retracted position.
FIG. 11 shows the interlock in an end view wherein appropriate flanges are formed on track extension 21 and concentric track bracket 22 to retain hinge pin 46 and fulcrum pin 50 . In addition, bearing races 51 and 52 are shown for achieving the sliding capability of track extension 21 within concentric track bracket 22 .
FIG. 12 shows a top view of the interlock mechanism. Concentric track bracket 22 has an upper slot 53 for accommodating the interlock mechanism. Concentric track bracket 22 is shown mounted to one section of a vehicle side panel 34 . Depending upon the particular styling of the vehicle, an opening or slot (not shown) may be provided elsewhere in panel 34 for accommodating the roller bracket and track extension (i.e., so that the track extension can slide out through the slot in order to extend beyond the rear end of the vehicle). For aesthetic purposes, it may be desirable to provide an end cap or other finish piece (not shown) at the end of the track extension that plugs the slot in the body panel when the track extension is in the retracted position.
While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. | A motor vehicle has a sliding door supported by front and rear roller brackets that move through corresponding roller tracks. By extending the length of the rear roller track supporting the sliding door to beyond the rear end of the vehicle when the sliding door itself is opened beyond a particular location, a larger door and door opening are possible for any particular vehicle size. This provides better occupant access to rear seats and increases the maximum cargo size that can be loaded through the door opening. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is claiming the benefit, Under 35 U.S.C. 119(e), of the provisional application filed on Nov. 30, 2001, under 35 U.S.C. 111(b), which was granted Ser. No. 60/334,256. The provisional application 60/334,256 is hereby incorporated by reference. The provisional application 60/334,256 is as of the date of filing of the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a filter media with at least two regions with distinct media properties that result in an enhanced sealing of filter media between individual layers or between the filter media and a sealing means. More specifically, the present invention relates to a surface property modification of filter media and/or a sealing surface to enhance the sealing of the filter media within various filter housings. More particularly, the present invention relates to a surface property modification which repels liquid at the points of contact between the porous filter material and the sealing surfaces of the filter housing. Most particularly, the present invention relates to an improved filter medium that results in an improved sealing of filters and provides means for fluid-gas transfer
2. Discussion of the Related Art
It is well known in the art that one of the most important aspects of a filter design, especially in critical fluid filter applications such as medical products and semi-conductor applications, is the prevention of filter failure.
In critical applications, even minor amounts of fluid bypass result in a nonconforming fluid for the application at hand. Therefore, providing good sealing between various components of a filter or filtration system is critical.
One of the most common, but not the most reliable, sealing mechanisms to date is a pinch seal. In a typical pinch seal the filter media is squeezed between two sealing surfaces. In a typical seal, special attention must be focused upon the amount of pressure imposed on the filter media to assure proper sealing and to minimize the possibility of fluid bypass. Special attention must be focused upon the structural properties of the media and its capability to handle the stress caused by the pinch seal. Typically, in a pinch seal, a designer would like to provide a maximum pressure at the seal without compromising the stability of the filter structure. The higher the pressure at the sealing surface, the higher the compression of the media at point of contact. Typically, this can result in a reduced pore size in the affected area, and also reduce the gap or pore size between the filter media and the sealing surface. This prevents fluid flow past the pinch seal as long as the pore size is small enough to block flow. Another way to stop flow past the seal is to block the pores proximate the seal with potting compound.
The present invention provides a better seal without the aforementioned problems. This is accomplished by making the seal material non-wetting to the fluid being filtered and, thereby, providing a liquid repellant seal. More specifically, a liquid repellant porous seal with a liquid wetting filter area. The wetability (fluid wetting properties) of the seal may be adjusted by methods known in the art. The present invention provides a differential wetability at the sealing surface.
The present invention teaches that the wetability of the seal may be decreased to prevent fluid bypass past the seal. At the same time, the main filter area is desired to be fluid wettable, especially for fluid filter applications, to provide fast priming times. In gravity feed systems or low pressure applications, the wetability of the filter medium is important as there is a minimum breakthrough pressure required to start fluid flow through a filter. The breakthrough pressure decreases with increased wetability. Therefore, the present invention provides a differential wetability of the filter media at the sealing surface. Also, it is noted that the surface property of the sealing surfaces, such as the housing, may be changed to enhance the seal.
In general, the wetability of a porous material depends on a number of parameters, including pore size and surface properties of the material involved. In addition, there will be a number of other advantages to the present invention that will be apparent from the descriptions provided and the applications shown.
Present day filter media, whether in the form of flat sheets of various shapes, such as circles, ovals, or other desired shapes, or in tubular form, are generally homogeneous throughout, and consist entirely of filter media without any treatment to the sealing regions to enhance sealing. This produces problems in the art. With filter media sheets, there tends to be leakage past the commonly used pinch seal, unless this seal is carefully designed. Such attention to the seal increases the cost of the filter housing holding the media, may result in additional components, and an increase in final product weight, to effect a proper seal. Sometimes, adhesives or other agents are needed to effect any seal at all. Also, since the pinch seal is typically wetted by the fluid, there is no possibility of a visual aide in discerning if the seal is adequate and the fluid being filtered is not bypassing the seal. A visual aide in detecting fluid bypass may provide an opportunity to save the fluid such that it may be processed in a single pass.
The same problems occur with tubular filters when attempting to provide effective seals at or near the ends of the filter tubes. The prior art is replete with special types of end caps and housing modifications designed to effectuate the seal between the tubular filter media, which is usually made of randomly oriented fibers (particles), and an end cap and/or housing. Again, these measures increase costs for the filter products. Thus, those skilled in the filter art continued to search for a better method of sealing filter media within filter housings.
In critical applications adhesive may be used to increase the reliability of the filter seal by typically filing the gaps or pores between the sealing surface and the media. The adhesive may be surface loaded in the area of the seal, or the adhesive may be present throughout the depth of the filter media for added protection against fluid bypass.
The addition of adhesive, typically provides a barrier to fluid bypass past the sealing surface. But in addition, it may provide added complications in certain applications. These include separation of various components of the adhesive, which may result in physical property changes in the seal such as bio-compatibility, thermal stability and chemical compatibility, decreased process time as the adhesive is typically thickened to control wicking of the adhesive into the filter media, and reduced versatility of the adhesive and/or the media as each application needs to be considered on a case by case basis to ensure a proper seal. Also, it is important for the adhesive to bond properly to the housing to provide an adequate seal. Delamination of the adhesive between the various components may result in fluid bypass.
If the adhesive is a multi-component, the various components of the adhesive may separate due to the capillary forces present in the filter media and may compromise the properties of the adhesive and the seal. Also, in certain instances this may result in bio-compatibility and/or leachability issues.
In addition, adhesives may have different physical properties than the filter media and the housing. Certain environmental conditions may result in a compromise of the seal. An example of such instance may be when the thermal expansion property of adhesives may not match that of the housing. Therefore, certain thermal fluctuations (such as those seen in typical medical applications requiring autoclaving) may result in a compromising of the seal. This is especially important in medical applications requiring autoclaved parts or heat or steam sterilization.
The present invention provides novel solutions and enhancements to these problems in the prior art. The present invention will describe a hydrophobic (hydrophobic in the context of this application is synonymous with liquid repellant) barrier that may be used in conjunction with the use of adhesives. The hydrophobic barrier will provide a restriction to the wicking of adhesive past a desired point. In addition, it provides a general means of treating media that may be used with various adhesives. Currently, the properties of the filter media and the adhesive are chosen such as to control the wicking of the adhesive. The present invention provides a novel concept, a barrier, such that these factors are not as important. The media may be used with a various adhesives, and one adhesive may be used with a variety of media. The barrier also provides a clear and distinct area where the adhesive will be present. Advantages include reduced variation in filter properties, such as flow rate, efficiency and capacity, as the usable filter area is clearly defined by the barrier.
The present invention also provides novel means to provide an enhanced sealing mechanism for filtration and separation applications. One novel concept provides a porous seal with enhanced seals to decrease possibility of bypass. The novel concept minimizes fluid hold-up volume within a filter and enables greater fluid recovery. It also decreases cost of the filtration system by the possibility of eliminating components such as adhesive, and also reduces the weight of the filter by providing a porous structure seal through elimination or minimization of adhesive usage. In special configurations to be described, the present invention provides an integral venting means within the filter that is an integral part of the sealing means.
Further, the present invention describes a novel concept that provides enhanced sealing of filter by providing a barrier to fluids. The barrier provides a means to prevent fluid contact across a pinch seal. In its' simplest form, the barrier provides a definite and clear barrier against fluid wicking or fluid migration. One of the advantages of this novel concept is that it prevents separation of multi-component adhesives. In addition, it broadens the selection criteria for filter media and/or adhesive. This is due to the fact that the barrier provides a broader range of adhesives that may be used with a given filter media structure. The influence of adhesive properties such as surface tension, viscosity, and gel time are minimized and, as such, provides a greater flexibility in the production of various filters. Also, the barrier enables combining a number of filters into a single filter housing. The single housing concept reduces the number of components and provides overall cost savings.
Providing multiple filters in a single housing with integral non-wetting barrier enables a number of novel concepts for filtration and separation systems. Fluids may be processed side by side. The barrier may be penetrated at elevated pressures providing unique separation and mixing applications. For example, the filter may be subjected to sufficient positive and negative pressure to drive fluid across the barrier. The pressure may be applied by various means known in the art such as centrifugation, infusion pumps, syringe, etc. A number of applications will be described in this application to demonstrate the novelty of this concept.
Other advantages of the present invention will be apparent from the description hereby provided.
SUMMARY OF THE INVENTION
The problems in the art are solved by the present invention by providing a novel surface treatment for portions of the filter media coming in contact with the filter media holder, such as a filter housing.
There are various methods known in the art for producing surface (material) property modifications. These include chemical, mechanical, plasma, corona and heat (flame) treatment. Preferred chemical treatments for hydrophobic applications are fluorinated, siliconized, fluorosilicon, polyolefin polymers which result in reducing the critical wetting surface tension of the material.
In general, most polymers have a low surface tension and may be used as coatings to modify the CWST of a material. Due to their low surface tension they are typically used to provide a liquid repellant region. Preferred chemical treatments for hydrophilic applications include polymers with a hydroxyl functional group such as Poly-vinyl Alcohol and cellulose, and a functionalized cellulose group such as cellulose acetate and ethyl cellulose, carboxylic acid functional group, amine functional group, sulfonic acid functional group. It should be noted that chemical treatments in varying quantity may be applied to various regions to provide distinct wetting properties. For example, the pinch seal region may be made more hydrophobic than the filtering region by applying a larger quantity of the hydrophobic binder to the pinch region. In general the regions may have varying compositions to provide for the desired functions pointed out in the invention.
In certain applications, an internal vent is provided by means of a novel surface treatment to provide for faster priming of the filter without entrapping gas upstream of the filter media, which may adversely effect the filtration process (increase filtration time, decrease efficiency).
The present invention provides for a porous media with at least two distinct surface property modifications in liquid filtration applications to enhance the performance of the filtration system, reduce the cost of the system, and provide a visual means of detecting possible fluid bypass.
The present invention is related to, but not limited to, filter media, fluid processing, gas venting, gas transfer, and fluid transfer. A means of providing a preferential fluid flow within a filter by liquiphobic (liquid repellant) or liquiphilic (liquid wetting) treatment of a porous medium is disclosed.
The present invention is most suited for, and related to, pinch seals where a porous media is sealed within a housing by pinching or flat gasket sealing of media within the housing. This method is commonly used in price/cost sensitive applications. One of the drawbacks of pinch sealing has been the possibility of fluid bypass.
One of the possibilities of bypass is due to preferential permeability or wetability of the media in the cross-flow direction. This situation is especially important with thick filter media over sealing surface length seals. The present invention reduces the risk of such bypass.
These benefits are achieved through the aforementioned surface property modification of the filter media, which is based on the relationship between the critical wetting surface tension (CWST) of the filter media being used, and the surface tension of the fluid being filtered.
For the purposes of the present application, the definition of the CWST of the media is not the one generally known in the art from U.S. Pat. No. 4,880,548 ('548), the specification of which is incorporated herein by reference. The ('548) patent defines a media to be wetting if it absorbs at least 9 out of the 10 test drops after 10 to 11 minutes at atmospheric pressure. Instead, it is a use based CWST.
In the present application the CWST of the filter media will be determined based on the particular application or intended use. As in the ('548) patent, a CWST for a series of materials can be determined, but they will all relate to a particular use or application, and may, or may not be relevant to any other use or application.
For example, if a quick priming filter element is desired, one which would not entrap gas in the upstream chamber for two minutes while the upstream chamber fills, and the filter inlet pressure is 40″ of fluid column, a satisfactory filter media would be one in which at least a portion of the filter media remains unwetted and capable of venting entrapped gas until the upstream chamber is filled. This requires testing of the filter media with a series of standard liquids with varying surface tensions in a sequential manner under test conditions which simulate actual desired operating conditions. This may be done by placing a number of drops (for example 10) or columns of test fluid (if under differential pressure) on representative portions of porous media, and allowing these to stand for a desired time (in this example two minutes). Observation is made after a desired time (two minutes). Wetting is defined as absorption or wetting of the porous media by at least nine of the ten drops or a reduction in the volume of nine out of ten columns by the equivalent of one drop per column within the desired time. Non-wetting is defined as the retention of a negative angle of contact (for drops), or a substantial retention of volume (for columns). For drops, nine out of ten drops must retain a negative angle of contact. For columns there should be substantially no loss of volume due to absorption by the media (less than one drop).
Testing is continued using liquids of successively higher or lower surface tension, until a pair has been identified, one wetting and one non-wetting, which are the most closely spaced in surface tension. The CWST according to the present application is then in that range. For convenience, the average of the two surface tensions is used as a single number to identify the CWST for the particular application.
Furthermore, the media in the above example does not need to be non-wetting for any more than the two minutes the fluid takes to fill the chamber and the gas to vent (perform its intended function). The media may be wetting after the time it takes to perform its intended function.
Any further references to CWST in the present application refer to the CWST as defined above.
From this definition, and knowledge in the art, it can be seen that if the surface tension (ST) of the fluid is less than the CWST of the filter media, then the fluid will wet the filter media, and the fluid being filtered will flow through the media. The greater the difference between the ST and the CWST, the faster the wetting or priming of the filter media, and the faster the fluid will begin to flow through the filter. Conversely, the closer the ST of the fluid being filtered is to the CWST of the filter media, the longer the priming time of the filter media. If the ST of the fluid being filtered is greater than the CWST of the filter media, the fluid being filtered will simply bead up on the filter media, and no flow will take place.
Using the above relationship between the ST of the fluid being filtered, and the CWST of the media being used, a surface property modification may be performed on the filter media by treatments known in the art such that liquids are repelled at the points of contact between the porous material and the sealing surfaces. For example, if the filter media is liquid wetting (ST of fluid<CWST of media) a portion of the filter media, most preferably the portion which will be in contact with the sealing surface, is treated such that it becomes liquid repellant (ST of fluid>CWST of media). It is also advantageous if the entire, or at least a portion of, the sealing surface of the housing which will be in contact with the treated porous media would also be liquid repellant. This may occur because of the material of which the housing is made, or by treating the surface(s) of the housing which are to contact the filter media.
The invention is not limited to surface treatment modification as the filter media may be a composite with appropriate wetting characteristics provided by methods well known in the art.
The liquid repellant porous media will result in a higher than normal liquid breakthrough pressure compared to a non-treated media of the same structure. Also if the porous media is liquid repellant throughout its depth, the fluid will not advance into the sealed portion, thereby reducing possible liquid holdup within the liquid repellant section of the porous media.
The present invention is well suited for low pressure applications, such as gravity feed systems. An important feature of the present invention is the creation of a fluid barrier that prevents liquid breakthrough past the sealing surface. Due to the low fluid pressure of such systems, this may be accomplished by surface modification of the porous material or media. For a liquid wetting filter media, the CWST of the media at the seal is reduced, so that the CWST of the media is less than the ST of the fluid being filtered, and therefore, the media will be liquid repellant at the seal.
For a liquid repellant material, the surface tension of the material at the seal may be increased further, to provide enhanced sealing.
Likewise, the central portions of the filter media may be treated to increase or decrease how fast wetting of the media takes place, i.e., how fast priming occurs. If a liquid wetting filter media is being used, the central portion may be treated to increase the CWST thereof, and make the media more liquid wetting than otherwise. This may be advantageous where it is desired to use a less costly media which is not particularly fast priming, but treatment in the above manner can make it prime as fast as a more costly material. Conversely, one media may be desirable for a particular application, but primes too fast. Treatment in the above manner can slow the priming time. Other advantageous applications are well within the scope of the present invention.
In one embodiment of the present invention, a flat sheet of a filter media made of a liquid wetting material is treated about the edge regions thereof so that the CWST of the material at the seal is reduced to a value less than the surface tension of the fluid being filtered, so that the material at the sealing surface is, in effect, liquid repellant.
In another embodiment of the present invention, a flat sheet of filter media made of a fluid repellant material is treated about its interior regions such that the CWST of the material at the interior regions is increased.
In a further embodiment of the present invention, a tubular filter made of a liquid wetting material or media is treated at its' sealing surfaces such that the CWST of the material at the sealing surfaces is reduced to a value less than the ST of the fluid being filtered, and thus, is liquid repellant at the sealing surfaces.
In yet another embodiment of the present invention, a filter media in a tubular configuration is made of a fluid repellant material and treated at its' interior such that it is liquid wetting in the interior regions.
In a still further embodiment of the present invention, a filter media holder is provided for use with the improved filter media of the present invention such that a visual indication of fluid bypass of the filter media is easily provided.
In another modification of the present invention, a flat sheet of filter media (single or multi-layer composition) made of a liquid wetting material has an annular portion near the edge of the filter material treated to reduce the CWST of the material at the sealing region of the filter sufficiently such that the media is liquid repellant.
In a still further embodiment of the present invention, a flat sheet of filter media of a predetermined shape, and made of a fluid repellant material, has an annular portion proximate the sealing region of the filter material treated such that the CWST of the material is decreased in the annular region.
Thus, it an object of the present invention to provide a surface treatment modification for a filter media which will enhance the sealing of the filter media within a filter holder or housing, or between filter media layers.
Another object of the present invention is to provide enhanced sealing between a porous media and a filter housing without the use of adhesives.
Another object of the present invention is to provide a filter media which has been surface treated and mounted in a filter housing to provide an effective seal with a reduced number of components.
A still further object of the present invention is to provide an improved surface treated filter media which achieves an effective seal, and is lighter in weight for the same application, than the known filter media.
Another object of the present invention is to provide a filter media having a liquid repellant porous sealing region and a liquid wetting filter area with minimum fluid hold-up volume within the filter media.
Another object of the present invention is to provide an improved filter housing for use with the surface treated filter media which provides a visible means of detecting fluid bypass, thus providing a visual means of detecting filter or housing failure.
Another object of the present invention is to provide a novel filter housing which, when used in combination with the surface treated filter media of the present invention, increases fluid recovery.
Another object of the present invention is to provide a filter media that has at least two distinct surface properties proximate to the sealing surface.
Another object of the present invention is to provide a filter media that provides a barrier to fluid migration past a sealing surface.
Another object of the present invention is to provide an improved adhesive bounded seal with a precise adhesive/non-adhesive boundary.
Another objective of the present invention is to provide a filter media (single or multi-layer) that prevents separation of multi-component fluid mixtures.
Another object of the present invention is to provide a filter media (single or multi-layer) that prevents the separation of multi-component adhesive at the sealing surface.
Another objective of the present invention is provide a non-wetting region proximate to the sealing surface which may be breached under elevated differential pressure across the seal.
Another object of the present invention is to provide a consolidated filter element with porous separating barriers that do not have a liquid communication means.
Another object of the present invention is to provide a liquid barrier across a sealing means.
Another object of the present invention is to decrease liquid hold-up volume within a sealing region.
Another object of the present invention is to provide an integral venting means integral within the filter media.
Another object of the present invention is to provide a venting means integral with an enhanced sealing means.
Another object of the present invention is to provide a filter with multiple separated compartments.
Another object of the present invention is to provide a platform for mixing, transporting, separating fluid(s) across a liquid repellant porous partition.
Further objects and advantages of the present invention will be apparent from the following description and appended claims, reference being made to the accompanying drawings forming a part of the specification wherein like reference characters designate corresponding parts in the several views. It should be noted that although two-dimensional filter media configurations are discussed within this application, other filter media configurations, such as corrugations, domed, tubular or, in general, three-dimensional configurations, are within the scope of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a known filter media of circular shape.
FIG. 2 is a diagrammatic sectional view, showing a representative filter holder holding the filter media of FIG. 1 .
FIG. 3 is a perspective view of a known filter media in tubular form.
FIG. 4 is a diagrammatic representation of one common way of sealing the filter media shown in FIG. 3 in a filter housing.
FIG. 5 is a perspective view of a construction embodying the present invention.
FIG. 6 is a sectional view, taken in the direction of the arrows, along the section line 6 - 6 of FIG. 5 .
FIG. 7 is a sectional view, in large part similar to FIG. 6 , but showing a modification of the present invention.
FIG. 7A is a sectional, elevational, view showing a modification of the construction shown in FIG. 7 .
FIG. 7B is a sectional, elevational, view showing a further modification of the construction shown in FIG. 7 .
FIG. 7C is a sectional, elevational, view showing a further modification of the construction shown in FIG. 7 .
FIG. 8 is a diagrammatic sectional view, showing the construction of FIG. 5 mounted in a novel filter housing.
FIG. 9 is a perspective view showing a filter media construction embodying a further modification of the present invention.
FIG. 10 is a sectional view, taken in the direction of the arrows, along the section line 10 - 10 of FIG. 9 .
FIG. 11 is a sectional view, in large part similar to FIG. 10 , showing a further modification of the present invention.
FIG. 11A is a sectional, elevational, view showing a modification of the construction shown in FIG. 11 .
FIG. 11B is a sectional, elevational, view showing a further modification of the construction shown in FIG. 11 .
FIG. 11C is a sectional, elevational, view showing a further modification of the construction shown in FIG. 11 .
FIG. 12 is a diagrammatic sectional view, showing the construction of FIG. 9 mounted in a novel filter housing.
FIG. 13 is a perspective view of a further modification of the present invention wherein a vent is added to the construction of FIG. 9 .
FIG. 14 is a sectional view, taken in the direction of the arrows, along the section line 14 - 14 of FIG. 13 .
FIG. 15 is a sectional view, in large part similar to FIG. 14 , showing a further modification of the present invention.
FIG. 15A is a sectional, elevational, view showing a modification of the construction shown in FIG. 15 .
FIG. 15B is a sectional, elevational, view showing a further modification of the construction shown in FIG. 15 .
FIG. 16 is a diagrammatic sectional view, showing the construction of FIG. 13 mounted within a novel filter housing.
FIG. 17 is an exploded perspective view of the construction shown in FIG. 16 .
FIG. 18A is a perspective view, partly fragmented, showing a further modification of the present invention.
FIG. 18B is a perspective view, showing a further modification of the present invention.
FIG. 18C is a diagrammatic view of an improved filter housing embodying the present invention which can utilize the constructions shown in FIGS. 18A and 18B .
FIG. 18D is a modification of the construction shown in FIG. C.
FIG. 18E is a view similar in part to FIG. 18D , but showing tapered walls on the end cap illustrated which are designed to slightly “crush” the end of the filter tube when it is sealed in the filter housing of FIG. 18C .
FIG. 18F is a view similar to FIG. 18E , but showing the filter tube of FIG. 18E fully installed in the end cap, with the end of the filter tube slightly “crushed”.
FIG. 18G is a view similar in part to FIG. 18 e , but showing the surface treatment only at the outer peripheral wall of the filter tube, and showing only a tapered, outer peripheral wall on the end cap.
FIG. 18H is a view similar in part to FIG. 18E , but showing the surface treatment only at the inner peripheral wall of the filter tube, and showing only a tapered, inner peripheral wall on the end cap.
FIG. 19 is a perspective view of a fluid filter construction embodying the present invention.
FIG. 20 is a front elevational view of the construction shown in FIG. 19 .
FIG. 21 is a sectional view, taken in the direction of the arrows, along the section line 21 - 21 of FIG. 20 .
FIG. 22 is a perspective view, similar in part to FIG. 13 , but showing the addition of a top or upper vent.
FIG. 23 is a perspective view, similar in part to FIG. 22 , but showing the upper vent overlapping the surface treatment modification and being constructed of the same material.
FIG. 24 is a perspective view, similar in part to FIG. 22 , but showing the upper vent overlapping the surface treatment modification and being constructed of a different material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-2 , a typical filter media 30 in a flat sheet form is shown. While the media is shown in a circular shape, the media may be in an oval, square, diamond or other desired shape. The filter media 30 may be made of more than one layer, if desired.
A section taken through the filter media 30 , such as shown in FIG. 2 , reveals no distinct surface property variation proximal to the sealing surface. Thus, nothing is found in the prior art filter media 30 itself to aid in sealing it in a typical filter housing 31 , such as is illustrated in FIG. 2 .
The typical filter housing 31 will normally be of a shape complimentary to the filter media 30 , and designed to pinch seal the filter media 30 between two halves of the filter housing. The filter housing 31 has a first half or portion 32 having a first circular side wall 33 , a first upstanding peripheral wall 34 at the periphery thereof, and a second, inwardly spaced, peripheral upstanding wall 35 spaced inwardly a predetermined desired distance from the upstanding outer peripheral wall 34 . A first annular space 39 is formed between the sidewalls ( 34 , 35 ). An outlet 36 is formed on the circular sidewall 33 for purposes to be described.
A mating second half or portion 40 has a second circular sidewall 41 , a second upstanding peripheral wall 42 , and a second, inwardly spaced, upstanding peripheral wall 43 . The second upstanding peripheral wall 43 is evenly spaced a predetermined distance from the second upstanding peripheral wall 42 to provide a second annular space 44 .
The dimensions of the first filter portion 32 and the second filter portion 40 are chosen such that the inside diameter of the first upstanding peripheral wall 34 is related in a predetermined, desired, manner to the outside diameter of the second upstanding peripheral wall 42 . Depending on how it is desired to fasten the first portion 32 and the second filter portion 40 , these dimensions may be chosen to provide a loose fit, an adjacent fit, or an interference fit between the first half 32 and the second half 40 of the filter housing 31 .
To assemble the filter housing, the filter media 30 will be placed in the filter housing 31 . The filter media 30 preferably has a diameter substantially equal to the inside diameter of the second upstanding peripheral wall 42 . The filter media may be laid in the second filter portion 40 and, because the second inwardly spaced upstanding peripheral wall 43 is of a height less than the second upstanding peripheral wall 42 , the filter will lay on top of the second inwardly spaced peripheral wall 43 .
The first or cover portion 32 of the filter housing 31 is then placed over the second filter portion 40 . Since the diameters of the first inwardly spaced peripheral upstanding wall 35 of the first filter portion 32 , and the second inwardly spaced peripheral wall portion 43 of the second filter portion 40 , have been chosen so that when the two halves of the filter 31 are assembled they are substantially directly opposite each other, and the height of the two walls have been carefully chosen, the filter media 30 will be “pinched” between the first inwardly spaced peripheral upstanding wall 35 and the second inwardly spaced upstanding peripheral wall 43 . The first portion 32 and the second portion 40 of the filter housing 31 may then be bonded, sonic welded, adhesively or otherwise joined to each other. Fluid will come in the inlet 46 , go through filter media 30 , and exit out the outlet 36 .
In some cases, to increase the reliability of the pinch seal, and reduce filter failure, adhesive is introduced to the first annular space 39 and the second annular space 44 when the filter housing 31 is assembled. However, because of lack of surface treatment modification of the filter media 30 , all of the aforementioned problems present in sealing flat sheet filter media may occur in one form or another in all the known prior art filter housings.
Referring to FIGS. 3 and 4 , a typical prior art tubular filter 50 is shown. The end 51 of the filter 50 shows no surface treatment modification, and typically none is found at either end of the tube 50 . Therefore, the sealing problems discussed above in regard to flat filter media 30 are also present with tubular filters 50 .
As shown in FIG. 4 , tubular filter 50 is generally sealed in a filter housing 47 between the filter head 48 and an end cap 49 . Filter bowl 52 seals the filter tube 50 within the filter housing 47 .
Referring now FIGS. 5-8 , there is shown a flat sheet of filter media 55 embodying the construction of the present invention. The flat sheet of media is shown in a circular shape, but may be of an oval, diamond, square or any other practical shape, and may be made of any media material. An annular shaped portion 56 , proximate the edge 57 of the filter media 55 , has been treated such that the CWST of the media is less that the ST of the fluid being filtered, and therefore, the annular portion 56 of the filter media 55 is liquid repellant with respect to the fluid being filtered. The interior 54 of the flat sheet 55 is less liquid repellant and the annular shaped portion or perimeter 56 of the filter media 55 is more liquid repellant.
As shown in FIG. 6 , it is preferred that the liquid repellant portion 56 extends entirely through the filter media 55 . However, in some applications, such as shown in FIGS. 7 and 13 , it may be desired that some surfaces of each side of the flat sheet of media 55 be treated only part way through with liquid repellant to produce a first annular liquid repellant portion 58 and a second annular liquid repellant portion 59 . In such an application, the liquid repellant may extend only part way through the filter media 55 , but not all the way through. While this version may be useful in some applications, it is not the most preferred embodiment, because the fluid being filtered may wick to the edge 57 , or beyond, resulting in possible fluid loss. However, it may be useful if fluid flow past the seal is desired without bypass at the sealing service.
Modifications which prevent wicking to the edge are shown in FIGS. 7A-7C . In FIG. 7A the filter media 55 has the annular or ring shaped treated portion 56 in the form of an inwardly radially extending U-shaped channel 56 C. In FIG. 7B , it is shown as an outwardly radially extending U-shaped channel 56 D. In FIG. 7C , the annular or ring shaped treated portion 56 is in the form of a box channel 56 E.
With reference to FIG. 8 , there is shown a diagrammatic view of a novel combination of a filter housing 60 , and the flat sheet media 55 , which together increase efficiency, reduce hold-up volume, and achieve the aforementioned advantages. The filter media 55 is shown in a pinch seal arrangement between two halves ( 61 , 62 ) of the filter housing 60 . The filter 60 consists of an inlet section 61 and an outlet section 62 . The inlet section 61 of filter 60 has an inlet 63 including port 63 A communicating with a first passage 64 , which is in fluid communication with a first or inlet chamber 65 through first port or outlet 64 A.
A more detailed embodiment of a construction embodying the present invention is shown in FIGS. 19-21 .
The filter 60 , as aforementioned, includes an inlet section 61 which is bonded to an outlet section 62 by a seal 80 . The seal 80 is preferably an ultrasonic seal, and may be full, or partial. It can be understood by those skilled in the art that other seals, such as heat seals, adhesive seals, or any other air tight seal may be used.
Inlet section 61 includes a recessed top wall 91 and a downstanding side wall 92 extending around the periphery of the top wall 91 . A first downstanding peripheral ridge 93 extends around the periphery of the downstanding sidewall 92 and forms a part of the mechanism which holds the filter element 55 in place, as will be more fully explained hereinafter.
A first protuberance 95 extends from the recessed top wall 91 and carries the inlet 63 and first passage 64 as previously described. A recess 96 provided by the combination of the top surface of the top wall 91 , and peripheral side walls 97 , almost completely surround the protuberance 95 .
A peripheral flange 98 extends from the peripheral side wall 97 and forms a groove 79 extending around the periphery of the inlet section 61 of the filter 60 . The groove 79 forms a portion of the construction by which the seal 80 between inlet section 61 and outlet section 62 of the filter 60 is formed.
The shape of the outlet section 62 of the filter 60 is complimentary in shape to the inlet section 61 so that the inlet section 61 may act as a closure to the outlet section 62 , or vice versa. It can be easily understood by those skilled in the art that the fluid filter 60 may be of any desired shape, such as the generally circular shape described, an oval shape, a diamond or any other desired shape. A filter media of any desired shape may be placed in a housing of any desired shape and still be well within the scope of the present invention.
Similar to the inlet section 61 , the outlet section 62 of the filter 60 has a bottom wall 110 and an upstanding side wall 111 . The top of the upstanding side wall 111 fits into the groove 79 in the inlet portion 61 , and is preferably sonically welded to form the seal 80 . A second protuberance 114 is provided on the exterior portion of the bottom wall 110 and carries the outlet 72 .
A second downstanding peripheral ridge 115 complimentary in shape to first downstanding peripheral ridge 93 is provided. First downstanding peripheral ridge 93 and/or second downstanding peripheral ridge 115 may be treated to increase or decrease their surface tension, if desired. It should be understood that the terms “upstanding peripheral ridge” and “down standing peripheral ridge” are used in the sense of describing a pair of substantially opposed peripheral ridges which provide for a pinch seal of a filter media. Other terms may be used to describe these ridges, such as “first” and “second”, or “left laterally extending” and “right laterally extending”, without departing from the scope and spirit of the present invention.
If desired, a plurality of ribs (not shown because they are well known in the art) is provided on the interior surface(s) of the bottom wall 110 , and/or top wall 96 , to help support the filter media 55 , and provide flow in the second or outlet chamber 68 of the filter 60 . In placing such ribs, one needs to be concerned with the volume occupied by the ribs.
The volume of the ribs [also] controls the amount of holdup volume of the filter. Typically, for many reasons, there are more ribs on the downstream side of the filter. The main reasons include the fact that the upstream chamber may be typically drained, therefore, the hold up volume on the downstream side becomes important. In addition, the downstream side is typically cleaner, and particulate contamination and blockage of the ribs are not as important. Also, the higher rib count downstream of the filter provides a better support. As fluid flows from the upstream side through the media, the fluid exerts a force on the media. The media, if not well supported, may collapse within the ribs. This could adversely affect the filtration/separation process, including important parameters such as process time, efficiency, and capacity.
When the outlet portion 62 and the inlet portion 61 are in mating relationships, the first down standing ridge 93 and the second downstanding ridge 115 may be in a 180□ opposed relationship. These ridges will provide the “pinch seals” indicated by the numeral 120 . Since the media which has been treated extends radially inwardly of the pinch seal 120 , a continuous vented area is provided in the filter chamber.
Returning now to the diagrammatic view of the filter shown in FIG. 8 , the outlet section 62 of filter housing 60 has a second or outlet chamber 68 which communicates with outlet 72 including port 72 A through second passageway 69 . The filter element 55 separates the first or inlet chamber 65 from the second or outlet chamber 68 .
The flat sheet of media or filter element 55 may consist of one or more layers, and be made of a wide variety of filter materials. Filter element 55 is held in place in housing 60 between first annular ridge 66 provided about the perimeter of the first or inlet chamber 65 formed in the inlet section 61 of the filter housing 60 , and the second annular ridge 70 formed in the outlet section 62 . Annular ridge 66 is provided to contact the media 55 , and the second annular ridge 70 is chosen to be in a predetermined desired position opposite the first annular ridge 66 , and pinch media 55 therebetween.
The first annular ridge 66 and the second annular ridge 70 are preferably positioned so that they contact the treated or annular or ring portion 56 of the filter media 55 , which did not become wetted out, while the interior portion 54 did become wetted out. Any gas entering the filter housing through any means may pass through the non-wetted portion of the filter media, extending inwardly beyond ridges 66 and 70 , into the downstream chamber 68 , allowing fluid to drain from the downstream lines (not shown), resulting in increased fluid recovery. It is desirable that at least the portion of the filter housing adjacent the perimeter or edge 57 of the media 55 be transparent or translucent, so that any fluid bypass past the first annular ridge and the second annular ridge, 66 and 70 respectively, can easily be observed.
In the embodiment illustrated, the filter element 55 has a liquiphilic (liquid wetting) center 54 , and a liquiphobic (liquid repellant) perimeter or edge 57 as previously described. In use, a biological fluid container (not shown), such as a blood container, is placed in fluid communication with inlet port 63 A. Similarly a biological fluid receiving bag (not shown) is placed in fluid communication by means well known in the art with outlet port 72 A. Fluid flow is initiated, and biological fluid flows in the inlet port 63 A through the first passage 64 , and through first port 64 A into inlet chamber 65 . In operation, as the biological fluid enters the inlet chamber 65 , the fluid may wick into the filter element 55 . The rate at which the biological fluid wicks into the filter element 55 will depend on the properties of the filter media being chosen, and the biological fluid being filtered. These properties include the pore size of the medium, the viscosity of the biological fluid, the surface tension of the biological fluid and the contact angle of the solid-liquid-gas interface. While the fluid level is rising in the inlet chamber 65 , any air entrapped in the inlet chamber 65 is passing through a portion of the filter media 55 which has not yet wetted. The treated perimeter or edge 57 (liquid repellant) assures this possibility.
As the fluid level continues to rise in inlet chamber 65 , at some point the biological filter element 55 will be sufficiently “wetted”, and the biological fluid being filtered will “breakthrough” the filter element 55 , and start flowing into the outlet chamber 68 . The fluid “breakthrough” depends on the pore size of the material, the surface tension and the contact angle, as well as the pressure differential across the filter element 55 .
The biological fluid, which has now started flowing though the filter element 55 , will first fill up outlet chamber 68 , and when outlet chamber 68 is sufficiently full, the biological fluid being filtered will enter second passageway 69 and pass into the biological fluid receiving container (not shown) through outlet 72 .
Due to the pressure differential across the filter element 55 , the biological fluid continues to flow up into second passage 69 . Eventually all of the biological fluid will be drained from the biological fluid container and will have flowed through passage 64 , in the presence of excess gas intended to maximize fluid recovery. It is at this point that one of the advantages of the liquid repellant portion being added to the filter media 55 clearly shows.
In a prior art construction, while all of the fluid flows through the filter media 55 into the downstream or outlet chamber 68 , the downstream chamber 68 and the downstream line (not shown) would remain full in typical low pressure applications, such as gravity feed systems, because the media remains saturated with fluid, due to inadequate pressure differential across the filter media to allow air to breakthrough the media. Thus, residual fluid will remain in the filter media, downstream chamber, and downstream lines resulting in a substantial hold-up volume.
The present invention, in addition to providing an enhanced sealing mechanism, provides a novel means to increase fluid recovery, and provides a means to vent gas from the upstream chamber. This is accomplished through providing a differential wetability of the filter media at or about the sealing interface between the filter media and its' sealing means. The liquid repellant section, which provided a means to expel gas from the upstream chamber 65 to the downstream chamber 68 at the onset of filter priming, will at the end of the filtration process, as gas enters the upstream chamber 65 , provides a means for gas to travel across the media through the liquid repellant portion to the downstream chamber to recover fluid in the downstream line. The integral gas vent and enhanced sealing means provides fast priming of the filter, as the filter media may be liquid wetting. This integral sealing and vent prevents gas entrapment in the upstream chamber as the liquid repellant portion provides a barrier to fluid and therefore providing a venting means as the upstream chamber is being filled. This is very important since, in typical filter applications, as the fluid enters the filter and is in contact with a filter media that is easily wetted by the fluid, due to capillary forces, the fluid typically wicks in advance of the upstream chamber fluid gas interface. Therefore, if there is no venting means, this will result in gas entrapment in the upstream chamber. Therefore, in the prior art, most media are chosen such that the filter media is not easily wetted by the fluid such that air is not trapped in the upstream chamber but at the same time not to be liquid repellant to such an extent that no fluid passes through the filter media. Therefore, the present invention provides many benefits that enhances the overall performance of the filter media. These include but are not limited to, the venting capability that prevents gas entrapment in the upstream chamber, provides increased fluid recovery, and provides fast priming of the filter. Also it prevents reduced filter media performance if a bubble of air is inadvertently introduced into the filter. In addition, the present invention provides the filter designer with a wide latitude in choosing the material for the filter media based on the critical wetting surface tension (CWST) of the filter media when used in comparison to the ST of the fluid to be filtered as shown by the following examples.
EXAMPLE 1
In a design where the liquid repellant region extends beyond the pinch seal, such as shown for example in FIG. 8 , a filter designer can choose the CWST of the filter media in a very broad range. In the case where the designer selects the CWST of the filter media to be much greater than the ST of the fluid being filtered, the filter media will be very hydrophilic (liquid wetting). The present example includes cases in which the liquid repellant region extends to cover the entire pinch seal, goes beyond the pinch seal towards the filter media edge, or fully extends to the edge of the filter media.
Using the housing of FIG. 8 , for example, as a fluid, preferably a biological fluid, enters the housing through the inlet section 61 , it will begin to fill the upstream chamber 65 . As fluid fills the upstream chamber 65 , gas exits the housing through the portions of the filter media 55 that has not been wetted by the fluid, i.e., the annular portion 56 . Since the filter media 55 has been chosen to be very hydrophilic, the filter 55 is fast priming, while at the same time gas freely passes through the annular portion 56 , and vents out of the gas chamber continuously. Since the media and fluid properties are such that no gas entrapment occurs, there is no need for a separate venting means.
The fluid will then continue to flow through the filter media 55 until the fluid entering the upstream chamber 65 is exhausted. Because of the vent provided by the treated annular portion 56 that is not wetted by the fluid, and which extends inwardly beyond ridge 70 , as gas enters the upstream chamber it will pass through non-wetted portion 56 and, therefore, in most cases fluid holdback will occur in the upstream and downstream chambers ( 65 , 68 ), while the inlet 64 and outlet 69 will be clear of fluid.
EXAMPLE 2
In a design where the liquid repellant region does not extend beyond the pinch seal, such as shown, for example, in FIG. 12 , the filter designer's choices for the CWST of the filter media is limited in comparison to Example 1.
Since the non-wetting region does not extend inwardly beyond the pinch seal, it is preferable for the filter media to have a CWST such that there is no air entrapment in the upstream chamber as fluid first enters the upstream chamber. [This limits the selection of the filter media as compared to example 1.] Under optimal conditions for each example, filter media in example 1 will wet the surface faster than Example 2 under similar conditions. The liquid repellant region, which provides an improved seal, is not wetted by the fluid throughout the filtration process.
As noted previously, in this example, the liquid repellant portion 56 of the filter medium 55 does not extend past the pinch seal. Therefore there is no gas venting means after gas enters the filter housing at the end of the filtration process. After the filtration process, fluid remains in the downstream chamber and downstream lines. The fluid retained in the downstream lines may be used for post evaluation purposes. For example, in the blood banking industry typically the downstream line is segmented, and the segments are used for various purposes, including quality assurance.
In this example, fluid enters the upstream chamber 65 and fills the upstream chamber. No air entrapment will occur in the upstream chamber 65 as the filter media 55 is slow priming (not immediately wetted by the fluid). Once the fluid wets the filter media 55 , and fills the downstream chamber 68 , fluid will enter the downstream line (not shown). At the end of the filtration process it is typically desired to filter substantially all of the fluid. Gas typically follows the fluid at the end of the filtration process. When the differential pressure across the filter media 55 is lower than the pressure required to push air through the wetted filter media air does not pass through the filter media. Fluid drains from the upstream chamber 65 under differential pressure and substantially all the fluid is filtered. Gas is trapped in the upstream chamber and the downstream chamber, outlet 69 , and the downstream lines are filled with fluid. The fluid in the downstream chamber 68 and line (not shown) may be used for post filtration samples. It is to be noted that Example 2 is most likely slower priming than Example 1.
EXAMPLE 3
In this example the designer has again chosen a media wherein the CWST of the media is greater or equal to the ST of the fluid being filtered such that no significant air entrapment would occur in absence of differential surface tension property proximal to the sealing means. In this example, An annular portion 56 , which includes a dome shaped, or other shaped, vent such as 76 shown in FIG. 13 , has been treated to be more liquid repellant than the filter media 55 . Vent portion 76 acts as a vent after substantially all of the fluid is filtered and gas substantially fills the upstream chamber 65 . The liquid repellant region, which is not wetted by the fluid, allows gas passage from the upstream chamber 65 into the downstream chamber 68 after substantially all the fluid is filtered. In order to recover as much of the fluid as possible, the fluid repellant region 56 extends further inwardly at the bottom of the filter to form a gas vent 76 . The gas passage through this inwardly extending section allows the downstream lines to be drained. By providing a narrower gap and providing ribs in the downstream chamber it is possible to drain the downstream chamber completely.
EXAMPLE 4
Example 4 envisions the same choice by the designer as Example 3, with an additional liquid repellant region or top or upper vent 130 at the top portion of the media, such as shown in FIG. 22 . The media shown in FIG. 22 may be identical to the media shown in FIG. 13 , except for the addition of the additional liquid repellant region or upper vent 130 . The upper vent 130 may be extending inwardly of the pinch seal to allow air to vent from the upstream chamber into the downstream chamber at the onset of the filtration process. This extra liquid repellant section or upper vent 130 is treated such that is not immediately wetted by the fluid. However, it is wetted during the filtration process. This additional liquid repellant section 130 will provide faster priming of the filter housing. It will also provide a means for preventing gas entrapment in the upstream chamber 65 as the upstream chamber is filled at the start of the process. In addition, it will prevent gas passage through the section at the end of the process such that all fluid in the upstream chamber 65 may empty from the upstream chamber. Further preferred embodiments of the present invention using these design considerations are discussed below.
Referring now to FIGS. 9-12 , there is shown a modification of the invention described in FIGS. 8-11 where the liquid repellant region does not extend inwardly past the sealing means. In this embodiment, an integral gas vent is not present. A benefit of the present invention, as described previously, is the enhanced sealing mechanism.
In this embodiment, in absence of a venting means, the filter media is typically chosen such that there is no significant gas entrapment present in the upstream chamber at the onset of filtration. Due to a lack of a venting means, at the end of the filtration process, as gas enters the upstream chamber, gas typically can not pass through the filter, due to fact that the pressure differential required to pass gas through the wetted filter media exceeds that present as gas enters the upstream chamber. Therefore, gas fills the upstream chamber and substantially all fluid is filtered.
For ease in illustrating the various surface treatment modifications of the filter construction, the diagrammatic view of FIGS. 8 , 12 and 16 , rather than the more detailed filter housing construction views shown in FIGS. 19-21 , will be used in the remainder of the application.
Referring to FIG. 9 there is shown a first modified sheet of flat media 55 A having a first modified or annular treated ring portion 56 A spaced a distance “C” from the edge 57 A of first modified filter element or sheet of media 55 A. Used in conjunction with modified filter media 55 A is first modified filter housing 60 A, shown in FIG. 12 . The construction of filter housing 60 and first modified filter housing 60 A is substantially identical except for the placement and dimensions of the second upstanding ridge 115 A formed on the outlet section 62 A and the first upstanding ridge 93 A formed on the inlet section 61 .
While first upstanding ridge 93 A and second upstanding ridge 115 A are still in an opposed relationship, their width has been increased to dimension D, which is wider than the width E of the first modified annular or ring portion 56 A, and may begin at the outer periphery of the first modified annular or ring portion 56 A and extend beyond the inner diameter of the modified annular or ring portion 56 A. Accordingly, dimension “D” may be greater than dimension “E”, and the first modified annular or ring portion 56 A may be co-extensive with the outer diameter of the annular upstanding ridges ( 93 A, 115 A).
Referring to FIG. 11 , it can be seen that in some instances the treated annular portion 56 A may not extend through the entire depth of the filter media 55 A but may instead have surface treated portions 56 A on both sides of the sheet of media 55 A.
While this version may be useful in some applications, it is not the most preferred embodiment, because the fluid being filtered may wick to the edge 57 A, or beyond, resulting in possible fluid loss.
Modifications which prevent this are shown in FIGS. 11A-11C . In FIG. 11A the first modified filter media 55 A has the first modified annular or ring shaped treated portion 56 A in the form of an inwardly radially extending U-shaped channel 56 F. In FIG. 11B , it is shown as an outwardly radially extending U-shaped channel 56 G. In FIG. 11C the first modified annular or ring shaped treated portion 56 A is in the form of a box channel 56 H.
A still further modification of the invention may be seen by referring to FIGS. 13-16 . FIGS. 13 and 14 show a second modified filter media 55 B mounted in a second modified filter housing 60 B ( FIG. 16 ), which may be similar to the first modified filter housing 60 A shown in FIG. 12 . In this instance, the dimensions C, D, and E may be equal and uniform around the second modified media 55 B, and may be identical to those of the first modified filter media 55 A except where the filter vent 76 is provided. The filter vent 76 is shown as a semi-circular shape, but may be of any desired shape, and instead of being a width of dimension D spaced a distance C from the edge, the filter vent is of a dimension F which begins at the inner periphery of the second modified annular or ring portion 56 B and extends for a distance F, which brings a portion of the filter vent 76 above the first and second downstanding peripheral ridges 93 B and 115 B respectively, which are pinch sealing the second modified filter element 55 B in modified filter housing 60 B.
In this modification of the invention, there is an extra passageway for air which extends above the ridges 93 B, 115 B pinching the second modified filter media 55 B. As the fluid being processed passes through the inlet chamber 65 B and through second modified media 55 B, any air entrapped in the inlet chamber 65 B will rise to the top of the inlet chamber 65 B. As the fluid continues to be filtered, the fluid level will drop down to the bottom of the inlet chamber 65 B, and any trapped air can now pass through the filter vent 76 , and up to the top of the inlet chamber 65 B. If a plurality of parallel ribs (not shown) are carefully placed downstream in the outlet chamber 68 B this air will carry any fluid remaining in the outlet chamber up and out through the outlet 72 . Thus, in this modification of the invention, not only the inlet chamber 65 B, but the outlet chamber 68 B, and the downstream line (not shown) will be empty, thus reducing hold back volume to a minimum.
Referring now to FIG. 15 , a modification of the second modified filter element 55 B is shown where the second modified annular or ring portion 56 B does not extend for the entire depth of the second modified filter media 55 B.
In FIG. 15 , there is shown filter vent 76 having a front surface portion 77 , a rear surface portion 78 , and a leg 83 connecting the front surface portion 77 and rear surface portion 78 proximate the middle thereof. The leg 83 is needed for the air to pass between the front surface portion 77 and rear surface portion 78 , and may be placed in any desired position between the two. Even if placed below the fluid level in the filter, the suction pressure is believed to be sufficient to cause the air remaining upstream after the filtering operation to pass through. While this is not a preferred embodiment because the fluid being filtered may wick to, and possibly past, the edge 57 B, it may be useful for some applications.
Modifications which prevent this are shown in FIGS. 15A-15B . In FIG. 15A the second modified filter media 55 B has the second modified annular or ring shaped treated portion 56 B in the form of an inwardly radially extending U-shaped channel 56 J. In FIG. 15B , it is shown as an outwardly radially extending U-shaped channel 56 K.
In FIG. 15A the leg 83 is shown connecting front surface portion 77 of the filter vent 76 and the rear surface portion 78 thereof at their outer extremities in the form of a radially inwardly extending channel. In FIG. 15B the leg 83 is placed at the innermost possible position to connect front surface portion 77 and rear surface portion 78 of filter vent 76 . As explained hereinabove the leg 83 can be at the position shown in FIG. 15A , the position shown in FIG. 15B , or any place in between and still perform satisfactorily.
With the foregoing explanation, additional benefits of the present construction may be seen. When the flat sheet of media has the annular or ring portion 56 treated or present for the entire depth of the flat sheet of media as shown in FIG. 10 , any fluid passing past the downstanding peripheral ridges ( 93 , 115 ) is an indication of fluid bypass or filter failure, since a higher pressure is needed to bypass the pinch seals than if the treated annular or ring portion 56 were absent. Thus, if the filter housing ( 60 , 60 A, 60 B) were transparent or translucent, at least around the periphery thereof, any fluid which might flow past the annular or ring portion ( 56 , 56 A, 56 B) could be easily observed by the user of the filter housing ( 60 , 60 A, 60 B) and the filter process could be stopped, and the fluid being filtered could be saved.
Referring now to FIGS. 18A-18H , it can be seen that the surface treatment modification of the present invention is not just useful with flat filter media or discs, but can also improve the sealing capabilities of tubular filters as well. In FIG. 18A there is a perspective view of tubular filter 120 having an upper edge region 121 A proximate the upper end 121 of filter 120 , and lower edge region 122 A proximate the lower end 122 of the filter 120 treated with the surface treatment modification of the present invention. The treated regions ( 121 A, 122 A) will preferably be of annular shape and may extend for the entire thickness of the filter tube, but may be of other shapes and cross sections if desired. For example, annular shaped treated regions may extend for a finite depth on the inside or outside of the tubular filter 120 .
By making the ends of the tubular filter 120 more liquid repellant, it is harder for liquid to bypass the ends of the filter tube when the filter tube is held between a pair of end caps, as is typical in prior art filter housings. Thus, a tubular filter 120 having its ends 121 , 122 , respectively treated with a liquid repellant is well within the scope of the present invention.
Referring now to FIG. 18B , there is shown a modification of the construction shown in FIG. 18A wherein the filter tube 120 has annular portions thereof ( 121 A, 122 B) treated with a surface treatment modification to be more liquid repellant than the remainder of the filter tube 120 . However, instead of being proximate the ends of the filter tube ( 121 , 122 ), they are spaced a short, predetermined distance X therefrom. This will provide a mechanism for sealing the filter tube 120 on its' outer and/or inner surface ( 120 A, 120 B) instead of, or in addition to, its' ends ( 121 , 122 ).
Referring now to FIG. 18C , there is shown a filter construction capable of accomplishing this. The filter construction shown in FIG. 18C may be identical to the filter construction shown in FIG. 4 , except that the end cap, now identified by the numeral 49 A for the purpose of clarity, has been provided with a first or outer upstanding peripheral wall 49 B, and a second or inner upstanding peripheral wall 49 C spaced inwardly a predetermined distance from first or outer upstanding peripheral wall 49 B to create a pair of spaced walls between which the lower end of the filter tube 120 A can be sealed.
The spacing between the walls 49 A, 49 B should be such as to put sufficient pressure on the treated annular portion 122 A to avoid fluid bypass.
The other end of the filter tube 120 A may be sealed in a similar manner by providing a modified upper end cap (not shown), or it may be sealed in a conventional manner.
Instead of a single treated region ( 121 a , 122 A) being provided proximate upper and/or the lower ends ( 121 , 122 ) of the tubular filter 120 being provided (as shown in FIG. 18A ), a pair of treated annular regions ( 122 C, 122 D) extending for a finite depth, less than the thickness of the tubular filter 120 , may be provided proximate the upper and/or lower end of the tubular filter 120 . This is shown on an enlarged scale in FIG. 18D .
Referring now to FIGS. 18E-18H , There are shown several modifications of the end cap 49 A illustrated in FIGS. 18C and 18D . In FIG. 18E , there is illustrated a further modified end cap, now identified by the numeral 150 for clarity. End cap 150 , as can end cap 49 A, may have an outer upstanding peripheral wall 150 A ( FIG. 18G ), an inner upstanding peripheral wall 150 B ( FIG. 18H ), or both FIGS. 18E , 18 F). Also walls 150 A and 150 B, as can walls 49 B, 49 C, can be in a concentric or non-concentric orientation with each other, can be of any desired height, and can be placed anywhere on the end cap ( 150 , 49 A) depending on the application.
Outer peripheral wall 150 A may have a first slanted surface 160 provided on its inner portion 162 . The angle which the slanted surface 160 makes with the top surface 164 may vary depending on the application.
Likewise, the inner peripheral upstanding wall 150 B may have a second slanted surface 168 provided on its outer portion 170 . A flat top surface 175 may be provided as part of the outer peripheral wall 150 B and/or the inner peripheral wall 150 B if desired.
The slanted portions ( 160 , 168 ) are designed to push inwardly in on, and slightly crush the surface treated portions ( 122 C, 122 D) as pressure is applied to the end cap 150 to seal the tubular filter 120 in a filter housing, as shown in FIG. 18F .
The height of the walls ( 49 B, 49 C) ( 150 A, 150 B) should be sufficient so that the inner wall ( 49 C, 150 B) and/or the outer wall ( 49 B, 150 A) contact at least a portion of the treated annular portion 122 C and/or 122 D.
FIG. 18G shows a modification of the construction shown in FIG. 18E wherein the end cap 150 has only an outer, upstanding, peripheral wall 150 A sealing against an outer surface treated portion 122 C.
FIG. 18H shows a modification of the construction shown in FIG. 18E wherein the end cap 150 has only an inner, upstanding, peripheral wall 150 B sealing against an inner surface treated portion 122 C.
Referring to FIG. 22 , there is shown a construction embodying the present invention, wherein a top or upper vent 130 is added to permit to allow air to vent from the upstream chamber into the downstream chamber at the onset of the filtration process for the purposes described above. The top or upper vent or upper surface treated area 130 can be treated with the same or different treatment as the vent 76 .
FIG. 23 shows a construction similar to that shown in FIG. 22 wherein the top or upper vent or upper surface treated area 130 overlaps the annular surface treated portion 56 B, and is treated with the same surface treatment modification.
FIG. 24 shows a construction similar to that shown in FIG. 22 wherein the top or upper vent or upper surface treated area 130 overlaps the annular surface treated portion 56 B, but is treated with a different surface treatment modification.
It may be desirable for some applications to have a top vent 130 as shown in FIGS. 22-24 , without the bottom vent 76 , and this is well within the scope of the present invention.
The present invention is not limited to the circular discs or tubular filters previously illustrated but may also be applied, as will be apparent, to other tubular or cylindrical elements that are pleated, formed and/or rolled. The shape of the treatment may vary to suit the applicability of the filter design. For example as shown in FIGS. 5 , 9 and 13 , concentric treatments are shown, but the present invention should be understood not to be limited as such.
Further, there are various chemical treatments known in the art for producing the surface treatment modifications. The preferred treatments for such applications are fluorinated or siliconized polymers for liquid repellant applications, and polyvinyl alcohol and cellulose acetate for liquid wetting applications. Other treatments will be apparent to those skilled in the art.
Many preferred embodiments of the present invention have been described herein. The scope of the present invention is broad, and many more embodiments of the invention can be developed using the teachings herein, and these are well within the scope of the present invention. For example, with reference to FIGS. 8 , 12 , 16 and 21 , the dimensions shown are limited to the example in regard to which they discussed. As long as the hydrophobically treated portion of the media being held in a pinch seal extends radially inwardly of the opposed upstanding walls forming the pinch seal, a vented area will be formed. Therefore, for example, in FIGS. 12 and 16 , dimension D may be larger or smaller than dimension E, depending on the application, and be well within the scope of the present invention.
Thus, by carefully considering the problems present with filtering fluids, a novel surface treatment has been developed which reduces hold-up volume and produces numerous other advantages when compared with prior art devices. | A novel surface treatment is provided for portions of filter media coming in contact with the filter media holder, such as a filter housing. In certain applications, the treatment is also applied to the filter media holder, depending on the application. Filter media having at least two distinct surface property modifications are provided in liquid filtration applications to enhance the performance of a filtration system, reduce the cost of the system, provide a visual means of detecting fluid bypass, and minimize fluid hold-up volume within the filter media, all with substantially no loss of performance performances parameters, even in steam sterilization applications. | 1 |
BACKGROUND OF THE INVENTION
[0001] Embodiments of the invention relate to elevator systems, and in particular, to controlling elevators based on detection of passengers in elevators.
[0002] Conventional elevator systems include a call button outside the elevator car and an operating panel inside the elevator car. A user calls an elevator from outside the elevator car, and typically indicates a desired direction (i.e. up or down). Upon entering the elevator, the user selects a desired floor.
[0003] Some elevator systems have begun to allow a user to request a particular floor from outside the elevator car. In such a system, a dispatch computer may receive the user's request and may assign a particular elevator car for the user. The computer may provide an indication to the user of which elevator car the user should use. In some systems, the user still must select the desired destination upon entering the elevator car. In other system, the elevator car is automatically controlled to travel to the requested destination. However, in such systems, if the user does not enter the recommended elevator, a decrease in efficiency occurs since the elevator may travel to a floor that no user in the elevator has requested.
BRIEF DESCRIPTION OF THE INVENTION
[0004] Embodiments of the present invention include an elevator system including a destination selection device configured to receive a user input from a user to select a destination and an elevator assignment system configured to receive the selection of the destination from the destination selection device, to assign a first elevator to the user based on the selection of the destination, to detect the user in a second elevator, to determine whether the second elevator is the same as the first elevator, and to perform at least one of assigning the destination to the second elevator and providing feedback to the user based on determining whether the second elevator is the same as the first elevator.
[0005] In the above embodiment, or in the alternative, the elevator assignment system may be configured to assign the second elevator to the user, and assign the destination to the second elevator, based on determining that the second elevator in which the user is detected is not the same as the first elevator assigned to the user.
[0006] In any one of the above embodiments, or in the alternative, the elevator assignment system may be configured to provide feedback to the user based on determining that the second elevator in which the user is detected is not the same as the first elevator assigned to the user.
[0007] In any one of the above embodiments, or in the alternative, the elevator assignment system may be configured to detect an elevator change confirmation in response to the feedback, and to assign the destination to the second elevator based on detecting the elevator change confirmation.
[0008] In any one of the above embodiments, or in the alternative, the destination selection device may be a portable communications device associated with the user.
[0009] In any one of the above embodiments, or in the alternative, the destination selection device may be a cell phone.
[0010] In any one of the above embodiments, or in the alternative, the elevator system may include a user identification element and an identification element analysis unit in the first elevator configured to detect the user's identification by analyzing the user identification element.
[0011] In any one of the above embodiments, or in the alternative, the user identification element may include biometric data of the user and the identification element analysis unit is a biometric data reader.
[0012] In any one of the above embodiments, or in the alternative, the identification element analysis unit may include a camera that recognizes the user based on physical characteristic recognition of the user.
[0013] In any one of the above embodiments, or in the alternative, the user identification element may include a wireless communication element configured to communicate wireles sly with the identification element analysis unit to provide a user's identification to the elevator assignment system.
[0014] In any one of the above embodiments, or in the alternative, the user identification unit may be located inside the destination selection device.
[0015] Embodiments of the invention further include an elevator control system including memory for storing elevator assignments and a user identification database and a processor. The processor may be configured to receive from a user a destination selection and to assign a first elevator to the user based on receiving the destination selection from the user. The processor may be configured to receive from a user identification analysis unit in a second elevator user identification data, and to assign the destination selected by the user to the second elevator based on receiving the user identification data from the user identification analysis unit in the second elevator.
[0016] In any one of the above embodiments, or in the alternative, the processor may be configured to determine whether the second elevator from which the user identification data is received is the same as the first elevator assigned to the user, and to change an elevator assigned to the user from the first elevator to the second elevator, and to control the second elevator to travel to the destination selected by the user, based on determining that the second elevator is different from the first elevator.
[0017] In any one of the above embodiments, or in the alternative, the processor may be configured to determine whether the second elevator from which the user identification data is received is the same as the first elevator assigned to the user, and to control the second elevator to travel to the destination selected by the user based on determining that the second elevator is the same as the first elevator.
[0018] In any one of the above embodiments, or in the alternative, the processor may be configured to compare the user identification data received from the second elevator with user identification data stored in the user identification database to identify the user.
[0019] Embodiments of the invention further include a method for controlling an elevator. The method includes receiving, from a user, a destination selection and assigning to the user a first elevator and notifying the user of the assignment. The method includes detecting the user in a second elevator and controlling the second elevator to travel to the destination selected by the user based on detecting the user in the second elevator.
[0020] In any one of the above embodiments, or in the alternative, the method may include determining whether the second elevator in which the user is detected is the same as the first elevator assigned to the user and changing an assignment of the user from the first elevator to the second elevator based on determining that the second elevator is different from the first elevator.
[0021] In any one of the above embodiments, or in the alternative, receiving the destination selection from the user may include receiving, by an elevator assignment system, a destination selection signal from a portable communication device associated with the user.
[0022] In any one of the above embodiments, or in the alternative, detecting the user in the second elevator may include detecting wireless signals from a wireless identification element associated with the user.
[0023] In any one of the above embodiments, or in the alternative, detecting the user in the second elevator may include detecting biometric data associated with the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0025] FIG. 1 illustrates an elevator system according to one embodiment of the invention;
[0026] FIG. 2 is a flow diagram of a method according to an embodiment of the invention;
[0027] FIG. 3 illustrates an example of a portable communications device according to an embodiment of the invention;
[0028] FIG. 4 illustrates an example of an identification element according to an embodiment of the invention; and
[0029] FIG. 5 illustrates a biometric identification element analysis system according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Conventional elevator systems require users to select a desired destination upon entering an elevator car. Embodiments of the invention receive destination requests from users and automatically detect the presence of users in an elevator car to control the elevator car to travel to the requested destination.
[0031] FIG. 1 illustrates an elevator system 100 according to an embodiment of the invention. FIG. 2 is a flow diagram of a method according to an embodiment of the invention. The system 100 includes an elevator car 101 and an elevator control system 110 . The system 100 also includes a destination-request device 120 usable by a user 130 to request a destination in block 201 of FIG. 2 . The destination-request device 120 may be a portable or stationary device. In one embodiment, the destination-request device is a portable communication device associated with the user 130 , such as the user's cell phone, or a cell phone registered to or by the user 130 . In another embodiment, the destination-request device 120 is a stationary panel or other stationary device located in the vicinity of an elevator bank or elevator doors, in a lobby, or in any other location accessible by the user 130 .
[0032] In an embodiment in which the destination-request device 120 is a portable communication device, the user 130 may log in or otherwise register and select a destination via a user interface 121 , such as a touch screen, keyboard, voice-activated controls, body-movement-activated controls, or any other method. Selecting a destination may include entering a floor number, business or tenant name, or any other information corresponding to a tenant of a building in which the elevator car 101 is located. The destination-request device 120 includes a communication unit 122 to transmit the destination request to the elevator control system 110 . The communication unit 122 may be any wired or wireless communication system, including a wired or wireless local-area network (LAN), wide area network (WAN), or any other type of network.
[0033] The elevator control system 110 receives the destination selection via a corresponding communication unit 111 and, in block 202 of FIG. 2 , assigns an elevator to the user with the elevator assignment unit 112 . The elevator assignment unit 112 may include any combination of processors and memory executing instructions that incorporate any algorithm to assign an elevator, including determining a closest elevator to the user 130 , a least-crowded elevator, an elevator capable of arriving at the selected destination, a particular type of elevator, such as a cargo elevator for service deliveries, or any other algorithm taking into account any predetermined criteria. In one embodiment, the elevator control system 110 controls an elevator to move to the user's location based on receiving the destination request. In one embodiment, the elevator control system 110 sends assignment information, such as an elevator number or other identifier, to the user 130 after assigning the elevator to the user 130 . The assignment information may be displayed on the destination-request device 120 or on another device, such as a display in the vicinity of a bank of elevators.
[0034] In embodiments of the invention, the elevator control system 110 determines whether the user 130 enters the assigned elevator and takes actions based on the determination whether the user entered the assigned elevator. Accordingly, in FIG. 1 , the user 130 is illustrated outside the elevator car 101 , representing a location at which the user requests a destination, and inside the elevator car 101 where the user's identity is detected.
[0035] In particular, the user has an identification (ID) element 131 that is associated with the user, and the elevator car 101 has an identification (ID) element analysis unit 103 to identify the user based on the ID element 131 . In block 203 of FIG. 2 , the ID element analysis unit 103 analyzes the ID element 131 of the user 130 in the elevator car 101 to determine the user's identity. The ID element 131 may be a device, biometric characteristics of the user 130 , or any other means of identifying a user. In one embodiment, the ID element 131 is a code or data generated by a portable communications device associated with the user 130 , such as a user's cell phone. The data may be transmitted wirelessly, such as via a wireless LAN, Bluetooth, near-field communication systems, or any other infrared, radio frequency or other wireless system. In one embodiment, the destination-request device 120 is a cell phone associated with the user 130 , and the ID element 131 is stored in, or part of, the cell phone.
[0036] The ID element 131 may also include any other device capable of emitting data, such as a radio-frequency identification (RFID) chip. Such an RFID chip may be powered off until an RF signal is received from the ID element analysis unit 103 that generates current in the RFID chip causing the RFID chip to emit identification data. In one embodiment, the ID element 131 is a card or badge, or is a chip embedded in the card or badge. While a few examples of devices have been provided by way of description, embodiments of the invention encompass any device capable of providing identification of a user 130 to an ID element analysis unit 103 .
[0037] In addition or in the alternative, the ID element 131 may include biometric data of a user. For example, the ID element analysis unit 103 may be a camera or scanner capable of recognizing a user's features, such as a face, fingerprint, retina, or any other biometric data that can be used to identify the user. The elevator control system 110 stores identification data, such as identifying codes or biometric data, in the identification (ID) database 113 and compares detected identification information with the data in the database 113 to identify the user 130 in the elevator car 101 .
[0038] The elevator control system 110 determines whether the elevator 101 in which the user 130 is located is the same elevator that was previously assigned to the user 130 . In path 204 of FIG. 2 , if the elevator control system 110 determines that the elevator 101 in which the user 130 is located is the same elevator that was assigned to the user 130 , the elevator control system 110 controls the elevator car 101 to travel to the previously-assigned destination. The path to the previously-assigned destination may be by way of any other number of destinations based on the presence of additional users in the elevator car 101 or additional elevator requests from users outside the elevator car 101 .
[0039] In path 206 of FIG. 2 , if the elevator control system 110 determines that the elevator car 101 is not the same elevator that was assigned to the user, then the elevator control system 207 may determine whether an elevator change is permitted. For example, in a system in which some elevators access only some floors, a user may not be allowed to ride in an elevator that accesses floors the user is not permitted to access, or which does not access the floor the user has requested. In block 208 , of FIG. 2 , the elevator control system 110 may provide feedback to the user, such as by providing visual, audio, or other messages via the user interface 104 or the destination-request device 120 . The feedback may be based on whether changes are permitted. For example, a feedback message may ask the user to confirm an elevator change by pressing a “door close” or “confirm change” button on the user interface 104 or destination-request device 120 in embodiments in which an elevator change is permitted. In addition, the feedback message may instruct the user to exit the elevator car 101 and enter another elevator in an embodiment in which an elevator change is not permitted. In these embodiments, the doors of the elevator car 101 may be controlled to remain open until a user action is detected, whether confirming an elevator change in path 210 of FIG. 2 or exiting the elevator in path 209 . In one embodiment, the elevator control system 110 may send a message to the user's portable communications device with information such as the recommended elevator, an increased arrival time based on the elevator in which the user is presently located, an indication that the elevator in which the user is located is going the wrong direction (i.e. the user wants to go up, but the elevator is going down), any information indicating to the user why the non-assigned elevator in which the user is located is not ideal for the user, or any other information. The user 130 may then be given the opportunity to leave the elevator prior to the doors closing, or remain on the elevator, at which time the elevator control system 110 may change the elevator assigned to the user to correspond to the elevator in which the user is located.
[0040] If it is determined that the user has exited the elevator in path 209 , the elevator doors may close and the elevator may continue to operate without the user. The user is then detected in another elevator in block 203 , and the process of determining whether the user is in the assigned elevator repeats.
[0041] If the user confirms the elevator change in path 210 , the elevator control system 110 may change the user's elevator assignment in block 211 and may then control the elevator to travel to the user's requested destination in block 205 . In one embodiment, the user confirmation of path 210 requires an action or operation by the user, such as pressing a button, speaking a confirmation, or otherwise interacting with the user interface 104 or the destination-request device 120 . In another embodiment, no user action is required, and the elevator control system 110 changes the elevator assignment based on the user simply remaining in the elevator for a predetermined period of time without performing any other operation or action, or without interacting with the user interface 104 or the destination-request device 120 .
[0042] While an embodiment has been described in which the elevator control system 110 provides feedback to the user, in another embodiment, one or both of the blocks 205 and 211 of FIG. 2 are performed automatically by the elevator control system 110 without any user-initiated actions after entering the elevator car 101 . For example, in one embodiment, the elevator control system 110 controls the elevator to travel to a requested destination or changes the requested destination without a user interacting with the user interface 104 in the elevator car (such as a control panel, keypad, audio interface, etc.), without requiring the user to move an ID badge or other user identification device or object into the vicinity of a reader or scanner, and without requiring the user to perform any other user-initiated action. Instead, the ID element analysis unit 103 may automatically detect the ID element 131 , and the elevator control system 110 may perform the assignment change of block 207 or the elevator destination control of block 205 based on the ID element detection.
[0043] In one embodiment, the elevator control system 110 provides additional feedback to the user in block 212 . The feedback may include, for example, audio, visual, tactile, or other notifications via a user interface 104 in the elevator car 104 or via a portable communications device, such as a cell phone, associated with the user. The content of the additional feedback may include the requested destination, time to arrival, or any other feedback. While FIG. 2 illustrates the providing of feedback downstream, or later than, the changing of the elevator assignment, it may be understood that the feedback may be provided prior to, or concurrently with, the changing of the elevator assignment, as described previously with respect to block 208 of FIG. 2 .
[0044] In addition, in one embodiment the user may request a change in destination after entering an elevator car, as indicated by path 209 of FIG. 2 . In such an embodiment, the elevator control system 110 may change the elevator assigned to the user (as illustrated in FIG. 2 ), or may simply change the destination of the elevator. For example, in an embodiment in which some elevators service only some destinations, a user may change a destination request to correspond to a location that is not serviced by the elevator in which the user is located. In such an embodiment, the elevator control system 110 may change the elevator assigned to the user, and may instruct the user, via a portable communications device, for example, how to access the assigned elevator. In another example, the user may realize that an incorrect destination was initially requested, and may request a different location serviced by the elevator. The elevator control system 110 may then merely change the destination of the elevator car 101 . In such an embodiment, an efficiency of the elevator system 100 is realized, since the elevator control system 110 may skip the erroneously-selected destination if no other users have requested the destination.
[0045] In block 213 of FIG. 2 , the elevator car 101 arrives at the requested destination.
[0046] While one ID element analysis unit 103 is illustrated in the box representing the elevator car 101 , embodiments of the invention encompass any system that identifies whether users have entered particular elevator cars 101 . For example, in one embodiment, ID element analysis units may be located at stationary locations at each door to an elevator on each separate floor of a building. In such an embodiment, each elevator car 101 has multiple ID element analysis units associated with it, so that each ID element analysis unit on each floor of the building tracks which users enter the particular elevator and which users leave the elevator, and the data from all of the ID element analysis units is transferred to the elevator control system 110 which tracks the occupancy of the elevators.
[0047] In addition, while an embodiment is illustrated in which the ID element analysis unit 103 identifies the ID element 131 of the user 130 to identify the user 130 , embodiments also encompass other functions of the ID element analysis unit 103 , such as tracking occupant who cannot be specifically identified. For example, in one embodiment guests to a building may be provided with badges that do not uniquely identify the guest, but instead identify the user as a “guest,” permitting the elevator control system 110 to track the location of the guest. In another embodiment, if the ID element analysis unit 103 is a biometric reader and does not recognize a particular user (i.e. the user is not in the ID database 113 ), the unidentified user may still be counted for purposes of determining the occupancy of the elevator car 101 or tracking the location of the unidentified user, while the user may be denied the destination-request function or access to predetermined locations in the building.
[0048] As previously discussed, embodiments of the invention encompass any type of ID element. FIG. 3 illustrates an embodiment in which the destination-request device is a portable communications device 300 . The portable communications device 300 includes a display panel 301 , user data entry buttons 302 , and an ID element 303 included in the portable communications device 300 . In one embodiment, the ID element includes code executed by a processor and transmitted wireles sly by an antenna. In another embodiment, the ID element 303 is an RFID chip embedded in the portable communications device 300 .
[0049] FIG. 4 illustrates an embodiment in which the ID element 402 is embedded in a badge 400 or identification card including identification information 401 , such as words, pictures, and other symbols. In such an embodiment, the ID element 402 may include an RFID chip, barcode, or other scannable or detectable code, symbol, design, or other feature.
[0050] FIG. 5 illustrates yet another embodiment in which the ID element analysis unit includes a camera 502 and biometric detector 504 to identify biometric characteristics of a user 503 in an elevator car 501 . For example, the camera 502 may identify facial or retinal characteristics, or the biometric detector 504 may detect fingerprints, palm prints, deoxyribonucleic acid (DNA) or other biological identifiers, or any other biometric data capable of identifying a user.
[0051] Technical effects of embodiments of the invention include increasing an efficiency of an elevator system by tracking users in elevators to reduce extra, erroneous, or unnecessary stops of the elevator, reducing the arrival of full elevators due to elevator calls from users outside the elevator, and providing security features to track users and grant access to destinations in a building based on a user's identification.
[0052] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | An aspect of an elevator system includes receiving, from a user, a destination selection and assigning to the user a first elevator and notifying the user of the assignment. The user is detected in a second elevator, and the second elevator is controlled to travel to the destination selected by the user based on detecting the user in the second elevator. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a gear device. More particularly, the present invention relates to a low noise type gear device wherein leakage of sound, generated by gear meshing and collision of splash and drops of a lubricant with a wall surface of the casing, and sound attributable to resonance of the casing, can be reliably prevented.
2. Description of the Related Art
Various conventional gear devices of the aforementioned type are in practical use. Among them, a typical conventional gear device (reduction gear) will briefly be described below with reference to FIG. 3.
In FIG. 3, reference numeral 1 designates a casing which is of an entirely closed box-shaped configuration. The casing 1 includes a side wall 1A and a side wall 1B. First bearing set 2A, second bearing set 2B and third bearing set 2C are fitted into both the side walls 1A and 1B of the casing 1. An input shaft 4 is rotatably supported by the third bearing set 2C while a first gear 3A is fixedly mounted on the input shaft 4. An intermediate shaft 5 is rotatably supported by the second bearing set 2B while a second gear 3B and a fourth gear 3D are fixedly mounted on the intermediate shaft 5. Similarly, an output shaft 6 is rotatably supported by the first bearing set 2A while a third gear 3C is fixedly mounted on the output shaft 6.
The fourth gear 3D is fixedly mounted adjacent to the second gear 3B on the intermediate shaft 5. Accordingly, the first gear 3A meshes with the second gear 3B and the third gear 3C meshes with the fourth gear 3D.
One end 4a of the input shaft 4 projects outward of an outer wall 1a of the casing 1, while one end 6a of the output shaft 6 projects outward of the outer wall 1a of the casing 1.
A sound-proofing member 7, molded of a rubber, a synthetic resin or the like, covers the whole outer wall 1a of the casing 1 so as to prevent sound generated by meshing engagement of the gears 3A to 3D and sound generated by collision of splash and drops of a lubricant utilized in the device with an inner wall 1b of the case 1 from traveling to the outside of the casing.
Although not illustrated for the purpose of simplification, another conventional gear device of the aforementioned type is constructed such that the bearing sets are arranged on the inner wall 1b of the casing 1, as opposed to being fitted into the wall. Otherwise, operation of this device is similar to that of the device illustrated in FIG. 3.
Conventional gear devices, constructed in the above-described manner, have several limitations. Specifically, in the case of the first-mentioned conventional gear device, a large space is required for installation, and moreover, it requires a large quantity of sound-proofing materials. Consequently, it is expensive to manufacture and apply.
Also, heat generated by meshing engagement of the respective gears in the casing cannot be easily diverged to the outside of the sound-proofing cover through the casing. For this reason, the bearings and other associated components may become thermally damaged.
In addition, the aesthetic appearance of the gear device is degraded and maintenance is difficult to perform due to the sound-proofing material on the casing.
In the case of the second conventional gear device discussed above, it unavoidably requires even larger dimensions, resulting in an increase in production cost. It should be added that this type gear device also does not operate satisfactorily.
SUMMARY OF THE INVENTION
The present invention has been made in order to solve the aforementioned problems. Thus, an object of the present invention is to provide a low noise type gear device which assures that leakage of gear meshing sound generated by and collision sound to the outside and generation of unpleasant noise attributable to resonance of the casing are prevented.
According to the present invention, there is provided a gear device including a casing having a plurality of bearings fitted therein, an input shaft, an intermediate shaft and an output shaft. The input shaft, the intermediate shaft and the output shaft are operatively connected to each other via gears fixedly mounted thereto. Laminated vibration damping and sound absorbing steel sheets are arranged inside of the casing.
In particular, a plurality of projection-shaped seats are formed on an inner wall of the casing, and a hollow space is formed between the inner wall of the casing and the laminated vibration damping and sound absorbing steel sheets by mounting the laminated steel sheets on the seats with bolts, or the like. The casing of the invention is constructed in a closed configuration.
With the gear device of the present invention, the laminated vibration damping and sound absorbing steel sheets are arranged around the inner wall of the casing with a space between the sheets and the inner wall. Accordingly, splash and drops of lubricant will collide with the laminated vibration damping steel sheets, not the wall of the casing. Thus, noisy sound and vibration are not emitted to the outside of the casing, resulting in a remarkable sound-proofing effect.
Unpleasant sounds generated by the meshing engagement of the gears also does not reach the casing, but is absorbed in the laminated vibration damping and sound absorbing steel sheets. Consequently, leakage of this sound to the outside is also prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a reduction gear in accordance with an embodiment of the present invention.
FIG. 2A is a fragmentary sectional view of the reduction gear shown in FIG. 1, particularly illustrating essential components for the reduction gear on an enlarged scale.
FIG. 2B is a fragmentary sectional view similar to FIG. 2A but of an alternative arrangement.
FIG. 3 is a cross-sectional view of a conventional reduction gear.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described in detail with reference to the accompanying drawings which illustrate a preferred embodiment of the present invention. It should be noted that same or similar components to those of the conventional gear device are represented by like reference numerals. FIG. 1 is a sectional view of gear device (a reduction gear) in accordance with the embodiment of the present invention, and FIG. 2A is a fragmentary sectional view of the reduction gear shown in FIG. 1, particularly illustrating essential components for the reduction gear on an enlarged scale.
In FIG. 1, reference numeral 1 designates a casing designed in a box-shaped closed configuration. The casing 1 includes a side wall 1A and a side wall 1B. A first bearing set 2A, second bearing set 2B and third bearing set 2C are fitted into the side walls 1A and 1B as illustrated. An input shaft 4, having a first gear 3A fixedly mounted thereon, is rotatably supported by the third bearing set 2C, and an intermediate shaft 5, having a second gear 3B and a fourth gear 3D fixedly mounted thereon, is rotatably supported by the second bearing set 2B. Similarly, an output shaft 6, having a third gear 3C fixedly mounted thereon, is rotatably supported by the first bearing set 2A.
The fourth gear 3D is fixedly mounted adjacent to the second gear 3B on the intermediate shaft 5. With this construction, the first gear 3A meshes with the second gear 3B, while the third gear 3C meshes with the fourth gear 3D.
One end 4a of the input shaft 4 projects out of the side wall 1B, while one end 6a of the output shaft 6 projects out of the side wall 1A.
The casing 1 is made of, e.g., a cast steel, or the like. A plurality of projection-shaped seats 20 are formed integral with an inner wall 1b of the casing 1 (see FIG. 2A). Laminated vibration damping and sound absorbing steel sheets 21, each having substantially the same shape as that of the inner wall 1b of the casing 1 are mounted on the end surfaces of the seats 20. Thus, the laminated vibration damping and sound absorbing steel sheets 21 are located inside of the inner wall 1b of the casing 1.
It should be noted that each laminated vibration damping and sound absorbing steel sheet 21 is designed to exhibit excellent vibration damping and sound absorbing properties as disclosed in an official gazette of, e.g., Japanese Examined Publication Patent No. 59-19180. Also, steel sheets 21 may have a laminated structure composed of a plurality of steel layers having respective resonance frequencies different from each other. Each of the shafts 4, 5 and 6 extends through a guide hole 21b which is formed in the laminated vibration damping and sound absorbing steel sheet 21.
A female-threaded hole 20b is formed through each seat 20, and the laminated vibration damping and sound absorbing steel sheet 21 is immovably secured to the inner wall 1b of the casing 1 by threadably engaging male-threaded fitting bolts 22 with the female-threaded holes 20b while extending through fitting holes 21a of steel sheets 21.
As is best seen in FIG. 2A, a hollow space 22 is formed between the laminated vibration damping and sound absorbing steel sheet 21 and the inner wall 1b of the casing 1. Thus, the laminated vibration damping and sound absorbing steel sheet 21 is maintained in a floating state with respect to the inner wall 1b of the casing 1 with the hollow space 22 located therebetween. It should be added that each seat 20 is not limited only to the integral structure integrated with the inner wall 1b of the casing 1 but it may be in the form of an independent member molded of a rubber or the like (see FIG. 2B). Also, steel sheets 21 may be fixed to seats 20 in any suitable manner.
With the reduction gear constructed in the above-described manner, as the input shaft 4 is rotated, the intermediate shaft 5 is rotated via the first gear 3A and the second gear 3B, and subsequently, the output shaft 6 is rotated via the fourth gear 3D and the third gear 3C. Consequently, rotation of the input shaft 4 is transmitted to the output shaft 6 with a predetermined speed reduction ratio. While rotation of the input shaft 4 is transmitted to the output shaft 6 in the above-described manner, lubricant (not shown) is scattered away from the respective gears 3A to 3D as they are rotated and then splash and drops of the lubricant collide with the respective laminated vibration damping and sound absorbing steel sheets 21 but do not reach the casing 1. Sound generated when the scattered splash and drops of lubricant collide with each laminated vibration damping and sound absorbing steel sheet 21 is absorbed in the laminated steel sheet 21. Thus, each laminated vibration damping and sound absorbing steel sheet 21 serves to prevent this sound from being emitted outside of the casing 1.
In addition, sound and vibration generated by meshing engagement of the respective gears 3A to 3D are mostly absorbed in the laminated steel sheets 21 without reaching the casing 1. Thus, leakage of this sound to the outside of the casing 1 can also be substantially prevented.
Based upon the results of a series of experiments, sound can be attenuated by a quantity of 5 to 10 dB(A) greater than the attenuation of conventional reduction gears having no vibration damping and sound absorbing means.
Since the reduction gear of the present invention is constructed in the above-described manner, the following advantages are obtained.
Arrangement of laminated vibration damping and sound absorbing steel sheets inside of the inner wall of the casing can prevent sound generated by meshing engagement of the respective gears from being transmitted to the casing. In addition, splash and drops of a lubricant scattered from the rotating gears will not collide with the casing due to the arrangement of the laminated vibration damping and sound absorbing steel sheets. Thus, leakage of the sound out of the casing can be reduced remarkably. In other words, the sound can be attenuated by a quantity of about 5 to 10 dB(A) compared with the conventional reduction gear.
Further, since there is no need to secure a sound-proofing material to the outer wall of the casing, the reduction gear itself can be designed with smaller dimensions.
Additionally, since a known design of fitting bearings into the side wall of the casing can be employed for the reduction gear, the latter can be constructed without the necessity of changing the present dimensions of the casing.
Of course, the present invention may utilize any number of shafts and gears arranged for reduction, or other purposes. For example, the present invention has been explained along the reduction gear, but the present invention may be applied to any gear device, e.g. a speed-increase gear. Also, in the drawing the casing of the gear device is illustrated in a closed box-shaped configuration, but the present invention may be applied to a casing having a complicated configuration such as a transmission case of an automotive vehicle.
The invention has been described through a preferred embodiment thereof. However, various modifications will be apparent to those skilled in the art. Such modifications do not depart from the scope of the subject invention as defined by the appended claims. | A low noise type reduction gear which assures that sound generated by collision of particles of a lubricant with a wall surface of a casing and sound attributable to resonance of the casing can substantially be attenuated by arranging laminated vibration damping steel sheets inside of the casing. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a kind of entertainment product, and in particular, to a feet-swinging-type roller skate of concave plastic panel utilizing front and rear two feet cross swinging toward both sides to make it forward.
BACKGROUND OF THE INVENTION
[0002] Although the existing feet-swinging-type roller skate has an ingenious structure and strong entertaining, there is also a room for improvement in appearance and manufacturing technique, which mainly has drawbacks such as the structure is more complex and the manufacturing is difficult etc.
SUMMARY OF THE INVENTION
[0003] The object of the present invention is to provide a feet-swinging-type roller skate of concave plastic panel, which structure is more simple, which manufacturing technique is more simple and convenient, which appearance is more perfect.
[0004] In order to solve the aforementioned technical problems, the technical solutions provided by the present invention are:
[0005] A feet-swinging-type roller skate of concave plastic panel, comprising a concave plastic panel and universal wheels, said concave plastic panel is in the shape of a concave-shaped top, the universal wheels are respectively mounted at the lower ends of the concave front top and rear top of the concave plastic panel, two feet-swinging-type roller skates of concave plastic panel are matched in pairs to use.
[0006] Further, the concave front top and rear top of said concave plastic panel each has one perforation for up and down, a downward protrusion of pot bottom shape is disposed below the perforation of the concave plastic panel, a connecting bolt of the top of said universal wheel passes through the perforation, a nut coordinated with said connecting bolt screws the bolt.
[0007] Further, a counterbore is disposed on the upper portion of said perforation, said nut falls into the counterbore after screwing.
[0008] Further, the feet-swinging-type roller skate of concave plastic panel futher comprising a cover, said cover places on said counterbore.
[0009] Further, said cover is a plastic cover.
[0010] Further, said concave plastic panel is injection molded.
[0011] Further, the concave front top and rear top of said concave plastic panel tilt slightly toward the front down.
[0012] Further, said concave plastic panel is an injection piece that the side thereof is concave shape and the overlook shape of the panel surface is olive shape, longitudinal and transverse reinforcing ribs are distributed on the whole bottom of said concave plastic panel.
[0013] Further, a bearing is inlaid into the top of the wheel fork of said universal wheel, one bolt is cup jointed inside the bearing bore, a PU wheel is connected to the wheel fork, one said universal wheel is connected with the perforation carrying a counterbore of the concave front top of said concave plastic panel via a nut, one said universal wheel is connected with the perforation carrying a counterbore of the concave rear top of said concave plastic panel via a nut, two said universal wheels form the same forward tilt angle with said concave plastic panel after connecting.
[0014] Further, said plastic cover is a plastic cover of dome shape, one said plastic cover is inlaid in the counterbore of the concave front top of the said concave plastic panel, the other one said plastic cover is inlaid in the counterbore of the concave rear top of said concave plastic panel.
[0015] The beneficial effects of the present invention are: the side of the concave plastic panel of the feet-swinging-type roller skate of concave plastic panel is a concave shape design, the overlook shape of the panel surface of the concave plastic panel is olive shape, such that the appearance of the feet-swinging-type roller skate of concave plastic panel is unique and beautiful and has modern feeling, and the production process is simple. The foothold of the feet-swinging-type roller skate of concave plastic panel is low off the ground, therefore which safety is good, which is easy to learn, and which has very strong interesting when playing.
DRAWINGS
[0016] FIG. 1 is a structure schematic and appearance effect view of the present invention;
[0017] FIG. 2 is a right swing forward effect view of the present invention;
[0018] FIG. 3 is a left swing forward effect view of the present invention .
[0019] In the drawings: 1 -concave plastic panel, 2 -universal wheel, 3 -plastic cover.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0020] The present invention will be illustrated below in more details in combination with embodiments and appended drawings for the purpose of making objects, technical solutions and advantages of the present invention more clear and obvious. It should be understood that specific embodiments illustrated herein are simply used to explain the present invention but not used to define the present invention.
[0021] The object of the present invention is achieved the followings: a feet-swinging-type roller skate of concave plastic panel comprises a concave plastic panel, universal wheels and plastic covers, two feet-swinging-type roller skates of concave plastic panel are front and rear matched in pairs to use, the concave plastic panel of the feet-swinging-type roller skate of concave plastic panel is in the shape of a concave-shaped top which is plastic injection molded, the concave front top and rear top of the concave plastic panel all tilt slightly toward the front down, the concave front top and rear top of the concave plastic panel each has one perforation carrying a counterbore, the concave front top and rear top of the concave plastic panel have downward protrusions of pot bottom shape at the bottom of the positions of perforations carrying counterbores, perforations carrying counterbores of the concave front top and rear top of the concave plastic panel each connects one universal wheel, two universal wheels are screwed into perforations carrying counterbores of the concave front top and rear top of the concave plastic panel by the connecting bolts of the tops of the universal wheels coordinating with nuts, and making the screwing places between nuts and the connecting bolts of the tops of the universal wheels locate in the counterbores of the concave front top and rear top of the concave plastic panel, and inlaying two plastic covers in the two counterbores.
[0022] The present invention will be more specifically illustrated below with reference to the appended drawings. As shown in FIG. 1 , the feet-swinging-type roller skate of concave plastic panel comprises concave plastic panel 1 , universal wheel 2 and plastic cover 3 ;
[0023] Said concave plastic panel 1 is an injection piece that the side thereof is concave shape and the overlook shape of the panel surface is olive shape, the concave front top and rear top of said concave plastic panel 1 all tilt slightly toward the front down, the concave front top and rear top of said concave plastic panel 1 each has one perforation carrying a counterbore, the concave front top and rear top of said concave plastic panel 1 have downward protrusions of pot bottom shape at the bottom of the positions of perforations carrying counterbores, longitudinal and transverse reinforcing ribs are distributed on the whole bottom of said concave plastic panel 1 , perforations carrying counterbores of the concave front top and rear top of said concave plastic panel 1 are used to connect universal wheels.
[0024] Said universal wheel 2 is a universal wheel that a bearing is inlaid into the top of the wheel fork, one bolt is cup jointed inside the bearing bore, a PU wheel is connected to the wheel fork, one said universal wheel 2 is connected with the perforation carrying a counterbore of the concave front top of said concave plastic panel 1 via a nut, one said universal wheel 2 is connected with the perforation carrying a counterbore of the concave rear top of said concave plastic panel 1 via a nut, two said universal wheels 2 form the same forward tilt angle with said concave plastic panel 1 after connecting.
[0025] Said plastic cover 3 is a plastic cover of dome shape, one said plastic cover 3 is inlaid in the counterbore of the concave front top of said concave plastic panel 1 , one said plastic cover 3 is inlaid in the counterbore of the concave rear top of said concave plastic panel 1 .
[0026] For the state diagram of the present invention when using, reference is made to FIG. 2 and FIG. 3 , wherein, FIG. 2 is a state diagram that two feet-swinging-type roller skates of concave plastic panel right swing forward; FIG. 3 is a state diagram that two feet-swinging-type roller skates of concave plastic panel left swing forward, moving ahead is achieved by left swinging and right swinging.
[0027] The Above-mentioned embodiments simply express the implementations of the present invention, which description is more specific and detailed, but it should not therefore be understood to limit the patent scope of the present invention. It should be pointed out that a number of deformations and improvements can be made for one having ordinary skill in the art without departing from the concepts of the present invention, these all belong to the protection scope of the present invention. So the protection scope of the present invention patent should be taken by appended claims as the standard. | A feet-swinging-type roller skate of concave plastic panel ( 1 ) comprises a concave plastic panel ( 1 ) and a universal wheel ( 2 ). The top of the two concave plastic panels ( 1 ) is in the shape of a concave. The front top and rear top of the concave plastic panel ( 1 ) are respectively provided with the universal wheel ( 2 ) on their lower ends. The feet-swinging-type roller skate of concave plastic panel ( 1 ) should be used in pairs. | 0 |
This invention relates to a programmable analog voltage multiplier circuit means and more particularly it relates to an improved programmable analog voltage multiplier circuit means of solid-state microstructure and integrated design including embodiments of FET multiplier, differential amplifier multiplier, vector-vector multiplier and vector-matrix multiplier arrangements thereof.
BACKGROUND OF THE INVENTION
Various types of solid-state microstructured and integrated circuits have been designed in the past. For example, U.S. Pat. No. 4,649,289 to T. Nakano concerns a repetitive integrated charging circuit for maintaining a node potential of a MOS dynamic circuit. The species of FIG. 3 is considered pertinent. The FIG. 3 circuit is generally made up of a capacitor, a transistor-capacitor arrangement and an oscillator. The capacitor is parallel connected to the node between the transistors of a MOS dynamic circuit and the transistor-capacitor arrangement. By reason of the oscillator timely charging the capacitor via the transistor-capacitor arrangement, the node potential is substantially maintained during use of the MOS dynamic circuit. U.S. Pat. No. 4,677,317 to H. Sakuma is of interest in disclosing a high voltage output signal producing circuit for one or more display elements and the like. The circuit is generally made up of at least two integrated, transistorized and capacitor interconnected signal processors of low power consumption for producing a high voltage output. U.S. Pat. No. 4,710,726 to Carucci discloses a tunable semiconductive MOS resistance network or circuit means of integrated construction and for operation in the nonsaturated or triode mode. The species of FIG. 1 is deemed pertinent. The circuit means of the FIG. 1 species is generally made up of two inputs, two outputs, two control inputs and a series of four matched MOS transistors of n-channel design. The two inputs and the two control inputs are connected to certain and different pairs of transistors of the series of four transistors so that the series of four transistors provides the desired combined transconductance output of different polarity to each output means of the circuit means. However, none of the aforediscussed references were remotely concerned with an improved programmable analog voltage multiplier circuit means (PAVMCM) to which a programmable analog voltage input is dynamically stored on a capacitor at high impedance input to a multiplier and the PAVMCM is useful in providing one or more multiplied outputs in various applications such as artificial neural networks (artificial intelligence) or pattern recognition as will now be described.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved programmable analog voltage multiplier circuit means (PAVMCM) of relatively low power consumption that is of integrated and micro-structure semi-conductance design so that it can readily be used in a wide number of applications including being operable during linear/nonlinear conditions.
Another object of the invention is to provide an improved analog voltage multiplier circuit means of microstructure and integrated design that is readily adaptable to be part of various integrated arrangements such as programmable analog voltage multiplier circuit means, programmable analog vector-vector multiplier circuit means and programmable analog vector-matrix multiplier circuit means.
Still another object of the present invention is to provide an improved analog voltage multiplier circuit having capacitor means interposed between switch means and a high impedance analog voltage (HIAV) programming input means of the circuit means where the HIAV programming input means can be the gate means of a field effect transistor means and where the capacitor means receives and dynamically stores a programmed analog voltage input of preselected value for applying the programmed analog voltage input to the programming input means of the circuit means.
Yet another object of the present invention is to provide an improved programmable voltage multiplier circuit means where the capacitor means thereof is the intrinsic capacitance of either the HIAV programming input means or the gate means of the FET means at the PAVMCM programming input thereof.
In brief summary, an improved programmable analog voltage multiplier circuit means, in one embodiment thereof, is generally made up of switch means, capacitor means and a HIAV programming input means, analog voltage input means and current source output means. The capacitor means is interposed between the switch means and the HIAV input means. Moreover, the capacitor means receives and dynamically stores a programmed analog voltage input and then applies the programmed input to its HIAV input means in response to the switch means. When the circuit means also receives an analog voltage input via its analog voltage input means, the product of these input means provides a multiplied current output to the current source output means. The HIAV programming input means can be the gate means of a FET means while the other input means is the drain thereof. Further, this circuit means with its HIAV programming input means is readily adaptable so as to provide a plurality of two or more PAVMCM that are summed together in row-like fashion so as to form a programmable analog vector-vector multiplier circuit means.
In another embodiment of the invention, a programmable double quadrant analog voltage multiplier circuit means is generally made up of two FET means of n-and p-channel design, switch means and capacitor means. The capacitor means is parallel interconnected to the gate means of both FET means and interposed between the switch means and the FET gate means. The n-and p-channel FET means are connected to current receiving means to form current source and sink outputs to the current receiving means. Analog voltage input means of different polarity are appropriately connected to nonprogramming input means of the FET means.
In still another embodiment of the invention a programmable, at least single quadrant, analog voltage multiplier circuit means is made up of a pair of FET means of the same channel design switch means and capacitor means. A reference analog voltage input is connected to the gate means of one FET means. The capacitor means is connected to the gate means of the FET means and interposed between the switch means and the gate means of the FET. A common analog voltage input is parallel interconnected to the nonprogramming input of each FET means. Current source output means of the FET means are separately connected to current differencing means. In a slight modification of this embodiment, the reference analog voltage input is also provided with switch means and capacitor means. One of the advantages of this modification is that it is a balanced design and is not subject to adverse effects in a high temperature environment. Such adverse effects can be drift in the stored analog voltage at the HIAV programming input means or the gate means of the FET means as caused by leakage currents when the PAVMCM is not a balanced design.
Another embodiment is a differential amplifier programmable double quadrant analog voltage multiplier circuit means. This circuit means is generally made up of a series of three FET means all of the same channel design, a pair of switch means and a pair of capacitor means. Two of the FET means of the series are associated with the separate pair of capacitor and switch means. A programmed analog voltage input is applied through the switch means to the gate means of the second FET means and stored in one of the capacitor means when the switch means opens. A reference analog voltage input is applied through the other switch means to input means of the third FET means and stored in the other capacitor means of the pair. A analog voltage input is applied to the gate means of the first FET means. The current source output of the first FET means is approximately proportioned to the square of the difference between gate-to-source voltage and the threshold voltage of the first FET means. Current source output means of the first FET means is parallel interconnected to the source means of the second and third FET means. The multiplied output is the difference in current values of the second and third FET means current output means. The second and third FET means current output means are connected to current differencing means.
A subthreshold differential amplifier programmable double quadrant analog voltage multiplier circuit means is also generally made up of a series of three FET means all of the same channel design, a pair of switch means and a pair of capacitor means. An analog low current input is parallel interconnected to the gate and drain means of another FET means and is further parallel interconnected to the gate means of the first FET means to form a current mirror arrangement so that the current output of the first FET means is linearly related to the analog low current input. A bias voltage is parallel connected to the source means of the other FET means and to the source means of the first FET means. The current output means of the first FET means of the series is parallel interconnected to the source means of the second and third FET means thereof and is of low value so that the second and third FET means operate in the subthreshold mode. The amplified and multiplied current output means of the second and third FET means are connected to current differencing means.
A programmable analog vector-matrix multiplier circuit means, in another embodiment of the invention, is generally made up of a series of programmable analog voltage multiplier circuit means (PAVMCM) such that two or more groups of PAVMCM of the series thereof are arranged relatively spaced from each other with each group defining a row and with two or more rows of the PAVMCM defining two or more columns so as to form a matrix of programmed analog voltages that are dynamically stored on capacitors at the HIAV input of the PAVMCM. The analog vector input is made up of a series of analog voltage inputs to the PAVMCM. Each analog voltage input of the series is applied to all the PAVMCM in a column. An analog vector output of the multiplied analog vector input and the matrix of weights with each element of the analog vector output being the summed multiplied output of each row of the PAVMCM. A programmed analog voltage input means is parallel interconnected to a series of X and Y switch means so as to allow analog voltages to be dynamically stored at the HIAV input of each PAVMCM of the series. The series of X and Y switch means are parallel interconnected to the capacitor means of each PAVMCM of the series thereof. To this end, each Y switch means of the series is connected to the capacitor means of its associated PAVMCM of the series. Each X switch means of the series is connected to the programmed analog voltage input means along a given row of the vector-matrix multiplier circuit means (VMMCM) before any Y switch means along the gives row thereof. Current source output means of a group of PAVMCM along any row of the VMMCM is connected to a current summing means. Separate analog voltage input means are provided for each column of two or more PAVMCM of the VMMCM. X and Y decoder means have output means connected to the X and Y switch means in such fashion that certain X and Y switch means are closed for selecting one or more capacitor means and associated PAVMCM so as to provide one or more multliplied current outputs during each operative cycle of VMMCM. To assist the operation of the VMMCM appropriate multiplexer means are provided for distributing the current differencing output means and the analog voltage input means. By reason of the current output means for each row of the VMMCM, it is readily adaptible for use, e.g., in an artificial neural network or for pattern recognition.
For any of the aforeaddressed embodiments metal oxide substrate FET (MOSFET) means are preferably used. Depending on the use requirements of any PAVMCM, the capacitor means can be the intrinsic capacitor means of either the HIAV programming input or the gate means of a FET means at the PAVMCM, programming inputs.
Other object and advantages of the invention will become apparent when taken in conjunction with the accompanying specification and drawings as follows:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view with parts broken away of an embodiment of the invention and illustrates a programmable analog vector-vector multiplier circuit means.
FIG. 2 is a diagrammatic view of a programmable analog voltage multiplier circuit means (PAVMCM) of the invention as another embodiment thereof.
FIG. 3 is a diagrammatic view of another embodiment of the invention.
FIG. 3A is an enlarged diagrammatic view as taken within the bounds of encompassing line 3A--3A of FIG. 3 and illustrates a slight modification thereof.
FIG. 4 is a diagrammatic view of a differential amplifier / PAVMCM of the invention.
FIG. 5 is a diagrammatic view of a subthreshold differential amplifier PAVMCM of the invention.
FIG. 6 is a diagrammatic view with parts broken away of another embodiment of a programmable analog vector-vector multiplier circuit means of the invention and similar to the embodiment of FIG. 1.
FIG. 7 is an enlarged diagrammatic view taken within the bounds of encompassing line 7--7 of FIG. 6 and illustrates further details of the invention.
FIG. 8 is a diagrammatic view with parts broken away of a programmable analog vector-matrix multiplier circuit means.
DETAILED DESCRIPTION OF THE INVENTION
With further reference to FIG. 1, a programmable analog vector-vector multiplier circuit means 10 of the invention is generally made up of a plurality of two or more programmable analog voltage multiplier circuit means (PAVMCM) 12 and 14 (only two are being shown) all preferably arranged in a single row. Each PAVMCM is provided with a high impedance analog voltage (HIAV) programming input means 16 and 18. Grounded capacitors 20 and 22 are connected to HIAV programming input means 16 and 18 of the PAVMCM. A PROM or RAM 24 receives a digital input for storage as controlled by the controller input. Programmed digital word output 26 of the PROM or RAM is controlled by the controller input and is connected to digital-to-analog (D/A) converter 28. Output 30 of the D/A converter provides a programmed analog voltage (PAV) input means. A pair of switches or FET means 32 and 34 have their input means parallel connected to PAV input means 30. The output means of switches 32 and 34 are connected to capacitors 20 and 22, respectively. Separate output means 36 and 37 of a decoder 38 is connected to the gate means of switches 32 and 34. Other output means of decoder 38 including the gate means of switches associated therewith are not shown for the sake of brevity.
Analog voltage input means in serial format 40 is connected to a serial-to-parallel multiplexer 42. Each output of the series of parallel outputs of multiplexer 42 is connected to the input means of its associated PAVMCM such as outputs 44 and 46 to input means 48 and 50 of PAVMCM 12 and 14. Current output means 52 and 54 of PAVMCM 12 and 14 are parallel interconnected to current receiving means 56.
When a PAV input is provided by D/A converter 28 and switch means 32 is closed by decoder 38 providing output 36, capacitor 20 dynamically stores the PAV input of input means 30. Upon switch means 32 being opened when there is no output in output means 36 from decoder 38, capacitor 20 then applies the dynamically stored PAV input to programming input means 16 of the PAVMCM. At the same time, output means 44 of multiplexer 42 provides a sequential analog voltage input from multiplexer 42 to input means 48 of the PAVMCM. By reason of PAVMCM 12 receiving a PAV input and an analog voltage input, the product is a multiplied current source output via output means 52 to current receiving means 56. Depending on the operation of decoder means 38 and multiplexer means 42 in providing more than one PAVMCM current output for each cycle of multiplier circuit means 10 and more than one sequential output, e.g. multiplied current outputs of output means 52 and 54 are effectively summed by current receiving means 56 during each operative cycle of multiplier circuit means 10 so as to form an analog vector-vector multiplied output.
Although only two PAVMCM are shown it is to be understood that any number of PAVMCM could be provided for vector-vector multiplier circuit means 10. Since input means 40 provides a series of analog voltage input means they can be of different values. But despite these different values, the multiplied current outputs of each PAVMCM even though of different value are still effectively summed by current receiving means 56 for each cycle of the vector-vector multiplier circuit means. For some operation modes of the vector-vector multiplier, the PAV input stored in either capacitor 20 or 22 is preferably a constant fixed value for a number of operation cycles. Since the PAV input is dynamically stored on capacitor 20 or 22, the PAV value can drift due to leakage through either switch 32 or 34. The PAV can be replenished to capacitors 20 and 22 by the memory controller writing appropriate digital words to D/A converter 28 so as to maintain the desired PAV input. The PAV inputs are again stored at capacitor 20 or 22 by appropriately opening and closing switches 32 and 34 in synchronization with PAV input 30. It should be evident that if multiplier circuit means 10 is comprised of only one PAVMCM then it is merely a PAVMCM.
As depicted in FIG. 2, in another embodiment of the invention, a programmable double quadrant analog voltage multiplier circuit means 60 is generally made up of n-channel FET means 62, p-channel FET means 64, a capacitor 66, and a switch 68. As in FIG. 1, a PROM or RAM 70 in conjunction with a D/A converter 72 provide a PAV input, via output means 74, to capacitor 66 for dynamic storage when switch 68 is closed by the output means of a decoder 76. Capacitor 66 is parallel interconnected by output means 78 and 80 to the gate means of FET means 62 and 64, respectively. The output means of analog voltage input means 82 and 84 of positive and negative voltage polarity relative to the voltage of current source and sink output means 88 and 90, respectively, are connected to the input means of FET means 62 and 64. Current receiving means 86 has an input parallel interconnected to current source and current sink output means 88 and 90 of FET means 62 and 64. When switch 68 is open after capacitor 66 dynamically stores a PAV input, then the capacitor simultaneously applies the stored PAV input to the gate means of FET means 62 and 64. If the PAV input is a positive polarity then current source output means 88 provides a positive current source output to receiving means 86 and its output means 92. This positive current source output is a product of the PAV input and Vx analog voltage input, if Vx has a positive polarity value for a given cycle of circuit means 60. On the other hand, if PAV input is a negative polarity, then current sink output means 90 provides a negative current sink output to receiving means 86 that is a multiplied product of the PAV and Vx (if Vx has a negative polarity value). The multiplied product will be a linear product of the PAV and Vx if FET means 62 and 64 are operated in the triode mode with the drain-to-source voltage of FET means 62 and 64 being smaller than the difference of the gate-to-source and the FET threshold voltages. The product will be non-linear if FET means 62 and 64 are operated in the saturated mode. Thus, circuit means 60 provides double quadrant multiplied current outputs via output means 92.
It should be evident that circuit means 60 would be operable if it only incorporated a single transistor of n- or p-channel, of course, current receiving means 86 by its output means 92 would then only be a single quadrant multiplied current output that is a product of the PAV and Vx analog input voltage. The product will be linear if the FEt means is operated in the triode mode and non-linear if operated in the saturated mode.
Another embodiment of the invention concerns a programmable, single, double or four quadrant analog voltage multiplier circuit means as depicted in FIG. 3. The circuit means is generally made up of a pair of n-channel FET means 98 and 100. A capacitor 102 is connected to the gate means of FET means 98. A switch 104, as controlled by output means 105 of decoder 106, is connected to capacitor 102. A PAV input of output means 107 of D/A coverter 108 is connected to switch means 104. A common analog voltage input means 110 is parallel interconnected via its output means to the input means of FET means 98 and 100. A reference analog voltage input means 112 is connected to the gate means of FET means 100. Current differencing means 114 has first and second input means 116 and 118 that are connected to the output means of FET means 98 and 100. It is noted here that generally the input impedance to the current differencing means is of low value and the voltage values of current input means 116 and 118 will change little as the input current is varied. Also, the current input means 116 and 118 have the voltage values that are close in magnitude.
In an operative embodiment of circuit means 96, PAV input of output means 107, analog voltage input means 110 and reference analog voltage input means 112 are all of positive polarity with respect to the voltage of current output means 116 and 118. With the PAV input being of greater value than reference analog voltage input means 112, then output means 120 of current differencing means 114 provides a multiplied output of positive polarity that is a product of a Vx input and the difference in voltage between a PAV input and a reference voltage input for a given cycle of circuit means 96 and that is located in the first quadrant. If the PAV input, reference voltage input and analog voltage are selected so that FET means 98 and 100 operate in the triode mode, than the current difference output will be a linear product of Vx input and the difference between a PAV input and a reference voltage input. If FET means 98 and 100 operated in the saturated mode, then the modified product will be non-linear. On the other hand, if reference analog voltage input means 112 is of greater value than the PAV input of output means 107, then current differencing means provides an output for net multiplied output 120 of negative value and in the second quadrant. Similarly, if the analog voltage input means is of negative polarity relative to the voltage of current output means 116 and 188 but reference analog voltage input means 112 is of positive polarity and lesser value than the PAV input (which is also of positive polarity), then the current differencing means 114 provides an output for multiplied output 120 of negative value and in the fourth quadrant. But, if the analog voltage input means is of negative polarity and the reference analog voltage input means is of greater value than the PAV input, the net multiplied output from output means 120 is positive and in the third quadrant.
Since capacitor 102 tends to have leakage current generated by switch 104, especially in a high temperature environment, and since switch 104 and capacitor 102 are only provided for FET means 98 of circuit means 96, the circuit means is not of balanced construction and thus is normally of limited use for high temperature operation. This imbalance results in a drift in the net multiplier output of output means 20. Where this drift is objectionable it can be minimized by frequently refreshing (replenishing) the PAV input stored on capacitor 102. Accordingly, a slight modification of circuit means 96 is provided as will now be described in FIG. 3A.
For the sake of simplicity corresponding reference numerals between the embodiments of FIGS. 3 and 3A refer to like parts. In the slightly modified circuit means 96' of FIG. 3A, a capacitor 122 is connected to the gate means of FET means 100. Switch means 124 is connected to the capacitor and a reference analog voltage input means 112. Output means 105 of the decoder is parallel interconnected to the gate means of FET means 98 and 100. By reason of this balanced construction of circuit means 96; the output means of the current differencing means (not shown) provides a net multiplied output with minimized drift and in different quadrants as aforedescribed in the embodiment of FIG. 3.
In another embodiment of the invention, a differential amplifier programmable two quadrant analog voltage multiplier circuit means 130 is disclosed in FIG. 4. This multiplier circuit means is generally made up of a series of three FET means 132, 134 and 136, a pair of capacitor means 138 and 140 and a pair of switch means 142 and 144. The control inputs of the pair of switch means are parallel interconnected to the output of decoder means 146.
A programmable analog voltage input of preselected value as provided by output means 148 of a D/A converter 150 is connected to switch means 142. A reference analog voltage input means 152 is connected to switch means 144. A bias voltage input means 154 is connected to the source means of first FET means 136. A bias means 154 to the source means of first FET means 136 provides the gate-to-source voltage thereof when analog voltage input means 156 provides analog voltage input 158. As the result of the gate-to-source voltage of FET means 136, it provides a current source output 160 to the source means of second and third FET means 132 and 134 thereof. It is noted here that first FET means, operates in the pentode mode and its current source output means is proportional to the square of the gate-to-source voltage minus a threshold term of FET means 136 that is provided by analog voltage input means 156.
When the output means of decoder means 146 provides an output for closing both switch means 142 and 144, output means 148 provides a programmable analog voltage (PAV) input to capacitor means 138 for receiving and dynamically storing same. At the same time, reference analog voltage input means 152 with switch means 144 being closed, as the result of the output means of decoder means 146, causes capacitor means 140 to receive and dynamically store the reference analog voltage (RAV) input of input means 152. Then when the RAV and the first PAV inputs are stored by capacitor means 138 and 140, the output of the output means of decoder means 146 for closing switches 142 and 144 is terminated. As the result of switch means 142 and 144 being opened, then the dynamically stored PAV and RAV inputs are applied to the gate means of second and third FET means 132 and 134 so as to provide the gate voltage therefor.
With the second and third FET means having gate voltages as aforedescribed, amplified multiplied current outputs from the drain means of the second and third FET means to the current source output means 162 and 164 are applied to differencing means 166 so as to provide a current differenced and multiplied product output to output means 168. If a PAV input, a RAV input and an analog voltage input are all the same polarity relative to bias voltage means 154 and the RAV input is less than the PAV input, then the output of output means 168 is positive and in the first quadrant for each operative cycle of the amplifier/multiplier circuit means. Moreover, the output of output means 168 is proportional to the product of the difference between the PAV and RAV voltages and the difference between the gate-to-source voltage of FET means 136 as supplied by analog input means 156 and a threshold voltage term intrinsic to FET means 136. On the other hand, if the RAV input is greater than the PAV input and the same polarity, then the output of output means 168 is negative and in the second quadrant as the result of the action of differencing means 166.
As depicted in FIG. 5, another embodiment is a subthreshold differential amplifier programmable two quadrant analog voltage multiplier circuit means 170. The subthreshold amplifer/multiplier circuit means is generally comprised of a series of three FET means 172, 174, 176, a pair of capacitor means 178 and 180 and a pair of switch means 182 and 184. Output means 186 of decoder means 188 is parallel interconnected to both switch means 182 and 184. Output means 190 of D/A converter 192 provides a programmable analog voltage (PAV) input of preselected value to switch means 182. A reference analog voltage (RAV) input means 194 is connected to switch means 184. A bias voltage input means 196 is parallel interconnected to the source means of first FET means 176 so as to provide a gate-to-source voltage therefor and to the source means of another FET means 198. Output means 200 of analog voltage input means includes a resistor 202, the current output means of which is parallel interconnected to the drain means and the gate means of FET means 198 so as to provide the gate voltage and drain-to-source voltage therfor. The current output means of resistor 202 is also interconnected to the gate means of first FET means 176 so as to provide the gate voltage thereof. It is noted here as the result of the relation between FET means 198 and 176 and the way they are configured in relation to each other, current output means 204 is linearly related and the mirror image of the current output of resistor 202. Therefore, current source output 204 of FET 176 is linearly related to the drain current of FET 198 and to the analog voltage input 200. Current source output means 204 of first FET means 176 is parallel interconnected to the source means of second and third FET means 172 and 174. It is noted that the current source output 204 is of low value so that the second and third FET means 172 and 174 are in subthreshold operation. Amplified/multiplied current source output means 206 and 208 are connected to separate input means of current differencing means 210. The current differencing means is provided with output means 212.
In an operative embodiment of the amplifier/multiplier circuit means of FIG. 5, analog voltage input 200 applied to resistor 202 results in a current source output of the resistor means 202 to the gate means of the first FET means 176 and to the drain means and the gate means of FET means 198 so as to cause a current source output of output means 204 to the source means of second and third FET means 172 and 174. With capacitor means 178 providing a stored PAV input to the gate means of second FET means 172 after switch means 182 is opened as the result of the action of the output means of decoder means 188, capacitor 180 provides a dynamically stored RAV input to the gate means of third FET means 174 so as to provide the gate voltage therefor. The current source output of output means 204 in being linearly related to the analog voltage input 200, a current difference of current output means 206 and 208 is formed and inputed to current differencing means 210. The output 212 of current differencing means 210 will be a product of the difference between the stored RAV and PAV and the difference between the analog voltage input and a fixed term. The fixed term is the difference between analog voltage 200 and the drain node voltage of FET 198 as divided by the resistance of resistor 202 so as to provide a current source. It should noted that resistor 202 could be replaced by a voltage to current generation circuit. With the PAV input, analog voltage input and RAV input all of positive polarity and with the RAV input being less than the PAV input, then output means 212 of the current differencing means is positive and in the first quadrant. However, if the RAV input is greater than the PAV input then the output of output means 212 is negative and in the second quadrant.
A slight modification of the programmable analog vector-vector multiplier circuit means 10 of FIG. 1 is shown in FIG. 6. For the sake of brevity corresponding parts of FIGS. 1 and 6 are reference numbered the same. However, each PAVMCM of multiplier circuit means 10' of FIG. 6 is configured differently than each PAVMCM of circuit means 10 of FIG. 1.
To this end, reference is made to FIG. 7, PAVMCM 12 is generally made up of a pair of FET means 216 and 218, second capacitor means 220 and second switch means 222. Capacitor means 220 in being connected to switch means 222 is also connected to the gate means of FET means 218. Output means 36 of decoder means 38 is provided with branch output means 224 for parallel interconnecting the decoder output means to switch means 222. A reference analog voltage input means 226 is connected to switch means 222. Output means 44 of multiplexer 42 is parallel interconnected to the input means of both FET means 216 and 218. Multiplied current source output means 52 of FET means 216 is connected to an input of current differencing means 228. Multiplied current source output means 230 of FET means 218 is connected to another input of the current differencing means as best shown in FIG. 7.
All PAVMCM of circuit means 10' in FIG. 6 are configured in similar fashion as PAVMCM 12'. Moreover PAVMCM 14', as generally shown in FIG. 6, is provided with multiplied current source output means 54 of one FET means (not shown) being parallel interconnected to output means 52 of PAVMCM 12' and differencing means 228. Multiplied current source output means 232 of the second FET means (not shown) of PAVMCM 14' is parallel interconnected to multiplied current source output means 230 of PAVMCM 12' and differencing means 228. Another output means 46 of multiplexer 42 is parallel interconnected to the input means of both FET means (not shown) of PAVMCM 14' and provides an analog voltage input thereto in response to input means 40 during use of multiplier circuit means 10'.
In an operative embodiment of circuit means 10' of FIG. 6 it is evident that each PAVMCM 12', 14', etc., of the series provides two separate multiplied current source outputs, e.g., the multiplied outputs of output means 52 and 230 of FET means 216 and 218 whenever output means 36 of decoder means 38 causes a PAV input of selected value and a RAV input to the gate means of FET means 216 and 218 respectively while at the same time output means 44 provides an analog voltage input to the input means of both FET means 216 and 218. By reason of decoder means 38 having output means for each PAVMCM 12', 14', etc., of circuit means 10' and by reason of multiplexer means 42 having output means for each PAVMCM 12', 14', etc. the two input means of differencing means 228 will have the multiplied and summed-current outputs of at least two PAVMCM for each cycle of the circuit means when at least two PAVMCM are actuated by the output means of both decoder means 38 and multiplexer means 42. If the multiplied current output of output means 230, 232, etc. of one or more PAVMCM 12', 14', etc. is less than the multiplied current source output of output means 52, 54, etc. thereof, then the output means of differencing means 228 will be in the positive quadrant for each cycle of the circuit means. The next cycle of circuit means 10' may involve a new set of analog voltage inputs of different values being established as inputs to PAVMCM 12', 14', etc. or may involve one or more PAV inputs being different values than before to PAVMCM 12', 14', etc. or any combination thereof. Thus, the circuit means is very flexible and is capable of providing a variety of different outputs.
A programmable analog vector-matrix multiplier circuit means 240 is depicted in FIG. 8. The circuit means is generally made up of a series of PAVMCM 242. The series of PAVMCM 242 are arranged in two or more groups with at least one PAVMCM in each group in spaced relation to the other PAVMCM of the series such that each group of the series defines a row while the PAVMCM of two or more rows of the series are also arranged in one or more columns so that the row-column relation of the series of PAVMCM of circuit means 240 results in the general arrangement of a matrix therefor.
A series of X switch means 244 and a series of Y switch means 246 are provided for circuit means 240. As is evident in FIG. 8, one X switch means of the series is associated with each row of PAVMCM of circuit means 240. Each X switch. means is arranged before any Y switch means of a given row of circuit means 240 and before any column thereof. Further, each Y switch means of the series of Y switch means is operatively associated with each PAVMCM 242 of the series such that separate pluralities of the series of Y switch means are arranged in separate columns where the separate columns of Y switch means 246 correspond to the plurality of columns of PAVMCM 242 of circuit means 240.
Output means 248 of D/A converter 250 is parallel interconnected to all X and Y switch means 244 and 246 of both series thereof. As in prior species of this invention PROM or RAM means 252 receives a digital input 254 and as result of a controller input 256 provides a digital output 258 during one or more programming cycles of circuit means 240. As the result of the action of D/A converter 250 in receiving digital output 258 for each cycle of the circuit means it provides a PAV input of selected value.
X decoding means 260 is provided with a series of output means corresponding to the groups of the PAVMCM in row-like fashion such as output means 262, 264 and 266. These output means 262, 264 and 266 are connected to the control input of their associated X switch means 244.
Y decoding means 268 are provided with a series of output means corresponding to the plurality of the PAVMCM in column-like fashion of circuit means 240 such as output means 270 and 272. These output means are interconnected to the control inputs of a plurality of Y switch means 246 of the first and last columns of the PAVMCM of circuit means 240 as depicted in FIG. 8.
Each PAVMCM 242 of circuit means 240 is preferably configured the same as the PAVMCM aforedescribed in FIG. 7. However, other PAVMCM embodiments as described in FIG. 2, FIG. 3, FIG. 4, FIG. 5, are also suitable for the PAVMCM 242 of circuit means 240. It is noted here that capacitor means 273 is provided with each PAVMCM 242 of circuit means 240 and is connected to the output means of its associated Y switch means 246 and the gate means of FET means 216. Decoder output means 270 at each PAVMCM 242 of the first column of the PAVMCM is provided with branch output means 224 parallel interconnected to the control input of switch means 222 (see FIG. 7). Thus, the Y switch means of each PAVMCM of circuit means 240 preferably also includes switch means 222. Similarly, a reference analog voltage (RAV) input means 226 of each PAVMCM 242 provides a RAV input to switch means 222 thereof.
It is evident that each PAVMCM 242 of circuit means 240 is configured in the same fashion (including the PAVMCM of the last column thereof) as for each PAVMCM of the first column thereof as just described.
By reason of the series of output means of X decoding means 260 such as output means 262, 264 and 266 and by reason of the series of output means of Y decoding means 268 such as output means 270 and 272, it should be evident during use of circuit means 240 that X and Y decoding means 260 and 268 could provide PAV to the HIAV input of any PAVMCM 242 in random fashion for any operative cycle of circuit means 240, e.g. output in X decoding output means 264 and output in Y decoding output means 272. When this occurs, PAVMCM of the second row of circuit means 240 and of the last column thereof as illustrated in FIG. 8 is selected for receiving a PAV from D/A converter 250. If more than one X decoding output means is provided with output during a given cycle of circuit means 240 then two or more PAVMCM are selected along the last column of the circuit means. Thus, X and Y decoding means 260 and 268 in conjunction with X and Y switching means 244 and 246 and 222 of the series thereof coordinate the selection of one or more PAVMCM 242 for programming during any cycle of the circuit means. It is further noted that the operation of the X and Y decoding means is synchronized with output means 248 of converter 250 so that a PAV input from the converter is timely and properly applied to the capacitor means of one or more PAVMCM.
A serial-to-parallel multiplexer means 274 receives via its input means 276 a series of analog voltage inputs of preselected values in serial format where these series of inputs are elements of a vector. The multiplexer means is provided with a series of output means corresponding to the number of columns in the matrix of the circuit means. For example, output means 44 is parallel interconnected to the input means of both FET means 216 and 218 (FIG. 7) of each PAVMCM 242 that makes up the front or first column of the circuit means. In similar fashion, e.g. output means 46 of the multiplexer means is parallel interconnected to the input means of both FET means (not shown) of each PAVMCM in the last column of the circuit means as illustrated in FIG. 8. Thus, each output means 44, 46, etc., of multiplexer means 274 provides an analog voltage input of preselected value to its associated column of the matrix for one or more operative cycles of circuit means 240.
A series of current differencing means are operatively associated with circuit means 240. A current differencing means is preferably provided for each row of the circuit means such as the series of three current differencing means 278, 280, and 282. Output means 52 and 230 of the PAVMCM in each row and the first column of the circuit means are connected to separate inputs 284 and 286 respectively of current differencing means 278, 280 or 282. In similar fashion, output means 54 and 232 of the PAVMCM in each row and the last column of the circuit means are parallel interconnected to output means 52 and 230 of the PAVMCM in its associated row to the output means of any other PAVMCM therein (not shown) and to inputs 284 and 286 respectively of differencing means 278, 280 or 282. Thus, both output means of a group of PAVMCM in any row of the circuit means are parallel interconnected to inputs 284 and 286 of a given differencing means 278, 280 or 282.
Each differencing means 278, 280 and 282 provides an analog voltage output V y n via output means 288, 290 and 292 to sample and hold S/H means 294, 296 and 298 and then to parallel-to-serial multiplexer means 300 having output means 302. This output means 302 as the result of circuit means 240 provides a series of one or more analog voltage outputs for each operative cycle of the circuit means.
In an operative embodiment of the circuit means of FIG. 8, PAV output means 248 preferably provides a series of PAV inputs of preselected and different values to each PAVMCM of circuit mean 240 with the series of PAV inputs being stored at capacitors 273 at the inputs to the PAVMCM by the action of the X and Y decoding means, such as in the manner aforedescribed.
In short, the X and Y decoding means function to selectively operate switch means 244, 246 and 222 along any row or column of the circuit means in any desired fashion. Whenever Y switch means 246 and 222 of any PAVMCM are closed and opened as the result of the action of the Y decoding means and a PAV is applied to a particular row through switch 244 as a result of the action of the X decoding circuitry, a PAV is stored on capacitor means 273 and 220 of a given PAVMCM 242 and a dynamically stored PAV input is made to the input means of both FET means 216 and 218 of the given PAVMCM.
After all of the PAV values have been stored on capacitor means 273 and 220 of all PAVMCM in circuit means 240, output means, e.g. 44, 46 of multiplexer means 274 provides a series of analog voltage inputs of preferably different values for each PAVMCM in each column of the circuit means to the input means of both FET means 216 and 218 of a given PAVMCM. Then output means 52 and 230 provide multiplied current source outputs to its associated differencing means 278, 280 or 282. The differencing means 278, 280 or 282 associated with a given row takes the difference of these combined outputs of more than one PAVMCM along the given row. The differenced output of the output means of any differencing means 278, 280 or 282 is then held by its S/H means 294, 296 or 298 at the end of any operative cycle of the circuit means so that another operative cycle of the circuit means may begin with minimal time delay while new analog voltage inputs 44, 46, etc. are provided by multiplexer 274. The analog voltage outputs of all S/H means 294, 296, 298 for each cycle of the circuit means are placed in serial format by the analog voltage output of multiplexer output means 302.
The next cycle of the circuit means programmable vector-matrix means 240 may involve a new set of analog voltage inputs of different values being established as inputs to PAVMCM 242 or may involve one or more analog voltage inputs being different values than before to PAVMCM 242 or any combination thereof. Thus, the circuit means is very flexible and is capable of providing a variety of different outputs.
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. | An improved programmable analog voltage multiplier circuit means (PAVMCM) cluding various embodiments thereof that are operable in linear/nonlinear fashion. The PAVMCM is generally made up of multiplier circuit means, at least one switch means and at least one capacitor means. The switch means is connected to a programmable analog voltage (PAV) input and the capacitor means. The circuit means is composed of a high impedance analog voltage (HIAV) programming input, an analog voltage input and current source output means. The capacitor means is connected to the switch means and the HIAV programming input. The capacitor means receives and dynamically stores a PAV input when the switch is closed and then applies the dynamically stored PAV input to the HIAV programming input of the circuit means when the switch is opened. The product of the PAV input and the analog voltage input for a circuit means provides the multiplied current output of the output means thereof. Because of the high impedance of a FET gate means, it may be used where its gate means is the programming input of the PAVMCM means. PAVMCM means can be formed using FET multiplier and differential amplifier multiplier circuit means. The PAVMCM can be arranged to form embodiments of analog vector-vector and analog vector-matrix multiplier circuit means. One of the advantages of the PAVMCM when configured as a vector-matrix multiplier circuit means is that it is useful in an artificial neural network as well as for pattern recognition. | 6 |
BACKGROUND
[0001] The present disclosure relates generally to integrated circuit (IC) designs, and more specifically to a layout design of six-transistor (6T) static random access memory (SRAM) cell.
[0002] A standard 6T SRAM cell has six transistors formed on a bulk semiconductor substrate. Among the six transistors, four are N-channel devices (NMOS transistors) categorized according to their functions as two pull-down transistors and two pass-gate transistors. The remaining two transistors are P-channel devices (PMOS transistors) functioning as pull-up transistors.
[0003] Conventionally, the pull-down transistor is located next to the pass-gate transistor, wherein an N-type doped region is implemented as the drains and the sources for both transistors. The pull-down transistors are required to withstand a high level of current, and are therefore designed to be large in physical size. Compared to the pull-down transistors, the pass-gate transistors are designed to be much smaller in physical size as they are not required to withstand such high level current. Thus, the doped regions of the pull-down transistors can be much wider than those of their adjacent pass-gate transistors. Due to the mismatched sizes of the pull-down transistor and the pass-gate transistor, the conventional SRAM cell is particularly susceptible to reliability defects caused by deviation of fabrication process.
[0004] Desirable in the art of IC designs are additional designs that can eliminate the width mismatch issue while reducing the overall size of the 6T SRAM cell.
SUMMARY
[0005] The present invention discloses a 6T SRAM cell. In one embodiment, the cell includes a first inverter having a first pull-up transistor and a first pull-down transistor serially coupled between a supply source and a complementary supply source, and a second inverter cross-coupled with the first inverter having a second pull-up transistor and a second pull-down transistor serially coupled between the supply source and the complementary supply source. The cell further includes a first pass-gate and second pass-gate transistors coupled to the first and second inverters, respectively. The first pass-gate transistor and the first pull-up transistor are respectively constructed on a first P-type well and a first N-type well adjacent to one another, which are overlaid by a first doped region and a second doped region of substantially the same width in alignment with one another, respectively.
[0006] The construction and method of operation of the invention, however, together with additional objectives and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 schematically illustrates a standard 6T SRAM cell.
[0008] FIG. 2 illustrates a conventional layout design for the 6T SRAM cell shown in FIG. 1 .
[0009] FIG. 3 illustrates a layout design for the standard 6T SRAM cell in accordance with one embodiment of the present invention.
DESCRIPTION
[0010] FIG. 1 schematically illustrates a standard 6T SRAM cell 100 , which includes a first inverter 102 , a second inverter 104 and two pass-gate transistors: a first pass-gate transistor 106 and a second pass-gate transistor 108 (both pass-gate transistors are NMOS transistors). The first inverter 102 includes a first pull-up transistor 110 (PMOS transistor) and a first pull-down transistor 112 (NMOS transistor) while the second inverter 104 includes a second pull-up transistor 114 (PMOS) and a second pull-down transistor 116 (NMOS transistor). The gates of the first pull-up transistor 110 and the first pull-down transistor 112 are coupled together at a node 118 along with the drains of the second pull-up transistor 114 and the second pull-down transistor 116 . The drains of the first pull-up transistor 110 and the first pull-down transistor 112 are also coupled together at a node 120 along with the gates of the second pull-up transistor 114 and the second pull-down transistor 116 . The sources of the first pull-up transistor 110 and the second pull-up transistor 114 are coupled to the supply source VCC, while the sources of the first pull-down transistor 112 and the second pull-down transistor 116 are coupled to the complementary supply source VSS. As for the first pass-gate transistor 106 , the gate is coupled to a wordline (WL), the source is coupled to a bitline (BL), and the drain is coupled to the node 120 . The second pass-gate transistor 108 is set up in a similar configuration where the gate is also coupled to a wordline (WL), the source is coupled to a bitline bar (BLB), and the drain is coupled to the node 118 .
[0011] During read or write operations of the device, both the first pass-gate transistor 106 and the second pass-gate transistor 108 are designed to be selected or turned on by the signals on the wordlines (WL). The bitline BL or bitline bar BLB will charge up to provide enough current to program or read the SRAM cell 100 .
[0012] FIG. 2 illustrates a conventional layout design 200 for the standard 6T SRAM cell shown in FIG. 1 . Referring to FIGS. 1 and 2 simultaneously, since the two sides of the standard 6T SRAM cell 100 are identical, only one side of the layout design that includes the second pass-gate transistor 108 , the second pull-up transistor 114 , and the second pull-down transistor 116 will be described in detail. The second pass-gate transistor 108 and the second pull-down transistor 116 are constructed on a P-type well 202 . An elongated N-type doped region 204 formed on the P-type well 202 is implemented as the drains and the sources of the second pass-gate transistor 108 and the second pull-down transistor 116 . An elongated gate structure 206 is placed above the N-type doped region 204 to form the gate of the second pass-gate transistor 108 , while another elongated gate structure 208 is placed above the N-type doped region 204 to form the gate of the second pull-down transistor 116 . A separate elongated P-type doped region 210 is formed under the gate structure 208 on an N-type well 212 to form the drain and the source of the second pull-up transistor 114 . The elongated gate structure 208 overlies the P-type doped region 210 to form the gate of the second pull-up transistor 114 .
[0013] This conventional layout design presents several reliability issues. Both the first and the second pull-down transistors 112 and 116 are required to withstand a high level of current and are designed to be large in physical size, while both the first and the second pass-gate transistors 106 and 108 are designed to be much smaller in physical size. This means that the elongated N-type doped region 204 for the first and the second pull-down transistors 112 and 116 will be much wider than the width of the same for the first and the second pass-gate transistors 106 and 108 . Due to the deviation of fabrication process, it is possible that the location of the elongated gate structure 208 would shift to an intermediate area 205 between the wider portion of the N-type doped region 204 and the narrower portion of the same. This mismatch between the wider and narrower portions of the N-type doped region 204 would change the channel length of the shifted gate structure 208 , thereby causing reliability issues.
[0014] The following will provide a detailed description of a layout design for a 6T SRAM cell constructed on a silicon-on-insulator (SOI) substrate by swapping the locations of the pull-up transistor and the pull-down transistor in accordance with one embodiment of the present invention. It is noted that while the proposed SRAM cell is constructed on the SOI substrate, the bulk-substrate may also be used as an alternative of the invention.
[0015] FIG. 3 illustrates a proposed layout design 300 for a 6T SRAM cell corresponding to the circuit diagram shown in FIG. 1 , in accordance with one embodiment of the present invention. The locations of the pull-up transistors and the pull-down transistors within the layout design are swapped compared to the conventional layout design shown in FIG. 2 . Referring simultaneously to FIGS. 1 and 3 , since the two sides of the 6T SRAM cell 100 are identical, only one side of the layout design shown in a block 302 , including the second pass-gate transistor 108 , the second pull-up transistor 114 , and the second pull-down transistor 116 , will be described in detail.
[0016] The first and the second pull-up transistors 110 and 114 are not required to withstand a high level of current, and therefore they can be designed much smaller in physical size than the first and the second pull-down transistors 112 and 116 . In order to reduce the width mismatch issue between the pull-down transistors and the pass-gate transistors, the locations of the pull-up transistors and the pull-down transistors within this layout design 300 are swapped compared with the conventional layout design. Since the second pull-up transistor 114 is a PMOS transistor, it is formed on an N-type well 304 that is placed right next to a P-type well 306 , on which the second pass-gate transistor is constructed. Similarly, the first pull-up transistor 110 is formed on a separated N-type well placed right next to a P-type well, on which the first pass-gate transistor 106 is constructed. The second pull-down transistor 116 and the second pass-gate transistor 108 are formed on the P-type well 306 . An elongated P-type doped region 308 is disposed to form the drain and source of the second pull-up transistor 114 (a similar elongated P-type doped region is disposed to form the drain and source of the first pull-up transistor 110 ). An elongated N-type doped region 310 is disposed to form the drain and source of the second pass-gate transistor 108 (similar elongated N-type doped region is used to form the drain and the source of the first pass-gate transistor 106 ). Since the materials used to form the second pull-up transistor 114 and the second pass-gate transistor 108 are doped with different types of impurities, a soft contact 312 that has a P-type portion and N-type portion is implemented at the junction of the two elongated doped regions 308 and 310 . An elongated gate structure 314 is placed above the N-type doped region 310 to form the gate of the second pass-gate transistor 108 , while an elongated gate structure 316 is placed above the P-type doped region 308 to form the gate of the second pull-up transistor 114 . An elongated N-type doped region 318 is implemented on the P-well 306 to form the drain and the source of the second pull-down transistor 116 . The elongated gate structure 316 also extends above the elongated N-type doped region 318 to form the gate of the pull-down transistor 116 . Note that the soft contact 312 is coupled to a contact 320 through metal interconnects (not shown in this figure), that is implemented at the elongated N-type doped region 318 to provide a connection between the drain of the second pull-down transistor 116 and the node 118 shown in FIG. 1 .
[0017] With this proposed layout design, the width mismatch issue is avoided where the width of the P-type doped region 308 for the pull-up transistor 114 and the width of the N-type doped region 310 for the pass-gate transistor remain the same. There is no intermediate area of a different width between these two doped regions. Thus, the SRAM cell fabricated based on the layout out design 300 is less susceptible to reliability issues, when the location of the gate structure shifts due to deviation of fabrication process. The widths of the first and the second pull-down transistors 112 and 116 can be increased independently to increase the beta-ratio (I DSAT of the pull-down transistor to I DSAT of the pass-gate transistor) while the widths of the first and the second pass-gate transistors 106 and 108 and the first and the second pull-up transistors 110 and 114 can also be increased together to lower the alpha-ratio (I DSAT of the pull-up transistor to I DSAT of the pass-gate transistor).
[0018] The substrate may be silicon, gallium arsenide, gallium nitride, strained silicon, silicon germanium, silicon carbide, carbide, diamond, and/or other materials, preferably silicon-on-insulator (SOI) substrate, such as a silicon-on-sapphire substrate, a silicon germanium-on-insulator substrate, or another substrate comprising an epitaxial semiconductor layer on an insulation layer. In this embodiment, all of the transistors are constructed on an SOI substrate, so that the various wells can be disposed next to each other without having an isolation structure interposed therebetween.
[0019] Table I compares test data of threshold voltage and off-state source current for the pass-gate transistors, the pull-down transistors, and the pull-up transistors within the two different standard 6T SRAM cells created based on the proposed layout design shown in FIG. 3 and the conventional layout design shown in FIG. 2 . For all three transistors, the threshold voltage (Vt) is increased by using the proposed layout design shown in FIG. 3 . For example, the threshold voltage of the pass-gate transistor is increased by 42.8 mV. The off-state source current (I soff ) for the pass-gate transistor and the pull-down transistor are also reduced by at least 50%, thereby demonstrating a significant decrease in sub-threshold leakage. For example, the off-state source current for the pass-gate transistor is reduced by 58.8%.
TABLE I STI UHD SRAM Devices STD layout 200 layout 300 Delta PG 0.12/0.115 Vt_gm (V) 0.3787 V 0.4215 V 42.8 mV PG 0.12/0.115 I soff (μA/ea) 34 14 −58.8% PD 0.18/0.1 Vt_gm (V) 0.4639 V 0.4874 V 23.5 mV PD 0.18/0.1 I soff (μA/ea) 45 21 −53.3% PU 0.11/0.11 Vt_gm (V) −0.2984 V −0.3176 V 19.2 mV PU 0.11/0.11 I soff (μA/ea) −153 −93 −39.2%
[0020] The above illustration provides many different embodiments or embodiments for implementing different features of the invention. Specific embodiments of components and processes are described to help clarify the invention. These are, of course, merely embodiments and are not intended to limit the invention from that described in the claims.
[0021] Although the invention is illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims. | A 6T SRAM cell includes a first inverter having a first pull-up transistor and a first pull-down transistor serially coupled between a supply source and a complementary supply source, and a second inverter cross-coupled with the first inverter having a second pull-up transistor and a second pull-down transistor serially coupled between the supply source and the complementary supply source. The cell further includes a first pass-gate and second pass-gate transistors coupled to the first and second inverters, respectively. The first pass-gate transistor and the first pull-up transistor are respectively constructed on a first P-type well and a first N-type well adjacent to one another, which are overlaid by a first doped region and a second doped region of substantially the same width in alignment with one another, respectively. | 8 |
The present invention is a divisional application of applicant's previous application having Ser. No. 016,721 filed Mar. 2, 1979, now U.S. Pat. No. 4,277,514, patented July 7, 1981.
BACKGROUND OF THE INVENTION
The present invention relates to objects such as documents and the like which have colored areas thereon that area difficult or impossible to reproduce using known color photocopiers or color photography wherein the photosensitive emulsions or materials used in the photocopiers or photography are sensitive both to reflections from the visible light wavelength range for humans and ranges adjacent thereto.
The recently developed technology for reproduction of colored pattern which utilizes sensitive emulsion or material, such as color photography and color copiers, is capable of reproducing patterns in a color which appears to be identical to that of the original. A potential undesirable application of this convenient technology is in unauthorized and criminal reproduction of valuable documents or color objects. Particularly when it is utilized for reproduction of paper money, stock certificates, bond certificates, stamps, checks, drafts, bills of lading, letters of guarantee, credit cards, various certificates, various coupons, various slips, and/or the objects with such nature, and if the reproductions of such objects should circulate in the market place or through various transactions, it would evidently cause disturbances in economic and financial activities, and would be serious enough to require action to maintain social justice.
Included in the means available in the prior art which are applicable for prevention of forgery of such objects of value are:
(1) The employment of particular kinds of paper such as paper having watermarks;
(2) Utilization of particular patterns such as fine, minute and/or complicated background camouflages or ground designs and hidden marks;
(3) Utilization of a particular process for representation of patterns such as mandatory employment of particular and sophisticated engraving machines for the production of plates;
(4) Employment of a particular, sophisticated and expensive printing process such as Sammel druck machines; and
Each of these means is inevitably accompanied by cost disadvantages. In addition, the recent development in the aforementioned technology for reproduction of colored patterns which is excellent in performance and simple in handling operation, has added another disadvantage to these conventional means for the prevention of reproduction. When a colored object is reproduced either directly with such color reproduction technology or indirectly with such technology which is utilized for production of blocks or plates with which printing will be made, some magnitude of discrepancy would be recognized between an original and the reproduction from the viewpoint of visibility, dimensional distortion of patterns and/or paper quality. Experts however, often have a difficult time identifying a colored object as a reproduction. Particularly, in view of the fact that ordinary transactions are carried out by personnel who are not professional in this technical field and who do not have or use sufficient time for making sure of the validity of paper money, securities and/or documents to be transferred by some means including direct comparison with the genuine piece, it would be unrealistic to assume that the aforementioned color reproduction technology will not be applied to the undesirable purposes of forgery.
Prior art techniques are known for thwarting unauthorized black and white reproductions of patterns which utilize camouflaging or distorting backgrounds and the like. Such prior art teaching is not drawn to color reproductions not to the particular method employed here.
SUMMARY OF THE INVENTION
Accordingly an object of the present invention is to provide a method of preventing color accurate reproduction of a colored pattern with photocolor copiers and color photography using photosensitive materials having spectral sensitivity in the wavelength ranges consisting of the human visible range and the adjacent wavelength ranges thereto, comprising, forming at least a portion of the colored pattern with a color material having a spectral reflection factor curve with high spectral reflection in at least one of the areas of wavelength below 450 nm and above 650 nm so that a reproduction of a colored pattern is in a color not perceivable by a direct human viewer of the colored pattern.
A further object of the invention is to provide such a method including forming at least portion of the colored pattern with color material having high spectral reflection in addition, within the human visible wavelength range at at least one location thereof so that the color perceived by direct observation of the pattern is different from that which is reproduced by the color photocopiers or color photography.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a diagram showing the special sensitivity of each photosensitive layer of the silver halogenide photosensitive emulsions respectively sensitive to three kinds of elementary color; blueviolet, green and red;
FIG. 2 is a diagram showing the spectral reflection factor of three kinds of presently available silver halogenide-based coloring matter each of which respectively develops colors; cyan, magenta and yellow on a color photograph;
FIG. 3 is the human relative luminosity curve shown in the visible wavelength range;
FIG. 4 is a diagram showing the spectral sensitivity of cobalt blue and the reproduction thereof by means of the color copying process;
FIG. 5 is a diagram comparing the spectral reflection factors of a kind of coloring matter produced by kneading one portion of cobalt blue and also one portion of disazo compound yellow and of chromium oxide;
FIG. 6 is a diagram comparing the spectral reflection factor of reproductions, produced by means of a Fuji CB color copier, model CB 430, of a kind of coloring matter produced by kneading one portion of cobalt blue and also one portion of disazo compound yellow and of chromium oxide.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Silver halogenide, zinc oxide, cadmium sulfide, and the like are presently utilized as the photosensitive emulsion or material employed for reproduction of colored patterns using color photography and color copiers. Out of such photosensitive emulsions or materials, silver halogenides generally show the spectral characteristics as illustrated in FIGS. 1 and 2.
FIG. 1 is a diagram showing the spectral sensitivity of each photosensitive layer of the silver halogenide photosensitive emulsions respectively sensitive to three kinds of elementary color; blueviolet (curve B), green (curve G) and red (curve R). While a photosensitive layer that is sensitive to blueviolet is expected to have a uniform sensitivity to the wavelength of light covering 400 nm through 500 nm, it actually has an irregular sensitivity in the wavelength range from slightly longer than 400 nm through considerably longer than 500 nm. While another photosensitive layer that is sensitive to green is expected to have a uniform wavelength covering 500 nm through 600 nm, it actually has an irregular sensitivity having double peaks around the middle of the wavelength range covering considerably shorter than 500 nm through considerably longer than 600 nm. Similarly, while the third photosensitive layer that is sensitive to red is expected to have a uniform sensitivity to the wavelength range covering 600 nm through 700 nm, it actually has an irregular sensitivity having a peak or a cliff (a pair of horizontal lines connected by a vertical line to form two levels with different elevations) in the middle of the wavelength range between 600 nm and 700 nm and covering a wide wavelength range from slightly longer than 500 nm through approximately 700 nm.
FIG. 2 is a diagram showing the spectral reflection factor of three kinds of presently available silver halogenide-based coloring matter each of which respectively develops three independent colors; cyan (curve C), magenta (curve M) and yellow (curve Y), on a color photograph. Each of these colors is developed in each color developing layer of a colorphotograph, keeping some quantitative relations with the magnitude of exposure of each of the aforementioned photosensitive layers, based on the principles defined in the subtractive color mixing process. It is well known that the three colors of the coloring matter are perspectively complementary colors of the three elementary colors. The following is noted in FIG. 2: (1) While yellow is expected to uniformly cover the wavelength range of 500 nm-700 nm, the actual reflection factor extends to the wavelength range of 400 nm-500 nm. (2) While magenta is expected to uniformly cover the two independent wavelength ranges of 400-500 nm and 600-700 nm, it actually does not show the expected magnitude of reflection factor in the wavelength range of 400-500 nm. (3) While cyan is expected to uniformly cover the wavelength range of 400-600 nm, it has a triangle peak around the wavelength range slightly shorter than 500 nm, although it scarcely covers the entire expected wavelength range.
In accordance with the subtractive color mixing process, which is used in the technology for reproducing colored patterns to be made by utilizing photosensitive emulsion or material, the photosensitive layer exposed to blueviolet is developed by superposition of cyan and magenta, the layer exposed to green is developed by superposition of cyan and yellow, and the layer exposed to red is developed by superposition of magenta and yellow.
FIG. 3 is the human relative luminosity curve. Referring to the figure, the magnitude or sensitivity of the human sense of sight varies depending on the wavelength of light to be seen and has a wide dispersion, ranging from 450 nm to 650 nm and centering around 550 nm. A certain intensity of light thus gives the human sense of sight a different magnitude of impression, depending on the range of wavelength of the light. Light with a wavelength close to 550 nm is thus sensed more strongly than light with a wavelength close to 400-450 nm or 650-700 nm. Also, it is seen that the human sense of sight is marginal in the wavelength ranges of 400-450 nm and 650-700 nm.
If a pattern is represented with a kind of coloring matter whose spectral reflection is limited to the wavelength range close to 700 nm, it can scarcely be seen or recognized as a color by humans because the reflection of such coloring matter can not stimulate the human eye. However, if the photosensitive emulsions or materials having the sensitivity as shown in FIG. 1 are employed, when the subtractive color mixing process is applied to reproduction of a pattern represented with the aforementioned kind of coloring matter, the reproduction will be represented by superposition of yellow and magenta both of which may be developed with the same magnitude. Therefore, the reproduction will have a special reflection factor diagram having a shape in which a large and flat peak is observed in the wavelength range of 600-700 nm on top of another flat zone observed in the wavelength range of 500-600 nm. Since the human relative luminosity curve shows marginal sensitivity in the wavelength range beyond 650 nm, the human sense of sight will be more stimulated by the wavelength range of 600-650 nm. This means the reproduction is seen as red. Here, it is noted that all of the monochromatic lights recognized within the wavelength range of 600-700 nm are represented as a compound light having the wavelength range entirely covering 600-700 nm. This color changing phenomenon is true also for the blueviolet range with the wavelength range of 400-500 nm and for the green range with the wavelength range of 500-600 nm.
This color changing effect is caused, since (1) the spectral reflection characteristic of a reproduction, produced by the color reproduction process utilizing photosensitive emulsion or material, is considerably different from that of the original color, and since (2) this change in spectral reflection characteristic gives much more influence to the human sense of sight due to the non-linear characteristic thereof. Therefore, this color changing effect is defined as an effect to change color caused by (1) the change in the spectral reflection characteristic for a reproduction of a specific kind of coloring matter having a strong spectral reflection factor in the wavelength range in which the magnitude of the human spectral luminous sensitivity is marginal, which is produced by the color reproduction process utilizing photosensitive emulsion or material having spectral sensitivity in at least one of the wavelength ranges consisting of the human visual range and the adjacent wavelength ranges, and by (2) magnification of the effect to the human sense of sight, because the change takes place in the wavelength range of 400-500 nm or 600-700 nm in which the human relative luminosity curve shows a sharp rise from zero.
A preferable example of the color changing effect will be described below. Referring to FIG. 4 which shows the spectral reflection factor diagram of cobalt blue (hereinafter referred to as (4a)) and the spectral reflection factor diagram of the reproduction of the same (hereinafter referred to as (4b)) produced by means of a Fuji CB color copier, model CB 430, produced by Fuji Photografic Film Co. of Japan. In the figure, the curve (a) represents the spectral reflection factor diagram of the coloring matter (4a) and the curve (b) represents that of the coloring matter (4b). Though curve (a) shows a sharply raised and strong spectral reflection factor range in the wavelength range beyond 650 nm, since the magnitude of the human spectral luminous efficacy is marginal in the wavelength range, the human sense of sight is stimulated only by the other strong spectral reflection factor range in the wavelength range of 400-500 nm, particularly by the wavelength range of 450-500 nm in which the human sense of sight has a rather strong sensitivity. As a result, coloring matter (4a) is seen as blue. However, curve (b) shows a considerably different characteristic, in which the spectral reflection factor in the wavelength range of 550-650 nm was increased. Therefore, coloring matter (4b) was changed in color and it is not seen as blue. As a result, an object colored with a kind of coloring matter having this color changing effect does not allow the color reproduction processes to be made by utilizing photosensitive emulsion or material to produce a reproduction having a color similar to that of the original.
The principle of this color changing effect will be described below, referring to a more preferable example. FIG. 5 compares the spectral reflection factors of a kind of coloring matter, produced by kneading one part cobalt blue with one part disazo compound yellow (hereinafter referred to as (A)), and of chromium oxide (hereinafter referred to as (B)). Referring to FIG. 5, curves A and B respectively represent the spectral reflection factor curves of the coloring matters (A) and (B). Within the wavelength range of 400-650 nm, both kinds of coloring matter show the same tendency in the spectral reflection characteristics. However, in the wavelength range beyond 650 nm, coloring matter (A) has a sharply raised strong spectral reflection factor range. Despite this, coloring matter (B) has a rather weak spectral reflection factor range. Since the magnitude of the human spectral luminous efficacy is marginal in the wavelength range in which the difference is observed for the spectral reflection characteristics, the human sense of sight can not distinguish one of these kinds of coloring matter from the other. As a result, when exposed to white light, the combined kinds of coloring matter (A) produce reflections similar to that of coloring matter (B), and both of them are seen as blue green. The reproductions of these kinds of coloring matter (A) and (B), however, produced by means of a Fuji CB color copier, model CB 430, give the spectral reflection factor diagram shown in FIG. 6. The figure is interpreted as follows. As to curve A'; (1) the sharply raised strong spectral reflection factor range disappears from below the wavelength range close to 512 nm and beyond 660 nm, (2) a strong spectral reflection factor range appeared in the wavelength range of 600-700 nm, (3) the magnitude of the spectral reflection factor increased in the wavelength range of 500-600 nm and (4) the variation in the magnitude of spectral reflection factor was moderated. On the other hand, as to curve B', no difference is observed from curve A' in the wavelength range of 400-530 nm, (2) no notable change was made for the wavelength range of 600-700 nm. As a result, the effect of the color reproduction process toward coloring matter (B) is not substantial and is limited to the chroma, causing no change in color. However, the effect of the same color reproduction process toward coloring matter (A) is considerably large, resulting in a change in color from blue to yellow or dark red.
Based on the principle of the subtractive color mixing process, the reasons why the same process caused different effects depending on the kinds of coloring matter applied thereto are considered as follows: (1) Although a spectral reflection factor range which is sharp in rise, high in value and wide in the width of the wavelength range exists in the less visible wavelength range beyond 650 nm, the human sense of sight can not recognize the reflection from this wavelength range. (2) The colors of both coloring matters (A) and (B) are determined by the reflection from the wavelength range close to 512 nm, and both are seen as the same color. (3) Due to the effects caused by the subtractive color mixing process, the reproduction of coloring matter (A) gained a strong and broad spectral reflection range in the wavelength range of 600-700 nm. (4) Out of the wavelength ranges of 600-700 nm, the wavelength range of 600-650 nm in which the magnitude of the human spectral luminous efficacy is large determined the color of the reproduction.
Gray is also considered to have a considerable magnitude of the color changing effect. In other words, when a spectral reflection factor diagram shows a flat curve along the entire wavelength range, excepting the wavelength range in which the human spectral luminous efficacy is marginal, the corresponding coloring matter is seen as gray. However, if the spectral reflection factor diagram shows a notable spectral reflection factor in at least one of the wavelength ranges of 650-700 nm and 400-450 nm, the reproduction of the coloring matter made by utilizing photosensitive emulsion is seen in red or in blue.
Three independent groups of coloring matter are included in the coloring matter having the color changing effect to which this invention is directed. The required characteristic of the first group is that (1) a notable spectral reflection range exists in the wavelength range of 400-450 nm preferably 420-450 nm and/or 650-700 nm preferably 650-680 nm, (2) the notable spectral reflection range supplies sufficient quantity of light to the photosensitive materials employed for the color reproduction process, (3) the magnitude of the notable spectral reflection factor is large and the difference between the magnitude and that of the wavelength slightly longer than 450 nm or slightly shorter than 650 nm is 30% or more, preferably 40% or more, and (4) the value of the spectral reflection factor at the wavelength slightly longer than 450 nm or slightly shorter than 650 nm is 40% or less, preferably 30% or less. The required characteristic of the second group is that, in addition to the three items specified for the first group, the value of the spectral reflection factor is approximately uniform for the entire wavelength range, excepting the wavelength range shorter than 450 nm or longer than 650 nm. This means the coloring matter is seen in gray by men. The required characteristic of the third group is that, in addition to the three items specified for the first group, the coloring matter has one or more sharply risen highly peaked spectral reflection range to determine the color of the coloring matter at some wavelength range within the wavelength range of 450-650 nm. This means the color of such coloring matter is either blue, green, violet, or some others.
Included in the coloring matter having the color changing effect to which this invention is directed are some kinds of inorganic pigment, some kinds of dye for cotton and some kinds of dye for polyester. More specifically, in addition to the coloring matter produced by kneading disazo compound yellow and cobalt blue referred to in the above, included are cobalt blue light, cobalt blue deep, deep cobalt violet, peacock blue A, carbazole violet, chromophthal violet B (Ciba Geigy make), and the like.
Completely no restrictions are imposed for the process to represent colored patterns on an object to implement this invention. In other words, any process for representation of colored patterns is acceptable. In addition to hand writing, any type of color representation process including letter press printing process, lithographic printing process, intaglio printing process and the like is acceptable. Further, no restrictions are imposed for the quality of the document or object to be represented by the colored patterns. In other words, any kind of object is acceptable, including paper, metal, wood, cloth, synthetic resin, and the like, and all are termed a document for convenience.
When two kinds of coloring matter, referred to in the explanation made referring to FIGS. 5 and 6, are used for production of a hidden mark, a remarkable effect can be expected for prevention of forgery. In other words, when a pattern represented with a kind of coloring matter having the color changing effect is surrounded by the other kind of coloring matter which is seen in the same color as the above and which does not have the color changing effect, the pattern becomes visible on a reproduction made by utilizing photosensitive emulsions or materials, though it can not be distinguished from the surrounding background on the original. In this case, when the difference in the magnitude of the reflection factor between the pattern and the background is 30% or more, preferably 40% or more, on the reproduction, a notable effect can be expected.
A preferred embodiment and example of the invention is shown below:
A pattern reading "This is a copy" was placed on a piece of fine quality paper with a kind of coloring matter which is a mixed composite containing one part of cobalt blue and one part of disazo compound yellow and which has a spectral reflection characteristic shown in FIG. 5(A). The space surrounding the above pattern was filled with another kind of coloring matter which is a mixture composite containing chromium oxide and which has a reflection factor characteristic shown in FIG. 5(B). Though the human sense of sight can not distinguish the pattern from the background, the photograph taken with KODAK EKTACHROME 64 Professional Film made by Eastman Kodak Co. of the U.S.A. presented the pattern reading "This is a copy" in red green on the background in green. A reproduction of the same by means of a Fuji CB color copier made by Fuji Photographic Film Co. of Japan also presented a similar pattern. The reflection factors of the coloring matter (A) in the wavelengths of 650 nm, 680 nm and 700 nm are, respectively, 30%, 80% and 90%. The reflection factors of the coloring matter (B) in the wavelengths of 650 nm, 680 nm and 700 nm are, respectively, 22%, 20% and 19%.
In conclusion, according to this invention, disadvantages pointed out above involved with the prior art, are removed. An object representing patterns thereon in accordance with this invention does not allow the color reproduction process to be made by utilizing photosensitive emulsion or material to make reproduction thereof in a color accurately resembling that of the original. The object is thus possibly utilized as an object whose reproduction is undesirable. An object representing patterns thereon in accordance with this invention allows non-professional personnel to distinguish a reproduction produced by utilizing photosensitive emulsion, from the original resulting in an effect to discourage a potential forger to try and circulate the forgery in the market place and in another effect not to allow the forgery to circulate in the market place. An object representing patterns thereon in accordance with this invention is possible to be produced without using any particular plates or blocks for printing purpose or any particular printing process, resulting in a reduction of cost for prevention of forgery of articles whose reproduction is undesirable.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A method of preventing color accurate reproduction of a colored pattern with color photocopiers or color photography using photosensitive materials having spectral sensitivity in the wavelength ranges consisting of the human visible range and the adjacent wavelength ranges thereto, comprising, forming at least portion of the colored pattern with a color material having a spectral reflection factor curve with high spectral reflection in at least one of the areas of wavelength below 450 nm and above 650 nm so that a reproduction of the colored pattern is in a color not perceivable by a direct human viewer of the colored pattern. The color material also has at least one high spectral reflection peak or area within the human visible wavelength range so that the perceived color of the colored pattern is different from a reproduced color using color photocopiers or photography. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of PCT International patent application serial no. PCT/CN2012/087851, filed Dec. 28, 2012, hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Adenosine is known to be an endogenous modulator of a number of physiological functions. At the cardiovascular system level, adenosine is a strong vasodilator and a cardiac depressor. On the central nervous system, adenosine induces sedative, anxiolytic and antiepileptic effects. On the respiratory system, adenosine induces bronchoconstriction. At the kidney level, it exerts a biphasic action, inducing vasoconstriction at low concentrations and vasodilation at high doses. Adenosine acts as a lipolysis inhibitor on fat cells and as an anti-aggregant on platelets.
[0003] Adenosine action is mediated by the interaction with different membrane specific receptors that belong to the family of receptors coupled with G proteins. Biochemical and pharmacological studies, together with advances in molecular biology, have allowed the identification of at least four subtypes of adenosine receptors: A 1 , A 2A , A 2b and A 3 . A 1 and A 3 are high-affinity, inhibiting the activity of the enzyme adenylate cyclase, and A 2A and A 2b are low-affinity, stimulating the activity of the same enzyme.
[0004] Analogs of adenosine able to interact as antagonists with the A 1 , A 2A , A 2b and A 3 receptors have also been identified. Selective antagonists for the A 2A receptor are of pharmacological interest because of their reduced level of side effects. In the central nervous system, A 2A antagonists can have antidepressant properties and stimulate cognitive functions. Moreover, data has shown that A 2A receptors are present in high density in the basal ganglia, known to be important in the control of movement. Hence, A 2A antagonists can improve motor impairment due to neurodegenerative diseases, for example, Parkinson's disease, senile dementia as in Alzheimer's disease, and psychoses of organic origin.
[0005] Some xanthine-related compounds have been found to be A 1 receptor selective antagonists, and xanthine and non-xanthine compounds have been found to have high A 2A affinity with varying degrees of A 2A vs. A 1 selectivity. Triazolo-pyrimidine adenosine A 2A receptor antagonists with different substitution at the 7-position have been disclosed previously, for example in WO 95/01356; U.S. Pat. No. 5,565,460; WO 97/05138; and WO 98/52568.
[0006] Parkinson's disease is characterized by progressive degeneration of the nigrostriatal dopaminergic pathway. The subsequent reduction in striatal dopamine levels is responsible for motor symptoms associated with Parkinson's disease, e.g., the loss of fine motor control or motor impairment manifested in those suffering from the disease. Current methodologies for alleviating motor symptoms associated with Parkinson's disease seek to replace dopamine either within the presynaptic terminal, for example, by administration of L-Dopa, directly through stimulation of the postsynaptic D 2 receptors, or by inhibiting metabolism, for example, by administration of monoamine oxidase type B (MAO-B) or catechol-O-methyltransferase (COMT). Long term use of such therapies is often associated with adverse events. For example, long term therapy with L-Dopa (currently the standard of care) is often associated with adverse events (e.g. motor complications), for example, “wearing-off”, “random on-off” oscillations, or dyskinesia. These motor complications arising from therapy administered to manage Parkinson's disease often become progressively more severe with continued treatment.
[0007] As mentioned above, A 2A receptors are present in high density in the basal ganglia and are known to be important in the control of fine motor movement. Highly selective A 2A antagonists have demonstrated their efficacy in reducing motor symptoms associated with neurodegenerative diseases. Accordingly, compounds that are A 2A receptor antagonists are believed to be useful in alleviating motor symptoms associated with Parkinson's disease. For example, U.S. Pat. No. 6,630,475 to Neustadt et al. (the '475 patent) describes the preparation of the compound of Formula PI:
[0000]
[0008] In the '475 patent, example Schemes 1 to 5, along with preparative Schemes 1 to 4, show general methods of preparing compounds of Formula PI. The '475 patent also describes that the compound of Formula I can be prepared as a pharmaceutically acceptable salt that may be useful for treating Parkinson's disease.
[0009] The use of A 2A receptor antagonists in the treatment of central nervous system diseases, in particular Parkinson's disease, and pharmaceutical compositions comprising said compounds, has elevated the need for potent, moderately lipophilic, brain penetrant inhibitors of the A 2A receptor. Such compounds would provide an expansion of the arsenal of compounds that are believed to have value in the treatment of central nervous system disorders, in particular treating or managing the progression of such diseases, for example, but not limited to, Parkinson's disease.
SUMMARY OF THE INVENTION
[0010] In one aspect, the invention provides one or more compounds, or a pharmaceutical salt thereof, believed to have utility as an A 2A -receptor antagonist that have the structure:
[0000]
[0011] wherein:
m and n are independently an integer of from 1 to 3, with the proviso that no more than two R G2a substituents are located on adjacent ring carbon atoms; R G2a is independently: (i) —OH; (ii) —CN; (iii) halogen (preferably —Cl or —F); (iv) —C 1-6 -linear alkyl, which is optionally substituted by one or more fluorine substituents, and preferably when fluorine-substituted, is —CF 3 ; or (v) —C 1-6 -alkoxy, which is optionally substituted by a C 1-4 -alkoxy moiety, and preferably when so substituted the alkoxy substitutent is —O—CH 3 , and in some embodiments where R G2a is an alkoxy-substituted-alkoxy moiety, preferably it is —O—(CH 2 ) 1-4 —OCH 3 ; R G4 and R G5 are:
(a) independently, for each occurrence, (i) —H; (ii) —F; or (iii) —C 1-6 -alkyl (linear, branched or cyclic), which is optionally substituted with one or more fluorine substituents; or, (b) R G4 and R G5 are taken together to form a carbonyl [—C(O)—] moiety, with the proviso that where in >1, R G4 and R G5 are not selected to form two adjacent carbonyl moieties; and,
[0017] M G1 is a moiety of the formula:
[0000]
[0018] wherein substituents R a1 , R a2 , R a3 , R a4 , R a5 , and R a6 , are defined as follows:
(a) R a6 is —H or —CH 3 ; and R a1 , R a2 , R a3 , R a4 and R a5 are independently:
(i) —H; (ii) an aromatic moiety of from 6 to 10 carbon atoms; or, (iii) —C 1-5 linear, branched or cyclic alkyl, which is optionally substituted with one or more of —F or —C 1-4 -alkyl substituents, wherein one or more carbon atoms in said optional C 1-4 -alkyl substituent is optionally substituted with one or more —F atoms; or,
(b) R a1 , R a2 , R a1 , and R a4 are independently: —H, —C 1-5 linear, —C 3-5 -branched or —C 3-5 -cyclic alkyl; and R a5 and R a6 together form a bridge of the formula: —CH 2 ) q —, providing a moiety of the structure:
[0000]
[0000] where “q” is 1 or 2, wherein q is 1 or 2;
(c) one pair of R a1 /R a2 or R a3 /R a4 together form an oxo-functional group, and each substituent of the other pair is hydrogen, providing a structure of Formula Ga 1 or Formula Ga 2 :
[0000]
(d) each of one pair of R a1 /R a2 or R a3 /R a4 is —H, and the other pair together comprise up to five carbon atoms which are cyclized, thereby providing a spirocycle of Formula Fb 3 or Formula Fb 4 :
[0000]
wherein p is an integer from 1 to 3; or,
R a1 , R a2 , R a3 , R a4 , R a5 , and R a6 are selected to provide an ethylene-bridged moiety of the formula:
[0000]
[0000] wherein:
(i) R a6 together with one of R a3 or R a4 form an ethylene bridge and any of R a1 , R a2 R a3 , R a4 , or R a5 , which are not part of said ethylene bridge are hydrogen; (ii) R a5 together with one of R a1 or R a2 form an ethylene bridge and any of R a1 , R a2 R a3 , R a4 , or R a6 which are not part of said ethylene bridge are hydrogen; or (iii) R a6 together with one of R a3 or R a4 , and R a5 together with one of R a1 or R a2 each form ethylene bridge, and any of R a1 , R a2 , R a3 , or R a4 which are not selected to form an ethylene bridge are hydrogen; and
[0029] R b2 is:
(a) —C 1-6 -alkyl, which is optionally substituted on one or more carbon atoms with: (i) halogen; (ii) C 1-6 -alkoxy; or (iii) C 1-6 -alkyl-SO 2 —; (b) —C(O)—R d , wherein, R d is: (i) aryl; (ii) C 1-6 -alkoxy; or (iii) C 1-6 -alkyl; (c) a mono- or polycyclic aryl moiety comprising from 5 to 10 carbon atoms which is optionally linked to a nitrogen of the piperazine moiety through a carbonyl carbon, thereby forming an amide linkage, and wherein the ring of said aryl moiety optionally comprises one or more substituents which are, independently:
(i) halogen, preferably F or Cl; (ii) C 1-6 -alkyl, which is optionally halogen substituted, and in some embodiments when substituted by halogen, preferably it is —CF 3 ; (iii) C 1-6 -alkoxy, preferably methoxy; (iv) C 1-6 -alkoxy-C 1-6 -alkoxide; (v) aryloxy of from 6 to 10 carbon atoms; (vi) C 1-6 -heterocycloalkyl comprising from 1 to 3 heteroatoms that are, independently for each occurrence, N, S, or O, wherein in some embodiments a -pyrrolidinyl moiety is preferable, and wherein said heterocycloalkyl may optionally include a carbonyl group (C═O), and wherein in some embodiments where said heterocycloalkyl comprises a carbonyl group, it is preferably a -pyrolidin-oneyl moiety; (vii) (R d1 ) 2 N—, wherein R d1 is independently —H or —C 1-6 -alkyl; (viii) nitrile; (ix) mono- or polycyclic heteroaryl of from 5 to 10 carbon atoms, comprising from 1 to 4 heteroatoms that are, independently for each occurrence, N, O, or S; or (x) —C(O)—OH; or,
(d) a mono- or polycyclic heteroaryl moiety comprising from 5 to 10 carbon atoms and from 1 to 4 heteroatoms that are, independently for each occurrence, N, O, or S, which is optionally linked to the nitrogen of the piperazine moiety through a carbonyl carbon, thereby forming an amide linkage, and wherein optionally one or more ring carbon atoms is substituted with a moiety that is, independently for each occurrence:
(i) -halogen; (ii) —C 1-6 -alkyl-sulfonyl; (iii) —C 1-6 -alkyl, which is optionally substituted with one or more substituents that are, independently for each occurrence, halogen or C 1-6 -alkoxide; (iv) —C 1-6 -alkoxide, which is optionally substituted with one or more substituents that are, independently for each occurrence, halogen or —C 1-6 -alkyl; (v) C 1-6 —C(O)—; (vi) —CN; or, (vii) C 1-6 C(O)O—.
[0051] In some embodiments a compound Formula A preferably has the structure of Formula AI, or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein:
[0052] n, M G1 , R G4 and R G5 are as defined for the compound of Formula A;
[0053] R G2 is independently:
(i) —OH; (ii) —CN; (iii) halogen (preferably —Cl or —F); (iv) —C 1-3 -linear alkyl, which is optionally substituted by one or more fluorine substituents, and preferably when fluorine substituted is —CF 3 ; or, (v) —C 1-6 -alkoxy, which is optionally substituted by a C 1-4 -alkoxy moiety, and preferably when so substituted the alkoxy substitutent is —O—CH 3 , and in some embodiments where R G2 is an alkoxy-substituted-alkoxy moiety, preferably it is —O—(CH 2 ) 1-4 —OCH 3 ; and,
[0059] R G3 is —H or —F.
[0060] In some aspects, the present invention is the provision of a pharmaceutical formulation comprising at least one compound of Formula A or a pharmaceutically acceptable salt thereof and at least one excipient. In another aspect the invention is directed to the use of compounds, and pharmaceutical formulations thereof, in the potential treatment of movement disorders in which A 2A receptors are involved.
[0061] In some aspects, the present invention is the provision of a method of treating central nervous system disorders by administering to a patient in need thereof a therapeutic amount of at least one compound of Formula A or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0062] As mentioned above, one aspect the invention provides one or more compounds believed to have utility as an A 2A -receptor antagonist that has the structure of Formula A or a pharmaceutically acceptable salt thereof:
[0000]
[0063] wherein n, m, M G1 , R G2A , R G4 and R G5 are as defined above.
[0064] In some embodiments, compounds of Formula A preferably have the structure of Formula B or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein:
[0065] R G3 is —F or —H;
[0066] R G4 and R G5 are independently for each occurrence: —H; C 1-6 -alkyl; or C 1-6 -alkoxy; or R G4 and
[0067] R G5 together with the carbon to which they are bonded represent a carbonyl moiety (—C(O)—);
[0068] R a1 , R a2 , R a3 , R a4 and R a5 are independently: —H; aryl; or C 1-5 -alkyl; and,
[0069] R b2 is:
(a) —C 1-6 -alkyl, which is optionally substituted on one or more carbon atoms with: (i) halogen; (ii) C 1-6 -alkoxy; or (iii) C 1-6 -alkyl-SO 2 —; (b) —C(O)—R c1 , wherein R d is: (i) aryl; (ii) C 1-6 -alkoxy; or (iii) C 1-6 -alkyl; (c) a mono- or polycyclic aryl moiety comprising from 5 to 10 carbon atoms that is optionally linked to the nitrogen of the piperazine moiety through a carbonyl carbon, thereby forming an amide linkage, and wherein one or more ring carbon atoms is optionally substituted with a moiety that is, independently for each occurrence:
(i) halogen, preferably F or Cl; (ii) C 1-6 -alkyl, which is optionally halogen substituted, and in some embodiments when substituted by halogen, preferably it is —CF 3 ; (iii) —C 1-6 -alkoxy, preferably methoxy; (iv) —C 1-6 -alkoxy-C 1-6 -alkoxide; (v) aryloxy of from 6 to 10 carbon atoms; (vi) C 1-6 -heterocycloalkyl comprising from 1 to 3 heteroatoms that are, independently for each occurrence, N, S or O, wherein in some embodiments the heterocycloalkyl is preferably a -pyrrolidinyl moiety, and wherein said heterocycloalkyl may optionally include a carbonyl group (C═O), and wherein in some embodiments where said heterocycloalkyl comprises a carbonyl group, it is preferably a -pyrolidin-oneyl moiety; (vii) (R d1 ) 2 N—, wherein R d1 is independently —H or —C 1-6 -alkyl; (viii) nitrile; (ix) mono- or polycyclic heteroaryl of from 5 to 10 carbon atoms comprising from 1 to 4 heteroatoms that are, independently for each occurrence, N, O or S; or, (x) —C(O)—OH; or
(d) a mono- or polycyclic heteroaryl moiety comprising from 5 to 10 carbon atoms and from 1 to 4 heteroatoms that are, independently for each occurrence, N, O or S, which is optionally linked to the nitrogen of the piperazine moiety through a carbonyl carbon, thereby forming an amide linkage, and wherein optionally one or more ring carbon atoms is substituted with a moiety that is, independently for each occurrence:
(i) -halogen; (ii) —C 1-6 -alkylsulfonyl; (iii) —C 1-6 -alkyl, which is optionally substituted with one or more substituents that are, independently for each occurrence, halogen or C 1-6 -alkoxide; (iv) —C 1-6 -alkoxide, which is optionally substituted with one or more substituents that are, independently for each occurrence, halogen or —C 1-6 -alkyl; (v) C 1-6 —C(O)—; (vi) —CN; or, (vii) C 1-6 C(O)O—. In some embodiments, compounds of Formula A preferably have the structure of Formula C, or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein q is 1 or 2 and R b2 is:
[0000]
[0092] In some embodiments, compounds of Formula A preferably have the structure of Formula F, or a pharmaceutically acceptable sale thereof:
[0000]
[0000] wherein each substituent of one pair of R a1 /R a2 or R a3 /R a4 is —H, and the other pair together form a cycloalkyl moiety of up to five carbon atoms, thereby providing a spirocycle of Formula Fb 3a or Formula Fb 4a :
[0000]
[0000] wherein p is an integer of from 1 to 4, and R b2 is as defined for compounds of Formula B, above.
[0093] In some embodiments, a compound of the invention is a compound of Formula B, or a pharmaceutically acceptable salt thereof:
[0000]
Formula B
[0094] wherein, R G3 is —H, and R G4 , R G5 , R a1 to R a5 , and R b1 are defined in Table I, below:
[0000]
TABLE I
Example
No.
R a1 /R a2 /R a5
R a3 /R a4
R b2
R G4 /R G5
Ex-1
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-2
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-3
—H/—H
—CH 3
—H/—H
Ex-8
—H/—CH 3 /—H
—CH 3 /—H
—H/—H
Ex-9
—H/—CH 3 /—H
—H/—H
—H/—H
Ex-10
—H/CH 3 /—H
—H/—H
—H/—H
Ex-12
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-13
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-14
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-15
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-16
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-17
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-18
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-19
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-20
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-21
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-22
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-23
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-24
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-25
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-26
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-27
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-28
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-29
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-30
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-31
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-32
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-33
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-34
—H/—CH 3 /—H
—H/—H
—H/—H
Ex-35
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-36
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-38
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-39
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-40
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-43
-cyclopropyl/—H/—H
—H/—H
—H/—H
Ex-44
-isopropyl/—H/—H
—H/—H
—H/—H
Ex-45
—CII 2 CII 3 /—II/—II
—II/—II
—II/—II
Ex-46
—CH 2 CH 3 /—H/—CH 3
—H/—H
—H/—H
Ex-47
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-48
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-49
—CH 3 /—H/—H
—H/—H
—CH 3 /—H
Ex-50
—CH 3 /—H/—H
—H/—H
—H/—CH 3
Ex-51
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-52
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-53
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-54
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-55
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-56
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-57
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-58
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-59
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-60
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-61
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-62
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-63
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-64
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-65
CH 3 /—H/—H
—H/—H
—H/—H
Ex-66
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-67
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-68
CH 3 /—H/—H
—H/—H
—H/—H
Ex-69
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-70
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-71
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-72
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-73
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-74
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-75
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-76
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-77
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-78
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-79
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-80
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-81
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-82
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-83
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-84
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-85
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-86
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-87
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-88
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-89
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-90
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-91
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-92
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-93
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-94
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-95
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-96
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-97
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-98
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-99
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-100
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-101
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-102
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-103
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-104
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-105
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-106
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-107
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-108
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-109
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-110
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-111
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-112
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-113
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-114
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-115
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-116
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-117
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-118
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-119
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-120
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-121
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-122
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-123
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-124
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-125
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-126
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-127
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-128
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-129
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-130
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-131
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-132
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-133
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-134
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-135
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-136
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-137
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-138
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-139
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-140
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-141
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-142
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-143
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-144
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-145
—CH 3 /—H 3 /—H
—H/—H
—H/—H
Ex-146
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-147
—CH 3 /—H/—H
—H/—H
F 3 C—H 2 C--
R G4 and R G5
together form
—(C═O)—
Ex-148
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-149
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-150
—CH 3 /—H/—CH 3
—H/—H
—H/—H
Ex-151
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-152
—CH 3 /—H/—H
—H/—H
—H/—H
Ex-180
—H/—H/—H
—CH 3 /—CH 3
—H/—H
Ex-181
—H/—H/—H
—H/—CH 3
—H/—H
Ex-182
—H/—H/—H
—H/—CH 3
—H/—H
Ex-183
—CH 3 /—CH 3 /—H
—H/—H
—H/—H
Ex-187
—H/—H/—H
—CH 3 /—CH 3
—H/—H
Ex-198
—H/—H/—H
—CH 3 /—H
—H/—H
Ex-199
—CH 3 /—CH 3 /—H
—H/—H
—H/—H
Ex-200
—CH 3 /—CH 3 /—H
—H/—H
—H/—H
Ex-201
—CH 3 /—H/—CH 3
—H/—H
—H/—H
Ex-202
—CH 3 /—CH 3 /—H
—H/—H
—H/—H
[0095] In some embodiments, a compound of the invention is a compound of Formula B, or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R G3 is —F, R a5 is —H, and the R G4 , R G5 , R a1 to R a4 , and R b2 are defined in Table II, below:
[0000]
TABLE II
Ex-
ample
No.
R a1 /R a2
R a3 /R a4
R b2
R G4 /R G5
Ex-11
—CH 3 / —H
—H/ —H
—H/—H
Ex-37
—H/ —CH 3
—H/ —H
—H/—H
Ex-41
—CH 3 / —H
—H/ —H
—H/—H
Ex-42
—CH 3 / —H
—H/ —H
—H/—H
Ex-178
—H/—H
—H/ —CH 3
—H/—H
Ex-184
—H/—H
—CH 3 / —CH 3
—H/—H
Ex-185
—H/—H
—CH 3 / —CH 3
—H/—H
Ex-186
—H/—H
—CH 3 / —CH 3
—H/—H
[0096] In some embodiments, a compound of the invention is a compound of Formula E, or a pharmaceutically acceptable salt thereof:
[0000]
[0097] wherein R b2 and R G3 are defined in Table III, below:
[0000]
TABLE III
Example
No.
R b2
R G3
Ex-210
—H
Ex-209
—H
Ex-211
—F
[0098] In some embodiments, the compounds of Formula A have the structure of Formula F, or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein each substituent of one pair of R a1 /R a2 or R a3 /R a4 is —H, and the other pair together form a spirocyclpropyl moiety, in accordance with the definition of R a1 to R a4 and R b2 presented in Table IV below:
[0000]
TABLE IV
Ex-
ample
No.
R a1 /R a2
R a3 /R a4
R b2
Ex-188
spirocyclo- propyl
—H/—H
Ex-189
spirocyclo- propyl
—H/—H
Ex-190
spirocyclo- propyl
—H/—H
Ex-191
spirocyclo- propyl
—H/—H
Ex-192
spirocyclo-
—H/—H
FCH 2 —CH 2 —
propyl
Ex-193
spirocyclo-
—H/—H
H 3 C—O—(CH 2 ) 2 —
propyl
Ex-194
spirocyclo- propyl
—H/—H
Ex-195
—H/—H
spiro- cyclo- propyl
Ex-196
spirocyclo-
—H/—H
F 3 C—(CH 2 ) 2 —
propyl
[0099] In some embodiments, compounds of the invention have the structure of Formula G, or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R b2 is —H (Ex-208); a 1-(4-fluorophenyl)-methanone substituent (Ex-204); a 1-(4-trifluoromethylphenyl)-methanone substituent (Ex-203), or a 2-[5-(trifluoromethyl)pyridinyl]-substituent (Ex-205).
[0100] In some embodiments, compounds of the invention preferably have the structure of Formula CC4a:
[0000]
[0000] or a salt thereof,
wherein R e is:
[0000]
[0101] In some embodiments, compounds of the invention preferably have the structure of Formula CC5a:
[0000]
[0000] or a salt thereof,
where “R f ” is:
[0000]
[0102] In some embodiments, compounds of the invention have the structure of Formula H, or a pharmaceutically acceptable salt thereof:
[0000]
[0103] In some embodiments, compounds of the invention have the structure of the Formula Ja or Formula Jb, or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R G3b is —H or —F; and R b2 is a mono- or polycyclic aryl moiety comprising from 5 to 10 carbon atoms, which is optionally linked to the nitrogen of the piperazine moiety through a carbonyl carbon, thereby forming an amide linkage, and wherein one or more ring carbon atoms thereof is optionally substituted with a moiety that is, independently for each occurrence:
(i) halogen, preferably F or Cl; (ii) C 1-6 -alkyl, which is optionally halogen substituted, and in such optional embodiments the halogen-substituted alkyl is preferably —CF 3 ; (iii) C 1-6 -alkoxy, preferably methoxy; (iv) C 1-6 -alkoxy-C 1-6 -alkoxide; (v) aryloxy of from 6 to 10 carbon atoms; (vi) C 1-6 -heterocycloalkyl comprising from 1 to 3 heteroatoms that are, independently for each occurrence, N, S or O, wherein in some embodiments the heterocycloalkyl it is preferably a -pyrrolidinyl moiety, and wherein said heterocycloalkyl may optionally include a carbonyl group (C═O), and wherein in some embodiments where said heterocycloalkyl comprises a carbonyl group, it is preferably a -pyrolidin-oneyl moiety; (vii) (R d1 ) 2 N—, wherein R d1 is independently —H or —C 1-6 -alkyl; (viii) nitrile; (ix) mono- or polycyclic heteroaryl of from 5 to 10 carbon atoms, comprising from 1 to 4 heteroatoms that are, independently for each occurrence, N, O or S; or, (x) —C(O)—OH.
[0114] In some embodiments, preferably compounds of the invention have the structural formula shown the Examples herein.
[0115] As described herein, unless otherwise indicated, the use of a compound in treatment means that an amount of the compound, generally presented as a component of a formulation that comprises other excipients, is administered in aliquots of an amount, and at time intervals, which provides and maintains at least a therapeutic serum level of at least one pharmaceutically active form of the compound over the time interval between dose administration.
[0116] Absolute stereochemistry is illustrated by the use of hashed and solid wedge bonds. As shown in Illus-I and Illus-II. Accordingly, the methyl group of Illus-I is emerging from the page of the paper and the ethyl group in Illus-II is descending into the page, where the cyclohexene ring resides within the plane of the paper. It is assumed that the hydrogen on the same carbon as the methyl group of Illus-I desends into the page, and the hydrogen on the same carbon as the ethyl group of Illus-II emerges from the page. The convention is the same where both a hashed and a solid rectangle are appended to the same carbon, as in Illus-III. he In Illus-III, the methyl group is emerging from the plane of the paper, the ethyl group is descending into the plane of the paper, and the cyclohexene ring is in the plane of the paper.
[0000]
[0117] As is conventional, ordinary “stick” bonds or “wavy” bonds are used where there is a mixture of possible isomers present, including a racemic mixture of possible isomers.
[0118] As used herein, unless otherwise specified, the following terms have the following meanings.
[0119] The phrase “at least one” used in reference to the number of components comprising a composition, for example, “at least one pharmaceutical excipient,” means that one member of the specified group is present in the composition, and more than one may additionally be present. Components of a composition are typically aliquots of isolated pure material added to the composition, where the purity level of the isolated material added into the composition is the normally accepted purity level of a substance appropriate for pharmaceutical use.
[0120] The phrase “at least one” used in reference to substituents on a compound or moiety appended to the core structure of a compound means that one substituent of the group of substituents specified is present, and more than one substituent may be bonded to chemically accessible bonding points of the core.
[0121] The phrase “one or more” means the same as “at least one,” whether used in reference to a substituent on a compound or a component of a pharmaceutical composition.
[0122] The terms “concurrently” and “contemporaneously” both include in their meaning (1) simultaneously in time (e.g., at the same time); and (2) at different times but within the course of a common treatment schedule.
[0123] The term “consecutively” means one following the other.
[0124] The term “sequentially” refers to a series administration of therapeutic agents that awaits a period of efficacy to transpire between administering each additional agent. Thus, after an effective time period subsequent to the administration of one component, the next component is then administered. The effective time period may be the amount of time given for realization of a benefit from the administration of the first component.
[0125] The phrases “effective amount” or “therapeutically effective amount” is meant to describe the provision of an amount of at least one compound of the invention or of a composition comprising at least one compound of the invention that is effective in treating or inhibiting a disease or condition described herein, and thus produces the desired therapeutic, ameliorative, inhibitory or preventative effect. For example, in treating a movement disorder with one or more of the compounds described herein, “effective amount” (or “therapeutically effective amount”) means, for example, providing the amount of at least one compound of Formula A that results in a therapeutic response in a patient afflicted with a movement disorder (“the condition”), including a response suitable to manage, alleviate, ameliorate or treat the condition; to alleviate, ameliorate, reduce or eradicate one or more symptoms attributed to the condition; and/or long-term stabilization of the condition, for example, as may be determined by the analysis of pharmacodynamic markers or clinical evaluation of patients afflicted with the condition.
[0126] The terms “patient” and “subject” mean an animal, such as a mammal (e.g., a human being), and is preferably a human being.
[0127] The term “prodrug” means compounds that are rapidly transformed, for example, by hydrolysis in blood, in vivo, to the parent compound, e.g., conversion of a prodrug of Formula A to a compound of Formula A, or to a salt thereof; a thorough discussion is provided in T. Higuchi and V. Stella, Pro-drugs as Novel Delivery Systems, Vol. 14 of the A.C.S. Symposium Series, and in Edward B. Roche, ed., Bioreversible Carriers in Drug Design, American Pharmaceutical Association and Pergamon Press, 1987, both of which are incorporated herein by reference. The scope of this invention includes prodrugs of the compounds of this invention.
[0128] The term “solvate” means a physical association of a compound with one or more solvent molecules. This physical association involves varying degrees of ionic and covalent bonding, including hydrogen bonding. In certain instances, a solvate will be capable of isolation, for example, when one or more solvent molecules are incorporated in the crystal lattice of the crystalline solid. The term “solvate” encompasses both solution-phase and isolatable solvates. Non-limiting examples of suitable solvates include ethanolates, methanolates, and the like. A “hydrate” is a solvate wherein the solvent molecule is H 2 O.
[0129] The term “substituted” means that one or more of the enumerated substituents (or, where a list of substituents are not specifically enumerated, the default substituents specified in this “Definitions” section for the particular type of substrate that contains variable substituents) can occupy one or more of the bonding positions on the substrate typically occupied by “—H”, provided that such substitution does not exceed the normal valency rules for the atom in the bonding configuration present in the substrate, and that the substitution ultimately provides a stable compound, e.g., mutually reactive substituents are not present geminal or vicinal to each other, and wherein such a compound is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture. When the text indicates optional substitution of a moiety (e.g. “optionally substituted”), the term means “if present, one or more of the enumerated (or default substituents for the specified substrate) can be present on the substrate in a bonding position normally occupied by a hydrogen atom,” in accordance with the definition of “substituted” presented herein.
[0130] As used herein, unless otherwise specified, the following terms used to describe moieties, whether comprising the entire definition of a variable portion of a structural representation of a compound of the invention or a substituent appended to a variable portion of a structural representation of a group of compounds of the invention, have the following meanings, and unless otherwise specified, the definitions of each term (i.e., moiety or substituent) apply when that term is used individually or as a component of another term (e.g., the definition of aryl is the same for aryl and for the aryl portion of arylalkyl, alkylaryl, arylalkynyl moieties, and the like). Moieties are equivalently described herein by structure, typographical representation or chemical terminology without intending any differentiation in meaning. For example, the chemical term “acyl”, defined below, is equivalently described herein by the term itself, or by typographical representations “R′—(C═O)—” or “R′—C(O)—”, or by the structural representation:
[0000]
[0131] “acyl” means an R′—C(O)—, where R′ is a linear, branched or cyclic alkyl; a linear, branched or cyclic alkenyl; or a linear, branched or cyclic alkynyl moiety, each of which moieties can be substituted; wherein the acyl substituent is bonded through the carbonyl carbon to the substrate of which it is a substituent, or —NH—SO 2 —R′, where —R′ is as previously defined; non-limiting examples of suitable acyl groups include formyl, acetyl, propanoyl, 2-methylpropanoyl, butanoyl and cyclohexanoyl;
[0132] “alkenyl” means an aliphatic hydrocarbon moiety that is not aromatic but includes in its structure at least one constituent of the structure —(R′C═CR′ 2 ) or —(R′C═CR′)—, where R′ is a defined substituent, for example —H or -alkyl; the alkenyl moiety can be incorporated into a linear hydrocarbon chain, or incorporated into a cyclic hydrocarbon chain (termed “cycloalkenyl”) and can comprise further, linear, branched or cyclic substituents depending from the carbon atoms of the chain, preferably the chain comprises about 2 to about 15 carbon atoms; more preferably from about 2 to about 12 carbon atoms; and more preferably chains comprise from about 2 to about 6 carbon atoms;
[0133] the term “substituted alkenyl,” unless specified otherwise by a recitation of specific substituents defining the term, means that the alkenyl group is substituted by one or more substituents that are independently for each occurrence: C 1-10 alkyl, C 3-10 cycloalkyl, and C 1-10 alkoxy;
[0134] “-alkoxy” means a moiety of the structure: alkyl-O— (i.e., the bond to the substrate moiety is through the ether oxygen), wherein the alkyl portion of the moiety is as defined below for alkyl; non-limiting examples of suitable alkoxy groups include methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy and heptoxy;
[0135] “alkoxyalkyl” means a moiety of the structure: alkoxy-alkyl- (i.e., the bond to the substrate moiety is through an alkyl moiety, which is terminated by, or substituted with, an alkoxy substituent that is not itself bonded to the substrate); non-limiting examples of alkoxyalkyl groups include H 3 C—(CH 2 ) y —O—CH 2 —(CH 2 ) x —, wherein “y” and “x” are independently an integer of from 0 to 6;
[0136] “alkoxycarbonyl” means a moiety of the structure alkyl-O—C(O)—, equivalently represented as [alkyl-O—(C═O)—] and also as R—O(C═O)—, where “R” is a defined alkyl moiety (i.e., the bond to the parent moiety is through the carbonyl carbon), wherein the alkyoxy portion of the moiety is as previously defined; non-limiting examples of suitable alkoxycarbonyl groups include methoxycarbonyl and ethoxycarbonyl;
[0137] “-alkyl” (including the alkyl portions of other moieties, such as trifluoromethyl-alkyl- and -alkoxy) means an aliphatic hydrocarbon chain comprising from about 1 to about 20 carbon atoms (that is, “C 1-20 alkyl”), preferably 1 to about 10 carbon atoms (herein “C 1-10 alkyl”), unless the term is modified by an indication that a shorter chain is contemplated, for example, an alkyl moiety of up to 8 carbon atoms (designated herein “C 1-8 -alkyl”); the term “alkyl,” unless specifically limited by another term, for example, “linear,” “branched” or “cyclic,” includes alkyl moieties that are linear (a hydrocarbon chain with no aliphatic hydrocarbon “branches” appended to it); branched (a main hydrocarbon chain comprising up to the maximum specified number of carbon atoms with a lower-alkyl chain appended to one or more carbon atoms comprising, but not terminating, the main hydrocarbon chain); and cyclic (the main hydrocarbon chain forms an cyclic aliphatic moiety of from 3 carbon atoms, the minimum number necessary to provide a cyclic moiety, up to the maximum number of specified carbon atoms), accordingly when unmodified, the term “C 1-X alkyl” refers to linear, branched or cyclic alkyl, and the “C 1-X ” designation means: for a cyclic moiety a ring comprising at minimum 3 carbon atoms up to “X” carbon atoms; for a branched moiety, a main chain of at least 3 carbon atoms up to “X” carbon atoms with at least one linear or branched alkyl moiety bonded to a carbon atom that does not terminate the chain; and for a linear alkyl, a moiety comprising one carbon atom (i.e., -methyl), up to “X” carbon atoms; when the term “alkyl” is modified by “substituted” or “optionally substituted” it means an alkyl group having substituents in accordance with the relevant definitions appearing below; where use of the terms “substituted” or “optionally substituted” modify “alkyl” and substituent moieties are not specifically enumerated, the substituents bonded to the alkyl substrate are independently for each occurrence (in accordance with definitions appearing herein): C 1-20 alkyl; halogen; -alkoxy; —OH; —CN; alkylthio-; amino, —NH(alkyl), —NH(cycloalkyl), —N(alkyl) 2 , —(C═O)—OH; —C(O)O-alkyl; —S(alkyl); or —S(O 2 )-alkyl; or -aryl; cycloalkyl moieties may alternatively, or in addition, be substituted with one or more “ring-system substituents” as that term is defined herein; examples of suitable alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, n-pentyl, heptyl, nonyl, decyl, fluoromethyl, trifluoromethyl and cyclopropylmethyl; where the term “alkyl” is indicated with two hyphens (i.e., “-alkyl-”) it indicates that the alkyl moiety is bonded in a manner that the alkyl moiety connects a substrate with another moiety, for example, “-alkyl-OH” indicates an alkyl moiety connecting a hydroxyl moiety to a substrate;
[0138] “lower alkyl” means a group comprising about 1 to about 6 carbon atoms in the chain (i.e., C 1-6 ); non-limiting examples of suitable lower alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, n-pentyl, and hexyl;
[0139] “alkylaryl” (or alkaryl) means an alkyl-aryl-group (i.e., the bond to the parent moiety is through the aryl group) wherein the alkyl group is unsubstituted or substituted as defined above, and the aryl group is unsubstituted or substituted as defined below; preferred alkylaryl moieties comprise a lower alkyl group; non-limiting examples of suitable alkylaryl groups include o-tolyl, p-tolyl and xylyl;
[0140] in general, as exemplified by the term “alkyl-aryl” defined above, a substituent that is the called out by the combination of terms used to define two other substituent fragments indicates that the substituent called out by the last term used is bonded to the substrate whilst the preceding term called out is bonded in turn to the substituent fragment it precedes, proceeding right to left to understand the order in which the various fragments are bonded to the substrate;
[0141] “alkynyl” means an aliphatic hydrocarbon group (chain) comprising at least one moiety of the structure:
[0000]
[0000] or the structure:
[0000]
[0000] wherein R′ is a defined substituent; the alkynyl moiety can be incorporated into a linear or branched hydrocarbon chain, or incorporated into a cyclic hydrocarbon chain (non-aromatic, termed “cycloalkynyl”); preferably hydrocarbon chains of an alkynyl moiety comprises about 2 to about 15 carbon atoms; more preferably alkynyl groups comprise about 2 to about 12 carbon atoms in the chain; and more preferably about 2 to about 4 carbon atoms in the chain;
[0142] “amino” means an —NR 2 group wherein R is selected independently for each occurrence from —H or alkyl; alkylamino means —NR′ 2 , wherein one R′ is -alkyl and the other is —H or -alkyl selected independently for each occurrence; non-limiting examples of alkylamino moieties are —NH—CH 3 (methylamino-) and —N(CH 3 ) 2 (dimethylamino);
[0143] “ammonium ion” means —N + R 3′ wherein R is independently —H, alkyl, substituted alkyl, or the cationic portion of a dissociated acid capable of producing an ammonium ion from an amine; when not explicitly shown in representations herein the presence of an ammonium ion presumes that a charge-balancing anion is associated with the ammonium ion moiety, which anion is derived from the anionic portion of the acid used to provide said ammonium ion; it will be appreciated that many of the nitrogen atoms present in compounds of the invention can be converted to an ammonium ion thereby providing a salt of the parent compound, which is within the scope of the invention;
[0144] “aryl” (sometimes abbreviated “ar”) means an aromatic monocyclic or multicyclic ring system comprising about 6 to about 14 carbon atoms (denoted herein also as “C 6-14 -aryl”), preferably about 6 to about 10 carbon atoms (“C 6-10 -aryl”); the aryl group can be optionally substituted with one or more independently selected “ring system substituents” (defined below); non-limiting examples of suitable aryl groups include phenyl
[0000]
[0000] which is also abbreviated herein “Ph” for convenience, and naphthyl
[0000]
[0000] wherein bonding can be through any of the carbons in the aromatic ring, and wherein any ring carbon atoms not participating in a bond to the substrate may have bonded to it a substituent other than —H, independently selected in each instance from the list of “ring-system substituents” defined herein, or as defined in each instance where the term is used in conjunction with an enumerated list of substituents;
[0145] “aryloxy” means an aryl-O— group (i.e., the moiety is bonded to a substrate through the ether oxygen), wherein the aryl group is unsubstituted or substituted as defined above; non-limiting examples of suitable aryloxy groups include phenoxy and naphthoxy;
[0146] “aryloxycarbonyl” means an aryl-O—C(O)— group (i.e., the bond to a substrate is through the carbonyl carbon), wherein the aryl group is unsubstituted or substituted as previously defined; non-limiting examples of suitable aryloxycarbonyl groups include phenoxycarbonyl and naphthoxycarbonyl;
[0147] a “carboxylic acid” moiety means a substituent having the formula “—C(O)—OH”, wherein the moiety is bonded to a substrate is through the carbonyl carbon;
[0148] “cycloalkyl,” defined above with the “alkyl” definition, means a non-aromatic mono- or multicyclic ring system comprising about 3 to about 20 carbon atoms that may be substituted as defined herein; the term includes multicyclic cycloalkyls, for example, 1-decalin, norbornyl, adamantyl and the like;
[0149] “halogen” means fluorine, chlorine, bromine or iodine; preferred halogens, unless specified otherwise where the term is used, are fluorine, chlorine and bromine; a substituent which is a halogen atom means —Cl, —Br or —I, and “halo” means fluoro, chloro, bromo or iodo substituents bonded to the moiety defined, for example, “haloalkyl” means an alkyl, as defined above, wherein one or more of the bonding positions on the alkyl moiety typically occupied by hydrogen atoms is instead occupied by a halo group; perhaloalkyl means that all bonding positions not participating in bonding the alkyl substituent to a substrate are occupied by a halogen, for example, perfluoroalkyl, where alkyl is methyl, means —CF 3 ;
[0150] “heteroaryl” means an aromatic monocyclic or multicyclic ring system comprising about 5 to about 14 ring atoms, preferably about 5 to about 10 ring atoms, in which one or more of the ring atoms is an element other than carbon, for example nitrogen, oxygen or sulfur, alone or in combination; preferred heteroaryl moieties comprise 5 ring atoms, for example, thiazole thiadiazole, imidazole, isothiazole, oxazole, oxadiazole, or pyrazole; the “heteroaryl” can be optionally substituted at chemically available ring atoms by one or more independently selected “ring system substituents” (defined below); the prefix aza, azo, oxa, oxo, thia or thio before the heteroaryl root name means that at least a nitrogen, oxygen or sulfur atom, respectively, is present as a ring atom, and in some embodiments 2 or more heteroatoms are present in a ring, for example, a pyrazole or a thiazole moiety; a nitrogen atom of a heteroaryl can be optionally oxidized to the corresponding N-oxide; non-limiting examples of heteroaryl moieties include:
[0000]
[0000] pyrazinyl, thienyl, pyrimidinyl, isoxazolyl, isothiazolyl, thiazolyl, pyrazolyl, furazanyl, pyrrolyl, pyrazolyl, 1,2,4-thiadiazolyl, pyrazinyl, pyridazinyl, quinoxalinyl, phthalazinyl, imidazo[1,2-a]pyridinyl, imidazo[2,1-b]thiazolyl, benzofurazanyl, indolyl, azaindolyl, benzimidazolyl, benzothienyl, quinolinyl, imidazolyl, thienopyridyl, quinazolinyl, thienopyrimidyl, pyrrolopyridyl, imidazopyridyl, isoquinolinyl, benzoazaindolyl, 1,2,4-triazinyl, benzothiazolyl, furopyridine, for example:
[0000]
[0000] and the like (unless otherwise noted, bonded to the substrate through any available atom that results in a stable bonding arrangement);
[0151] “heterocyclyl” (or heterocycloalkyl) means a non-aromatic saturated monocyclic or multicyclic ring system comprising about 3 to about 10 ring atoms, preferably about 5 to about 10 ring atoms, in which one or more of the atoms in the ring system is an element other than carbon, for example nitrogen, oxygen or sulfur, alone or in combination; there are no adjacent oxygen and/or sulfur atoms present in the ring system; preferred heterocyclyl moieties contain about 5 to about 6 ring atoms; the prefix aza, oxa or thia before the heterocyclyl root name means that at least one nitrogen, oxygen or sulfur atom, respectively, is present as a ring atom; the heterocyclyl can be optionally substituted by one or more independently selected “ring system substituents” (defined below); the nitrogen or sulfur atom of the heterocyclyl can be optionally oxidized to the corresponding N-oxide, S-oxide or S,S-dioxide; non-limiting examples of suitable monocyclic heterocyclyl rings include piperidyl, pyrrolidinyl, piperazinyl, morpholinyl -
[0000]
[0000] (where unless otherwise noted the moiety is bonded to the substrate through any of ring carbon atoms C2, C3, C5, or C6), thiomorpholinyl, thiazolidinyl, 1,3-dioxolanyl, 1,4-dioxanyl, tetrahydrofuranyl, tetrahydrothiophenyl, tetrahydrothiopyranyl, and the like;
[0152] “tetrahydropyranyl” moiety means a 6-member cyclic ether of the formula:
[0000]
[0000] where the bond line having an open end in the center of the structure and terminated at the other end with a wavy line indicates that the substituent is bonded to the substrate to which it is attached through any of carbon atoms 1 to 5, and wherein any of the bonding positions on carbons 1 to 5 normally occupied by a hydrogen atom, that is, the bonding positions on carbon atoms 1 to 5 that are not occupied by the bond to the substrate can optionally be occupied by specified or optional substituents;
[0153] “piperidinyl” means:
[0000]
[0154] where the open bond line terminated on one end with a wavy line indicates the ring atom through which the moiety is bonded to the substrate (i.e., any of carbon atoms 2 to 6 (left-hand structure) or the ring nitrogen atom (right-hand structure)), and wherein any of the bonding positions on the nitrogen atom or on carbon atoms 2 to 6 not participating in a bond to the substrate and normally occupied by a hydrogen atom can be bonded to a specified or optional substituent, and wherein R′, if present, is either —H or another specified substituent;
[0155] “pyridinyl” means:
[0000]
[0000] where, the bond-terminated-with-wavy-line indicates that the pyridinyl moiety is bonded to the substrate at any of carbon atoms 2 to 6, and wherein any of the bonding positions on carbons 2 to 6 normally occupied by a hydrogen atom, that is, any position on carbon 2 to 6 that is not the bond to the substrate can optionally be occupied by a specified substituent;
[0156] “quinoline” means:
[0000]
[0000] where the bond-terminated-with-wavy-line indicates that the moiety is bonded to the substrate through any of carbon atoms 2 to 8, and wherein any of the bonding positions on carbon atoms 2 to 8 normally occupied by a hydrogen atom, that is, any bonding positions on carbon atoms 2 to 8 that are not bonded to the substrate can optionally be occupied by one of a list of enumerated substituents;
[0157] for any of the foregoing ring-system moieties, bonding of the moiety through a specific ring carbon atom (or heteroatom) is sometimes described for convenience and “bonded through C—X to C—Y carbon atoms,” where “X” and “Y” are integers referring to the carbon atoms, for example, as numbered in the examples above;
[0158] “hydroxyl moiety” and “hydroxy” means an HO— group; “hydroxyalkyl” means a substituent of the formula: “HO-alkyl-”, wherein the alkyl group is bonded to the substrate and may be substituted or unsubstituted as defined above; preferred hydroxyalkyl moieties comprise a lower alkyl; non-limiting examples of suitable hydroxyalkyl groups include hydroxymethyl and 2-hydroxyethyl; and
[0159] bonding sequence is indicated by hyphens where moieties are represented in text, for example -alkyl, indicates a single bond between a substrate and an alkyl moiety, -alkyl-X, indicates that an alkyl group bonds an “X” substituent to a substrate, and in structural representation, bonding sequence is indicated by a wavy line terminating a bond representation, for example:
[0000]
[0000] indicates that the methylphenyl moiety is bonded to a substrate through a carbon atom ortho to the methyl substituent, while a bond representation terminated with a wavy line and drawn into a structure without any particular indication of a atom to which it is bonded indicates that the moiety may be bonded to a substrate via any of the atoms in the moiety which are available for bonding, for example:
[0000]
[0000] indicates that the naphthalene moiety may be bonded to the substrate through any of carbons 1 to 8.
[0160] Any carbon or heteroatom with unsatisfied valences in the text, schemes, examples, structural formulae and any Tables herein is assumed to have a hydrogen atom or atoms of sufficient number to satisfy the valences.
[0161] The term “pharmaceutical composition” as used herein encompasses both the bulk composition and individual dosage units comprised of more than one (e.g., two) pharmaceutically active agents such as, for example, a compound of the present invention and an additional agent as described herein, along with any pharmaceutically inactive excipients. As will be appreciated by the ordinarily skilled artisan, excipients are any constituent which adapts the composition to a particular route of administration or aids the processing of a composition into a dosage form without itself exerting an active pharmaceutical effect. The bulk composition and each individual dosage unit can contain fixed amounts of the afore-said “more than one pharmaceutically active agents.” The bulk composition is material that has not yet been formed into individual dosage units.
[0162] This invention also includes the compounds of this invention in isolated and purified form obtained by routine techniques. Polymorphic forms of the compounds and pharmaceutically acceptable salts thereof are intended to be included in the present invention. Certain compounds of the invention may exist in different isomeric (e.g., enantiomers, diastereoisomers, atropisomers) forms. The invention contemplates all such isomers both in pure form and in admixture, including racemic mixtures.
[0163] All stereoisomers (for example, geometric isomers, optical isomers and the like) of the present compounds (including prodrugs of compounds of the invention as well as the salts and solvates of the inventive compounds and their prodrugs), such as those which may exist due to asymmetric carbons present in a compound of the invention, and including enantiomeric forms (which may exist even in the absence of asymmetric carbons), rotameric forms, atropisomers, and diastereomeric forms, are contemplated within the scope of this invention. Individual stereoisomers of the compounds of the invention may be isolated in a pure form, for example, substantially free of other isomers, or may be isolated as an admixture of two or more stereoisomers or as a racemate. The chiral centers of the present invention can have the S or R configuration as defined by the IUPAC 1974 Recommendations. The use of the terms “salt,”, “solvate,” “prodrug” and the like, is intended to equally apply to salts, solvates and prodrugs of isolated enantiomers, stereoisomer pairs or groups, rotamers, tautomers, or racemates of the inventive compounds.
[0164] Diasteromeric mixtures can be separated into their individual diastereomers on the basis of their physical chemical differences by methods well known to those skilled in the art, for example, by chiral chromatography and/or fractional crystallization. As is know, enantiomers can also be separated by converting the enantiomeric mixture into a diasteromeric mixture by reaction with an appropriate optically active compound (e.g., chiral auxiliary such as a chiral alcohol or Mosher's acid chloride), separating the diastereomers and converting (e.g., hydrolyzing) the individually isolated diastereomers to the corresponding enantiomers.
[0165] Where the compounds of the invention form salts by known, ordinary methods, these salts are also within the scope of this invention. Reference to a compound of the invention herein is understood to include reference to salts thereof, unless otherwise indicated. The term “salt(s),” as employed herein, denotes acidic salts formed with inorganic and/or organic acids, as well as basic salts formed with inorganic and/or organic bases. In addition, when a compound of the invention contains both a basic moiety, for example, but not limited to, a nitrogen atom, for example, an amine, pyridine or imidazole, and an acidic moiety, for example, but not limited to a carboxylic acid, zwitterions (“inner salts”) may be formed and are included within the term “salt(s)” as used herein. Pharmaceutically acceptable salts (i.e., non-toxic, physiologically acceptable salts) are preferred. Salts of the compounds of the invention may be formed, for example, by reacting a compound of the invention with an amount of acid or base, for example, an equivalent amount, in a medium in which the salt precipitates or in an aqueous medium wherein the product is obtained by lyophilization. Acids (and bases) which are generally considered suitable for the formation of pharmaceutically useful salts from basic (or acidic) pharmaceutical compounds are discussed, for example, by S. Berge et al., Journal of Pharmaceutical Sciences (1977) 66(1) 1-19; P. Gould, International J. of Pharmaceutics (1986) 33 201-217; Anderson et al, The Practice of Medicinal Chemistry (1996), Academic Press, New York; in The Orange Book (Food & Drug Administration, Washington, D.C. on their website); and P. Heinrich Stahl, Camille G. Wermuth (Eds.), Handbook of Pharmaceutical Salts: Properties, Selection, and Use , (2002) Intl. Union of Pure and Applied Chemistry, pp. 330-331. These disclosures are incorporated herein by reference.
[0166] Where it is possible to provide an acid addition salt with a compound, in general, acid addition salts include, but are not limited to, acetates, including trifluoroacetate salts, adipates, alginates, ascorbates, aspartates, benzoates, benzenesulfonates, bisulfates, borates, butyrates, citrates, camphorates, camphorsulfonates, cyclopentanepropionates, digluconates, dodecylsulfates, ethanesulfonates, fumarates, glucoheptanoates, glycerophosphates, hemisulfates, heptanoates, hexanoates, hydrochlorides, hydrobromides, hydroiodides, 2-hydroxyethanesulfonates, lactates, maleates, methanesulfonates, methyl sulfates, 2-naphthalenesulfonates, nicotinates, nitrates, oxalates, pamoates, pectinates, persulfates, 3-phenylpropionates, phosphates, picrates, pivalates, propionates, salicylates, succinates, sulfates, sulfonates (such as those mentioned herein), tartarates, thiocyanates, toluenesulfonates (also known as tosylates) undecanoates, and the like.
[0167] Exemplary basic salts include ammonium salts, alkali metal salts such as sodium, lithium, and potassium salts, alkaline earth metal salts such as calcium and magnesium salts, aluminum salts, zinc salts, salts with organic bases (for example, organic amines) such as benzathines, diethylamine, dicyclohexylamines, hydrabamines (formed with N,N-bis(dehydroabietyl)ethylenediamine), N-methyl-D-glucamines, N-methyl-D-glucamides, t-butyl amines, piperazine, phenylcyclohexyl-amine, choline, tromethamine, and salts with amino acids such as arginine, lysine and the like. Basic nitrogen-containing groups may be converted to an ammonium ion or quarternized with agents such as lower alkyl halides (e.g. methyl, ethyl, propyl, and butyl chlorides, bromides and iodides), dialkyl sulfates (e.g. dimethyl, diethyl, dibutyl, and diamyl sulfates), long chain halides (e.g. decyl, lauryl, myristyl and stearyl chlorides, bromides and iodides), aralkyl halides (e.g. benzyl and phenethyl bromides), and others.
[0168] All such acid and base salts are intended to be pharmaceutically acceptable salts within the scope of the invention, and all acid and base salts are considered equivalent to the free forms of the corresponding compounds for purposes of the invention.
[0169] Compounds of the invention may exist in exist in different tautomeric forms. All such forms are embraced and included within the scope of the invention. Examples of well-known tautomeric forms include, but are not limited to, ketone/enol tautomeric forms, imine-enamine tautomeric forms, and for example heteroaromatic forms such as the following moieties:
[0000]
[0170] Where a compound of the invention can exist in more than one such form, representation or presentation of one tautomeric form of such compound is considered herein equivalent to presentation of all the tautomeric forms in which the compound exists.
[0171] The term “purified,” “in purified form” or “in isolated and purified form” for a compound refers to the physical state of said compound after being isolated from a synthetic process or natural source or combination thereof. Thus, the term “purified,” “in purified form” or “in isolated and purified form” for a compound refers to the physical state of said compound after being obtained from a purification process or processes described herein or well known to the skilled artisan, and in sufficient purity to be characterized by standard analytical techniques described herein or well known to the skilled artisan.
[0172] A functional group in a compound termed “protected” means that the group is in modified form to preclude undesired side reactions at the protected site when the compound is subjected to a reaction. Suitable protecting groups will be recognized by those with ordinary skill in the art as well as by reference to standard textbooks such as, for example, T. W. Greene et al, Protective Groups in organic Synthesis (1991), Wiley, New York.
[0173] When a variable (e.g., aryl, heterocycl, R 3 , etc.) appears more than once in any moiety or in any compound of the invention, the selection of moieties defining that variable for each occurrence is independent of its definition at every other occurrence unless specified otherwise in the variable definition.
[0174] As used herein, the term “composition” is intended to encompass a product comprising the specified ingredients in the specified amounts, and any product which results, directly or indirectly, from combination of the specified ingredients in the specified amounts.
[0175] The present invention also embraces isotopically-labeled compounds of the present invention that are structurally identical to those recited herein, but for the fact that a statistically significant percentage of one or more atoms in that form of the compound are replaced by an atom having an atomic mass or mass number different from the atomic mass or mass number of the most abundant isotope usually found in nature, thus altering the naturally occurring abundance of that isotope present in a compound of the invention. Examples of isotopes that can be preferentially incorporated into compounds of the invention include isotopes of hydrogen, carbon, nitrogen, oxygen, phosphorus, fluorine and chlorine, for example 2 H, 3 H, 13 C, 14 C, 15 N, 18 O, 17 O, 31 P, 32 P, 35 S, 18 F, and 36 Cl, respectively. It will be appreciated that other isotopes may be incorporated by know means also.
[0176] Certain isotopically-labeled compounds of the invention (e.g., those labeled with 3 H and 14 C) are useful in compound and/or substrate tissue distribution assays. Tritiated (i.e., 3 H) and carbon-14 (i.e., 14 C) isotopes are particularly preferred for their ease of preparation and detection. Further, substitution with heavier isotopes such as deuterium (i.e., 2 H) may afford certain therapeutic advantages resulting from greater metabolic stability (e.g., increased in vivo half-life or reduced dosage requirements) and hence may be preferred in some circumstances. Isotopically labeled compounds of the invention can generally be prepared by following procedures analogous to those disclosed in the Schemes and/or in the Examples herein below, by substituting an appropriate isotopically labeled reagent for a non-isotopically labeled reagent. Such compounds are included also in the present invention.
[0177] As mentioned above, in one aspect the invention provides pharmaceutical formulations (pharmaceutical compositions) suitable for use in blocking adenosine A2a receptors found in the basal ganglia, comprising at least one compound of Formula A presented herein, or a pharmaceutically acceptable salt thereof, and at least one pharmaceutically acceptable carrier. It will be appreciated that pharmaceutically formulations of the invention may comprise more than one compound of the invention, for example, the combination of two or three compounds of the invention, each present by adding to the formulation the desired amount of the compound in a pharmaceutically acceptably pure form. It will be appreciated that compositions of the invention may comprise, in addition to one or more of compounds of the invention, one or more other compounds which also have pharmacological activity, for example, as described herein below.
[0178] While formulations of the invention may be employed in bulk form, it will be appreciated that for most applications the inventive formulations will be incorporated into a dosage form suitable for administration to a patient or subject, each dosage form comprising an amount of the selected formulation that contains an effective amount of said one or more compounds of the invention. Examples of suitable dosage forms include, but are not limited to, dosage forms adapted for: (i) oral administration, e.g., a liquid, gel, powder, solid or semi-solid pharmaceutical composition that is loaded into a capsule or pressed into a tablet and may comprise additionally one or more coatings which modify its release properties, for example, coatings that impart delayed release or formulations that have extended release properties; (ii) a dosage form adapted for intramuscular administration (IM), for example, an injectable solution or suspension, and that may be adapted to form a depot having extended release properties; (iii) a dosage form adapted for intravenous administration (IV), for example, a solution or suspension, for example, as an IV solution or a concentrate to be injected into a saline IV bag; (iv) a dosage form adapted for administration through tissues of the oral cavity, for example, a rapidly dissolving tablet, a lozenge, a solution, a gel, a sachette or a needle array suitable for providing intramucosal administration; (v) a dosage form adapted for administration via the mucosa of the nasal or upper respiratory cavity, for example a solution, suspension or emulsion formulation for dispersion in the nose or airway; (vi) a dosage form adapted for transdermal administration, for example, a patch, cream or gel; (vii) a dosage form adapted for intradermal administration, for example, a microneedle array; and (viii) a dosage form adapted for delivery via rectal or vaginal mucosa, for example, a suppository.
[0179] For preparing pharmaceutical compositions from the compounds described by this invention, generally pharmaceutically active compounds are combined with one or more pharmaceutically inactive excipients. These pharmaceutically inactive excipients impart to the composition properties that make it easier to handle or process, for example, lubricants or pressing aids in powdered medicaments intended to be tableted, or adapt the formulation to a desired route of administration, for example, excipients that provide a formulation for oral administration, for example, via absorption from the gastrointestinal tract, transdermal or transmucosal administration, for example, via adhesive skin “patch” or buccal administration, or injection, for example, intramuscular or intravenous, routes of administration. These excipients are collectively termed herein “a carrier.”
[0180] Pharmaceutical compositions can be solid, semi-solid or liquid. Solid form preparations can be adapted to a variety of modes of administration and include powders, dispersible granules, mini-tablets, beads, and the like for example, for tableting, encapsulation, or direct administration. Typically formulations may comprise up to about 95 percent active ingredient, although formulations with greater amounts may be prepared.
[0181] Liquid form preparations include solutions, suspensions and emulsions. Examples of liquid forms of medicament include, but are not limited to, water or water/surfactant mixtures, for example a water-propylene glycol solution, which can be employed in the preparation of formulations intended, for example, for parenteral injection, for example, as a solvent or as a suspending medium for the preparation of suspensions and emulsions where a medicament comprises constituents that are insoluble in water or water/surfactant mixtures. Liquid form preparations may also include solutions or suspensions for intranasal administration and may also include, for example, viscosity modifiers to adapt the formulation for application to particular mucosa tissues accessible via nasal administration.
[0182] Aerosol preparations, for example, suitable for administration via inhalation or via nasal mucosa, may include solutions and solids in powder form, which may be in combination with a pharmaceutically acceptable propellant, for example, an inert compressed gas, e.g. nitrogen. Also included are solid form preparations that are intended to be converted, shortly before use, to a suspension or a solution, for example, for oral or parenteral administration. Examples of such solid forms include freeze dried formulations and liquid formulations adsorbed into a solid absorbent medium.
[0183] The compounds of the invention may also be deliverable transdermally or transmucosally, for example, from a liquid, suppository, cream, foam, gel, or rapidly dissolving solid form. It will be appreciated that transdermal compositions can take also the form of creams, lotions, aerosols and/or emulsions and can be provided in a unit dosage form which includes a transdermal patch of any know in the art, for example, a patch that incorporates either a matrix comprising the pharmaceutically active compound or a reservoir that comprises a solid or liquid form of the pharmaceutically active compound.
[0184] Examples of pharmaceutically acceptable carriers and methods of manufacture for various compositions mentioned above may be found in A. Gennaro (ed.), Remington: The Science and Practice of Pharmacy, 20 th Edition, (2000), Lippincott Williams & Wilkins, Baltimore, Md.
[0185] Preferably, the pharmaceutical preparation is in a unit dosage form. In such form, the preparations subdivided into suitably sized unit doses containing appropriate quantities of the active component, e.g., an effective amount to achieve the desired purpose.
[0186] The actual dosage employed may be varied depending upon the requirements of the patient and the severity of the condition being treated. Determination of the proper dosage regimen for a particular situation is within the skill in the art. For convenience, the total daily dosage may be divided and administered in portions during the day as required.
[0187] In another embodiment the present invention provides for use of the compounds described herein for the potential treatment, management, alleviation or amelioration of conditions or disease states which can be, or are believed to be, treated, managed, alleviated or ameliorated by specific blocking of adenosine A2a receptors, for example, central nervous system diseases or disorders, including but not limited to the treatment of movement disorders (e.g., tremors, bradykinesias, gait, dystonias, dyskinesias, tardive dyskinesias, other extrapyramidal syndromes, Parkinson's disease and disorders associated with Parkinson's disease). The compounds of the invention also have the potential for use in preventing or lessening the effect of drugs that cause movement disorders.
[0188] In accordance with the present invention, blocking adenosine A2a receptors is accomplished by administering to a patient in need of such therapy an effective amount of one or more compounds of the invention, or a pharmaceutically acceptable salt thereof.
[0189] In some embodiments it is preferred for the compound to be administered in the form of a pharmaceutical composition comprising the compound of the invention, or a salt thereof, and at least one pharmaceutically acceptable carrier (described below). It will be appreciated that pharmaceutical formulations of the invention may comprise more than one compound of the invention or a salt thereof, for example, the combination of two or three compounds of the invention, each present by adding to the formulation the desired amount of the compound or a salt thereof that has been isolated in a pharmaceutically acceptably pure form.
[0190] As mentioned above, administration of a compound of the invention to effect antagonism of A2a receptor sites, which is believed to be beneficial in the treatment of central nervous system diseases, is preferably accomplished by incorporating the compound into a pharmaceutical formulation incorporated into a dosage form, for example, one of the above-described dosage forms comprising an effective amount of at least one compound of the invention (e.g., 1, 2 or 3, or 1 or 2, or 1, and usually 1 compound of the invention), or a pharmaceutically acceptable salt thereof, for example. Methods for determining safe and effective administration of compounds that are pharmaceutically active, for example, a compound of the invention, are known to those skilled in the art, for example, as described in the standard literature, for example, as described in the “Physicians' Desk Reference” (PDR), e.g., 1996 edition (Medical Economics Company, Montvale, N.J. 07645-1742, USA), the Physician's Desk Reference, 56 th Edition, 2002 (published by Medical Economics company, Inc. Montvale, N.J. 07645-1742), or the Physician's Desk Reference, 57 th Edition, 2003 (published by Thompson PDR, Montvale, N.J. 07645-1742); the disclosures of which is incorporated herein by reference thereto. The amount and frequency of administration of the compounds of the invention and/or the pharmaceutically acceptable salts thereof will be regulated according to the judgment of the attending clinician considering such factors as age, condition and size of the patient as well as severity of the symptoms being treated. Compounds of the instant invention can be administered at a total daily dosage of up to 1,000 mg, which can be administered in one daily dose or can be divided into two to four doses per day.
[0191] In general, in whatever form administered, the dosage form administered will contain an amount of at least one compound of the invention, or a pharmaceutically acceptable salt thereof, which will provide a therapeutically effective serum level of the compound in some form for a period of at least 2 hours, preferably at least four hours, and preferably longer. In general, as is known in the art, dosages of a pharmaceutical composition providing a therapeutically effective serum level of a compound of the invention, e.g., a compound of Formula A, can be spaced in time to provide serum level meeting or exceeding the minimum therapeutically effective serum level on a continuous basis throughout the period during which treatment is administered. As will be appreciated the dosage form administered may also be in a form providing an extended release period for the pharmaceutically active compound which will provide a therapeutic serum level for a longer period, necessitating less frequent dosage intervals. As mentioned above, a composition of the invention can incorporate additional pharmaceutically active components or be administered simultaneously, contemporaneously, or sequentially with other pharmaceutically active compositions as may be additionally needed in the course of providing treatment. Such additional therapeutic agents can include compounds with dopaminergic activity, for example, i) L-DOPA; ii) DOPA decarboxylase inhibitors; and iii) COMT inhibitors.
[0192] Those skilled in the art will appreciate that treatment protocols utilizing at least one compound of Formula A can be varied according to the needs of the patient. Thus, compounds of Formula A used in the methods of this invention can be administered in variations of the protocols described above. For example, the compounds of this invention can be administered discontinuously rather than continuously during the treatment cycle.
[0193] There follows general synthetic schemes by which compounds of the invention may be prepared.
PREPARATIVE SCHEMES
Preparative Schemes: “Right-Side” Precursors
[0194] As shown in Preparative Schemes AI through ART below, compounds of the invention may be prepared by reacting a suitably functionalized triazole (“right-side” precursor), which supplies the “right-side” of the product compound desired, with a suitably functionalized “left-side” precursor, which provides either the “left-side” of the desired product compound directly, or provides an intermediate product in which the “left-side” fragment has incorporated into one or more a suitably reactive substituents that, through subsequent reactions at such reactive substituents, afford the desired product. Additionally, some of the coupling schemes illustrated below can be employed using intermediate compounds that contain certain reactive substituents (which may be present as a protected form of the reactive site), thereby yielding product compounds that contain sites that can be further reacted to provide additional compounds of the invention that are derivatives of the parent compound.
Scheme AI and AII—
[0195] Preparation of Compounds of the Invention Via Joining Appropriate “Free-Amine” Precursors Providing the “Right-Side” Portion of a Compound of the Invention with a Suitably Substituted Reagent Supplying the “Left-Side” of the Desired Product
[0196] With reference to Scheme AI, some compounds of the invention can be prepared by reacting suitably-substituted compound 19 (a precursor forming the “right-side” of a compound of the invention) with a suitably substituted aryl-boronic acid or heteroaryl-boronic acid precursor supplying a “left-side” fragment of the desired compound. As mentioned in the preamble, it will be appreciated that the reagent supplying the “left-side” fragment may include one or more reactive moieties that can be subsequently derivatized to supply a compound of the invention rather than reacting a complete “left-side” fragment that provides the desired compound of the invention directly from this coupling reaction. It will be appreciated that certain heteroarylboronic acid or arylboronic acid compounds are available as articles of commerce, including those in which the heteroaryl or aryl portion of the compound contains substituents suitable for further reaction, and which can therefore be utilized to form a precursor from which desired compounds of the invention can be prepared, as will be illustrated in the Examples below.
[0000]
[0197] As shown also in Scheme AI, a compound 19 in the presence of sodium hydride can be reacted with a reagent having a “left-side” fragment that contains a hydroxyl moiety, thereby providing a product which joins the “left-side” and “right-side” fragments with an alkoxy (—O—CH 2 —) “linker” in place of the chloro-substituent present in compound 19. In such synthetic procedures, R AI can be alkyl, substituted alkyl, aryl (substituted or unsubstituted), heteroaryl (substituted or unsubstituted) bicycloalkylaryl (substituted or unsubstituted) or bicycloalkylheteroaryl (substituted or unsubstituted). In AI, the reaction shown is catalyzed by Pd(dppf)Cl 2 which is a palladium(2 + ) catalyst available as an article of commerce complexed with dichloromethane (DCM) (1,1′-Bis(diphenylphosphino)ferrocene-palladium(II)dichloride)
[0198] Amide-substituted compounds of the invention can be prepared in accordance with Scheme AII
[0000]
[0199] Thus, a suspension of P23 (the preparation of which is discussed further below) in DMF treated with an amine, for example, a cyclic amine, e.g. a piperidine or piperazine moiety (shown in AII as (R′—R″)═NH), diisopropylethyl amine (DIPEA) and 2,4,6-tripropyl-1,3,5,2,4,6-trioxatriphosphoriane-2,4,6-trioxide (T3P) at room temperature provides the corresponding amide compound P24, which can be obtained from the reaction mixture by treating the reaction mixture with saturated NaHCO 3 and extracting with dichloromethane (DCM). Specific examples of these compounds are presented in the Examples below.
Scheme AIII—
[0200] Preparation of Compounds of the Invention from DMoB-Protected Triazole Precursor and a “Left-Side” Precursor that is: (i) a Primary or Secondary Amine; (ii) an Alkyne or (iii) a Boronic Acid
[0000]
[0201] Scheme AIII illustrates several transformations that can provide a compound of the invention, or a precursor thereof, from hydroxy-functionalized compound 13, after conversion to the corresponding mesyl-functional group (compound 14) via treatment with mesyl chloride (MsCl). Compound 14 can subsequently be reacted with a primary amine and the product deprotected to provide an amine-linked compound of the invention (compound 16A) or a precursor thereof.
[0202] Alternatively, compound 14 can be deprotected (using TFA) and reacted with a “left-side” precursor having a suitable reactive nitrogen (for example, a secondary amine shown) under suitable conditions (in the presence of potassium iodide and DIPEA (Hunig's base, diisopropylethylamine), thereby providing compounds of the invention (or a precursor thereof) in which the “left-side” and “right-side” fragments are linked by a secondary-amino or a cyclo-amino moiety (compound 16). Alternatively, the methoxy-functional group of compound 14 is converted to the corresponding methylchloride (compound 15).
[0203] As shown, compound 15 can be deprotected and reacted with a secondary- or cycloamine “left-side” precursor in the same manner as compound 14, to provide a compound of the invention or an intermediate thereof, or in the protected form compound 15 can be reacted with an appropriately substituted aryl- or heteroaromatic boronic acid in the presence of a suitable palladium catalyst (in accordance with the similar reaction shown in Scheme AI, above) to provide an aryl-substituted or heteroaryl-substituted triazole of the invention (or an intermediate thereof). As illustrated in Scheme AIII also, compound 15 can alternatively be reacted with sodium azide followed by reaction with a suitable aryl-alkyne, then deprotected to provide triazole-functionalized compounds of the invention or a precursor thereof.
[0204] With reference to Schemes AI to AIII, it will be appreciated that any synthetic scheme that provides any of compounds 13, 14, 15 or 19 can be employed to provide a suitable “right-side” precursor utilized in Schemes AI to AIII to ultimately provide a compound of the invention. It will be appreciated as well that any synthetic scheme that provides compound 4 (see Scheme B1) can be employed to provide a suitable quinolin-azole precursor for use in Scheme AII.
[0205] In some of the schemes above and throughout, reference is made to “X-phos precatalyst” that is utilized to provide a carbon-carbon bond between a heteroaryl-boronic acid reagent and the chloromethyl substituent shown in the schemes (e.g. compounds 15 and 19). As used herein, this phrase refers to dicyclohexylphosphino-2′,4′,6′-triisopropyl-1,1′-biphenyl)[2-(2-aminoethyl)phenyl]palladium(II) chloride), which is commercially available. Alternately, in some schemes, the catalyst employed is 1,1′-Bis(diphenylphosphino)ferrocene-palladium(II)dichloride (Pd(dppf)Cl 2 ), (for convenience abbreviated herein as PdCl 2 (dppf) 2 -CH 2 Cl 2 ) also is an article of commerce. In general, suitable aryl-boronic acids and heteroaryl-boronic acids are also commercially available or are readily prepared from commercially available boronic acid compounds.
Preparative Schemes B:
Synthetic Pathways Suitable for Preparation of “Right-Side” Precursor Compounds
[0206] Preparative Schemes BI (which provide free amine products) and BII (infra, which provides protected amine products) illustrate general routes for preparing a “right-Side” precursor that can be employed in the general Schemes AI to AIII, shown above to prepare compounds of the invention. These are followed by several specific examples of preparation of variously functionalized “right-side” precursor compounds useful in synthesis of compounds of the invention.
Schemes BI
Preparation of Heteroaryl-Triazole Compounds of the Invention by Preparation and Cyclization of Heteroarylhydrazine-Substituted Quinazoline-Precursor Compounds.
[0207] Scheme BI illustrates several paths for the preparation of triazole precursor comopounds. The substituted triazole compounds thus prepared are useful as a precursor in the preparation of substituted pyridine-triazole compounds of the invention, specific examples of which are described herein below.
[0208] As shown in the Schemes of BI, one or more —CH 2 — moieties that will ultimately link the triazolo “core” of the “right-side” fragment of a compound of the invention to the “left-side” fragment can be incorporated into the “right-side” precursor at this stage of the synthesis.
[0000]
[0209] In Schemes of BI, “PG” is an acetyl or dimethoxybenzyl (DMB) protecting group (BIc illustrates an acetyl protecting group).
[0210] Schemes BIa and BIb illustrate two routes for preparing a hydrazine precursor in which the hydrazine intermediate ultimately contains an aryl- or heteroaryl-hydrazine-quinoline moiety prior to cyclization (where R 10 is a substituted aryl or substituted heteroaryl, for example, benzene or halopyridine). In route BIa, a quinazoline precursor, compound 4 can be reacted either with a hydrazine derivative, compound 4B (where R 10 is a functionalized heteroaryl) and subsequently deprotected to provide compound 6B. In route BIb, compound 4 can be reacted with hydrazine directly, deprotected to provide a hydrazinyl-quinazolin-amine intermediate, and the hydrazinyl-quinolin-amine subsequently reacted with an R 10 -acid, wherein R 10 is a functionalized heteroaryl moiety, for example, 2-(2-bromopyridin-3-yl)acetic acid, to provide compound 6B. Prepared by either route, the hydrazinyl-quinoline intermediate, 6B, can be cyclized to provide a triazole compound of the invention. As mentioned herein, this is also useful for providing an R 10 -substituted triazole precursor containing one or more reactive substituents that can be subsequently derivatized to provide additional compounds of the invention. Scheme BIc illustrates the use of a hydrazine derivative that provides a hydroxy-functionalized triazole compound (compound 7c), and Scheme BId illustrates conversion of the alcohol-functionalized triazole of compound 7c to the corresponding chloride compound 8. The latter two routes of Scheme BI provide a “right-side” precursor which is widely useful in coupling piperazine “left-side” precursor compounds, as is illustrated herein.
[0211] Scheme BIc is illustrated further by the preparation of (5-amino-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)methanol (compound 7c1) in accordance therewith:
[0000]
[0212] Accordingly, Compound 7c1 was prepared by taking a portion of compound 4 (4.0 g, 14.1 mmol) thus prepared suspended in THF (300 ml). To the suspension was added 2-hydroxyacetohydrazide (1.39 g, 15.5 mmol, compound 4a wherein “n”=1), followed by DIPEA (1.71 g, 17.9 mmol). This mixture was stirred at 60° C. for 48 h, then concentrated in vacuo. The residue thus obtained was dissolved in MeOH (200 ml) and H 2 O (100 mL). K 2 CO 3 was added. The mixture was stirred at 65° C. for 2 h, cooled to RT. MeOH was removed in vacuo. The precipitates were collected by filtration, cooled to 0° C., washed with H 2 O, DCM/Hexanes (1:1), and dried in vacuum oven to afford N′-(2-amino-8-methoxyquinazolin-4-yl)-2-hydroxyacetohydrazide (compound 6c1, which is compound 6c wherein “n”=1). The identity of the product was confirmed by LC/MS in accordance with the procedure described herein (LC/MS=264 [M+1]).
[0213] A portion of compound 6c1 thus prepared (3.5 g, 13.3 mmol) was stirred with N,O-Bis(Trimethylsilyl)acetamide (100 mL) at 120° C. for 3 h, cooled to RT, concentrated in vacuo with heating to remove trimethylsilyl N-(trimethylsilyl)acetimidate completely. MeOH was added to the residue and the mixture was concentrated in vacuo. The solids obtained were suspended in MeOH, cooled and filtered. The precipitate were washed with MeOH, dried and concentrated to afford (5-amino-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)methanol (compound 7c1). The identity of the product was confirmed by LC/MS in accordance with the procedure described herein (LC/MS=246 [M+1]).
[0214] In the same manner, Scheme BId is illustrated by the preparation of compound 8a (compound 8 wherein “n”=1) from compound 7c1:
[0000]
[0215] Thus, with reference to Scheme BId, above, a portion of compound 7c1 previously prepared (2.8 g, 11.4 mmol) was mixed with SOCl 2 (10 ml) and the mixture stirred at 65° C. for 45 min. The mixture was then cooled to RT, concentrated to remove SOCl 2 completely, and the residue was suspended in DCM and filtered. The precipitates were collected and dried to afford 2-(chloromethyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (compound 8a). The identity of the product was confirmed by LC/MS in accordance with the procedure described herein (LC/MS=264 [M+1]).
[0000] Preparative Schemes P: Preparation of triazole precursors
[0216] Scheme PI illustrates the preparation of compound PI-4, useful in providing “right-side” triazole precursor compounds (see e.g., Schemes BIa to BIc, above), from commercially available 2-amino-3-methoxy-benzoic acid.
[0000]
Preparation of N-(8-methoxy-4-(1H-1,2,4-triazol-1-yl)quinazolin-2-yl)acetamide (compound PI-4)
[0217] N-(8-methoxy-4-(1H-1,2,4-triazol-1-yl)quinazolin-2-yl)acetamide (compound PI-4) was prepared from a benzoic acid starting material in accordance with Scheme PI by adding into a solution of 2-amino-3-methoxybenzoic acid (compound PI-1) (50 g, 299 mmol) in EtOH (400 ml), cyanamide (18.86 g, 449 mmol) and concentrated HCl (12 ml, 299 mmol). The reaction mixture thus provided was refluxed overnight and then cooled to room temperature. The precipitates were collected through filtration, washing with cold ethanol to yield compound PI-2 (50 g). A portion of compound PI-2 thus provided (10 g, 52.3 mmol) was suspended in acetic anhydride (60 ml, 52.3 mmol). The suspension was placed into a sealed tube and heated at 130° C. for 40 minutes, providing N-(4-hydroxy-8-methoxyquinazolin-2-yl)acetamide (compound PI-3). The identity of the product was confirmed by LC/MS in accordance with the procedure described herein (LC/MS=259 [M+1]).
[0218] In a subsequent step, a portion of compound PI-3 thus provided (7 g, 30.0 mmol) was suspended in acetonitrile (300 ml) and added thereto was 1,2,4-triazole (20.73 g, 300 mmol), DIPEA (15.31 ml, 90 mmol), and then dropwise was added POCl 3 (8.22 ml, 90 mmol). This reaction mixture was stirred at room temperature overnight. The yellow precipitates formed were filtered and washed with EtOH twice and then ether to afford N-(8-methoxy-4-(1H-1,2,4-triazol-1-yl)quinazolin-2-yl)acetamide (compound PI-4).
[0219] The PI synthetic scheme was carried out by substituting 3-hydroxypropanehydrazide (compound 4a in Scheme BI where “n”=2) in place of 2-hydroxyacetohydrazide used in the previous preparative example. When this substitution was made, scheme PI provided 2-(2-chloroethyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (compound 8b, compound 8 in Scheme BI where “n”=2). Isolation and purification of 8b was carried out in a DCM/Hexane mixture instead of DCM alone, and the identity of the product was confirmed by LC/MS (LC/MS=279 [M+1]).
[0220] When the PI synthetic procedure was carried out using 4-hydroxybutanehydrazide (compound 4a in Scheme BI where “n”=3) in place of 3-hydroxypropanehydrazide used in the previous preparative example, producing thereby 2-(2-chloropropyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (compound 8c, compound 8 in Scheme BI where “n”=3). Compound 8c was isolated by evacuating the SOCl 2 from the reaction mixture and using the residue as prepared. The product was confirmed by LC/MS (LC/MS=293 [M+1]).
[0221] It will be appreciated that preparative scheme PI can be carried out starting with other methoxy-benzoic acid starting materials in place of compound PI-1 (2-amino-3-methoxybenzoic acid) to provide variously-substituted “right-side” triazole precursors for use in preparing compounds of the invention. For example, carrying out Scheme PI using 2-amino-5-fluoro-3-methoxybenzoic acid enables, after a process of Scheme BI, the provision of compound 8d (2-(chloromethyl)-9-fluoro-7-methoxy-[1, 2, 4]triazolo[1,5-c]quinazolin-5, LC/MS=282.1 [M+1]). In the same manner, employing 2-amino-4-fluoro-3-methoxybenzoic acid enables the preparation of compound 8e.
[0000]
[0222] It will be appreciated that in some procedures employing fluorinated amino-methoxybenzoic acid starting materials, the step of preparing an acetamide-protected analog of compound 3 may be eliminated and the free-base may be employed in the reactions instead of employing an acetamide-protected form of the compound. Such a scheme is illustrated in preparative example PII, wherein compound 8F is prepared starting with 2-amino-4,6-difluorobenzoic acid (compound PIM).
[0000]
Step A
Preparation of 2-amino-6,8-difluoroquinazolin-4-ol (Cmpd PII-2)
[0223] To a solution of the 2-amino-4,6-difluorobenzoic acid (Cmpd PII-1, 5 g, 28.9 mmol)) in acetonitrile (20 ml) was added cyanoamide (1.821 g, 43.3 mmol)) and concentrated hydrochloric acid (3 ml). Reaction mixture was refluxed overnight, cooled to room temperature, and then the precipitate was collected through filtration, washing with acetonitrile to yield the desired product 2-amino-6,8-difluoroquinazolin-4-ol (Cmpd PII-2). Retention time: 0.10, LC/MS=198 [M+1].
Step B
Preparation of 6,8-difluoro-4-(1H-1,2,4-triazol-1-yl)quinazolin-2-amine (Cmpd PII-3)
[0224] To a stirred solution of 2-amino-6,8-difluoroquinazolin-4-ol (2 g, 10.14 mmol) and triazole (7.01 g, 101 mmol) in acetonitrile (30 mL), POCl 3 (10.63 ml, 60.9 mmol) was added slowly in one over 1 h making sure to maintain the temperature below 60° C. The reaction was stirred overnight at room temperature, cooled to room temperature, and then the precipitate was collected through filtration, washing with acetonitrile to yield the desired product 6,8-difluoro-4-(1H-1,2,4-triazol-1-yl)quinazolin-2-amine (Cmpd PII-3) as a colorless solid. Retention time: 0.20, LC/MS=249 [M+1].
Step C
Preparation of N′-(2-amino-6,8-difluoroquinazolin-4-yl)-2-hydroxyacetohydrazide (Cmpd PII-4)
[0225] Into a stirred mixture of 2-hydroxyacetohydrazide (0.18 g, 2.0 mmol) in 20 mL of THF was added 6,8-difluoro-4-(1H-1,2,4-triazol-1-yl)quinazolin-2-amine (Cmpd PII-3, 0.18 g, 2.0 mmol). The mixture was stirred at room temperature overnight, then the solvent was evaporated under reduced pressure. DCM was added to the residue and the solid was filtered off. The yellow solid was dissolved in water and the residue was filtered off and retained. Acetonitrile was added into the aqueous phase with stirring until precipation and the solid was filtered again. Solids were collected and dried in vacuo at room temperature to give N′-(2-amino-6,8-difluoroquinazolin-4-yl)-2-hydroxyacetohydrazide (Cmpd PII-4) as a yellow solid. The identity of the product was verified by LC/MS—Retention time: 0.54, LC/MS=270 [M+1].
Step D
Preparation of (5-amino-7,9-difluoro-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)methanol (Cmpd PII-5)
[0226] N′-(2-amino-6,8-difluoroquinazolin-4-yl)-2-hydroxyacetohydrazide (Cmpd PII-4, 0.8 g, 2.97 mmol) was added to a stirred, cooled room temperature mixture of BSA (12 g, 60 mmol) and the mixture was stirred at 120° C. for 2 h. After 2 hours, BSA was removed under vacuum and 5 mL of MeOH was added slowly. The solvent was removed under vacuum, water was added, and the mixture was filtered and washed with dichloromethane to give (5-amino-7,9-difluoro-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)methanol as yellow solid. Retention time: 1.35, LC/MS=252[M+1].
Step E
Preparation of 2-(chloromethyl)-7,9-difluoro-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (8F)
[0227] A portion of Cmpd PII-5, prepared in the previous step (0.4 g, 1.60 mmol) was suspended in 5 mL of SOCl 2 and DCM (10 mL). The mixture was stirred at RT for 1 h, concentrated in vacuo to remove SOCl 2 completely. The residue was suspended in DCM/Hex (1:2), cooled to 0° C., filtered, and the solid was dried in vacuum oven to give 2-(chloromethyl)-7,9-difluoro-[1,2,4]triazolo[1,5-c]quinazolin-5-amine. Retention time: 1.68, LC/MS=270 [M+1].
[0228] It will be appreciated that by using the PI and PII synthesis procedures described above with variously substituted aminobenzoic acid starting material, other precursors with various substituents on the “aryl-ring” of the triazole “right-side” precursor compound may be prepared. Accordingly, following the procedure of PI with 2-amino-3-bromo-benzoic acid will provide compound 8G, and employing 2-amino-3-trifluoromethyl-benzoinc acid as a starting material will provide compound 8H:
[0000]
[0229] Moreover, compound 8G can be employed to prepare additional analogs, for example, using Scheme PI(a), the cyano-functionalized analog can be prepared.
[0000]
[0230] In accordance with Scheme PI(a), a mixture of Protected-8G-alcohol prepared in accordance with PI (200 mg; 0.45 mmol), zinc cyanide (31.7 mg; 0.27 mmol) and PdCl 2 (dppf) 2 :CH 2 Cl 2 were dissolved in DMF (1 mL) and water (0.1 mL). The resulting clear red solution was degassed with nitrogen, stirred and heated at 120° C. for 14 hr. MS analysis of the reaction mixture showed absence of the starting bromo tricyclic alcohol and presence of the product nitrile (MH + =391). The reaction mixture was quenched with water, and organics were extracted with EtOAc. The organic extract was further washed with water, brine and dried over solid anhydrous Na 2 SO 4 . The crude product was purified by preparative TLC, developing the plate with EtOAc-CH 2 Cl 2 (1:1) to provide the cyano analog of protected 8G-alcohol (herein CN-8G-alcohol isolated as beige solid).
[0231] The compound CN-8G-alcohol thus prepared was dissolved (140 mg; 0.36 mmol) in CH 2 Cl 2 (2 mL) and CDCl 3 (2 mL). The solution was cooled in an ice bath and treated sequentially with Et 3 N (40 mg; 55 uL; 0.395 mmol) and MsCl (49 mg; 0.43 mmol), taking care not to use even a slight excess of Et 3 N to avoid quaternary salt formation. The ice bath was removed after 5 minutes, and the reaction mixture was stirred at RT for 45 minutes when the analysis (TLC, MS) showed absence of alcohol. The reaction mixture was diluted with EtOAc and washed with water, brine, dried and concentrated to obtain the crude mesylate.
[0232] The crude mesylate prepared in the previous step was redissolved in acetone (3 mL), treated with solid LiCl (76 mg; 1.79 mmol) and was stirred with heating at 58° C. for 3 hr. After confirming the complete formation of the tricyclic chloride (MH + =408/410), the reaction mixture was cooled to RT and acetone was removed under house vacuum. The residue was dissolved in CH 2 Cl 2 /CHCl 3 (4:1) and washed with water, brine and concentrated to obtain a beige solid. The crude product thus obtained was purified by preparative TLC (30% EtOAc-CH 2 Cl 2 ) to furnish compound protected-8H as off-white solid.
General Preparative Scheme MI: Preparation of “Protected-Amine,” “Right-Side” Triazole Precursors
[0233] Scheme BII illustrates the preparation of a “protected-amine” “right-side” precursor from commercially available 2-amino-3-methoxy-benzoic acid. As was shown in Scheme BI, Scheme BII illustrates that one or more —CH 2 — moieties, which will ultimately link the triazolo “core” portion of the “right-side” fragment of a compound of the invention to the “left-side” fragment, can be incorporated into the “Right-side” precursor at this stage of the synthesis.
[0000]
Preparative Example PIII
Preparation of (5-(2,4-dimethoxybenzylamino)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)methanol (compound 13a) in accordance with Scheme BII
[0234]
[0235] With reference to Scheme BII, above, (5-(2,4-dimethoxybenzylamino)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)methanol (compound 13a, which is compound 13 of Scheme BII where “n”=1) was prepared starting from compound 1 by placing into a reaction vessel a suspension of compound 1 (3 g, 17.95 mmol) in water (100 ml) and acetic acid (1.099 ml, 19.20 mmol) maintained at 55-60° C., and adding thereto a solution of KOCN (3.49 g, 43.1 mmol) in water (7 mL). After about 4 hours of stirring at 55-60° C., the reaction was cooled to ambient temperature and solid NaOH (31.6 g, 790 mmol, 35-44eq) was added quickly in one portion.
[0236] The resultant pale brownish cloudy solution became clear and then became white murky solution after 10 min. The reaction mixture was cooled to 0° C. and Conc. HCl (around 38 mL) was added to make pH 4-5 while maintaining the reaction mixture at 0° C., generating a white precipitate. The reaction mixture was filtered, and the solids obtained were washed with water (500 mL) and dried under vac. oven overnight to afford compound 9. The identity of compound 9 was verified by LC/MS in accordance with the procedure listed herein (193 [M+1]
[0237] A stirred suspension of compound 9 prepared above (2.0 g, 10.41 mmol) in neat POCl 3 (9.70 ml, 104 mmol) was heated to 105° C. overnight. After 16 hrs, the murky solution became clear and the reaction mixture was cooled down. The POCl 3 was evaporated until solution became solid. The crude product thus obtained was mixed with EtOAc (500 mL) and the mixture poured into a 12 L beaker. Aqueous NaHCO 3 (aq) was added and the mixture was stirred for 30 min. The crude product solids became soluble in EtOAc and any remaining POCl 3 was quenched. The resulting organic layer was washed with NaHCO 3 (aq), and brine solution, dried over MgSO4, filtered and concentrated, yielding pale yellowish solid product, compound 10. The identity of compound 10 was verified by LC/MS in accordance with the procedure listed herein (230 [M+1].
[0238] Thus prepared, compound 10 (15.2 g, 66.4 mmol) was dissolved in THF (664 ml), and to this solution was added DIPEA (13.91 ml, 80 mmol) and 2-hydroxyacetohydrazide (with reference to Scheme BII, compound 5 where “n”=1, 5.98 g, 66.4 mmol). The reaction mixture was stirred at 65° C. overnight, then the reaction mixture was cooled to RT and the solvent was evaporated. The crude product was redissolved in DCM and stirred for 30 min providing a pale yellowish precipitate. The precipitate was filtered and washed with DCM then dried in vacuo to afford compound 11a (with reference to Scheme BII, compound 11 wherein “n”=1). The identity of compound 11a was verified by LC/MS in accordance with the procedure listed herein (283 [M+1]).
[0000]
[0239] Compound 11a thus obtained (14.7 g, 52.0 mmol) was suspended in dioxane (520 ml) and added thereto was DIPEA (22.71 ml, 130 mmol) and (2,4)-dimethoxyphenyl-methanamine (10.16 ml, 67.6 mmol). The reaction mixture was heated to 100° C. for 16 hrs. then cooled to room temperature. The reaction was filtered and washed with dioxane until no yellow solution came out and washed with hexane several times and dried in vacuo to afford compound 12a (with reference to Scheme BII, compound 12, wherein “n”=1). The identity of compound 12a was verified by LC/MS in accordance with the procedure listed herein (414 [M+1]).
[0240] Thus obtained, compound 12a (20.3 g, 49.1 mmol) was placed into a tube, BSTA (144 ml, 589 mmol) was added and the tube was sealed. The sealed reaction mixture was heated to 130° C. overnight. Afterward, the reaction mixture was cooled down, transferred to a rotary evaporator and the BSTA was evaporated from the rotary evaporator for one hour in a water bath heated to 70° C.
[0241] The crude material thus obtained was dissolved in MeOH (170 mL) and 2.5 mL of conc. HCl was added. The solution became murky and after 10 min, the precipitate that had formed was filtered and washed with water (5×) and the solids were washed 2× with DCM (50 mL) followed by 1× with water, then dried under vac. oven overnight to afford as a pale yellow powder, compound 13a. The identity of compound 13a was verified by LC/MS in accordance with the procedure listed herein (396 [M+1]).
[0242] It will be appreciated that by selecting an appropriate hydrazide (compound 5, Scheme BII) analogs of compound 13a having an alkoxy-substituent where “n”>1 can be prepared. For example, following Scheme BII using 3-hydroxypropanehydrazide (Scheme BII, compound 5 where “n”=2) to react with compound 10 in place of 2-hydroxyacetohydrazide used as compound 5 in Preparative Example PII (“n”=1), ultimately yields compound 13b (shown above) from this procedure.
[0243] Once the hydroxy-substituted “right-side” precursor is prepared, for example, compounds 13a, 13b, or 13c, the hydroxy-substituted compound can be reacted to provide additional functionality at that location, for example, conversion to the corresponding chloride as shown in Scheme PIV.
[0000]
[0244] Thus, compound 13b-C1 (13x-C1 where “x” is “b” and “r” is 1) was prepared by suspending 2-(5-amino-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)ethanol (4 g, 15.4 mmol) in DCM (50 mL) and SOCl 2 (50 ml). The mixture was stirred at RT for 1 h, concentrated in vacuo to remove SOCl 2 completely. The residue was suspended in DCM/Hex (1:2), cooled to 0° C., filtered and dried to afford the titled compound LC/MS=279 [M+1].
[0245] In the same manner, compound 13c-C1 (13x-C1 where “x” is “c” and “r” is 2) was prepared by suspending 3-(5-amino-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)propan-1-ol in (240 mg, 0.878 mmol) in SOCl 2 (25 ml) and DCM (50 ml). The mixture was stirred at RT for 1 h, concentrated in vacuo to remove SOCl 2 completely to afford the titled compound. LC/MS=293 [M+1].
[0246] Variations on this procedure can provide a triazolo core with different functionality. For example, a 7-methoxy 9-fluoro-triazole can be prepared in accordance with the following scheme in a similar procedure by starting with -amino-5-fluoro-3-methoxybenzoic acid in accordance with Scheme E3, below.
[0247] A variation of synthesis Scheme BII is shown in Scheme PV (below). Thus, after obtaining compound 10 in accordance with Scheme BII, compound 10 was reacted with a hydrazinyl-oxopropanoate to provide compound P11b. In turn, compound 11b was reacted as shown in Scheme PV to provide “right-side” precursor P23, which is useful in preparing amide-substituted triazole compounds of the invention, for example, compounds Ex-153 and Ex-154 (described herein below).
[0000]
[0248] In accordance with the foregoing, to a stirred suspension of compound 10 (3.0 g, 13.10 mmol, prepared in accordance with general Scheme BII) in THF (30 mL) was added ethyl 3-hydrazinyl-3-oxopropanoate (2.01 g, 13.75 mmol) and DIPEA (6.86 ml, 39.3 mmol). The reaction mixture was heated to 55° C. overnight then cooled to ambient temp. and the solvent was evaporated. To the residue, DCM and water were added and the mixture extracted with DCM (×3). The organic extract was evaporated to afford compound P11b, (3.1 g, 67%) used as prepared.
[0249] To a pressure tube of P11b (2.1 g, 6.20 mmol) was added 90 mL ammonia (2M in isopropanol). The pressure tube was sealed and heated to 105 C overnight. The reaction mixture was cooled to room temperature and evaporated solvent. The crude product, compound P21 (2.72 g, 8.54 mmol), without further purification was mixed with N,O-bistrimethylsilyl acetamide (BSTA, 20.9 ml, 85 mmol) and the mixture sealed in a pressure tube then heated, with stirring, to 130° C. for 4 hrs. The reaction mixture was cooled to ambient temperature, then transferred to a rotary evaporator and the solvent removed. The residue was purified by silica chromatography (1/1 EtOAc/Hex to 10% MeOH/DCM) yielding ethyl 2-(5-amino-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)acetate. This product was suspended in THF (20 mL) and water (4 mL), mixed with LiOH—H 2 O. The mixture was stirred at room temperature overnight, then the solvent was evaporated and the residue dried under vac. oven overnight to yield P23.
General Preparation of “Left-Side” Precursors
Preparative Example PVI
Preparation of Piperazine-Functional “Left-Side” Precursors
[0250]
[0251] (Step 1) To a microwave tube was added (S)-4-N-Boc-2-methylpiperazine, 11 (250 mg, 1.248 mmol), 4-fluorobromobenzene (240 mg, 1.373 mmol), potassium tert-butoxide (140 mg, 1.248 mmol), Tris(dibenzylideneacetone)dipalladium-chloroform adduct (64.6 mg, 0.062 mmol), 2-dicyclohexylphosphino-2′,6′-di-I-propoxy -1,1′-biphenyl (87 mg, 0.187 mmol) and toluene (416 μl). The reaction mixture was microwaved at 100° C. for 2 hrs. The solvent was evaporated and EtOAc was added. The organic layer was washed with water, dried over MgSO4, filtered, and concentrated.
[0252] The crude product was purified by ISCO (EtOAc/Hex=1/5) to give the desired product 13, which was confirmed by LC/MS=295 [M+1].
[0253] (Step 2) To a stirred solution of 13 (210 mg, 0.713 mmol) in DCM (446 μl) was added 4M HCl in dioxane solution (5 mL). The reaction mixture was stirred at RT overnight.
[0254] The solvent was evaporated and the crude product was concentrated under high vac. to give the desired product, 13, which yielded LC/MS=195 [M+1].
EXAMPLES
Example 1
Preparation of Cycloamine-Triazole Compounds in Accordance with Scheme E1—Coupling “Right-Side” Piperazine-Precursor with Aryl or Heteroaryl-Halo Precursor
[0255] Piperazine precursor compounds were prepared using the reaction chemistry shown in Scheme AIII to provide Ex-E2-pre piperazine-functionalized compounds (where the piperazine functional group is HN—R″). Compounds of the invention were prepared from the piperazine precursor in accordance with Scheme E1.
[0000]
[0256] Thus, in accordance with Scheme E1, the compound of Ex-199 was prepared by suspending 80 mg of dihydridochloride salt (80 mg) of a compound of 2-((2,2-dimethylpiperazin-1-yl)methyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (the compound of Formula Ex-E2-pre where HNR 15 is as shown below in Table V for Ex-199) was suspended in DIPEA (101 μL) with 2-fluoro-5-(trifluoromethyl)pyridine (47.8 mg, reagent X—R 16 for Ex-199 in Table V) and heated at 80° C. overnight, then diluted with DCM. The organic layer was separated, washed with sat. aq NHCl 4 then water, dried over MgSO 4 , filtered and concentrated. The residue was purified by silica chromatography (EtOAc/Hex=1/1 to 100% EtOAc) to yield Ex-199.
[0257] All of the compounds of the form Ex-E2b from Scheme E1 shown in Table V were prepared in a similar manner from the appropriate piperazine precursor and appropriate X—R 16 reagent.
[0000]
TABLE V
Example
LC/MS
No
HN—R 15
X—R 16
R 16 —NR 15 —
[M + 1]
Ex-199
487 [M + 1]
Ex-200
514 [M + 1]
Ex-201
464 [M + 1]
Ex-202
464 [M + 1]
Ex-203
538 [M + 1]
Ex-204
488 [M + 1]
Ex-205
511 [M + 1]
Example 2
Preparation of Cycloamine-Triazole and Derivative Compounds in Accordance with Scheme AIII—Coupling “Right-Side” Precursor with Amine or Cycloamine Exemplied in Scheme E3 with Piperazine
[0258] Scheme E2 illustrates preparation of compounds of the invention in accordance with general Scheme AIII to prepare compounds of the structure of Compound 16 by coupling a functionalized piperidine reagent and a suitable chloro-functionalized “right-side” triazole precursor.
[0000]
[0259] Thus, in accordance with Scheme E2, to a stirred solution of the hydridochloride salt of compound 8a (80 mg, 0.267 mmol) in DMF (2665 μl) was added piperazine (78 mg, 0.293 mmol, prepared in accordance with preparative Example PIII, above), DIPEA (186 μl, 1.066 mmol), and KI (8.85 mg, 0.053 mmol). The reaction mixture was heated to 80° C. and stirred overnight. After cooling to ambient, NH 3 C1(aq) was added. The resulting precipitate was filtered, washed, dried and purified by flash chromatography (ISCO) (EtOAc/Hex=1/1 to 10% MeOH/DCM) to give compound EX-181 (62 mg). The identity of the product was confirmed by LC/MS (LC/MS=422 [M+1]).
[0260] Using the coupling procedure described above in Scheme E2 and various “Left-side” amino-functionalized “left-side” precursor compounds, additional examples of compounds of the invention described above were prepared which have the general structure:
[0000]
[0000] where R d is defined in Table VI
[0000]
TABLE VI
Ex-
ample
No.
R d
LC-MS
Ex-10
440 [M + 1]
Ex-180
448 [M + 1]
Ex-181
422 [M + 1].
Ex-182
423 [M + 1].
Ex-183
436 [M + 1].
Ex-187
448 [M + 1]
Ex-188
412 [M + 1].
Ex-189
490 [M + 1]
Ex-190
490 [M + 1]
Ex-191
434 [M + 1].
Ex-192
386 [M + 1].
Ex-193
398 [M + 1].
Ex-194
444 [M + 1].
Ex-195
434 [M + 1].
Ex-196
436 [M + 1].
Ex-197
436 [M + 1].
Ex-198
422 [M + 1].
Ex-208
366 [M + 1].
Ex-209
448 [M + 1]
Ex-210
432 [M + 1]
Ex-34
Rt = 1.84 [M + 1] = 438
Ex-35
Rt = 1.81 [M + 1] = 438
Ex-43
448 [M + 1].
Ex-44
450 [M + 1].
Ex-45
436 [M + 1].
[0261] Using the coupling procedure described above in Scheme E2, an appropriate “right-side” precursor and various amino-functionalized “Left-side” precursor compounds, additional examples of compounds of the invention were prepared which have the general structure:
[0000]
[0000] where R d is defined in Table VIa
[0000]
TABLE Via
Example No.
R d
LC-MS
Ex-178
422 [M + 1]
Ex-184
466 [M + 1]
Ex-185
515 [M + 1]
Ex-186
466 [M + 1]
Ex-206
448 [M + 1]
Ex-207
448 [M + 1]
Ex-211
454 [M + 1]
[0262] The synthesis presented in Scheme E2, above, was repeated using compound 8d (preparative Scheme PI, above) and an appropriate “left-side” precursor in accordance with reaction Scheme E3 to prepare (R)-9-fluoro-2-((4-(4-fluorophenyl)-2-methylpiperazin-1-yl) methyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (compound Ex-178).
[0000]
[0263] Thus, in accordance with Scheme E3, Hunig′s Base (0.093 mL, 0.533 mmol) was added to a stirred, room temperature mixture of (R)-1-(4-fluorophenyl)-3-methylpiperazine (41.4 mg, 0.213 mmol) in DMF (1 mL) and the mixture was stirred at room temperature for 10 min. 2-(chloromethyl)-9-fluoro-7-methoxy-[1, 2, 4]triazolo[1,5-c]quinazolin-5-amine (50 mg, 0.178 mmol) and potassium iodide (1.473 mg, 8.88 μmol) were added thereafter, and the resultant mixture was kept stirring at 80° C. overnight. The mixture was cooled, water (8 mL) was added and the yellow precipitate was collected and washed with water, dried. The yellow solid obtained was further purified by column chromatography on silica gel Teledyne ISCO Si; 24 g prepacked, eluting with CH 2 Cl 2 /MeOH=20:1 to give R)-9-fluoro-2-((4-(4-fluorophenyl)-2-methylpiperazin-1-yl)methyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (compound Ex-178) as a light yellow solid. LC/MS=422.2 [M+1].
[0264] This same synthetic procedure was carried out using an appropriately functionalized “left-side” piperazine precursor to provide compounds of the invention have the structure of Formula E3-A:
[0000]
[0000] , Formula E3-A, wherein R a1 to R a4 and R b2 are each defined in Table VII.
[0000]
TABLE VII
Exam-
LC/MS
ple No.
R a1 /R a2
R a3 /R a4
R b2
[M + l]
Ex-11
—CH 3 /—H
—H/—H
440.2
Ex-37
—H/—CH 3
—H/—H
Ex-41
—CH 3 /—H
—H/—H
Ex-42
—CH 3 /—H
—H/—H
Ex-178a
—H/—H
—CH 3 /—H
422.2
[0265] The synthesis presented in Scheme E3, above, was repeated using compound 8a and an appropriate “left-side” functionalized piperazine precursor to provide compounds of the invention, for example, compound Ex-170:
[0000]
[0266] Thus, compound Ex-170 was prepared by combining 2-(chloromethyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (40 mg, 0.15 mmol) in DMF (2 mL) with DIPEA (39 mg, 0.30 mmol) and mopholine (26 mg, 0.30 mmol). The mixture was stirred at ambient for 48 hours. The product (Ex-170, Table VIII) was purified using Gilson® reverse phase HPLC (acetonitrile (0.1% TFA)/H2O with 0.1% TFA). The compound was characterized by LC/MS [M+1=391].
[0267] This same procedure was carried out to provide additional compounds of the invention having the Formula E3-B:
[0000]
[0000] where R e is defined in Table VIII.
[0000]
TABLE VIII
Reten-
Ex-
tion
ample
Time
No.
R e
LC-MS
(min)
Ex-170
391 [M + 1]
1.38
Ex-171
482 [M + 1]
Ex-172
423 [M + 1]
1.68
Ex-173
473 [M + 1]
1.82
Ex-174
405 [M + 1].
1.45
Ex-175
458 [M + 1]
1.97
Ex-176
440 [M + 1]
1.78
Ex-177
476 [M + 1]
2.09
Ex-212
390 [M + 1]
1.77
[0268] The compounds shown in Table IX were also prepared using the synthesis procedure of E3 and an appropriately substituted piperazine “left-side” precursor.
[0000]
TABLE IX
Example
Ret. Time
No.
Structure
M + 1
(min)
Ex-1
422.2
1.85
Ex-2
404.2
1.71
Ex-9
404.2
1.497
Ex-10
422.2
1.565
[0269] The synthesis process presented in Scheme E3, above, was repeated using compound 8b (preparative Example PI, above) and an appropriate piperazine reagent in accordance with Scheme E3ab:
[0000]
Preparation of 7-methoxy-2-(2-(piperidin-1-yl)ethyl)-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (Ex-163)
[0270] Into a vessel was placed 2-(2-chloroethyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (compound 8b, 150 mg, 0.54 mmol), 5-fluoro-2-(piperazin-1-yl)pyrimidine (92 mg, 1.1 mmol), DIPEA (105 mg, 0.81 mmol) and KI (269 mg, 1.62 mmol) in DMF (50 mL), and the mixture was stirred at 80° C. for 18 h. The mixture was cooled down to RT, diluted with DCM, washed with H 2 O (3×), dried and concentrated. Chromatography purification MeOH/DCM (1:30-1:20-1:10) afforded the compound Ex-163, which was characterized using. LC/MS=424 [M+1].
[0271] Using a procedure similar to that used in the preparation of compound Ex-163, compounds of the invention having the structure of Formula E3-C were prepared:
[0000]
[0000] where “R e ” is defined in Table X.
[0000]
TABLE X
Ex-
Retention
ample
Time
No.
R f
LC-MS
(min)
Ex-163
424 [M + 1]
1.95
Ex-164
423 [M + 1]
1.96
Ex-165
405 [M + 1]
1.81
Ex-166
404 [M + 1]
1.97
Ex-167
439 [M + 1]
1.83
Ex-168
436 [M + 1]
1.74
Ex-169
437 [M + 1]
1.66
[0272] Compound Ex-158 was prepared in accordance with Scheme E3-ac from compound 8c (preparative Example PI, above) and an appropriate piperazine reagent.
[0000]
Preparation of 7-methoxy-2-(3-morpholinopropyl)-[1,2,4]triazolo[1,5-c]quinazolin-5-amine
[0273] Into a vessel was placed 2-(3-chloropropyl)-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-5-amine (compound 8c, 80 mg, 0.286 mmol), 1-(pyridin-2-yl)piperazine (75 mg, 0.86 mmol), and KI (142 mg, 0.858 mmol) in DMF (2 mL). The mixture was stirred at 80° C. for 18 h. The mixture was cooled down to RT, diluted with DCM, washed with H 2 O (3×), dried and concentrated. Chromatography purification MeOH/DCM (1:30-1:20-1:10) afforded compound Ex-158, which was characterized by LC/MS=419 [M+1].
[0274] Using the procedure shown in Scheme E3-ac and an appropriate piperazine derivative, the compounds of Formula E3-D were prepared:
[0000]
[0000] where “R g ” is defined in Table XI.
[0000]
TABLE XI
Retention
Example
Time
No.
Structure
LC-MS
(min)
Ex-158
419 [M + 1]
1.77
Ex-159
450 [M + 1]
1.73
Example 3
Preparation of Compounds of the Invention Via DIPEA-Mediated Coupling of a Piperazine “Left-Side” Precursor and Triazolo “Right-Side” Precursor
[0275] Additional compounds of the invention were prepared in accordance with general preparative scheme AI from triazole “right-side” precursor 8F (prep scheme PII) and an appropriate piperazine reagent in accordance with Scheme E3-ac:
[0000]
[0276] Using this same procedure, compounds of Formula E3-E were prepared:
[0000]
[0000] wherein R b2 is defined in Table XII.
[0000]
TABLE XII
Retention time (min)
Example No.
R 2b
LC-MS [M + 1].
Ex-160
1.46 433
Ex-161
1.41 434
Example 4
Preparation of Cycloamine-Triazole Piperazine Compounds Using Palladium Catalyst in Accordance with Scheme AIII from DMB-Protected “Right-Side” Piperazine-Substituted Precursor (Ex-E4-Pre) and Appropriately-Substituted Aryl Bromide
[0277] Using the process described in Scheme E3, the compound Ex-E4-pre was prepared from Compound 8a-Protected (see general prep Scheme AIII (preparation of cmpd 15) and Scheme BId) and an appropriate acyl-protected piperazine precursor as shown in Scheme E4.
[0000]
[0278] The compound Ex-55 was prepared from Compound Ex-E4-pre and an appropriately substituted aromatic reagent Scheme E4-ab.
[0000]
[0279] Accordingly, into a vessel containing the compound of Formula Ex-E4-pre previously prepared ([(R)—N-(3,5-dimethoxybenzyl)-7-methoxy-2-((2-methylpiperazin-1-yl)methyl)-[1,2,4]triazolo[1,5-c]quinazolin-5-amine], 30 mg, 0.063 mmol) dissolved in THF (628 uL), was added Chloro(2-dicyclohexylphosphino-2′,6′-di-i-propoxy-1,1′-biphenyl)[2-(2-aminoethylphenyl)]-palladium(II) (X-Phos, 9 mg, 0.013 mmol), 3-bromobenzotrifluoride (27.46, 0.0123 mmol) and finally potassium tert-butoxide (22 mg, 0.188 mmol). The reaction mixture was heated at 100° C. for 15 h then cooled to ambient temperature of 21° C. 10% w/v citric acid (1000 uL) was added followed by dichloromethane (2×1000 uL). The organic layers were separated and then concentrated in vacuo via a Genevac. The residue thus collected was then dissolved in trifluoroacetic acid (300 uL, 3.89 mmol) and heated to 40 C for 4 h and then allowed to stir at 21° C. for 8 hours. The reaction was then diluted with DMSO (1000 uL) and was purified by reverse phase semi prep HPLC Waters XBridge (CH 3 CN/H 2 O/NH 4 OH, C18, 5 u, 19×100 mm system) to yield compound Ex-55 as a solid, which was characterized using LC/MS=472 [M+1].
[0280] Compounds of the invention having the structure of Formula E4-A were prepared by using this same method by reacting an appropriate aryl moiety with the compound of Formula Ex-E4-pre in accordance with Scheme E4-ab:
[0000]
[0000] Formula E4-A, wherein R b2 is defined in Table XIII, below.
[0000]
TABLE XIII
Example
Retention
No.
R b2
[M + 1]
Time
EX-55
472
1.07
EX-56
422
0.95
EX-57
422
0.96
EX-58
438
1.02
EX-59
429
0.89
EX-60
429
0.89
EX-61
429
0.87
EX-62
406
0.75
EX-63
455
0.81
EX-64
418
1.04
EX-65
418
0.99
EX-66
418
0.98
EX-67
434
0.90
EX-68
434
0.91
EX-69
405
0.71
EX-70
405
0.70
EX-71
454
1.10
EX-72
454
1.07
EX-73
434
0.87
Example 5
Compounds of the Invention Prepared According to General Scheme AIII to Provide Compounds of Structure 16a in Accordance with Synthesis Scheme E5
[0281] “Right-side” precursors having substituents in the R E5a position as defined in Table XIV (below) were employed to prepare piperidine-substituted compounds of the invention using the synthesis procedure described in general scheme AIII, as shown in Scheme E5.
[0000]
[0282] Accordingly, the compound Ex-4-B—CN (compound Ex-4-B where substituent R E5a is —CN), (110 mg; 0.27 mmol), 1-(4-fluorophenyl)-3(R)-methyl piperazine hydrochloride (85 mg; 0.37 mmol) and Hunig's base (0.14 mL; 104 mg; 0.807 mmol) in anhydrous DMF (1 mL) was stirred and heated at 80° C. for 18 hr. The reaction mixture was cooled to RT, diluted with water and extracted with EtOAc. The organic extract was washed with water and brine. Combined aqueous layers were back extracted with CH 2 Cl 2 . Both organic extracts were combined, dried over solid anhydrous Na 2 SO 4 and concentrated to yield a beige solid. The crude product was purified by preparative TLC (5% CH 3 OH—CH 2 Cl 2 ) and the major fluorescent band that was the 2,4-dimethoxybenzyl protected form of Ex-4-C-CN (Ex-4-C wherein substituent R E5a is —CN) was isolated as an off-white solid that was characterized by LC/MS=567 (MH + ).
[0283] The isolated product from the previous step was dissolved in CH 2 Cl 2 :TFA (1 mL each) and stirred at 57° C. for 4 hr. The clear reaction mixture had become deep purple and MS showed complete deprotection of the DMB group to give the desired product. The solvents were removed on a rotary evaporator and the residual TFA was removed by azeotrope formation with toluene to give a yellow sticky semi-solid. This material was treated with 7% NH 3 in methanol, stirred for 10 minutes and concentrated to obtain a beige solid. The crude product was purified by preparative TLC (CH 2 Cl 2 with 7% NH 3 in methanol, 96:4) to afford compound Ex-156, an off-white solid characterized using LC/MS: 417 (MH + ); R t =2.02.
[0000]
[0284] Compound Ex-157 (Ex-4-C, wherein —R Ex5a is —Br) and Compound Ex-155 (compound Ex-4-C, wherein R Ex5a is —CF 3 ) were prepared using the procedure of Scheme E5, and are listed in Table XIV with their corresponding characterization data.
[0000]
TABLE XIV
Example No.
Structure
M + 1 (R t )
EX-157
470 (2.13)
Ex-156
417 (2.02)
EX-155
460 (1.93)
Example 6
Preparation of [1,2,4]triazolo[1,5-c]quinazolin-2-yl)-1-(4substituted-piperazin-1-yl)ethanone compounds from 2-(5-amino-7-methoxy-[1,2,4]triazolo[1,5-c]quinazolin-2-yl)acetic acid “right-side” precursor and an appropriately-substituted piperazine reagent
[0285]
[0286] To a stirred suspension of E11-A (0.025 g, 0.081 mmol) followed by Dichloromethane (5 ml), 4-fluorophenylpiperazine (0.031 g, 0.161 mmol), DIPEA (0.070 ml, 0.404 mmol), and 1-propanephosphonic acid cyclic anhydride (0.096 ml, 0.161 mmol). The reaction was stirred room temperature overnight.
[0287] The reaction mixture was concentrated, diluted with water (˜0.5 mL) and then dissolved in DMSO (˜4 mL).
[0288] The residue was purified by preparative HPLC (Reverse phase C-18, Phenomenex Gemini, Axia 150×21.2 mm, 5 u), eluting with 10-95% Acetonitrile/Water+0.1% TFA (20 mL/min) over 10 min. to give the product as a TFA salt. LCMS M+H=450
[0289] Using a similar procedure, the compound of Formula Ex-153 was also prepared from a suitably substituted piperazine “left-side” precursor and the compound of Formula P23 (see Scheme AII):
[0000]
[0290] The compound of Formula Ex-153 was characterized by LC/MS (Rt 0.51, Meth B, [M+1]=419]
Example 7
Preparation of Compound of the Invention Ex-50 from “Right-Side” Precursor of Formula 13a
[0291]
Step A
5-[(2,4-dimethoxybenzyl)amino]-7-methoxy[1,2,4]triazolo[1,5-c]quinazoline-2-carbaldehyde
[0292] To a dichloromethane (50 mL) solution of {5-[(2,4-dimethoxybenzyl)amino]-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-2-yl}methanol (compound 13a prepared in accordance with general preparative procedure PII, above, 1,000 mg, 2.53 mmol) was added 1,1,1-tris(acetyloxy)-1,1-dihydro-1,2-benziodoxl-3-(1H)-one (1,126 mg, 2.66 mmol). The reaction mixture was stirred at room temperature for 30 minutes, washed with saturated sodium bicarbonate solution and then with brine, dried (magnesium sulfate), filtered, and concentrated in vacuo. Chromatography over silica gel, eluting with hexanes/ethyl acetate, afforded the title compound as a white solid. 1 H NMR (500 MHz, DMSO-d 6 ) δ 10.19 (s, 1H), 8.59 (t, J=5.8 Hz, 1H), 7.84 (dd, J=7.9, 1.3 Hz, 1H), 7.37 (t, J=7.9 Hz, 1H), 7.30 (dd, J=8.0, 1.3 Hz, 1H), 7.26 (d, J=8.4 Hz, 1H), 6.57 (d, J=2.4 Hz, 1H), 6.42 (dd, J=8.4, 2.4 Hz, 1H), 4.70 (d, J=5.7 Hz, 2H), 3.90 (s, 3H), 3.84 (s, 311), 3.71 (s, 3H); LC-MS: m/z 394.1 (M+H).
Step B
(±)-1-{5[(2,4-dimethoxybenzyl)amino]-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-2-yl}ethanol
[0293] To a tetrahydrofuran (10 mL) solution of 5-[(2,4-dimethoxybenzyl)amino]-7-methoxy[1,2,4]triazolo[1,5-c]quinazoline-2-carbaldehyde (537 mg, 1.37 mmol) at 0° C. was added 3.0 M tetrahydrofuran solution of methylmagnesium chloride (1.0 mL, 3.0 mmol). The reaction mixture was stirred in an ice-bath for 45 minutes and then at room temperature for 1.5 hours. It was quenched with saturated ammonium chloride solution and extracted with ethyl acetate (3×50 mL). The combined organic layers were washed with brine and concentrated in vacuo to afford the crude solid. It was recrystallized from ethyl acetate/hexanes to afford the title compound as an off-white solid. 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.09 (t, J=6.1 Hz, 1H), 7.76 (d, J=8.0 Hz, 1H), 7.30 (t, J=7.7 Hz, 1H), 7.26-7.20 (m, 2H), 6.57 (d, J=2.3 Hz, 1H), 6.43 (dd, J=8.3, 2.5 Hz, 1H), 5.58 (d, J=5.1 Hz, 1H), 4.99 (quintet, J=6.1 Hz, 1H), 4.68 (d, J=5.9 Hz, 2H), 3.89 (s, 3H), 3.84 (s, 3H), 3.71 (s, 3H), 1.55 (d, J=6.6 Hz, 3H); LC-MS: m/z 410.1 (M+H).
Step C
(±)-1-{5-[(2,4-dimethoxybenzyl)amino]-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-2-yl}ethyl methanesulfonate
[0294] To a dichloromethane (20 mL) solution of (±)-1-{-[4(2,4-dimethoxybenzyl)amino]-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-2-yl}ethanol (437 ing, 0.865 mmol) and diisopropylethylamine (0.75 mL, 4.3 mmol) was added methanesulfonyl chloride (0.25 mL, 3.2 mmol). The reaction mixture was stirred for 15 minutes at room temperature. It was washed with water and with brine, dried (magnesium sulfate), and concentrated in vacuo. Chromatography over silica gel, eluting with hexanes/ethyl acetate, afforded the title compound as a white solid. 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.24 (t, J=6.0 Hz, 1H), 7.78 (d, J=7.9 Hz, 1H), 7.39-7.26 (m, 1H), 7.25 (d, J=8.3 Hz, 2H), 6.57 (d, J=2.4 Hz, 1H), 6.43 (dd, J=8.2, 2.6 Hz, 1H), 6.01 (q, J=6.6 Hz, 1H), 4.69 (d, J=6.2 Hz, 2H), 3.89 (s, 3H), 3.84 (s, 3H), 3.71 (s, 3H), 3.27 (s, 3H), 1.83 (d, J=6.6 Hz, 3H); LC-MS: m/z 488.0 (M+H).
Step D
(±)-2-(1-chloroethyl)-N-(2,4-dimethoxybenzyl)-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-5-amine
[0295] To an acetone (15 mL) solution of (±)-1-{5-[(2,4-dimethoxybenzyl)amino]-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-2-yl}ethyl methanesulfonate (340 mg, 0.697 mmol) was added lithium chloride (150 mg, 3.54 mmol). The reaction mixture was refluxed for 24 hours and concentrated in vacuo. It was dissolved in dichloromethane (50 mL), washed with saturated sodium bicarbonate solution, dried (magnesium sulfate), and concentrated in vacuo to afford the title compound as a crude solid. It was used in the subsequent reaction without further purification. 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.21 (t, J=6.0 Hz, 1H), 7.78 (dd, J=7.9, 1.3 Hz, 1H), 7.32 (t, J=8.0 Hz, 1H), 7.27-7.23 (m, 2H), 6.57 (d, J=2.3 Hz, 1H), 6.43 (dd, J=8.3, 2.5 Hz, 1H), 5.57 (q, J=6.8 Hz, 1H), 4.68 (dd, J=6.3, 2.5 Hz, 2H), 3.89 (s, 3H), 3.84 (s, 3H), 3.71 (s, 3H), 1.98 (d, J=6.7 Hz, 3H); LC-MS: m/z 428.0 (M+H).
Step E
N-(2,4-dimethoxybenzyl)-2-{1-[(2R)-4-(4-fluorophenyl)-2-methylpiperazin-1-yl]ethyl}-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-5-amine
[0296] To a N,N-dimethylformamide (5 mL) solution of (3R)-1-(4-fluorophenyl)-3-methylpiperazine (158 mg, 0.813 mmol) and (±)-2-(1-chloroethyl)-N-(2,4-dimethoxybenzyl)-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-5-amine (300 ing, 0.701 mmol) was added potassium iodide (148 mg, 0.892 mmol) and diisopropylethylamine (0.30 mL, 1.7 mmol). The reaction mixture was heated to 80° C. for 18 hours. It was cooled to room temperature and diluted with saturated ammonium chloride solution. It was extracted with ethyl acetate (3×25 mL), and the combined organic layers were washed with water and with brine, dried (magnesium sulfate), and concentrated in vacuo. Chromatography over silica gel, eluting with hexanes/ethyl acetate, afforded the title compound as two separated diastereomers.
[0297] Less polar diastereomer 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.11 (t, J=6.0 Hz, 1H), 7.78 (d, J=7.9 Hz, 1H), 7.30 (t, J=7.9 Hz, 1H), 7.28-7.19 (m, 2H), 7.00 (t, J=8.7 Hz, 2H), 6.91-6.86 (m, 2H), 6.57 (d, J=2.3 Hz, 1H), 6.44 (dd, J=8.4, 2.3 Hz, 1H), 4.69 (d, J=6.0 Hz, 2H), 4.55 (q, J=6.9 Hz, 1H), 3.89 (s, 3H), 3.84 (s, 3H), 3.71 (s, 3H), 3.40 (d, J=11.2 Hz, 1H), 3.24 (d, J=10.6 Hz, 1H), 2.99-2.84 (m, 1H), 2.89-2.83 (m, 1H), 2.67-2.51 (m, 3H), 1.44 (d, J=6.8 Hz, 3H), 1.20 (d, J=6.2 Hz, 3H); LC-MS: m/z 586.1 (M+H).
[0298] More polar diastereomer 1 H NMR (500 MHz, DMSO-d 6 ) δ 7.98 (t, J=6.1 Hz, 1H), 7.77 (dd, J=7.9, 1.3 Hz, 1H), 7.30 (t, J=7.9 Hz, 1H), 7.26 (d, J=8.4 Hz, 1H), 7.23 (dd, J=8.0, 1.4 Hz, 1H), 7.02-6.94 (m, 2H), 6.89-6.84 (m, 2H), 6.58 (d, J=2.4 Hz, 1H), 6.45 (dd, J=8.4, 2.4 Hz, 1H), 4.75-4.64 (m, 2H), 4.64-4.57 (m, 1H), 3.89 (s, 3H), 3.84 (s, 3H), 3.71 (s, 3H), 3.45 (d, J=11.3 Hz, 1H), 3.38 (d, J=11.5 Hz, 1H), 3.13 (dt, J=11.7, 2.9 Hz, 1H), 2.63 (td, J=11.1, 2.9 Hz, 1H), 2.59-2.48 (m, 1H), 2.41 (td, J=11.4, 2.9 Hz, 1H), 2.36 (t, J=10.6 Hz, 1H), 1.58 (d, J=7.0 Hz, 3H), 1.29 (d, J=6.1 Hz, 3H); LC-MS: m/z 586.1 (M+H).
Step F
2-{1-[(2R)-4-(4-fluorophenyl)-2-methylpiperazin-1-yl]ethyl}-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-5-amine
[0299] The less polar diastereomer of N-(2,4-dimethoxybenzyl)-2-{1-[(2R)-4-(4-fluorophenyl)-2-methylpiperazin-1-yl]ethyl}-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-5-amine (78 mg, 0.133 mmol) was charged with trifluoroacetic acid (2 mL) and heated at 50° C. for 3 hours. The reaction mixture was concentrated in vacuo and charged with a 2.0 M methanolic solution of ammonia (4 mL), precipitating one diasteromer of the title compound as a white solid. 1 H NMR (500 MHz, DMSO-d 6 ) δ 7.79 (s, 2H), 7.76 (d, J=8.1 Hz, 1H), 7.29 (t, J=7.9 Hz, 1H), 7.21 (d, J=7.9 Hz, 1H), 7.00 (t, J=8.7 Hz, 2H), 6.89 (dd, J=8.9, 4.7 Hz, 2H), 4.53 (q, J=6.9 Hz, 1H), 3.89 (s, 3H), 3.39 (d, J=11.3 Hz, 1H), 3.24 (d, J=11.8 Hz, 1H), 2.94-2.89 (m, 1H), 2.89-2.83 (m, 1H), 2.66-2.53 (m, 3H), 1.43 (d, J=6.8 Hz, 3H), 1.20 (d, J=6.2 Hz, 3H); LC-MS: m/z 436.0 (M+H).
[0300] The more polar diastereomer of N-(2,4-dimethoxybenzyl)-2-{1-[(2R)-4-(4-fluorophenyl)-2-methylpiperazin-1-yl]ethyl}-7-methoxy[1,2,4]triazolo[1,5-c]quinazolin-5-amine (100 mg, 0.171 mmol) was charged with trifluoroacetic acid (2 mL) and heated at 50° C. for 3 hours. The reaction mixture was concentrated in vacuo and charged with a 2.0 M methanolic solution of ammonia (4 mL). The reaction mixture was concentrated in vacuo to afford a crude solid. Chromatography over silica gel, eluting with hexanes/ethyl acetate, afforded the other diasteromer of the title compound. 1 H NMR (500 MHz, DMSO-d 6 ) δ 7.77 (s, 2H), 7.74 (dd, J=8.0, 1.2 Hz, 1H), 7.29 (t, J=8.0 Hz, 1H), 7.21 (d, J=7.9 Hz, 1H), 6.98 (t, J=8.7 Hz, 2H), 6.86 (dd, J=8.9, 4.7 Hz, 2H), 4.59 (q, J=7.1 Hz, 1H), 3.89 (s, 3H), 3.45 (d, J=11.1 Hz, 1H), 3.37 (d, J=11.4 Hz, 1H), 3.13 (d, J=11.5 Hz, 1H), 2.63 (td, J=11.1, 2.8 Hz, 1H), 2.55-2.46 (m, 1H), 2.42 (td, J=11.4, 2.9 Hz, 1H), 2.35 (t, J=10.6 Hz, 1H), 1.57 (d, J=7.0 Hz, 3H), 1.28 (d, J=6.1 Hz, 3H); LC-MS: m/z 436.0 (M+H).
[0301] It will be appreciated that by applying the foregoing methods, all of the compounds presented in Tables can be prepared.
A2a Activity of Compounds of the Invention
[0302] Binding affinities of compounds of the invention for the human A2a receptor were determined in a competition binding assay using Scintillation Proximity technology. Thus, 0.3 ug of membranes from HEK293 cells expressing the human A2a receptor were incubated with a compound of the invention at concentrations ranging from 3000 nM to 0.15 nM in a reaction mixture containing also 0.5 nM of a tritiated form of 5-amino-7-[2-phenethyl]-2-(furan-2-yl)-7H-pyrazolo[4,3-e][1,2,4]triazolo-[1,5-c]pyrimidine (the tritiated compound) and 100 ug of wheatgerin agglutin-coated yttrium silicate SPA beads for one hour at room temperature with agitation. The beads were then allowed to settle to the bottom of the wells for 1 hr, after which the membrane-associated radioactivity was determined by scintillation counting in a TopCount microplate reader. Ki values were determined using the Cheng-Prusoff equation.
Summary of Materials and Methods Used in A2a Activity Determination:
Materials
[0000]
HEK293 cells expressing the human, rat, dog or monkey adenosine 2a receptor (Purchased from Perkin-Elmer # RBHA2AM400UA).
The Tritiated compound was prepared in-house by MRL Radiochemistry according to published methods.
Wheatgerm agglutinin-coated yttrium silicate SPA beads (GE Healthcare #RPNQ0023). Dilute to 25 mg/ml in assay buffer.
Assay Buffer was prepared in house: Dulbecco's calcium and magnesium free phosphate buffered saline+10 mM MgCl 2
Adenosine deaminase from calf intestine, 10 mg/2 ml (Roche #10 102 105 001).
DMSO
A2a antagonist standard (9-chloro-1-(2-furanyl)-[1,2,4]triazolo1,5-c]quinazolin-5-amine from Tocris Bioscience)
Compound Dilution
[0000]
Make eight 1:3 serial dilutions in 100% DMSO from a 3 mM compound stock
Transfer 50 nl of compound into a 384-well OptiPlate (Perkin Elmer).
Typically, final concentrations of compound used in the assay ranged from 3000 nM to 0.152 nM.
Radioisotope
[0000]
Dilute a solution of the Tritiated compound to 1.25 nM in assay buffer. This is a 2.5× solution. The final concentration in the assay is 0.5 nM. Calculate the concentration by counting two 5 ul aliquots.
Membrane Preparation
[0000]
Use 0.25 ug of membrane/well. Dilute membranes to 9.7 ug/ml in assay buffer. Treat with 20 ug/ml adenosine deaminase (ADA) for 15 minutes at room temperature to degrade endogenous adenosine.
Membrane-Bead Mixture
[0000]
Use 100 ug/well wheatgerm agglutinin-coated yttrium silicate SPA beads.
Mix ADA-treated membranes and SPA beads together for 30 min prior to assay.
Assay Assembly
[0000]
To the Perkin-Elmer Optiplate-384 containing the compound titration add 20 ul of 2.5× solution of the Tritiated compound and 30 ul of the membrane-bead mixture. Incubate for one hour at room temperature with agitation.
Include total binding (assay buffer+1% DMSO) and non-specific binding (CGS15943, 1 uM) wells.
Counting
[0000]
Allow the beads to settle for one hour.
Count in TopCount.
Calculations
[0000]
A curve fitting program (i.e., Prism, Activity Base, Chemcart) is used to determine the EC50.
[0322] The Ki value is calculated using the Cheng-Prusoff equation.
[0000] Ki=EC50/(1+(radioligand concentration/Kd))
[0323] Using the foregoing assay method, the following results were obtained using various of the compounds of the invention described herein. Each example compound tested is reported in the following format: Example number: A2a EC50 reported in nM. Thus, for example, the compound Ex-1 was determined to have an EC50 using the above-described assay, of 4.251 nM, and is accordingly reported as “Ex-1: A2a=4.251”:
Ex-1: A2a=4.251; Ex-2: A2a=10.1; Ex-3: A2a=189.7; Ex-4: A2a=43.54; Ex-5: A2a=6.785; Ex-6: A2a=4.023; Ex-7: A2a=20.91; Ex-8: A2a=21.25; Ex-9: A2a=44; Ex-10: A2a=54.67; Ex-11: A2a=7.682; Ex-12: A2a=87.95; Ex-13: A2a=87.1; Ex-14: A2a=52.77; Ex-15: A2a=8.097; Ex-16: A2a=36.51; Ex-17: A2a=26.7; Ex-18: A2a=26.9; Ex-19: A2a=29.6; Ex-20: A2a=51.7; Ex-21: A2a=20.3; Ex-22: A2a=10; Ex-23: A2a=17.7; Ex-24: A2a=14.4; Ex-25: A2a=34.5; Ex-26: A2a=21.8; Ex-27: A2a=6.8; Ex-28: A2a=15.6; Ex-29: A2a=18.6; Ex-30: A2a=9.2; Ex-31: A2a=49.1; Ex-32: A2a=78.3; Ex-33: A2a=35.9; Ex-34: A2a=18.5; Ex-35: A2a=3.7; Ex-36: A2a=18.1; Ex-37: A2a=48.9; Ex-38: A2a=37.5; Ex-39: A2a=13.3; Ex-40: A2a=22.6; Ex-41: A2a=18.1; Ex-42: A2a=28.3; Ex-43: A2a=2.108; Ex-44: A2a=3.6; Ex-45: A2a=5.7; Ex-46: A2a=50.2; Ex-47: A2a=59.2; Ex-48: A2a=18.2; Ex-49: A2a=4.9; Ex-50: A2a=139.4; Ex-51: A2a=73.8; Ex-52: A2a=48.5; Ex-53: A2a=15.93; Ex-54: A2a=106; Ex-55: A2a=5.2; Ex-56: A2a=8.5; Ex-57: A2a=4.178; Ex-58: A2a=12.4; Ex-59: A2a=30.9; Ex-60: A2a=18.8; Ex-61: A2a=11.4; Ex-62: A2a=26.5; Ex-63: A2a=1.444; Ex-64: A2a=13.1; Ex-65: A2a=7.0; Ex-66: A2a=3.0; Ex-67: A2a=8.9; Ex-68: A2a=7.71; Ex-69: A2a=39.8; Ex-70: A2a=92.8; Ex-71: A2a=11.5; Ex-72: A2a=6.7; Ex-73: A2a=2.1; Ex-74: A2a=31.82; Ex-75: A2a=47.4; Ex-76: A2a=13.48; Ex-77: A2a=9.691; Ex-78: A2a=4.537; Ex-79: A2a=21.12; Ex-80: A2a=19.37; Ex-81: A2a=68.2; Ex-82: A2a=627.6; Ex-83: A2a=47.65; Ex-84: A2a=57.21; Ex-85: A2a=7.682; Ex-86: A2a=3.325; Ex-87: A2a=21.47; Ex-88: A2a=22.16; Ex-89: A2a=72.24; Ex-90: A2a=53.5; Ex-91: A2a=42.25; Ex-92: A2a=5.2; Ex-93: A2a=4.6; Ex-94: A2a=1.848; Ex-95: A2a=3.098; Ex-96: A2a=3.411; Ex-97: A2a=18.18; Ex-98: A2a=39.66; Ex-99: A2a=46.29; Ex-100: A2a=29.4; Ex-101: A2a=4.954; Ex-102: A2a=2.14; Ex-103: A2a=5.559; Ex-104: A2a=23.13; Ex-105: A2a=16.79; Ex-106: A2a=4.728; Ex-107: A2a=6.98; Ex-108: A2a=5.268; Ex-109: A2a=4.664; Ex-110: A2a=1.105; Ex-111: A2a=0.9182; Ex-112: A2a=1.597; Ex-113: A2a=27.30; Ex-114: A2a=12.25; Ex-115: A2a=1.388; Ex-116: A2a=3.033; Ex-117: A2a=12.7; Ex-118: A2a=1.246; Ex-119: A2a=1.974; Ex-120: A2a=20.75; Ex-121: A2a=13.24; Ex-122: A2a=4.858; Ex-123: A2a=4.248; Ex-124: A2a=2.824; Ex-125: A2a=1.026; Ex-126: A2a=2.393; Ex-127: A2a=3.076; Ex-128: A2a=0.964; Ex-129: A2a=11.58; Ex-130: A2a=0.8983; Ex-131: A2a=0.6984; Ex-132: A2a=2.041; Ex-133: A2a=1.684; Ex-134: A2a=4.566; Ex-135: A2a=10.7; Ex-136: A2a=11.42; Ex-137: A2a=20.57; Ex-138: A2a=14.28; Ex-139: A2a=81.77; Ex-140: A2a=4.929; Ex-141: A2a=2.339; Ex-142: A2a=16.49; Ex-143: A2a=13.89; Ex-144: A2a=20.12; Ex-145: A2a=18.37; Ex-146: A2a=6.348; Ex-147: A2a=6.6; Ex-148: A2a=18; Ex-149: A2a=13.42; Ex-150: A2a=15.02; Ex-151: A2a=2.217; Ex-152: A2a=2.2; Ex-153: A2a=7.3; Ex-154: A2a=2.6; Ex-155: A2a=136.4; Ex-156: A2a=740; Ex-157: A2a=14.4; Ex-158: A2a=7.1; Ex-159: A2a=24.4; Ex-160: A2a=343.4; Ex-161: A2a=524.9; Ex-162: A2a=74.2; Ex-163: A2a=7.8; Ex-164: A2a=2.5; Ex-165: A2a=3.3; Ex-166: A2a=13.5; Ex-167: A2a=11.5; Ex-168: A2a=4.1; Ex-169: A2a=2.6; Ex-170: A2a=157; Ex-171: A2a=30.4; Ex-172: A2a=13.3; Ex-173: A2a=22.6; Ex-174: A2a=37.5; Ex-175: A2a=5.6; Ex-176: A2a=8.9; Ex-177: A2a=12.7; Ex-178: A2a=19.3; Ex-180: A2a=1.1; Ex-181: A2a=19.9; Ex-182: A2a=10.2; Ex-183: A2a=5.0; Ex-184: A2a=16.4; Ex-185: A2a=5.7; Ex-186: A2a=3.5; Ex-187: A2a=5.8; Ex-188: A2a=12.6; Ex-189: A2a=3.1; Ex-190: A2a=6.7; Ex-191: A2a=8.2; Ex-192: A2a=153.1; Ex-193: A2a=127.8; Ex-194: A2a=24.8; Ex-195: A2a=41.6; Ex-196: A2a=95.7; Ex-197: A2a=32.4; Ex-198: A2a=8.25; Ex-199: A2a=10.8; Ex-200: A2a=15.6; Ex-201: A2a=50.2; Ex-202: A2a=29.1; Ex-203: A2a=8.5; Ex-204: A2a=11.5; Ex-205: A2a=4.1; Ex-206: A2a=30.9; Ex-207: A2a=144.8; Ex-208: A2a=143.1; Ex-209: A2a=9.4; Ex-210: A2a=7.7; Ex-211: A2a=9.9. | Disclosed are compounds of Formula A: (structurally represented) where “RG1”, “RG2a”, “RG4”, “RG5”, “MG1”, “n” and “m” are defined herein which compounds are antagonists of A2A receptor. Disclosed herein also are uses of the compounds described herein as antagonists of the A2a receptor in the potential treatment or prevention of neurological disorders and diseases in which A2A receptors are involved. Disclosed herein also are pharmaceutical compositions comprising these compounds and uses of these pharmaceutical compositions. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to control of prostheses and the like and more particularly relates to an electromyographic sensor.
BACKGROUND OF THE INVENTION
[0002] Electromyographic (“EMG”) sensors are well known. EMG sensors in particular are known for their use in the control of electrically powered prosthetic systems. An individual can have an EMG sensor affixed to a portion of his or her body, and issue instructions to a prosthesis attached to the EMG sensor by voluntarily sending muscular signals to the EMG sensor. The EMG sensor detects the electric signal of the muscles and generates a control or input signal that is delivered to the prosthetic system. In this manner, the user voluntarily controls the prosthesis. One example of a prior art EMG sensor is the Otto Bock brand of myographic electrode (EMG sensor), from Otto Bock, Two Carlson Parkway North, Suite 100, Minneapolis, Minn. 55447-4467, model number 13E125.
[0003] Existing EMG sensors used in the control of electrically powered prosthetic systems, including those found in products from Otto Bock, such as their 12K42 and 12K50 ErgoArm Elbows and 12K44 ErgoArm Elbow Hybrd Plus, all utilize a wiring system that connects the electrode (sensor) to control electronics. Users of prosthetic systems utilizing currently existing EMG sensors frequently encounter problems associated with the wiring system. Examples of problems associated with the wiring system include wire defects and damage, and wire connection errors, which can all be difficult to detect. In addition, existing wiring systems are often mechanically complex due to the complexity of wire routing between the electrode and control electronics. Wiring systems also occupy valuable space, and thereby increase the size of prostheses, add weight and impair agility and increase user fatigue. Even small reductions in weight can have significant performance improvements.
[0004] The physical impact and damage from daily usage coupled with the need for sensitive proportional control in prosthetic systems, make high demands on the reliability and stability of control signals from EMG sensors. As such, prosthetic systems utilizing existing EMG sensors are limited by the reliability of their wiring systems.
[0005] Telemetry of biological data has been researched for many years (Stoller, 1986; Jeutter, 1982). EMG data has proven itself useful in rehabilitation. It has been used to control myoelectric prostheses for many years and has been shown to be useful for human interfaces and gait analysis, as well (Giuffrida J P and Crago P E, “Reciprocal EMG control of elbow extension by FES,” IEEE Trans Neural Syst Rehabil Eng, 2001, December; 9(4), pp. 338-45; Brudny J, Hammerschlag P E, Cohen N L and Ransohoff J, “Electromyographic rehabilitation of facial function and introduction of a facial paralysis grading scale for hypoglossal-facial nerve anastomosis,” Laryngoscope, 1988, April; 98(4), pp. 405-10; Manal K, Gonzalez R V, Lloyd D G and Buchanan T S, “A real-time EMG-driven virtual arm,” Comput Biol Med, 2002, January; 32(1), pp. 25-36; Barreto A B, Scargle S D and Adjouadi M, “A practical EMG-based human-computer interface for users with motor disabilities,” J Rehabil Res Dev, 2000, January-February; 37(1), pp. 53-63; Chang G C, Kang W J, Luh J J, Cheng C K, Lai J S, Chen J J and Kuo T S, “Real-time implementation of electromyogram pattern recognition as a control command of man-machine interface,” Med Eng Phys, 1996, October; 18(7), pp. 529-37; Quanbury A O, Foley C D, Winter D A, Letts R M, and Steinke T, “Clinical telemetry of EMG and temporal information during gait,” Biotelemetry, 1976; 3(3-4), pp. 129-137; Letts R M, Winter D A, and Quanbury A O, “Locomotion studies as an aid in clinical assessment of childhood gait,” Can Med Assoc J, 1975, May 3; 112(9), pp. 1091-5; Winter D A, “Pathologic gait diagnosis with computer-averaged electromyographic profiles,” Arch Phys Med Rehabil, 1984, July; 65(7), pp. 393-8; Perry J, Bontrager E L, Bogey R A, Gronley J K and Barnes L A, “The Rancho EMG analyzer: a computerized system for gait analysis,” J Biomed Eng, 1993, November; 15(6), pp. 487-96; and Harlaar J, Redmeijer R A, Tump P, Peters R and Hautus E, “The SYBAR system: integrated recording and display of video, EMG, and force plate data,” Behav Res Methods Instrum Comput, 2000, February; 32(1), pp. 11-6). Specifically, wireless transmission of EMG data has been used in research for several years. Previous wireless systems have been large, power consumptive, and unwieldy. Only recently with the advent of new technologies has miniaturization and lowered power consumption been available for wireless EMG systems. Several systems have been developed for research (Mohseni P, Nagarajan K, Ziaie B, Najafi K, and Crary S B, “An ultralight biotelemetry backpack for recording EMG signals in moths,” IEEE Trans Biomed Eng, 2001, June; 48(6), pp. 734-7; Langenbach G E, van Ruijven L J, and van Eijden T M, “A telemetry system to chronically record muscle activity in middle-sized animals,” J Neurosci Methods, 2002, Mar 15; 114(2), pp. 197-203; and Meile T and Zittel T T, “Telemetric small intestinal motility recording in awake rats: a novel approach,” Eur Surg Res, 2002, May-June; 34(3), pp. 271-4). One system, Noraxon TeleMyo 2400T, has recently become available commercially. Such systems have demonstrated the potential for miniaturized wireless EMG transmission and have demonstrated that further development of systems for wireless EMG transmission is desirable. Indeed, a self-contained wireless EMG system addressing the problems of rehabilitation systems such as prosthetics and communication and computer access, has not yet been developed.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a novel electromyographic sensor that obviates or mitigates at least one of the above-identified disadvantages of the prior art.
[0007] A unique wireless electromyogram (EMG) electrode prototype is provided. It can be used for control of powered, upper-extremity prostheses and for Morse code generation by people with conditions such as Amyotrophic Lateral Sclerosis (ALS), and other conditions that limit accessibility to communications and computer equipment. The electrode uses a standard differential pair of metal contacts and a ground contact at the skin interface. It also uses state-of-the-art electronics for wireless data transmission. The EMG electrode is an improvement over commercially available electrodes because it eliminates the need for a wiring harness to connect the electrode to control electronics. This addresses frustrating problems associated with wiring, especially in prostheses—wire failure and wire routing. The new electrode will improve reliability and decrease the mechanical complexity caused by routing for wiring harnesses. The EMG electrode will also be a means of input for communication and computer access which will not hinder or tether the user since it does not use wires for transmission of signals. The electrode will also be useful for untethered measurement of EMG for use in gait analysis.
[0008] The desire to use wireless technology for transmitting sensor data has been around for a long time; however, the technology to create systems at the size needed and at a low cost was not available. The technology is now available. Developments in the cellular communications industry and exercise monitoring industry have created the technology infrastructure necessary to make these systems practical and reliable.
[0009] An aspect of the invention provides an electromyographic sensor comprising electrodes for placement in contact with tissue. The electrodes are for receiving electrical signals from the tissue. The sensor also includes a circuit connected to the electrodes for converting the signals into a format suitable for wireless transmission. The sensor also includes a transmitter connected to the circuit and for broadcasting the signals.
[0010] The circuit can be based on at least one of analog signal processing; digital signal processing; and adaptive filtering.
[0011] The sensor can further comprise a receiver. The receiver is operable to receive additional signals that include instructions for instructing how the circuit is to process the signals.
[0012] The broadcasting of the signal can be based on radio frequency, infra-red and/or acoustic technology, or other wireless formats.
[0013] The broadcasting can be based on at least one of amplitude modulated analog signals; frequency modulated analog signals; code division multiple access digital signals and orthogonal frequency multiple access digital signals.
[0014] The circuit can be further operable to add an identifier to the signal such that the sensor is uniquely identifiable.
[0015] The transmitter can include means for varying transmission power thereof according to a desired operating range.
[0016] Power for the circuit can be provided by a battery housed within the sensor, such as a rechargeable battery based on NiMH or other battery chemistries such as Lithium-ion (“Li-ion). The battery can be configured to be rechargeable via wireless means.
[0017] Another aspect of the invention provides a man-machine interface based on an electromyographic sensor of the above-mentioned type. The man machine interface can be selected from a group consisting of a pointing device such as a computer mouse, a trackball, a tablet and others; a sensor for a prosthesis; a sensor for a rehabilitation device; a sensor for gait or movement analysis. These interfaces can be used, for example, to optimize exercise and training, to evaluate workplaces, and to improve ergonomics.
[0018] Another aspect of the invention provides a prosthetic system comprising an electromechanical prosthetic limb and a controller connected to the limb for issuing movement instructions thereto. The controller includes a wireless receiver. The system also includes an electromyographic sensor of the above-mentioned type.
[0019] Another aspect of the invention provides a movement analysis system comprising a plurality of electromyographic sensors of the above-mentioned type and a computing apparatus having a receiver operable to receive the signals, the computing apparatus operable to generate a computerized representation of the movement based on the signals.
[0020] Another aspect of the invention provides an electromyography method comprising the steps of:
receiving electrical signals from electrodes in contact with tissue; converting the signals into a format suitable for wireless transmission; and, wirelessly broadcasting the signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will now be described by way of example only, and with reference to the accompanying drawings, in which:
[0025] FIG. 1 is a representation of a prior art prosthetic system including a prior art electromyographic sensor;
[0026] FIG. 2 is a representation of a prosthetic system including an electromyographic sensor in accordance with an embodiment of the invention;
[0027] FIG. 3 is a block diagram of the sensor in FIG. 2 ;
[0028] FIG. 4 is a block diagram of the transceiver in FIG. 2 ;
[0029] FIG. 5 is a left side view of the sensor in FIG. 2 ;
[0030] FIG. 6 is a bottom view of the sensor in FIG. 2 ;
[0031] FIG. 7 is a front view of the sensor in FIG. 2 ; and,
[0032] FIG. 8 is an exploded front view of the sensor of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0033] Referring now to FIG. 1 , a prior art prosthetic system is indicated generally at 30 . System 30 includes an electromechanical prosthetic limb 34 that is connected to a controller 36 having a separate power supply 38 . Controller 36 is connected via a ribbon cable 42 to an electromyographic sensor 46 . Sensor 46 is an Otto Bock brand of myographic electrode, model number 13E125. Sensor 46 can be affixed to any tissue on the wearer of limb 34 that can be activated by the wearer so that impulses can be sent to sensor 46 for the purposes of controlling limb 34 . Ribbon cable 42 carries power to sensor 46 from power supply 38 . Cable 42 also carries signals generated by sensor 46 to controller 36 . In turn, controller 36 is operable to interpret such received signals and issue instructions to limb 34 to cause limb 34 to move in a particular fashion. Cable 42 presents certain problems for system 30 , in that its length can limit the tissue that can be used by the wearer. As yet a further problem, cable 42 can become tangled and therefore interfere with the overall operation of limb 34 . Still further problems can arise, such as wire breakage and the presence of the cable adds overall mass to system 30 .
[0034] Referring now to FIG. 2 , a prosthetic system in accordance with an embodiment of the invention is indicated generally at 60 . System 60 comprises an electromechanical prosthetic limb 64 that is connected to a controller 68 having a separate power supply 72 . Collectively, limb 64 , controller 68 and power supply 72 can be viewed as a man machine interface 76 , and other types of man machine interfaces within the scope of the invention will be discussed below.
[0035] System 60 also includes a wireless transceiver 80 that connects to controller 68 . System 60 also includes a wireless electromyographic sensor 84 that is operable to communicate with controller 68 via transceiver 80 over a wireless link 88 .
[0036] Referring now to FIG. 3 , sensor 84 is shown in greater detail in the form of a block diagram. Sensor 84 includes a first, second and third electrodes indicated at 92 , 96 and 100 respectively. Electrodes 92 , 96 and 100 are for placement in contact with living tissue in order to receive electrical signals from the wearer of system 60 . Electrode 96 is a ground, whereas electrodes 92 and 100 can receive varying signals in relation to ground electrode 96 . Those of skill in the art will now appreciate that electrodes 92 , 96 and 100 are substantially the same as prior art electrodes as found on prior art sensor 46 and generate signals accordingly.
[0037] Electrodes 92 , 96 and 100 each feed into an amplifier 104 to boost the value of the signals received therefrom. In turn, amplifier 104 is connected to a filter 108 that is configured to remove any unwanted signals from signals received from electrodes 92 , 96 and 100 . (An example of such unwanted signals would be ambient sixty hertz signals in North America commonly found on individuals that are in the proximity of sixty hertz electrical devices.). The electrode section of the device thus detects and processes electromyographic signals at the surface (i.e. surface EMG signals). Filter 108 is a sharp analog notch filter at about sixty hertz to reduce or eliminate power line noise. Filter 108 also filters frequencies higher than about one thousand hertz. (i.e. at about a three dB cut-off at higher than about one-thousand-five-hundred Hz).
[0038] Filter 108 , in turn, outputs its signal to an analog-to-digital converter 112 for converting signals from electrodes 92 , 96 and 100 into digital format. Next, the signals from analog-to-digital converter 112 are outputted to an encoder 116 for placing the digitized signals into a format suitable for wireless transmission. The output from encoder 116 is then delivered to a radio 120 for transmission over link 88 via an antenna 124 .
[0039] Referring now to FIG. 4 , transceiver 80 is shown in greater detail in the form of a block diagram. Transceiver 80 includes its own antenna 128 which interacts with link 88 . Antenna 128 is connected to a radio 132 which in turn is connected to a decoder 136 . Thus, wireless signals sent from sensor 84 over link 88 are thus received at transceiver 80 and are eventually passed to decoder 136 where they are returned to substantially the same form as they arrived at encoder 116 . The output from decoder 136 is then passed to a digital-to-analog converter 140 , and finally to a filter 144 to remove any unwanted noise. Thus, the output from filter 144 is delivered to the controller 68 in man machine interface 76 . In general, it should now be understood that the signal received at electrodes 92 , 96 and 100 is delivered in a substantially readable form from the output of filter 144 using the aforementioned components. However, it is to be understood that other sets of components that transmit over a wireless link such as link 88 are within the scope of the invention.
[0040] The format of link 88 is not particularly limited. For example, frequency-Shift-Keying (“FSK”) at about 433 MHz can be used to transmit the processed signal. As another example, presently more preferred, signals are transmitted using Amplitude-Shift Keying (“ASK”) in the about 902-928 MHz Industrial Scientific and Medical (“ISM”) band. ASK modulation is used to reduce and/or minimize power consumption. If the non-digitized, raw signals are needed, they can be transmitted by changing a few components in the circuit and using Frequency Modulation (FM) transmission. EMG electrode signal channels are programmable (902-928 MHz) and because of the bandwidth of the signals and the method of transmission, transmission of multiple channels of EMG data is possible, thereby reducing the likelihood of interference from other sensors that may be nearby. The 902-928 MHz band is presently preferred in which one can operate in North America, however, there are many cordless phones and other devices that operate in this band. Therefore, to further reduce the likelihood of interference, it can be desired to include further intelligence inside the sensor 84 and transceiver 80 by assigning an ID to each sensor 84 so that transceiver 80 cannot be activated by another device.
[0041] It is also presently preferred, thought not shown in FIG. 3 for simplicity sake, to include an interface so that sensor 84 can be programmed for different frequencies (for example, 902-928 MHz), identifiers, etc. It can also be desirable that sensor 84 be programmable using software so that the output power and/or range of radio 120 is adjustable.
[0042] Referring now to FIGS. 5-8 , various further views of sensor 84 are shown. As best seen in FIG. 8 , sensor 84 includes a power supply 148 that is self contained within sensor 84 . A presently preferred self-contained power supply is a single-cell rechargeable Li-Ion battery, having enough power for operating the circuits in sensor 84 for several hours of continuous operation. Also as seen in FIG. 8 , sensor 84 has a two-part outer housing 152 . The bottom of housing 152 frames electrodes 92 , 196 , 100 . Housing 152 holds a printed circuit board 156 that carries the components shown in FIG. 3 .
[0043] While only specific combinations of the various features and components of the present invention have been discussed herein, it will be apparent to those of skill in the art that desired subsets of the disclosed features and components and/or alternative combinations of these features and components can be utilized, as desired. For example; the electromyographic sensor described herein can be modify for use with a plurality of different types of man machine interfaces, including prosthetic limbs, computing pointing devices, etc.
[0044] The present invention provides a novel electromyographic sensor. This wireless electromyographic technology can contribute in several areas of rehabilitation, from functional electrical stimulation (“FES”) control to facial function rehabilitation (Giuffrida, 2001; Brudny, 1988; Manal, 2002). Specifically, it can be a core component of human interface devices (Barreto, 2000; Chang, 1996) for which the elimination and/or reduction of wired connections is desirable, and can improve the reliability of powered, upper-extremity prostheses by eliminating the need for wires between electrodes and control electronics. The electromyographic sensor can also enable individuals who are paralyzed to communicate with a computer or any other devices with the contraction of any muscle in the body. For individuals with conditions such as amyotrophic lateral sclerosis (“ALS”), the electromyographic sensor can allow them to use their facial muscles for Morse code generation, for example, for communication.
[0045] The electromyographic sensor can also be useful for the transmission of sensor data in gait analysis, providing EMG data which would aid in the assessment and treatment of gait anomalies (Quanbury, 1976; Letts, 1975; Winter, 1984; Perry, 1993; Harlaar, 2000). The wireless EMG system would be self-contained and smaller—an improvement over prior art systems such as the Noraxon TeleMyo 2400T. Also, the base technology of wireless data transmission could be used for transmission of other sensor data needed for gait analysis, such as shear force data. This would benefit gait analysis by enabling collection of a full data suite without tethering the subject.
[0046] As an additional example, the shape of electrodes 92 , 96 and 100 can have shapes that are suitable for the location in which they are to be mounted. Thus, the shapes are not particularly limited.
[0047] The above-described embodiments of the invention are intended to be examples of the present invention and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the invention which is defined solely by the claims appended hereto. | An electromyographic sensor is provided. The sensor includes electrodes for receiving signals from tissue when the electrodes are placed in contact with the tissue. The sensor also includes circuitry for converting the signals into a format suitable for transmission. the sensor also includes a transmitter for transmitting the signals to a receiver. The receiver can be part of a controller for a prosthetic limb, or the like. | 0 |
This application is a division of application Ser. No. 07/843,672, filed Feb. 28, 1992, now U.S. Pat. No. 5,402,072.
FIELD OF THE INVENTION
This invention relates to high-density passive boards and substrates. In particular, a system and apparatus is described for using modified resistance and capacitance measurements for the testing and fault isolation of high-density passive boards and substrates.
BACKGROUND OF THE INVENTION
Chip carriers, substrates, and passive boards used for electronic component packaging usually include metal interconnections, voltage planes, and dielectric materials such as ceramic, glass ceramic, silicon-oxide, polymer, and/or epoxy glass. An exemplary board used for electronic component packaging is shown in FIG. 1. In this figure, circuit board 5 is a multi-layer circuit board which has not been populated with electrical components. At least one of the layers within circuit board 5 is a power plane 4. Furthermore, at least one other of the layers is a ground plane 6. A plurality of interconnection networks, hereinafter "nets", are also included in circuit board 5. Circuit board 5 is shown including NET 1 and NET 2. Each net may be distributed either across a single layer or across multiple layers within circuit board 5.
As the packaging density in such boards continues to increase, the metal interconnections which make up each net are getting smaller and closer together. This continual miniaturization of the metal interconnections within circuit boards leads to an increase in the probability of a variety of defects. For example, the points of a conductor network which should be connected together may have one (or more) discontinuities in the conductor path(s). This results in an "open circuit" condition with substantially infinite resistance between certain sections of the network. A further defect occurs when two independent conductor networks or conductor areas which are intended to have no electrical connection, and therefore, substantially infinite internet resistance, in fact display an unacceptable, low value of internet resistance. This is commonly referred to as a "short circuit". In addition, a conductive pathway may be defective because it displays one or more sections having resistances which exceed an acceptable level. This defect is referred to as a "resistive fault".
In a properly manufactured high-density passive board, the resistance between terminals of a common conductor network is normally in the range of from a few milliohms to many ohms. This resistance is dependent on the length and cross section of the conductors. Furthermore, the resistance between independent networks should approach infinity. This resistance typically exceeds 100 megohms.
A necessary step in the manufacture of high-density substrates, chip carriers, and passive boards is to test the proper continuity and isolation of all nets before any electronic components are mounted. Continuity testing measures relatively low resistance within particular networks. Open circuits and resistive faults are thus typical defects which are found in continuity testing. Isolation testing measures the expected high resistance levels that should exist between conductors. Short circuits are typical defects which are found in conducting isolation testing.
A common continuity and isolation test method uses cluster probes which match and contact to test pads on the substrate surface. By controlling the switching matrix, resistance from a network under test to all other networks in the substrate can be measured. This is a relatively fast testing method, however, it lacks flexibility. Substrates with different designs usually require different cluster probes or bed-of-nail fixtures. In addition, complexity and long lead-time to produce custom cluster probes makes this technique costly, especially for early manufacturing where product design may not be fixed.
Another isolation test is the so called point-to-point testing wherein two moving probes are used on an X-Y positioning mechanism. This flexible probing method can perform individual tests between all possible pairs of nets. An exemplary "moving probe" mechanism is disclosed in U.S. Pat. No. 4,565,966 (Burr et al.). Burr discloses the testing of passive substrates using moving probes in a series of two-point resistance measurements. In this manner, the continuity of individual nets may be verified. In addition, using this method a series of one-point measurements may be made to determine the capacitance of a network relative to a reference plane or to indicate short-circuits between nets through excessive internet capacitance. While this approach has great flexibility, it suffers from several severe practical difficulties which limit its effectiveness and speed. These include a need for switching between resistance and capacitive test modes, difficulty of detecting a low-capacitance net shorted to a high-capacitance net when testing the high capacitance net, and an inability to distinguish between a high-resistance short to a net and a leakage path directly to ground. Furthermore, this method relies on simple scalar matching of capacitance values during the defect isolation process. In this manner, the continuity of nets which display excessive capacitance is checked against a potentially long list of other nets showing similar capacitance.
SUMMARY OF THE INVENTION
Apparatus is disclosed for locating defects in a circuit board used for interconnecting electronic components. Such a board includes a first net, a second net, and at least one common plane which is either a power plane or a ground plane. The apparatus includes a first probe and a second probe which make contact with the first net at respectively different locations. A continuity testing circuit is coupled to the first and second probes for determining the continuity of the first net. An additional circuit is coupled to either the first probe or the second probe, to determine leakage currents within the board simultaneously with the continuity testing.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of an unpopulated high-density circuit board.
FIG. 2 is a block diagram which shows the basic system organization of the test circuitry.
FIG. 3 is a block diagram, partly in schematic form, which is useful for describing the operation of the test circuit shown in FIG. 2.
FIG. 4 is a schematic diagram of the test circuit shown in FIG. 3.
FIG. 5 is a block diagram, partly in schematic diagram form, which provides a detailed drawing of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A first exemplary embodiment of the present invention is shown in FIG. 2. In this first embodiment, unit under test (UUT) 100 is a multilayer circuit board which has not been populated with electrical components. At least one of the layers within UUT 100 is a power plane (not shown). Furthermore, at least one of the other layers within UUT 100 is a ground plane. All of the ground planes and all of the power planes within UUT 100 are collectively referred to as common planes. UUT 100 also includes a plurality of nets which may be distributed either across a single layer or across multiple layers within UUT 100. In FIG. 2, UUT 100 is shown to include NET 1 and NET 2, although UUT 100 may include additional nets.
As shown in FIG. 2, test circuitry 10 can functionally be divided into three separate testing circuits: Floating Current testing circuit 20, Direct Current DC testing circuit 30, and Alternating Current (AC) testing circuit 40. Each testing circuit will be separately discussed with reference to FIG. 3.
FIG. 3 is a circuit diagram which provides a detailed drawing of the test circuit shown in FIG. 2. FIG. 4 is a schematic diagram of the test circuit shown in FIG. 3. As shown in FIG. 3, internal resistances R 1 and R 12 and internal capacitances C 1 , C 2 and C 12 are also shown within UUT 100. Internal resistances R 1 and R 12 represent paths of leakage current within UUT 100. Internal capacitances C 1 , C 2 and C 12 represent capacitances within UUT 100. The significance of these internal resistances and capacitances is discussed below.
As shown in FIG. 3, test circuitry 10 includes a plurality of electrical components. Direct Current (DC) voltage source 101 is coupled to one or more common planes within UUT 100 through resistive element 141. Alternating Current (AC) voltage source 102 is coupled to selected common planes within UUT 100 through capacitive element 142. Probes 151 and 152 each make electrical contact with Net 1 at respectively different locations along the net. Floating current source 121 includes two supply terminals, a plus terminal and a minus terminal, which are respectively coupled to the two probes 151, 152. Isolation amplifier 122 which may be, for example, a conventional operational amplifier, includes two input terminals, namely an inverting terminal and a noninverting terminal, which are respectively coupled to the two probes 151, 152. Isolation amplifier 122 also includes an output terminal. In an exemplary embodiment of the present invention, isolation amplifier 122 is implemented with part number ISO-100, manufactured by Burr Brown, Inc.
Current-to-voltage converter 123 is an operational amplifier having two input terminals, namely an inverting terminal and a non-inverting terminal. Current-to-voltage converter 123 also has an output terminal. The non-inverting terminal of current-to-voltage converter 123 is coupled to a source of reference potential (e.g. ground) while the inverting terminal is coupled to probe 152. A feedback resistor 143 is connected between the output terminal and the inverting terminal of current-to-voltage converter 123. In an exemplary embodiment of the present invention, current-to-voltage converter 123 is implemented with part number 0P97, manufactured by PMI, Inc.
Phase reference generator 103 generates a phase reference signal based upon an input signal received from AC voltage source 102. The output terminal of phase reference generator 103 is coupled to one input terminal of phase sensitive detector 111. The second input terminal of phase sensitive detector 111 is coupled, through coupling capacitor 153, to the output terminal of current-to-voltage converter 123. A second phase sensitive detector 113 also includes two input terminals. The first input terminal of phase sensitive detector 113 is coupled, through ninety degree phase shift circuit 112, to the output terminal of reference generator 103. The second input terminal of phase sensitive detector 113 is coupled, through coupling capacitor 153 to the output terminal of current-to-voltage converter 123. Signal readings for determining leakage currents within UUT 100 are taken from a plurality of locations within test circuitry 10, including the output terminal of current-to-voltage converter 123, the output terminal of phase sensitive detector 111 and the output terminal of phase sensitive detector 113.
In an exemplary embodiment of the present invention, phase sensitive detector 111 and phase sensitive detector 113 are each implemented with part number DG302, manufactured by Siliconix, Inc. Furthermore, in an exemplary embodiment of the present invention, ninety degree phase shift circuit 112 is implemented with a R-C network around part number LF356, manufactured by National Semiconductor, Inc. Although only one ninety degree phase shift circuit 112 is shown in FIG. 3, it is understood that a plurality of ninety degree phase shift circuits may be used simultaneously, each with a different R-C circuit for phase shifting a respective signal of a specific frequency by ninety degrees.
The output signals available on the respective output terminals of isolation amplifier 122, current to voltage converts 123 and phase sensitive defectors 111, 113 may be received by a computer system 114 for performing the signal measurements and calculations described herein below. In an exemplary embodiment of the present invention, computer system 114 may be an analog computer or a digital computer which receives test signals through an A/D converter.
Floating Current testing circuit 20 includes Floating Current source 121, isolation amplifier 122 and test probes 151, 152. Floating Current testing circuit 20 is used to measure the resistance between two points (e.g. two end points) within NET 1. If there is proper conductivity between two points within NET 1, then the resistance between any two points along NET 1 is very low. Alternatively, if there is improper conductivity between any two points along NET 1 (e.g. as a result of a physical breakage in a tracing) then the resistance between two points along NET 1 may be extremely high (possibly infinite). Thus, by determining the resistance between various points along NET 1, the conductivity of NET 1 can be determined.
Floating current testing circuit 20 operates as follows. Probes 151 and 152 are each brought into physical contact with NET 1 at a respectively different location along the net. Floating Current source 121 provides a constant source of current. Floating Current source 121 induces a current in NET 1 between probes 151 and 152, thus generating a voltage across the two input terminals of Isolation Amplifier 122. If the resistance of NET 1 is low, and a current flow is induced in NET 1, a small voltage appears across the input terminals to isolation amplifier 122 (in accordance with Ohm's law). Accordingly, a relatively small signal will appear on the output terminal of isolation amplifier 122. Similarly, if the resistance of NET 1 is high, the current flow induced in NET 1 produces a relatively large voltage across the input terminals to isolation amplifier 122 (in accordance with Ohm's law). Accordingly, a large signal will appear on the output terminal of isolation amplifier 122. By reading the output signal of isolation amplifier 122, the conductivity of NET 1 can thus be determined.
DC testing circuit 30 includes DC voltage source 101, resistive component 141, test probe 152 and current-to-voltage converter 123. One end of resistive component 141 is coupled to DC voltage source 101. A second end of resistive component 141 is coupled to one or more of the common planes within UUT 100. R 1 is an implied resistance which represents a path for current flow between NET 1 and any of the selected common planes. Thus, if there is an undesirable short between NET 1 and any of the power or ground planes within UUT 100, the value of R 1 may be very low (e.g. close to zero ohms). Alternatively, if there is no undesirable short (i.e. no conductivity) between NET 1 and any of the power or ground planes within UUT 100, then the value of R 1 may be extremely high (e.g. close to infinite). Assuming a short does exist, current will flow from DC voltage source 101, through resistive component 141, into the power and ground planes, through R 1 , through test probe 152 and into current-to-voltage converter 123. Current-to-voltage converter 123 is a wideband amplifier. If the resistance of R 1 is low, a relatively large current is induced in R 1 which results in a relatively large voltage on the output terminal of current-to-voltage converter 123. Alternately, if the resistance of R 1 is high, a relatively small current is induced in R 1 which results in a relatively small voltage on the output terminal of current-to-voltage converter 123. Thus, the direct current component of the output signal of current-to-voltage converter 123 is inversely proportional to the resistance of R 1 . The level of the output signal provided by current-to-voltage converter 123 is thus indicative of the presence (or absence) of a short between NET 1 and any of the power or ground planes.
AC testing circuit 40 includes AC voltage source 102, capacitive element 142, probe 152, current-to-voltage converter 123, coupling capacitor 153, signal reference generator 103, phase sensitive detectors 111,113 and ninety degree phase shift circuit 112. Internal resistance R 1 and internal capacitance C 1 are shown coupled between NET 1 and the plurality of power and ground planes. Internal capacitance C 2 is shown coupled between NET 2 and the plurality of power and ground planes. Internal resistance R 12 and internal capacitance C 12 are shown coupled between NET 2 and NET 1.
Capacitors C 1 , C 2 and C 12 represent capacitance between NET 1 and the plurality of common planes, between NET 2 and the plurality of common planes, and between NET 1 and NET 2, respectively. More broadly stated, C 1 represents the main component of capacitive current, namely the direct capacitance between NET 1 and the plurality of common planes. C 2 and C 12 represent other components of the capacitive current, namely between the plurality of common planes and the other nets, and via net to net capacitance.
Probe 152 is coupled to current-to-voltage converter 123 which is a virtual grounded receiver. Current-to-voltage converter 123 draws current from the net under test. Thus, the net under test is at approximately ground potential. Because the receiver is at a virtual ground, extra capacitance (within limits) to ground on the input to current-to-voltage converter 123 has very little effect on the operation of test circuitry 10. Floating circuits such as floating current source 121 may be added to the input of the receiver circuit without disturbing the capacitance measurement. Using Floating Current testing circuit 20, an open net may be detected. If an open net is detected, it is helpful to measure the capacitance between each end of the net and the common planes to determine the probable location of the break. To effect this mode of testing AC testing circuit 40 can be switched from probe 151 to probe 152 allowing both capacitances to be measured. The delay associated with such switching has very little effect on the overall tester throughput since it occurs on only the small fraction of nets which are open rather than during the test cycle of every net in the substrate.
AC testing circuit 40 operates as follows. Analyzing current flows from AC voltage source 102, there are potentially four paths.
In the first path, current flows through capacitor C 1 , into NET 1, into current-to-voltage converter 123, through coupling capacitor 153 and into phase sensitive detectors 113 and 111. Phase sensitive detectors 111 and 113 compare this received signal with signals that are respectively in phase with and quadrature phase related to the signal received from reference signal generator 103. The quadrature signal is obtained by transmitting the AC phase reference signal provided by the reference circuit to phase sensitive detector 113 via the ninety degree phase shift circuitry 112. The output signal of phase sensitive detector 113 is proportional to the capacitance of C 1 .
In the second path, current flows from AC voltage source 102, and through capacitances C 2 and C 12 before reaching current-to-voltage converter 123. Thus C 2 and C 12 (if they exist) cause the intensity of the output signal from current-to-voltage converter 123 to increase.
In the third path, current flows from AC voltage source 102, through R 1 , through current-to-voltage converter 123 and into phase sensitive detector 111.
In the fourth path, current flows from AC voltage source 102, through C 2 , through R 12 and through current-to-voltage converter 123. The output of current-to-voltage converter 123 is detected by phase sensitive detector 111.
As previously stated, the resistance to NET 1 from the common planes may be solely a function of R 1 . Alternately, it is possible that the resistance to NET 1 from the common planes may be a function of R 1 and R 12 . Because the output of phase sensitive detector 111 is merely indicative of the total resistance between the common planes and NET 1, it is impossible, looking solely at this output, to tell if the leakage current is caused by R 1 or a combination of R 1 and R 12 . This problem is alleviated by comparing the output signal of phase sensitive detector 111 with the DC output signal of the current-to-voltage converter 123. If these two signals are the same, then only R 1 exists. If these two signals are different, then the leakage current is caused by a combination of R 1 and R 12 .
In order to resolve the resistive leakage value between NET 2 and NET 1 (R 12 ), and the capacitance of NET 2 to a common plane (C 2 ), two signals are obtained from probe 152 at two respectively different frequencies, w 1 and w 2 . Using two signals from the probe, and knowing the two frequencies, w 1 and w 2 , the behavior of the system is described by equations (1) and (2). ##EQU1##
In these equations, w equals w 1 or w 2 and i 0 , v 1 and v 2 correspond to the respective current and voltages indicated in FIG. 4.
The inventors have determined that these equations can be solved and then simplified so that the two unknowns, R 12 and C 2 , can be calculated. Thus, for C 12 much less than C 2 the inventors have formulated the following equations: ##EQU2##
A 3 is determined by the following relationship:
A 3 =Output signal of Phase Sensitive Detector 111-1/R.sub. 1 (taken at w 1 )
Alternately, A 3 is determined by the following relationship where the frequency w is taken at w 1 : ##EQU3##
A 4 is determined by the following relationship:
A 4 =Output signal of Phase Sensitive Detector 111-1/R 1 (taken at w 2 ).
Alternately, A 4 is determined by equation (6) where the frequency w is taken at w 2 : ##EQU4##
In order to obtain these values, the resistance of resistor 143 (the feedback resistor of current-to-voltage converter 123) is desirably between 1K ohm and 1 megohm, the current from DC voltage source 101 and AC voltage source 102 is desirably between 1/10 and 100 microamps, and the voltage from DC voltage source 101 and AC voltage source 102 is between 1 and 200 volts. In an exemplary embodiment of the present invention, as shown in Table I, the following parameters are used:
TABLE I______________________________________Item Parameter______________________________________Resistor 141 1K ohmsCapacitor 142 1 microfaradResistor 143 1 megohmDC Voltage Source 101 10 Volt SupplyAC Voltage Source 102 10 Volt Supply______________________________________
The resistance and capacitance of the Net to Ground and Net to Net leakage paths may be determined using equations (7) through (10). ##EQU5##
These equations assume:
(w.sub.1 R.sub.12 (C.sub.12 +C.sub.2)).sup.277 (10)
In addition, k, which is a very small number, may be determined by the following equation: ##EQU6##
However, in order to utilize the equations provided above, k is determined by experimentally measuring C 12 and C 2 on a known good board in accordance with well known capacitance measurement techniques.
B 1 is proportional to the output signal of phase sensitive detector 113 at w 1 .
For a special case in which NET 1 and NET 2 are shorted together, C 2 can be deduced from measurements taken at a single frequency. This is possible because, for NET 1 and NET 2 shorted together, R 12 is very low. Thus, in such a situation, C 12 is bypassed By determining C 1 statistically, the value of C 2 can be deduced from the output signal of phase sensitive detector 113.
In addition, R 1 may be determined using equation (12):
V.sub.123 =K.sub.R /R.sub.1 (12)
where V 123 is the DC output voltage of current-to-voltage converter 123, K R is a proportionality constant determined by the gain of current-to-voltage converter 123 and the output voltage of DC voltage source 101.
A further consideration in the testing of unpopulated circuit boards relates to capacitance testing in complex substrates. A common method for determining capacitive shorts in an unpopulated circuit board involves a single capacitance measurement which is made for a net relative either to a single external reference plane, or to one or more internal reference planes which are all driven in parallel by a common signal. This results in a single capacitance value which represents a total capacitance of the net to all internal reference planes. However, this technique may not be suitable for a complex substrate. In a complex substrate there may be dozens of different wiring planes and four or more electrically separated sets of common planes. For example, one commonly used multi-layer-ceramic substrate includes dozens of reference planes which are internally and/or externally connected to form four distinct sets of planes representing three different operating potentials and a reference potential (e.g. ground).
In an alternative embodiment of the present invention, by simultaneously driving different groups of planes with slightly different frequencies (e.g. 18 kHz, 19 kHz, 20 kHz, and 21 kHz), the individual capacitances of the net under test to each set of planes can be determined simultaneously. This measurement scheme provides useful data about the net under test for possible use in improved defect detection, defect isolation, and process monitoring and control.
The method described above is entirely feasible because the various planes can be driven with independent signals using reasonable drive currents. For example, given two sets of 200 mm square voltage planes separated by 0.1 mm of ceramic with a dielectric constant of 5, the capacitance between two sets of ten planes each in an alternating layer stack-up is approximately 0.35 μF. At a difference frequency of 1 kHz, the capacitive impedance between these sets of planes is over 450 Ohms. If the two sets of planes are each driven by a respective voltage source at a respective frequency, with each voltage source supplying an amplitude of 10 Volts, then the peak current circulating between each voltage source is less than 50 mA. Such currents and coupling impedances are entirely within a probe contact and driver tolerances. Thus, it is entirely feasible and practical to drive different sets of voltage planes at slightly different frequencies.
Using analog and/or digital signal processing, it is possible to measure capacitive currents at each frequency despite the presence of potentially large `noise` currents at nearby frequencies. In an exemplary embodiment of the present invention, several phase-sensitive-detectors (PSDs) with either one or two PSDs operating at each of the driving frequencies are used to simultaneously monitor the output signal of a single current-to-voltage converter connected to one of the probe leads. Two PSDs at each frequency are preferred since both in-phase and out-of-phase components are desired.
A PSD operating with a particular reference frequency produces a DC output proportional to the input amplitude at the desired frequency, superimposed AC signals at the difference frequency of the desired frequency, and any extraneous signal. Thus, the use of PSDs, without additional hardware, may be insufficient for the intended application. To separate out the desired frequency from any nearby frequencies, one technique which is commonly used is to couple the output of the PSD to the input of a low pass filter. However, by simply using a low pass filter, it is difficult to simultaneously reject difference frequencies of around 1 Hz, while simultaneously providing a fast (e.g. 1 ms) measurement and settle-out time. An alternative technique makes use of the fact that the external `noise` frequencies to be filtered out are known, apriori and, in fact, can be accurately synchronized with the PSD `reference` frequency and the other drive frequencies through a common clock. Thus, the output of the PSD can be accurately averaged over one period of the difference frequency to eliminate the effect of that frequency.
If the multiple driving frequencies for the planes are chosen with equal increments therebetween, then all of the possible difference frequencies are harmonics of the basic or minimum frequency difference. With frequencies of 18, 19, 20, and 21 kHz, for example, any one particular PSD output need only be averaged over 1 ms to exactly cancel all other signal contributions. This averaging can be carried out in an analog fashion with a gated integrator circuit having a 1 ms on-time. This averaging can also be carried out in a digital fashion by continuously sampling the PSD output at a much higher frequency than the difference frequency and performing a moving average of the appropriate number of samples to cover exactly one period of the minimum difference frequency.
In this manner, the superimposed AC signal and any extraneous signals are averaged to a value of zero. Thus, the signal remaining is proportional to only the input amplitude at the desired frequency.
In an exemplary embodiment of the present invention, as shown in FIG. 5, the output signals may be sampled at 100 kHz, using the same clock signal that is used to generate the drive signals. A moving average of 100 samples then provides a very accurate measure of the amplitude at the frequency and phase of the particular PSD being monitored, with extremely low contamination of the signal by the potentially larger signals occurring at the other frequencies.
As shown in FIG. 5, a plurality of AC voltage sources 202a through 202x, each supplying AC voltage at a different frequency (e.g. 17 kHz, 18 kHz, etc.) are shown respectively coupled to a plurality common planes 200a through 200x. Each AC voltage source 202a through 202x is also shown coupled to a respective plurality of phase reference generators 203a through 203x. Each phase reference generator 203a through 203x generates a respective in-phase phase reference signal based upon the input signal received from respective AC voltage sources 202a through 202x. The output signal of current-to-voltage converter 223, which may be identical to current-to-voltage converter 123 of FIG. 3, is coupled to phase sensitive detectors 211a through 211x and 213a through 213x. Phase sensitive detectors 211a through 211x compare the output of current-to-voltage converter 223 with signals which have the same phase as the respective in-phase output signals of reference signal generators 203a through 203x. By coupling the respective output terminals of phase reference generators 203a through 203x to the respective input terminals of phase sensitive detectors 213a through 213x via ninety degree phase shift circuits 212a through 212x, the output of current-to-voltage converter 223 is compared with a plurality of signals which are quadrature phase related to the respective signals received from reference signal generators 203a through 203x. The output terminal of each phase sensitive detector is then coupled to a respective averaging circuit (280a through 280x, 281a through 281x) as previously described. Each filtered output is analogous to the output signal of current-to-voltage converter 123 of FIG. 3.
Thus, using this signal processing approach, it is possible to simultaneously and accurately measure the capacitive contributions of individual reference planes, or groups of planes using short measurement times.
The independent capacitance measurements described above are useful for the open-short testing of substrates for several reasons.
First, this approach increases the ability of the tester to detect when a long net is shorted to a much shorter net. If only one total capacitance value is measured, then it is impossible to detect a long net shorted to a net whose capacitance is smaller than the allowable statistical variation in the long net. For example, a 30 pF net shorted to a 3 pF net is detected when measuring the 3 pF net. However, if the system tolerances are greater than 10 percent, then when the 30 pF net is measured, the short to the 3 pF net may not be detected. If only one total capacitance is measured, it is difficult to isolate the defect since the shorter net is desirably tested against a larger list of candidate nets. By contrast, if the defect is detected twice, the defect may be isolated by comparing the obtained capacitance reading with similar capacitance readings obtained from in the relatively short list of defects found.
Returning to the previous example, if independent net-to-plane capacitances are used, the 30 pF net may have four distinct capacitance values which nominally add up to a total of 30 pF. In typical substrates many long nets may travel large distances in substrate layers that are distinct from those near the substrate surface where most of the short nets are located. Therefore, the 30 pF net may have substantially reduced capacitance relative to the plane to which the short net is closest. Assuming that the four measured values for the long net are desirably 10 pF, 5 pF, 15 pF and 0 pF, and the capacitance for the short net is desirably 3 pF, 0 pF, 0 pF and 0 pF, the measured value for the long net shorted to the shorter net is then 13 pF, 5 pF, 15 pF and 0 pF. With this information, shorts can be detected by individually comparing the measured capacitances relative to a given set of planes with expected capacitance values. In the example above, the 3 pF net now represents a 30 percent increase above the expected value of the 30 pF net in the first `component` of the capacitance `vector`. Thus, the 3 pF net is detectable if the process variations are below 30 percent.
A second advantage of the independent capacitance measurements described above is that defect isolation is greatly simplified because a characteristic `vector` for each net, rather than a single `scalar` measurement, is provided. Therefore, nets which are shorted can be tested against other nets in the order of the `distance` between the nets in the multi-dimensional measurement space. For example, if a 30 pF net is shorted to another 30 pF net, and the measurement from one net (hereinafter "the test net") of the pair reads 10 pF, 10 pF, 30 pF and 10 pF, then the remaining nets can be sorted by `distance` to this point in measurement space. Thus, time is not wasted testing the test net against other 60 pF (total) nets whose characteristic vector is, for example, 30 pF, 20 pF, 10 pF and 0 pF. Many different mathematical norms may be used to define `distance` as described above, depending on calculation complexity and perhaps statistical arguments related to the measurement errors. Exemplary definitions of "distance" (or the length of the vector difference between any two measurement vectors) include the maximum error in an individual component, the sum of the absolute values of the components, the dot product of a vector with itself (sum of squares error), and Euclidean distance (square root of sum of squares).
The distance can also be scaled to more heavily weight the data from planes which are known to have tighter tolerances. In this manner, if, for example, the planes in a polyimide circuit board can be driven separately from the planes in a ceramic circuit board, then large tolerances in one system may not necessarily diminish the defect detection capability in the other system.
A further advantage of this approach is the ability to independently measure the leakage from the net to the various sets of reference planes. This information can be used to isolate the location of the leakage defect to one particular set of planes.
While the invention has been described in terms of an exemplary embodiment, it is contemplated that it may be practiced as outlined above with modifications within the spirit and scope of the appended claims. | Apparatus and method are disclosed for performing testing and fault isolation of high density passive boards and substrates. Using a small number of moving probes, simultaneous network resistance and network capacitance measurements may be performed. Thus, test time is minimized by eliminating the need for electrical switching and/or excessive probe movement during the test of a normal circuit board network. Simultaneous network capacitance and network leakage measurement are also achieved using phase-sensitive detection. Dual-frequency measurement techniques allow the measurement of both the capacitance value and resistance value of a leakage path between a network being measured and an unknown network. Any leakage resistance between a network under test and ground or power planes within the circuit board may also be determined from the measurements. Simultaneous independent net-to-plane capacitance characterization is also achieved using signals of mutually independent frequencies accompanied by minimal signal processing. Thus, improved defect detection capabilities are obtained. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method for producing α-hydroxycarboxylic acid and optically active α-hydroxycarboxylic acid, both of which are useful as a pharmaceutical intermediate or the like.
[0002] As a method for producing α-hydroxycarboxylic acid, hydrolysis of cyanohydrin is known. Such hydrolysis is generally carried out in an aqueous solvent containing cyanohydrin and an acid catalyst (e.g. concentrated hydrochloric acid), after hydrolysis, the reaction solution is a single solution.
[0003] However, for the above hydrolysis reaction, there are some problems in that the reaction solution becomes dark brown due to the generation of a colored substance, or the removal of by-products is difficult, resulting in the difficulty of obtaining of a good yield of high purity α-hydroxycarboxylic acid.
[0004] Furthermore, optically active α-hydroxycarboxylic acid have previously been produced by a method, which comprises: obtaining optically active cyanohydrin by the asymmetric addition of hydrogen cyanide to a corresponding carbonyl compound in an organic solvent such as an alcoholic solvent, an ester solvent, an ethereal solvent, a carboxylic solvent and a hydrocarbon-based solvent, in the presence of enzymes such as (S)-hydroxynitrilelyase and (R)-hydroxynitrilelyase extracted from plants or enzymes produced by a gene recombinant microorganism, into which a gene of those enzymes is incorporated; and hydrolyzing the obtained optically active cyanohydrin (e.g. Synthesis, July 1990, 575-578 ; Tetrahedron Letters, 32, 2605-2608 (1991); Japanese Patent Application filed Nos. 63-219388 and 5-317065; WO98/30711).
[0005] In these methods, hydrolysis is performed after the isolation of optically active cyanohydrin, or in consideration of efficiency, hydrolysis is performed without the removal of the reaction solvent used in the production process of the optically active cyanohydrin.
[0006] The known methods for synthesizing optically active α-hydroxycarboxylic acid by hydrolysis of optically active cyanohydrin include, for example, a method described in Synthesis, July 1990, 575-578 and a method described in Tetrahedron Letters, 32, 2605-2608 (1991), wherein reaction with concentrated hydrochloric acid at room temperature is followed by reaction at reflux temperature.
[0007] With regard to these methods, however, since a large amount of hydrochloric acid, about 30 times the amount of cyanohydrin by molar ratio is used, industrial application of these methods involves many disadvantages such as the high-cost raw materials, low productivity related to the necessity of a huge reactor, a large amount of waste liquid and so on. Furthermore, for the reason that generally α-hydroxycarboxylic acid of interest is highly soluble in water, in a case where, after reaction with a large amount of acid, the substance is purified by operations such as extraction or crystallization, a large amount of substance may disadvantageously remain in aqueous solution, having low yield.
[0008] Still more, where inappropriate reaction conditions are applied to a reaction, a side reaction or racemization reaction may often occur, resulting in a low yield and low optical purity of α-hydroxycarboxylic acid.
OBJECTS AND SUMMARY OF THE INVENTION
[0009] The object of the first aspect of the present invention is to provide a method for producing high purity α-hydroxycarboxylic acid.
[0010] The object of the second and third aspects of the present invention is to provide an industrially advantageous method for producing optically active α-hydroxycarboxylic acid.
[0011] As a result of thorough studies by the present inventors directed toward the object of the first aspect above, we have found that the object can be achieved by hydrolyzing cyanohydrin in the presence of a hydrocarbon solvent, thereby completing the first aspect of the present invention.
[0012] That is to say, the first aspect of the present invention comprises the following features of invention.
[0013] (1) A method for producing α-hydroxycarboxylic acid, which comprises hydrolyzing cyanohydrin in the presence of a hydrocarbon solvent.
[0014] (2) The method for producing α-hydroxycarboxylic acid according to (1) above, which comprises separating and removing the hydrocarbon solvent phase from a reaction solution after hydrolysis reaction.
[0015] (3) The method for producing α-hydroxycarboxylic acid according to (1) or (2) above, wherein the hydrolysis reaction is carried out using mineral acid.
[0016] Moreover, as a result of thorough studies by the present inventors to improve the yield and optical purity of optically active α-hydroxycarboxylic acid, we have found that, in a case where an alcoholic solvent, an ester solvent, an ethereal solvent, a carboxylic solvent or a hydrocarbon-based solvent is used as a reaction solvent in the production process of optically active cyanohydrin, followed by the removal of the solvent and hydrolysis, both the yield and optical purity of optically active α-hydroxycarboxylic acid are improved, compared with a case where hydrolysis is performed without removing the solvent; thereby completing the second aspect of the present invention.
[0017] That is to say, the second aspect of the present invention comprises the following features of invention.
[0018] (1) A method for producing optically active α-hydroxycarboxylic acid, which comprises: producing optically active cyanohydrin by performing a reaction between a carbonyl compound and hydrogen cyanide, using a solvent comprising at least one organic solvent selected from a group consisting of an alcoholic solvent, an ester solvent, an ethereal solvent and a carboxylic solvent; removing the above organic solvent from the above reaction solvent; and hydrolyzing the remaining reaction mixture without isolating optically active cyanohydrin.
[0019] (2) The method for producing optically active α-hydroxycarboxylic acid according to (1) above, wherein the amount of the above organic solvent in the reaction mixture subjected to hydrolysis is less than 10 weight %.
[0020] (3) The method for producing optically active α-hydroxycarboxylic acid according to (1) or (2) above, wherein the hydrolysis reaction is carried out using mineral acid.
[0021] As a result of further thorough studies by the present inventors directed toward the object of the third aspect of the present invention, we have found that the object can be achieved by hydrolyzing optically active cyanohydrin, using at most 10 equivalents of mineral acid relative to the above optically active cyanohydrin under the condition that maximum temperature on reaction time is 90° C. or less; thereby completing the third aspect of the present invention.
[0022] That is to say, the third aspect of the present invention comprises the following feature of invention.
[0023] (1) A method for producing optically active α-hydroxycarboxylic acid, which comprises hydrolyzing optically active cyanohydrin, using at most 10 equivalents of mineral acid relative to said optically active cyanohydrin under the condition that maximum temperature on reaction time is 90° C. or less.
[0024] Furthermore, the present inventors have found that the crystal with high packing density of optically active α-hydroxycarboxylic acid can be obtained by crystallizing optically active α-hydroxycarboxylic acid in an aqueous solution, thereby completing a fourth aspect of the present invention.
[0025] That is to say, the fourth aspect of the present invention comprises the following features of invention.
[0026] (1) A method for producing optically active crystalline α-hydroxycarboxylic acid, which comprises crystallizing optically active α-hydroxycarboxylic acid in an aqueous solution.
[0027] (2) The method for producing optically active crystalline α-hydroxycarboxylic acid according to (1) above, which comprises crystallizing optically active α-hydroxycarboxylic acid in the presence of a non-miscible organic solvent.
[0028] (3) An optically active crystalline chloromandelic acid, which is obtained by the production method according to (1) or (2) above.
[0029] (4) A method for producing optically active crystalline α-hydroxycarboxylic acid, which comprises crystallizing the optically active α-hydroxycarboxylic acid obtained by the method according to the first, second or third aspect of the present invention, in an aqueous solution.
[0030] The method of the first aspect of the present invention is to produce α-hydroxycarboxylic acid by hydrolyzing cyanohydrin in the presence of a hydrocarbon solvent and converting the cyano group of the above cyanohydrin into a carboxyl group, and according to the present method, it becomes possible to easily remove colored substances and by-products generated during the hydrolysis reaction, resulting in the simple production of high purity α-hydroxycarboxylic acid.
[0031] In the first aspect of the present invention, cyanohydrin used as a material for the present invention is not particularly limited, as long as it has, in a molecule thereof, at least one pair consisting of a hydroxyl group and a cyano group which bind to an identical carbon atom.
[0032] An example of cyanohydrin used for the present invention includes the compound shown in the following formula (I):
[0033] wherein
[0034] R 1 and R 2 may be different from or identical to each other, independently representing a hydrogen atom, a halogen atom, an amino group, an amino group mono- or di-substituted with a monovalent hydrocarbon group containing at most 14 carbon atoms, a mercapto group or a monovalent hydrocarbon group containing at most 22 carbon atoms, in the above hydrocarbon group, each of —CH 2 — and CH 2 in —CH 3 may be substituted with a carbonyl group, a sulfonyl group, —O— or —S—, ═CH 2 may be substituted with ═O or ═S; or C—H in —CH 2 , C—H in —CH 3 , C—H in >CH—, C—H in ═CH— and C—H in ═CH 2 may be substituted with N or C-halogen, or
[0035] R 1 and R 2 may together form a divalent group.
[0036] The monovalent hydrocarbon group containing at most 22 carbon atoms in the above formula (I) includes a linear or branched chain hydrocarbon group, a monocyclic hydrocarbon group with or without side chain, a polycyclic hydrocarbon group with or without side chain, a spiro hydrocarbon group with or without side chain, a ring-assembled structural hydrocarbon group with or without side chain, or a chain hydrocarbon group with the above cyclic-hydrocarbon. It includes any saturated or unsaturated hydrocarbon group, with the exception that unsaturated hydrocarbon groups having an allene structure (C═C═C) are excluded. The linear or branched chain hydrocarbon group includes, for example, saturated chain hydrocarbon groups such as a linear alkyl group containing at least 1 carbon atom and a branched alkyl group containing at least 3 carbon atoms; unsaturated chain hydrocarbon groups such as a linear alkenyl group containing at least 2 carbon atoms, a branched alkenyl group containing at least 3 carbon atoms, a linear alkynyl group containing at least 3 carbon atoms, a branched alkynyl group containing at least 4 carbon atoms, a linear alkadienyl group containing at least 4 carbon atoms and a branched alkadienyl group containing at least 5 carbon atoms. The monocyclic hydrocarbon group includes, for example, saturated monocyclic hydrocarbon groups such as a cycloalkyl group without side chain which contains at least 3 carbon atoms and a cycloalkyl group with side chain which contains at least 4 carbon atoms in total; unsaturated monocyclic hydrocarbon groups such as a cycloalkenyl group without side chain which contains at least 4 carbon atoms, a cycloalkynyl group with side chain which contains at least 5 carbon atoms in total, a cycloalkadienyl group without side chain which contains at least 5 carbon atoms and a cycloalkadienyl group with side chain which contains at least 6 carbon atoms in total. The unsaturated monocyclic or polycyclic hydrocarbon group includes an aromatic hydrocarbon group including: an aromatic group without side chain which contains 6 to 22 carbon atoms in total such as a phenyl group, a 1-naphthyl group, a 2-naphthyl group and a 9-anthryl group; an aromatic group with side chain which contains at least 7 carbon atoms in total; a phenylphenyl group containing 12 carbon atoms and a phenylphenyl group with side chain which contains at least 13 carbon atoms in total, which are also included in a ring-assembled structural hydrocarbon group. The polycyclic hydrocarbon group includes a condensed cyclic hydrocarbon group without side chain which contains at least 6 carbon atoms, a condensed cyclic hydrocarbon group with side chain which contains at least 7 carbon atoms in total, a bridged cyclic hydrocarbon group with out side chain which contains at least 7 carbon atoms, a bridged cyclic hydrocarbon group with side chain which contains at least 8 carbon atoms in total, a spiro hydrocarbon group without side chain which contains at least 9 carbon atoms in total and a spiro hydrocarbon group with side chain which contains at least 10 carbon atoms in total. In addition, the above condensed cyclic hydrocarbon group without side chain includes those which contain at least 9 carbon atoms in total when one of its condensed rings is a benzene ring, and the above condensed cyclic hydrocarbon group with side chain includes those which contain at least 10 carbon atoms in total when one of its condensed rings is benzene ring. The ring-assembled structural hydrocarbon group includes a cycloalkyl-cycloalkyl group without side chain which contains at least 6 carbon atoms in total, a cycloalkyl-cycloalkyl group with side chain which contains at least 7 carbon atoms in total, a cycloalkylidene-cycloalkyl group without side chain which contains at least 6 carbon atoms in total and a cycloalkylidene-cycloalkyl group with side chain which contains at least 7 carbon atoms in total. “A cyclic hydrocarbon with side chain” in these cyclic hydrocarbons, corresponds to one having a chain hydrocarbon group attached to its ring. Such chain hydrocarbon group having a cyclic hydrocarbon includes a linear alkyl group which is substituted with an aromatic group without side chain and contains at least 7 carbon atoms in total, a linear alkyl group which is substituted with an aromatic group with side chain and contains at least 8 carbon atoms in total, a branched alkyl group which is substituted with an aromatic group without side chain and contains at least 9 carbon atoms in total, a branched alkyl group which is substituted with an aromatic group with side chain and contains at least 10 carbon atoms in total, a linear alkenyl group which is substituted with an aromatic group without side chain and contains at least 8 carbon atoms in total, a linear alkenyl group which is substituted with an aromatic group with side chain and contains at least 9 carbon atoms in total, a branched alkenyl group which is substituted with an aromatic group without side chain and contains at least 9 carbon atoms in total, a branched alkenyl group which is substituted with an aromatic group with side chain and contains at least 10 carbon atoms in total, a linear alkynyl group which is substituted with an aromatic group without side chain and contains at least 8 carbon atoms in total, a linear alkynyl group which is substituted with an aromatic group with side chain and contains at least 9 carbon atoms in total, a branched alkynyl group which is substituted with an aromatic group without side chain and contains at least 10 carbon atoms in total, a branched alkynyl group which is substituted with an aromatic group with side chain and contains at least 11 carbon atoms in total, a linear alkadienyl group which is substituted with an aromatic group without side chain and contains at least 10 carbon atoms in total, a linear alkadienyl group which is substituted with an aromatic group with side chain and contains at least 11 carbon atoms in total, a branched alkadienyl group which is substituted with an aromatic group without side chain and contains at least 11 carbon atoms in total, a branched alkadienyl group which is substituted with an aromatic group with side chain and contains at least 12 carbon atoms in total, a linear alkyl group which is substituted with a cycloalkyl group without side chain and contains at least 4 carbon atoms in total, a linear alkyl group which is substituted with a cycloalkyl group with side chain and contains at least 5 carbon atoms in total, a branched alkyl group which is substituted with a cycloalkyl group without side chain and contains at least 6 carbon atoms in total, a branched alkyl group which is substituted with a cycloalkyl group with side chain and contains at least 7 carbon atoms in total, a linear alkenyl group which is substituted with a cycloalkyl group without side chain and contains at least 5 carbon atoms in total, a linear alkenyl group which is substituted with a cycloalkyl group with side chain and contains at least 6 carbon atoms in total, a branched alkenyl group which is substituted with a cycloalkyl group without side chain and contains at least 6 carbon atoms in total, a branched alkenyl group which is substituted with a cycloalkyl group with side chain and contains at least 7 carbon atoms in total, a linear alkynyl group which is substituted with a cycloalkyl group without side chain and contains at least 5 carbon atoms in total, a linear alkynyl group which is substituted with a cycloalkyl group with side chain and contains at least 6 carbon atoms in total, a branched alkynyl group which is substituted with a cycloalkyl group without side chain and contains at least 7 carbon atoms in total, a branched alkynyl group which is substituted with a cycloalkyl group with side chain and contains at least 8 carbon atoms in total, a branched alkadienyl group which is substituted with a cycloalkyl group without side chain and contains at least 8 carbon atoms in total, a branched alkadienyl group which is substituted with a cycloalkyl group with side chain and contains at least 9 carbon atoms in total.
[0037] Hereinafter, each of an aromatic group without side chain, an aromatic group with side chain, and a phenylphenyl group or a phenylphenyl group with side chain, is referred as an aryl group, and a linear or branched alkyl group substituted with the aryl group or groups is referred as an aralkyl group. Other cyclic hydrocarbon groups referring to both one having side chains on its ring and one having no side chains, are simply referred as, for example, cycloalkyl groups, unless otherwise specified. Also, chain hydrocarbon groups referring to both linear one and branched one are simply referred as, for example, alkyl groups.
[0038] When —CH 2 — in the above hydrocarbon group is substituted with a carbonyl group, sulfonyl group, —O— or —S—, a ketone, sulfone, ether or thioether structure is introduced therein, respectively. When —CH 2 — in —CH 3 is substituted with a carbonyl group, —O— or —S—, it converts into a formyl (aldehyde) group, a hydroxyl group or a mercapto group, respectively. When a terminal ═CH 2 is substituted with ═O or ═S, a ketone or thioketone structure is introduced therein. When each C—H in —CH 2 — is substituted with N, it converts into —NH—. When C—H in >CH— is substituted with N, it converts into >N—. When C—H in ═CH— is substituted with N, it converts into ═N—. When C—H in a terminal —CH 3 is substituted with N, —NH 2 is introduced therein. When C—H in ═CH 2 is substituted with N, it converts into ═NH. Further, each C—H in —CH 3 , —CH 2 —, ═CH—, ═CH or >CH— is substituted with a C-halogen, the carbon is substituted with a halogen atom. The substitution of carbon chains with —O—, —S— or N corresponds to oxa-, thia- or aza-substitution of the hydrocarbon group, respectively. For example, when these substitution take place in a ring carbon of the hydrocarbon ring, the hydrocarbon ring converts into a heterocyclic ring respectively containing oxygen, sulfur or nitrogen. The substitution of CH 2 and C—H in the hydrocarbon group may independently take place and it may further take place when CH 2 or C—H still remains on the carbon after the prior substitution. Further, the above substitutions may bring the conversion of-CH 2 —CH 3 into —CO—O—H, a carboxylic acid structure.
[0039] A halogen atom, herein, refers to a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, but a fluorine atom, a chlorine atom and a bromine atom are preferable.
[0040] Accordingly, the above hydrocarbon group may be selected from any chain hydrocarbon group and hydrocarbon group having ring-structured hydrocarbon group such as cyclic hydrocarbon groups, for example, saturated chain hydrocarbon groups such as linear or branched alkyl groups; unsaturated chain hydrocarbon groups such as linear or branched alkenyl groups, linear or branched alkynyl groups and linear or branched alkadienyl groups; saturated cyclic hydrocarbon groups such as cycloalkyl groups; unsaturated cyclic hydrocarbon groups such as cycloalkenyl groups, cycloalkynyl groups and cycloalkadienyl groups; and aromatic hydrocarbon groups such as aryl groups, aralkyl groups and arylalkenyl groups.
[0041] In more detail, the linear or branched alkyl groups include a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a 1-methylpropyl group, a pentyl group, a 1-methylbutyl group, a hexyl group, a 1-methylpentyl group, a heptyl group, a 1-methylhexyl group, a 1-ethylpentyl group, an octyl group, a nonyl group, a decyl group, an undecyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a 2-methylpropyl group, a 2-methylbutyl group, a 3-methylbutyl group, a 2-methylpentyl group, a 3-methylpentyl group, a 4-methylpentyl group, a methylhexyl group, a methylheptyl group, a methyloctyl group, a methylnonyl group, a 1,1-dimethylethyl group, a 1,1-dimethylpropyl group, a 2,6-dimethylheptyl group, a 3,7-dimethyloctyl group and a 2-ethylhexyl group; cycloalkylalkyl groups include a cyclopentylmethyl group and a cyclohexylmethyl group; cycloalkyl groups include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a methylcyclopentyl group, a cyclohexyl group, a methylcyclohexyl group, a cycloheptyl group and a cyclooctyl group; and bicycloalkyl groups include a norbornyl group, a bicyclo [2.2.2] octyl group and an adamantyl group.
[0042] The linear or branched alkenyl groups include a vinyl group, an allyl group, a crotyl group (a 2-butenyl group) and an isopropenyl group (a 1-methylvinyl group); cycloalkenyl or cycloalkadienyl groups include a cyclopentenyl group, a cyclopentadienyl group, a cyclohexenyl group and a cyclohexadienyl group.
[0043] The linear or branched alkynyl groups include an ethynyl group, a propynyl group and a butynyl group. The aryl groups include a phenyl group, a 1-naphthyl group, a 2-naphthyl group, a 2-phenylphenyl group, a 3-phenylphenyl group, a 4-phenylphenyl group, a 9-anthryl group, a methylphenyl group, a dimethylphenyl group, a trimethylphenyl group, an ethylphenyl group, a methylethylphenyl group, a diethylphenyl group, a propylphenyl group and a butylphenyl group.
[0044] The aralkyl groups include a benzyl group, a 1-naphthylmethyl group, a 2-naphthylmethyl group, a phenethyl group (a 2-phenylethyl group), a 1-phenylethyl group, a phenylpropyl group, a phenylbutyl group, a phenylpentyl group, a phenylhexyl group, a methylbenzyl group, a methylphenethyl group, a dimethylbenzyl group, a dimethylphenethyl group, a trimethylbenzyl group, an ethylbenzyl group and a diethylbenzyl group.
[0045] The arylalkenyl groups include a styryl group, a methylstyryl group, an ethylstyryl group, a dimethylstyryl group and a 3-phenyl-2-propenyl group.
[0046] The above hydrocarbon groups, in which the CH 2 group is substituted with a carbonyl group, a sulfonyl group, O or S, or the C—H group is substituted with N or C-halogen, include groups having one or more structures such as ketone, aldehyde, carboxylic acid, sulfone, ether, thioether, amine, alcohol, thiol, halogen and heterocycles (e.g. an oxygen-containing heterocycle, a sulfur-containing heterocycle, a nitrogen-containing heterocycle, etc.) The oxygen-containing heterocycle, sulfur-containing heterocycle and nitrogen-containing heterocycle correspond to cyclic hydrocarbon groups in which their ring carbon is substituted with oxygen, sulfur and nitrogen, respectively. These heterocycles may contain two or more heteroatoms.
[0047] These substituted hydrocarbon groups may include a ketone structure such as an acetylmethyl group and an acetylphenyl group; a sulfone structure such as a methanesulfonylmethyl group; an ether structure such as a methoxymethyl group, a methoxyethyl group, an ethoxyethyl group, a methoxypropyl group, a butoxyethyl group, an ethoxyethoxyethyl group, a methoxyphenyl group, dimethoxyphenyl group and phenoxymethyl group; a thioether structure such as a methylthiomethyl group and a methylthiophenyl group; an amine structure such as an aminomethyl group, a 2-aminoethyl group, a 2-aminopropyl group, a 3-aminopropyl group, a 2,3-diaminopropyl group, a 2-aminobutyl group, a 3-aminobutyl group, a 4-aminobutyl group, a 2,3-diaminobutyl group, a 2,4-diaminobutyl group, a 3,4-diaminobutyl group, a 2,3,4-triaminobutyl group, a methylaminomethyl group, a dimethylaminometyl group, a methylaminoethyl group, a propylaminomethyl group, a cyclopentylaminomethyl group, an aminophenyl group, a diaminophenyl group, an aminomethylphenyl group; an oxygen-containing heterocycle such as a tetrahydrofuranyl group, a tetrahydropyranyl group and a morphorylethyl group; an oxygen-containing aromatic ring such as a furyl group, a furfuryl group, a benzofuryl group and a benzofurfuryl group; a sulfur-containing heterocycle such as a thienyl group; a nitrogen-containing aromatic ring such as a pyrrolyl group, an imidazoyl group, an oxazoyl group, a thiadiazoyl group, a pyridyl group, a pyrimidyl group, a pyridazinyl group, a pyrazinyl group, a tetrazinyl group, a quinolyl group, an isoquinolyl group, a pyridylmethyl group; an alcohol structure such as a 2-hydroxyethyl group, a 2-hydroxypropyl group, a 3-hydroxypropyl group, a 2,3-dihydroxypropyl group, a 2-hydroxybutyl group, a 3-hydroxybutyl group, a 4-hydroxybutyl group, a 2,3-dihydroxybutyl group, a 2,4-dihydroxybutyl group, a 3,4-dihydroxybutyl group, a 2,3,4-trihydroxybutyl group, a hydroxyphenyl group, a dihydroxyphenyl group, a hydroxymethylphenyl group and a hydroxyethylphenyl group; a thiol structure such as a 2-mercaptoethyl group, a 2-mercaptopropyl group, a 3-mercaptopropyl group, a 2,3-dimercaptopropyl group, a 2-mercaptobutyl group, a 3-mercaptobutyl group, a 4-mercaptobutyl group, a mercaptophenyl group; a halogenated hydrocarbon group such as a 2-chloroethyl group, a 2-chloropropyl group, a 3-chloropropyl group, a 2-chlorobutyl group, a 3-chlorobutyl group, a 4-chlorobutyl group, a fluorophenyl group, a chlorophenyl group, a bromophenyl group, a difluorophenyl group, a dichlorophenyl group, a dibromophenyl group, a chlorofluorophenyl group, a trifluorophenyl group, a trichlorophenyl group, a fluoromethylphenyl group and a trifluoromethylpheyl group; a compound having both an amine structure and an alcohol structure such as a 2-amino-3-hydroxypropyl group, a 3-amino-2-hydroxypropyl group, a 2-amino-3-hydroxybutyl group, a 3-amino-2-hydroxybutyl group, a 2-amino-4-hydroxybutyl group, a 4-amino-2-hydroxybutyl group, a 3-amino-4-hydroxybutyl group, a 4-amino-3-hydroxybutyl group, a 2,4-diamino-3-hydroxybutyl group, a 3-amino-2,4-dihydroxybutyl group, a 2,3-diamino-4-hydroxybutyl group, a 4-amino-2,3-dihydroxybutyl group, a 3,4-diamino-2-hydroxybutyl group, a 2-amino-3,4-dihydroxybutyl group and an aminohydroxyphenyl group; a hydrocarbon group substituted with a halogen and a hydroxyl group such as a fluorohydroxyphenyl group, a chlorohydroxyphenyl group; and a carbon structure such as a carboxyphenyl group.
[0048] The cyanohydrin shown in the above formula (I) includes: 2-aryl-2-hydroxyacetonitrile such as mandelonitrile (2-hydroxy-2-phenylacetonitrile), 3-phenoxymandelonitrile (2-hydroxy-2-(3-phenoxyphenyl)acetonitrile), 4-methylmandelonitrile (2-hydroxy-2-(p-tolyl)acetonitrile), 2-chloromandelonitrile (2-(2-chlorophenyl)-2-hydroxyacetonitrile), 3-chloromandelonitrile (2-(3-chlorophenyl)-2-hydroxyacetonitrile), 4-chloromandelonitrile (2-(4-chlorophenyl)-2-hydroxyacetonitrile), 3-nitromandelonitrile (2-hydroxy-2-(3-nitrophenyl)acetonitrile), 3,4-methylenedioxymandelonitrile (2-hydroxy-2-(3,4-methylenedioxyphenyl) acetonitrile), 2,3-methylenedioxymandelonitrile (2-hydroxy-2-(2,3-methylenedioxyphenyl)acetonitrile), 2-benzyl-2-hydroxyacetonitrile and 2-(2-furyl)-2-hydroxyacetonitrile; 2-alkyl-2-hydroxyacetonitrile such as 2-hydroxy-2-methylacetonitrile, 2-hydroxy-2-propylacetonitrile, 2-hydroxy-2-isopropylacetonitrile, 2-butyl-2-hydroxyacetonitrile and 2-cyclohexyl-2-hydroxyacetonitrile; 2,2-dialkyl-2-hydroxyacetonitrile such as 2-ethyl-2-hydroxy-2-methylacetonitrile, 2-butyl-2-hydroxy-2-methylacetonitrile, 2-hydroxy-2-methyl-2-propylacetonitrile, 2-hydroxy-2-isopropyl-2-methylacetonitrile, 2-hydroxy-2-methyl-2-pentylacetonitrile, 2-hydroxy-2-methyl-2-(2-methylpropyl)acetonitrile and 2-hydroxy-2-methyl-2-(3-methylbutyl)acetonitrile; 2-alkyl-2-alkenyl-2-hydroxyacetonitrile such as 2-hydroxy-2-methyl-2-(2-propenyl)acetonitrile and 2-(3-butenyl)-2-hydroxy-2-methylacetonitrile; 2-alkyl-2-(haloalkyl)-2-hydroxyacetonitrile such as 2-(3-chloropropyl)-2-hydroxy-2-methylacetonitrile; 2-(1-(protected amino)alkyl)-2-hydroxyacetonitrile such as 2-(1-alkoxycarbonylamino)-2-cyclohexylethyl)-2-hydroxyacetonitrile; 2-alkylthioalkyl-2-hydroxyacetonitrile such as 2-hydroxy-2-(2-methylthioethyl)acetonitrile; and 2-acyl-2-hydroxyacetonitrile such as 2-hydroxy-2-pivaloilacetonitrile.
[0049] A divalent group represented by R 1 and R 2 is not particularly limited, and the examples include an alkylene group containing 2 to 22 carbon atoms, norbornane-2-ylidene and 2-norbornene-5-ylidene.
[0050] The cyanohydrin used for the first aspect of the present invention can be obtained by known methods, i.e. by allowing alkali cyanide to act on a corresponding carbonyl compound or its sodium hydrogensulfite adduct. In a case of the use of cyanohydrin of the above formula (I), wherein R 1 and R 2 are different from each other, any of a (S)-form and an (R) form can be used, and this compound can be produced by, for example, such methods as an optical resolution of cyanohydrin obtained by acting alkali cyanide with a corresponding carbonyl compound or its sodium hydrogensulfite adduct; a method of asymmetricly adding hydrogen cyanide to a corresponding carbonyl compound in the presence of enzymes such as (S)-hydroxynitrilelyase and (R)-hydroxynitrilelyase extracted from plants (e.g. Synthesis, July 1990, 575-578 ; Tetrahedron Letters, 32, 2605-2608 (1991); Japanese Patent Application Filed Nos. 63-219388, 5-317065 and 9-227488); a method of asymmetricly hydrolyzing a material obtained by chemical synthesis of racemic cyanohydrinester, using enzymes (e.g. Japanese Patent Application Filed No. 62-65688); and a method of asymmetricly adding hydrogen cyanide to a corresponding carbonyl compound in the presence of enzymes produced by a gene recombinant microorganism, into which a gene of enzymes such as (S)-hydroxynitrilelyase and (R)-hydroxynitrilelyase is incorporated (e.g. WO98/30711, Japanese Patent Application Filed No. 9-227488).
[0051] Mineral acid is preferably used for the hydrolysis in the first aspect of the present invention. The examples of such mineral acid include hydrochloric acid, sulfuric acid, nitric acid, boracic acid, phosphoric acid and perchloric acid, hydrochloric acid being preferable.
[0052] If an overfull usage of hydrolytic catalyst is used to cyanohydrin, it would be economically disadvantageous and lead to the decrease of the yield. However, the extremely low usage of catalyst would lead to a slow and insufficient reaction, or, in the use of optically active cyanohydrin as a material, it would lead to the reduction in the optical purity of the α-hydroxycarboxylic acid of interest. Accordingly, the preferable amount of hydrolytic catalyst is generally 1.5 to 10 equivalents to cyanohydrin, preferably 1.5 to 8 equivalents, and more preferably 2 to 7 equivalents.
[0053] Hereinafter, the hydrocarbon solvent used in the first aspect of the present invention is described. The hydrocarbon solvent used in the first aspect of the present invention is not particularly limited, as long as it is an organic compound consisting of carbon atoms and hydrogen atoms only, and it exists as a liquid at the reaction temperature of hydrolysis and separates from an aqueous phase.
[0054] Such carbon solvents include any of a linear or branched chain hydrocarbon, a cyclic hydrocarbon with or without side chain, and a chain hydrocarbon wherein the above cyclic hydrocarbon group is substituted. In addition, these hydrocarbons may have an unsaturated bond in a molecule thereof. Some representatives of the above hydrocarbon solvents are shown below.
[0055] The linear or branched chain hydrocarbon includes pentane, hexane, heptane, octane and these structural isomers, e.g. chain hydrocarbons containing 5 to 16 carbon atoms, such as 2-methylpentane and 3-methylpentane.
[0056] The cyclic hydrocarbon with or without side chain includes cyclopentane, cyclohexane and structural isomers thereof, e.g. saturated monocyclic hydrocarbons containing 6 to 16 carbon atoms, such as methylcyclopentane and methylcyclohexane, and aromatic hydrocarbons such as benzene, toluene, trimethylbenzene, o-xylene, m-xylene, p-xylene or an isomeric mixture of xylene.
[0057] Among these hydrocarbon solvents, benzene, toluene and p-xylene are preferable, and toluene is more preferable.
[0058] A mixed solvent consisting of the combination of at least two of the above hydrocarbon solvents may also be used.
[0059] In the production method of the first aspect of the present invention, the above cyanohydrin is hydrolyzed in the presence of the above hydrocarbon solvent. That is, the reaction is performed by adding a hydrocarbon solvent, water containing a hydrolytic catalyst and cyanohydrin as a material to a reaction vessel. When left at rest, the reaction solution divides into both a hydrocarbon solvent phase and an aqueous phase, so it is preferable to perform hydrolysis, while stirring the reaction solution appropriately.
[0060] The usage of a hydrocarbon solvent in the first aspect of the present invention is 10 to 200 weight % to cyanohydrin as a material, and preferably 20 to 100 weight %. The amount of water in the reaction mixture at initiation of the reaction is preferably 7 to 50 equivalents to cyanohydrin, and more preferably 10 to 40 equivalents.
[0061] In the production method of the first aspect of the present invention, when the maximum temperature at hydrolysis exceeds 90° C., the generation of by-products and coloration increases, or the purity of α-hydroxycarboxylic acid of interest is reduced. On the other hand, a reaction temperature of 40° C. or less leads to the reaction proceeding insufficiently, resulting in a decrease of the yield. Accordingly, the temperature of reaction solution at hydrolysis is preferably 40 to 90° C., and more preferably 50 to 80° C. In addition, the reaction time is preferably 1 to 24 hours, 2 to 12 hours being more preferable.
[0062] After completion of the reaction, the α-hydroxycarboxylic acid of interest is isolated from the reaction solution. If the reaction solution is left at rest after hydrolysis, it divides into both a hydrocarbon solvent phase containing colored substances and by-products, and an aqueous phase containing α-hydroxycarboxylic acid. So, at that moment, the hydrocarbon solvent phase is separated and removed from the reaction solution. Then, extraction is performed by adding an organic solvent such as ethyl acetate to the remaining aqueous phase, and if necessary, the organic phase is washed with water and the solvent removed from the organic phase, thereby obtaining high purity α-hydroxycarboxylic acid of interest.
[0063] In the production method of the first aspect of the present invention, impurities such as colored substances and by-products generated during hydrolysis are extracted from the aqueous phase to the hydrocarbon solvent phase, while the α-hydroxycarboxylic acid of interest remains in the aqueous phase, so that high purity α-hydroxycarboxylic acid can easily be obtained, while suppressing the coloration of the reaction solution (an aqueous phase) and α-hydroxycarboxylic acid.
[0064] The method of the second aspect of the present invention is to prevent reduction of the yield and optical purity of optically active α-hydroxycarboxylic acid caused by the use of an alcoholic solvent, an ester solvent, an ethereal solvent and/or a carboxylic solvent used in the production process of optically active cyanohydrin. The process of producing optically active cyanohydrin is not particularly limited, as long as these solvents are used as reaction solvents.
[0065] An example of the production process of optically active cyanohydrin includes a production process of optically active cyanohydrin by asymmetrically adding hydrogen cyanide to a carbonyl compound shown in the following formula (II):
R 1 —CO—R 2 (II)
[0066] wherein
[0067] R 1 and R 2 are different from each other, independently representing a hydrogen atom or a monovalent hydrocarbon group containing at most 22 carbon atoms, and
[0068] in the above hydrocarbon group, each of —CH 2 — and CH 2 in —CH 3 may be substituted with a carbonyl group, a sulfonyl group, —O— or —S—, ═CH 2 may be substituted with ═O or ═S; or C—H in —CH 2 , C—H in —CH 3 , C—H in >CH—, C—H in ═CH— and C—H in ═CH 2 may be substituted with N or C-halogen, or
[0069] R 1 and R 2 may together form an asymmetric divalent group,
[0070] in the above organic solvent(s), in the presence of enzymes such as (S)-hydroxynitrilelyase and (R)-hydroxynitrilelyase extracted from plants or enzymes produced by a gene recombinant microorganism, into which a gene of those enzymes is incorporated (e.g. Synthesis, July 1990, 575-578 ; Tetrahedron Letters, 32, 2605-2608 (1991); Japanese Patent Application filed Nos. 63-219388,5-317065 and 9-227488; WO98/30711).
[0071] The monovalent hydrocarbon group containing at most 22 carbon atoms in the above formula (II) includes a linear or branched chain hydrocarbon group, a monocyclic hydrocarbon group with or without side chain, a polycyclic hydrocarbon group with or without side chain, a Spiro hydrocarbon group with or without side chain, a ring-assembled structural hydrocarbon group with or without side chain, or a chain hydrocarbon group with the above cyclic-hydrocarbon. It includes any saturated or unsaturated hydrocarbon group, with the exception of unsaturated hydrocarbon groups having an allene structure (C═C═C). The linear or branched chain hydrocarbon group includes, for example, saturated chain hydrocarbon groups such as a linear alkyl group containing at least 1 carbon atom and a branched alkyl group containing at least 3 carbon atoms; unsaturated chain hydrocarbon groups such as a linear alkenyl group containing at least 2 carbon atoms, a branched alkenyl group containing at least 3 carbon atoms, a linear alkynyl group containing at least 3 carbon atoms, a branched alkynyl group containing at least 4 carbon atoms, a linear alkadienyl group containing at least 4 carbon atoms and a branched alkadienyl group containing at least 5 carbon atoms. The monocyclic hydrocarbon group includes, for example, saturated monocyclic hydrocarbon groups such as a cycloalkyl group without side chain which contains at least 3 carbon atoms and a cycloalkyl group with side chain which contains at least 4 carbon atoms in total; unsaturated monocyclic hydrocarbon groups such as a cycloalkenyl group without side chain which contains at least 4 carbon atoms, a cycloalkynyl group with side chain which contains at least 5 carbon atoms in total, a cycloalkadienyl group without side chain which contains at least 5 carbon atoms and a cycloalkadienyl group with side chain which contains at least 6 carbon atoms in total. The unsaturated monocyclic or polycyclic hydrocarbon group includes an aromatic hydrocarbon group including: an aromatic group without side chain which contains 6 to 22 carbon atoms in total such as a phenyl group, a 1-naphthyl group, a 2-naphthyl group and a 9-anthryl group; an aromatic group with side chain which contains at least 7 carbon atoms in total; a phenylphenyl group containing 12 carbon atoms and a phenylphenyl group with side chain which contains at least 13 carbon atoms in total, which are also included in a ring-assembled structural hydrocarbon group. The polycyclic hydrocarbon group includes a condensed cyclic hydrocarbon group without side chain which contains at least 6 carbon atoms, a condensed cyclic hydrocarbon group with side chain which contains at least 7 carbon atoms in total, a bridged cyclic hydrocarbon group without side chain which contains at least 7 carbon atoms, a bridged cyclic hydrocarbon group with side chain which contains at least 8 carbon atoms in total, a spiro hydrocarbon group without side chain which contains at least 9 carbon atoms in total and a spiro hydrocarbon group with side chain which contains at least 10 carbon atoms in total. In addition, the above condensed cyclic hydrocarbon group without side chain includes those which contain at least 9 carbon atoms in total when one of its condensed rings is a benzene ring, and the above condensed cyclic hydrocarbon group with side chain includes those which contain at least 10 carbon atoms in total when one of its condensed rings is benzene ring. The ring-assembled structural hydrocarbon group includes a cycloalkyl-cycloalkyl group without side chain which contains at least 6 carbon atoms in total, a cycloalkyl-cycloalkyl group with side chain which contains at least 7 carbon atoms in total, a cycloalkylidene-cycloalkyl group with out side chain which contains at least 6 carbon atoms in total and a cycloalkylidene-cycloalkyl group with side chain which contains at least 7 carbon atoms in total. “A cyclic hydrocarbon with side chain” in these cyclic hydrocarbons, corresponds to one having a chain hydrocarbon group attached to its ring. The above chain hydrocarbon group having a cyclic hydrocarbon group includes a linear alkyl group which is substituted with an aromatic group without side chain and contains at least 7 carbon atoms in total, a linear alkyl group which is substituted with an aromatic group with side chain and contains at least 8 carbon atoms in total, a branched alkyl group which is substituted with an aromatic group without side chain and contains at least 9 carbon atoms in total, a branched alkyl group which is substituted with an aromatic group with side chain and contains at least 10 carbon atoms in total, a linear alkenyl group which is substituted with an aromatic group without side chain and contains at least 8 carbon atoms in total, a linear alkenyl group which is substituted with an aromatic group with side chain and contains at least 9 carbon atoms in total, a branched alkenyl group which is substituted with an aromatic group without side chain and contains at least 9 carbon atoms in total, a branched alkenyl group which is substituted with an aromatic group with side chain and contains at least 10 carbon atoms in total, a linear alkynyl group which is substituted with an aromatic group without side chain and contains at least 8 carbon atoms in total, a linear alkynyl group which is substituted with an aromatic group with side chain and contains at least 9 carbon atoms in total, a branched alkynyl group which is substituted with an aromatic group without side chain and contains at least 10 carbon atoms in total, a branched alkynyl group which is substituted with an aromatic group with side chain and contains at least 11 carbon atoms in total, a linear alkadienyl group which is substituted with an aromatic group without side chain and contains at least 10 carbon atoms in total, a linear alkadienyl group which is substituted with an aromatic group with side chain and contains at least 11 carbon atoms in total, a branched alkadienyl group which is substituted with an aromatic group without side chain and contains at least 11 carbon atoms in total, a branched alkadienyl group which is substituted with an aromatic group with side chain and contains at least 12 carbon atoms in total, a linear alkyl group which is substituted with a cycloalkyl group without side chain and contains at least 4 carbon atoms in total, a linear alkyl group which is substituted with a cycloalkyl group with side chain and contains at least 5 carbon atoms in total, a branched alkyl group which is substituted with a cycloalkyl group without side chain and contains at least 6 carbon atoms in total, a branched alkyl group which is substituted with a cycloalkyl group with side chain and contains at least 7 carbon atoms in total, a linear alkenyl group which is substituted with a cycloalkyl group without side chain and contains at least 5 carbon atoms in total, a linear alkenyl group which is substituted with a cycloalkyl group with side chain and contains at least 6 carbon atoms in total, a branched alkenyl group which is substituted with a cycloalkyl group without side chain and contains at least 6 carbon atoms in total, a branched alkenyl group which is substituted with a cycloalkyl group with side chain and contains at least 7 carbon atoms in total, a linear alkynyl group which is substituted with a cycloalkyl group without side chain and contains at least 5 carbon atoms in total, a linear alkynyl group which is substituted with a cycloalkyl group with side chain and contains at least 6 carbon atoms in total, a branched alkynyl group which is substituted with a cycloalkyl group without side chain and contains at least 7 carbon atoms in total, a branched alkynyl group which is substituted with a cycloalkyl group with side chain and contains at least 8 carbon atoms in total, a branched alkadienyl group which is substituted with a cycloalkyl group without side chain and contains at least 8 carbon atoms in total, a branched alkadienyl group which is substituted with a cycloalkyl group with side chain and contains at least 9 carbon atoms in total.
[0072] Hereinafter, each of an aromatic group without side chain, an aromatic group with side chain, and a phenylphenyl group or a phenylphenyl group with side chain, is referred as an aryl group, and a linear or branched alkyl group substituted with the aryl group or groups is referred as an aralkyl group. Other cyclic hydrocarbon groups referring to both one having side chains on its ring and one having no side chains, are simply referred as, for example, cycloalkyl groups, unless otherwise specified. Also, chain hydrocarbon groups referring to both linear one and branched one are simply referred as, for example, alkyl groups.
[0073] When —CH 2 — in the above hydrocarbon group is substituted with a carbonyl group, sulfonyl group, —O— or —S—, a ketone, sulfone, ether or thioether structure is introduced therein, respectively. When —CH 2 — in —CH 3 is substituted with a carbonyl group, —O— or —S—, it converts into a formyl (aldehyde) group, a hydroxyl group or a mercapto group, respectively. When a terminal ═CH 2 is substituted with ═O or ═S, a ketone or thioketone structure is introduced therein. When C—H in —CH 2 — is substituted with N, it converts into —NH—. When C—H in >CH— is substituted with N, it converts into >N—. When C—H in ═CH— is substituted with N, it converts into ═N—. When C—H in a terminal —CH 3 is substituted with N, —NH 2 is introduced therein. When C—H in ═CH 2 is substituted with N, it converts into ═NH. Further, each C—H in —CH 3 , —CH 2 —, ═CH—, ═CH or >CH— is substituted with a C-halogen, the carbon is substituted with a halogen atom. The substitution of carbon chains with —O—, —S— or N corresponds to oxa-, thia- or aza-substitution of the hydrocarbon group, respectively. For example, when these substitution take place in a ring carbon of the hydrocarbon ring, the hydrocarbon ring converts into a heterocyclic ring respectively containing oxygen, sulfur or nitrogen. The substitution of CH 2 and C—H in the hydrocarbon group may independently take place and it may further take place when CH 2 or C—H still remains on the carbon after the prior substitution. Further, the above substitutions may bring the conversion of-CH 2 —CH 3 into —CO—O—H, a carboxylic acid structure.
[0074] A halogen atom, herein, refers to a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, but a fluorine atom, a chlorine atom and a bromine atom are preferable.
[0075] Accordingly, the above hydrocarbon group may be selected from any chain hydrocarbon group and hydrocarbon group having ring-structured hydrocarbon group such as cyclic hydrocarbon groups, for example, saturated chain hydrocarbon groups such as linear or branched alkyl groups; unsaturated chain hydrocarbon groups such as linear or branched alkenyl groups, linear or branched alkynyl groups and linear or branched alkadienyl groups; saturated cyclic hydrocarbon groups such as cycloalkyl groups; unsaturated cyclic hydrocarbon groups such as cycloalkenyl groups, cycloalkynyl groups and cycloalkadienyl groups; and aromatic hydrocarbon groups such as aryl groups, aralkyl groups and arylalkenyl groups.
[0076] In more detail, the linear or branched alkyl groups include a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a 1-methylpropyl group, a pentyl group, a 1-methylbutyl group, a hexyl group, a 1-methylpentyl group, a heptyl group, a 1-methylhexyl group, a 1-ethylpentyl group, an octyl group, a nonyl group, a decyl group, an undecyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a 2-methylpropyl group, a 2-methylbutyl group, a 3-methylbutyl group, a 2-methylpentyl group, a 3-methylpentyl group, a 4-methylpentyl group, a methylhexyl group, a methylheptyl group, a methyloctyl group, a methylnonyl group, a 1,1-dimethylethyl group, a 1,1-dimethylpropyl group, a 2,6-dimethylheptyl group, a 3,7-dimethyloctyl group and a 2-ethylhexyl group; cycloalkylalkyl groups include a cyclopentylmethyl group and a cyclohexylmethyl group; cycloalkyl groups include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a methylcyclopentyl group, a cyclohexyl group, a methylcyclohexyl group, a cycloheptyl group and a cyclooctyl group; and bicycloalkyl groups include a norbornyl group, a bicyclo [2.2.2] octyl group and an adamantyl group.
[0077] The linear or branched alkenyl groups include a vinyl group, an allyl group, a crotyl group (a 2-butenyl group) and an isopropenyl group (a 1-methylvinyl group); cycloalkenyl or cycloalkadienyl groups include a cyclopentenyl group, a cyclopentadienyl group, a cyclohexenyl group and a cyclohexadienyl group.
[0078] The linear or branched alkynyl groups include an ethynyl group, a propynyl group and a butynyl group. The aryl groups include a phenyl group, a 1-naphthyl group, a 2-naphthyl group, a 2-phenylphenyl group, a 3-phenylphenyl group, a 4-phenylphenyl group, a 9-anthryl group, a methylphenyl group, a dimethylphenyl group, a trimethylphenyl group, an ethylphenyl group, a methylethylphenyl group, a diethylphenyl group, a propylphenyl group and a butylphenyl group.
[0079] The aralkyl groups include a benzyl group, a 1-naphthylmethyl group, a 2-naphthylmethyl group, a phenethyl group (a 2-phenylethyl group), a 1-phenylethyl group, a phenylpropyl group, a phenylbutyl group, a phenylpentyl group, a phenylhexyl group, a methylbenzyl group, a methylphenethyl group, a dimethylbenzyl group, a dimethylphenethyl group, a trimethylbenzyl group, an ethylbenzyl group and a diethylbenzyl group.
[0080] The arylalkenyl groups include a styryl group, a methylstyryl group, an ethylstyryl group, a dimethylstyryl group and a 3-phenyl-2-propenyl group.
[0081] The above hydrocarbon groups, in which the CH 2 group is substituted with a carbonyl group, a sulfonyl group, O or S, or the C—H group is substituted with N or C-halogen, include groups having one or more structures such as ketone, aldehyde, carboxylic acid, sulfone, ether, thioether, amine, alcohol, thiol, halogen and heterocycles (e.g. an oxygen-containing heterocycle, a sulfur-containing heterocycle, a nitrogen-containing heterocycle, etc.) The oxygen-containing heterocycle, sulfur-containing heterocycle and nitrogen-containing heterocycle correspond to cyclic hydrocarbon groups in which their ring carbon is substituted with oxygen, sulfur and nitrogen, respectively. These heterocycles may contain two or more heteroatoms.
[0082] These substituted hydrocarbon groups may include a ketone structure such as an acetylmethyl group and an acetylphenyl group; a sulfone structure such as a methanesulfonylmethyl group; an ether structure such as a methoxymethyl group, a methoxyethyl group, an ethoxyethyl group, a methoxypropyl group, a butoxyethyl group, an ethoxyethoxyethyl group, a methoxyphenyl group, dimethoxyphenyl group and phenoxymethyl group; a thioether structure such as a methylthiomethyl group and a methylthiophenyl group; an amine structure such as an aminomethyl group, a 2-aminoethyl group, a 2-aminopropyl group, a 3-aminopropyl group, a 2,3-diaminopropyl group, a 2-aminobutyl group, a 3-aminobutyl group, a 4-aminobutyl group, a 2,3-diaminobutyl group, a 2,4-diaminobutyl group, a 3,4-diaminobutyl group, a 2,3,4-triaminobutyl group, a methylaminomethyl group, a dimethylaminometyl group, a methylaminoethyl group, a propylaminomethyl group, a cyclopentylaminomethyl group, an aminophenyl group, a diaminophenyl group, an aminomethylphenyl group; an oxygen-containing heterocycle such as a tetrahydrofuranyl group, a tetrahydropyranyl group and a morphorylethyl group; an oxygen-containing aromatic ring such as a furyl group, a furfuryl group, a benzofuryl group and a benzofurfuryl group; a sulfur-containing heterocycle such as a thienyl group; a nitrogen-containing aromatic ring such as a pyrrolyl group, an imidazoyl group, an oxazoyl group, a thiadiazoyl group, a pyridyl group, a pyrimidyl group, a pyridazinyl group, a pyrazinyl group, a tetrazinyl group, a quinolyl group, an isoquinolyl group, a pyridylmethyl group; an alcohol structure such as a 2-hydroxyethyl group, a 2-hydroxypropyl group, a 3-hydroxypropyl group, a 2,3-dihydroxypropyl group, a 2-hydroxybutyl group, a 3-hydroxybutyl group, a 4-hydroxybutyl group, a 2,3-dihydroxybutyl group, a 2,4-dihydroxybutyl group, a 3,4-dihydroxybutyl group, a 2,3,4-trihydroxybutyl group, a hydroxyphenyl group, a dihydroxyphenyl group, a hydroxymethylphenyl group and a hydroxyethylphenyl group; a thiol structure such as a 2-mercaptoethyl group, a 2-mercaptopropyl group, a 3-mercaptopropyl group, a 2,3-dimercaptopropyl group, a 2-mercaptobutyl group, a 3-mercaptobutyl group, a 4-mercaptobutyl group, a mercaptophenyl group; a halogenated hydrocarbon group such as a 2-chloroethyl group, a 2-chloropropyl group, a 3-chloropropyl group, a 2-chlorobutyl group, a 3-chlorobutyl group, a 4-chlorobutyl group, a fluorophenyl group, a chlorophenyl group, a bromophenyl group, a difluorophenyl group, a dichlorophenyl group, a dibromophenyl group, a chlorofluorophenyl group, a trifluorophenyl group, a trichlorophenyl group, a fluoromethylphenyl group and a trifluoromethylpheyl group; a compound having both an amine structure and an alcohol structure such as a 2-amino-3-hydroxypropyl group, a 3-amino-2-hydroxypropyl group, a 2-amino-3-hydroxybutyl group, a 3-amino-2-hydroxybutyl group, a 2-amino-4-hydroxybutyl group, a 4-amino-2-hydroxybutyl group, a 3-amino-4-hydroxybutyl group, a 4-amino-3-hydroxybutyl group, a 2,4-diamino-3-hydroxybutyl group, a 3-amino-2,4-dihydroxybutyl group, a 2,3-diamino-4-hydroxybutyl group, a 4-amino-2,3-dihydroxybutyl group, a 3,4-diamino-2-hydroxybutyl group, a 2-amino-3,4-dihydroxybutyl group and an aminohydroxyphenyl group; a hydrocarbon group substituted with a halogen and a hydroxyl group such as a fluorohydroxyphenyl group, a chlorohydroxyphenyl group; and a carbon structure such as a carboxyphenyl group.
[0083] An asymmetric divalent group represented by R 1 and R 2 is not particularly limited, and the examples include norbornane-2-ylidene and 2-norbornene-5-ylidene.
[0084] The carbonyl compound shown in the above formula (II) includes: aromatic aldehyde such as benzaldehyde, m-phenoxybenzaldehyde, p-methylbenzaldehyde, o-chlorobenzaldehyde, m-chlorobenzaldehyde, p-chlorobenzaldehyde, m-nitrobenzaldehyde, 3,4-methylenedioxybenzaldehyde, 2,3-methylenedioxybenzaldehyde, phenylacetoaldehyde and furfural; aliphatic aldehyde such as acetoaldehyde, butylaldehyde, isobutylaldehyde, valeraldehyde and cyclohexanealdehyde; saturated aliphatic ketone such as ethylmethylketone, butylmethylketone, methylpropylketone, isopropylmethylketone, methylpentylketone, methyl(2-methylpropyl)ketone and methyl(3-methylbutyl)keton; unsaturated aliphatic ketone such as methyl(2-propenyl)ketone and (3-butenyl)methylketone; alkyl(haloalkyl)ketone such as (3-chloropropyl)methylketone; 2-(protected amino)aldehyde such as 2-(alkoxycarbonylamino)-3-cyclohexylpropionealdehyde; and alkylthio aliphatic aldehyde such as 3-methylthiopropionealdehyde.
[0085] In the production process of optically active cyanohydrin in the method of the second aspect of the present invention, a solvent comprising at least one organic solvent selected from a group consisting of an alcoholic solvent, an ester solvent, an ethereal solvent and a carboxylic solvent is used as a reaction solvent.
[0086] The alcoholic solvent includes aliphatic alcohol such as methanol, ethanol, propanol, isopropanol, 1-butanol, 2-butanol, isobutanol, t-butanol, hexanol, n-amylalcohol and cyclohexanol as well as benzylalcohol and so on.
[0087] The ester solvent includes aliphatic ester such as methyl formate, methyl acetate, ethyl acetate, butyl acetate and methyl propionate.
[0088] The ethereal solvent includes aliphatic ether such as diethyl ether, dipropyl ether, diisopropyl ether, dibutyl ether, t-butylmethyl ether, dimethoxyethane and tetrahydrofuran.
[0089] The carboxylic solvent includes aliphatic carboxylic acid such as acetic acid.
[0090] Apart from the solvents listed above, the reaction solvent used in the second aspect of the present invention may also comprise a hydrocarbon-based solvent such as n-pentane, n-hexane, cyclohexane, benzene, toluene and xylene, and an aqueous buffer of pH 7 or less such as a citrate buffer, a phosphate buffer and an acetate buffer.
[0091] In the production process of optically active cyanohydrin in the method of the second aspect of the present invention, the use of the carbonyl compound of the above formula (II) as a material results in the generation of optically active cyanohydrin corresponding to the above compound shown in the following formula (III):
[0092] wherein R 1 and R 2 have the same definitions as R 1 and R 2 in the above formula (II), and C* represents an asymmetric carbon atom. Subsequent to that, in the method of the second aspect of the present invention, the as-is optically active cyanohydrin obtained in the first step, without isolation, is used for hydrolysis of the second step.
[0093] In the method of the second aspect of the present invention, an alcoholic solvent, an ester solvent, an ethereal solvent and/or a carboxylic solvent used as a reaction solvent in the first step were removed at that stage. Where a hydrocarbon-based solvent such as n-pentane, n-hexane, cyclohexane, benzene, toluene and xylene is used in combination with these organic solvent, the hydrocarbon-based solvent may not be removed.
[0094] Methods for removing the above solvent include, evaporation under an ordinary or reduced pressure, extraction with water and so on, but among these methods, evaporation under a reduced pressure is preferable in that this method is simple, having less influence on the second step.
[0095] Preferably, the removal of a reaction solvent in the first step of the second aspect of the present invention is preferably performed so that the amount of an alcoholic solvent, an ester solvent, an ethereal solvent and a carboxylic solvent in a reaction mixture subjected to hydrolysis is less than 10 weight %, and more preferably 5 weight %.
[0096] It is preferable to use mineral acid in performing hydrolysis in the second step of the second aspect of the present invention. Examples of mineral acid used herein include hydrochloric acid, sulfuric acid, nitric acid, boracic acid, phosphoric acid and perchloric acid, being hydrochloric acid preferable.
[0097] The preferable usage of mineral acid is 1 to 10 equivalents to optically active cyanohydrin which is contained in a reaction mixture subjected to hydrolysis. The usage of mineral acid of more than 10 equivalents to optically active cyanohydrin would be economically disadvantageous, resulting in the decrease of yield. However, the usage of mineral acid of less than 1 equivalent to optically active cyanohydrin would lead to a slow and insufficient reaction, or the reduction in the optical purity of optically active α-hydroxycarboxylic acid of interest. The more preferable usage of mineral acid is 2 to 8 equivalents to optically active cyanohydrin.
[0098] Preferably, hydrolysis is performed under the condition of the maximum reaction temperature of 40 to 90° C. The maximum reaction temperature of more than 90° C. would bring on the increase of by-products and coloration. On the other hand, the maximum reaction temperature of less than 40° C. would result in the insufficient proceeding of reaction. Furthermore, in both cases, the optical purity of optically active α-hydroxycarboxylic acid of interest is reduced. The maximum reaction temperature is more preferably 40 to 80° C. Where the reaction temperature is less than 40° C., the reaction time is preferably set at 15 hours or less, more preferably 3 hours or less.
[0099] In hydrolysis reaction, a reaction solvent may be used, but such a solvent is not only particularly effective but may also reduce yield or optical purity, so it is preferable not to use solvents other than water. At the initiation of reaction, the amount of water contained in a reaction mixture including water contained in mineral acid used, is preferably 7 to 50 equivalents to optically active cyanohydrin, and more preferably 10 to 40 equivalents.
[0100] After reaction, to isolate α-hydroxycarboxylic acid of interest from the obtained reaction solution (which, at times, may become, a slurry), the solution is extracted with an organic solvent and is washed, as needed, and then the solvent is vaporized and exsiccated.
[0101] As stated above, by converting the cyano group of optically active cyanohydrin into a carboxyl group, while maintaining the configuration of the above optically active cyanohydrin, α-hydroxycarboxylic acid can be produced.
[0102] The method of the third aspect of the present invention is a method for producing optically active α-hydroxycarboxylic acid by conversion of the cyano group of optically active cyanohydrin used as a material into a carboxyl group, while maintaining the configuration of the above optically active cyanohydrin, and according to the present method, it becomes possible to selectively produce optical isomers depending on the selection of (S)-form or (R)-form of cyanohydrin as a material.
[0103] The optically active cyanohydrin used as a material in the third aspect of the present invention is not particularly limited, as long as the cyanohydrin is an optically active substance (optically active α-hydroxynitrile) having, in a molecule thereof, at least one pair consisting of a hydroxyl group and a cyano group binding to an identical carbon atom. The optical purity of the above cyanohydrin is not particularly limited, as long as the purity is more than 80%, but an optical purity of 90 to 100% is preferable.
[0104] An example of optically active cyanohydrin used in the third aspect of the present invention includes a compound shown in the following formula (IV):
[0105] wherein
[0106] C* is an asymmetric carbon atom;
[0107] R 1 and R 2 are different from each other, independently representing a hydrogen atom, a halogen atom, an amino group, an amino group mono- or di-substituted with a monovalent hydrocarbon group containing at most 14 carbon atoms, a mercapto group or a monovalent hydrocarbon group containing at most 22 carbon atoms, in the above hydrocarbon group, each of —CH 2 — and CH 2 in —CH 3 may be substituted with a carbonyl group, sulfonyl group, —O— or —S—, ═CH 2 may be substituted with ═O or ═S; or C—H in —CH 2 , C—H in —CH 3 , C—H in >CH—, C—H in ═CH— and C—H in ═CH 2 may be substituted with N or C-halogen, or
[0108] R 1 and R 2 may together form an asymmetric divalent group.
[0109] The monovalent hydrocarbon group containing at most 22 carbon atoms in the above formula (IV) includes a linear or branched chain hydrocarbon group, a monocyclic hydrocarbon group with or without side chain, a polycyclic hydrocarbon group with or without side chain, a spiro hydrocarbon group with or without side chain, a ring-assembled structural hydrocarbon group with or without side chain, or a chain hydrocarbon group with the above cyclic-hydrocarbon. It includes any saturated or unsaturated hydrocarbon group, with the exception of unsaturated hydrocarbon groups having an allene structure (C═C═C). The linear or branched chain hydrocarbon group includes, for example, saturated chain hydrocarbon groups such as a linear alkyl group containing at least 1 carbon atom and a branched alkyl group containing at least 3 carbon atoms; unsaturated chain hydrocarbon groups such as a linear alkenyl group containing at least 2 carbon atoms, a branched alkenyl group containing at least 3 carbon atoms, a linear alkynyl group containing at least 3 carbon atoms, a branched alkynyl group containing at least 4 carbon atoms, a linear alkadienyl group containing at least 4 carbon atoms and a branched alkadienyl group containing at least 5 carbon atoms. The monocyclic hydrocarbon group includes, for example, saturated monocyclic hydrocarbon groups such as a cycloalkyl group without side chain which contains at least 3 carbon atoms and a cycloalkyl group with side chain which contains at least 4 carbon atoms in total; unsaturated monocyclic hydrocarbon groups such as a cycloalkenyl group without side chain which contains at least 4 carbon atoms, a cycloalkynyl group with side chain which contains at least 5 carbon atoms in total, a cycloalkadienyl group without side chain which contains at least 5 carbon atoms and a cycloalkadienyl group with side chain which contains at least 6 carbon atoms in total. The unsaturated monocyclic or polycyclic hydrocarbon group includes an aromatic hydrocarbon group including: an aromatic group without side chain which contains 6 to 22 carbon atoms in total such as a phenyl group, a 1-naphthyl group, a 2-naphthyl group and a 9-anthryl group; an aromatic group with side chain which contains at least 7 carbon atoms in total; a phenylphenyl group containing 12 carbon atoms and a phenylphenyl group with side chain which contains at least 13 carbon atoms in total, which are also included in a ring-assembled structural hydrocarbon group. The polycyclic hydrocarbon group includes a condensed cyclic hydrocarbon group without side chain which contains at least 6 carbon atoms, a condensed cyclic hydrocarbon group with side chain which contains at least 7 carbon atoms in total, a bridged cyclic hydrocarbon group with out side chain which contains at least 7 carbon atoms, a bridged cyclic hydrocarbon group with side chain which contains at least 8 carbon atoms in total, a spirohydrocarbon group without side chain which contains at least 9 carbon atoms in total and a spiro hydrocarbon group with side chain which contains at least 10 carbon atoms in total. In addition, the above condensed cyclic hydrocarbon group without side chain includes those which contain at least 9 carbon atoms in total when one of its condensed rings is a benzene ring, and the above condensed cyclic hydrocarbon group with side chain includes those which contain at least 10 carbon atoms in total when one of its condensed rings is benzene ring. The ring-assembled structural hydrocarbon group includes a cycloalkyl-cycloalkyl group without side chain which contains at least 6 carbon atoms in total, a cycloalkyl-cycloalkyl group with side chain which contains at least 7 carbon atoms in total, a cycloalkylidene-cycloalkyl group without side chain which contains at least 6 carbon atoms in total and a cycloalkylidene-cycloalkyl group with side chain which contains at least 7 carbon atoms in total. “A cyclic hydrocarbon with side chain” in these cyclic hydrocarbons, corresponds to one having a chain hydrocarbon group attached to its ring. Such chain hydrocarbon group having a cyclic hydrocarbon group includes a linear alkyl group which is substituted with an aromatic group without side chain and contains at least 7 carbon atoms in total, a linear alkyl group which is substituted with an aromatic group with side chain and contains at least 8 carbon atoms in total, a branched alkyl group which is substituted with an aromatic group without side chain and contains at least 9 carbon atoms in total, a branched alkyl group which is substituted with an aromatic group with side chain and contains at least 10 carbon atoms in total, a linear alkenyl group which is substituted with an aromatic group without side chain and contains at least 8 carbon atoms in total, a linear alkenyl group which is substituted with an aromatic group with side chain and contains at least 9 carbon atoms in total, a branched alkenyl group which is substituted with an aromatic group without side chain and contains at least 9 carbon atoms in total, a branched alkenyl group which is substituted with an aromatic group with side chain and contains at least 10 carbon atoms in total, a linear alkynyl group which is substituted with an aromatic group without side chain and contains at least 8 carbon atoms in total, a linear alkynyl group which is substituted with an aromatic group with side chain and contains at least 9 carbon atoms in total, a branched alkynyl group which is substituted with an aromatic group without side chain and contains at least 10 carbon atoms in total, a branched alkynyl group which is substituted with an aromatic group with side chain and contains at least 11 carbon atoms in total, a linear alkadienyl group which is substituted with an aromatic group without side chain and contains at least 10 carbon atoms in total, a linear alkadienyl group which is substituted with an aromatic group with side chain and contains at least 11 carbon atoms in total, a branched alkadienyl group which is substituted with an aromatic group without side chain and contains at least 11 carbon atoms in total, a branched alkadienyl group which is substituted with an aromatic group with side chain and contains at least 12 carbon atoms in total, a linear alkyl group which is substituted with a cycloalkyl group without side chain and contains at least 4 carbon atoms in total, a linear alkyl group which is substituted with a cycloalkyl group with side chain and contains at least 5 carbon atoms in total, a branched alkyl group which is substituted with a cycloalkyl group without side chain and contains at least 6 carbon atoms in total, a branched alkyl group which is substituted with a cycloalkyl group with side chain and contains at least 7 carbon atoms in total, a linear alkenyl group which is substituted with a cycloalkyl group without side chain and contains at least 5 carbon atoms in total, a linear alkenyl group which is substituted with a cycloalkyl group with side chain and contains at least 6 carbon atoms in total, a branched alkenyl group which is substituted with a cycloalkyl group without side chain and contains at least 6 carbon atoms in total, a branched alkenyl group which is substituted with a cycloalkyl group with side chain and contains at least 7 carbon atoms in total, a linear alkynyl group which is substituted with a cycloalkyl group without side chain and contains at least 5 carbon atoms in total, a linear alkynyl group which is substituted with a cycloalkyl group with side chain and contains at least 6 carbon atoms in total, a branched alkynyl group which is substituted with a cycloalkyl group without side chain and contains at least 7 carbon atoms in total, a branched alkynyl group which is substituted with a cycloalkyl group with side chain and contains at least 8 carbon atoms in total, a branched alkadienyl group which is substituted with a cycloalkyl group without side chain and contains at least 8 carbon atoms in total, a branched alkadienyl group which is substituted with a cycloalkyl group with side chain and contains at least 9 carbon atoms in total.
[0110] Hereinafter, each of an aromatic group without side chain, an aromatic group with side chain, and a phenylphenyl group or a phenylphenyl group with side chain, is referred as an aryl group, and a linear or branched alkyl group substituted with the aryl group or groups is referred as an aralkyl group. Other cyclic hydrocarbon groups referring to both one having side chains on its ring and one having no side chains, are simply referred as, for example, cycloalkyl groups, unless otherwise specified. Also, chain hydrocarbon groups referring to both linear one and branched one are simply referred as, for example, alkyl groups.
[0111] When —CH 2 — in the above hydrocarbon group is substituted with a carbonyl group, sulfonyl group, —O— or —S—, a ketone, sulfone, ether or thioether structure is introduced therein, respectively. When —CH 2 — in —CH 3 is substituted with a carbonyl group, —O— or —S—, it converts into a formyl (aldehyde) group, a hydroxyl group or a mercapto group, respectively. When a terminal ═CH 2 is substituted with ═O or ═S, a ketone or thioketone structure is introduced therein. When C—H in —CH 2 — is substituted with N, it converts into —NH—. When C—H in >CH— is substituted with N, it converts into >N—. When C—H in ═CH— is substituted with N, it converts into ═N—. When C—H in a terminal —CH 3 is substituted with N, —NH 2 is introduced therein. When C—H in ═CH 2 is substituted with N, it converts into ═NH. Further, each C—H in —CH 3 , —CH 2 —, ═CH—, ≡CH or >CH— is substituted with a C-halogen, the carbon is substituted with a halogen atom. The substitution of carbon chains with —O—, —S— or N corresponds to oxa-, thia- or aza-substitution of the hydrocarbon group, respectively. For example, when these substitution take place in a ring carbon of the hydrocarbon ring, the hydrocarbon ring converts into a heterocyclic ring respectively containing oxygen, sulfur or nitrogen. The substitution of CH 2 and C—H in the hydrocarbon group may independently take place and it may further take place when CH 2 or C—H still remains on the carbon after the prior substitution. Further, the above substitutions may bring the conversion of-CH 2 —CH 3 into —CO—O—H, a carboxylic acid structure.
[0112] A halogen atom, herein, refers to a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, but a fluorine atom, a chlorine atom and a bromine atom are preferable.
[0113] Accordingly, the above hydrocarbon group may be selected from any chain hydrocarbon group and hydrocarbon group having ring-structured hydrocarbon group such as cyclic hydrocarbon groups, for example, saturated chain hydrocarbon groups such as linear or branched alkyl groups; unsaturated chain hydrocarbon groups such as linear or branched alkenyl groups, linear or branched alkynyl groups and linear or branched alkadienyl groups; saturated cyclic hydrocarbon groups such as cycloalkyl groups; unsaturated cyclic hydrocarbon groups such as cycloalkenyl groups, cycloalkynyl groups and cycloalkadienyl groups; and aromatic hydrocarbon groups such as aryl groups, aralkyl groups and arylalkenyl groups.
[0114] In more detail, the linear or branched alkyl groups include a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a 1-methylpropyl group, a pentyl group, a 1-methylbutyl group, a hexyl group, a 1-methylpentyl group, a heptyl group, a 1-methylhexyl group, a 1-ethylpentyl group, an octyl group, a nonyl group, a decyl group, an undecyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a 2-methylpropyl group, a 2-methylbutyl group, a 3-methylbutyl group, a 2-methylpentyl group, a 3-methylpentyl group, a 4-methylpentyl group, a methylhexyl group, a methylheptyl group, a methyloctyl group, a methylnonyl group, a 1,1-dimethylethyl group, a 1,1-dimethylpropyl group, a 2,6-dimethylheptyl group, a 3,7-dimethyloctyl group and a 2-ethylhexyl group; cycloalkylalkyl groups include a cyclopentylmethyl group and a cyclohexylmethyl group; cycloalkyl groups include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a methylcyclopentyl group, a cyclohexyl group, a methylcyclohexyl group, a cycloheptyl group and a cyclooctyl group; and bicycloalkyl groups include a norbornyl group, a bicyclo [2.2.2] octyl group and an adamantyl group.
[0115] The linear or branched alkenyl groups include a vinyl group, an allyl group, a crotyl group (a 2-butenyl group) and an isopropenyl group (a 1-methylvinyl group); cycloalkenyl or cycloalkadienyl groups include a cyclopentenyl group, a cyclopentadienyl group, a cyclohexenyl group and a cyclohexadienyl group.
[0116] The linear or branched alkynyl groups include an ethynyl group, a propynyl group and a butynyl group. The aryl groups include a phenyl group, a 1-naphthyl group, a 2-naphthyl group, a 2-phenylphenyl group, a 3-phenylphenyl group, a 4-phenylphenyl group, a 9-anthryl group, a methylphenyl group, a dimethylphenyl group, a trimethylphenyl group, an ethylphenyl group, a methylethylphenyl group, a diethylphenyl group, a propylphenyl group and a butylphenyl group.
[0117] The aralkyl groups include a benzyl group, a 1-naphthylmethyl group, a 2-naphthylmethyl group, a phenethyl group (a 2-phenylethyl group), a 1-phenylethyl group, a phenylpropyl group, a phenylbutyl group, a phenylpentyl group, a phenylhexyl group, a methylbenzyl group, a methylphenethyl group, a dimethylbenzyl group, a dimethylphenethyl group, a trimethylbenzyl group, an ethylbenzyl group and a diethylbenzyl group.
[0118] The arylalkenyl groups include a styryl group, a methylstyryl group, an ethylstyryl group, a dimethylstyryl group and a 3-phenyl-2-propenyl group.
[0119] The above hydrocarbon groups, in which the CH 2 group is substituted with a carbonyl group, a sulfonyl group, O or S, or the C—H group is substituted with N or C-halogen, include groups having one or more structures such as ketone, aldehyde, carboxylic acid, sulfone, ether, thioether, amine, alcohol, thiol, halogen and heterocycles (e.g. an oxygen-containing heterocycle, a sulfur-containing heterocycle, a nitrogen-containing heterocycle etc.) The oxygen-containing heterocycle, sulfur-containing heterocycle and nitrogen-containing heterocycle correspond to cyclic hydrocarbon groups in which their ring carbon is substituted with oxygen, sulfur and nitrogen, respectively. These heterocycles may contain two or more heteroatoms.
[0120] These substituted hydrocarbon groups may include a ketone structure such as an acetylmethyl group and an acetylphenyl group; a sulfone structure such as a methanesulfonylmethyl group; an ether structure such as a methoxymethyl group, a methoxyethyl group, an ethoxyethyl group, a methoxypropyl group, a butoxyethyl group, an ethoxyethoxyethyl group, a methoxyphenyl group, dimethoxyphenyl group and phenoxymethyl group; a thioether structure such as a methylthiomethyl group and a methylthiophenyl group; an amine structure such as an aminomethyl group, a 2-aminoethyl group, a 2-aminopropyl group, a 3-aminopropyl group, a 2,3-diaminopropyl group, a 2-aminobutyl group, a 3-aminobutyl group, a 4-aminobutyl group, a 2,3-diaminobutyl group, a 2,4-diaminobutyl group, a 3,4-diaminobutyl group, a 2,3,4-triaminobutyl group, a methylaminomethyl group, a dimethylaminometyl group, a methylaminoethyl group, a propylaminomethyl group, a cyclopentylaminomethyl group, an aminophenyl group, a diaminophenyl group, an aminomethylphenyl group; an oxygen-containing heterocycle such as a tetrahydrofuranyl group, a tetrahydropyranyl group and a morphorylethyl group; an oxygen-containing aromatic ring such as a furyl group, a furfuryl group, a benzofuryl group and a benzofurfuryl group; a sulfur-containing heterocycle such as a thienyl group; a nitrogen-containing aromatic ring such as a pyrrolyl group, an imidazoyl group, an oxazoyl group, a thiadiazoyl group, a pyridyl group, a pyrimidyl group, a pyridazinyl group, a pyrazinyl group, a tetrazinyl group, a quinolyl group, an isoquinolyl group, a pyridylmethyl group; an alcohol structure such as a 2-hydroxyethyl group, a 2-hydroxypropyl group, a 3-hydroxypropyl group, a 2,3-dihydroxypropyl group, a 2-hydroxybutyl group, a 3-hydroxybutyl group, a 4-hydroxybutyl group, a 2,3-dihydroxybutyl group, a 2,4-dihydroxybutyl group, a 3,4-dihydroxybutyl group, a 2,3,4-trihydroxybutyl group, a hydroxyphenyl group, a dihydroxyphenyl group, a hydroxymethylphenyl group and a hydroxyethylphenyl group; a thiol structure such as a 2-mercaptoethyl group, a 2-mercaptopropyl group, a 3-mercaptopropyl group, a 2,3-dimercaptopropyl group, a 2-mercaptobutyl group, a 3-mercaptobutyl group, a 4-mercaptobutyl group, a mercaptophenyl group; a halogenated hydrocarbon group such as a 2-chloroethyl group, a 2-chloropropyl group, a 3-chloropropyl group, a 2-chlorobutyl group, a 3-chlorobutyl group, a 4-chlorobutyl group, a fluorophenyl group, a chlorophenyl group, a bromophenyl group, a difluorophenyl group, a dichlorophenyl group, a dibromophenyl group, a chlorofluorophenyl group, a trifluorophenyl group, a trichlorophenyl group, a fluoromethylphenyl group and a trifluoromethylpheyl group; a compound having both an amine structure and an alcohol structure such as a 2-amino-3-hydroxypropyl group, a 3-amino-2-hydroxypropyl group, a 2-amino-3-hydroxybutyl group, a 3-amino-2-hydroxybutyl group, a 2-amino-4-hydroxybutyl group, a 4-amino-2-hydroxybutyl group, a 3-amino-4-hydroxybutyl group, a 4-amino-3-hydroxybutyl group, a 2,4-diamino-3-hydroxybutyl group, a 3-amino-2,4-dihydroxybutyl group, a 2,3-diamino-4-hydroxybutyl group, a 4-amino-2,3-dihydroxybutyl group, a 3,4-diamino-2-hydroxybutyl group, a 2-amino-3,4-dihydroxybutyl group and an aminohydroxyphenyl group; a hydrocarbon group substituted with a halogen and a hydroxyl group such as a fluorohydroxyphenyl group, a chlorohydroxyphenyl group; and a carbon structure such as a carboxyphenyl group.
[0121] The cyanohydrin shown in the above formula (IV) includes: 2-aryl-2-hydroxyacetonitrile such as mandelonitrile (2-hydroxy-2-phenylacetonitrile), 3-phenoxymandelonitrile (2-hydroxy-2-(3-phenoxyphenyl)acetonitrile), 4-methylmandelonitrile (2-hydroxy-2-(p-tolyl)acetonitrile), 2-chloromandelonitrile (2-(2-chlorophenyl)-2-hydroxyacetonitrile), 3-chloromandelonitrile (2-(3-chlorophenyl)-2-hydroxyacetonitrile), 4-chloromandelonitrile (2-(4-chlorophenyl)-2-hydroxyacetonitrile), 3-nitromandelonitrile (2-hydroxy-2-(3-nitrophenyl)acetonitrile), 3,4-methylenedioxymandelonitrile (2-hydroxy-2-(3,4-methylenedioxyphenyl) acetonitrile), 2,3-methylenedioxymandelonitrile (2-hydroxy-2-(2,3-methylenedioxyphenyl)acetonitrile), 2-benzyl-2-hydroxyacetonitrile and 2-(2-furyl)-2-hydroxyacetonitrile; 2-alkyl-2-hydroxyacetonitrile such as 2-hydroxy-2-methylacetonitrile, 2-hydroxy-2-propylacetonitrile, 2-hydroxy-2-isopropylacetonitrile, 2-butyl-2-hydroxyacetonitrile and 2-cyclohexyl-2-hydroxyacetonitrile; 2,2-dialkyl-2-hydroxyacetonitrile such as 2-ethyl-2-hydroxy-2-methylacetonitrile, 2-butyl-2-hydroxy-2-methylacetonitrile, 2-hydroxy-2-methyl-2-propylacetonitrile, 2-hydroxy-2-isopropyl-2-methylacetonitrile, 2-hydroxy-2-methyl-2-pentylacetonitrile, 2-hydroxy-2-methyl-2-(2-methylpropyl)acetonitrile and 2-hydroxy-2-methyl-2-(3-methylbutyl)acetonitrile; 2-alkyl-2-alkenyl-2-hydroxyacetonitrile such as 2-hydroxy-2-methyl-2-(2-propenyl)acetonitrile and 2-(3-butenyl)-2-hydroxy-2-methylacetonitrile; 2-alkyl-2-(haloalkyl)-2-hydroxyacetonitrile such as 2-(3-chloropropyl)-2-hydroxy-2-methylacetonitrile; 2-(1-(protected amino)alkyl)-2-hydroxyacetonitrile such as 2-(1-alkoxycarbonylamino)-2-cyclohexylethyl)-2-hydroxyacetonitrile; 2-alkylthioalkyl-2-hydroxyacetonitrile such as 2-hydroxy-2-(2-methylthioethyl)acetonitrile; and 2-acyl-2-hydroxyacetonitrile such as 2-hydroxy-2-pivaloilacetonitrile.
[0122] An asymmetric divalent group represented by R 1 and R 2 is not particularly limited, as long as the above groups can convert a carbon atom, to which the groups bind, into an asymmetric carbon, and the examples include norbornane-2-ylidene and 2-norbornene-5-ylidene.
[0123] The optically active cyanohydrin used in the third aspect of the present invention may be any of a (S)-form and an (R) form, and this compound can be produced by, for example, such methods as an optical resolution of cyanohydrin obtained by acting alkali cyanide with a corresponding carbonyl compound or its sodium hydrogensulfite adduct; a method of asymmeticly adding hydrogen cyanide to a corresponding carbonyl compound in the presence of enzymes such as (S)-hydroxynitrilelyase and (R)-hydroxynitrilelyase extracted from plants (e.g. Synthesis, July 1990, 575-578 ; Tetrahedron Letters, 32, 2605-2608 (1991); Japanese Patent Application filed Nos. 63-219388, 5-317065 and 9-227488); a method of asymmetricly hydrolyzing a material obtained by chemical synthesis of racemic cyanohydrinester, using enzymes (e.g. Japanese Patent Application filed No. 62-65688); and a method of asymmetricly adding hydrogen cyanide to a corresponding carbonyl compound in the presence of enzymes produced by a gene ricombinant microorganism, to which a gene of enzymes such as (S)-hydroxynitrilelyase and (R)-hydroxynitrilelyase is incorporated (e.g. WO98/30711, Japanese Patent Application filed No. 9-227488).
[0124] The third aspect of the present invention is characterized in hydrolyzing optically active cyanohydrin, using at most 10 equivalents of mineral acid relative to the optically active cyanohydrin under the condition that maximum temperature when reacting is less than 90° C.
[0125] Examples of mineral acid used in the third aspect of the present invention include hydrochloric acid, sulfuric acid, nitric acid, boric acid, phosphoric acid and perchloric acid, hydrochloric acid being preferable.
[0126] The usage of more than 10 equivalents of mineral acid relative to optically active cyanohydrin would be economically disadvantageous, resulting in a decrease of yields. However, the extremely low usage of mineral acid would lead to a slow and insufficient reaction, or a reduction in the optical purity of the optically active α-hydroxycarboxylic acid of interest. The preferable usage of mineral acid is 1.5 to 8 equivalents relative to optically active cyanohydrin, and more preferably 2 to 7 equivalents.
[0127] A maximum reaction temperature of more than 90° C. would bring on the increase of the generation of by-products and coloration, resulting in the reduction of the optical purity of optically active α-hydroxycarboxylic acid of interest. The maximum reaction temperature is preferably 40 to 80° C., more preferably 45 to 70° C. Where the reaction temperature is less than 40° C., the reaction time is preferably set at 15 hours or less, more preferably 3 hours or less.
[0128] A reaction solvent may be used, but such a solvent is not particularly effective and may also reduce yield or optical purity, so it is preferable not to use solvents other than water. At initiation of the reaction, the amount of water contained in a reaction mixture including water in the mineral acid used, is preferably 7 to 50 equivalents relative to optically active cyanohydrin, and more preferably 10 to 40 equivalents.
[0129] After reaction, to isolate the α-hydroxycarboxylic acid of interest from the obtained reaction solution (which, at times, may be a slurry), the solution is extracted with an organic solvent and is washed, as needed, and then the solvent is vaporized and exsiccated.
[0130] The fourth aspect of the present invention is a method for producing optically active crystalline α-hydroxycarboxylic acid, which comprises crystallizing optically active α-hydroxycarboxylic acid in an aqueous solution. This crystallization may be carried out in the presence of a non-miscible organic solvent, and an example of such an organic solvent includes a hydrocarbon solvent such as benzene, toluene, and o-, m- and p-xylene, n-hexane, n-heptane, n-octane. Where the crystallization is carried out in the presence of a non-miscible organic solvent, the ratio between an aqueous solution and the organic solvent is preferably 1:0.05-1:1. An optically active crystalline α-hydroxycarboxylic acid is deposited by cooling the above optically active α-hydroxycarboxylic acid solution. The cooling temperature is not particularly limited, as long as the temperature is set at, or below, a temperature at which the optically active α-hydroxycarboxylic acid solution to be used becomes a saturated solution, but preferably at 30° C. or less, more preferably at 25° C. or less. It is better to perform the cooling as slowly as possible, preferably at a cooling rate of 0.5° C./min or less.
[0131] As optically active α-hydroxycarboxylic acid to be used in the fourth aspect of the present invention, the optically active α-hydroxycarboxylic acid produced by the method of the first, second or third aspect of the present invention may be used. In such a case, crystallization may directly be performed by adding an appropriate amount of water to a reaction solution, without isolating optically active α-hydroxycarboxylic acid from the reaction solution after hydrolysis.
[0132] The crystalline α-hydroxycarboxylic acid obtained by the production method of the fourth aspect of the present invention has a higher packing density crystal when compared with the crystals obtained by the previous methods. For example, in a case where optically active 2-chloromandelic acid is used as optically active α-hydroxycarboxylic acid, optically active crystalline 2-chloromandelic acid whose packing density is usually more than 0.5, preferably more than 0.55 and more preferably more than 0.60, can be obtained by the method of the fourth aspect of the present invention, while the packing density of the same crystal obtained by the previous methods is less than 0.50.
[0133] According to the first aspect of present invention, it becomes possible to provide a method for easily producing high purity α-hydroxycarboxylic acid, which contains almost no colored substances and by-products. Furthermore, according to the production method of the first aspect of present invention, since the configuration of cyanohydrin does not change before and after hydrolysis, even though optically active cyanohydrin is used, a corresponding optically active α-hydroxycarboxylic acid can be obtained, while maintaining its optical purity.
[0134] According to the second and third aspects of the present invention, optically active α-hydroxycarboxylic acid can be produced with high yield and high purity.
[0135] According to the fourth aspect of the present invention, optically active crystalline α-hydroxycarboxylic acid can be obtained with high packing density and high optical purity.
[0136] This specification includes part or all of the contents as disclosed in the specifications of Japanese Patent Applications Nos. 2000-166382, 2000-171186 and 2000-350695, which are the bases of the priority claim of the present application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0137] The present invention is further described in the following examples. The example is provided for illustrative purposes only, and is not intended to limit the scope of the invention.
EXAMPLE 1
[0138] 25.2 g (0.150 mol) of (R)-2-chloromandelonitrile whose optical purity is 98% e.e., 46.9 g of 35% hydrochloric acid (HCl 0.450 mol) and 7.56 g of toluene were placed into a 100 ml flask and stirred at room temperature for 1 hour, followed by reaction with heating at 70° C. for 4 hours. After cooling to room temperature and leaving at rest, the upper phase, toluene was removed. 50 g of ethyl acetate was added to the remaining aqueous phase and mixed in a separatory funnel, while shaking, followed by separation of the organic phase from the water phase. The water phase was extracted with 50 g of ethyl acetate, and the obtained organic phase was mixed with the previous organic phase, then the mixture was washed with 15 g of water. The thus obtained solution containing the (R)-2-chloromandelic acid was exsiccated under a reduced pressure, and then washed with 25 g of toluene and dried to obtain 26.9 g of (R)-2-chloromandelic acid. The optical purity was 96.6% (e.e.) The yield of the obtained (R)-2-chloromandelic acid was 94.4%.
EXAMPLE 2
[0139] The same reaction as in Example 1 was carried out to produce (R)-2-chloromandelic acid, with the exception that the amount of toluene was set at 25.2 g.
EXAMPLE 3
[0140] The same reaction as in Example 1 was carried out to produce (R)-2-chloromandelic acid, with the exception that benzene was used instead of toluene.
EXAMPLE 4
[0141] The same reaction as in Example 1 was carried out to produce (R)-2-chloromandelic acid, with the exception that p-xylene was used instead of toluene.
CONTROL EXAMPLE 1
[0142] The same reaction as in Example 1 was carried out to produce (R)-2-chloromandelic acid, with the exception that toluene was not added.
[0143] The results of Examples 1 to 4 and Control example 1 are shown in the following Table 1.
TABLE 1 Hydrocarbon solvents Coloration Yield of Purity of (ratio of weight of reaction R-2CMA carboxylic Optical purity No. to cyanohydrin) solution (%) acid (%) (% e.e.) Example 1 toluene light orange 94.4 99.0 96.6 (0.3) Example 2 toluene extremely 93.6 99.3 96.7 (1.0) light yellow Example 3 benzene light orange 94.1 99.1 96.6 (0.3) Example 4 p-xylene light orange 93.8 98.8 96.4 (0.3) Control 1 none dark reddish brown 93.6 96.5 96.2
PREPARATION EXAMPLE 1
Preparation of S-hydroxynitrilelyase
[0144] (Preparation of S-hydroxynitrilelyase)
[0145] According to genetic engineering procedures, S-hydroxynitrilelyase was prepared using a yeast saccharonyces cerevisae as a host. That is to say, according to standard techniques, total mRNA was extracted from the leaf of Manihot utilissima. Then, using the obtained mRNA as a template, cDNA synthesis was carried out to produce cDNA. Meanwhile, based on the sequence of S-hydroxynitrilelyase gene from Manihot utilissima described in a reference ( Arch. Biochem. Biophys. 311, 496-502 (1994)), the following primers were synthesized. With regard to the synthesized DNA of each of the following SEQ ID NOS: 1 and 2, a sequence listing is provided.
Sense primer: (SEQ ID NO: 1) ggggaattcatggtaactgcacattttgttctgattc Antisense primer: (SEQ ID NO: 2) ggggtcgacctcacggattagaagccgccg
[0146] With the synthesized primers, PCR (90° C., 30 seconds; 55° C., 30 seconds; 72° C., 60 seconds; 35 cycles in total) was carried out using the above cDNA as a template, to obtain a S-hydroxynitrilelyase gene. The analysis of the gene sequence showed that the sequence of the S-hydroxynitrilelyase gene matched with the sequence shown in the reference.
[0147] Subsequently, the obtained PCR fragments were inserted between the promoter and terminator of an expression vector, YEp352-GAP, to obtain a yeast episomic expression vector, YEp352-GC. This vector was transformed to a yeast saccharomyces cerevisae Inv-Sc1 strain according to standard techniques, and then the obtained strains were cultured on a minimum selective medium, which did not contain uracil, so that recombinant yeast YEp352-GC-S2 strains containing an expression vector YEp352-GC were obtained.
[0148] Then, the obtained recombinant yeast YEp352-GC-S2 strains were cultured in a YNBDCas liquid medium (6.7 g/L Yeast nitrogen hase without amino acid (Difco), 20 g/L glucose, 20 g/L casamino acid, 40 mg/mL L-tryptophan) for 24 hours to produce S-hydroxynitrilelyase in a cell thereof. Cells were collected from a recombinant cell culture solution by centrifugation, and then the obtained cell bodies were crushed by bead mill. The crushed cell bodies-containing solution was centrifuged to prepare a crude enzyme solution. The solution was roughly purified by ammonium sulfate fractionation, and the obtained solution was used as a S-hydroxynitrilelyase solution for the following experiments.
[0149] (Immobilization of S-hydroxynitrilelyase)
[0150] The above-prepared S-hydroxynitrilelyase was immobilized to Micro Bead Silica Gel 300A (Fuji Silysia Chemical Ltd.) The immobilization of enzyme was carried out by adding 200 g of carrier to 1.0L of S-hydroxynitrilelyase solution (activity: 64U/ml, 0.02M HEPES-Na buffer (pH 6.0)), stirring the mixture at 4° C. for 24 hours, and performing the adsorption immobilization of enzyme protein to the carrier.
[0151] (1 st Step: Synthesis of Optically Active Cyanohydrin with Immobilized Enzyme)
EXAMPLE 1′
[0152] 200 g of immobilized enzyme, 1.2L of t-butylmethyl ether (tBME) saturated with 10 mM phosphate buffer (pH 5.5), 127.2 g (2.0 mol) of benzaldehyde and 49.2 g (3.0 mol) of hydrocyanic acid were placed into a 2L-volume flask, and stirred at 20° C. for 1 hour. After reaction, the amount and optical purity of the obtained cyanohydrin were determined by analyzing the reaction solution by HPLC.
EXAMPLE 2′
[0153] The same reaction as in Example 1′ was carried out, with the exception that ethyl acetate was used as a solvent, instead of tBME.
EXAMPLE 3′
[0154] 5.0 L of 25 weight % methanol solution containing 0.1M benzaldehyde, 0.3M hydrocyanic acid and 0.05M sodium acetate, and 50 g of immobilized enzyme were placed into a 5L-volum flask, followed by the same reaction as in Example 1′.
REFERENCE EXAMPLE
[0155] The same reaction as in Example 1′ was carried out, with the exception that hexane was used as a solvent, instead of tBME.
[0156] The results of the above reactions are shown in Table 2.
TABLE 2 Optical purity Solvent Invert ratio (%) (% ee) Example 1′ tBME 98 more than 99.9 Example 2′ ethyl acetate 97 more than 99.9 Example 3′ methanol/water 96 99.8 Reference example hexane 96 99.8
[0157] (2 nd Step: Hydrolysis)
EXAMPLE 1A
[0158] After the reaction solution of Example 1′ was filtrated to remove immobilized enzyme, 2.3 g of para-toluene sulfonate monohydrate was added thereto and shaken. After that, one quarter of the obtained reaction solution (which corresponds to 0.5 mol of initiation material) was concentrated with an evaporator until the amount of tBME became 2 weight %, and transferred into a 300 mL flask with a reflux condenser. 156 g of 35% hydrochloric acid (HCl, 1.5 mol) was added thereto, and stirred at room temperature for 1 hour, followed by further stirring at 70° C. for 5 hours. After cooling the mixture to room temperature, 175 g of ethyl acetate was added thereto and mixed in a separatory funnel, while shaking, the organic phase was separated from water phase. Water phase was extracted with 175 g of ethyl acetate again, and the obtained organic phase was mixed with the previous organic phase, then the mixture was washed with 50 g of water. Such obtained organic phase was exsiccated under a reduced pressure, and then washed with 80 g of toluene and dried to obtain 71.7 g of s-mandelic acid. The purity of s-mandelic acid (including R-form) was determined to be 98.8%, and the optical purity was 99.0% (e.e.) (HPLC).
EXAMPLE 1B
[0159] The same reaction as in Example 1A was carried out, with the exception that the amount of tBME was set at 5 weight %.
EXAMPLE 2A
[0160] The reaction solution of Example 1′ was filtrated to remove immobilized enzyme, and then using one quarter of the obtained reaction solution, the same reaction as in Example 1A was carried out with the amount of ethyl acetate of 3 weight % in material.
EXAMPLE 2B
[0161] The same reaction as in Example 2A was carried out, with the exception that the amount of ethyl acetate was set at 8 weight %.
EXAMPLE 3A
[0162] The reaction solution obtained in Example 3′ was filtrated, and 0.58 g of para-toluene sulfonate monohydrate was added thereto and shaken. The whole amount of the obtained reaction solution was concentrated until the amount of methanol became 5 weight %, and then the same reaction as in Example 1A was carried out.
REFERENCE EXAMPLE
[0163] The reaction solution obtained in Reference example of the 1 st step was filtrated to remove immobilized enzyme, and then using one quarter of the obtained reaction solution, the same reaction as in Example 1A was carried out with the amount of hexane of 15 weight % in material.
CONTROL EXAMPLES 1′ TO 3′
[0164] The same reaction as in Examples was carried out, with the exception that the amount of solvent remaining in the material for hydrolysis was changed.
[0165] The results of the hydrolysis reactions are shown in Table 3.
TABLE 3 Yield of Amount of solvent carboxylic Optical purity No. (wt %) acid (%) (% ee) Example 1A tBME (2) 95 99.0 Example 1B tBME (5) 93 98.3 Example 2A ethyl acetate (3) 94 98.8 Example 2B ethyl acetate (8) 92 97.9 Example 3′ methanol (5) 95 97.1 Reference example hexane (15) 96 98.5 Control example 1′ tBME (15) 86 89.0 Control example 2A ethyl acetate (12) 89 86.4 Control example 2B ethyl acetate (20) 85 84.0 Control example 3′ methanol (15) 90 92.5
EXAMPLE 1″
[0166] 25.2 g (0.150 mol) of (R)-2-chloromandelonitrile and 46.9 g (HCl 0.450 mol) of 35% hydrochloric acid were placed into a 100 ml flask. After stirring at room temperature for 1 hour, the mixture was heated to 50° C. followed by reaction for 15 hours. After cooling the reactant to room temperature, 50 g of ethyl acetate was added thereto and mixed in a separatory funnel, while shaking, thereby separating the organic phase from aqueous phase. The aqueous phase was extracted with 50 g of ethyl acetate, and the obtained organic phase was mixed with the previous organic phase, then the mixture was washed with 15 g of water. The thus obtained solution containing (R)-2-chloromandelic acid of interest was exsiccated under a reduced pressure, and then washed with 25 g of toluene and dried to obtain 26.5 g of (R)-2-chloromandelic acid. The purity of (R)-2-chloromandelic acid by HPLC was 99.0%, and the optical purity was 97.0% (e.e.) The yield of the obtained (R)-2-chloromandelic acid was 94%, and the packing density was 0.49.
EXAMPLES 2″ AND 3″, AND CONTROL EXAMPLES 1″ AND 2″
[0167] (R)-2-chloromandelic acid was produced by the same method as described in Example 1″, with the exception that the amount of 35% hydrochloric acid used, reaction temperature and reaction time were changed.
[0168] The reaction conditions and results are shown in Table 4.
[0169] Each of the maximum reaction temperature in Examples 1″ to 3″ and Control examples 1″ and 2″ was 50° C., 80° C., 50° C., 100° C. and 50° C., respectively.
TABLE 4 Acid Reaction Reaction yield Purity (%) of Optical (R)-2- (Usage temperature & (%) of carboxylic purity CIMA* No. molar ratio) Reaction time carboxylic acid acid (% e.e.) yield (%) Example 1″ 35% HCl RT* 1 h 98 99.0 97.0 94 (3.0) 50° C. 15 h Example 2″ 35% HCl RT* 1 h 97 98.5 92.6 87 (3.0) 80° C. 3 h Example 3″ 35% HCl RT* 1 h 98 99.3 98.0 94 (6.0) 50° C. 12 h Control 35% HCl RT* 1 h 93 93.2 59.5 70 example 1″ (3.0) 100° C. 2 h Control 35% HCl RT* 1 h 96 99.0 96.6 68 example 2″ (20) 50° C. 12 h
CRYSTALLIZATION EXAMPLE
[0170] Hydrolysis was carried out at 5 times the scale of Example 1″. That is, 126 g (0.75 mol) of (R)-2-chloromandelonitrile and 234.5 g (HCl 2.25 mol) of 35% hydrochloric acid were placed into a 50 ml flask, and the mixture was stirred at room temperature for 1 hour. Then, the mixture was heated to 50° C., and reaction was performed for 15 hours.
[0171] After completion of the reaction, 120 g of water was added to the reaction solution, followed by stirring at 50° C. for 10 minutes to homogenize the solution. This solution was divided into 5 equal portions at a temperature of 50° C., then crystallization was carried out for each portion under different conditions. Each crystallization example is shown below.
EXAMPLE 1S
[0172] The reaction solution, into which water was added, was cooled to 20° C. at constant cooling rate for 90 minutes followed by keeping at 20° C. for 2 hours, and then the solution was filtrated. The obtained crystal was washed with 10 g of water and then with 15 g of toluene, followed by drying, thereby obtaining 25.3 g of (R)-2-chloromandelic acid. The purity of (R)-2-chloromandelic acid was determined to be 99.3% by HPLC, the optical putiry being 98.7% (ee). The yield of the obtained (R)-2-chloromandelic acid was 89.0%. The packing density of the obtained (R)-2-chloromandelic acid was determined to be 0.58 by the method described later.
EXAMPLE 2S
[0173] The same reaction as in Example 1S was carried out, with the exception that cooling was initiated after adding 15 g of toluene. The yield of (R)-2-chloromandelic acid was 24.6 g. The purity of (R)-2-chloromandelic acid was 99.6%, the optical purity being 99.5% (ee). The yield of the obtained (R)-2-chloromandelic acid was 87.2%, the packing density being 0.62.
EXAMPLE 3S
[0174] The same reaction as in Example 2S was carried out, with the exception that cooling time was set at 30 minutes. The yield of (R)-2-chloromandelic acid was 24.8 g. The purity of (R)-2-chloromandelic acid was 99.4%, the optical purity being 99.3% (ee). The yield of the obtained (R)-2-chloromandelic acid was 87.7%, the packing density being 0.60.
EXAMPLE 4S
[0175] The same reaction as in Example 2S was carried out, with the exception that the reaction solution was cooled to 5° C. The yield of (R)-2-chloromandelic acid was 24.9 g. The purity of (R)-2-chloromandelic acid was 99.3%, the optical purity being 99.1% (ee). The yield of the obtained (R)-2-chloromandelic acid was 88.0%, the packing density being 0.63.
EXAMPLE 5S
[0176] The same reaction as in Example 2S was carried out, with the exception that p-xylene was used instead of toluene. The yield of (R)-2-chloromandelic acid was 24.8 g. The purity of (R)-2-chloromandelic acid was 99.4%, the optical purity being 99.1% (ee). The yield of the obtained (R)-2-chloromandelic acid was 87.6%, the packing density being 0.62.
[0177] (Determination of Packing Density)
[0178] About 20 g of crystal was naturally dropped through a 20 mm-diameter funnel into a 50 mL graduated cylinder, and the packing density of the crystal was calculated by measuring the weight and volume of the crystal.
TABLE 5 Final Optical temperature cooling Yield of Purity purity Filling density hydrocarbon (° C.) time (min) products (%) (%) (% ee) (g/cm 3 ) Example 1S none 20 90 89.0 99.3 98.7 0.58 Example 2S toluene 20 90 87.2 99.6 99.5 0.62 Example 3S toluene 20 30 87.7 99.4 99.3 0.60 Example 4S toluene 5 90 88.0 99.3 99.1 0.63 Example 5S p-xylene 20 90 87.6 99.4 99.1 0.62
[0179] All the publications, patents and patent applications cited herein are incorporated herein by reference in their entirely.
1
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DNA
Artificial Sequence
Description of Artificial Sequencesynthetic
DNA
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ggggaattca tggtaactgc acattttgtt ctgattc 37
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30
DNA
Artificial Sequence
Description of Artificial Sequencesynthetic
DNA
2
ggggtcgacc tcacggatta gaagccgccg 30 | The present invention relates to:
a method for producing α-hydroxycarboxylic acid, which comprises hydrolyzing cyanohydrin in the presence of a hydrocarbon solvent;
a method for producing optically active α-hydroxycarboxylic acid, which comprises: producing optically active cyanohydrin by performing a reaction between a carbonyl compound and hydrogen cyanide, using a solvent comprising at least one organic solvent selected from a group consisting of an alcoholic solvent, an ester solvent, an ethereal solvent and a carboxylic solvent; removing said organic solvent from said reaction solvent; and hydrolyzing the remaining reaction mixture without isolating optically active cyanohydrin;
a method for producing optically active α-hydroxycarboxylic acid, which comprises hydrolyzing optically active cyanohydrin, using at most 10 equivalents of mineral acid relative to said optically active cyanohydrin under the condition that maximum temperature when reacting is 90° C. or less; and
a method for producing optically active crystalline α-hydroxycarboxylic acid, which comprises crystallizing optically active α-hydroxycarboxylic acid in an aqueous solution. | 2 |
FIELD OF THE INVENTION
The present invention is related generally to scanning devices (e.g., RFID and bar-code readers) and, more particularly, to using such devices for establishing location.
BACKGROUND OF THE INVENTION
Shoppers are familiar with the machine-readable tags, such as laser-readable bar codes or Radio Frequency Identification (“RFID”) tags, attached to products in stores. These tags are read during checkout, and an accurate list of the items purchased is presented to the user, along with billing information and, sometimes, related advertising.
In addition to making customer check-out faster and more accurate, these product tags help the merchant to track his inventory. By knowing which products and how many of them leave the store, an automated system can place re-stock orders when supplies are running low or alert the merchant when a particular product is selling poorly.
In a related scenario, a merchant or wholesaler actively inventories the stock on hand by scanning the machine-readable tags in a given location (e.g., on a particular shelf in a warehouse). The read-out (from the tags) of the items actually present can be cross-referenced against a list of items presumed to be present (produced by, e.g., an inventory system that tracks products coming into and products leaving a given area). If discrepancies due to theft or due to inaccurate scanning are found, they can be corrected.
Taking inventory by scanning for machine-readable tags placed on the items has some shortcomings, however. In addition to the obvious problems of missing, duplicate, or wrongly applied tags, the nature of the scanning process itself allows for some inaccuracies. When a user initiates a scan from a hand-held scanning device, the device makes a record of all of the tags that it “sees” during the scan. But it is not always certain that the scan registers all of the tags in the location that the user intended to scan and registers none of the tags in locations that the user did not intend to scan. There are several possible reasons for this. Some scanners (e.g., RFID scanners) can identify tags at a wide angle from the direction in which the scanner is pointing when the scan is initiated. Also, the range of the scan can vary from moment to moment depending on environmental circumstances. (Radio noise can limit the effective range of radio-based scans, while dust can limit laser scans.) These and other characteristics of the scanners typically in use today mean that the user may not know exactly the scope of the scan. For example, the user may wish to inventory the products on one shelf in a warehouse. However, if the user is not very careful with positioning and pointing the scanner during the scan, the scanner may miss some of the items on the shelf or may pick up items on other, nearby, shelves.
BRIEF SUMMARY
The above considerations, and others, are addressed by the present invention, which can be understood by referring to the specification, drawings, and claims. According to aspects of the present invention, a scanning device tells its user how to best orient the scanning device to scan a target location. (For example, the target location can be a shelf or a bin in a warehouse, the location marked with RFID chips or laser-readable bar-codes.) The user approaches the target location and initiates a scan. The results of the scan are analyzed and compared to information about the target location. (This information may be downloaded to the scanning device from a central server that hosts a database of location information for the premises.) Based on the analysis, the user is told how to re-orient the scanning device, if that is necessary to achieve an acceptable re-scan of the target location.
For example, if the scan results include the target location but also include a location other than the target location, then the orientation of the scanning device was close to acceptable but not quite good enough. The central server knows the relative locations of the target location and of the scanned non-target locations. Based on this information, the user is told how to re-orient the scanning device so that the next scan reads the target location but not the non-target locations.
Some scanning technologies provide a measurement of distance from the scanning device to the scanned tag. For RFID tags, some scanners record the strength of the signal returned from every RFID tag seen during the scan, and this signal strength serves as a proxy for the distance. Other proxy distance measurements are possible for this and for other scanning technologies. Some embodiments of the present invention use these distance measurements to, for example, ignore scanned tags that are farther away than a threshold distance. Also, a scan may be deemed to be acceptable when the target location is closer by a significant amount than any non-target scanned location.
Several possibilities are contemplated for a user interface that tells the user the results of a scan. A very simple interface could present a sound or light that tells the user roughly how close he is to an acceptable orientation. (E.g., a red light means the scan did not read the target location at all; yellow means the target location was read but so too were non-target locations; and green means the scanner orientation was acceptable.) In a preferred embodiment, a screen on the scanning device presents a two-dimensional map based on the scan results and on the known relative locations of the target location and of nearby non-target locations. Locations on the map are highlighted to tell the user the results of the scan and to direct him to re-orient the scanning device if necessary.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
While the appended claims set forth the features of the present invention with particularity, the invention, together with its objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:
FIGS. 1 a and 1 b are overviews of a representational environment in which the present invention may be practiced;
FIG. 2 is a schematic drawing of an exemplary scanning device;
FIGS. 3 a and 3 b together are a flowchart of an exemplary method for orienting a scanning device with respect to a target location; and
FIGS. 4 a , 4 b , and 4 c are drawings of an exemplary user interface on a scanning device.
DETAILED DESCRIPTION
Turning to the drawings, wherein like reference numerals refer to like elements, the invention is illustrated as being implemented in a suitable environment. The following description is based on embodiments of the invention and should not be taken as limiting the invention with regard to alternative embodiments that are not explicitly described herein.
FIG. 1 a presents a stylized layout of a typical warehouse or store 100 . A warehouse 100 often includes numerous rows 102 of shelves or bins 104 . To allow the warehouser to track the merchandise, each type of merchandise is assigned to be stored on one or more particular shelves 104 .
Inventorying the merchandise stored in the warehouse 100 is an ongoing task. As part of the inventory process, the contents of the shelves 104 are checked to make sure that all of the merchandise is properly stored and to check that the expected amount of merchandise is present in the warehouse 100 . To perform the inventory, a user is given a hand-held scanning device 106 . The scanning device 106 scans for tags affixed to the merchandise and records the tags found during the scan. Some scanning devices 106 use a laser to read bar-code tags (e.g., the UPC tags found on grocery-store items); other scanning devices 106 use a radio to read RFID tags.
The scanning device 106 may communicate with one or more wireless hubs 108 (e.g., Wi-Fi hubs) installed throughout the warehouse 100 . The scanning device 106 can communicate through the hubs 108 to a central server 110 that contains inventory information and a current map of the shelves in the warehouse 100 . In many embodiments, the scanning device 106 holds a current map of the entire warehouse 100 ; the map is updated as needed by the central server 110 . The central server 110 can send commands to the user of the scanning device 106 and can receive the results of the scans.
When the user wishes to inventory the items stored on a particular shelf 104 (called the “target shelf” or “target location”), the user orients the scanning device 106 and initiates a scan. However, the scan will be accurate only if the user correctly orients the scanning device 106 with respect to the target location 104 during a scan. If the scanning device 106 is not correctly oriented, then the scan may miss items actually present on the target shelf 104 or may register items on neighboring shelves.
Aspects of the present invention help the user to correctly orient the scanning device 106 so that he can get an accurate scan of the target location 104 . FIG. 1 b shows an array of shelves 104 . To facilitate proper orienting of the scanning device 106 , the shelves are tagged with RFID or laser-scan tags 114 . ( FIG. 1 b shows one embodiment of the tagged shelves 104 , but the positioning and number of tags 114 can be varied to optimize the detection of the tags 114 , the variations among embodiments based on particularities of the scanning environment.) As explained in greater detail below, a scan registers these tags 114 (as well as registering tags on merchandise). The scanning of these tags 114 is used to determine, and to correct if necessary, the orientation of the scanning device 106 with respect to the target location 104 . Note that the labels 112 on the shelves 104 (e.g., “C 1 R 1 ” for “column 1 , row 1 ”) are for purposes of the present discussion and need not actually appear on the shelves 104 in the warehouse 100 .
FIG. 2 shows some relevant elements of a typical scanning device 106 . A transceiver 200 allows communication with the hubs 108 for communication with the central server 110 and for roughly determining the position of the scanning device 106 , as discussed below. A second transceiver 204 performs the scan (laser or radio). A processor 202 runs the two transceivers 200 , 204 and controls a user interface 206 . The user interface 206 receives commands from the user (e.g., a command to initiate a scan) and presents results of the scan. Embodiments of the user interface 206 are discussed below.
The flowchart of FIGS. 3 a and 3 b presents one embodiment of the methods of the present invention. The user of the scanning device 106 is told to scan a particular shelf 104 . (The command could come from the central server 110 and be delivered to the scanning device 106 via a hub 108 .) In step 300 , the user approaches the target location 104 . For example, the user may have in his head the general layout of the warehouse 100 and may know how to get reasonably close to the target location 104 . Also, for many warehouses 100 a map has been made that correlates received signal strengths from the wireless hubs 108 with a physical location in the warehouse 100 . Using this map, the scanning device 106 can analyze the signals it is receiving from the hubs 108 and know its rough location in the warehouse 100 . The scanning device 106 can then tell the user how to come close to the target location 104 . (Generally speaking, GPS does not work very well in a typical warehouse 100 .) In some embodiments, the central server 110 knows approximately where the user is currently standing (e.g., near the previous target location) and can send instructions to the user to get him close to the next target location 104 . At the end of step 300 , the user is within a couple of meters of the target location 104 .
For purposes of the present discussion, assume that the user is now facing the array of shelves shown in FIG. 1 b , and assume that the target location is C 2 R 1 . FIGS. 4 a , 4 b , and 4 c illustrate one possible user interface 206 of the scanning device 106 . On a screen of the scanning device 106 is shown a two-dimensional display of the local environment. In FIG. 4 a , the target location C 2 R 1 is highlighted for the user. (In actual embodiments, the highlighting can be a bright color, e.g., blue, rather than the diagonal stripes of FIG. 4 a .) A simpler alternative user interface 206 is described below.
In step 302 , the user orients the scanning device 106 as best he can with respect to the target location 104 and, in step 304 , initiates a scan.
The scanning device 106 receives the results of the scan in step 306 . At a minimum, the results of the scan include a list of tags read during the scan. In some embodiments, an actual distance or a “proxy” distance is associated with each tag on that list. This measures the approximate distance from the scanning device 106 to the tag at the time of the scan. A measurement is a “proxy” distance when the scanning technology does not measure this distance directly. Some RFID technologies record the strength of the signal returned from each tag read during the scan, and this signal strength can be used as a proxy distance measurement (of course, a weaker signal means a greater proxy distance). Other RFID technologies run a sequence of scans at different power levels to measure proxy distances. Tags read with a lower power are considered to be nearer than tags that can only be read with a higher power. Other proxy distance measurements are possible and may be used. When scanning devices 106 that determine actual distances become more widespread, their distance measurements can replace these proxy distances. While distance measurements, whether actual or proxy, are very useful (see step 310 below), embodiments of the present invention are also useful even with scanning devices 106 that provide no distance measurements of any kind.
In step 308 , the results of the scan are analyzed, either locally by the processor 202 of the scanning device 106 or remotely by the central server 110 . Because any merchandise tags registered during the scan are irrelevant for purposes of properly orienting the scanning device 106 , these tags are ignored for now, and the following discussion only concerns those tags 114 affixed to specific shelves 104 .
Properly speaking, step 310 is an optional part of the analyzing step 308 . If distance measurements are available (either actual or proxy), then those tags 114 read during the scan that are too far away (e.g., more than a first threshold distance away) can be ignored during the analysis of step 308 .
The set of location tags 114 read during the scan (excluding the tags filtered-out in step 310 , if any) is analyzed in step 308 to determine whether or not the orientation of the scanning device 106 during the scan was appropriate. In general, there are three possible results of this analysis (that is, three possible “determined presence conditions” of the target location 104 ): (1) The target location 104 was not definitively found. (“Definitive” here means that the signal strength of the target location 104 is greater than the first threshold mentioned above.) (2) The target location 104 is found definitively but not uniquely. (3) The target location 104 is found both definitively and uniquely. Result (3) is the desired one.
Different analysis algorithms can be used to characterize the results of the scan into one of the three possible presence conditions mentioned above. As a simple example, the target location 104 is found definitively and uniquely if its location tag 114 is the one and only location tag remaining on the scan list. If proxy distances are available, then the target location 104 can also be found definitively and uniquely if (a) its location tag 114 is on the list and (b) the proxy distance for the target location's tag 114 is less, by at least a threshold amount, than the distance of any other location tag on the list.
Again if distance measurements are available, the target location 104 is found definitively but not uniquely if (a) its location tag 114 is on the list and (b) the proxy distance for the target location's tag 114 is not less, by at least the threshold amount, than the distance of at least one other location tag on the list.
In step 312 , the determined presence condition of the target location 104 is presented to the user via the user interface 206 of the scanning device 106 . A very simple user interface 206 could simply indicate which of the three possibilities applies. For example, a “stoplight” could be shown: Red means not definitively found, Yellow means found definitively but not uniquely, and Green means found definitively and uniquely. Alternatively, a specific sound could be played to indicate the determined presence condition.
A more useful two-dimensional interface 206 is illustrated in FIGS. 4 a , 4 b , and 4 c . In this interface, the boxes representing the nearby shelves are colored to indicate the determined presence condition. In one embodiment, the following rules are used for the coloring:
Color gray any shelf whose location tag 114 either was not read during the scan or that was excluded from consideration in step 310 . Also, color all shelves gray if the target location 104 was not read during the scan. If the target location 104 was read during the scan, then:
Color yellow any shelf whose location tag 114 generated a fairly strong signal (e.g., above a second threshold). If the target location 104 returned a very strong signal (e.g., above a third threshold), and if that signal is significantly stronger than the signals returned by neighboring locations, then color green any shelf whose location tag 114 generated a very strong signal. If more than one green shelf is found, then re-assign the green shelves to yellow.
Using these rules, the orientation of the scanning device 106 was close but not exact (i.e., the target location 104 was found definitively but not uniquely) if the user interface 106 shows a number of yellow boxes. FIG. 4 b shows this possibility (pretend that the boxes representing shelves C 2 R 1 and C 2 R 2 are colored yellow). FIG. 4 c shows the case where the target location 104 was found definitively and uniquely (box C 2 R 1 is colored green).
The specific user interface 206 of FIGS. 4 a , 4 b , and 4 c illustrates a useful function not available with the simpler “stoplight” interface. Consider FIG. 4 b . The user, on seeing this on the screen of the scanning device 106 , knows not only that the most recent scan was close but not quite good enough, but he also sees what was wrong with the scan. Clearly, the scanning device 106 that produced the results of FIG. 4 b was pointed too low. Thus, this user interface 206 can tell the user (in step 314 ) how to correct the orientation of the scanning device 106 to get a better scan.
In step 316 , the user repeats the scan, if necessary, until a good result (target location 104 found definitively and uniquely) is achieved. When a good result is achieved, the user knows that the list of merchandise tags found in the scan (the list filtered, as appropriate, for actual or proxy distance) truly represents the entire contents of the target location 104 and does not include merchandise tags from neighboring shelves. Of course, the methods of the present invention are not limited to the case of taking inventory but are useful whenever a target location needs to be scanned for whatever reason.
In view of the many possible embodiments to which the principles of the present invention may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of the invention. For example, other user interfaces employ other formats to present the scan results. Therefore, the invention as described herein contemplates all such embodiments as may come within the scope of the following claims and equivalents thereof. | Disclosed is a method for a scanning device to tell its user how to best orient the scanning device to scan a target location. The user approaches the target location and initiates a scan. The results of the scan are analyzed and compared to information about the target location. Based on the analysis, the user is told how to re-orient the scanning device, if that is necessary to achieve an acceptable re-scan of the target location. In a preferred embodiment, a screen on the scanning device presents a two-dimensional map based on the scan results and on the known relative locations of the target location and of nearby non-target locations. Locations on the map are highlighted to tell the user the results of the scan and to direct him to re-orient the scanning device if necessary. | 6 |
This is a continuation of application Ser. No. 07/940,406 filed Sep. 3, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and arrangement of adaptively multiplexing a plurality of video signals after being digitally encoded, and more specifically to such a method and arrangement wherein a transmission bit rate of each video signal is effectively determined using a look-up table.
2. Description of the Prior Art
It is known in the art to adaptively multiplex a plurality of video signals after digital encoding and then transmit the multiplexed signals over a transmission path (channel). One of such techniques has been disclosed in a paper entitled "Statistical Performance Analysis of an Interframe Encoder for Broadcast Television Signals" by Toshio KOGA, et el., IEEE Transactions on Communications, Vol. COM-29, No. 12, December 1981, pages 1868-1876.
Before turning to the present invention it is deemed preferable to briefly discuss the known technique with reference to FIG. 1 which corresponds to FIG. 9 given in the prior art on page 1873.
Three channels of video and audio signals, denoted by V1-A1, V2-A2 and V3-A3, are respectively applied to encoders 10a-10c which in turn apply control signals CONT1-CONT3 to an adaptive bit sharing multiplexer (ABS-MUX) 12. Each of the Control signals CONT1-CONT3 indicates a memory occupancy value of a buffer (not shown) provided in the corresponding encoder (10a, 10b or 10c). The multiplexer 12 determines bit rates to be assigned to the encoders 10a-10c with the total bit rate kept constant at 60 Mbits/s. The average bit rate per channel is 20 Mbit/s in the three-channel arrangement as shown.
The bit rate assignment determination is performed every 153.6 μs (viz., one adaptive bit sharing (ABS) frame time). The ABS frame (hereinlater may be referred to as a frame) is composed of 18 sub-frames each of which includes 512 bits. The bit rate assignment is implemented by changing the number of sub-frames assigned to each channel in one frame. For example, in the case of the three-channel multiplexing, the number of sub-frames assigned to each channel is selected from 5, 6, 7 and 8 with the total number of the sub-frames allocated to the three channels being kept constant at 18. Since one frame has 18 sub-frames in this particular case, the bit rates to be assigned to the three incoming signal channels are combinations selected among 16.7 Mbite/s, 20.0 Mbits/s, 23.3 Mbits/s and 26.7 Mbits/s, which respectively correspond to 5, 6, 7 and 8 sub-frames.
An adaptive bit sharing demultiplexer 14 is arranged to receive a multiplexed data Dm transmitted over a transmission path 16, generates three data D1'-D3' which are replicas of the original data D1-D3, and extract clocks CLKS from the received data. The reproduced data D1'-D3' are respectively applied to decoders 18a-18c together with the clocks. The decoders 18a-18c produce three pairs of video and audio signals V1'-A1', V2'-A2' and V3'-A3' corresponding to the original signals applied to the decoders 10a-10c.
By adaptively selecting three of the four predetermined bit rates and assigning them to the three channels every frame, the prior art is advantageous in simplifying the bit rate assignment operations. Thus, the overall operation time at the transmitter can effectively be reduced.
However, this prior art has encountered the problems set forth below in that the number of bit rates available is restricted to four.
For the sake of description it is assumed that: (a) each of the two video signals V1 and V2 provides picture information including rapid motions of images and/or subject to frequent switching of picture scenes (for example) and thus (b) each of the signals V1, V2 is preferable to be transmitted at the maximum bit rate (viz., 26.7 Mbits/s) for exhibiting reasonable reproduced picture quality. In this instance, the total of the two bit rates assigned to V1 and V2 is 53.4 (=26.7×2) Mbits/s. This means that the remaining bit rate is 6.6 Mbits/s. Therefore, even if the third video signal V3 provides still pictures and hence can be transmitted without degrading signal quality at less than 6.6 (=60.0-53.4) Mbits/s, the video signal V3 has to be transmitted at 16.7 Mbits/s (viz., the minimum bit rate). Accordingly, one of the video signals V1, V2 is undesirably transmitted at 23.3 Mbits/s while the other is transmitted at 20 Mbits/s. Thus, each of V1 and V2 is transmitted at the bit rate lower than that preferable. Accordingly, the reproduced signals of V1 and V2 are inevitably degraded in terms of signal quality.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method wherein a large number of combinations of bit rates are rapidly obtained using a look-up table to which a plurality of control signals indicative of buffer occupancy values are applied.
It is an object of the present invention to provide a hardware arrangement wherein a large number of combinations of bit rates are rapidly obtained using a look-up table to which a plurality of control signals indicative of buffer occupancy values are applied.
More specifically an aspect of the present invention comes in a method of adaptively multiplexing a plurality of video channel data, a multiplexed data including a plurality of frames each of which contains a plurality of sub-frames to which the plurality of video channel data are adaptively allocated, comprising the steps of: (a) determining a memory occupancy value of a buffer which is provided in each of a plurality of video channels and to which the corresponding video information is applied; (b) generating a plurality of control signals each of which indicates the memory occupancy value of the corresponding buffer; (c) accessing a lock-up table which includes a plurality of video channel assignment data for assigning the plurality of video channel data to the plurality of sub-frames, and deriving one of the channel data assignment data; and (d) multiplexing the plurality of video channel data using the one of the channel data assignment data.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become more clearly appreciated from the following description taken in conjunction with the accompanying drawings in which like elements ere denoted by like reference numerals and in which:
FIG. 1 is a block diagram showing the prior art arrangement discussed in the opening paragraphs of the instant disclosure;
FIG. 2 is a block diagram showing the hardware arrangement to which the present invention is applicable;
FIG. 3 is a block diagram showing one of the encoders depicted in FIG. 2;
FIGS. 4 and 5 are figures which depict a frame format of multiplexed data and the manner in which it is organized in accordance with the present invention;
FIG. 6 shows an example of a look-up table which is used in connection with the present invention;
FIG. 7 is a block diagram showing details of the adaptive bit sharing multiplexer illustrated in FIG. 2;
FIG. 8 is a timing chart which shows the timing with which operations are carried out in the encoder of FIG. 3; and
FIG. 9 is a figure which depicts the another frame format of multiplexed data according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is now made to FIG. 2, wherein there is shown a hardware arrangement to which the present invention is applicable.
As illustrated, the arrangement of FIG. 2 generally includes two main sections 20 and 22, which are interconnected via a transmission path 24, for transmitting and receiving multiplexed video signals including audio information.
The transmission section 20 is provided with, in this particular embodiment, four encoders 26a-26d, an adaptive bit sharing multiplexer 28, a sub-frame assignment controller (viz., a channel bit rate controller) 30 and a transmitter 32. The controller 30 includes a look-up table 34. On the other hand, the receiver section 22 is provided with a receiver 36, an adaptive bit sharing demodulator 38 and four decoders 40a-40d.
The present invention is particularly concerned with the provision of the sub-frame assignment controller 30 for effectively increasing freedom or flexibility of assigning sub-frames to four channels CH1-CH4.
The encoders 26a-26d are supplied with four pairs of video/audio signals V1-A1, V2-A2, V3-A3 and V4-A4 via the channels CH1-CH4, respectively.
FIG. 3 shows in block diagram form the encoder 26a. The other encoders 26b-26d are respectively configured in the same manner as shown in FIG. 3.
In FIG. 3, the incoming video signal V1 is applied to a video encoder 50 and subject to interframe encoding thereat. The encoded data, which takes the form of variable length encoded sequences, are applied to a video buffer 51. A buffer occupancy determiner 52 is provided to determine the amount of video information stored in the buffer 52. As an alternative, the determiner 52 can be arranged to detect an increasing rate of information stored in the buffer per one frame duration. An encoder controller 56 receives a buffer occupancy value signal 54 from the determiner 52 and controls an encoding parameter (e.g., quantizing step) depending on the signal 54 in a manner which confines an average video information encoded within a predetermined range. The buffer occupancy determiner 52 also outputs a control signal B1 which indicates the buffer occupancy of the encoded video information at the buffer 51. The control signal B1 issues at a predetermined time interval which will be referred to later.
The audio signal A1 is stored in an audio buffer 58 after being encoded by an audio encoder 60. An encoding parameter of the encoder 60 is kept constant and hence the encoded audio information is stored at a fixed rate into the buffer 58.
Before further discussing the arrangement of FIG. 3, multiplexed data Dm generated by the adaptive multiplexer 28 will be discussed with reference to FIG. 4. As shown in FIG. 4, one frame of the multiplexed data Dm starts with a 1-bit frame sync code which is followed by a 32-bit sub-frame assignment code G. Next come 16 sub-frames (SF) each of which has bit length of 512. Since it has been assumed that the number of video channels is 4 (viz., CH1-CH4) which can be denoted by 2-bits, the code G is provided with 32 bits.
A frame of the multiplexed data Dm will further be discussed with reference to FIG. 5. The instant embodiment is arranged to include all the video data D1-D4 in the first four sub-frames 1-4 in an appropriate order. Further, each of the sub-frames 1-4 reserves short time duration for audio information as indicated by AU1-AU4. The remaining sub-frames 5-16 are adaptively allocated to one or more video channel data depending upon the above mentioned signals B1-B4 each indicative of the buffer memory occupancy (value) of the corresponding video buffer.
FIG. 6 shows a table previously stored in the look-up table 34. In FIG. 6, notation "/" is added to partition groups of same video channel data numbers merely for purposes of easy reading of the table. The able ie used to rapidly derive one sub-frame allocation data in response to the four control signals B1-B4 applied to the look-up table. AS mentioned above, the sub-frames 1-4 have already been allocated to D1-D4 as illustrated in FIG. 6.
It has been assumed that each of the four control signals B1-B4 exhibits 8 levels (viz., 3 bits necessary). Thus, there exist 4096 (=2 12 ) different combinations of B1-B4. In the event that the control signal B1 (for example) takes a higher level, it indicates that the buffer occupancy of the video channel CH1 (viz., the data thereof D1) increases. This means that the bit rate of the channel CH1 should be elevated and thus many sub-frames should be allocated to the CH1.
However, the video channel data allocation to the sub-frames must relatively be determined considering the levels of the other signals B2-B4. That is, in the case where B1=0, B2=0, B3=0 and B4=7 (row number 0008 of look-up table (LUT)), the channel data D4 takes up eleven sub-frames, while the channel data D1 uses only one sub-frames and each of channel data D2, D3 two sub-frames. On the other hand, in the case where each of the control signals B1-B4 indicates the highest level 7 (although rarely occurs) at the row No. 4096, three sub-frames are equally assigned to each of the channel data D1-D4 as shown. Similarly, when each of B1-B4 assumes a lowest level 0 at row No. 0001, three sub-frames are equally assigned to each of the video channels D1-D4. Lastly, if B1-B4 respectively assume levels of 0, 2, 7 and 3 at row No. 0187, the channel data D1-D4 are respectively assigned 1, 3, 8 and 4 considering all the levels of B1-B4.
The output derived from the look-up table 34 is applied to the adaptive bit sharing multiplexer 28 as the sub-frame assignment signal G.
Reference is made to FIG. 7, there is shown a block diagram of the adaptive bit sharing multiplexer 28 which includes a timing controller 100, a sync code generator 102 and a multiplexing section 104. The controller 100 is supplied with the sub-frame assignment code G and also receives a clock CLK from the transmitter 32 (FIG. 2). The timing controller 100 counts pulses of the clock CLK and generates the frame timing signal FRt at the beginning of each frame. The signal FRt is applied to the encoders 26a-26d. Further, the timing controller 100 generates four channel timing signals CHt using the sub-frame assignment code G. The four channel timing signals CHt's are applied to the encoders 26a-26d. The clock CLK is also applied to the encoders 26a-26d. Four groups each of which includes CLK, FRt and CHt, which are directed to the encoders 26a-26d, are respectively denoted by C1-C4 as shown.
The operations of the FIG. 3 arrangement will be discussed with timing chart of FIG. 8.
A multiplexer controller 62 (FIG. 3) is supplied with the frame and channel timing signals FRt, CHt ((a) and (b) of FIG. 8), and issues an audio timing signal Sa ((c) of FIG. 8) with a predetermined pulse width when receiving simultaneously the two timing signals FRt, CHt. On the other hand, a gate 64 allows the clock CLK to pass therethrough when the channel timing signal CHt assumes a high level. The clock CLK outputted from the gate 64 is denoted by CLKg ((d) of FIG. 8). A clock splitter 66 divides the clock signal CLKg using the audio timing signal Sa. More specifically, the clock splitter 66 issues a clock Ra, which is splitted from the clock signal CLKg, during the time interval for which the audio timing signal Sa assumes a high level. The clock Ra ((f) of FIG. 8) is applied to the audio buffer 58. On the other hand, the clock splitter 66 relays the clock CLKg to the video buffer 51 as a clock Rv when the audio timing signal Sa assumes a low level ((e) of FIG. 8).
The video and audio buffers 51, 58 apply the information stored therein to a multiplexer 68 in synchronism with the timing signals Rv, Ra respectively applied thereto. The multiplexer 68 combines the information from the buffers 51, 58 using the audio timing signal Sa and then generates the channel data D1 therefrom. The sub-frame data including AU1 is combined into the multiplexed data Dm at the multiplexing section 104 at the position of the sub-frame 1 in this case. It is understood that if the channel timing signal CHt assumes a high level during time durations denoted by T1 and T2 (FIG. 8), the multiplexer 68 generates data D1's which will be combined into fifth and sixth sub-frames at the multiplexer section 104. Two delay circuits 70, 72 are provided to adjust operation timing but can be omitted depending on circuit configuration.
For a better understanding of the embodiment, FIG. 8 shows, at portions (h)-(j), three timing charts of the signals CHt's of the groups C2-C4.
Returning to FIG. 7, the multiplexing section 104 is supplied with the four channel data D1-D4 from the encoders 26a-26d. The section 104 combines the frame sync code from the sync code generator 102, the sub-frame assignment code G and the channel data D1-D4 under control of the timing controller 100. Thus, the multiplexed data Dm as shown in FIG. 5 is transmitted via the transmitter 32 (FIG. 2) to the receiver 36 (FIG. 2) over the transmission path 34.
FIG. 9 shows another format of the multiplexed data Dm. In this case, four channel data indicating signal S1-S4 are added to the corresponding sub-frames. Thus, the aforesaid sub-frame assignment code G can be omitted.
Since the present invention is concerned with the transmission side, the receiver will not be described in detail for the sake of brevity. It is understood to those skilled in the art to realize the receiver when being informed of the details of the frame format of the data transmitted.
The adaptive sub-frame assignment may be implemented every frame. However, it is within a scope of the present invention to carry out the sub-frame assignment at a predetermined frame interval.
It will be understood that the above disclosure is representative of one possible embodiment of the present invention and its variant and that the concept on which the invention is based is not specifically limited thereto. | A method of adaptively multiplexing a plurality of video channel data is disclosed. A multiplexed data includes a plurality of frames each of which contains a plurality of sub-frames. The video channel data are adaptively allocated to the sub-frames. A memory occupancy value of a buffer, which is provided in each of a plurality of video channels, is determined. The buffer is arranged to receive the corresponding video information. A plurality of control signals are produced each of which indicates the memory occupancy value of the corresponding buffer. Following this, a look-up table is accessed which includes a plurality of video channel assignment data for assigning the video channel data to The sub-frames. Thus, one of the channel data assignment data is derived from the look-up table. The video channel data are then multiplexed using one of said channel data assignment data derived from the look-up table. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a divisional application of U.S. patent application Ser. No. 11/415,378, now allowed, filed on May 2, 2006, now U.S. Pat. No. 7,578,511 the contents of which are incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a trash storage device, and more particularly to a trash cart that stores daily trash and makes the transportation of the trash to the curb on pick-up day easier with a wheeled system. The trash cart is designed to protect the trash from animals, allow for ventilation, and to be decorative so as not to be an eyesore next the building in which it is stored. The trash cart can also be customized with decorative panels so as to match or complement the building next to which it is installed.
BACKGROUND OF THE INVENTION
Everyday life includes many chores that need to be done on a recurring basis. Home and business owner's daily storage and the task of taking out the garbage can be particularly challenging. In most areas, homeowners need to take the trashcans to the curb for pickup by the municipal or private garbage collectors at least once and most often several times a week. This can mean carrying, or rolling several individual trash cans to the front curb, which can be anywhere from ten feet away from the house to several hundred feet away from the house.
For many homeowners this task is done early in the morning, rather than the night before pickup because animals, such as raccoons, fox, deer and the like often get into the trash cans and throw trash all over the lawn while looking for food. Currently, one of the only alternatives currently available to prevent waking up to a lawn full of trash is to take the trashcans to the curb the morning of pickup. Often, taking the trashcans to the curb the morning of pickup usually means it is done when the homeowner is dressed and rushing to work.
Individual trashcans with wheels are easier to get to the curb than non-wheeled trashcans since they do not have to be carried. However, the wheeled trash cans do very little to protect the cans from being toppled and opened by animals if left outside overnight. Some trash cans use the handles from which they are pulled to lock the cover of the trashcan closed. Although a good concept, the handles are usually easily opened by determined rodents looking for their next meal and therefore are of little help.
Another problem associated with using individual trashcans is the fact that the homeowner can transport only one wheeled trash can at a time to the curb. Therefore, it is often necessary for the homeowner to make several trips to complete the task. Making several trips can be time consuming and depending on the distance and incline from the house to the curb can be exhausting. This fact alone makes the option of using individual trashcans less attractive than the trash cart of the present invention.
Between the assigned days for garbage pick up is the ongoing problem of daily garbage storage. Many people store garbage in their garage until pick up day. This often causes a space issue with cars and/or other items being stored as well as odors permeating the structure. Others opt to keep their garage outside using a multiple of solutions in order to ward off animals. This includes ropes and bungee cords attempting to secure the garbage and/or adding weighted objects to the top of the trashcans. Each time a homeowner adds trash, they must re-secure the trashcan covers.
There are devices available today that are used to transport trashcans to the curb for pick up but these devices are not enclosed, leaving the trash cans/garbage exposed to animals. Since the trash cans are not protected against animals, these devices must be stored inside and therefore are only marginally better than individual wheeled trash cans and do not solve the problem of garage space.
Another problem faced by homeowners with trashcan transportation devices and trashcans available on the market today is that they are often unattractive. In stark contrast, the trash cart of the present invention has decorative panels that can be used to either match or complement the building next to which it is stored.
Finally many of the transportation carts available on the market today are made of flimsy tube piping making the overall structure un-sturdy.
Therefore in view of the foregoing shortcomings, what is needed is a trash cart that is sturdy enough to allow a homeowner to store their daily garbage, move the garbage to the curb easily and allow the homeowner to bring the cart to the curb the night before without worrying about the animals getting into the trash. Additionally, the cart is decorative so as to complement a building when stored on the side of the house or left at the curb for pickup. The present invention contains all of these attributes and more and solves the problems and shortcomings described above.
SUMMARY OF THE INVENTION
The present invention is directed to a trash cart comprising a front panel, a back panel, a right side panel, a left side panel, a top panel, and a bottom panel all of which are configured so that when they are attached they form an enclosure. The top panel of the trash cart may be configured to have at least one hinge means designed to attach one edge of the top panel of the trash cart to a second edge of the back panel. The result of this configuration is an enclosure having a hinged top panel that can be opened to expose the interior of the enclosure.
The structure may also have a front panel having at least one hinge means that is configured so as to be in direct communication with at least one door, the door being contiguous with the front panel of the trash cart when closed and exposes an interior portion of the trash cart when opened. In an alternative embodiment of the trash cart, the trash cart is configured to have two doors on a hinge means that open in opposite directions to expose the interior of the trash cart.
In still another embodiment the trash cart the trash cart is configured to have at least one wheeled axle located at the back portion of the bottom panel of the trash cart and at least one leg of the same height as the wheel is attached to the front portion of the bottom panel of the trash cart so that the trash cart is leveled. The wheeled axle makes transporting of trashcans in the trash cart easier for the user. In an alternative embodiment of the invention, a second wheeled axle is attached to the front bottom panel of the trash cart replacing the leg previously mentioned. The four-wheeled trash cart is designed to handle more weight than the single axel version.
Both the single and multiple axel version of the present invention may be equipped with a steering mechanism that will allow the user to maneuver the trash cart to the curb on pick-up day and back to the storage place once the trash is collected.
Another embodiment of the invention is directed to a trash cart kit. The trash cart kit comprises a front panel, a back panel, a left side panel, a right side panel, a top panel, and a bottom panel. Each panel having the proper holes, fasteners and bolts that can be used to assemble the individual panels together to form an enclosure. On the outside portion of the front panel, the back panel, the left side panel, the right side panel, and the top panel is an attaching means for attaching decorative panels. The kit can have several different decorative panels that can make the enclosure complement the building in which it belongs or an ornate structure such as plastic overlay design (such as basket weave) wrought iron design, stucco, wood frame, vinyl shingles, aluminum siding or the like to give it a unique look.
The top panel can be hinged to the back panel so that it can open to reveal the trashcans stored inside. In one embodiment of the trash cart the top panel of the trash cart can be split in more than one portion, preferable two portions. Each of the aforementioned portions is configured so that they can be hinged to the back panel so as to open together or independently. The front panel can be designed so as to have a single or double doors hinged so that the door(s) can be opened to reveal the trash cans store within the enclosure.
As with the other embodiments described above, the trash cart kit may include one or two axles that can be attached to the bottom portion of the trash cart. Each axle may have at least one wheel, preferably two wheels, so as to support the trash cart and make it easy to move from one place to another. The kit may also contain illustrative instructions that describe how the described components fit together.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1
( 05 ) a full view of the trash cart with doors and top lids closed.
( 10 ) top panel
( 15 ) top hinges
( 20 ) top handle
( 25 ) right side panel
( 30 ) steering means
( 35 ) front axle
( 40 ) front wheel
( 45 ) rear axle
( 50 ) rear wheel
( 55 ) front door hinges
( 60 ) left front door
( 65 ) front lip
( 70 ) right front door
( 75 ) trash can
( 80 ) front door handle
( 85 ) structural front portion
( 90 ) separator panel
FIG. 2
( 100 ) a full view of the trash cart with doors opened.
( 105 ) top hinges
( 110 ) top panel
( 115 ) separator panel
( 120 ) back panel
( 125 ) right side panel
( 130 ) steering means
( 135 ) right front door
( 140 ) front axle
( 145 ) front wheel
( 150 ) hooks for carrying bulky material
( 155 ) front lip
( 160 ) bottom panel
( 165 ) rear axle
( 170 ) rear wheel
( 175 ) left side panel
( 180 ) left front door
( 185 ) front support members
( 190 ) top handles
FIG. 3
( 200 ) is a full view of the trash cart with doors open and on and top lid open.
( 205 ) open left top panel portion
( 210 ) left top handle
( 215 ) top panel hinges
( 220 ) closed right top panel portion
( 225 ) right side panel
( 230 ) steering means
( 235 ) open right front door
( 240 ) front axle
( 245 ) front wheel
( 250 ) back panel
( 255 ) separator
( 260 ) front lip
( 265 ) rear axle
( 270 ) wheel lock
( 275 ) rear wheel
( 280 ) left side panel
( 285 ) opened left front door
( 290 ) interior portion of trash cart
( 295 ) structural front member
( 300 ) interior space
FIG. 4
( 400 ) a schematic of the kit assembly.
( 405 ) top panel
( 410 ) top panel hinges
( 415 ) separator panel
( 420 ) front panel handle
( 425 ) back panel
( 430 ) right side panel
( 435 ) left side panel
( 440 ) bottom panel
( 445 ) separator panel
( 450 ) wheel
( 455 ) axle
( 460 ) steering means
( 465 ) structural supports
( 470 ) left front door
( 475 ) right front door
( 480 ) steering connection
( 485 ) instructions
( 490 ) fasteners and bolts
FIG. 5
( 500 ) is a top view of a panel with attaching hooks and decorative panels.
( 505 ) fastener for decorative panels
( 510 ) wrought iron decorative panel
( 515 ) decorative brick panel
( 520 ) decorative vinyl siding panel
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a decorative trash cart that is designed to provide outside storage of trashcans while preventing egress into the trashcans by animals. The trash cart of the present invention is also designed to be mobile so as to make moving the trashcans in the trash cart to the curb faster and easier than without a trash cart. These and other features are shown in FIGS. 1-5 of the present document and are further described below.
One embodiment of the trash cart of the present invention shown in FIG. 1 comprises, a top panel ( 05 ), a bottom panel (shown in FIG. 2 ), a right side panel ( 25 ), a left side panel (shown in FIG. 2 ), a front panel and a back panel (shown in FIG. 2 ). The panels are arranged and fastened to each other so as to create an enclosure having a top, bottom, front, back and two walls.
The top panel ( 10 ) of the trash cart ( 05 ) may be split into two portions by a separator panel ( 90 ) so that each of the two portions of the top panel ( 10 ) can be lifted independently by handles ( 20 ) revealing the top of the trash cans ( 75 ) within. The top panel ( 10 ) is connected to the back panel by multiple hinges ( 15 ) making it easy to lift the top panel portions so as to gain access to the trashcans ( 75 ). This feature can be used when trash is being placed into one of the trashcans ( 75 ) within the cart and there is no need to expose the other trashcans ( 75 ). Having the split top panel on hinges makes it easier for the user to gain access to the trashcans ( 75 ) within the cart.
When the trashcans are filled and they need to be taken out, the top panel ( 10 ) can be opened and the trashcan lifted over the front panel out of the trash cart ( 05 ). This may be done when the trashcans are light, but if this is done when the trashcans are heavy it can cause a strain on the lifters back. It can also be messy if the trashcans are over filled. For this reason and others, the front panel of the trash cart can have at least one door that when closed is flush with the rest of the front panel. In one embodiment of the invention, the front panel comprises a left front door ( 60 ) and a right front door ( 70 ) that is contiguous with the structural front portion ( 85 ) of the trash cart. The left front door ( 60 ) and the right front door ( 70 ) are connected to the structural front portion ( 85 ) by front door hinges ( 55 ) and each door can be equipped with front door handles ( 80 ) so as to make it easy for the user to open the front doors. The front doors may be locked using a latch or a keyed system.
The front panel may also have a front lip ( 65 ) that is in communication with the lower portion of the front panel. The front lip is designed to stop the trashcans ( 75 ) from falling out of the trash cart once the front doors are opened after the cart has been moved. Since the trashcans ( 75 ) may shift during movement of the trash cart, the front lip ( 65 ) is designed to prevent the trashcans ( 75 ) from accidentally falling out when opened.
In another embodiment of the invention, the trash cart ( 05 ) can be equipped with either just a rear axel ( 45 ) having at least one rear wheel ( 50 ) or a front axle ( 35 ) and a rear axle ( 45 ). The front axle ( 35 ) having at least one wheel ( 40 ) and the rear axle ( 45 ) having at least one wheel ( 50 ). In a preferred embodiment of the invention, the front axle ( 35 ) and the rear axle ( 45 ) each have two wheels. One of the two wheels is attached to each end of the axles so as to distribute the load in the trash cart. The rear axle ( 50 ) can be attached to the bottom portion of the bottom panel of the trash cart so as to be stationary. The front axle ( 40 ) on the other hand can be pivotally attached so as to provide the trash cart with some maneuverability.
In addition, the front axle ( 35 ) can be attached to a steering means ( 30 ) that when maneuvered can cause the front axle to turn in the direction that the user wants the trash cart ( 05 ) to move towards. The steering means ( 30 ) can also be used to pull the trash cart to the intended site whether it is to the curb for trash pick-up or back to the storage spot on the side of the building.
As mentioned above, the trash cart ( 05 ) can be equipped with a separator ( 90 ) and a front lip ( 65 ). These structures are designed to aid in keeping the trashcans ( 75 ) in place while the trash cart ( 05 ) is moved from one place to another. The trash cart ( 05 ) can also be equipped with locking trim that can be attached to the interior portion of the bottom panel of the enclosure that will prevent the trashcans ( 75 ) from moving during movement of the trash cart ( 05 ).
The overall construction of the panels can be made out of wood, wrought iron, aluminum, stainless steel, powder coated aluminum, plastic, polyvinyl chloride, powder coated steel, plastic coated metal, man-made materials, new-age materials, or any other material that is washable, and strong and durable enough for the intended use of the trash cart. The trash cart should be designed so as to have enough holes in the structure so as to allow amble ventilation so as to prevent spontaneous combustion of the trash. The holes are also needed to allow rain water and water used to clean the trash cart to run out of the structure so as to prevent pooling of excess water.
FIG. 2 shows the trash cart of the present invention with the front doors in the open position. The trash cart ( 100 ) comprises a top panel ( 110 ), a bottom panel ( 160 ), a right side panel ( 125 ), a left side panel ( 175 ), and a back panel ( 120 ). As in FIG. 1 , the above panels are arranged and fastened to each other so as to create an enclosure having a top, bottom, front, back and two walls. A separator ( 115 ) divides the interior space into two separate portions so as to keep the two trashcans separate. Although FIGS. 1 and 2 are shown having two doors, two top panels, one separator creating two compartments, it is well within the scope of the invention to have additional doors and compartments.
The right front door ( 135 ) and left front door ( 180 ) can be opened so as to be flat against the structural front portion ( 185 ) of the front panel. Using special hinges, the front doors can be made to wrap around the structural front portion ( 185 ) of the front panel so as to remain flat against the left side panel ( 175 ) and the right side panel ( 125 ) when in the opened position. Once in this position, the doors can be latched back so as to not swing close unexpectedly. This feature is extremely helpful when the user is power washing the interior of the trash cart or when the trashcans are being removed from the trash cart and the cart is on unleveled ground.
As in FIG. 1 , the top panel ( 110 ) of the trash cart ( 100 ) may be split into two portions by a separator panel ( 115 ) so that each of the two portions of the top panel ( 110 ) can be lifted independently by handles ( 190 ) revealing the interior portion of the trash cart ( 100 ). The top panel ( 110 ) is connected to the back panel by multiple hinges ( 105 ).
As shown in FIG. 2 , the trash cart ( 100 ) is equipped with a rear axel ( 165 ) having wheels ( 170 ) attached to each end of the rear axle ( 165 ) and a front axle ( 140 ) having wheels ( 145 ) attached to each end of the front axle ( 140 ). The rear axle ( 165 ) is fixed to the bottom portion of the bottom panel ( 160 ) and the front axle ( 140 ) is pivotally attached to a different portion of bottom panel so that the axle can shift from side to side so as to steer the trash cart.
The front axle ( 140 ) is attached to steering means ( 130 ) that when maneuvered causes the front axle and it's attached wheels to turn in the direction that the user wants the trash cart ( 100 ) to move towards. As stated above in FIG. 1 , the steering means ( 130 ) can also be used to pull the trash cart to the intended site. The wheels of the front and/or back wheels can be equipped with a locking mechanism to prevent the trash cart from rolling if left on uneven ground. The trash cart can also be equipped with a hook system ( 150 ) (not shown) that can be attached to the side and or back of the trash cart that can be used to carry bulky items such as an old latter, old doors, and the like to the curb on pick-up day.
FIG. 3 shows another view of the present invention wherein the front doors are in the open position and one of the top panel portions is in the lifted position. All of the components of the trash cart of FIG. 2 are also in the embodiment shown in FIG. 3 . The embodiment shown in FIG. 3 shows a locking mechanism ( 270 ) on the rear axle that is designed to lock the wheels in placed so as to prevent the trash cart from rolling if left on un-even ground. This same mechanism can be attached to the front axle instead of the rear axle or on both the front and rear axle of the trash cart. It is within the scope of the invention to use the locking wheel mechanism in all of the embodiments described herein.
Still another embodiment of the invention is directed to a trash cart kit comprising a top panel ( 405 ), top panel hinges ( 410 ), separator panel ( 415 ), front panel handle ( 420 ), back panel ( 425 ), right side panel ( 430 ), left side panel ( 435 ), bottom panel ( 440 ), separator panel ( 445 ), wheels ( 450 ), axles ( 455 ), steering means ( 460 ), structural supports ( 465 ), left front door panel ( 470 ) right front door panel ( 485 ), steering connection ( 480 ), instructions to assemble the trash cart ( 485 ), and various fasteners, bolts and pins necessary to connect all of the parts together. The trash cart kit is shown in FIG. 4 and is designed to be easily assembled. The trash cart kit is easier to ship, store, and package, all of which results in savings that can be passed on to the consumer. In addition, compact packaging also allows the consumer to transport the trash cart from the store to home without a truck.
The trash cart, once assembled, has all of the features, attributes and benefits of the fully assembled versions shown in FIGS. 1-3 . The trash cart kit can also includes special fasteners that allow the owner to decorate the trash cart so as to be pleasing to the eye, match the structure in which is stored next to or to just to personalize the cart. For example, the kit can include special fasteners and a printable plate that can be engraved and/or printed with the name and/or address of the owner.
In still another embodiment of the invention, the panels can be almost completely solid having only a few holes for water drainage and/or ventilation. The fasteners can be attached to the top panels ( 405 ),
back panel ( 425 ), right side panel ( 430 ), left side panel ( 435 ), bottom panel, left front door panel ( 470 ) and right front door panel allowing for decorative panels to be attached. The decorative panels can be made out of material selected from the group consisting essentially of wood, wrought iron, aluminum, stainless steel, powder coated aluminum, plastic, polyvinyl chloride, powder coated steel, plastic coated metal, man-made materials, new-age materials, or any other material that is washable, strong enough and durable enough for trash cart wear. Custom panels can be made so as to match any structure or to make any trash cart unique.
Another feature that can be added to the trash cart is an internal light that turns on automatically using a light sensor when either the top panel or front doors are opened. This light can be powered by solar or energy from a battery. The same solar charge/battery pack can be used to power an odor control unit that emits a scent to mask the smell of the trash either on a timer or using a malodorous detector that activates the fragrance emitter when odors reach a certain detectable level. All of these features are known in the art but are unique when incorporated into the present invention.
FIG. 5 gives several examples of decorative panels. These are only examples and many other designs can be used and are anticipated to fall with the scope of the invention. These panels should be weather resistant; however, making the trash cart from a virtually indestructible material will allow the cart to last while changing the decorative panels on the outside would allow the trash cart to look new even though the internal structure is old. This is a direct savings to the consumer and opens up an additional market for decorative panels.
The above embodiments of the present invention can be manufactured using well-established manufacturing techniques used in similar industries today. The technique used to make the present invention is directly related to the material used to make the trash cart. For example, if plastic is used to make the trash cart then the well-established technique of cast molding maybe used. If metals are used to make the trash cart, then welding and/or drop forging of metals maybe used to make the trash cart. And finally, if wood is used to make the present invention then standard wood milling and carpentry techniques can be used. The aforementioned list is not meant to be an exhaustive list designed to cover all of the possible techniques that can be used to make the invention but are only offered as examples. One skilled in the art would manufacture the trash cart using techniques available at the time the trash cart is manufactured.
The materials used to make the present invention should be durable enough to withstand the abuse often associated with trash cans but must be light enough so that the trash cart can be moved easily and without undue effort just to carry the weight of the trash cart.
In another embodiment of the invention, the trash cart is equipped with a motor that is in direct communication with at least one wheel and/or axle of the trash cart that when powered would rotate the wheel and/or axle so as to move the trash cart in the forward or reverse direction. The motor can be powered by gas, electric or some combination of each and can be controlled by either a remote control device or a direct control device.
So as not to allow egress of small animals into the main compartment of the trash cart, the panels should have predominately solid construction having only strategic holes for ventilation and water drainage. The enclosure should also be designed to keep most of the rainwater from getting into the structure. To achieve this task the structure is designed to have a slanted roof so as allow rain to run off of the top panel and avoid pooling of excess water. Although the main compartment of the trash cart is predominately solid construction the homeowner is able to achieve a more airy look using the decorative overlay panels. In other words, the overlay panels, once attached, would allow the home owner to achieve the wrought iron look that by definition has large spaces between each segment—spaces too large to be able to keep animals from getting into the trash cart—while still protecting the trash from animals.
As with most things in life, the trash cart of the present invention would be able to marketed as a standard model containing the basic structure to the deluxe model comprising the basic model plus the add-on features such as decorative overlay panels, outside lighting, odor diffuser, motor with remote control as well as other added features that complement the basic features of the invention. The trash cart can be designed to fit one or more trashcans, preferably two trashcans.
In summary, the present invention is directed to a trash cart that is mobile, easy to get trash cans in and out of, protects the trash cans from animal destruction, is durable, decorative and allows the user to store and transport the trash cans to the curb for collection quickly and without getting soiled.
While the invention has been illustrated and described with respect to specific illustrative embodiments and modes of practice, it will be apparent to those skilled in the art that various modifications and improvements may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited by the illustrative embodiment and modes of practice. | The present invention is directed to a trash cart, namely an enclosed trash cart having a top and front doors that swing open on a hinged system. The enclosed trash cart is connected to at least one wheel axle having wheels that allow the cart to be transported from a storage area to the curb for garbage pickup. The trash cart can also have an attachment system that gives the owner the option of overlaying a number of different external decorative panels to the trash cart making the cart both functional and decorative. The trash cart of the present invention enables a homeowner to store daily garbage outside the home or garage in a decorative enclosure that keeps the garbage protected from animals and makes it easy to transport garbage to the curb on pick-up day. | 1 |
THE FIELD OF THE INVENTION
The present invention relates to the field of high-quality audio loudspeakers and more particularly to enclosed loudspeakers with ported or sealed acoustical chambers for manipulation of driver backwaves. The speakers of the present invention comprise one or more acoustical chambers with multiple layers of damping materials which become less dense as the distance from the driver increases. Additionally, the acoustical chambers of preferred embodiments of the present invention decrease in cross sectional area, to a minimum cross-sectional area equal to that of the driver's surface area, and narrow to this “minimum” at the greatest distance from a driver.
BACKGROUND
Loudspeakers are essentially transducers which convert electrical energy into physical, acoustical energy. The design of typical basic loudspeakers has not changed for decades. Generally, a loudspeaker driver consists of a frame or housing, a cone or other diaphragm attached to a voice coil, a surround and spider suspension and a permanent magnet. Sound is created by moving the diaphragm to create sound waves in the air around the diaphragm. This is accomplished through electromagnetic attraction and repulsion of the voice coil. The outer periphery of the diaphragm is connected to the housing or frame by a flexible surround which allows the diaphragm to move freely and helps somewhat to keep the diaphragm and voice coil in proper alignment. The voice coil is typically a coil of wire which forms an inductor. As electrical current passes through the coil it produces a magnetic field. The voice coil is placed in close proximity to a permanent magnet which provides a permanent magnetic field which react with the variable magnetic field of the coil thereby causing the coil to be repelled or attracted according to the field of the coil and the polarity and magnitude of the coil current. The spider and surround keep the coil in precise alignment with the permanent magnet so that minute changes in current in the coil can accurately produce diaphragm movement and sound.
The physical characteristics of drivers can make them more suitable for reproducing sounds in certain frequency ranges. High frequency sound requires a driver that can react quickly, but which does not need a diaphragm that must displace a substantial distance. Low frequency sound requires a driver that can displace longer distances, but which does not need to react as quickly. Consequently, larger drivers, called woofers, are typically used to reproduce low frequency sound while very small, rigid drivers, called tweeters, are used for high frequency sound. A high-quality loudspeaker will generally have multiple drivers for reproducing sound in a variety of frequency ranges. Many loudspeakers will have at least a woofer, midrange and a tweeter to reproduce the entire audible sound spectrum, however, as the following disclosure will reveal, this can be achieved in other ways.
One problem inherent in typical driver design is the “backwave” created when the diaphragm rebounds from an extended position. This creates a sound wave which emanates from the back of the diaphragm which, if not controlled, may interfere with and even cancel the primary sound wave created by the diaphragm.
One method of dealing with backwave interference is to mount the driver in a sealed enclosure that will absorb the majority of the backwave preventing it from reaching the listener. This is commonly known as an “acoustic suspension” speaker. Another popular method of dealing with backwave emissions is to allow part of the wave to reach the listening area through a vent or port. This is known as a “bass reflex” design. Yet another method involves the use of a passive radiator or “drone driver” which vibrates with the backwave thereby absorbing energy and helping eliminate the backwave. All of these methods help somewhat to eliminate backwave interference, however they do so at the cost of lost energy and performance.
Backwave interference can also be dealt with using a bipolar speaker configuration. The typical bipolar configuration utilizes two identical drivers which are mounted in the front and back of a speaker enclosure. These two drivers are driven in-phase so that identical waves are emitted from the front and back of the enclosure. This eliminates the backwave cancellation problem because the waves are in-phase, but the drivers can suffer from a decreased response and lost energy due to the need to overcome increased pressure in the enclosure.
Another problem inherent with woofers which must move fair distances in order to reproduce low frequencies and large outputs is that of inertia. Once a driver diaphragm is displaced it must return to a neutral position before subsequent displacement. Inertia makes stopping a diaphragm at a neutral position difficult after a substantial displacement. Ideally, a woofer would need to increase its mechanical impedance as the distance from its neutral, or static, position increases. However, even if a driver is designed to near mechanical perfection, with the restorative force being equal to that of the initial current, stopping the driver at the “neutral” position remains a challenge.
An additional problem with current speaker technology is caused by misalignment of the voice coil with the permanent magnet due to distortion of the diaphragm or cone. Driver surrounds and spiders must be flexible to provide the necessary response to electrical input, but this makes the driver diaphragm extremely susceptible to unequal air pressure across its surface area. As a diaphragm encounters unequal air pressure due to enclosure discontinuities or air flow patterns, the diaphragm distorts causing the attached voice coil to rotate off its central axis. This causes the precisely balanced magnetic fields of the permanent magnet and the voice coil to misalign thereby causing an inductive variance and increased current draw from the amplifier. This results in decreased power handling, poorer response and inaccurate reproduction of sound.
What is needed is an apparatus and method for controlling driver backwaves and the air pressure and flow at the rear of the driver.
Backwave and air pressure problems are complicated by the fact that while a build-up of pressure is deleterious to linear operation, a certain amount of back pressure can help control driver inertial problems. The helpful portion of the back pressure relates directly to the mechanical movement of the driver and is purely an attempt to control over-excursion. Hence, a decrease in cross sectional area allows for a measure of pressure build-up. The minimum cross sectional area being that of the radiating area of the driver in question helps to ensure that modulation through pressure build-up is kept to a minimum.
SUMMARY AND OBJECTS OF THE INVENTION
Some embodiments of the present invention comprise loudspeakers with drivers mounted in an enclosure having a chamber through which sound waves, which do not directly emanate to the exterior of the enclosure, are directed to the exterior. These interior sound waves may be back waves which emanate from the back of a driver which is directed toward the exterior of the enclosure or they may be primary front waves emanating from drivers which are directed to the interior of the enclosure such as in some multipolar configurations.
Backwaves returning to the cone can cause reinforcements of identical waves, or cancellations with adjacent frequencies. Since sound travels more slowly through denser materials (in acoustics, many “damping” materials have fractional multipliers defining exactly how much the speed of sound is slowed through said material), a graduated system is established wherein the densest combination of materials is closest to the driver. The lowest density is at the greatest distance. Thus, the speed of sound increases with the distance to the driver's radiating surface. Once the sound has traveled to the furthest point of the enclosure, the denser mediums closer to the driver now represent a source of great impedance.
The interior chamber of some embodiments of the present invention may have almost any geometric configuration that will accept damping material. Preferred embodiments have shapes with progressively smaller cross-sections, however cross-sections smaller than that of the driver are not preferred.
The damping structure of preferred embodiments of the present invention decreases in density as its distance from a driver increases. This decrease in density creates a decrease in resistance experienced by a sound wave which helps direct the sound wave to a destination and help prevent sound waves from following an opposite path. The effect is much like a pressurized fluid following a path of least resistance. The damping material is placed in a manner that will promote movement of sound waves from the driver through the chamber and toward the exterior of the enclosure.
This sound wave direction is achieved by arranging the damping material in a configuration of decreasing density as the distance along the path from driver to exterior of enclosure increases. Preferred embodiments also have damping material configured to increase in density from the center of the sound path to the perimeter of the chamber.
Damping material density may be varied by using materials of non-uniform density however, these materials can be difficult to produce and control. Material density may also be controlled by using distinct layers of uniform density material which can have a constant thickness throughout a specific section of the chamber or which may be tapered thereby decreasing the overall density of the chamber without abrupt changes. Material density may also be varied with layers of constant thickness when the thickness is changed in successive sections of the chamber.
Accordingly, it is an object of some embodiments of the present invention to provide a loudspeaker with improved sound reproduction.
It is another object of some embodiments of the present invention to provide a loudspeaker with reduced cancellation.
It is yet another object of some embodiments of the present invention to provide a loudspeaker with reduced interference.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to a specific embodiment thereof which is illustrated in the appended drawings. Understanding that these drawings depict only a typical embodiment of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a cross-sectional view of an apparatus of a first embodiment of the present invention showing sectionalized and layered damping material.
FIG. 2 is a cross-sectional view of an apparatus of a second embodiment of the present invention showing tapered damping material.
FIG. 3 is a cross-sectional view of an apparatus of a third embodiment of the present invention showing tapered damping material.
FIG. 4 is a cross-sectional view of an apparatus of a fourth embodiment of the present invention showing sectionalized and layered damping material.
FIG. 5 is a cross-sectional view of an apparatus of a fifth embodiment of the present invention showing an enclosure with damping material in a pattern of progressively lower density as distance from the drivers increases.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, preferred embodiments of the present invention are described by referring to functional diagrams, schematic diagrams, functional flow charts, program flow charts and other graphic depictions which help to illustrate either the structure or processing of preferred embodiments used to implement the apparatus, system and method of the present invention. Using the diagrams and other depictions in this manner to present the invention should not be construed as limiting of its scope.
In reference to FIG. 1 , a first embodiment of the present invention comprises a speaker enclosure 2 with an exterior driver 4 and an interior driver 6 mounted therein. An acoustical chamber 8 is formed in enclosure 2 . Chamber 8 extends from driver 6 to the exterior of the enclosure and may terminate at the exterior in a port 10 or some other type of opening. Chamber 8 , as shown in this embodiment, may be regarded as having three sections. A first section 12 begins near driver 6 and extends vertically to the top of vertical enclosure partition 20 terminating at first dashed line 14 . Second section 16 extends from dashed line 14 around the comer to second dashed line 18 and third section 22 extends from line 18 to the exterior of enclosure 2 . This first embodiment of the present invention incorporates damping material layers of roughly constant thickness in each section. The thickness of the layers varies from section to section in order to create areas of diminishing density or damping as the distance from driver 6 increases.
In first section 12 an outer layer 24 of low to medium density foam surrounds the periphery of section 12 . Outer layer 24 may vary widely in thickness, however a range of thickness from 2 inches to 3 inches performs well for drivers in the sub-woofer to mid-range categories. The remainder of first section 12 is filled with an inner layer 26 of low density polyester batting having a density or damping lower than that of outer layer 24 .
Second section 16 has an outer layer 28 of low to medium density foam around its periphery. However, in second section 16 , this outer layer has a thickness of about 1″. The remainder of second section 16 is filled with an inner layer 30 of low density polyester batting. The decreased thickness of outer layer 28 in relation to outer layer 24 provides a decreased overall density or damping in second section 16 as compared to first section 12 .
Third section 22 also has an outer layer 32 of low to medium density foam. Outer layer 32 may have a thickness substantially equal to or less than that of outer layer 28 because the decreased density of third section 22 is provided by an inner layer 34 substantially without damping material. Some damping material may be used in inner layer 34 , particularly when outer layer 32 has a thickness less than that of outer layer 28 , provided the overall density or damping of third section 22 is less than that of second section 16 .
A second embodiment of the present invention may be understood in reference to FIG. 2 wherein an enclosure 2 , exterior driver 4 , interior driver 6 , acoustical chamber 8 and port or exit 10 have a configuration similar to that of FIG. 1 . Chamber 8 may have a longitudinal axis 40 which roughly follows the centroid of transverse cross-sections through chamber 8 . Axis 40 can be said to follow the approximate center of the path between driver 6 and exit 10 although substantial deviations from center may occur without affecting the purpose of the present invention. The damping material of this second embodiment is arranged to provide decreased density or damping as the distance, along axis 40 , from driver 6 increases while also generally increasing in density as the transverse distance from axis 40 increases. This is achieved by using a tapered outer layer 42 of low to medium density foam which decreases in thickness from a position proximate to driver 6 to a position proximate to point of exit 10 . The density transition of chamber 8 is further enhanced with tapered inner layer 44 typically composed of low-density polyester batting, and which completely fills the remainder of chamber 8 near driver 6 , but which does not fully extend to exit point 10 without substantial decrease in thickness, density or damping characteristics. Inner layer 44 may decrease in thickness or may simply stop short of exit point 10 so as to provide a decreased density at that end of chamber 8 near exit 10 .
Another, third, embodiment of the present invention, as shown in FIG. 3 , comprises an enclosure 50 containing external driver 52 and internal driver 54 and further comprising an acoustical chamber 56 with a longitudinal centroidal axis 58 . Chamber 56 has a circular cross-section in this particular shown embodiment, however, the cross-sectional shape of chamber 56 is not critical to the advantages of the present invention and nearly any cross-sectional shape will prove adequate. In this particular embodiment, chamber 56 and axis 58 are linear, however, the path of chamber 56 and, consequently, that of axis 58 may be circuitous, making multiple bends if necessary, to complete its course from driver to exterior of enclosure.
Chamber 56 is lined with a first outer layer 60 of damping material composed of foam or some other moderate density damping material. Outer layer 60 has a tapered thickness which becomes thinner as its distance from driver 54 increases. Outer layer 60 preferably begins proximate to driver 54 with a maximum thickness and extends toward exit 70 tapering to a minimal thickness or terminating at any point between driver 54 and exit 70 . When drivers 54 and 52 are typical subwoofer to midrange drivers a maximum thickness of about 2″ to about 3″ is preferred.
A second intermediate damping layer 62 having a density less than that of outer layer 60 resides in chamber 54 inside outer layer 60 . Second layer 62 may be composed of low to medium density foam, low to medium density polyester batting or some other damping material. Second layer 62 also has a thickness which tapers to become thinner as the distance from driver 54 increases. Second layer 62 may taper to a minimal thickness or terminate at any point between driver 54 and exit 70 so long as the overall density or damping of the chamber decreases with distance from driver 54 .
A third inner or axial layer 64 of damping material may be placed inside second layer 62 . Third layer 64 is composed of a damping material with a density or damping less than that of the material of which second layer 62 is composed. Third layer 64 may fill the entire space remaining within chamber 56 or may fill a portion of that space with an axial cone, as shown, with some other shape which provides a decreasing density as the distance from driver 54 increases.
When third layer 64 does not fill the remaining space in chamber 56 a fourth layer 66 may be formed in the remaining space in chamber 56 . Fourth layer 66 will have a density less than that of the other layers when it is the innermost layer as shown in this embodiment. Fourth layer 66 may be filled with a low-density damping material or may simply be filled with ambient air.
A fourth embodiment of the present invention is shown in FIG. 4 and has an enclosure 50 , exterior driver 52 , interior driver 54 , chamber 56 , exit 70 , and axis 58 similar to that of the third embodiment, however this fourth embodiment comprises a first section 72 , second section 74 and third section 76 which are portions of chamber 56 . Each successive section progressing from driver 54 to exit 70 decreases in overall density or damping. First section 72 contains a first outer layer 80 of damping material around its perimeter and a first inner layer 82 of damping material inside first outer layer 80 with first inner layer 82 having a density or damping effect less than that of first outer layer 80 . In this embodiment, first outer layer 80 has a uniform thickness throughout first section 72 while first inner layer 82 fills the remainder of first section 72 .
Second section 74 comprises a second outer layer 84 having a thickness which is less than the thickness of first outer layer 80 . Inside second outer layer 84 is second inner layer 86 which is typically composed of the same material as first inner layer 82 . The overall density or damping effect of second section 74 is less than that of first section 72 due to the decrease in thickness of second outer layer 84 relative to first outer layer 80 .
Third section 76 comprises a third outer layer 88 which has a thickness equal to or less than that of second outer layer 84 . Third inner layer 90 may be filled with a damping material with a density lower than that of second inner layer 86 , however, preferred embodiments are void of structural damping material containing only ambient air. The reduction in density of the material in third inner layer 90 or the lack of substantial material therein serves to reduce the overall density or damping effect of third section 76 below that of second section 74 . This fourth embodiment differs from the third embodiment in that the outer layers of damping material have uniform thickness throughout each section of the chamber. Also different quantities of layers are used. Different variations of these concepts which achieve the same progressive reduction in density or damping effect along the chamber are to be considered within the scope of the present invention.
A fifth, alternative embodiment of the present invention, as shown in FIG. 5 , comprises a speaker enclosure 100 with a first external driver 92 and a second external driver 94 mounted therein. Speaker enclosure 100 also comprises an exit 102 from which sound within enclosure 100 may emanate. When multiple drivers are positioned in close proximity ajunction chamber 110 may be constructed to direct the combined sound from the drivers to a single exit point 102 . This may be achieved by lining the sides and floor of junction chamber 110 with a first outer layer of damping material 96 . This first outer layer 96 may have voids therein to accommodate drivers 92 & 94 . A first inner layer 108 composed of low density damping material fills the remainder of junction chamber 110 .
This fifth embodiment further comprises a progressive damping chamber 112 which has a progressively decreasing density or damping effect as the distance from junction chamber 110 increases. Progressive chamber 112 comprises second outer layer 98 composed of a first damping material which is tapered or otherwise shaped to have a decreased thickness as its distance from junction chamber 110 increases. Progressive chamber 112 further comprises a second inner layer 104 of damping material with a density less than that of second outer layer 98 which may fill the remainder of progressive chamber 112 or may be shaped to have a void 106 therein such that the overall density or damping effect of progressive chamber 112 decreases toward exit 102 .
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrated and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | The present invention relates to a novel acoustical chamber for enclosed loudspeakers which help direct and control sound waves within the enclosure thereby enhancing sound output. The present invention utilizes a method of progressive damping which utilizes multiple layers of damping material or layers of material with variable density or damping characteristics within an enclosed chamber. The damping material is arranged such that the density of the material in the chamber decreases as the distance from the driver increases. The damping materials may also be configured such that the density of the material in the chamber increases as the transverse distance from the center of the chamber increases, that is, the density of the material along the outer surfaces of the chamber is denser than material which is transversely inward from the outer surfaces. | 7 |
This is a continuation-in-part of now abandoned provisional application Ser. No. 60/090,270 filed Jun. 22, 1998.
FIELD OF THE INVENTION
This invention relates to fluorinated alkynoic acids, to the preparation thereof, and to the use thereof as anti-convulsive therapeutic agents. The fluorinated alkynoic acids of the invention are comparable to valproic acid in their utility for the prevention of seizures, but have reduced teratogenic potential. Consequently, this invention provides effective anti-epileptic agents with a greater margin of safety than valproic acid with respect to teratogenic potential. Certain compounds of this invention also exhibit comparable or reduced sedative effects relative to valproic acid, and certain compounds of the invention exhibit a longer duration of activity than valproic acid.
BACKGROUND OF THE INVENTION
Epilepsy affects roughly 1% of the world'population. Among the drugs employed for control of epileptic seizures is valproic acid. Valproic acid (also referred to as VPA, valproate, or 2-propylpentanoic acid) is an effective anticonvulsant, but it has a short duration of action. More seriously, VPA suffers from serious side effects, among them sedation, potentially fatal hepatotoxicity, and teratogenicity. Hepatotoxicity is particularly a problem in young children, especially children on polytherapy. The VPA-induced hepatic fatality rate among the latter patient category is reported to be 1/500 (F. E. Dreifuiss et al., Neurology (1987), 37, 379-385). Valproic acid has been shown to induce neural tube defects in mice, and it is estimated that the risk of spina bifida among newborns of women taking VPA during pregnancy is 1-2% (Centers for Disease Control, Morbidity and Mortality Weekly Report (1983), 32(33), 438-439).
There has been a considerable effort to discover analogues of valproic acid that are equally effective, but that have a greater margin of safety. See, for example, H. Nau et al., PCT application WO 94/06743, wherein a variety of modifications to the alkyl chains of valproic acid are made, and the related U.S. Pat. No. 5,786,380, which is hereby incorporated in its entirety by reference.
With regard to teratogenicity, it has been reported that introduction of a triple bond into the 4-position of valproic acid greatly increases teratogenicity, but that this effect is largely confined to the S-(−) enantiomer. Addition of a methyl group to the end of the triple bond abolished teratogenicity, while maintaining anticonvulsant activity (H. Nau, R.-S. Hauck, K. Ehlers, Pharmacology & Toxicology (1991), 69, 310-321.) These results indicated that separation of teratogenicity and anticonvulsive activity was possible. Sedative side effects were also separated from anticonvulsant activity in some analogues (M. Elmazar, R.-S. Hauck, H. Nau, J. Pharm. Sci . (1993), 82, 1255-1288.)
Alpha-branched carboxylic acids with an alpha-fluorine are little known. P. Crowley et al., in European patent application EP 468681, refers to 2-ethyl-2-fluorobutanoic acid as a fungicide intermediate, and a method for its preparation. Takeuchi refers to several examples of this class of compound in a publication relating to methods of preparing tertiary alkyl fluorides (Y. Takeuchi et al., J. Org. Chem . (1993), 58(13), 3483-3485).
The valproic acid analogue 2-fluoro-2-propyl-4-pentenoic acid has also been reported. The compound was used as a probe for studies of valproic acid hepatotoxicity and metabolism. (W. Tang et al., Chem. Res. Toxicol . (1995), 8(5), 671-682; M. Jurima-Romet et al., Toxicology (1996), 112(1), 69-85; W. Tang and F. Abbott, Drug Metab. Dispos . (1997), 25(2), 219-227.) In the above references, the presence of the 2-fluoro substituent was reported to reduce hepatotoxicity relative to 2-propyl-4-pentenoic acid. Anticonvulsant, sedative or teratogenic properties of the fluorinated compound were not disclosed.
Alpha-fluorinated valproic acid, 2-fluoro-2-propylpentanoic acid, has also been reported (Ph.D. thesis of Wei Tang, University of British Columbia, 1996). The anticonvulsant activity and pharmacokinetics of this compound were studied, and its pharmaceutical potential was speculated upon (F. Abbott, W. Tang, J. Palaty, J. Pharmacol. Exp. Ther . (1997), 282, 1163-1172). The compound was reported to be less potent than VPA, and the hepatotoxic, sedative, or teratogenic properties were not disclosed.
Valproic acid analogues with terminal trifluoromethyl groups have been reported: 5,5,5-trifluoro-2-(3,3,3-trifluoropropyl) pentanoic acid (K. Yamaguchi and M. Taninaka, Japanese patent Application 4-21652 (1992), and 5,5,5-trifluoro-2-n-propyl pentanoic acid (Hiroshima et al., Japan. J. Psychopharmacol . (1992) 12, 427). These compounds, too, are less potent than VPA.
SUMMARY OF THE INVENTION
This invention relates to 2-fluoro-2-alkyl-4-alkynoic acid compounds, pharmaceutical compositions containing them, and their use to treat or prevent convulsions. This invention also provides processes for the preparation of these compounds. The preferred 2-fluorinated carboxylic acids of the invention possess anticonvulsant activity comparable or superior to that of valproic acid, but exhibit reduced teratogenicity, and a longer duration of activity as well.
The compounds of this invention may also be used to treat and/or prevent affective disorders such as for example bipolar depression, especially the manic phase; and migraine, especially for prophylaxis of attacks.
The compounds of the invention have the following structure:
wherein R 1 is C 3 to C 10 alkyl, C 3 to C 6 cycloalkyl, or cyclopropylmethyl, and R 2 is C 1 to C 3 alkyl or cyclopropyl, and the pharmaceutically acceptable salts, esters, and amides thereof. The term alkyl as used herein refers to both branched and straight-chain alkyl groups. Preferred embodiments of this invention are those wherein R 2 is methyl. R 1 is preferably C 3 to C 8 alkyl, and more preferably C 3 to C 5 alkyl. In the most preferred embodiments, R 2 is methyl and R 1 is C 3 to C 5 alkyl.
The invention also provides a method of treating and/or preventing convulsions due to a variety of causes, by administering to an individual in need of such treatment a therapeutically or prophylactically effective amount of at least one of the compounds of the invention.
An object of this invention is to provide compounds useful for preventing or reducing seizure activity.
Another object of this invention is to provide anticonvulsant pharmaceutical compositions comprising at least one compound of this invention.
Yet another object of this invention is to provide methods of preventing or reducing seizure activity by administering to an individual in need of such treatment a pharmaceutical composition of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example of a method for preparing the compounds of this invention.
DETAILED DESCRIPTION OF THE INVENTION
This invention provides compounds having the following structure:
wherein R 1 is C 3 to C 1 alkyl, C 3 to C 6 cycloalkyl, or cyclopropylmethyl, and R 2 is C 1 to C 3 alkyl or cyclopropyl, and the pharmaceutically acceptable salts, esters, and amides thereof. The term alkyl as used herein refers to both branched and straight-chain alkyl groups. Preferred embodiments of this invention are those wherein R 2 is methyl. R 1 is preferably C 3 to C 8 alkyl, and more preferably C 3 to C 5 alkyl. In the most preferred embodiments, R 2 is methyl and R 1 is C 3 to C 5 alkyl.
These compounds can be prepared by methods known in the art for the preparation of other alpha-fluoro carboxylic acids. For example, treatment of the corresponding alpha-hydroxy ester with diethylaminosulftir trifluoride (DAST) provides the alpha-fluoro ester, which upon hydrolysis provides the acid (P. Crowley et al., 1992, European patent application EP 468681). Alternatively, the corresponding alpha-amino acid can be subjected to diazotization in the presence of fluoride ion, to effect a deaminative fluorination (J. Barber, R. Keck, J. Retey, Tetrahedron Letters (1982), 23, 1549-1552). The Reformatsky reaction can be carried out on alpha-bromo-alpha-fluoro esters (Y. Takeuchi et al., J. Org. Chem . (1993), 58(13), 3483-3485) to introduce a side chain. Alternatively, the corresponding ester enolate or silyl enol ether can be fluorinated with fluorine or a “positive fluorine” source, such as an N-fluoro pyridinium salt, N-fluoro amide, or N-fluoro imide (see, e.g., E. Differding, G. Ruegg, Tetrahedron Letters (1991), 32, 3815-3818). In the particular embodiment exemplified below, the lithium enolate of the corresponding ester is fluorinated with N-fluoro benzenesulfonimide, but it will be understood that other methods of synthesis are within the scope of this invention.
The starting esters for the exemplified process are in many cases commercially available; alternatively they may be obtained by methods known in the art, for example the malonic ester synthesis described in M. Elmazar, R.-S. Hauck, H. Nau, J. Pharm. Sci . (1993), 82, 1255-1288. The well-known acetoacetate variation of the malonic ester synthesis is also applicable. In the example below, direct alkylation of a straight-chain ester enolate is employed. Other methods of synthesis will be apparent to those skilled in the art, and this invention is not limited by the particular synthetic method exemplified herein.
In general terms, this invention provides a process for preparation of compounds of structure I, which comprises the steps of:
a) alkylating a compound of structure
wherein R 3 is lower alkyl or benzyl and R 4 is H, lower alkyl, lower alkoxy, or benzyloxy, with an alkylating reagent of structure
R 2 —C≡C—CH 2 —X (III)
wherein X is a suitable leaving group, and wherein R 2 is C 1 to C 3 alkyl or cyclopropyl, in the presence of a suitable base, so as to obtain a compound of structure
(b) in the cases where R 4 is lower alkoxy or benzyloxy, hydrolysis, decarboxylation, and re-esterification of compound IV; or in cases where R 4 is H or lower alkyl, deacylation of compound IV, so as to obtain a compound of structure
(c) enolization of compound V with a suitable base, in an inert solvent;
(d) addition of a fluorinating reagent, so as to obtain a compound of structure
and
(e) hydrolysis of the ester moiety.
Suitable identities of group R 4 will be apparent to those skilled in the art. Preferred R 4 groups are alkoxy groups which are readily saponified, such as methoxy or ethoxy, or other carboxylic acid protecting groups which are readily removed by other means, such as tert-butoxy, benzyloxy, and the like. It will be appreciated that the term “hydrolysis” as used in steps (b) and (e) is intended to encompass the deprotecting operations appropriate to the nature of R 4 , for example saponification in the case of lower alkoxy groups, acidolysis in the case of tert-butoxy groups or hydrogenolysis in the case of benzyloxy groups. Similar considerations apply to the group R 3 , which is preferably lower alkyl such as methyl or ethyl but which may be another carboxy-protecting group, such as for example, tert-butyl, benzyl, and the like. It will be apparent that in step (b), where R 3 is removed and then re-introduced, the practitioner will have the opportunity to change the identity of R 3 if it is desired to do so.
Where R 4 is H or alkyl, the preferred groups are those which lend themselves to deacylation of the group COR 4 ; in these cases R 4 is most preferably H or methyl. Deacylation may be accomplished by treatment with, for example, sodium hydroxide or ammonia, or other methods known in the art.
Suitable leaving groups X may be selected from, but are not limited to, the halogens chlorine, bromine, or iodine, or sulfonate ester groups such as methanesulfonyloxy or toluenesulfonyloxy. Suitable bases for step (a) may be chosen from, but are not limited to, alkali metal alkoxides, calcium and magnesium alkoxides, alkali metal hydrides, and the like.
Suitable bases for step (c) will be apparent to those skilled in the art, since a number of procedures for enolizing esters have been published. Preferred bases will be those with a sufficiently high pK a to substantially deprotonate the compound V, and which are also non-reactive with the functional groups of the compound V. Examples may be chosen from, but are not limited to, the lithium or sodium salts of hindered disubstituted amines, such as lithium diisopropylamide or lithium hexamethyldisilazide.
In an alternative process, compounds of formula (I) may be prepared by the process comprising the steps of:
a) alkylating a compound of structure
wherein R 3 is lower alkyl or benzyl with an alkylating reagent of structure
R 2 —C≡C—CH 2 —X (III)
wherein X is a suitable leaving group, and wherein R 2 is C 1 to C 3 alkyl or cyclopropyl, in the presence of a suitable base, so as to obtain a compound of structure
(b) enolization of compound V with a suitable base, in an inert solvent;
(c) addition of a fluorinating reagent, so as to obtain a compound of structure
and
(d) hydrolysis of the ester moiety.
Modifications to the exemplified procedures can also be made. For example, in the fluorination step, inert solvents other than THF may be employed, such as dioxane, di-alkyl ethers, dimethoxyethane and other polyethers, toluene, heptane, and the like. Additives such as hexamethylphosphoramide, tetramethylethylenediamine, or tetramethylurea can be employed in the alkylation and fluorination reactions, and as described above a variety of bases such as alkali metal hydride, amide, alkoxide, or hexamethyldisilazide salts could be employed in the deprotonation and enolization reactions.
Alpha-fluorination of a straight-chain alkyl or alkynyl ester, acid, or amide prior to alkylation might also be carried out, if deemed desirable by the practitioner. Such modifications could be made for any reason, for example to improve the yield or to reduce process costs, without departing from the scope of this invention.
By the methods exemplified or described herein, the following compounds may be prepared from the appropriate starting materials, which may be chosen based upon the principles disclosed above:
Example 1 2-ethyl-2-fluoro-4-hexynoic acid
Example 2 2-cyclopropyl-2-fluoro-4-hexynoic acid
Example 3 2-fluoro-2-n-propyl-4-hexynoic acid
Example 4 2-n-butyl-2-fluoro-4-hexynoic acid
Example 5 2-fluoro-2-n-pentyl-4-hexynoic acid
Example 6 2-fluoro-2-n-hexyl-4-hexynoic acid
Example 7 2-fluoro-2-n-heptyl-4-hexynoic acid
Example 8 2-fluoro-2-n-octyl-4-hexynoic acid
Example 9 2-ethyl-2-fluoro-4-heptynoic acid
Example 10 2-fluoro-2-n-propyl-4-heptynoic acid
Example 11 2-n-butyl-2-fluoro-4-heptynoic acid
Example 12 2-fluoro-2-n-pentyl-4-heptynoic acid
Example 13 2-fluoro-2-n-hexyl-4-heptynoic acid
Example 14 2-fluoro-2-n-heptyl-4-heptynoic acid
Example 15 2-fluoro-2-n-octyl-4-heptynoic acid
Example 16 2-fluoro-2-n-propyl-4-cyclopropyl-4-pentynoic acid.
Example 17 2-cyclopropylmethyl-2-fluoro-4-hexynoic acid
In one embodiment of this invention, these acids are provided in the form of pharmaceutically acceptable salts or prodrugs. Salt forms may be employed, for example, in order to obtain more crystalline materials, for purposes of ease of manufacturing or formulating, or they may be employed where more water-soluble forms of the compounds are desirable, for example in parenteral or oral liquid formulations. Both salt and pro-drug forms may be employed in order to improve the bioavailability or pharmacodynamics of a preparation.
Suitable salts are, for example, tris(hydroxymethyl)-ammonium, ammonium, sodium, potassium, calcium, and magnesium salts. Salt forms may be prepared by methods well-known in the art, for example by neutralization or by ion exchange. Compositions derived from partial neutralization of the acid are also contemplated to be within the scope of this invention. In general, suitable pharmaceutically acceptable salt forms, and methods for their preparation, will be apparent to those skilled in the art.
Suitable prodrugs are, for example, lower alkyl esters, alkoxy-alkyl esters, hydroxy-alkyl esters, and amides. The preferred lower alkyl esters are C 1 to C 4 alkyl esters. The amides may be unsubstituted on nitrogen, or may carry one or two nitrogen substituents such as alkyl, alkoxy-alkyl, hydroxy-alkyl, amino-alkyl, and the like.
Combinations of drug and pro-drug compounds, for example in compositions intended to provide both rapid onset and prolonged activity, will be apparent to those skilled in the art, and are contemplated to be within the scope of this invention.
It will be apparent to those skilled in the art that the compounds of the invention, and the salts and prodrugs thereof, may exist in enantiomeric forms. The pure enantiomers may be resolved from the racemate by methods well-known in the art, for example by fractional recrystallization of diastereomeric amine salts, by chromatography of diastereomeric derivatives, or by chiral column chromatography. Alternatively, enantiomeric forms may be prepared by chiral synthesis, for example by alkylation or fluorination of chiral hydrazones (R.-S. Hauck, H. Nau, 1989 , Toxicology Letters , 49, 41-48) or by alkylation or fluorination of chiral oxazolidinone derivatives (H. Nau et al., 1994, PCT International Application WO 94/06743). The R and S enantiomers, the racemates, and non-racemic mixtures of enantiomers are all contemplated to be within the scope of this invention.
Another object of this invention is to provide a method of treating individuals with epilepsy, or others in need of anticonvulsant therapy, with compounds of formula I or salts and prodrugs thereof. Mammals, and in particular humans, who would benefit from this method of treatment include those exhibiting, or at risk for exhibiting, any type of seizure. For example, the methods of this invention are useful for treating individuals with idiopathic generalized seizures such as absence, myoclonic and tonic-clonic seizures and partial seizures. Individuals suffering from epilepsy, in particular, are expected to benefit from administration of the compounds of this invention. The method of the invention comprises administering to an individual a therapeutically effective amount of at least one compound of formula I or a salt or prodrug thereof, which is sufficient to reduce or prevent seizure activity.
The dose of the compound used in the treatment of such disease will vary in the usual way with the seriousness of the disorder, the weight and metabolic health of the sufferer, and the relative efficacy of the compound employed. The preferred initial dose for the general patient population will be determined by routine dose-ranging studies, as are conducted for example during clinical trials. Therapeutically effective doses for individual patients may be determined by titrating the amount of drug given to the individual to arrive at the desired therapeutic or prophylactic effect while minimizing untoward side effects, as is currently done with valproic acid. Dosages may be similar to those used with VPA, however they may be adjusted appropriately, based on the potencies and kinetic parameters disclosed herein or as determined by routine methods. For example, the compound 2-fluoro-2-n-propyl-4-hexynoic acid (example 3) would be expected to be useful at dosages which are about 1.5 times greater than those used for VPA. A preferred initial dose for this compound, accordingly, may be estimated to be between about 10 and 100 mg/kg/day, more preferably between 20 and 50 mg/kg/day. This initial dose may be varied so as to obtain the optimum therapeutic effect in the patient. Generally, a dose of between 1 and 150 mg/kg/day of the compounds of the invention would be expected to be administered to an individual, either singly or in divided doses.
This invention also provides pharmaceutical compositions useful for providing anticonvulsant activity, which comprise at least one compound of the invention. In addition to comprising at least one of the compounds described by formula I or a salt or prodrug thereof, the pharmaceutical composition may also comprise one or more additives such as preservatives, excipients, fillers, wetting agents, binders, disintegrants, buffers, and carriers. Suitable additives may be for example magnesium and calcium carbonates, carboxymethylcellulose, starches, sugars, gums, magnesium or calcium stearate, coloring or flavoring agents, and the like. There exists a wide variety of pharmaceutically acceptable additives for pharmaceutical dosage forms, and selection of appropriate additives is a routine matter for those skilled in art of pharmaceutical formulation.
The compositions may be in the form of tablets, capsules, powders, granules, lozenges, suppositories, reconstitutable powders, or liquid preparations such as oral or sterile parenteral solutions or suspensions.
In order to obtain consistency of administration it is preferred that a composition of the invention is in the form of a unit dose. Unit dose forms for oral administration may be tablets, capsules, and the like, and may contain conventional excipients such as binding agents, for example syrup, acacia, gelatin, sorbitol, tragacanth, or polyvinylpyrrolidone; and carriers or fillers, for example lactose, sugar, maize-starch, calcium phosphate, sorbitol or glycine. Additives may include disintegrants, for example starch, polyvinylpyrrolidone, sodium starch glycolate or microcrystalline cellulose; preservatives, and pharmaceutically acceptable wetting agents such as sodium lauryl sulfate.
In addition to unit dose forms, multi-dosage forms are also contemplated to be within the scope of the invention. Delayed-release compositions, for example those prepared by employing slow-release coatings, micro-encapsulation, and/or slowly-dissolving polymer carriers, will also be apparent to those skilled in the art, and are contemplated to be within the scope of the invention.
The solid oral compositions may be prepared by conventional methods of blending, filling, tabletting or the like. Repeated blending operations may be used to distribute the active agent throughout those compositions employing large quantities of fillers. Such operations are conventional in the art. The tablets may be coated according to methods well known in normal pharmaceutical practice, for example with an enteric coating.
Oral liquid preparations may be in the form of, for example, emulsions, syrups, or elixirs, or may be presented as a dry product for reconstitution with water or other suitable vehicle before use. Such liquid preparations may contain conventional additives such as suspending agents, for example sorbitol syrup, methyl cellulose, gelatin, hydroxyethylcellulose, carboxymethylcellulose, aluminum stearate gel, and hydrogenated edible fats; emulsifying agents, for example lecithin, sorbitan monooleate, or acacia; non-aqueous vehicles (which may include edible oils), for example almond oil or fractionated coconut oil, oily esters such as esters of glycerin, propylene glycol, or ethyl alcohol; preservatives, for example methyl or propyl p-hydroxybenzoate or sorbic acid; and if desired conventional flavoring or coloring agents.
For parenteral administration, fluid unit dosage forms are prepared utilizing the compound and a sterile carrier, and, depending on the concentration used, can be either suspended or dissolved in the carrier. In preparing solutions the compound can be dissolved in water or saline for injection and filter sterilized before filling into a suitable vial or ampoule and sealing. Advantageously, additives such as local anaesthetics, preservatives and buffering agents can be dissolved in the vehicle. Suitable buffering agents are, for example, phosphate and citrate salts. To enhance the stability, the composition can be frozen after filling into the vial and the water removed under vacuum. Parenteral suspensions are prepared in substantially the same manner, except that the compound is suspended in the vehicle instead of being dissolved, and sterilization cannot be accomplished by filtration. The compound can be sterilized by conventional means, for example by exposure to radiation or ethylene oxide, before being suspended in the sterile carrier. Advantageously, a surfactant or wetting agent is included in the composition to facilitate uniform distribution of the compound.
EXAMPLES
A. Preparation of the Compounds
Example 8: 2-fluoro-2-octyl-4-hexynoic acid.
A solution of 0.055 mol of lithium diisopropylamide (LDA) in 100 ml tetrahydrofuran (THF) was cooled to −78° C. under an inert atmosphere, and 0.055 mol of methyl decanoate in THF was added dropwise with stirring. The mixture was allowed to warm over one hour to −20° C., then cooled again to −78° C. A solution of 1-bromo-2-butyne (0.050 mol) in THF (20 ml) was added dropwise, and the mixture allowed to warm to room temperature overnight. Aqueous 6N HCl (100 ml) was added, and the product extracted with ethyl ether, dried with anhydrous sodium sulfate, concentrated, and distilled in vacuo to provide methyl 2-(2-butynyl)decanoate as an oil.
This ester was again deprotonated with LDA in THF, as described above, and at −78° C. a solution of N-fluoro benzenesulfonimide (1.1 equivalents) in THF was added dropwise. The mixture was allowed to warm to room temperature, quenched with saturated ammonium chloride solution, and worked up as above. Chromatography on silica gel with 5% ethyl acetate in hexane provided methyl 2-(2-butynyl)-2-fluorodecanoate as an oil.
The methyl ester (0.016 mol) was saponified by dissolving it in 30 ml of methanol, adding 10 ml of water and 0.016 mol of lithium hydroxide, and stirring at room temperature for 24 hours. The methanol was removed in vacuo, and the residue was extracted once with ethyl ether. The aqueous solution was then acidified with hydrochloric acid and extracted again with ether. The ether extract was worked up as above, and chromatographed on silica gel with 25% ethyl acetate in hexane to provide the title compound as an oil in 26% overall yield. 1 H NMR (CDCl 3 ): δ0.84 (3H, t, J=7 Hz), 1.24 (12H, M), 1.76 (3H, t, J=2 Hz), 1.88 (2H, m), 2.70 (2H, m) 9.40 (1H, br).
Examples 1-7 and 9-17 are prepared by the same method, from the appropriate starting materials.
B. Biological Activities of the Compounds
The anti-convulsive activity of the compounds of the invention was determined by the PTZ convulsion test (E. Swinyard et al., 1969, “Laboratory Evaluation of Antiepileptic Drugs, Review of Laboratory Methods,” Epilepsia 10, 107-119; E. Swinyard, J. Woodhead, in Antiepileptic Drugs , 2nd ed., D. Woodbury, J. Penry, C. Pippenger, eds., Raven Press, New York, 1982, 111-126). Briefly, animals were dosed intraperitoneally with the sodium salt of the compound to be tested, and then challenged after 15 minutes with a subcutaneous injection of pentylenetetrazole (65 mg/kg). The percentage of animals that were protected from seizure (defined as at least one episode of continuous seizure activity lasting at least five seconds) is reported in Table 1 as “Anticonvulsant Activity %”.
The sedative activity of the compounds was determined by the “Rotorod” test (Dunham, Miya, 1957 , J. Am. Pharm. Assoc ., 46, 208-209). Animals were dosed with the sodium salt of the compound to be tested, and after 15 minutes they were placed on the ROTOROD apparatus (Rotorod, Ugobasile, Italy). The percentage of animals that fell from the rod is reported as “Sedative Activity %” in Table 1.
The teratogenic potential of the compounds was determined by injecting pregnant animals on day 8 of gestation with the sodium salt of the compound to be tested, and by examining the fetuses on day 18 of gestation (H. Nau, 1985 , Toxicol. Appl. Pharmacol ., 80, 243-250; H. Nau, W. Loscher, 1986 , Fund. Appl. Toxicol ., 6, 669). The percent of fetuses exhibiting exencephaly is reported as “Teratogenic Activity %” in Table 1.
TABLE 1
Anti-convulsive activity sedation, and teratogenic potential.
(Doses in mmol/kg; see text for definitions of % activity)
COMPOUND
ANTICONVULSIVE
SEDATIVE
TERATOGENIC
(EXAMPLE
ACTIVITY
ACTIVITY
ACTIVITY
NO.)
% (DOSE)
% (DOSE)
% (DOSE)
(3)
20(1.5)
0(1.5)
2(3.0)
(5)
80(1.5)
40(1.5)
1(1.5)
(7)
60(0.5)
100(1.5)
0(1.0)
(8)
40(0.25)
100(1.5)
0(0.5)
VPA
60(1.0)
40(1.5)
50(3.0)
While the examples presented above describe a number of embodiments of this invention, it is apparent that the compounds, compositions, and methods of this invention can be altered to provide alternative embodiments which nonetheless utilize the methods of this invention. That such alternative embodiments may not have been expressly presented is not to be considered a disclaimer of those alternative embodiments. Therefore, it will be appreciated that the scope of this invention is not limited to the specific embodiments which have been presented above by way of example, and that such alternative embodiments will be within the literal scope of the claims or will be equivalent thereto. All references cited herein are hereby incorporated by reference in their entirety. | Alpha-fluorinated alkynoic acids and pharmaceutical compositions containing these compounds are provided, which are useful for the treatment and prevention of seizures such as are associated with epilepsy. The compounds of the invention exhibit reduced side effects, relative to valproic acid, with regard to sedation and teratogenic potential. | 2 |
This is a continuation-in-part of my application No. 07/804,120 filed Dec. 6, 1991, abandoned.
The subject of the present invention is a control device for an asynchronous motor having two directions of rotation used for driving a roller-blind, rolling shutter, door or similar objects, comprising a control point equipped with Raising, Lowering and Stop contacts which can be operated manually and whose operation ensures the rotation of the motor in the desired direction and its stopping respectively.
PRIOR ART
In most known installations comprising a roller-blind, a rolling shutter or a door controlled by an asynchronous motor having two directions of rotation, the windings corresponding to each of the directions of rotation are connected to the electrical power supply by the intermediary of contacts of the control point marked by the words Raising and Lowering. It is therefore important that, during the wiring, the Raising and Lower-ing contacts are each connected to the winding for which the supply of power results in a rotation of the motor in such a way as to actually cause a raising or a lowering of the roller-blind, of the rolling shutter or of the door. Now, the actual raising and lowering of the roller-blind, of the rolling shutter or of the door does not depend only on the correct marking of the conductors when connecting up but also on the orientation of the motor. This motor can in fact be in one of two symmetrical positions, depending on whether it is installed on one side or the other side of the embrasure in which the roller-blind, the shutter or the door is mounted, the effect obtained being either a raising or a lowering, depending on the position of the motor, for the same direction of rotation of the latter.
This represents a constraint which is difficult to manage. It is generally necessary to carry out a preliminary powering up and a test before proceeding with the final connection. Such an operation is a waste of time and furthermore it is not always possible to carry out easily because of the sometimes very difficult access to the motor.
Further, certain installations are known in which the correct power supply for the windings of the motor is provided by remote controlled contacts located in the motor itself and controlled by built-in electronics which generally also manage the automatic stoppings of the motor. The contacts are remote controlled from a control box located at the control point. Access to the contacts, for repair purposes, is therefore impossible without dismantling the motor and consequently without also dismantling a part of the installation. Furthermore, a large amount of wiring is necessary between the control point, often distant from the motor, and the motor, this wiring also comprising the power supply for the motor.
SUMMARY OF THE INVENTION
The purpose of the present invention is to produce a control device overcoming the disadvantages of the known installations, that is to say a control device capable of being used with a conventional motor, requiring minimum wiring and having great flexibility in its possibilities of installation.
For this purpose, the control device according to the invention comprises, between the control point and the motor, a control box and a power supply unit containing a logic processing unit, in which a program for reversing the direction of rotation of the motor is stored, and means of switching controlled by the logic processing unit for the power supply of one or other of the windings of the motor, the control point comprising means of implementing the reversal program.
The control box can be placed at the most appropriate place, generally in the proximity of the motor. The wiring between the control point and the control box can consist in a single cable with four conductors of small cross-section. Integration of the control box with the motor is possible without further provisions. The installation has great flexibility.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the device according to the invention will be described with reference to the appended drawing in which:
FIG. 1 is a general block diagram of an installation comprising a motor;
FIG. 2 shows the block diagram of the logic processing unit;
FIG. 3 shows the Input/Output interface on the motor side; and
FIG. 4 shows the flowchart of the program for reversing the direction of rotation of the motor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The installation shown as a block diagram in FIG. 1 comprises an asynchronous motor 1 having two directions of rotation whose three input terminals are connected by three conductors to a control box 2 which is itself connected by four wires to a control point 3 fitted with four push buttons M, D, S, and IS. The push button M operates a Raising contact, the push button D operates a Lowering contact, the push button S operates a contact having on the one hand the usual function of a Stop contact and on the other hand an additional function Depressing the stop contact and the reverse installation contact IS simultaneously, causes the lowering and raising contacts to operate in a reverse order. The reverse order being that the raising and lowering contacts will upon subsequent activation always turn the motor in a direction opposite from the direction they turned the motor prior to activating the reverse installation contact. As usual, P and N denote the main power supply.
The control box 2 houses a logic processing unit (LPU) 4 comprising a microcomputer 5, on this occasion an INTEL 8051 microcomputer with its ROM and RAM memories associated with an EPROM memory. The microcomputer 5 is supplied by the intermediary of a stabilized power supply 6 and it is connected, on the one hand, to the control point 3 by an "operating" interface 7 and, on the hand, to the motor 1-by an I/O interface 8.
The interface 8 is shown in greater detail in FIG. 3. It comprises two relays R1 and R2 respectively operating a contact CT1 and CT2. The relays R1 and R2 are controlled by the microcomputer 5. The closing of the contact CT1 has the effect of connecting the phase P of the mains to the Raising conductor M, while the closing of the contact CT2 has the effect of connecting this same phase to the Lowering conductor D going to the motor 1. The contacts CT1 and CT2 therefore ensure the rotation of the motor 1 in one direction or in the other.
The main reversal program is stored in the ROM memory.
The flowchart of the programs of the microcomputer 5 is shown in FIG. 4.
Instruction 11 is an initialization instruction.
Instruction 12 is an instruction for loading the saved direction of rotation flag.
Instruction 13 is an instruction for scanning the contacts of the control point 3.
Instruction 14 tests the state of the contact IS.
Instruction 15 is an instruction for the complementing of the direction reversal flag.
Instruction 16 tests if the reversal flag is equal to zero.
Instruction 17 is an instruction to read the direction of rotation flag.
Instruction 19 tests if the flag is equal to zero.
Instruction 21 is an instruction to activate the output of the microcomputer 5 corresponding to the contact CT1 with the Lowering contact and of the contact CT2 with the Raising contact or to deactivate the contacts CT1 and CT2 if the contact S is operated alone, which corresponds to a stop command.
Instruction 22 is an instruction to activate the output of the microcomputer 5 corresponding to the contact CT1 when the Raising contact of the control point is activated and the corresponding output of the contact CT2 when the Lowering contact of the control point is activated or to deactivate CT1 and CT2 if the contact S is activated alone.
Instruction 18 is an instruction for testing if the contact S is activated.
Instruction 20 is an instruction for the complementing of the direction of rotation flag.
Instruction 23 is an instruction to save the direction of rotation flag.
Instruction 24 is an instruction to reset the reversal flag to zero.
The functioning of the device is as follows:
On powering up, the device is initialized by instruction 11. In particular, the counter of the microcomputer 5 and the flag are reset to zero.
Instruction 12 loads the direction of rotation flag into the RAM memory, this direction of rotation having been previously saved by instruction 23, then calls instruction 13 which scans the contacts of the control point 3.
In the absence of any action on the contact IS, instruction 14 calls instruction 16 which tests that the reversal flag=0. Instruction 16 calls instruction 17 which reads the direction of rotation flag, then instruction 19 tests its value.
If the flag=0, instruction 19 calls instruction 21 which is the subroutine for activating the contact CT1 if the Lowering contact D is operated, for activating the contact CT2 if the Raising contact M is operated and for deactivating the contacts CT1 and CT2 if the stop contact S is operated. The program loops back.
If the user notices that the effect produced by operating the Raising M/Lowering D contacts does not correspond with the desired direction, he then operates the contact IS. In this case, instructions 12 and 13 run as before. Instruction 14 tests that the contact IS is activated and calls instruction 15 which complements the reversal flag to 1.
The latter being at 1, instruction 16 calls instruction 18.
If the user operates the contact S at that moment, instruction 18 calls instruction 20 which complements the value of the corresponding flag (here at 1) and then calls instruction 23 which saves this value in the EPROM memory.
Instruction 24 resets the reversal flag to zero and the program loops back.
In the absence of action on the contact IS, instructions 11, 12, 13, 14, 16 and 17 run as previously described and then instruction 19 tests that the flag=1 and calls instruction 22 which is the subroutine inverse to 21. The contact CT1 is activated with the Raising contact M and the contact CT2 is activated with the Lowering contact D.
If the operator does not operate the contact S at the end of instruction 16 testing that the reversal flag=1, the program loops back until the user operates this contact S allowing the reversal of the direction of rotation, or the contact IS, retaining the current direction of rotation.
Since the value of the direction of rotation flag is reloaded at each loop of the program by instruction 12, the current direction of rotation is retained even after a failure of the mains supply.
The following two examples illustrate the use of the present invention.
EXAMPLE 1
Let us suppose that the blind does not roll down when the operator actuates the contact D. In this event the operator operates simultaneously the contacts IS and S. Then the programm instruction 14 tests that the contact IS is activated and calls instruction 15 which complements the reversal flag to 1. Instruction 15 calls instruction 16 which tests that the reversal flag is not equal to zero so that instruction 16 is called which tests that the contact S is activated. Instruction 18 calls then instruction 20 which complements the direction of rotation flag. The new direction of rotation is then memorized in the RAM of the microcomputer and at the next time the operator (or the user) actuates the contact D the blind will correctly roll down.
Additionally the value of the direction of rotation is is saved in the EPROM memory.
If the blind correctly rolls down when the contact D is actuated and rolls up when the contact M is actuated, the operator has no reason to actuate the contact 15. Moreover the user should not actuate the contact IS and this contact is preferably masked so that it could not be untimely actuated.
EXAMPLE 2
Let us suppose that the blind does correctly roll down when the operator actuates the contact D. The blind is then ready for use. Suppose that the roller-blind is rolled up and that the user wants that the blind rolls down.
The user actuates the contact D. The programm being running instruction 14 test that the contact IS is not actuated and calls instruction 16 which tests that the reversal flag=0. Instruction 16 calls then instruction 17 which reads the direction of rotation flag, loaded in the RAM. The value of this flag may be 1 or 0 depending on the preliminary setting by the installator. Assuming that the flag=0, then instruction 19 calls instruction 21 which activates the contact CT1 and the blind rolls down. | The present invention provides controls for driving roller blinds, rolling shutters and doors. The controls include a two directional motor, a control panel, switches, power supply, and a logic processing unit which are all interconnected to allow the user to partially or fully raise and lower the blinds. The direction of the blinds can be changed at any time and also stopped at any time. | 4 |
[0001] This application is a divisional application of U.S. patent application Ser. No. 10/564,998 which received a 371 filing date of Jun. 6, 2006, which is a 371 filing of PCT/NZ2004/000165 filed on Jul. 27, 2004. These applications claim priority from New Zealand Application No. 527313 which was filed on Jul. 30, 2003. All of these references are hereby incorporated by reference in their entirety.
FIELD OF INVENTION
[0002] This invention relates to patient interfaces particularly though not solely for use in delivering Continuous Positive Airways Pressure (CPAP) therapy to patients suffering from obstructive sleep apnoea (OSA). In particular the present invention relates to forehead rest pads on patient interfaces.
BACKGROUND OF TOE INVENTION
[0003] In the art of respiration devices, there are well known variety of respiratory masks which cover the nose and/or mouth of a human user in order to provide a continuous seal around the nasal and/or oral areas of the face such that gas may be provided at positive pressure within the mask for consumption by the user. The uses for such masks range from high altitude breathing (i.e., aviation applications) to mining and fire fighting applications, to various medical diagnostic and therapeutic applications.
[0004] One requisite of such respiratory masks has been that they provide an effective seal against the user's face to prevent leakage of the gas being supplied. Commonly, in prior mask configurations, a good mask-to-face seal has been attained in many instances only with considerable discomfort for the user. This problem is most crucial in those applications, especially medical applications, which require the user to wear such a mask continuously for hours or perhaps even days. In such situations, the user will not tolerate the mask for long durations and optimum therapeutic or diagnostic objectives thus will not be achieved, or will be achieved with great difficulty and considerable user discomfort.
[0005] U.S. Pat. No. 5,243,971 and U.S. Pat. No. 6,112,746 are examples of prior art attempts to improve the mask system. U.S. Pat. No. 5,570,689 and PCT publication No. WO 00/78384, and U.S. Pat. No. 6,119,693 are examples of attempts to improve the forehead rest.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to attempt to provide a patient interface which goes some way to overcoming the abovementioned disadvantages in the prior art or which will at least provide the industry with a useful choice.
[0007] Accordingly in a first aspect the present invention consists in a device for delivering a supply of gases to a user comprising:
[0008] a patient interface, in use in fluid communication with said supply of gases,
[0009] a forehead rest engaging said interface including a deformable resilient member configured to in use rest against the face of a patient, said deformable resilient member when compressed in use creating a uniformly and gradually increasing force, while evenly distributing the pressure on the area of the forehead of said patient that contacts said resilient member.
[0010] Preferably said deformable resilient member has a top surface and a base connected by two side walls, said side walls being thin and in use are compressible.
[0011] Preferably said top surface is substantially thicker than said side walls.
[0012] Preferably said top surface includes additional support at its centre to limit its collapse.
[0013] Preferably said side walls are capable of folding under compression.
[0014] Preferably said deformable resilient member is moulded from silicone.
[0015] Alternatively said deformable resilient member is extruded from silicone.
[0016] In a second aspect the present invention consists in a device for delivering a supply of gases to a user comprising:
[0017] a patient interface, in use in fluid communication with said supply of gases,
[0018] a forehead rest engaging said interface including a deformable resilient member configured to in use rest against the face of a patient, said deformable resilient member being of a hollow conical shape where in use and under compression the top part of said hollow cone deforms or the side walls of said cone deform.
[0019] Preferably said deformable resilient member is moulded from silicone.
[0020] Alternatively said deformable resilient member is extruded from silicone.
[0021] In a third aspect the present invention consists in a device for delivering a supply of gases to a user comprising:
[0022] a patient interface, in use in fluid communication with said supply of gases,
[0023] a forehead rest engaging said interface, an adjustable deformable resilient member mounted on said forehead rest, said adjustable deformable resilient member configured to in use rest against the face of a patient, said resilient member is height adjustable such that said patient can adjust the distance between said forehead rest and the face of said patient.
[0024] Preferably said adjustable deformable resilient member is at least one adjustable strap attached and adjustable on said forehead rest.
[0025] Alternatively said adjustable deformable resilient member is a member rotatably mounted on said forehead rest.
[0026] In the alternate form the adjustable deformable resilient member being rotatable relative to said forehead rest
[0027] In a further form said resilient member has two ends, one of the resilient member being fixed to the forehead rest, the other end of the strap is free, said free end capable of sliding relative to said forehead rest, said sliding of free end of strap allowing said user to adjust the height between said forehead rest and said forehead of said user.
[0028] Preferably said forehead rest includes a plurality of recesses, the free end of the strap including a slideable sleeve, said slideable sleeve sliding relative to said forehead rest and slideably moving said strap to adjust the height of said resilient member, said sleeve also capable of being fixed into any one of the recesses, said recesses allowing varying degrees of height adjustment.
[0029] Preferably said forehead rest also including an aperture, said fixed end of strap fixed to said forehead rest by engaging into said aperture.
[0030] Preferably said strap includes a plurality of protrusions at each end, said protrusions at said fixed end of said strap engaging with said aperture to fix said strap to said forehead rest, said protrusions at said free end of said strap engaging with said sleeve to connect said strap to said sliding sleeve.
[0031] Preferably said forehead rest is substantially T shaped, said forehead rest comprising two lateral arms extending outward from a vertical arm, said resilient member attached to at least one lateral arm of said forehead rest.
[0032] Alternatively said forehead rest is substantially I shaped.
[0033] In a further form said strap has a fixed end and a movable end, said fixed end fixed to the forehead rest, said movable end is arranged on said forehead rest to form a substantially circular shape that provides a cushioning effect should a force be applied.
[0034] Preferably said movable end of said strap being threaded through an aperture in the arm to form said circular shape, said movable end of said strap being adjustable on said forehead rest to allow a user to adjust the size of the circular shape created by said strap.
[0035] Preferably said strap includes a plurality of spaced apart apertures on the strap, said forehead rest including a protrusion extending outward from said forehead rest, said protrusion capable of engaging with any one of said apertures on said strap to fix the movable end of said strap and fix the size of said circular shape, said plurality of spaced apart holes on strap allowing a user to adjust the size of said circular shape.
[0036] Preferably said forehead rest includes a holding sleeve, said holding sleeve holding said strap in a substantially correct orientation relative to the forehead rest and protrusion on said forehead rest.
[0037] Preferably said forehead rest is a substantially I shaped piece.
[0038] In another form said strap is arranged on said forehead rest to form two arced sections relative to said forehead rest, said arced sections resting against a user's head and providing a cushioning effect.
[0039] Preferably said forehead rest includes at least one aperture, said strap curled through said aperture to form a middle section extending in the opposing direction to said arced sections.
[0040] Preferably said strap is folded back on itself to form said middle section, said strap having two ends, both ends of said strap fixed to opposing ends of said forehead rest.
[0041] Preferably said forehead rest includes a lip at each end of said forehead rest, said rest comprising an abutment at each end of said strap, said abutment engaging with said lip to fix each end of said strap to said forehead rest.
[0042] Preferably said forehead rest includes a pair of apertures said strap curling through both said apertures to form said middle section and arced sections.
[0043] Preferably said middle section can be pulled through or pushed through said aperture or apertures in order to increase or decrease the size of said arced sections.
[0044] Preferably said strap includes a plurality of spaced apart notches along the edge of said strap, said notches capable of engaging with said aperture or apertures to hold said middle section in place, said notches providing incremental positions for the middle section to be held and said notches providing incremental sizes of said arced sections.
[0045] Preferably said strap has notches along both edges of said strap to provide for better grip and engagement with said aperture or apertures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] One preferred form of the present invention will now be described with reference to the accompanying drawings,
[0047] FIG. 1 is a block diagram of a humidified continuous positive airway pressure (system) as might be used in conjunction with the present invention,
[0048] FIG. 2 is an illustration of the nasal mask in use according to the preferred embodiment of the present invention,
[0049] FIG. 3 shows a perspective view of the mask with cushion,
[0050] FIG. 4 is a cutaway view of the mask showing the cushion,
[0051] FIG. 5 is a cutaway view of the periphery of the outer membrane,
[0052] FIG. 6 is a cutaway view of the periphery of the mask body portion,
[0053] FIG. 7 shows a prior art forehead rest in isolation,
[0054] FIG. 8 shows a section view of the prior art forehead rest of FIG. 7 ,
[0055] FIG. 9 shows a perspective view of the forehead rest cushion of FIG. 7 ,
[0056] FIG. 10 is a section of a further prior art forehead rest cushion,
[0057] FIG. 11 is a section of perspective view of the forehead rest cushion of FIG. 10 ,
[0058] FIG. 12 is a back view showing the slots in the forehead rest for each cushion to lock into,
[0059] FIG. 13 is a perspective view of a first embodiment of a forehead rest cushion of the present invention,
[0060] FIG. 14 is a perspective view of a second embodiment of a forehead rest cushion of the present invention,
[0061] FIG. 15 is an alternative perspective view of the forehead rest cushion of FIG. 14 ,
[0062] FIG. 16 is a section of the forehead rest cushion of FIG. 14 ,
[0063] FIG. 17 is a side view of a third embodiment of a forehead rest cushion of the present invention,
[0064] FIG. 18 is an alternative perspective view of the forehead rest cushion of FIG. 17 ,
[0065] FIG. 19 is a section view of the forehead rest cushion of FIG. 17 ,
[0066] FIG. 20 is a perspective view of a fourth embodiment of a forehead rest cushion of the present invention,
[0067] FIG. 21 is a section of the forehead rest cushion of FIG. 20 ,
[0068] FIG. 22 is a perspective view of a fifth embodiment of a forehead rest cushion of the present invention,
[0069] FIG. 23 is a sixth embodiment of a forehead rest cushion of the present invention,
[0070] FIG. 24 is a seventh embodiment of a forehead rest cushion of the present invention,
[0071] FIG. 25 is a perspective view of an eighth embodiment of a forehead rest cushion of the present invention,
[0072] FIG. 26 is a perspective view of a ninth embodiment of a forehead rest cushion of the present invention,
[0073] FIG. 27 is a perspective view of a tenth embodiment of a forehead rest cushion of the present invention, where the forehead rest cushion is adjustable to a user's requirements,
[0074] FIG. 28 is a perspective view of an eleventh embodiment of a forehead rest cushion of the present invention, this embodiment also being incapable of being adjusted by the user,
[0075] FIG. 29 is a perspective view of a twelfth embodiment of the forehead rest cushion of the present invention, where the forehead rest cushion is adjustable,
[0076] FIG. 30 is a perspective view of a thirteenth embodiment of a forehead rest cushion of the present invention, this embodiment also being adjustable,
[0077] FIG. 31 is a perspective view of a fourteenth embodiment of a forehead rest cushion of the present invention,
[0078] FIG. 32 is a perspective view of a fifteenth embodiment of a forehead rest cushion of the present invention, and
[0079] FIG. 33 is a perspective view of a sixteenth embodiment of a forehead rest cushion of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0080] The present invention provides improvements in the delivery of humidified gases therapy. In particular a patient interface is described which is more comfortable for the user to wear and reduces leakage as compared with the prior art. It will be appreciated that the patient interface as described in the preferred embodiment of the present invention can be used in respiratory care generally or with a ventilator but will now be described below with reference to use in a humidified CPAP system. It will also be appreciated that the present invention can be applied to any form of patient interface including, but not limited to, nasal masks, oral masks and mouthpieces.
[0081] With reference to FIG. 1 a humidified Continuous Positive Airway Pressure (CPAP) system is shown in which a patient 1 is receiving humidified and pressurised gases through a patient interface 2 connected to a humidified gases transportation pathway or inspiratory conduit 3 . It should be understood that delivery systems could also be VPAP (Variable Positive Airway Pressure) and BiPAP (Bi-level Positive Airway Pressure) or numerous other forms of respiratory therapy. Inspiratory conduit 3 is connected to the outlet 4 of a humidification chamber 5 which contains a volume of water 6 . Inspiratory conduit 3 may contain heating means or heater wires (not shown) which heat the walls of the conduit to reduce condensation of humidified gases within the conduit. Humidification chamber 6 is preferably formed from a plastics material and may have a highly heat conductive base (for example an aluminium base) which is in direct contact with a heater plate 7 of humidifier 8 . Humidifier 8 is provided with control means or electronic controller 9 which may comprise a microprocessor based controller executing computer software commands stored in associated memory.
[0082] Controller 9 receives input from sources such as user input means or dial 10 through which a user of the device may, for example, set a predetermined required value (preset value) of humidity or temperature of the gases supplied to patient 1 . The controller may also receive input from other sources, for example temperature and/or flow velocity sensors 11 and 12 through connector 13 and heater plate temperature sensor 14 . In response to the user set humidity or temperature value input via dial 10 and the other inputs, controller 9 determines when (or to what level) to energise heater plate 7 to heat the water 6 within humidification chamber 5 . As the volume of water 6 within humidification chamber 5 is heated, water vapour begins to fill the volume of the chamber above the water's surface and is passed out of the humidification chamber 5 outlet 4 with the flow of gases (for example air) provided from a gases supply means or blower 15 which enters the chamber through inlet 16 . Exhaled gases from the patient's mouth are passed directly to ambient surroundings in FIG. 1 .
[0083] Blower 15 is provided with variable pressure regulating means or variable speed fan 21 which draws air or other gases through blower inlet 17 . The speed of variable speed fan 21 is controlled by electronic controller 18 (or alternatively the function of controller 18 could carried out by controller 9 ) in response to inputs from controller 9 and a user set predetermined required value (preset value) of pressure or fan speed via dial 19 .
Nasal Mask
[0084] According to a first embodiment of the present invention the patient interface is shown in FIG. 2 as a mask. It will be appreciated the patient interface could equally be a nasal mask, full face, oral mask or mouth piece, endotracheal tube or cannula by way of example. The mask includes a hollow body 102 with an inlet 103 connected to the inspiratory conduit 3 . The mask 2 is positioned around the nose of the user 1 with the headgear 108 secured around the back of the head of the patient 1 . The restraining force from the headgear 108 on the hollow body 102 and the forehead rest 106 ensures enough compressive force on the mask cushion 104 , to provide an effective seal against the patient's face.
[0085] The hollow body 102 is constructed of a relatively inflexible material for example, polycarbonate plastic. Such a material would provide the requisite rigidity as well as being transparent and a relatively good insulator. The expiratory gases can be expelled through a valve (not shown) in the mask, a further expiratory conduit (not shown), or any other such method as is known in the art.
Mask Cushion
[0086] Referring now to FIGS. 3 and 4 in particular, the mask cushion 1104 is provided around the periphery of the nasal mask 1102 to provide an effective seal onto the face of the user to prevent leakage. The mask cushion 1104 is shaped to approximately follow the contours of a patient's face. The mask cushion 1104 will deform when pressure is applied by the headgear 1108 to adapt to the individual contours of any particular user. In particular, there is an indented section 1150 intended to fit over the bridge of the user's nose as well as a less indented section 1152 to seal around the section beneath the nose and above the upper lip.
[0087] In FIG. 4 we see that the mask cushion 1104 is composed of a inner foam cushion 1110 covered by an outer sealing sheath 1112 . The inner cushion 1110 is constructed of a resilient material for example polyurethane foam, to distribute the pressure evenly along the seal around the user's face. The inner cushion 1110 is located around the outer periphery 1114 of the open face 1116 of the hollow body 1102 . Similarly the outer sheath 1112 may be commonly attached at its base 1113 to the periphery 1114 and loosely covers over the top of the inner cushion 1110 .
[0088] In the preferred embodiment shown in FIGS. 3-6 the bottom of the inner cushion 1110 fits into a generally triangular cavity 1154 in the hollow body 1102 . The cavity 1154 is formed from a flange 1156 running mid-way around the interior of the hollow body.
[0089] The outer sheath 1112 fits in place over the cushion 1110 , holding it in place. The sheath 1112 is secured by a snap-fit to the periphery 1114 of the hollow body. In FIGS. 5-6 the periphery 1114 is shown including an outer bead 1158 . The sheath 1112 includes a matching bead 1159 , whereby once stretched around the periphery, the two beads engage to hold the sheath in place.
Forehead Rest
[0090] A prior art nasal mask 102 including a forehead rest 106 is shown in FIGS. 2 and 7 . The forehead rest 106 may move freely in proximity to the mask body 102 and user, but with no lateral movement or may be permanently fixed or adjustably fixed.
[0091] Referring to FIG. 7 , at the top end 142 (around the user's forehead) of the bridge member 136 harnessing slots (not shown) are provided which allow straps from the headgear to be inserted to secure the mask to the headgear. For the user's comfort one or more resilient cushions 140 are provided on the T-piece of the forehead rest 142 the top end of the bridge member 136 , to rest on the forehead of the user. The cushion 140 is constructed by injection moulding or extruding, from silicone or any foam materials as is known in the art for providing cushioning. In FIG. 7 a second cushion 143 is shown at the other end of the section 142 .
Forehead Rest Cushion
[0092] Referring now to FIGS. 8 and 9 the prior art forehead rest cushion 140 is illustrated. The cushion 140 , in cross section, includes an outer curved member 210 and a inner curved member 212 both of which are attached at each end to a straight base member 214 . The inner curved member 212 is a substantially similar curved shape to the outer curved member 210 . The inner member 212 and outer member 210 may be coterminous, the inner member may attach to the outer member 210 or both may attach to the base 214 separately.
[0093] When the cushion 140 comes into contact with the user's face the outer curved member 210 deforms as more pressure is applied to the cushion towards the face. This comprises of the first mode of deformation. Once the outer curved member 210 deforms enough to contact the inner curved member a second mode of deformation occurs.
[0094] As will be appreciated if the outer curved member is flatter than the second curved member 212 the first mode requires less force. The relative curvature and thickness of each can be varied to give a characteristic first mode and second mode. Once in the second mode of deformation extra force is required to deform both the first curved member 210 and the second curved member 212 . This configuration described above results in more even deformation force across the load bearing surface of the cushion 216 and also results in a more progressive force of cushioning when the cushion 120 is deformed.
[0095] A further prior art embodiment of a forehead rest cushion is shown in FIGS. 10 and 11 . This forehead rest cushion 140 has an outer curved member 220 attached at either end to a straight base member 222 . A inner inverted curved member 224 is inverted with respect the outer curved member 220 and is attached at either end two points on the 226 , 228 on the outer curved member 220 . The inner inverted curved member is lower in overall height than the outer curved member 220 such that a first mode of deformation occurs when the outer curved member 220 is deformed. A second mode of deformation occurs when the inner inverted curved member 224 contacts the base member 222 . The outer curved member 220 and the inner inverted curved member 224 deform simultaneously. The forces across the load bearing surface 230 are further distributed by virtue of a generally quadrilateral member 232 including as one side the base member 222 which attaches over the inner inverted curved member 220 approximately at its ends and at its load bearing point 234 . The quadrilateral member 232 provides additional stiffness and reduces lateral deformation.
[0096] These prior art forehead rests have a base member that includes a flange 240 which engages with a slot 2138 in the forehead rest 106 to lock the forehead rest cushion in place. The flange 240 first slides through aperture 2139 as seen in FIG. 12 .
[0097] In the preferred forms of the forehead rest cushion of the present invention will now be described with reference to FIGS. 13 to 26 , 31 and 32 . With each of the embodiments as described in relation to these figures the forehead rest cushion or pad allows for a controlled compression of the cushion. Each cushion is capable of being compressed under a force and will return to its original position (as shown in the Figures) when the force ceases.
[0098] A first embodiment of the forehead rest cushion is shown in FIG. 13 . This forehead rest cushion 300 has a flange 301 that is able to be attached to a forehead rest, such as that rest 106 shown in FIG. 7 or 12 . The flange 301 slides through the aperture 2139 in the T-piece 2140 of the forehead rest 106 . The cushion 300 is substantially rectangular in shape with an upper wall 302 and lower wall 303 , with the flange being attached to the lower wall 303 . The side walls are corrugated or concertinaed such that these walls 304 , 305 collapse when a force is placed on the upper wall 302 . As described above, as the cushions are made from a plastics material, such as silicone or foam, the folds forming the side walls will return to the original form when any compression force ceases.
[0099] FIG. 14 shows a second embodiment of a forehead rest cushion of the present invention. This forehead rest cushion 306 is a cushion that is in the general shape of a parabolic cone. The cushion has an open top 307 that can be seen in FIG. 15 , this open top 307 allows the edge 308 of the cushion 306 to roll inwards when the top of the cone shaped cushion is compressed, or a force placed air on. This cushion may be attached to a forehead rest, such as the T-piece forehead rest as shown in FIGS. 7 and 12 by any appropriate means, for example, gluing or the like and may include a flange such as that described above with reference to FIG. 13 .
[0100] In alternative embodiments any of the forehead rest cushion of the present invention as shown in the Figures may have an alternative attachment mechanism such as an arrow head type barb or protrusion, which fits into apertures on the forehead rest. Alternatively, any of the cushions may be provided with an aperture in place of the flange that is able to be slid about an arm of the forehead rest.
[0101] A third embodiment of the forehead rest cushion of the present invention is shown in FIGS. 17 , 18 and 19 . This cushion 309 has a conical body 310 with a flattened circular top 311 . This cushion is either injection moulded, extruded, or stamped from a sheet of material and is preferably made of a thermoplastic elastomer, silicone or foam. Again, when a force is applied to the top 311 the inner areas of the top roll inwards down towards the top of the cone body 310 . For example, as shown in FIG. 19 in a section view when a force A is placed on the top 311 the inner area of the top 311 moves downwards and the outer areas, shown as 311 ′, move upwards or simply adjust to the shape of the area of user's forehead it abuts.
[0102] Reference is now made to FIGS. 20 and 21 where the force embodiment of the forehead rest cushion of the present invention is shown this forehead rest cushion 312 is of a hemispherical shape and also allows for a two stage cushioning when a force is placed upon it. The cushion 312 has a hemispherical body 313 suspended above a platform 314 and also has a flange 315 allowing the cushion 312 to be slotted into an aperture in a forehead rest, such as that described above. The hemispherical body 313 is suspended above platform 314 on small supports 316 , 317 . This cushion 312 is preferably moulded from a thermoplastics material, silicone or foam.
[0103] A fifth embodiment of the forehead rest cushion is shown in FIG. 22 . The cushion 318 is shaped in the form of an “M” or generally rectangular with a recess 319 formed in the top wall 320 of the cushion 318 . Therefore, two inner vertical walls 321 , 322 are formed parallel to the outer vertical walls 323 , 324 . When a force is applied to the upper wall 320 the recessed part 319 and vertical walls 322 , 321 are pushed downwards towards the lower wall 325 . When the apex 326 of the recessed part 319 hits the lower wall 325 the cushion may still be compressed, but at a different rate of force such that the compression of this cushion 318 is a two stage compression. The recess 319 in the middle of the cushion 318 therefore provides more uniform pressure across the top wall 320 of the cushion. As with other forms as described above this forehead cushion 318 is supplied with a flange 327 attached to the lower wall 325 allowing the cushion 318 to be attached to the forehead rest.
[0104] Reference is now made to FIG. 23 where a sixth embodiment of the forehead rest cushion of the present invention is shown. This cushion 328 is of a similar form to that described in relation to FIG. 13 , but its top or upper wall 329 is curved and the side walls 330 , 331 merely form one corrugation or fold. When a force is placed upon the upper wall 329 the side walls 330 , 331 fold in upon themselves. Again, this cushion has a flange 332 attached to its lower wall 333 to allow the cushion 328 to be attached to the forehead rest.
[0105] A seventh embodiment of the forehead rest cushion as shown in FIG. 24 , this cushion is very similar in form to that of the prior art cushion as shown in FIG. 8 but its upper wall 335 is split in two and its inner wall 336 is horizontal in nature and not curved. Again, this cushion 334 has a flange 337 that allows it to be attached to a forehead rest. This cushion provides a two stage compression where the inner wall provides stability to the cushion 334 .
[0106] The eighth embodiment of the forehead rest cushion of the present invention is shown in FIG. 25 . This cushion 318 has a base member 319 having a flange similar to as described above in relation to the prior art cushions. The flange 340 allows the cushion 338 to be attached to a forehead rest. Two vertical walls 341 , 342 extend upwards nearer the centre of the base member 339 , and a curved upper member in the shape of a partial oval is attached above the vertical walls 341 , 342 . When a force is placed on the curved upper member 343 the vertical walls 341 , 342 initially support the force placed on the upper member 343 . The outer edges 344 , 345 of the upper member 343 are able to freely roll inwards to give further controlled support to the cushion 338 .
[0107] A ninth embodiment of the forehead rest cushion of the present invention is shown in FIG. 26 . This cushion 346 has a base member 347 and a flange attached to it to enable the cushion to be attached to a forehead rest. Extending outwards and upwards from the edges of the base member 347 are arms 349 , 350 . These arms 349 , 350 are curved inwardly towards one another and may overlap. When a force is placed on the upper 350 arm, the arm 350 moves down towards the lower arm 349 . If enough force or a continued force is provided to the upper arm 350 , the upper arm 350 will continue to compress against and push the lower arm 349 towards the centre of the cushion 346 and the base member 347 . These independent inwardly rolled arms 349 , 350 allow for a two stage compression that is controlled when a force being placed on the upper arm 350 .
[0108] A fourteenth embodiment forehead rest cushion of the present invention is shown in FIG. 31 . This cushion 351 has a similar shape to the prior art cushion of FIG. 9 and includes a base member 354 and a flange 353 which engages with a slot 2138 in the forehead rest to lock the forehead rest cushion in place. The flange 353 slides through and fixes in the aperture 2139 as seen in FIG. 12 . The cushion 351 is substantially rectangular in shape but with an upper wall 352 that is slightly curved at its edges where it meets the side walls 355 , 356 of the cushion. The upper wall is thicker in width than the side walls 355 , 356 to provide additional strength and control to the cushion. Furthermore, the relative thickness of the upper wall 352 compared to the side walls 355 , 356 prevents the cushion 351 from caving in. This helps provide a uniform pressure on the user's forehead.
[0109] A further embodiment of a forehead rest cushion is shown in FIG. 32 . This cushion 357 is exactly the same shape as that cushion of FIG. 31 , but this cushion has an additional curved short wall 358 extending below and following the contour of the upper wall 359 . This short wall 358 provides for additional support to the upper wall 359 when a force is placed upon it.
[0110] FIGS. 27 to 30 and 33 illustrate forehead rest cushions that can be adjusted to a user's preference. Firstly referring to FIG. 27 a rotating substantially circular or cam shaped cushion 360 rotatably mountable between two legs 361 , 362 , which are each attached and extend outwards from the forehead rest or mask base, for example, one on either side of the T-piece as shown in FIG. 12 . As the cushion 360 rotates in the direction of Arrow B the offset is increased or decreased.
[0111] FIG. 28 shows a further embodiment of the cushion of FIG. 27 . This cushion 363 additionally has a plurality of fixed attachments 364 , similar to the flange on the cushions described above. Each of these can be attached to the forehead support in turn to provide an adjustable cushion.
[0112] A twelfth embodiment of a forehead rest cushion of the present invention is shown in FIG. 29 . This cushion 365 is effectively a strap or flexible elongate member (preferably made of a flexible plastics material) attached to one arm 366 of a T or to an I piece of a forehead rest. In the case of a T-shaped forehead rest, such as that shown in FIG. 12 , two cushions of this type would be provided one for each of the two arms of the T-shaped forehead rest. The strap 365 is provided with a pair of protrusions 367 , 368 at each of its ends 369 , 370 such that a recess is formed between each set of protrusions. Each end 369 , 370 is fixed to the arm 366 by appropriate means, such as a sleeve 371 or aperture 372 on the arm 366 . In particular, the upper end 369 of the strap 365 is fixed to the arm 366 in the aperture 372 and the lower end 370 is slideably adjustable by way of a slideable sleeve 371 capable of sliding and being fixed into any one of a number of recesses 373 formed on the edge 374 of the arm 366 .
[0113] A further embodiment of an adjustable forehead rest cushion is shown in FIG. 30 . This adjustable cushion 375 is a strap or flexible elongate member where a first end 376 of its two ends 376 , 377 is fixed to an arm 379 (similar to that arm 366 described above). The second end 377 of the two ends is threaded about and around such that a substantial part of the strap forms a circular shape that provides a cushioning effect should a force be placed upon it. The second end 377 after being threaded through an aperture 381 in the arm 379 , and possibly an further holding sleeve 380 formed on the arm 379 , is fixed to the other side of the arm 379 , for example by pressing a protrusion 382 through a hole 383 formed in the strap 375 . The size of the circular cushion formed can be adjusted as a plurality of spaced apart holes are provided in the strap and the strap can be pulled through the arm and the protrusion 382 fixed in each hole dependent on the requirements of the user.
[0114] Yet still a further embodiment of an adjustable forehead rest cushion is shown in FIG. 33 , where a double loop strap 384 is formed into two arced cushions 385 , 386 . Each of the apexes of the arced cushions 385 , 386 would in use rest against a user's forehead to provide additional comfort while wearing a mask or interface similar to that described above. The strap 384 has abutments 387 , 388 formed at each end that fit under lips 389 , 390 formed in an arm 391 (such as, a one T-piece arm of the forehead rest as described above in relation to FIG. 12 , or an I shaped forehead rest as is known in the prior art and particularly described in New Zealand patent application number 524439 of Fisher & Paykel Healthcare Limited). The middle section 392 of the strap 384 has a plurality of notches 393 cut in each of its edges. The strap 384 is threaded through two apertures formed in the middle of the arm 391 , such that a substantial portion of the middle section 392 extends out from the arm 391 in an opposing direction to the arced cushions 385 , 386 . The middle section 393 can be pulled further through the arm or to pushed back through the apertures in the arm using the notches 393 as incremental positions for the middle section to be held in, to decrease or increase the size of the arced cushions 385 , 386 .
[0115] The forehead rest cushion embodiments shown in FIGS. 27 to 30 and 33 are all user adjustable. In particular the forehead rest cushions shown in these figures are height adjustable and allow the user to adjust the amount cushioning the forehead rest cushions can provide. The height of the forehead rest cushion is the distance between the forehead rest 106 and the face or forehead of the user. The height adjustable forehead rest cushion allows a user to adjust the distance between the forehead rest and the lace of the patient. This allows a user to adjust the amount of cushioning provided by the forehead rest cushion.
[0116] In other forms of the forehead rest cushion of the present invention the cushion may be an inflatable member that can be manually inflated using a syringe or a hand or finger operated compression pump, or automatically inflated using a compressible reservoir or the like. | A patient interface that is comfortable for a user to wear is disclosed. The patient interface includes a forehead rest and cushion. In particular the cushion includes a deformable resilient member that when compressed creates a uniformly and gradually increasing force while evenly distributing the pressure on the forehead of the patient. | 0 |
FIELD OF THE INVENTION
The present invention relates to a weft feeler for textile looms, to be used, especially but not exclusively in connection with water looms, the weft feeler including a movable unit with a feeler subjected to a retaining effect by the unbroken or entire weft and which can be moved if the weft is broken.
SUMMARY OF THE INVENTION
The invention provides an assembly synchronously oscillating with the loom and bearing a slidable unit with a feeler, a photo-electric system comprising an optical beam generator and a photo-electric sensor, and an intercepting screen, said photo-electric system generating a signal when the feeler is not retained by the weft.
In practice, the oscillating assembly comprises a body provided with two spaced extensions respectively carrying the optical generator and the photo-electric sensor; the screen being mounted on the slidable unit and constituted as a longitudinally oriented finned screen positioned to be inserted in the space between the two extensions to intercept the optical beam.
Said slidable unit may be biased by resilient means to the intercepting position, and it can be stressed by the reed thrust action and by the retaining action of the weft against the action of the resilient means to be displaced to a offset position in which the finned screen is out of the path of the optical beam.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood from the following description and accompanying drawing which illustrates a non-restrictive embodiment. In the drawing:
FIG. 1 is a side view of the device in cooperating condition with the structure of the fabric being formed;
FIG. 2 is similar to FIG. 1 but showing the device in intercepting position;
FIG. 3 is a plan view taken along line III--III in FIG. 1;
FIG. 4 is a section, partly broken away, taken along line IV--IV in FIG 1;
FIG. 5 shows the connection of the device with the sley: and,
FIG. 6 shows the cooperation of the device with the fabric being woven.
DETAILED DESCRIPTION
In the accompanying drawing, T indicates the fabric which is diverted immediately downstream of its formation zone by members 1 and 3, the former being convex and the latter concave. Numeral 5 indicates the reed of the sley, designed to intersect the warps 0 to act on the weft deposited in the warp entry, indicated at B.
The present device is mounted on a shaft 7. The shaft 7 can oscillate in synchronism with the working cycles of the machine as shown in FIG. 5 wherein crank C is connected to trace rod R connected to reed 5 pivotably mounted at 5A. On shaft 7 there is mounted on oscillating assembly 9, which follows the movements synchronized with the loom of the shaft 7. On the assembly 9 there is adjustably mounted, by means of bolts 10, a support 12 for a body 14 including means for generating an optical beam (for instance, an infra-red beam) and for the reception of said beam. In particular, the body 14 has two extensions 14A and 14B (see FIG. 4) which are symmetrical with respect to the plane of axial symmetry of the device (indicated by X--X in FIGS. 3 and 4). One of the two extensions e.g. extension 14A carries the optical beam generator L and the other extension 14B carries the receiving and detecting system F of a photo-electric type, the beam extending along the transverse axis indicated by Y--Y. Numeral 15 indicates a connection cable to energize the generator and to receive signals from the photo-electric detector. The oscillating assembly 9 also includes a pair of guide stems 16 extending perpendicularly to axis Y--Y. A slidable unit 18 is slidably mounted for guided movement on stems 16 and for this purpose has two guide extensions 18A, 18B slidingly mounted on the stems 16. Unit 18 includes a head 18C for a wire feeler 20 which is insertable between two warp threads, and a central finned screen 22, which is adapted to extend into the interspace between the two extensions 14A, 14B and thus intercept the optical beam along the axis Y--Y. Thus, when finned screen 22 is located in the position shown in FIG. 2 it blocks passage of the beam to the receiver irrespective of the angular position of the assembly 9. Springs 24 wound on the guide stems 6 urge the slidable unit 18 in the direction of arrow f1, i.e. in the direction to locate the slidable unit in the position of FIG. 2. A thrust force acting in the direction opposite to the arrow f1 (opposite the force of the springs 24) can move the unit into the position of FIGS. 1 and 3. A positionally adjustable stop 26 defines the stop position of unit 18 after displacement thereof in a direction opposite to the arrow f1.
With angular oscillation of the shaft 7, and thus with oscillation of the assembly 9, the wire feeler 20 is moved from the retracted position (FIG. 2) to the insertion position (FIG. 1), wherein the wire 20 penetrates between two contiguous warps and is subjected to the action of the inserted weft and the sley which carries the weft against the interlacing already formed. More specifically, with reference to FIG. 6, therein can be seen the fabric T already formed, as well as the weft W 0 already inserted as last weft into the fabric. The successive weft W, immediately after being laid before the reed 5, is moved thereby in the direction of the arrow f10. When the reed 5 and the weft W are away from the fabric T, i.e. the weft W 0 , the assembly 18, 20 is lowered and the wire 20 is located in back of the weft W 0 . The reed 5 pushes the weft W to the position shown against the wire 20, also moving the assembly 18, 20 to the illustrated position, against the action of the springs 24 urging said assembly in the direction of the arrow f10. When the sley, i.e. the reed 5 is returned in the direction opposite to the arrow f10, the weft W has been already tied by the action of the reversal, i.e. the crossing of the warp yarns 0. This weft W therefore prevents the assembly 20, 18 from being thrust by the springs 24 to follow the reed 5 in the direction of the arrow f12; this is prevented as long as the wire 20 does not move upwardly again and is released from the fabric. If the weft W is not present or is broken, it does not exert the above braking effect, and the assembly 18, 20 is urged by the springs 24 in the direction of the arrow f12, to follow within certain limits the initial movement of the sley 5 in a direction opposite to the arrow f10. This different behavior of the assembly 18, 20 in the presence of and in the absence of the sound weft W causes the production of a signal by the action of the screen 22. In the case of a broken weft, the screen 22 comes into alignment with the extensions 14A, 14B before this would happen in the case of a sound weft, capable then of resisting the thrust of the springs 24. In other words, if the weft is broken or missing, the assembly 18, 20, 22 advances before (rather than after) the wire 20 is lifted. At this state, the slidable unit 18 is moved to the position shown in FIG. 1 wherein the springs 24 are compressed, and the unit 18 is retained by the present weft just inserted and engaged by the warp exchanges. In the absence of the weft or with slackening weft upon the return of the sley from the position of FIG. 1 to the position of FIG. 2 (apart from the angular position of assembly 9), the feeler 20 also retreats, and the unit 18 therewith, back to the position of FIG. 2 with respect to the assembly 9 (not yet raised back). The optical beam between the extensions 14A, 14B is thus intercepted by the finned screen 22, which is in the position of FIG. 2. There is then generated an operational stop signal for the stoppage of the machine due to breakage of the weft or to irregularity in the insertion of the weft. In practice, there may be provided a cam profile on an axle rotating with the loom working cycle, said profile allowing the stopping action in an adjustable set time during a cycle; said allowing action must cease before the wire feeler 20 advances, possible entraining the weft which is only weakly retained by the interlacing of the warps and thus in condition of having a relatively slow advance possibility.
It is contemplated that the drawing only shows an illustration of one embodiment of the invention, which can be varied in form and arrangement without departing from the scope and spirit of the invention. | A weft feeler device for a loom comprising a movable assembly sychronously oscillatable with the loom and carrying a sliding unit on which is mounted a feeler, subjected to the retaining effect of a weft, and a screen. The assembly carries a photo-electric system comprising an optical beam generator and a photo-electric sensor. Upon breakage of a weft thread, the slidable unit is not retained and the screen occupies a position in which it blocks the optical beam. | 3 |
FIELD OF THE INVENTION
This invention relates generally to oil/water emulsion treating methods and apparatuses, and, more particularly, to oil/water emulsion treating methods and apparatuses employing an elongate horizontal separation vessel.
BACKGROUND OF THE INVENTION
Petroleum as it is naturally produced from an underground formation, is in most cases a mechanical mixture of oil, entrained gas and salt water, some of which latter may be present as an oil/brine emulsion. It is desirable, and usually necessary to treat the petroleum thus produced at the wellhead, for the separation and removal of the entrained gas and emulsified brine, in order to render the oil pipelineable. Usually, the separated salt water is pumped back into the formation, in order to assist in maintaining the pressure therein, and also to resolve the salt water disposal problem. Separated gas is vented or flared, if in small quantities, and if in commercial volumes, is delivered to a pipeline for distribution. The equipment used for this three-phase separation is known as a treater, and is generally quite familiar to those to whom the present invention will be addressed.
Such treaters normally involve the heating of the produced petroleum, in order to lower the viscosity of the fluid phase, and also to assist in the separation of the entrained gas. Brine droplets are coalesced either mechanically, as by forcing the emulsion through a series of perforated baffles; or electrostatically as by forcing the emulsion through a high-energy, electrically charged field; or chemically, by means of surface-active chemical agents which reduce the surface tension on the water droplets, thereby allowing them to coalesce into larger drops for separation by gravity. Frequently, two or more coalescing methods are employed in a treater.
Treaters have evolved in design from early developed open vats which maintained the produced petroleum in stationary condition for several days, permitting the entrained gas to freely separate to atmosphere and the salt water to separate to the bottom of the vat by gravity. There evolved heating methods in order to expedite the treatment by reducing the viscosity of the oil, as described. Subsequent development evolved the heater-treater which is the current state-of-the art comprising an elongated enclosed tank having a burner-fired heater section and a downstream treater section for a continuous flow, with a series of perforated baffles positioned within the treater section transversely to the flow of fluids; the perforated baffles function to promote the even distribution over the full cross-sectional area of the treater section of the fluids in motion, and to cause a pressure drop within the fluid across the perforated baffles which results in a release of entrained gases, which then collect in the upper volume of the tank for removal. However, salt water emulsions within the oil have continued to be inefficiently treated by gravity settling and baffling of the flow following heating: thus, further measures have been necessary in order to cause coalescing of the small droplets of brine into larger drops which could be settled out by gravity.
The conventional treatment has the operational disadvantages of being time-consuming, due to the residence-time required in the treater and the requirement that the petroleum be heated to a sufficiently high temperature to reduce the viscosity thereof so that coalescing of the emulsified droplets will be encouraged. The maintenance of a large quantity of oil at a relatively high temperature is costly of energy, and requires the equipment involved to be capable of sustained operation at the temperatures involved.
Treaters in current use are normally tanks in the form of elongated horizontal cylinders divided by means of internal partitions into compartments through which the petroleum will sequentially flow. Burner-fired heaters are normally included in the upstream heater section for heating the emulsion to the desired temperature, during which most of the entrained gas and some of the brine will separate from the emulsion. The partially demulsified brine then flows into a treater section, in substantially gas-free state, encountering a series of baffles adapted to encourage even flow of fluids and to avoid the formation of flow channels within the fluid body, thereby to assist in separation of remaining gases and coalescing of water droplets, and their separation by gravity to the bottom of the tank for ultimate discharge removal.
Various techniques of improvement have heretofore been employed in order to minimize treatment time and heat energy consumption. In my U.S. Pat. No. 4,329,159, “Energy Saving Heavy Crude Oil Emulsion Treating Method and Apparatus for Use Therewith” (which is incorporated herein in its entirety by this reference), there is described a method and apparatus of the type described, additionally including a number of metallic apertured grid electrodes suspended adjacent apertured baffles, the electrodes being supplied with electrical energy. A series of longitudinally spaced electrical fields of high potential are thereby created, which cause droplets of emulsified brine to move in violent random fashion, the droplets coalescing and collecting into drops of sufficient weight as to fall by gravity to the lower portion of the treater section for removal.
In my U.S. Pat. No. 4,919,777, “Electrostatic/Mechanical Emulsion Treating Method and Apparatus” (which is incorporated herein in its entirety by this reference), there is described an improved method and apparatus of this type, wherein, immediately downstream of the apertured grid electrodes, the flow is directed downwardly through a plurality of inclined open-ended tubes arranged in bundle-fashion.
Unfortunately, most such prior art methods and the apparatuses are inherently inflexible in operation. The apparatuses are designed for a narrow range of operating parameters, such as flow rate, oil/water ratio, salinity, temperature, viscosity, etc. After the apparatuses are manufactured and installed, they are only effective when operating within these narrow design operating ranges. When operating conditions change, an entirely new apparatus must be designed, built and installed. This is a special problem for crude oil producers, because crude oil/water emulsions produced in an oil field can vary dramatically from well to well, and even within the same well from day to day.
Accordingly, there is a need for further improvements in methodology and apparatuses which will overcome these problems in the prior art.
SUMMARY
The invention satisfies this need. The invention is an emulsion separating treater comprising: (a) a generally horizontally elongate enclosed tank having a longitudinal axis, a first end and an opposed second end, (b) an emulsion inlet port, (c) an oil outlet port and a water outlet port, (d) a louver stack located within the tank between the oil inlet port and the oil outlet port, the louver stack being disposed perpendicular to the longitudinal axis of the tank and comprising a plurality of at least four parallel plates each having an upstream edge and a downstream edge, adjoining upstream edges defining a plurality of generally horizontal inlet openings and adjoining downstream edges defining a plurality of generally horizontal outlet openings, and (e) an adjustment mechanism for adjusting the opening widths from outside of the tank.
DRAWINGS
These features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying figures where:
FIG. 1 is a perspective view of the preferred embodiment apparatus of the invention, with a longitudinal portion thereof cut away to illustrate the interior of the apparatus;
FIG. 2 is an end view of the apparatus of FIG. 1 depicting the heater section;
FIG. 3 is a top plan view of the apparatus of FIG. 1 with a portion cut away to illustrate the position of the several components and the location of certain outlets;
FIG. 4 is a longitudinal cross-sectional view of the apparatus of FIG. 1;
FIG. 5 is an isometric detail view of a louver stack useful in the invention;
FIG. 6 is a diagrammatic side view of a louver stack useful in the invention; and
FIG. 7 is a diagrammatic front view of a louver stack useful in the invention.
DETAILED DESCRIPTION
The following discussion describes in detail one embodiment of the invention and several variations of that embodiment. This discussion should not be construed, however, as limiting the invention to those particular embodiments. Practitioners skilled in the art will recognize numerous other embodiments as well.
The invention is an emulsion separating treater 10 useful for separating water droplets from an oil/water emulsion. The treater 10 comprises an elongate horizontal tank 12 having disposed therein one or more louver stacks described in greater detail below.
The tank 12 is a fully enclosed vessel, typically made from a steel. The tank is elongate and generally disposed in the horizontal. The tank has a first end 16 , an opposed second end 18 and a longitudinal axis 20 .
In the embodiment illustrated in the drawings, a two-stage heater section 22 is disposed proximate to the first end 16 of the tank 12 and a treater section 24 is disposed proximate to the second end 18 of the tank 12 . A transverse bulkhead 26 separates the tank 12 into these two functional sections 22 and 24 . A longitudinal bulkhead 28 extends from the first end 16 of the tank 12 to the transverse bulkhead 26 thereby defining a first longitudinally extending heater compartment 30 and a second longitudinally-extending heater compartment 32 , situated side-by-side and connected in series. The longitudinal bulkhead 28 has an upper opening 54 and a lower opening 56 , both located adjacent the first end 16 of the tank 12 .
Within the two heater compartments 30 and 32 are substantially identical first and second heaters 34 and 36 , respectively. Each heater 34 and 36 has a tubular lower leg 38 , a tubular upper leg 40 and a U-shaped end connector 42 . The lower leg 38 of each heater 34 and 36 extends through the first end 16 of the tank 12 . The upper leg 30 of each heater 34 and 36 is connected in fluid tight communication to a stack 44 which extends upwardly outside of the tank 12 . The temperature of the emulsion is monitored and controlled in the first heater section 34 by a first temperature sensor/controller 46 and in the second heater compartment 32 by a second temperature sensor/controller 48 .
The tank 12 comprises an emulsion inlet port 50 through which emulsion can be delivered continuously into the heater section 22 . The emulsion inlet port 50 desirably has a normally-open manually operated inlet valve 52 associated therewith.
In the embodiment illustrated in the drawings, the transverse bulkhead 26 is divided by the longitudinal bulkhead 28 into a left half 58 and a right half 60 . The left half 58 is solid, while the right half 60 has a lower opening 62 , an upper opening 64 and an intermediate opening 66 defined therein.
Disposed within the treater section 24 is at least one louver stack 68 disposed perpendicular to the longitudinal axis 20 of the tank 12 . The louver stack 68 comprises a plurality of at least four parallel plates 70 . Each parallel plate 70 has an upstream edge 72 and a downstream edge 74 . The distance between the upstream edge 72 and the downstream edge 74 of each plate 70 (i.e., the width of each plate 70 ) is between about 6 inches and about 36 inches, typically between about 16 inches and about 20 inches. Adjoining upstream edges 72 of the parallel plates 70 define a plurality of generally horizontal inlet louver openings 76 through which an oil/water emulsion flowing through the tank 12 must pass. Similarly, adjoining downstream edges 74 of the parallel plates 70 define a plurality of generally horizontal outlet louver openings 78 from which emulsion passing through the louver stack 68 must exit the louver stack 68 . Each of the plates 70 is inclined downwardly so that each inlet louver opening 76 is at an elevation slightly higher than its corresponding outlet louver opening 78 . By this design, emulsion flowing into each inlet louver opening 76 is diverted downwardly as it passes through the louver stack 68 .
Typically, the louver plates 70 are made from a metal, such as a steel. The louver openings 76 and 78 are typically 0.25 inches to 1.75 inches when maximized. The number of plates 70 in each louver stack 68 will depend upon the diameter of the tank 12 . For a 6 foot diameter tank, the typical number of plates 70 in each louver stack 68 is 70-80. In a 12 foot diameter tank 12 , the typical number of plates 70 in each louver stack 68 is 125-150.
Some or all of the parallel plates 70 within the louver stack 68 are movable with respect to adjacent plates 70 so that the width of at least some of the louver openings 76 and 78 are adjustable from outside the tank 12 . This can be accomplished in many different ways. In the embodiments illustrated in FIGS. 6-7, this is accomplished by making each of the plates 70 pivotable about horizontal axes 80 disposed between the upstream edge 72 and the downstream edge 74 of each plate 70 . As best seen in FIG. 6, to narrow the flow path through the louver stack 68 , every other plate 70 is pivoted clockwise, while the remaining plates 70 are pivoted counterclockwise. By this action, half of the inlet louver openings 76 and half of the outlet louver opening 78 are narrowed.
FIG. 7 illustrates a push/pull rod mechanism 82 for adjusting the louver opening widths from outside the tank 12 . In FIG. 7, a push/pull rod 84 is movable in a left/right direction. The distal end 86 of the push/pull rod 84 is attached to a rocker arm 88 which pivots about a pivot axis 90 . The rocker arm 88 has a control arm 92 and a pair of oppositely disposed operation arms. In the drawings, these operation arms are designated as first operation arm 94 and second operation arm 96 . At the distal end 98 of the first operation arm 94 , a first connecting rod 100 extends upwardly and attaches to the downstream edges 74 of alternating plates 70 in the louver stack 68 . At the distal end 102 of the second operation arm 96 , a second connecting rod 104 extends upwardly and attaches to the downstream edges 74 of the remaining plates 70 in the louver stack 68 . Thus, when the push/pull rod 84 is slid to the right in FIG. 7, the rocker arm 88 is rotated in a counterclockwise direction, thereby pushing the second connecting rod 104 upward and pulling the first connecting rod 100 downward. By this operation, the first and second connecting rods 100 and 104 draw alternating adjacent pairs of the upstream edges 72 and the downstream edges 74 of the plates 70 closer together, thereby causing the widths of one half of the louver openings 76 and 78 to narrow. To re-widen the widths of the louver openings 76 and 78 , the push/pull rod 84 is slid back to the left, towards the original orientation illustrated in FIG. 7 . Alternatively, a similar push/pull rod mechanism 82 can be attached to the upstream edge 72 of each plate 70 . In such a design, the operation of the push/pull rod mechanism 82 would be the same as described above, except it would operate in reverse.
In a typical embodiment of the invention 10 , the louver openings 76 and 78 are adjustable by at least 0.5 inches. Preferably, the louver openings 76 and 78 are continually adjustable from a full open position to a fully closed position.
Typically, the apparatus 10 will comprise a plurality of spaced apart louver stacks 68 which define a plurality of discrete demulsifying units 108 disposed in series within the treater section 24 . The embodiment illustrated in FIGS. 1-4 has five demulsifying units 108 . The treater 10 may contain any desired number of demulsifying units 108 and such specific configurations will normally be determined by the characteristics of the emulsion to be treated.
Preferably, an electrostatic field inducer 110 , such as an electrostatic grid, is transversely disposed in vertical alignment immediately upstream of each louver stack 68 . The electrostatic field inducers 110 are supported from the tank 12 by conventional electrical insulating means (not shown). An electrical current-supplying transformer (not shown) supplies high voltage to the electrostatic field inducers 110 . The electrostatic field inducers 110 impart an electrostatic charge to the water component of the emulsion as it passes through the electrostatic field inducers. Such electrostatic charge facilitates the separation of water from oil in the emulsion as the emulsion passes through the grounded louver stack 68 .
Proximate to the second end 18 of the tank 12 , an angularly disposed baffle 112 extends inwardly into tank 12 and is connected at its inner edge to a vertical transverse baffle 114 having an upper horizontal edge. The upper horizontal edge of the transverse baffle 114 acts as an oil weir 116 and determines the depth of the emulsion throughout the apparatus 10 . Baffles 112 and 114 , together with the interior surface of tank 12 adjacent the second end 18 of the tank 12 , cooperate to define a reservoir 118 into which substantially brine-free oil is discharged.
The transverse baffle 114 serves a three-fold purpose: first, it automatically maintains the liquid level within the sections 22 and 24 at a desired depth; second, it prevents commingling of brine and gas-free oil within the reservoir 118 with the emulsion being treated in the treater section 24 ; and third, it allows gas and brine-free oil to be withdrawn from the reservoir 118 without affecting the liquid level of emulsion in the heater section 22 and in the treater section 24 .
The second end 18 of the tank 12 also has a gas outlet 120 , a brine-free oil outlet 122 and a brine outlet pipe 124 positioned therein. The gas outlet 120 extends by its vertical standpipe 126 into a gas zone 128 in the upper portion of the tank 12 . The brine outlet pipe 124 extends into the lower interior of the tank 12 and is ported for ingress of the brine for continuous discharge to exterior brine removal facilities (not shown).
A number of inverted, longitudinally-spaced boxes 130 extend longitudinally along the interior bottom portion of tank 12 . The boxes 130 have openings 132 in the sides thereof through which sand and silt (not shown) may flow to the interior thereof. The interior of each box 130 is connected to a first slurry conduit 134 that extends outwardly through the tank 12 to a valve 136 . Second slurry conduits 138 are connected to each valve 136 and extend to a header 140 adapted to carry settled particulate solids as a slurry when the valves 136 are opened to pressures substantially lower than that within the tank 12 . This permits the accumulated sand (with some brine) to be flushed to a disposal site.
In operation, the first and second heaters 34 and 36 supply heat to the heater compartments 32 and 34 at the first end 16 of the tank 12 . An oil/water emulsion sequentially flows into the tank 12 , via the emulsion inlet port 50 , through the two heater compartments 32 and 34 and thence into the treater section 24 . The horizontal flow is at a relatively slow flow rate on the order of one-quarter foot to one foot per minute.
The heat supplied by the first heater 34 as the emulsion flows along the upper leg 40 of the first heater 34 is typically only that necessary to lower the viscosity of the emulsion to the extent free gas and free brine separate therefrom. Free gas escapes from the emulsion at this point and the density of the emulsion decreases. The emulsion then flows downwardly and then longitudinally within the first heater 34 towards the second end 18 of the tank 12 . The temperature of the emulsion is further increased due to the heating effect of the lower leg 38 of the first heater 34 , thereby freeing additional gas and brine from the emulsion.
The gas released in the first heater compartment 30 flows through the upper opening 54 in the longitudinal bulkhead 28 into the upper portion of the second heater compartment 32 . Water that separates from the emulsion in the first heater compartment 30 flows transversely through the lower opening 56 in the longitudinal bulkhead 28 into the second heater compartment 32 , together with the partially heated emulsion.
As emulsion flows through the second heater compartment 32 , it is further heated by the second heater 36 . Such further heating is typically only sufficient to lower the viscosity of the emulsion to the point where the remaining dissolved gas is separated from the emulsion. The temperature in the second heater compartment 32 also lowers the viscosity of the emulsion to the extent that a portion of the emulsified brine separates from the emulsion. The separated emulsified brine coalesces into droplets that flow by gravity downwardly to the bottom portion of the second heater compartment 32 and merge with the brine that has flowed to the lower portion of the second heater compartment 32 from the first heater compartment 30 .
Emulsion that is substantially free of gas but still contains a substantial quantity of emulsified brine next flows through the intermediate opening 66 in the transverse bulkhead 26 into the treater section 24 . Gas flows from the second heater compartment 32 into the upper portion of the treater section 24 through the upper opening 64 in the transverse bulkhead 26 . Brine that is collected in the lower portion of the heater section 22 flows through the lower opening 62 in the transverse bulkhead 26 into the lower portion of the treater section 24 . It will be appreciated that the flow of gas, brine and emulsion is substantially horizontal, thereby offering low resistance to the rise of gas bubbles and the falling of brine droplets.
In the treater section 24 , the emulsion flows to the region of the first demulsifying unit 108 . Here, the emulsion passes through the first electrostatic grid 110 , where the brine droplets are subject to high potential electrostatic fields surrounding the electrodes, and take on an electrostatic charge therefrom. When so charged, these droplets rapidly move about repelling, attracting and colliding with one another, in energetic action since all droplets receive a charge, regardless of size. Droplets collide with sufficient energy to overcome the emulsifying forces, and combine into larger drops.
Immediately downstream of the first electrostatic grid 110 , movement of the emulsion progresses to the first louver stack 68 . The emulsion enters the first louver stack 68 through the inlet louver opening 76 . Within the first louver stack 68 , the electrified emulsion contacts the grounded metal plates 70 and adhesion of the electrified brine droplets occurs. At the metal plates 70 , the brine droplets lose their charge and trickle downwardly towards the outlet louver openings 78 and then fall by gravity to the bottom of the tank 12 . Also, the deposition of minute brine particles upon the plate 70 causes other droplets to coalesce therewith, thus producing minor streams which trickle downwardly by gravity to the bottom of the tank 12 .
The emulsion then continues downstream through successive demulsifying units 108 . In each successive demulsifying unit 108 , more and more of the brine within the emulsion is removed.
As brine is removed from the emulsion, the resulting demulsified oil is of lesser density than the emulsion and rises to the top of the emulsion for accumulation as an upper strata of oil. The upper strata of oil is free of gas and brine. As the emulsion continues to be supplied to the heater section 22 , the liquid level rises in the treater section 24 , causing the oil, free of gas and brine, to flow over the weir 116 into the reservoir 118 from which it may be either intermittently or continuously withdrawn without disturbing the liquid level of the emulsion being treated in the treater section 24 .
The apparatus 10 maintains a gas-emulsion interface in the treater section 24 and a water-emulsion interface at a predetermined level in the lower portion of the treater section 24 , thereby facilitating uniform operation of the treater 10 for continuous feed conditions.
The invention provides the operator with the ability to slow down the flow rate (or, conversely, speed up the flow rate) to maximize the efficiency of the apparatus 10 depending upon changes in the characteristics of the emulsion feed stream. The operator can easily manipulate the flow rate through the apparatus 10 from outside the tank 12 by reducing or expanding the width of the louver openings 76 and 78 within the louver stacks 68 .
It will be understood by those familiar with the art that under certain conditions, it may be unnecessary to employ electrostatic charging of the emulsion. Moreover, it will be understood by those familiar with the art that under other certain conditions, it may be unnecessary to employ heating at the upstream end of the apparatus 10 .
The invention provides the operator with the ability to accommodate a wide range of A.P.I. gravities of crude oil emulsion, and provides the operator with the ability to deal with emulsions of other differing characteristics, such as differing viscosity characteristics. The invention further provides the operator with the ability to accommodate differing input rates to the apparatus, and gives the operator the ability to accommodate surging emulsion input flow rates. The invention still further gives the operator an opportunity to dislodge occasional plugging problems within the demulsifying units. The invention also provides the operator with the ability to correct miscalculations and misassumptions in the initial design of the apparatus components.
Having thus described the invention, it should be apparent that numerous structural modifications and adaptations may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove and as described hereinbelow by the claims. | A treater for electrostatically and/or mechanically separating emulsified brine from oil during longitudinal flow through a horizontally elongate metal tank. Emulsion is directed through a louver stack made up of a large number of inclined parallel plates. The openings on the upstream end and on the downstream end of this louver stack are adjustable from outside of the metal tank, so as to allow the operator to adjust the flow rate through the treater as operating parameters change. | 1 |
TECHNICAL FIELD
[0001] This invention relates generally to low temperature or cryogenic refrigeration and, more particularly, to the operation of a cryocooler.
BACKGROUND ART
[0002] Cryocoolers are employed to generate refrigeration and to provide that refrigeration for applications such as high temperature superconductivity and magnetic resonance imaging. Failure of the cryocooler can have severe consequences for such application systems. It is desirable therefore to operate a cryocooler so as to avoid the failure of the cryocooler while it is on line.
[0003] Accordingly, it is an object of this invention to provide a method for operating a cryocooler so as to reduce or eliminate the likelihood of the cryocooler failing while it is on line and providing critical refrigeration to an application such as a magnetic resonance imaging system or a high temperature superconductivity application.
SUMMARY OF THE INVENTION
[0004] The above and other objects, which will become apparent to those skilled in the art upon a reading of this disclosure, are attained by the present invention which is:
[0005] A method for operating a cryocooler for providing refrigeration to a refrigeration load comprising:
(A) generating refrigeration by operating a cryocooler having a regenerator, a cold heat exchanger and a thermal buffer tube; (B) monitoring temperature trending of at least one of the regenerator, the cold heat exchanger, the thermal buffer tube and the refrigeration load, and employing the temperature trending to calculate a service time; and (C) servicing the cryocooler if the calculated service time is less than a predetermined value.
[0009] As used herein the term “temperature trending” means temporal temperature such as, for example, rate of temperature change, circumferential temperature variation, or temperature profile.
[0010] As used herein the term “service time” means the time remaining for a component before it needs maintenance or replacement.
[0011] As used herein the term “regenerator” means a thermal device in the form of porous distributed mass or media, such as spheres, stacked screens, perforated metal sheets and the like, with good thermal capacity to cool incoming warm gas and warm returning cold gas via direct heat transfer with the porous distributed mass.
[0012] As used herein the term “thermal buffer tube” means a cryocooler component separate from the regenerator and proximate the cold heat exchanger and spanning a temperature range from the coldest to the warmer heat rejection temperature for that stage.
[0013] As used herein the term “indirect heat exchange” means the bringing of fluids into heat exchange relation without any physical contact or intermixing of the fluids with each other.
[0014] As used herein the term “direct heat exchange” means the transfer of refrigeration through contact of cooling and heating entities.
[0015] As used herein the term “frequency modulation valve” means a valve or system of valves generating oscillating pressure and mass flow at a desired frequency.
BRIEF DESCRIPTION OF THE DRAWING
[0016] The sole FIGURE is a schematic representation of one preferred embodiment of a cryocooler system which may be employed in the practice of this invention.
DETAILED DESCRIPTION
[0017] In general the invention is a method for operating a cryocooler using temperature trending as a diagnostic tool to provide advance warning of a cryocooler system failure or degradation which facilitates timely intervention to service or replace one or more components of the cryocooler before the operation of the application receiving the refrigeration from the cryocooler is compromised.
[0018] The FIGURE illustrates one preferred embodiment of a cryocooler which will benefit from the practice of this invention. Referring now to the FIGURE, cryocooler working gas, such as helium, neon, hydrogen, nitrogen, argon, oxygen and mixtures thereof, with helium being preferred, is compressed in oil flooded compressor 1 . The compressed working gas is passed in line 10 to coalescing filter or filters 2 which is part of the oil removal train which also includes adsorptive separator 3 and ultrafine filter 4 . The working gas passes from coalescing filter 2 to adsorptive separator 3 in line 11 , and from adsorptive separator 3 to ultrafine filter 4 in line 12 .
[0019] Coalescing filter 2 removes oil droplets and mist, and adsorptive separator bed 3 removes oil vapor. Ultrafine filter 4 removes any remaining micro particulates and extra fine oil mist. At the end of the oil removal train, the oil related impurity or contamination level of the working gas in line 13 is less than 1 ppbv. Typical bed materials for the adsorptive bed 3 could be a zeolite, activated carbon and alumina. Heat of compression from the working gas is removed in an aftercooler 5 which may be located anywhere between the frequency modulation valve 15 and compressor discharge line 11 . Rotary frequency modulation valve 15 connects clean discharge 14 or suction 19 of the compressor with line 18 to produce necessary oscillations to drive the coldhead. The rotary valve is driven by a motorized system (not shown). The operating frequency of the cryocooler may be up to the range of from 50 to 60 hertz, although it is typically less than 30 hertz, preferably less than 10 hertz, and most preferably less than 5 hertz.
[0020] The pulsing working gas applies a pulse to the hot end of regenerator 20 thereby generating an oscillating working gas and initiating the first part of the pulse tube sequence. The pulse serves to compress the working gas producing hot compressed working gas at the hot end of the regenerator 20 . The hot working gas is cooled, preferably by indirect heat exchange with heat transfer fluid 22 in heat exchanger 21 , to produce warmed heat transfer fluid in stream 23 and to cool the compressed working gas of the heat of compression. Examples of fluids useful as the heat transfer fluid 22 , 23 in the practice of this invention include water, air, ethylene glycol and the like. Heat exchanger 21 is the heat sink for the heat pumped from the refrigeration load against the temperature gradient by the regenerator 20 as a result of the pressure-volume work generated by the compressor and the frequency modulation valve.
[0021] Regenerator 20 contains regenerator or heat transfer media. Examples of suitable heat transfer media in the practice of this invention include steel balls, wire mesh, high density honeycomb structures, expanded metals, lead balls, copper and its alloys, complexes of rare earth element(s) and transition metals. The pulsing or oscillating working gas is cooled in regenerator 20 by direct heat exchange with cold regenerator media to produce cold pulse tube working gas.
[0022] Thermal buffer tube 40 and regenerator 20 are in flow communication. The flow communication includes cold heat exchanger 30 . The cold working gas passes in line 60 to cold heat exchanger 30 and in line 61 from cold heat exchanger 30 to the cold end of thermal buffer tube 40 . Within cold heat exchanger 30 the cold working gas is warmed by indirect heat exchange with a refrigeration load thereby providing refrigeration to the refrigeration load. This heat exchange with the refrigeration load is not illustrated. One example of a refrigeration load is for use in a magnetic resonance imaging system. Another example of a refrigeration load is for use in high temperature superconductivity.
[0023] The working gas is passed from the regenerator 20 to thermal buffer tube 40 at the cold end. Preferably, as illustrated in the FIGURE thermal buffer tube 40 has a flow straightener 41 at its cold end and a flow straightener 42 at its hot end. As the working gas passes into thermal buffer tube 40 it compresses gas in the thermal buffer tube and forces some of the gas through heat exchanger 43 and orifice 50 in line 51 into reservoir 52 . Flow stops when pressures in both the thermal buffer tube and the reservoir are equalized.
[0024] Cooling fluid 44 is passed to heat exchanger 43 wherein it is warmed or vaporized by indirect heat exchange with the working gas, thus serving as a heat sink to cool the compressed working gas. Resulting warmed or vaporized cooling fluid is withdrawn from heat exchanger 43 in stream 45 . Preferably cooling fluid 44 is water, air, ethylene glycol or the like.
[0025] In the low pressure point of the pulsing sequence, the working gas within the thermal buffer tube expands and thus cools, and the flow is reversed from the now relatively higher pressure reservoir 52 into the thermal buffer tube 40 . The cold working gas is pushed into the cold heat exchanger 30 and back towards the warm end of the regenerator while providing refrigeration at heat exchanger 30 and cooling the regenerator heat transfer media for the next pulsing sequence. Orifice 50 and reservoir 52 are employed to maintain the pressure and flow waves in appropriate phase so that the thermal buffer tube generates net refrigeration during the compression and the expansion cycles in the cold end of thermal buffer tube 40 . Other means for maintaining the pressure and flow waves in phase which may be used in the practice of this invention include inertance tube and orifice, expander, linear alternator, bellows arrangements, and a work recovery line connected back to the compressor with a mass flux suppressor. In the expansion sequence, the working gas expands to produce working gas at the cold end of the thermal buffer tube 40 . The expanded gas reverses its direction such that it flows from the thermal buffer tube toward regenerator 20 . The relatively higher pressure gas in the reservoir flows through valve 50 to the warm end of the thermal buffer tube 40 . In summary, thermal buffer tube 40 rejects the remainder of pressure-volume work generated by the compression and frequency modulation system as heat into warm heat exchanger 43 .
[0026] The expanded working gas emerging from heat exchanger 30 is passed in line 60 to regenerator 20 wherein it directly contacts the heat transfer media within the regenerator to produce the aforesaid cold heat transfer media, thereby completing the second part of the cryocooler refrigeration sequence and putting the regenerator into condition for the first part of a subsequent cryocooler refrigeration sequence. Pulsing gas from regenerator 20 passes back to rotary valve 15 and in suction conduit 19 to compressor 1 .
[0027] The performance of the cryocooler may degrade with time. The degradation or change in performance could be due to contamination and associated freezing, cold plunger and associated equipment failure in the coldhead, and damage to other internal coldhead hardware. The contamination could be due to failure or equipment sub-performance in the oil removal train, impure working gas supply, air leakage through the flanges, off gassing of the components especially elastomers and plastics, or products from oil degradation. As a result the temperature of cold heat exchanger 30 degrades with time. The rate of degradation could be different depending on the causes in play. For example, it will be different for freezing of different contaminants and their respective amounts. Some contaminants such as hydrogen could freeze within the cold heat exchanger 30 , cold end of the regenerator 20 or cold end of the thermal buffer tube 40 ; however moisture will freeze close to the warm end of regenerator 20 if it enters into the system while the cryocooler is operating. The same moisture could accumulate at colder locations if present before the cryocooler started its operation. In addition various failures will also impact the cryocooler performance differently. This phenomenon is captured only by observing the rate of change within a meaningful time interval (critical time interval τ critical ).
[0028] Temperatures may be measured using temperature probes such as thermocouples, diodes and the like. These probes could be mounted on the surface of the equipment. The signal from the probes may be received by temperature reading equipment that could stand alone or be computer driven. The signal is interpreted by the temperature reading equipment as a temperature value or values. A data acquisition system connected to this temperature reading equipment logs and/or plots the data as a function of time. The data is preferably plotted in a graphical form to help visualization.
[0029] The following graph depicts a noisy temperature signal and τ critical in a pictorial manner.
In the case where the cryocooler under its design load operates at a temperature T c and the maximum temperature that could be tolerated for the operation of a superconducting system is T h , one can define the cryocooler operating window as between T c and T h . The invention uses the time-averaged rate of temperature change to monitor the system. The time averaged temperature change is defined by
〈 ⅆ T ⅆ t 〉 τ critical
and the time averaging eliminates measurement noise. If
〈 ⅆ T ⅆ t 〉 τ critical
is negative then, the diagnostics system provides warning to the operator or control system to ensure that the cryogenic system does not get colder than T c .
[0030] If
〈 ⅆ T ⅆ t 〉 τ critical
is positive—i.e., the system is warming, then the estimated time to service is given by the following formulas
Δ t service = ( Th - T ) 〈 ⅆ T ⅆ t 〉 τ critical
[0031] The following graph depicts a temperature data and Δt service in a pictorial manner.
For example, in a cryocooler application where Tc and Th are 20 and 30K, respectively, at time t, the cryocooler cold heat exchanger temperature T is 24K at constant heat load. The operator or control system measured T=23.8K at time t=−20 h. The service time is calculated as follows:
〈 ⅆ T ⅆ t 〉 τ critical = ( 24 - 23.9 ) / 20 = 0.005 K / h then Δ t service = ( 30 - 24 ) / 0.005 = 1200 h or 1200 / 24 = 50 days .
If the calculated service time is larger than 100 days, then nothing is required. If the calculated service time between 10-100 days, check other influential cryocooler parameters such as pressure, pressure drops and other diagnostic data available to warn the operators to closely watch the cryogenic system. If the calculated service time is less than 10 days, make necessary changes while system is running. If the trend does not reverse, then replace or repair the coldhead or the pressure wave generation system. Additionally, the cryocooler may be serviced when
( T h −T )≦0.1( T h −T c ).
[0032] Other temperature readings than cold heat exchanger 30 temperature could also be used for monitoring purpose. For example the temperature of the refrigeration load could be monitored. Also, the circumferential temperature variation of the regenerator 20 could provide information on onset of flow maldistribution within the regenerator. Preferably temperatures are monitored at the mid-axial location of the regenerator.
[0033] The following graph shows a profile of an ideal regenerator and one with a maldistribution. Corresponding midpoint temperature profiles are also depicted.
[0034] Additionally, the change in thermal buffer tube 40 axial temperature profile can also be a very good diagnostic tool. The ideal thermal buffer tube temperature profile in pulse tube geometry is linear as shown in graph below. When a cryocooler develops problems this profile deviates from the ideal or initial profile as shown, thus the thermal buffer tube temperature would be different than its ideal or initial value.
[0035] The displacer type thermal buffer tube in cryocooler exhibit different temperature profile that can also be used as diagnostic tool as shown in the graph below. Typical temperature profile is drawn as initial and the profile will shift as the displacer seals wear with time. Normalized remaining life as a function of temperature T* at a prescribed location L* is also drawn. This temperature could be used to predict when the cryocooler displacer and seals should be serviced.
[0036] Although the invention has been described in detail with reference to certain preferred embodiments, those skilled in the art will recognize that there are other embodiments of the invention within the spirit and the scope of the claims. | A method for operating a cryocooler which provides opportunity for timely intervention prior to failure thus enhancing the reliability of the provision of the refrigeration wherein temperature trending of at least one cryocooler component or the refrigeration load is monitored and used to calculate a service time. | 5 |
[0001] The invention refers to a machine tool with a work spindle which has a tool supply which has tool tongs for receiving machining tools, a relative movement between tool magazine and work spindle being provided for exchanging, respectively replacing, machining tools on the work spindle.
BACKGROUND OF THE INVENTION
[0002] So-called one-spindle machine tools are sufficiently known. Also multi-spindle machine tools are known. In these in a machine tool a work spindle is provided. The machine tools of this type are often used for cutting machining. The advantage of these machine tools is the high cutting capacity.
[0003] For replacing, respectively exchanging, machining tools on the work spindles a procedure known as “pick-up technique” is used. It is known to design the tool magazine stationary for the tool change procedure, and the work spindle moves towards the tool magazine. For putting-in or removing the tool a relative movement between the tool magazine disc and the work spindle is required, which is derived, for example, from the movement of the work spindle.
[0004] A machine tool of the kind described before is designed, for example, as two-spindles machine tool with two-disc magazine. A machine tool is provided here where on one machine column two headstocks are provided with one work spindle each which can be shifted independently of each other in vertical and horizontal direction. On the top surface of the machine column there is a tool storage comprising two disc or plate magazines independent of each other and arranged close to each other. The disc or plate magazines have tongs-like receivers for holding machining tools. These two-spindles machine tools, however, are considerable more expensive to manufacture and to maintain then one-spindle machines.
[0005] Another device for machining work pieces is known from the state of the art. This device has a stand on which at least one spindle head with a work spindle is supported which can be adjusted in at least one direction. The device also has at least one tool change magazine from which tools can be taken and in which tools can be deposited.
[0006] In the state of the art a machine tool is known. In this machine tool with a one- or multi-spindle unit for picking up tools which can be shifted in preferably three directions of axis, as well as with a tool magazine, the tool magazine and the one- or multi-spindle unit can be moved in order to change the tools at least at times simultaneously relatively to each other.
[0007] For an application of the machine tool as efficient as possible it is known to provide tool magazines which pick up tools redundantly, in order, for example, to exclude an interruption of the machining when the tools are worn. Of course, the tool magazine also serves for providing a plurality of different machining tools for different machinings on the work spindle.
[0008] Machine tools of this kind therefore have to be designed in such a way that a number of machining tools as high as possible is available.
BRIEF ABSTRACT OF THE INVENTION
[0009] It is an object of the invention to provide machine tools as described in the beginning, which have a density of tools in their tool magazines as high as possible.
[0010] The problem according to the invention is solved, as described above, by a machine tool which has only one work spindle which carries and drives a machining tool which can be exchanged, as well has a tool supply which has tool tongs for receiving machining tools. Even with such an alternative machine tool a relative movement between tool magazine and work spindle is provided for exchanging, respectively replacing, machining tools at the work spindle. In order to solve the problem according to the invention it is suggested here that the tool supply is shared out between at least two partial magazines. Eventually it is decisive to optimise the available circumference while the surface or the extension of the tool supply is as minimal as possible. It is therefore more convenient to share out the tool supply between two partial magazines then to realise the complete surface in one magazine. The result are clearly smaller partial units which can be handled easier and which can be also manufactured more economically. The suggestion optimises the available number of tongs considerably.
[0011] In a modification it is suggested here that the partial magazine is designed as a tool magazine disc rotating around a rotational axis. According to this variant it is suggested to use in the same way a tool magazine disc as partial magazine in the sense of this part of the invention.
[0012] The single work spindle may be designed here mobile in such a way that it can reach the respective partial magazines distanced from each other. In the sense of the invention it is possible here to design the partial magazine either as tool magazine disc or even as chain magazine or the like. Here, for example, the anyway present, big lifting movement of suitable machine tools during the tool change is used again in order to reach the partial magazines far away.
[0013] Alternatively it is, of course, also possible that the partial magazines can be shifted and be brought to the work spindle in order to carry out the tool change.
[0014] It is convenient that the partial magazines are arranged above the work spindle. However, they may also be arranged on the side of the work spindles or below them. In this respect the invention is not limited. Furthermore all other references and also all other possible combinations of features go for this part of the invention; it is, in particular, possible to arrange tool tongs radially or at a certain angle on the partial magazines designed as tool magazine disc.
[0015] The problem is also solved by a machine tool as described, and it is provided there that the tongs axis of the tool tongs is arranged on the respective tool magazine disc radially, respectively the tongs axis forms an acute angle alpha with the connection line between the rotational axis and the tool magazine disc, and the tool axis of the machining tool resting in the tool tongs.
[0016] The tool tongs is formed by a receiver which interacts with the shank of the machining tool. Furthermore suitably designed holding devices are provided which guarantee that the machining tool is held securely in the tool tongs and cannot fall out unintentionally. The tool tongs here do not require necessarily two tongs claws interacting with each other, the term tool tongs is meant rather as generic term describing every possibility of picking up and holding machining tools in the tool magazine discs of the machine tools of this kind.
[0017] The tool tongs have a certain longitudinal extension. This longitudinal extension is often also the symmetric axis of the tool tongs. In this respect the main direction of this longitudinal extension is seen as tongs axis which coincides in a special modification of the invention with the symmetric axis of the tool tongs. Therefore, however, the tongs axis is defined in such that the tool axis, that is the rotational axis of the machining tool and the center of gravity of the tool tongs are part of the tongs axis.
[0018] The tool tongs is here designed so slim that it tapers accordingly to the inside, that is away from the machining tool, so that the arrangement of the machining tool on the circumference of the tool magazine disc is carried out in a density as high as possible as by providing a high number of tool tongs, of course, also a high number of machining tools can be stored on the tool magazine disc.
[0019] A similarly advantageous arrangement is also the one where the tongs axis forms an acute angle with the connection line between the rotational axis of the tool magazine disc and the tool axis of the machining tool resting in the tool tongs. A certain tilting in the direction of the respective tangent (relative to the rotational axis) reduces unmeasurably the storage capacity of the tool magazine disc for tools, however, offers certain advantages for loading and unloading the tools in the spindle. In particular, if the spindles are positioned close to each other it is also possible by means of such an arrangement to exchange simultaneously the tools of several spindles.
[0020] The invention here makes several different constructive suggestions. First of all, it is possible that the machine tool according to the invention provides for at least two machining spindles two (or even more) tool magazine discs. Conveniently the work spindles here are shared out between a suitable number of work spindle groups, the number of these groups corresponds with the number of tool magazine discs.
[0021] In the sense of the invention it is irrelevant here whether the number of work spindles per group is identical or differs. Both variants are possible here.
[0022] Compared with the solutions known from the state of the art the invention has the advantage that a tool change is made considerably easier by the particular way of arrangement in the tool magazine, in particular the storing in specially designed and specially arranged tool tongs. The tool change is carried out essentially faster and has the advantage to be little prone to malfunctions. In the solutions known from the state of the art the tool receivers are either designed only tongs-like, or they have tongs which are arranged for a change in an inconvenient manner, or they themselves are designed in such a way that the tool change is only possible in certain positions. This procedure is quite expensive and frequently leads to malfunctions. Additionally the loss of time is considerable through this procedure. The invention removes the described disadvantages by arranging the tongs axis of the tool tongs on the respective tool magazine disc radially, respectively by the fact that the tongs axis forms an acute angle with the connection line between the rotational axis of the tool magazine disc and the tool axis of the machining tool resting in tool tongs. The solutions known from the state of the art are also characterized by a disadvantageous angle of the arrangement of the tool tongs, respectively the tool receivers.
[0023] The other constructive modification possible according to the invention is an arrangement where one disc is provided for a plurality of spindles, respectively spindle groups, or for all work spindles of a machine tool. The problem according to the invention is thus solved in many differing ways. The invention achieves here that a large number of machining tools are provided without enlarging the floor space required by the machine tool.
[0024] This effect is increased if, in a modification of the invention, it is provided that the tool magazine discs are arranged above the work spindle. Usually the space above the machine tool is not used, however, the floor space of the hall is quite restricting for the number of machine tools, in particular, if they have to be interlinked. Advantageously therefore the tool magazine discs are arranged above the work spindles, and taken to the work spindle on demand.
[0025] In a preferred modification of the invention it is provided the machine tool has two tool magazine discs which stand close to each other at least in the tool change position.
[0026] The tool change position is here the arrangement in which the tool change takes place, that is the tool magazine disc is at the respective work spindle in order to exchange the tool.
[0027] The orientation of the tool magazine discs close to each other, at least during the tool change, makes it possible with two tool magazine discs at two work spindles or groups of work spindles, which are also orientated close to each other, to change the tools simultaneously. This increases the efficiency as the change process is carried out for all work spindles simultaneously.
[0028] This modification according to the invention makes here also several designs possible. First of all, it is possible that both tool magazine discs are shifted essentially parallel, and thus actually the whole time, as well as during the change process, are arranged relatively close to each other. By such a design it is, for example, possible, to provide a common drive for the tool magazine discs.
[0029] In another modification it is possible that the tool magazine discs are provided in waiting positions far away from each other, outside the working area, and are brought in the tool position only for the tool change, as described. This modification makes it possible to carry out the tool exchange in the waiting position economically favorably as, for example, tool magazine discs are shifted accordingly to the outside where they are reached easily by the staff.
[0030] In a preferred modification of the invention it is provided that the two rotational axes of the two tool magazine discs are orientated parallel and/or the two tool magazine discs are in one plane. By such a design the construction is made easier, as also the work spindles are supported in the space in the same way and are often moved in the same way. The control of the complete machine tool according to the invention is made easier by that accordingly. This arrangement also achieves that the tool axes are parallel to the axes, and thus the exchange, respectively the replacing, of the tools is possible in a simple manner. In the same way it is also an advantage if the two tool magazine discs are in the same plane. Exactly if the work spindles are designed and installed identically, a simple geometric relation is made by that, and, in particular, the common exchange is made easier which leads to a corresponding time saving.
[0031] The invention does not exclude here solutions in which the geometric relations mentioned before do not exist. Of course, also arrangements belong to the scope of the invention where the rotational axes are not parallel to each other, or the tool magazine discs are tilted to each other or arranged in parallel planes.
[0032] It is an advantage here that the invention provides that the first tool magazine disc is assigned to the first work spindle, respectively a first group of work spindles, and also the second tool magazine disc to the second work spindle, respectively a second group of work spindles. Such an arrangement can be realized, of course, also with more than two tool magazine discs without any problems. These partial systems are then synchronized to each other, and, if necessary, designed again redundant in themselves.
[0033] It is an advantage if for the tool magazine discs a guide is provided along which the tool magazine disc can be moved linear in a linear movement, and can be brought to the work spindle in a tool change position. Different modifications are possible for the design of the guide. In particular, such a design has the advantage that the tool magazine disc can be brought in a waiting position outside the working area, and be parked there where it does not interfere. Alternatively it is, of course, possible not to move the tool magazine disc, but to bring the work spindles to the tool magazine disc. These kinematic surroundings also belong to the invention. It is also provided here that the linear movement is also used for carrying out in a relative movement for replacing, respectively exchanging, the machining tools. In particular sharing out the different axes of movement between different elements saves effort as an orthogonal movement of elements, for example the cross table for work spindles, is accordingly expensive.
[0034] In view of the construction it is provided here that a slide moves on the guide, and the tool magazine disc is on the slide. In another embodiment of the invention it is possible here that several tool magazine discs can be moved in a common guide identically. For example, a slide beam is provided which can be moved on the guide, and the slide beam carries two or more tool magazine discs. Such an arrangement can be used, for example, when both tool magazine discs have to be approached simultaneously for the replacing/exchanging procedure. The effort for the drive is cut in two.
[0035] Besides this dependent movement of the tool magazine discs it is, in an alternative, provided according to the invention that several tool magazine discs can move independently of each other. For that purpose then suitable individual drives and also guides, respectively guide elements like slides, are provided. It is also pointed out here that an identical as well as an independent movement of the work spindles belongs to the invention in the same way.
[0036] Furthermore, besides a parallel guide of several tool magazine discs, it is, according to the invention, also provided that each of several tool magazine discs has its own guide, and the respective directions for movement form with each other an angle, in particular an obtuse or an acute angle, as it is indicated, for example, in FIG. 6 or FIG. 8 . Such a design has the result that the tool magazine discs can be brought closely to each other for the change process, and in this way serve work spindles standing also closely to each other, however, then are removed far away from each other for the waiting position, and thus, for example, are easily accessible for maintaining the tools by the staff. The diagonal arrangement of these different guides, however, has advantages for exchanging and replacing the tools themselves, as it will be described further down, in particular if the distance between the spindles with respect to the diameter of the tool magazine disc is small. Also a solution where the tool magazine discs drift apart diametrically, that means at an angle of 180°, be it in vertical, horizontal or diagonal direction, belongs to the invention.
[0037] In a preferred modification of the invention it is provided that the tool magazine disc is designed like a ring, and has a rotational drive. Conveniently here the rotational drive is set in the opening of the ring, and thus a drive as balanced as possible is realized. Alternatively to that it is possible to realize the tool magazine disc as actually plate-like, continuous disc, and to arrange the drive on the shaft forming the rotational axis.
[0038] According to the invention it is possible to design the rotational drive individually for each tool magazine disc, which makes it possible to position several tool magazine discs each independently of each other. Alternatively it is also possible to couple these rotational drives accordingly in order to optimize also the rotational drive by this.
[0039] In a modification of the invention it is provided that the tool magazine disc is designed as polygon. According to his modification of the invention it becomes evident that by the formulation as tool magazine disc not expressly a circular design is provided but this disc may actually be designed as polygon. Such a design has advantages in the production. A big advantage according to the invention is the fact that the tool tongs are arranged in a circle concentrically around the rotational axis. By such an arrangement a high density of tools is reached on the tool magazine disc. The single tool tongs have to be arranged space-saving one beside the other, and all tool tongs are located ideally at the same positioning of the tool magazine disc at the respective same place when the machining tool has to be replaced.
[0040] In a preferred modification of the invention it is provided that in the tool change position the spindle axis of the work spindle and the rotational axis form a straight line parallel to the linear movement. In this preferred case of the invention the linear movement of the tool magazine disc serves as movement in order to either pick up the machining tool out of the tool tongs or to deposit it there. Particularly clever is such an arrangement if the guide of the tool magazine disc is tilted, as for example indicated in FIG. 6 . The arrangement is provided here such that—although relatively large tool magazine discs are used—the movement of the tool magazine disc can be used directly in order to pick up or deposit the machining tool.
[0041] Alternatively to that it is provided that in the tool change position the connection line of the spindle axis of the work spindle and the rotational axis forms an acute angle with the linear movement. In this case differing from the previously described one it is even possible to remove the tool directly from the tool tongs or to deposit it there. This is favored by a design of the tool tongs adapted to this. Such a design is shown, for example, in FIG. 8 where such a modification becomes important in particular if two spindles are supposed to be loaded, respectively unloaded, by one tool magazine disc.
[0042] In another modification according to the invention it is suggested that he relative movement results from an interference of at least two movements, for example of the tool magazine disc and/or the work spindle. It is not only provided, according to the invention to derive the relative movement, which serves for exchanging and replacing the machining tool, only from one movement, for example of the tool magazine disc or the work spindle, but, according to the invention, the interference of two movements and the resulting alternative movement is used. By a clever interference of these movements, namely a resultant is achieved which is in the orthogonal field of the two single movements. By selecting the respective speeds of the single movements the orientation of the resultant can be adjusted. Here even different movements of one and the same element, for example of the tool magazine disc, can be interfered in the sense of the invention.
[0043] In a particular embodiment of the suggestion mentioned above it is provided in another modification according to the invention that the relative movement results from interference of the linear movement of the tool magazine disc and a linear movement of the work spindle. In such a design, of course, a certain mobility of the work spindle is required; this mobility should be, for example, parallel to the plane where the tool magazine disc is located.
[0044] However, if it is possible to do without a separate drive for the movement, respectively positioning, of the spindle, as it is, for example, possible with arrangements where the work piece is moved, another modification according to the invention suggests that the relative movement results from an interference of the linear movement of the tool magazine disc and a rotation of the tool magazine disc around its rotational axis. The required drives which are present anyway are thus used one more time surprisingly convenient. The linear movement, which is required anyway for approaching the tool magazine disc, as well as the rotational drive which is provided for selecting and positioning the desired tool tongs with the desired machining tool, is thus used one more time, connected with each other only with a suitably small effort of programming.
[0045] According to another modification of the invention it is provided that several work spindles are combined to a group of work spindles and, if necessary, are also stored in a common headstock. It is, in particular, provided that the work spindles are shared out between two groups of spindles, a first and a second group of work spindles, and these groups of work spindles can be moved either independently of each other or simultaneously to each other. According to the invention it is possible here to use a central drive for both, respectively all, groups of work spindles. From that results then a respective dependent movement of these two groups. It may be carried out, of course, also in respective different directions, for example with the help of a suitable gear. However, the movement can here be also identical, for example, so that the different groups of work spindles are arranged on a common headstock, and this headstock is once driven commonly centrally. Alternatively it is, of course, also possible that both groups of work spindles have their respective own autonomous drives by means of which the work spindles can each be selected, moved and positioned independently of each other in any way.
[0046] In all modifications mentioned above it is, of course, clear that the work spindles, respectively the headstock, is designed slide-like and can be moved on a guide. Of course, this basic mobility makes also a positioning of the work spindles possible, for example for or during machining.
[0047] According to the invention it is also suggested that one tool magazine disc supplies one, two or more work spindles with machining tools. According to the invention it is therefore provided that a tool magazine disc supplies also a group of work spindles. Because of the task according to the invention, namely to provide a high density of machining tools, it is now possible by means of the invention, to just provide even a larger number of machining spindles with only one tool magazine disc, for example a tool magazine disc for a group of two or three or even more work spindles. This unit is then, for example, provided in a machine tool according to the invention double, symmetric. The flexibility, but also the efficiency of such a machine tool according to the invention is increased considerably, and it is achieved here to combine in the invention cleverly the features efficiency and flexibility which are otherwise opposed. The invention reaches a high cutting capacity with a large number of machining tools which can be used differently. It has turned out here to be convenient that the tool tongs are arranged on the tool magazine disc in two or more circles. By means of such a clever arrangement of these circles, which are as a rule also concentric (concentric around a rotational axis) the packing density of the tools, respectively the tool tongs, is increased additionally.
[0048] Conveniently in another modification of the invention it is suggested that the tool tongs of a circle are assigned to a particular work spindle. It is, of course, possible, to arrange the machining spindles in the respective spindle group, respectively in the headstock, in such a way that they are arranged for the change process each time in the same circle line. As, however, by the multi-line arrangement of the tool tongs the number of the available machining tools can be increased it is convenient to select the arrangement of the tool spindles accordingly so that, for example, a horizontal arrangement of machining spindles, one beside the other, is possible. However, the invention allows any variant of this.
[0049] It is in particular also provided that the tool magazine disc has in the region of an interior and/or exterior tool tongs an opening through which the machining tool is guided when it is loaded in or unloaded from the tool magazine disc. This opening is chosen here larger then the receiver of the tongs, and the machining tool is here to be moved essentially parallel to the rotational axis, respectively the spindle axis, which may be realised, however, by the center sleeve drive of the tool spindle, which is provided anyway, in Z-direction or a separate Z-axis for the tool magazine disc in a simple manner in the frame of the machine control.
[0050] Of course, the arrangement of the tool tongs on the circumference of the tool magazine disc is chosen in such a way that a free access of the machining tool into the tongs is secured, if necessary, suitable recesses or indentations or even borings are provided in the tool magazine disc.
[0051] Another essential advantage of the invention is in particular the fact that with the relative movement the simultaneous change of the machining tools of two or more work spindles is possible. According to the invention it is provided that at least one tool magazine disc changes simultaneously the machining tools of several work spindles. Besides a high density of machining tools, a high variability because of a large number of machining tools the tool change takes only little time through the simultaneous change.
[0052] It is conveniently provided that the relative movement is orientated in the space between the tongs axes of the tool tongs which are in tool change position with respect to the respective work spindle. Removing or putting in the machining tool in the tool tongs is carried out here, as already mentioned, along a line which forms an acute angle with the linear movement, however, the respective deviations for the concerned tool tongs, which are as a rule adjacent, are the same. Conveniently here the bisecting line of the angle formed by the respective tongs axes is used for the relative movement.
[0053] In another modification according to the invention it is provided that the machine tool has only one tool magazine disc which supplies at least two work spindles with machining tools. Such a design is shown, for example, in FIG. 1 or FIG. 3 . The tongs axis here forms an acute angle with the connection line between the rotational axis, the tool magazine disc and the tool axis of the machining tool resting in the tool tongs. This acute angle does not interfere as, in particular, the tool tongs also in the back region are designed securely enough and thus do not interfere with each other. Even with a corresponding small acute angle alpha it remains, according to the invention, possible to provide a high number of machining tools.
[0054] In another modification of the invention it has been found that the diameter of the circle in which the tool tongs are arranged is large compared with the distance of the spindle axes. This proportion in size is preferably more than 5. This means the diameter is five times the distance of the spindle axes. According to the invention thus a comparatively large tool magazine disc is proposed which, because of its considerable circumference, serves additionally for receiving a large number of machining tools. An advantageous interval of this proportion of sizes is between 6 and 12. A very good use is made of the space if the diameter is set at about 9 to 10 times in the distance of the spindles, because then the complete width of the machine tool can be used optimally. Besides a large number of machining tools, which may be provided here, also the tilting of the individual tool tongs relatively to the connection line of rotational axis and tool axis is smaller. At this point it is referred also to FIG. 1 as an example.
[0055] In another advantageous embodiment of the invention it is suggested that the connection line of the tool axes of two machining tools which are arranged in the respective tool tongs and which are suited to get exchanged in the work spindles simultaneously, is rectangular to the tongs axis of the respective tool tongs. By the linear movement of the tool magazine disc ideally the replacing and exchanging process of the tool is made possible for a plurality of tool tongs. Several possibilities to arrange the machining tools result from that. For example they may be arranged in a sequence as follows: ababcdcdefef, the same letters referring to the respective machining tools of different spindles which are arranged on the tool magazine disc and which are each simultaneously exchanged, respectively replaced. The presented arrangement makes it possible here to arrange the two spindles comparatively close to each other, with a small distance (see FIG. 1 ).
[0056] Alternatively an arrangement like abcdefg abcdefg is possible, the middle distance between the respectively matching tool pairs being clearly larger. The result of that is a larger distance between the two spindle axes. Additionally it is referred to FIG. 3 .
[0057] The arrangement is here, according to the invention, chosen in such a way that the distance of the spindle axes is such that on the tool magazine disc between the tool tongs available each time for a tool change process one or more other tool tongs are provided. By means of that the space available on the tool magazine disc is used optimally, with respect to the present work spindles.
[0058] In another modification of the invention it is provided that the machine tool has two tool magazine discs and a first tool magazine disc is provided for a first group of several work spindles, and a second tool magazine disc is provided for a second group of several work spindles, and the tool tongs are arranged on the tool magazine discs in different circles, and the tongs axis forms an acute angle with the connection line between the rotational axis of the tool magazine disc and the tool axis of the machining tool resting in the tool tongs. This modification according to the invention is shown, for example, in FIG. 4 . The suggestion realises an arrangement of tool tongs on the tool magazine discs in two or more circles. Here basically a larger number of tools can be stored. The particular advantages of this feature are referred to. Furthermore it is also a result of this arrangement that the connection line of the tool tongs of two machining tools which are arranged in the respective tool tongs and which are suited to be exchanged simultaneously in the work spindles, is rectangular to the tongs axes of the respective tool tongs. The design makes a very simple exchange possible as the relative movement can be derived from the linear movement of the tool magazine disc.
[0059] It can be seen clearly in the figure that the distance of the two headstocks is less than the distance of the respective rotational axis of the tool magazine discs. The slightly tilted arrangement of the tongs axes makes it possible to change in one linear movement of the two tool magazine discs the tools on four spindles altogether which are orientated relatively close to each other. The advantage of time in this change procedure is considerable.
[0060] It is convenient that the spindle axis is orientated parallel to the rotational axis. This produces relatively simple geometric proportions. The same goes also for the arrangement according to another modification of the invention according to which the tool axis of the machining tool held in the tool tongs is parallel to the rotational axis.
[0061] In the embodiments which still have to be discussed it is shown that the tool magazine discs are arranged on the machine column which also carry the work spindles. Of course, also another design is possible, namely in such a way that these are held by a column which is opposite, that means located on the opposite side. It may also be provided in a modification that the tool magazine discs dive below the work spindles in a waiting position. However, it is an advantage if the tool magazine discs, as provided in another modification according to the invention, are arranged above the work spindles as, by means of that, their access is improved.
[0062] In another aspect of the invention it has been found that the density of machining tools can be increased, in particular by an advantageous design of the tool tongs.
[0063] Tool tongs of the known type are designed in such a way that they have at least one contact sickle bent like a half-circle which interacts with the machining tool which has to be picked up in its rotational symmetric shank region, and the tool tongs has furthermore a holding device for holding the machining tool. In order to solve the problem according to the invention, that is to achieve a density of tools as high as possible in the tool magazines, respectively the tool magazine discs; it is suggested that the end regions of the contact sickle recede relatively to the half-circle of the shank. The only possible loading and unloading direction here corresponds at the same time with the orientation of the tongs axis in this known tool tongs. Known contact sickles embrace in an angle region of 180° a receiving opening in which half of the shank region of the machining tool submerges. The result from that is a single direction in which the tool tongs can be loaded, respectively unloaded, with the machining tools. That is rectangular to this diameter. In order to be able to offer machining tools even in complicated arrangements of work spindles such an embodiment would interfere, respectively would require to turn the known tool tongs around a large angle.
[0064] However, if according to this solution of the problem of the invention the end region of the contact sickle is set back, the result will be a plurality of different directions how the tool tongs can be loaded and unloaded. Instead of a fixed direction which coincides with the tongs axis a complete angle field will open, each time depending on the design of the end region of the contact sickle in which the tool tongs can be loaded and unloaded reliably.
[0065] This suggestion here does not only offer the advantage for the compensation of different directions of the relative movement. At the same time this arrangement compensates even an error so that the exact guide and positioning of the machining tools is not decisive anymore here. Therefore the arrangement according to the invention makes it possible to do with a small effort in this region as the arrangement is able to compensate production tolerances without questioning the practical use.
[0066] In a preferred embodiment of the invention it is provided that the holding device is designed as holding sickle, and the holding sickle is in contact with the shank. As a rule, the holding device is used when the machining tool has to be held in the tool tongs. Here the holding device may be designed as a mechanically active flap, the flap then having the design of a holding sickle, or it maybe designed, in another modification of the invention, for example as magnetically active arrangement or equipped with locking bolts and the like.
[0067] A preferred modification of the invention provides that on the end region of the holding sickle holding catches are provided which engage in a holding way in a recess provided on the machining tool. Such an arrangement can be controlled easily mechanically and requires small expenses.
[0068] In order not to restrict the large variability in the orientation of the relative movement it is convenient that the end regions of the holding sickle are set back relatively to the half-circle of the shank. This suggestion follows basically the same idea as the arrangement of the contact sickle. It is favourable here that the recess on the machining tool has a suitable extension in order to guarantee, nevertheless, that the holding catch of the end region, even if the end region of the holding sickle is set back, engages there reliably.
[0069] It is another advantage if the holding sickle is designed to be folded around a folding axis, in particular as spring supported, folding holding sickle. Such a design can be manufactured very easily and mechanically reliably. In another embodiment of the invention it is provided that on the contact sickle an orientation pin is provided which is in particular flattened and which interacts with an orientation nick of the machining tool. The arrangement of an orientation pin in an orientation nick serves as protection against twisting in order to make sure that the machining tool is orientated correctly, in particular held by the tool tongs with reference to a point-symmetry or reflexion-symmetry.
[0070] The flattening of the orientation pin has the reason in the large range of possible directions of the relative movement and does not interfere with them.
[0071] It is an advantage if the contact sickle, respectively the holding sickle, covers an angle range of 40° to 170°, preferably 120° to 160°, in particular from 135° to 145°. Depending on the design of this angle range where the machining tool sits close to the contact sickle, eventually the angle range results in which the machining tool can be loaded or unloaded in the tool tongs. Conveniently here a symmetric design is striven for so that the receding of the respective end regions is shared equally and may be between 5° and 10° per side. Good results are reached with an angle of about 10° to 30°, in particular at about 20°, as here, on the one hand, a good possibility for fastening may be realised and, on the other hand, a high variability is provided for the direction of loading and unloading the tool tongs. As described also the holding sickle has in a modification an according design, however, this may not be necessarily the same design as the one of the contact sickle, but it has to be seen alternatively. It is, in particular possible, to design a foldable holding sickle in such a way that it does not deviate from the design of the contact sickle, however, does not interfere with it, as the holding sickle is folded away during the loading and unloading process.
[0072] Several modifications are provided for the design of the end regions of the holding sickle. The end regions may, for example, end abruptly, or, as described in another variant according to the invention, they may drift tangentially to the tool axis of one of the machining tools held in the tool tongs. In such a design this tangent would support on a certain range guiding the introducing or removal of the machining tool in the tool tongs.
[0073] In this connection it belongs also to the scope of the invention that, of course, this tangent can be guided beyond the half-circle. As, however, this region projecting tangentially does no more come close to the shank of the machining tool, if it is held by the tongs, this solution is described identically with the arrangement where the contact region of the contact sickle is set back, and does therefore no more offer a contact possibility.
BRIEF DESCRIPTION OF THE DIFFERENT VIEWS OF THE DRAWINGS
[0074] The invention is shown in drawing schematically.
[0075] In the figures:
[0076] FIGS. 1 to 8 each a front view of different modifications of the machine tool according to the invention,
[0077] FIG. 9 a top view of a tool tongs according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0078] In FIG. 1 a first modification of the machine tool 1 according to the invention is shown. The machine tool 1 is formed by a machine bed 10 , along which in upward direction the machine column 11 extends. The work spindles 2 rest on the machine bed 10 . In the example shown here two work spindles are indicated, a first work spindle 21 and a second spindle 22 . The two spindles 21 , 22 are imbedded in a headstock 23 , and can be shifted by the slides 24 on a guide path 25 in X-direction.
[0079] Reference number 20 indicates the spindle axis of the work spindle 2 .
[0080] In the example shown here a tool magazine disc 3 is provided which is arranged above the work spindle 2 .
[0081] It is an advantage that the tool magazine disc 3 is designed in such a way that it can be shifted here vertically along the drawn Y-axis. By means of this an accordingly expensive compound rest guide in the work spindle can be done without. In order to reach the Y-movement of the tool magazine disc a guide is provided, and the tool magazine disc 3 is able to be moved and positioned on it accordingly. The result is that the tool magazine disc 3 is arranged above the work spindles 2 , and the relative movement for exchanging and replacing the machining tools 5 is derived from this linear movement.
[0082] On the tool magazine disc a plurality of tool tongs 4 , here grouped in pairs, are arranged. These tool tongs 4 are orientated essentially radially to the rotational axis 30 of the tool magazine disc 3 . The tongs axis 40 of the tool tongs 4 has a certain tilting angle alpha. This tilting angle alpha extends, on the one hand, between the tongs axis 40 and, on the other hand, up to the connection line between the rotational axis 30 , the tool magazine disc 3 and the tool axis 50 of the machining tool resting in the tool tongs 4 .
[0083] In each case the large number of tool tongs can be seen clearly which are available for exchange. The arrangement here is done in such a way that the connection line 33 of the tool axes of two machining tools, which each are arranged in the respective tool tongs 4 ′ and 4 ″ is rectangular to the respective tongs axes of the respective tool tongs 4 ′, 4 ″. In this case of the arrangement the tongs axis 40 is parallel to the direction of movement Y of the tool magazine disc. It can also be seen clearly that the distance of the tool axes in the concerned tool tongs 4 ′, 4 ″ corresponds just with the distance of the spindle axes 20 , 20 ′.
[0084] In a preferred embodiment of the invention it is provided that the angle alpha between the tongs axis and the rotational axis 30 —tool axis 50 is acute, in particular within an interval of 0:1° to 35°, preferably within the interval of 50 to 35°. For example, FIG. 1 , FIG. 3 , FIG. 4 show different modifications how this acute angle is realised. However, it is possible in every case to arrange a large number of tool tongs on the tool magazine disc 3 .
[0085] FIG. 2 shows that a tool magazine disc 3 with radially arranged tool tongs 4 , as it is then used for example also in FIG. 5 , can also be used in a very simple machine, namely as tool supply for only one spindle. This tool supply is formed here only by this one tool magazine disc.
[0086] In contrast to the embodiment in FIG. 1 , in FIG. 3 the tilting angle alpha is larger and also different. The reason for that is finally that in the modification according to the invention shown in FIG. 3 two spindles 2 , 2 ′ with a larger distance have to be supplied by one tool magazine disc.
[0087] Again the two spindles 2 , 2 ′ can be shifted on a common guide path 24 , for example a slide. As, however, the distance between the spindles 2 , 2 ′ is clearly more, it is possible to arrange a larger number of other machining tools between the parallel orientated tool tongs 4 ′, 4 ″. Eventually the tool magazine disc 3 has to be positioned in the way now shown in FIG. 3 , that is the respective chosen pair of tools has to be positioned exactly above the respective spindles in order to exchange, respectively replace, the tool then after lowering the tool magazine disc 3 along the direction Y by a relative movement.
[0088] As the construction of the different machine tools according to the modifications shown in the different figures is essentially always the same, in the following a repetition of the respective identical components is left out. Rather the essential differences are pointed out.
[0089] In FIG. 4 another modification of the invention is shown. In the example shown here two times two spindles 2 are provided. The machine is constructed essentially symmetric. The four overall spindles (it is also called a four-spindle machine) are combined in two spindle groups each with two work spindles 2 .
[0090] The four spindles, respectively two spindle groups with two work spindles each, are on a common guide path 24 , for example a slide and can be moved again in X-direction.
[0091] In this embodiment two tool magazine discs are provided. The one on the left hand side is indicated by 35 , the tool magazine disc on the right hand side is indicated by reference number 36 . The left spindle group is assigned here to the tool magazine disc 35 , the right one to the tool magazine disc 36 .
[0092] The tow tool magazine discs 35 , 36 can be shifted vertically by means of one or two guides. By means of that the tool magazine discs 35 , 36 are tilted towards the work spindles 2 . Thus in a change process up to 4 tools altogether are exchanged, respectively replaced.
[0093] In order to achieve this, the respective interacting pairs of tool tongs 4 , 4 ′ are, similar as in the solution according to FIG. 3 , orientated to each other parallel.
[0094] As two work spindles 2 have to be supplied simultaneously with tools eventually the tool tongs 4 are in two different circles 37 , 38 . The circles 37 , 38 are arranged here concentrically around the rotational axis 30 . The arrangement is chosen here in such a way that the exterior circle 37 supplies the tool tongs 4 , which are meant for the spindle 2 a , which is at a larger distance to the rotational axis 30 then the adjacent spindle 2 b . The spindle 2 b is supplied with tools by the tool tongs of the interior circle 38 . Basically this arrangement can be extended also to arrangements where instead of two spindles per spindle group three, four or even more spindles are provided.
[0095] While in the FIGS. 1 to 4 the relative movement R was parallel to the linear movement Y of the respective disc magazine, the situation in the modification according to FIG. 5 is different.
[0096] In the example shown in FIG. 5 two tool magazine discs 3 are provided which are shown in two different positions, the arrangement in waiting position being indicated by 3 ′, and the position, where the tool magazine disc is in the bottom change position, by 3 . In order to position it the tool magazine disc 3 is positioned each time on a guide 32 . The tool magazine discs can be positioned together or independently of each other. In the example shown here to one tool magazine disc 3 each time only one work spindle 2 is assigned. Therefore all tools necessary for that, respectively all tool tongs, are arranged in a concentric circle.
[0097] In contrast to the example of the embodiment according to FIG. 2 where the rotational axis 30 , the tool axis 40 and the spindle axis 20 form a straight line which extends vertically and which is also parallel to the linear movement of the tool magazine disc, there is an angle here between these two orientations.
[0098] In other words the relative movement R is not parallel to the linear movement Y by means of which in the modifications according to FIGS. 1 to 4 before the relative movement R has been derived.
[0099] The reason is that the work spindles 2 are no more positioned below the rotational axis 30 , but each time towards the interior of the machine.
[0100] In a modification according to the invention, however, it is now suggested that the relative movement results from an interference of at least two movements, for example the tool magazine disc 3 and the tool spindle 2 . In the example shown here the spindles 2 each are on their own slide 24 , 24 ′, and can be moved on the guide path 25 in X-direction. The linear movement Y of the tool magazine disc 3 extends rectangular to it. When these two movements interfere cleverly a relative movement R as indicated results. That means the tongs axis 40 is again parallel to this relative movement R, although no movement component is offered parallel to the relative movement R. This makes it possible to position, in a simple way, and in particular using double the already present elements, work spindles 2 closely, and to provide nevertheless a large number of machining tools 5 in the respective tool magazine discs.
[0101] Similar to FIG. 5 also FIG. 6 shows an arrangement where two tool magazine discs 3 (again shown in two positions) supply only two work spindles 2 with tools. However, here the linear movement Y is again parallel to the relative movement R. The result is, however, a V-like design of the guide paths, respectively the respective linear movements Y and Y′ of the left and right tool magazine disc 3 . They cut at an acute angle beta. An interference of the movements is not necessary, therefore the spindles 2 are again arranged on a common slide 24 .
[0102] In an advantageous embodiment of the invention it is provided that the work spindles 2 are arranged in the working area of the machine tool, and a tool magazine door 6 is provided which can be opened for the tool change process in order to bring the tool magazine disc(s) in the region of the work spindle(s) 2 . For that purpose two modifications are shown in FIG. 5 , respectively FIG. 6 . In FIG. 5 it is shown that the tool magazine door 6 is arranged suspended, in particular shifting on the machine column 11 . For that the guide rail 60 is provided. In FIG. 6 , in contrast to that, the other variant is shown where the tool magazine door is designed portal-like, supported by the machine column 10 . For that purpose, if necessary, on the machine column 10 guide rails 61 are provided. The design of the tool magazine door 6 in FIG. 5 is groove-like, the design in FIG. 6 is portal-like, covering the spindles.
[0103] To prevent the construction of the tool magazine doors 6 from becoming to large and thus inconvenient it is provided in another modification according to the invention that the tool magazine door 6 consists of several door elements in the way of a telescope which, on the other hand, are designed either suspended or movable in a supporting manner.
[0104] The situation shown in FIG. 7 is similar to the modification according to the invention already presented in FIG. 5 . Here also only the differences are pointed out in order to avoid repetitions. In contrast to the solution according to FIG. 5 here two spindle groups with two spindles each are provided which have to be supplied with tools by one tool magazine disc 3 each.
[0105] In the center between the two tool magazine discs a central linear drive is provided which makes the linear movement in Y-direction (here vertically) possible. For each spindle group again an individual slide 24 , 24 ′ is provided.
[0106] It can be seen now that the tongs axis 40 , which is orientated radially to the rotational axis 30 , is, in the embodiment shown in FIG. 7 , no more parallel to the relative movement R. The relative movement R is rather orientated in such a way that it extends between two tongs axes 40 , 40 ′, for example as bisecting line of the angle. Finally the tools are loaded or unloaded with a certain angle error simultaneously at the spindles 2 of a spindle group in the tool tongs 4 , and provisions have to be taken to compensate this angle error, that is the deviation of the orientation of the relative movement R with respect to the tongs axis 40 , 40 ′. For that purpose serves a special design on the tool tongs 4 which, in particular, will be discussed in FIG. 9 .
[0107] In order to reach again out of the rectangular to each other orientated linear movement Y and the spindle movements X the relative movement R, which is diagonally to it, these two components of movement are interfered in a clever way. The angle error which remains nevertheless is small and identical because of the bisecting line of the angle as direction of the relative movement.
[0108] In another modification according to the invention it is suggested to carry out the relative movement R through interference of the linear movement Y and a rotational movement of the tool magazine disc 3 in order to reach their rotational axis 30 . By means of this, with respect to the relevant points, namely the concerned tool tongs 40 , 40 ′, also a component of movement arises which is orthogonal to the linear movement Y, and which can be cleverly combined in such a way that the diagonally orientated relative movement arises. It can be seen clearly that by means of such an arrangement a comparatively close distance is possible either of the individual spindles or even the spindle groups on their independent slide 24 , 24 ′. The space between the two tool magazine discs 3 is used cleverly. Eventually this results in a smaller construction width of the machine tool according to the invention.
[0109] In the same way as the arrangements of FIGS. 7 and 5 are similar, also the arrangements of FIGS. 6 and 8 are relatively similar. In FIG. 8 again the linear movements Y, Y′ of the two tool magazine discs are directed towards each other in V-shape. They cut each other below the respective tool magazine discs at the angle beta. Again there is an angle error sigma between the connection line of the spindle axis 20 of the work spindle 2 and the rotational axis 30 . This angle error is compensated by an advantageous design of the tool tongs. As in FIG. 6 also in FIG. 8 the relative movement R is derived from the linear movement Y.
[0110] In FIG. 9 the tool tongs also belonging independently to the invention are shown. The tool tongs 4 have a bent contact sickle 41 interacting with the machining tool 5 , which has to be picked up, in its rotational symmetric shank region 52 . The tool tongs 4 have furthermore a holding device which makes sure that the machining tool does not fall out of the tool tongs. The holding device is, in the example shown here, designed as holding sickle 43 . In the chosen view the contact sickle 41 is concealed by the holding sickle 43 . Therefore the contact sickle 41 is shown with a dashed line.
[0111] In order to achieve that the exchanging and replacing of the tools, in particular in the embodiments according to FIGS. 7 and 8 can be carried out without any problems, the angle between the relative movement R and the tongs axis 40 has to be taken into consideration. In the known tool tongs the tool was loaded or removed in the tongs parallel to the tool axis 40 . In order to compensate this “error” it is suggested according to the invention that the end regions 42 of the contact sickle are set back relatively to the half-circle of the shank 52 . This angular setting back is indicated by reference number 46 . In this example it is about 20°.
[0112] The invention provides furthermore that the holding device is designed as holding sickle 43 , and that the holding sickle 43 has contact to the shank 52 .
[0113] The machining tool 5 has diametrically arranged recesses 51 , into which holding catches 47 provided at the end regions 44 of the holding sickle 43 engage in a holding way.
[0114] This end regions 44 of the holding sickle 43 are also set back relatively to the half circle 52 . This receding distance corresponds with the same angular receding distance as for the end region 42 of the contact sickle 41 . Additionally, however, in the invention it is also provided that the end regions of the holding sickle 43 drift tangentially 47 to the tool axis 50 of the machining tool 5 held in the tool tongs. The orientation of this tangent 470 is elongated in the drawing of FIG. 9 in such a way until it cuts the tongs axis 40 . Reference number 45 indicates the angle error existing between the tangent 470 and the tongs axis 40 . Until up to this angle error 45 , by means of the tool tongs according to the invention, tools may be conveyed in or out without any problems. The use of these tool tongs in the arrangements according to FIGS. 7 and 8 make it therefore possible to compensated the angle error resulting there, and to achieve a quick change of the machining tools on the machine tools according to the invention.
[0115] The holding sickle 43 is designed in such a way that it can be folded around the folding axis 49 .
[0116] The angle error field 45 realised here is, for example, 25°. The symmetric design has to be taken into consideration, because of which the actual field is +/−25°. Depending on the design of the angular distance 46 of course this angle error can be adjusted.
[0117] In order not to disturb the free introducing of the machining tool 5 in the tool tongs 4 not even by the known orientation pins, the orientation pin 48 is flattened and thus engages in the orientation nick 53 of the machining tool 5 .
[0118] As far as a spindle has been described it is the same as a work spindle.
[0119] Although the invention has been described by exact example which are illustrated in the most extensive detail, it is pointed out that this serves only for illustration, and that the invention is not necessarily limited to it because alternative embodiments and methods become clear for experts in view of the disclosure. Accordingly changes can be considered which can be made without departing from the contents of the described invention. | The invention refers to a machine tool with only one work spindle which carries and drives an exchangeable machining tool. Furthermore a tool supply is provided which has tool tongs for receiving machining tools. For exchanging and replacing the machining tools a relative movement is provided. It is suggested to share out the tool supply between at least two partial magazines. | 8 |
BACKGROUND OF THE INVENTION
In the field of high-speed printing devices of the type which are especially suitable for use in connection with electronic business systems, the wire matrix type of printer has come into increasing use. In this type of printer, letters, numbers and symbols are formed from a series of dots produced by the impact of the ends of a plurality of wire elements on record media.
A wire matrix printer of the type that may be used with the present invention is disclosed in U.S. Pat. No. 3,882,985 entitled "Tiltable Matrix Print Head to Permit Viewing of Characters", by George N. Liles. Each of the individual wire printing elements of the wire matrix printer is driven by a solenoid that is energized when a printing stroke of that particular wire is required. A solenoid is generally defined as an electrically energized inductor which may consist of one or more layers of windings so as to form an electromagnet. A circuit for driving the solenoids must therefore be capable of quickly driving the solenoid with an adequate and repeatable magnitude of force and in addition the solenoid driving circuit must enable a rapid recovery of the solenoid from the printing stroke in preparation for the next stroke. This must all be done while simultaneously protecting the solenoid winding against damage from overheating. In such applications we are therefore faced with conflicting requirements, namely a high voltage must be applied to the solenoid in order to decrease its activation time, but this high voltage, in turn, will cause a high level of current to flow through the solenoid winding causing heating in excess of design limits.
In U.S. patent application Ser. No. 627,736 entitled "Drive Circuit", by John W. Stewart et al., which application is assigned to NCR Corporation, the assignee of the present invention, there is disclosed a circuit for coupling a supply voltage to a solenoid so as to inhibit the circuit if the supply voltage exceeds predetermined variations.
Another prior art circuit of interest is disclosed in U.S. Pat. No. 3,549,955 entitled "Drive Circuit For Minimizing Power Consumption In Inductive Load" by T. O. Paine. The circuit disclosed in the patent utilizes two differing threshold voltage levels, one of which initially allows the driving voltage applied to the solenoid to be applied for a period which is sufficient to permit the current through the solenoid to exceed the "pull-in" current. The circuit then automatically terminates the driving voltage and the current through the solenoid is permitted to decay to a value just exceeding the "drop-out" current. The circuit then continues to cycle on and off to alternately drive current through the solenoid and to permit it to decay.
SUMMARY OF THE INVENTION
The purpose of the present invention is to provide a drive circuit for solenoid energization which circuit minimizes the activation time of the solenoid by periodically applying a driving voltage to the solenoid for periods of time which are sufficient to increase the current in the solenoid to a maximum desired level. A current level detector detects the current level through the solenoid and disconnects the driving voltage when the current through the solenoid exceeds the maximum desired level. A timing means fixes the interval between the application of the driving voltages so as to maintain the level of current flow through the solenoid below a desired level. Regulation of the solenoid current is effected by repeating the on-off cycles of the driver. For a given power supply voltage, the present circuit provides the fastest possible turn-on and turn-off time of the solenoid while maintaining low power dissipation and conserving solenoid energy.
From the foregoing it can be seen that it is an object of the present invention to provide an improved solenoid driver circuit.
It is a further object of the present invention to provide a solenoid driver circuit utilizing current regulation while maintaining low activation times.
These and other objects of the present invention will become more apparent when taken in conjunction with the following description and drawings which drawings form a part of the specification and wherein like characters indicate like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a coil driver circuit;
FIG. 2 is a schematic diagram of a pulse width bus driver which may be used in conjunction with the coil driver circuit of FIG. 1;
FIG. 3 is a schematic diagram of a current level reference circuit which may be used with the current driver circuit of FIG. 1; and
FIGS. 4A to 4I are waveforms taken at points in the driver circuit of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 there is shown an individual solenoid driver circuit. In a wire matrix print head there are a plurality of solenoids, one for each of the print wires; therefore a corresponding number of solenoid driver circuits are used, one for each solenoid. Starting from the input side of the circuit, the NPN transistor Q4 has its base coupled to the terminal 12 by means of a resistor R6. Terminal 12 receives a PULSE WIDTH BUS signal from the pulse width driver circuit (described in FIG. 2). The emitter of transistor Q4 is connected to a PRINT DATA signal terminal 14 and to a positive 5 volt source applied to terminal 16, via a resistor R7. The collector of transistor Q4 is connected to the base of a Darlington pair Q6, hereinafter referred to as transistor Q6, by means of a resistor R9. The PNP transistor Q5 has its emitter connected directly to terminal 10 and to its base by means of a capacitor C1. The collector of transistor Q5 is connected to the base of an NPN Darlington pair Q7, hereinafter referred to as transistor Q7, by means of a resistor R12 and to a -28 volt terminal 18 by means of a capacitor C3. The base of transistor Q5 is coupled to a positive 28 volt source applied to terminal 19 by means of resistors R8 and R11. The base of transistor Q5 is also coupled to the base of the NPN Darlington pair Q8, hereinafter referred to as transistor Q8, by means of the series connection of capacitors C2 and R15. The base of the transistor Q7 is connected to the terminal 18 by means of resistor R13 with the emitter of transistor Q7 connected directly to terminal 18. The collector of transistor Q7 is connected to the juncture point of capacitor C2 and resistor R15. The juncture point of resistors R8 and R11 is connected to the base of transistor Q6 by means of resistor R10. The base of transistor Q6 is connected to the juncture point of resistor R15 and capacitor C2 by means of the series connection of capacitor C4 and resistor R14. The collector of transistor Q6 is connected to one end of the solenoid 20. The collector of transistor Q6 is also connected to the terminal 18 by a diode CR5. The emitter of transistor Q6 is connected to the opposite end of solenoid 20 by a diode CR4. The collector of transistor Q8 is connected to the opposite end of solenoid 20, and by means of a capacitor C5 to its base. The base of transistor Q8 is connected to terminal 18 by means of resistor R16. The emitter of transistor Q8 is connected directly to terminal 18.
In operation a print cycle will begin when a positive 5 volt level PULSE WIDTH BUS signal is applied to terminal 12 and the PRINT DATA SIGNAL applied to terminal 14 goes low. In this condition transistor Q4 will be turned on and driven into saturation. The voltage differential across R9 will supply base current to turn on transistor Q6. Transistor Q6 operates as the positive 28 volt driver. As transistor Q6 saturates, it raises one end of the solenoid winding to +28 volts, and it also raises the potential across R14 and R15. This potential supplies base current for transistor Q8, the negative 28 volt driver. As transistor Q8 saturates, it forces the other end of the solenoid winding to -28 volts. The net voltage applied across the solenoid winding is thus 56 volts. Both transistors Q6 and Q8 remain saturated until the solenoid current reaches the desired level. This level is set by the voltage difference between the plus 28 volt supply and the level of the voltage on terminal 10 supplied by the current level reference bus. The current flowing through the solenoid creates a voltage drop in R11. This drop is fed to the base of Q5 through R8. As the selected current level is reached, Q5 becomes forward biased and turns on. The collector current of Q5 acts to charge C3, which sets the off-time period of the solenoid driver circuit. In the preferred embodiment this period was set to be between 32 and 60 microseconds. As C3 charges, base current is supplied by R12 to transistor Q7. This turns on transistor Q7 and causes its collector potential to become more negative. This in turn creates a current flow in C2 which increases the base current of Q5. This effectively is a re-generative feedback path which assures that Q5 and transistor Q7 will drive each other into saturation after turn-on is initiated. The desired effect is to turn the driver off at the desired current level. This is accomplished as transistor Q7 saturates and captures the base current source of transistor Q8, turning -28 volt driver off. As transistor Q8 turns off the collector potential becomes more positive because the solenoid is acting to maintain its established current flow. Diode CR4 limits the maximum positive excursion of the collector. With CR4 in conduction the net solenoid coil voltage is limited to approximately -2 volts because of the voltage across transistor Q6 and CR4. This clamped voltage prevents the rapid decay of solenoid current and magnetic flux in the print head. This clamp voltage is maintained for approximately 45 microseconds. The time is determined by the discharge time of capacitor C3. Capacitor C3 begins to discharge when Q5 turns off. This occurs when transistor Q8 turns off and transfers the solenoid current to CR4. The transfer eliminates current flow in R11 and thus turns off Q5. When C3 discharges sufficiently it turns transistor Q7 off; this in turn allows a current path through R14 and R15 which effectively turns on transistor Q8. As transistor Q8 turns on it must carry the solenoid current plus the recovery current for CR4. The recovery current is a charge stored in the diode which must be removed before the diode can come out of saturation. Since the current in R11 is also the sum of these two currents it is possible that the peak current in R11 may exceed the normal regulated current value during the recovery period of the diode. In order to prevent this peak current from turning the driver back off, R8 and C1 provide the necessary delay time in the current sense circuit to allow CR4 to recover. With CR4 out of saturation, transistor Q8 saturates and again supplies 56 volts to the solenoid 20. The solenoid current increases and the driver again turns off. This cycle is repeated as many times as necessary until the pulse width signal applied to terminal 12 elapses. At this time the PULSE WIDTH BUS signal drops to logic ground potential and Q4 turns off; this removes the base drive for transistor Q6 and it turns off. As transistor Q6 turns off collector potential is driven negative by the solenoid 20. The negative limit is provided by CR5 which limits the collector potential to the negative supply potential -28 volts. As the collector of transistor Q6 moved negative it removed the potential across R14 and R15, thus eliminating the base current for transistor Q8 which in turn, turns off. The solenoid again causes the collector potential of transistor Q8 to increase with the voltage being limited by CR4. This current is now being returned to the power supply by the solenoid through CR4 and CR5. The voltage across the coil at this point is approximately 60 volts and of a polarity which is opposite to the initially applied voltage source.
Referring to FIG. 2, a circuit which may be used to provide the PULSE WIDTH BUS signal is shown. Terminal 21 which receives an INHIBIT signal is connected to the base of an NPN transistor Q3 by means of a series connection comprised of diode CR1 and resistor R2. The collector of transistor Q3 is connected to terminal 24 which in turn receives a positive 5 volts from a potential source not shown. An NPN transistor Q1 has its base connected to terminal 22 by resistor R1 and its emitter connected directly to ground. Terminal 22 receives a PULSE WIDTH TIMER OUTPUT signal from a source not shown. The signal on terminal 22 is made positive for a period of time corresponding to a desired print cycle, generally by a timing circuit. For each application the print cycle may vary in length and be controlled by differing circuits, all of which is well within the skill of the art and is not shown for purposes of clarity. The collector of Q1 is connected to the base of a PNP transistor Q2 by means of a resistor R4. The bases of transistors Q3 and Q2 are connected by a resistor R3. The collector of transistor Q2 is connected to ground by a series connection comprised of diode CR2 and resistor R5. The output of the driver circuit is connected to terminal 26 and to the collector of transistor Q2. In operation, when a positive INHIBIT signal is received on input terminal 21 along with a positive PULSE WIDTH TIMER OUTPUT signal being received on terminal 22, transistors Q1 and Q3 along with transistor Q2 are turned on and saturate. The positive voltage applied to the collector of Q3 is then felt at the output terminal 26; this positive level signal, the PULSE WIDTH BUS signal, is in turn applied to terminal 12 of the solenoid driver shown in FIG. 1. When a positive signal level is not available on either terminal 21 or 22 transistors Q3 and Q2 remain in the off condition and the voltage level of terminal 26 is substantially 0 volts.
Referring now to FIG. 3, a current level reference circuit which may be used in conjunction with the solenoid driver circuit of FIG. 1 is shown. Terminal 28 is connected to a positive 28 volt potential source and to the base of transistor Q9 by means of resistor R21. The collector of transistor Q9 is also connected to terminal 28. The emitter of transistor Q9 is connected to ground by resistor R22 and to its collector by means of an electrolytic capacitor C6. The output signal of the current level reference circuit labeled "CURRENT LEVEL REFERENCE BUS", is taken from the emitter of transistor Q9 and is applied to terminal 10 of the solenoid driver circuit shown in FIG. 1. A 5.6 volt zener diode CR6 is connected by means of resistor R17 to ground at the anode end and at the cathode end to terminal 28. Resistor R20 parallels resistor R21 and is used to achieve the accurate total resistance value needed to maintain the base biasing of transistor Q9 at a relatively constant level. The same is true for the parallel combination of resistors R18 and R19.
Referring to FIG. 4, the waveforms associated with a typical solenoid activation (print) cycle are shown. We can see that the PULSE WIDTH BUS signal shown in FIG. 4B at the initiation of a print cycle goes from 0 to +5 volts. The collector of transistor Q6 rises from a -28 volts to a positive 28 volts and current commences to flow in the solenoid 20 as shown in FIG. 4A. The collector of transistor Q7 moves from approximately -28 volts upwards towards the value of approximately -23 volts as shown in FIG. 4D. The base of transistor Q8 follows the waveform shown in FIG. 4E. FIG. 4F illustrates the waveform present at the collector of transistor Q8. The waveform at the emitter of transistor Q6 is shown in FIG. 4G with the solenoid voltage being shown in FIG. 4H. The waveform shown in FIG. 4I depicts the timing signal that is present at the collector of Q5.
The following is a list of component parts utilized in the preferred embodiment of the invention.
______________________________________ResistorsR1 1000Ω 5% 1/4 watt carbon compositionR2 3600Ω 2% 1/2 watt metal filmR3 510Ω 2% 1/2 watt metal filmR4 680Ω 2% 1/2 watt metal filmR5 560Ω 5% 1/4 watt carbon compositionR6, 7 5600Ω 5% 1/4 watt carbon compositionR8 47Ω 5% 1/4 watt carbon compositionR9 1600Ω 2% 1/2 watt metal filmR10 620Ω 5% 1/4 watt carbon compositionR11 1Ω 2% 3 watt wirewoundR12 30KΩ 5% 1/4 watt carbon compositionR13, 19 11KΩ 5% 1/4 watt carbon compositionR14, 17 2400Ω 2% 1/2 watt metal filmR15 300Ω 5% 1/4 watt carbon compositionR16 330Ω 2% 1/4 watt metal filmR18 1200Ω 2% 1/2 watt metal filmR20 620Ω 2% 1/2 watt metal filmR21 6200Ω 5% 1/4 watt carbon compositionR22 8200Ω 5% 1/4 watt carbon compositionTransistorsQ1, 3, 4, 9 2N3904Q2 2N3906Q5 2N5400Q6 2N6041Q7 MPSA-13Q8 2N6044DiodesCR1, 2, 3 IN914CR4 IN4934CR5 IN4002CR6 IN7524CapacitorsC1 .01uf mylar 100VC2, 3 470pf ceramic 1000VC4, 5 220pf ceramic 1000VC6 12uf tantalum 6V______________________________________
While there has been shown what is considered to be the preferred embodiment of the invention, it will be manifest that many changes and modifications may be made therein, without departing from the essential spirit of the invention. It is intended, therefore, in the annexed claims, to cover all such changes and modifications as may fall within the true scope of the invention. | A circuit for applying a driving voltage to an inductive load for a period of time sufficient to increase the current in the load to a maximum desired level, and for disconnecting the driving voltage for fixed intervals between each application so as to maintain the level of current flow through the inductive load below the maximum desired level so as to permit the application of a high drive voltage without causing excessive heating in the inductor. | 7 |
This application is a division of application Ser. No. 08/624,267, filed Mar. 29, 1996, now U.S. Pat. No. 5,664,965.
BACKGROUND OF THE INVENTION
1. i. Field of the Invention
The present invention relates to electrical connectors and more particularly to means for fixing electrical connectors to printed circuit boards.
2. Brief Description of Prior Developments
Various means have been disclosed in the prior art for fixing electrical connectors on a PCB. U.S. Pat. No. 5,336,111, for example, discloses a boardlock device which fits into a pair of generally aligned apertures in the connector and the circuit board. On the lower board engagement section, legs diverge outwardly to a pair of vertexes and when the boardlock is fully inserted into the apertures the vertexes will be positioned beneath the circuit board so as to hold it in engagement with the connector.
A disadvantage to such means of fixing a connector to a circuit board is that a number of different boardlocks will be required so that connectors may be suitably fixed to any of the conventional board thicknesses which may be encountered.
A need, therefore, exists for a means for a device which is capable of reliably and economically fixing an electrical connector to a PCB.
SUMMARY OF THE INVENTION
In the assembly of the present invention, a component of an electrical connector having a mounting foot with a mounting aperture is positioned on a PCB which also has a mounting aperture so that the mounting apertures are aligned. A boardlock is axially inserted into the aligned mounting apertures. An upper mounting foot engagement means engages the mounting foot of the electrical connector component. Parallel resilient legs depend from the mounting foot engagement means and are positioned axially in the aligned slots.
A first board engagement means is positioned on one of the depending legs, and a second board engagement means is positioned on the other of the depending legs. The first and second board engagement means are axially displaced from one another. Consequently a PCB of one thickness may be engaged by the first board engagement means while a PCB of another thickness may be engaged by the second board engagement means. A single boardlock may therefore be used on boards of different thicknesses. The need to design and manufacture multiple types of boardlocks for every conventional thickness of PCB and to keep such boardlocks in stock in manufacturing operations is thus avoided.
Also encompassed within the invention is a boardlock for fastening a component of an electrical connector to a PCB which includes a mounting foot engagement means. A first leg depends from the mounting foot engagement means and has a first PCB engagement means adapted to engage a PCB of one thickness. A second leg also depends from the mounting foot engagement means and has a second PCB engagement means adapted to engage a PCB of another thickness.
Finally, a method of fastening a component of an electrical connector to a PCB is also encompassed within the invention. This method comprises the steps of aligning the mounting footer aperture with the PCB aperture; then axially inserting the boardlock into the aligned apertures; and then selectively engaging the PCB with either the first or the second PCB engagement means depending on the thickness of
BRIEF DESCRIPTION OF THE DRAWINGS
The assembly of the present invention is further described with reference to the accompanying drawings in which:
FIG. 1 is a side elevational view of a boardlock used in the assembly of the present invention;
FIG. 2 is an end view of the boardlock shown in FIG. 1;
FIG. 3 is a vertical cross sectional view of the boardlock shown in FIG. 1 as engaged with a mounting foot of a connector;
FIG. 4 is a side elevational view of the assembly shown in FIG. 3;
FIG. 5 is a bottom perspective view of the assembly shown in FIG. 4;
FIG. 6 is a vertical cross sectional view of a preferred embodiment of the entire assembly of the present invention which comprises the assembly shown FIG. 4 as mounted on a PCB;
FIG. 7 is a cross section through VII--VII in FIG. 6;
FIG. 8a is a top plan view of an alternate preferred embodiment of the assembly of the present invention in which the boardlock is shown engaged with a receptacle before engagement with a printed circuit board;
FIG. 8b is a side elevational view of the assembly shown in FIG. 8a;
FIG. 8c is a side elevational view of the assembly shown in FIG. 8b after the receptacle and boardlock are engaged with the PCB;
FIG. 9a is a front elevational view of the second preferred embodiment shown in FIGS. 8a-8c in which the receptacle and boardlock are shown prior to engagement with a different PCB; and
FIG. 9b is a side elevational view of the assembly shown in FIG. 9a after the receptacle and boardlock have been engaged with the PCB.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-2, the boardlock used in the assembly of the present invention is shown generally at numeral 10. This boardlock will preferably be comprised of a single metallic body which has at its upper side a mounting foot engagement section shown generally at numeral 12. This mounting foot engagement section will have a top surface 14 and lateral projections 16, 18, 20 and 22 for grasping a slot in the mounting foot as will be explained hereafter. Beneath the mounting foot engagement section there is a beam member shown generally at 24 which extends perpendicularly from the longitudinal axis of the boardlock. This beam member includes a minor lateral side 26 and a major lateral side 28. The minor lateral side has a top edge 30 and a bottom edge 32 and a major lateral side has a top edge 34 and a bottom edge 36. Depending downwardly from the mounting foot engagement section there are opposed resilient legs which are shown generally at numerals 38 and 40. Between these legs there is a medial recess 42 and the legs have respectively bottom edges 44 and 46. Leg 38 has an arcuate edge 48 with a lateral projection 58. Leg 40 has an arcuate edge 52 with a projection 54. The body of the boardlock is also characterized by major opposed planar sides 56 and 58. The longitudinal axis of the boardlock is shown at A--A.
Referring to FIGS. 3-5 it will be seen that the boardlock 10 will be used to mount the receptacle shown in fragment at numeral 60. This receptacle has a mounting foot 62 with a slot 64. At the bottom side of the slot there is a widened lower recess 66, and within there are a number of peripheral recesses as at 68 which receive projections as at 16 of the mounting foot engagement section of the boardlock. As a result of the interaction of these projections on the boardlock and the recesses in the mounting foot slot the boardlock is securely fixed to the mounting foot and receptacle. The longitudinal axis of the boardlock and the mounting aperture is shown at A--A in FIGS. 3-4. It will be understood that this axis is similarly positioned in other drawings where it is not specifically shown.
Referring to FIGS. 6 and 7, a boardlock 110 similar to the boardlock described in FIGS. 1-5 is fixed to a mounting foot 162 of a receptacle 160 by means of the mounting foot engagement section 112. The beam 124 is positioned in a recess 166 in the mounting foot. The mounting foot 162 is superimposed over a PCB shown generally at numeral 170 and the slot 164 in the mounting foot is generally aligned with an aperture 172 in the PCB. The legs 138 and 140 of the boardlock extend into the aperture in the PCB and the arcuate edges of these legs 148 and 152 respectively bear against the inner peripheral surface 174 of this aperture. The PCB has a top surface 176 and a bottom surface 178. The top surface as at 134 of the beam bears against the mounting foot and the bottom surface as at 136 bears against the top surface of the PCB. The projection 154 on the leg 140 bears against the bottom surface 178 of the PCB. From FIG. 6 it will also be seen that a second PCB shown in phantom lines at numeral 180 may be engaged by the same boardlock. That second PCB has a aperture 180 with an inner peripheral surface 184 which is also aligned with the slot 164 in the mounting foot. The PCB 180 also has a top surface 186 on which the mounting foot and the bottom surface of beam 124 rests. The arcuate edges of the legs bear against the inner peripheral surface 184 of aperture 182, and projection 150 on leg 138 bears against the bottom edge 188 of PCB 180 to secure the receptacle 160 in place on that PCB. Those skilled in the art will appreciate that PCB 170 may have, for example, a conventional thickness of 0.062 in and PCB may have a conventional thickness of 0.093 in. It will thus be appreciated that a single boardlock 110 will effectively engage a receptacle to either a 0.062 in. PCB or a 0.093 in. PCB.
Referring to FIGS. 8a-9b, a second preferred embodiment of the assembly of the present invention is shown. In this embodiment a boardlock 10 also similar to the boardlock described in FIGS. 1-5 is fixed to a mounting foot 262 of a receptacle 260 by means of the mounting foot engagement section (not shown) like the previously described boardlock. The beam (not shown) is positioned in a recess (not shown) in the mounting foot. The mounting foot is superimposed over a PCB shown generally at numeral 270 and the slot 264 in the mounting foot is generally aligned with an aperture 272 in the PCB. The legs 238 and 240 of the boardlock extend into the aperture in the PCB and the arcuate edges of these legs 248 and 252 respectively bear against the inner peripheral surface 274 of this aperture. The PCB has a top surface 276 and a bottom surface 278 as in the other embodiments. The top surface of the beam bears against the mounting foot and the bottom surface bears against the top surface of the PCB. A lead in device 290 extends downwardly adjacent the slot in the mounting foot of the receptacle. This lead in device is comprised of a semi circular element 292 and 294 which are positioned adjacent the planar surfaces 256 and 258 of the legs of the boardlock.
Referring particularly to FIGS. 8a-8c, the engagement of the boardlock to the board as would be seen from the side is illustrated. As will be seen from FIGS. 8a and 8b, the lead in device 290 assists in aligning the receptacle with the aperture 272. When this alignment is accomplished, downward pressure is applied to the receptacle to engage the lead in device along with the boardlock with the PCB 270. PCB 270 may, for example, have a thickness of 0.062 in. From FIG. 8c it will be seen that when the mounting foot 262 is superimposed on the top surface 276 of the PCB the arcuate edges of the legs 248 and 252 will bear against the peripheral surface 274 of the aperture. At this point the projection 254 from the arcuate edge 252 will bear against the bottom surface 278 of the PCB. The projection 250 which is spaced axially downwardly from projection 254 will not be engaged by the board 270. Referring, however, to FIGS. 9a and 9b the use of this assembly is shown in engaging a connector to a thicker PCB to a connector. Referring particularly to FIG. 9a, the operation of the assembly from its front is shown. As downward pressure is applied to the receptacle 260, the mounting foot approaches the top surface 286 of the PCB 280, the semi cylindrical members guide the boardlock toward the aperture 282. Referring particularly to FIG. 9b when the PCB is at rest on this surface, the protection 250 bears against the bottom surface 288 of the PCB. Thus it is again illustrated that a single boardlock will serve to fix a receptacle on two boards of different thicknesses.
It will be appreciated that a means for efficiently and inexpensively mounting an electrical connector on a PCB has been described in which a single boardlock may be used on several board thicknesses.
Those skilled in the art will also appreciate that although the embodiments illustrated included only one PCB engaging projection on each leg that it would be possible to have several axially spaced projections on each leg to adapt the device to engage more than two board thicknesses.
While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims. | Disclosed is an assembly which comprises a printed circuit board on which there is mounted a component of an electrical connector. The printed circuit board and the electrical connector component have aligned mounting apertures. A boardlock member extends axially through these apertures and has a mounting foot engagement structure from which two resilient spaced legs depend. These spaced legs each have projections which are axially spaced from one another so that the connector member may engage a circuit board of one thickness on the projection of one leg and also engage a circuit board of another thickness by the projection on the other leg. | 8 |
FIELD OF THE INVENTION
[0001] The following invention relates generally to instrumentalities for projecting into space payloads based on the motive force of compressed gas contained within a gas cylinder. More specifically, the instant invention is directed to a handheld device fashioned to be evocative of a baton or billy club having an open end which discharges a missile type projectile such as a bean bag, squash ball, paint ball, or other instrumentalities such as a reel of coiled line to propel the launched item to a remote location.
BACKGROUND OF THE INVENTION
[0002] Handheld devices intended to subdue assailants or other people without resorting to extreme, life threatening measures such as the use of firearms have included gas propelled projectiles. Some devices have used the expanding gases associated as a product of combustion when using gun powder, for example to propel soft rubber bullets.
[0003] While the intent has always been to use less than lethal force in subduing a person exhibiting extreme antisocial behavior, incidents still occur where a rubber bullet, for example can hit a particularly sensitive part of a person's body having unintended consequences, even death. It is important to recognize that not all inappropriate conduct should mandate the same response. That is to say, a nonviolent demonstration should not elicit the same response as would be advised when confronted by a large enraged mammal.
[0004] The following patents reflect the state of the art of which Applicant is aware and is included herewith to discharge Applicant's acknowledged duty to disclose prior art. It is respectfully stipulated, however, that none of the patents teach singly nor render obvious when considered in an inconceivable, permissible combination, the nexus of the instant invention as described herein after and as particularly claimed.
[0005] Four of the patents, signed to M. B. Associates of San Ramon, Calif., U.S. Pat. No. 3,710,720, 3,728,809, 3,830,214, and 3,889,652 collectively appear to reflect the commonly understood structure associated with a handheld launcher of the type disclosed herein. These progenitors, however, fail to provide the sophistication based on today's needs. For example, these devices were susceptible to failure and damage from stresses induced during use and preexisting during manufacture. In addition, these devices failed to benefit from ballistic modules which allow differing payloads for differing situations. In addition, in order to achieve the muzzle velocity required for efficacy, these devices typically required more than one gas cylinder. These devices do not reflect the precise need to collimate exhausted gas from the cylinder to achieve maximum projectile velocity. Other deficiencies will become evident during the course of exploration of the instant invention.
[0006] The remaining citations show the state of the art further and diverge more starkly from the invention described hereinafter.
SUMMARY OF THE INVENTION
[0007] The instant invention is distinguished over the known prior art in the multiplicity of ways.
[0008] For example, most notably, the invention includes a ballistic module which is standardized in exterior contour so that any of a multiplicity of different payloads can be utilized at the discretion of the possessor of the launcher.
[0009] Moreover, the instant invention is distinguished over the known prior art in its ability to direct energy in a most efficacious manner so that the payload to be dispensed from the launcher will benefit from such optimization.
[0010] In addition, sophisticated molding techniques have been incorporated into the device in order to make the device “transparent” (stealthlike) both during transport and in utilization.
[0011] In addition, the device includes means for imparting rotation on the object propelled such that the trajectory of the object propelled is more accurately controlled and at the same time, damage is not done to the launcher since it is made from specially molded material.
[0012] By having such an optimized system, the durability, versatility and accuracy of the device will have been attained without any of the attendant defects and unwanted consequences associated with the prior art.
OBJECTS OF THE INVENTION
[0013] Accordingly, it is an object of the present invention to provide a new, novel and useful launcher to propel missiles from a handheld device using expanding gas.
[0014] A further object of the present invention is to provide a device as characterized above in which a ballistic module is dimensioned to be received within a barrel of the launcher, the module having any of multiplicity of payloads with a standardized exterior so that the versatility of the launcher will have been increased thereby.
[0015] A further object of the present invention is to provide a device as characterized above which is extremely safe to use, durable in construction and accurate.
[0016] A further object of the present invention is to provide a device as characterized above which lends itself to mass production techniques.
[0017] A further object of the present invention is to provide a device as characterized above which can temporarily disable a person without permanently harming the person.
[0018] A further object of the present invention is to provide a device as characterized above which allows the launcher to propel a line to a remote site.
[0019] Viewed from a first vantage point, it is an object of the present invention to provide a handheld gas propelled missile launcher, comprising in combination a barrel having an interior bore, a ballistic module dimensioned to be received within said bore, said module including a payload spaced from a gas cylinder by a gas cylinder opening means, and a handle at an end of said barrel adjacent said gas cylinder, said handle including means to move said gas cylinder against said opening means.
[0020] These and other objects will be made manifest when considering the following detailed specification when taken in conjunction with the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0021] FIG. 1 is a perspective view of the apparatus according to the present invention from one end.
[0022] FIG. 2 is a second perspective view from an opposite end thereof.
[0023] FIG. 3 is a similar perspective with the breach of the device open to allow insertion of a ballistic module within an interior bore.
[0024] FIG. 4 is an end view of the outlet muzzle of the device.
[0025] FIG. 4A is an exploded detail of rifling on that muzzle.
[0026] FIG. 5 is a section of the barrel showing the rifling of FIGS. 4 and 4 A taken along lines 5 - 5 of FIG. 1 .
[0027] FIG. 6 is a sectional view taken along lines 6 - 6 of FIG. 1 .
[0028] FIG. 7 is a sectional view similar to FIG. 6 showing the device in a just loaded configuration.
[0029] FIG. 8 is similar to FIG. 7 showing the device in a cocked position suitable for firing.
[0030] FIG. 9 is a detail when the device has just been fired.
[0031] FIG. 10 is a view similar to FIGS. 7 and 8 showing the just fired position.
[0032] FIG. 11 is a perspective view showing a projectile emanating from the muzzle of the device.
[0033] FIG. 12 is a sectional view taken along lines 12 - 12 of FIG. 3 showing the ballistic module just prior to firing.
[0034] FIG. 13 is a view similar to FIG. 12 with a compressed gas cylinder having just been penetrated.
[0035] FIG. 14 shows the effects of the gas cylinder having been penetrated and discharging the projectile.
[0036] FIG. 15 is a perspective view of a perforated disc which discharges the gas from the cylinder.
[0037] FIG. 16 is a view similar but opposite from FIG. 15 showing the focusing of the exhaust gas from the cylinder through perforations as it passes into a projectile chamber.
[0038] FIG. 17 is an exploded parts view of one module.
[0039] FIG. 18 is a sectional view of the FIG. 19 exploded parts view.
[0040] FIG. 19 is another exploded parts view of the ballistic module with a step-down sleeve to accommodate a smaller gas cylinder.
[0041] FIG. 20 is a perspective view showing a different type of projectile.
[0042] FIG. 21 is a sectional view taken along lines 21 of FIG. 20 .
[0043] FIG. 22 is an exploded parts view of FIGS. 20 and 21 .
[0044] FIG. 23 is an end view of a spool shown in FIGS. 21 and 22 as it would appear adjacent to the gas cylinder.
[0045] FIG. 24 is a perspective view of a hollowed, modified projectile as it appears from an interior of the barrel with a set screw removed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] Considering the drawings, wherein like numerals denote like parts, reference number 10 is directed to the launcher according to the present invention.
[0047] In its essence, the launcher 10 includes a barrel 2 , having a reinforced barrel end 20 adjacent a handle 50 . The barrel 2 and handle 50 are adapted to move between a first closed position ( FIG. 1 ) to a second open position ( FIG. 3 ) so that a ballistic module 90 can be placed within an interior of the barrel 2 for launching.
[0048] More particularly, the barrel 2 includes an integrally formed, substantially cylindrical bore 4 . A muzzle end of the bore 4 includes rifling 6 configured as elongate channels spirally deployed within the interior bore and terminating at an open, free end of the barrel, remote from the handle 50 . More particularly, and with reference to FIGS. 4, 4A and 5 , the rifling 6 is shown as transitioning into the surface of the bore 4 by means of radius corner 8 at each side of the rifling channel 6 . Preferably, the depth ranges between 0.025″-0.045″. At its minimum depth, the channel depth of 0.025 inches is equal to the dimension 12 shown in FIG. 4A . The thickness is no greater than a multiple of the ideal channel width (0.375″), preferably the thickness ranging from 10-20 times the width. The end of the rifling channel 6 remote from the free end of the barrel terminates in a smooth taper 14 as it transitions to a portion of the bore's smooth cylindrical interior. Only approximately ⅓ of the free end of the bore 4 is provided with rifling 6 . As is well known, the spirally disposed rifling imparts rotation on the projectile resulting in truer flight of the projectile. Rifling twist ranges 0.110-150 and preferably 0.130″ exists over a rifling length of 2.75″ (i.e. 2.75″-2.975″).
[0049] What is especially remarkable about the rifling in the instant invention, however, is that unlike the prior art, the rifling is integrally formed in the barrel at the time the barrel is injection molded. Prior art techniques relied on subsequent broaching. Typically, a mandrel or other preform defines the void of the bore 4 and includes the rifling characteristics in mirror image on an exterior surface, where upon when the mold is opened and the mandrel removed, the injection molded article will have the contours thus described herein above on the interior bore at a free end thereof. To facilitate this, the mandrel may include radially extensible members which assist in forming the rifling. Rifling formed in this manner assures a truer trajectory, but more importantly does not tear or harm the payload.
[0050] Another attribute of the instant invention during formation of the barrel includes the positioning of inlet gates for the injection molded material to be pressed into the mold. The gates are at remote distal extremities of the barrel and injected under relatively high pressure but at a slow rate of material introduction so that long chains of the injected material can remain integral with one another in providing greater strength for the barrel. Molding cycle time is also kept relatively long to increase barrel stability. For example, cycle time may range from 3 to 10 minutes.
[0051] A breech end of the barrel remote from its muzzle end includes a reinforced thickened barrel end 20 adjacent handle 50 . The reinforced barrel end 20 , as shown in FIG. 1 includes a pintle support 16 projecting up from the thickened end and allowing a hinge mechanism operatively associated with the handle to be connected thereto. The hinge mechanism will be described in detail herein after.
[0052] The barrel end 20 further includes a shoulder 24 facing adjacent the free end of the barrel having an opening 24 a to receive a hinge pin that passes through the pintle support 16 . In addition, the barrel end 20 includes a flange 18 separated from the shoulder 24 by means of a recess 22 that extends partially around the barrel 2 . The remainder of the barrel 2 is supported by the thickened barrel end 20 . One extremity of the recess 22 defines an end wall 26 having a depth equal to the thickness of the shoulder 24 as it relates to the recess 22 . In addition, the area where the flange 18 terminates adjacent the end wall 26 includes a shallower end wall 28 which is remote from the pintle support 16 . The deep end wall 26 and the shallow end wall 28 will have significance that shall be appreciated hereinafter. Flange 18 also supports a groove 32 on an inner periphery thereof, the groove 32 having a purpose to be assigned. Flange 18 also includes a purchase area 34 contoured as a recess in an edge of the flange 18 adjacent the handle 50 . An edge of flange 18 nearest handle 50 also supports a spring biased ball 36 whose purpose will be appreciated hereinafter.
[0053] Details of the handle 50 can now be explored with respect to FIGS. 1 through 3 and 6 through 8 . In its essence, the handle 50 is formed as a molded monolith 52 . The monolith 52 has a hollow central core 54 extending longitudinally along its entire extent. The hollow central core 54 communicates with a longitudinally and radially extending track way 66 . The track way 66 includes first and second notches 70 which are in communication with the track way but transversely offset into the handle's monolith 52 so as to provide first and second stop members. A free end of the handle 50 includes a knob 56 which has a hole 77 in axial alignment with the central hollow core 54 . An area remote from the knob 56 adjacent the barrel includes a raised portion 58 defining a hilt. The span between the knob 56 and the hilt 58 includes a gripping area 62 featuring a plurality of circumferential annular ribs 64 longitudinally spaced on the gripping area.
[0054] As shown in the drawings, an actuator 60 projects up from the track way 66 and is constrained to operate within the track way 66 by means of an actuator slide 74 having an exterior diameter complemental to the central hollow core inner diameter 54 . The actuator 60 is operatively connected to the slide 74 by means of an actuator stem 72 having a substantially cylindrical contour whose cross sectional area is complemental to the cross sectional area of the notches 70 formed in the monolith 52 . Thus, as shown in drawings 7 and 8 , for example, the actuator 60 can be moved from a first at rest position (e.g. FIG. 7 ) to a second “ready” position (e.g. FIG. 8 ). The actuator 60 is at rest in the FIG. 7 position. When oriented in the FIG. 8 position, the actuator had been moved within the notch 70 against spring pressure.
[0055] More specifically, the slide 74 has a spring retainer 78 configured as a long elongate stem projecting from a face of the slide adjacent the knob 56 . The hole 77 in the knob 56 is dimensioned to allow the spring retainer 78 to project partially outwardly therefrom. The retainer 78 captures an actuator spring 76 within the central hollow 54 and over the retainer 78 . Thus, energy is stored in spring 76 when deployed as in FIG. 8 by its having been compressed and held in the compressed configuration by the actuator stem 72 being captured in notch 70 . When oriented as in FIG. 8 , when the actuator stem 72 is placed back in axial alignment with the track way 66 , the actuator 60 will move in the direction of the arrow C with considerable force.
[0056] Prior to orientation of the actuator as thus described, the handle should first be moved to its open FIG. 2 position to allow the ballistic module 90 to be placed within the breach of the barrel 2 . Handle 50 therefore includes a door 40 held captive in the closed FIG. 2 position by means of the spring biased ball 36 discussed earlier. The door 40 can move from a closed position of FIG. 2 to an open position of FIG. 3 by pressing release pin 38 located on the door 40 in the direction of the arrow A shown in FIG. 2 . This overcomes the spring tension on the spring biased ball and plunger 36 allowing the door to swing in the direction of the arrow B of FIG. 2 .
[0057] More particularly, the door 40 includes a cover 42 which overlies recess 22 of the barrel. The cover 42 includes a thin portion 42 a and a thick cylindrical portion 42 b. The thin portion 42 a has an edge 44 that is in tangential registry with an edge of shoulder 24 so that the outer surface of the cover 42 is parallel with the outer surface of the shoulder 24 . The cover 42 includes an end wall edge 46 complemental to the end wall 26 , 28 of the recess 22 . The cover 42 also includes an end wall edge 48 complemental to an end wall 29 located on a shelf 30 which extends from a lower part of flange 18 , ( FIG. 3 ) and helps to define groove 32 .
[0058] As shown in FIG. 3 , the thick cylindrical portion 42 b of the cover moves from an exposed position to a sealed position when placed in tangential registry with the shelf 30 projecting from an end of the barrel 2 proximate to the handle 50 , and extending immediately away from the groove 32 . As shown in FIG. 3 , the end wall edge 48 adjacent the shelf 30 includes sufficient material to provide support for a hinge 48 a which passes through a hole contained on the material of the thick portion 42 b passes through the pintle support 16 and residing in the hole 24 a of shoulder 24 .
[0059] As shown in FIG. 3 , the device 10 when in the open position can receive the ballistic module 90 within the interior breach of the device. The ballistic module 90 includes a flange 92 at a terminal extremity so that when the module 90 is placed within the bore 4 at an end remote from the muzzle, the ballistic module flange 92 seats within the groove 32 of the barrel 2 and the finger purchase area 34 located on flange 18 allows a spent module 90 to be retracted from the barrel and replaced with a fresh load. FIG. 6 is a section view showing how the purchase area 34 allows clearance for a finger to grasp ballistic module flange 92 , in the FIG. 3 open position.
[0060] FIGS. 6 through 10 also show details of an end of the slide 74 remote from its actuator spring 76 . More particularly, an actuator stem 88 projects from an end of the slide 74 remote from the spring retainer 78 . Stem 88 includes a return spring 86 which is shown in a relaxed state in FIG. 6 , and in a compressed state in FIG. 9 . When the spring 86 is compressed, the actuator 60 is in an extreme position shown in FIG. 9 , and the actuator stem 88 projects into the breach and penetrates an opening 94 contained in the end of the module surrounded by the flange 92 . With the stem 88 as shown in FIG. 9 , a gas cylinder 100 moves to the left of FIG. 9 along the direction of the arrow D.
[0061] The stem 88 contacts the cylinder 100 the actuator 60 and its stem 72 are released from notch 70 . In addition, however, a safety 80 is included which prevents the stem 88 from advancing far enough to contact the cylinder 100 . The safety 80 is formed as an annular band 82 captured within an annular track way 81 . The annular band 82 includes an ear 83 defining a thumb tab so that the safety 80 can be moved from a first position ( FIG. 6 ) in which the stem 72 of the actuator 60 is held to the right preventing the actuator stem 88 from full penetration into the ballistic module 90 and a second position ( FIG. 10 ) in which the stem 72 is received within a slot 85 formed within the band 82 by rotation of the band 82 about the double ended arrow E so that the actuator stem 88 is free to advance forwardly and push the compressed gas cylinder 100 in the direction of the arrow D. The spring 86 allows the stem 88 to return to an at rest position by balancing the spring pressure of the return spring 86 against that of the actuator spring 76 whereby the stem 72 is clear of the safety 80 and the annular band 82 can be rotated to the locked position shown in FIG. 6 preventing inadvertent discharge.
[0062] FIGS. 12 through 14 show the sequence in which the gas cylinder 100 is initially protected from the stem 88 ( FIG. 12 ) to the actuation of the stem 88 along the arrow D by virtue of spring motion 76 along the direction of the arrow C ( FIG. 8 ) and then the return effect in the direction opposite from D (shown in FIG. 14 ) caused by the return spring 86 .
[0063] The cylinder 100 is contained within the ballistic module 90 which is generally configured as an elongate cylinder having an open end remote from the stem 88 . The area of the module 90 which circumscribes the cylinder 100 includes a generally cylindrical peripheral wall 102 having a series of annular ribs 104 spaced along the periphery of the ballistic module 90 . As is commercially available, the compressed gas cylinder 100 may include a threaded neck portion 103 having a sealed end 105 which can be punctured by means of a pin 106 ( FIG. 15 ) to allow the contents under pressure to escape. By advancement of the stem 88 , as described herein above, the cylinder 100 coacts against the pin 106 fracturing the sealed end 105 allowing the gas to escape.
[0064] More particularly, the ballistic module 90 supports a disc 108 at an end of the gas cylinder chamber which is remote from the module flange 92 . More specifically, the module 90 includes the peripheral wall 102 stepping up to a larger diameter by means of a sleeve 116 , the step up defining the abutment 112 which provides a stop member for the disc 108 . The additional diameter imposed by the sleeve 116 transitions to a plurality of longitudinal ribs 114 having the same diameter as sleeve 116 and overlying the peripheral wall 102 . In conjunction with the peripheral ribs 104 , ribs 114 provide rigidification and support for the peripheral wall 102 . The disc 108 is held against the abutment 112 by means of a gas focusing retainer 118 , the retainer 118 having a substantially conically tapering inner bore 117 such that it narrows and frictionally engages neck 103 of the cylinder 100 by a “wiper” type construction. Retainer 118 is an effective energy director meaning it will increase muzzle velocity by at least 20%. The conically tapering bore 122 is frictionally retained by threading on the threaded neck and is used to press the disc 108 against the abutment 112 . Importantly, the conical flare directs escaping gas, focusing it to the muzzle through disc 108 . A retention ring 124 appears at an opposite end of the cylinder 100 remote from the retainer 118 to hold the opposite end of the gas cylinder in fixed registry within the interior of the peripheral wall 102 . As thus described, puncture of the cylinder 100 directs all gas to the muzzle.
[0065] In addition to the pin 106 , the disc 108 has a plurality of gas passage ways 126 passing through the disc 108 radially offset from the pin 106 . A face of the disc 108 remote from the pin 106 exhibits a raised boss 128 which extends from the gas passage ways 126 to a disc like plate 130 which supports an opposite end of the pin 106 . Passage ways 126 as they pass through the wall of the boss 128 form a shaped hole having a “teardrop” narrowing such that the end of the air passage way nearest the plate 130 is slightly smaller than the rest of the air passage way. Like the retainer 118 , the result is that there is acceleration of the air and collimation or focusing of the air as it exits, such as a converging nozzle. FIG. 14 shows the exit path of the contents of the gas cylinder being removed upon puncturing the cylinder. Because of the retainer ring 124 , the tendency of the cylinder to move in the direction of the arrow F will have been kept to a minimum and as a consequence gas moving out in the direction of the arrow G exits with considerable velocity to launch the projectile.
[0066] A variation of the above described cylinder can be seen in FIGS. 18 and 19 . In this situation, a smaller dimensioned cylinder 100 ′ is circumscribed by a cylindrical sleeve 102 ′ which nests in tangential registry within the conventional peripheral wall 102 . In addition, because the length of the smaller cylinder 100 ′ requires it, a plug 125 is placed adjacent an end of the smaller cylinder 100 ′ remote from the end which addresses the pin 106 . The plug 125 includes a peripheral notch 123 to receive the retaining ring 124 . In this manner, the two commonly available compressed gas cylinders can be accommodated by a single device 10 .
[0067] Various projectiles can be used in conjunction with the instrumentality described herein above. For example, FIG. 17 and 18 show a “bean bag” 140 being deployed. The bean bag 140 is inserted into the sleeve 116 and is retained there by means of a stopper 142 . The stopper is a substantially circumferential band having an exterior diameter having complemental to the interior bore of the sleeve 116 . The bean bag 140 is similarly dimensioned and an end opposite the stopper 142 is held in place within the sleeve by a force distribution plug 144 . Like stopper 142 , the plug 144 is also an annular band having first and second annular wipers 146 separated from each other by a necked down intermediate portion so that the two wipers provide a good seal maximizing force upon rupture of the cylinder 100 , 100 ′. Because of the rifling, a bean bag or other fabric type projectile will not “edge” (fly like a Frisbee”) it will always 100% of the time unfurl and have a flat (pancake type) flight.
[0068] Upon rupture, all expanding gas force is delivered from the cylinder, focused in conical bore 117 , through the passage ways 126 and focused in four distinct streams against a rear wall 141 of the bean bag 140 . This allows the bean bag 140 to be released from the barrel with considerable force. The dimensioning of the stopper 142 is strategically selected to provide a minimal impediment to the bean bag exiting but also has sufficient friction to assure that the bean bag will not fall out when the device 10 has its muzzle facing downwardly. The bean bag 140 can be formed from absorbent material to receive a substance such as pepper spray so that upon impact a mist of the spray will assist in disabling the target. Although element 140 has been characterized as a bean bag it could be a projectile having different attributes apart from that which is commonly understood by bean bag. For example, the projectile 140 could also be contoured as a paintball.
[0069] FIGS. 20 through 24 reflect another alternative for a payload.
[0070] Instead of the bean bag 140 , a nose cone 240 having a rounded leading area is provided. The rounded nose cone 240 is received within the sleeve 116 , similar to the bean bag 140 . The nose cone 240 includes an annular band 242 at a trailing portion thereof which leads to a notch 244 that circumscribes the nose cone aft of the band 242 and is directed inwardly. Thereafter, a comical flare 246 projects from the notch and diverges away from the leading edge of the nose cone 240 so that in conjunction with the band 242 , the conical flare 246 provides a seal within the interior of the sleeve 116 . The nose cone 240 is generally of solid material but includes a toroidal recess 248 that has a substantially constant cross-section just radially inward of the band 242 but tapers so that the cavity runs parallel to the taper of the nose cone 240 as it extends forwardly. The interior of the toroidal recess 248 may remain hollow or may include ballast 250 shown in the drawing as particulate matter such as shot or bb's, for example to enhance the trajectory of the nose cone. The shot or bb's are retained within the recess 248 by means of an end plate 249 . The nose cone 240 also includes a system 252 in the recess 248 having an interior bore with threads 254 which face outwardly away from the leading edge of the nose cone and exposed within the conical flare 246 . The exterior wall of stem 252 serves as one wall defining the toroidal recess 248 . As shown in FIG. 21 , the innermost radial wall of the toroidal recess has a substantially constant radius from along a longitudinal centerline. The stem 252 , by virtue of its interior threads, can receive a screw 256 to hold the end plate 249 in fixed position so that the ballast 250 is captured within the toroidal recess 248 . The screw 256 also serves as an attachment point for a tether 258 having a free end fixed to the screw 256 and a remote end deployed on a spool 260 . As shown in FIGS. 21 and 23 , the spool 260 includes a plurality of the strands of the tether wrapped on a spindle 262 formed as an interior surface of hub 264 . One end of the spool 260 includes a dished out area 266 adjacent disc 108 described herein above. The dished out area 266 includes passage ways 268 passing through the hub 264 and leading to outlets 270 . The passage ways 268 are in alignment with the air passage ways 126 of the disc 108 so that air flow is substantially unrestricted as it exits the disc and enters the dished out area and through the passage ways 268 and then to the outlets 270 . Note that in FIG. 22 , the element 272 corresponds to the pin 106 of FIG. 15 but instead passes through a center core of the hub 264 , the pin 272 configured as a screw and is used to strike air cylinder as discussed with respect to pin 106 . The passage way openings adjacent the dish area 266 bear the same geometrical contour as discussed with respect to the air passage ways 126 as shown in FIG. 16 . When deployed, the nose cone 240 will payout the tether to a remote location.
[0071] Moreover, having thus described the invention, it should be apparent that numerous structural modifications and adaptations may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove and as described hereinbelow by the claims. | A handheld gas propelled missile launcher which deploys projectiles of varying payloads through the muzzle, and a ballistic module for changing payloads expeditiously. | 5 |
FIELD OF THE INVENTION
The present invention relates to the control of degassification of molten sulfur. More particularly, the present invention relates to the control, by selective oxidation, of the release of dissolved hydrogen sulfide from molten sulfur produced by the Claus process.
BACKGROUND OF THE INVENTION
The present invention relates to a process for inhibiting hydrogen sulfide released from molten sulfur. Elemental sulfur is produced on a commercial scale according to the Claus process in which hydrogen sulfide and oxygen react to produce elemental sulfur and water. The sulfur produced is separated, in the molten form, in sulfur condensers and withdrawn for transportation or use such as in the production of sulfuric acid.
An inherent feature of this process is the presence, in the produced molten sulfur, of dissolved hydrogen sulfide which not only contaminates the product but also poses potential hazards in several areas. In addition to creating nuisance odors in the vicinity of molten sulfur, hydrogen sulfide may be present in such quantities as to reach toxic levels when loading and unloading the sulfur. Further, when dissolved hydrogen sulfide in molten sulfur contaminates the vapor space in storage tanks and vessels, there is a threat that the lower explosive limit of hydrogen sulfide will be reached.
Normally in a gas/liquid system the adsorption rate of the gas is lower at higher temperatures. Thus, in principle, the hot, molten sulfur stream in contact with a gaseous phase containing hydrogen sulfide, as found in a Claus plant, should not represent a serious problem if dissolution is the only adsorption process. However, hydrogen sulfide is known to combine with the sulfur to form hydrogen polysulfides. The formation of the polysulfides is favored at the high temperatures of the Claus process. This is particularly true during the initial oxidation step in the furnace and boiler where the major portion of the sulfur is also produced. Unfortunately, the kinetics of the reverse reaction at lower temperatures characteristic of hydrogen sulfide removal are extremely slow. Thus, the polysulfides are inherently produced in the Claus process, and once formed are extremely slow in decomposing. Consequently, the apparent solubility of hydrogen sulfide in liquid sulfur is unexpectedly high due to the formation of polysulfides. The subsequent release or removal is slow and difficult, frequently involving significant quantities of hydrogen sulfide being released.
In response to this problem a number of methods have been suggested or developed to remove hydrogen sulfide from molten sulfur produced by the Claus process. Release of dissolved hydrogen sulfide has been carried out by agitating the molten sulfur by various means, by providing a sulfur lift through air bubbles and by circulating the sulfur over a stripping column. Mechanical agitation has also been employed. Released hydrogen sulfide is often removed by a sweep gas such as air, Claus tail gas or nitrogen.
The use of solid catalyst to convert hydrogen polysulfide to hydrogen sulfide and removal with a purge gas containing oxygen is disclosed in U.S. Pat. No. 4,844,720. United Kingdom Patent Specification 1,433,822 discloses the use of a nitrogen containing compound and an oxidizing gas to convert hydrogen polysulfides to hydrogen sulfide which is removed from molten sulfur. Exemplary nitrogen containing compounds disclosed therein are ammonia, amines including alkylamines or hydroxyalkylamines or urea or substituted urea.
The removal of odor from air or gas streams by scrubbing with a dilute alkaline solution of sodium hypochlorite and passing the solution through a nickel-based catalyst on a ceramic matrix is disclosed by Valentin et al. in the A New Process for Controlling Effluent Treatment Odors, BHR Group Conference Series Publication (1993), Second International Conference on Advances in Water and Effluent Treatment 1993, pages 107-117.
The effects of hydrogen peroxide, sodium/calcium hypochlorite and ferrous/ferric salts on hydrogen sulphide desolved in waste water is described in Evaluation of Chemicals to Control The Generation of Malodorus Hydrogen Sulfide in Waste Water, M. Tomar and T. Abdullah, Water Resources Volume 28 No. 12, pages 2545-2552, 1994.
SUMMARY OF THE INVENTION
The present inventors discovered a new method for controlling the odor and hazaards resulting from hydrogen sulfide gas evolution from molten sulfur. The method of the present invention selectively oxidizes hydrogen sulfide in molten sulfur by the addition of a hypohalide such as hypochlorite. The method of the present invention involves adding hypohalides to molten sulfur. It was discovered that hypohalides selectively oxidize hydrogen sulfide. The selective oxidation of hydrogen sulfide inhibits the evolution of hydrogen sulfide gas from the molten sulfur. By selective oxidation, it is meant that even in molten sulfur, where hydrogen sulfide concentrations are very low (as low as 10 ppm), the hypohalides oxidize the hydrogen sulfide preferentially over sulfur. This is evidenced by the efficacy of hypohalides in controlling hydrogen sulfide gas in the headspace over molten sulfur containing hydrogen sulfide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present inventors have discovered that the problems resulting from hydrogen sulfide gas evolution from molten sulfur could be controlled by treatment with a hypohalide. The addition of a hypohalide to molten sulfur was found to inhibit the volatilization of hydrogen sulfide gas. The preferred hypohalide is hypochlorite. It is believed that other hypohalides such as hypobromite will also provide this unexpected result. Commercially, hypochlorite compounds are usually supplied as salts of sodium or calcium; NaOCl or Ca(OCl) 2 , respectively. The addition of such salts of hypochloride to molten sulfur was found to selectively oxidize hydrogen sulfide, a relatively minor component of sulfur prepared via the Claus process. The following is a possible reaction pathway for the reaction of sodium hypochlorite with hydrogen sulfide.
NaOCl+H.sub.2 S→H.sub.2 O+S+NaCl
The hypohalide of the present invention may be added in an amount ranging from about 1 to 1,000 moles hypohalide per mole of hydrogen sulfide or hydrogen polysulfide present in the system being treated. The molten sulfur treated in accordance with the present invention is typically at a temperature of from about 115° C. to 450° C. The hypohalide of the present invention is preferrably added continuously to molten sulfur although batchwise addition may be employed. The hypohalide of the present invention may be added as an aqueous stream having a hypohalide concentration of from about 1% to 10% at a pH of from about 7-14.
The present invention will now be further described with reference to a number of specific examples which are intended to be illustrative and not as restricting the scope of the present invention.
Testing was conducted using a molten sulfur sample collected from a Claus unit at a Gulf Coast refinery as well as with a sample of reagent grade elemental sulfur. The sulfur was liquefied and added to vials for headspace gas chromatography. While maintaining the sulfur in the molten state, the sulfur in the vials was overpressured at 10 psig with a mixed gas containing 2000 ppm H 2 S in nitrogen. The vials were placed in an oven at 138° C. for approximately 16 hours to achieve equilibration of the H 2 S between the vapor and liquid phases. Treatments were added to the molten sulfur and allowed a 16 to 18 hour reaction period with the molten sulfur at 138° C. These conditions were chosen to be representative of both the temperature and residence time of sulfur in a sulfur pit.
H 2 S concentrations above the molten sulfur were analyzed by gas chromatography using a detector specific for sulfur compounds. Results of these analyses are shown below for four experiments, tests 1-4.
______________________________________TEST #1Sulfur - Sample form Gulf Coast RefineryUntreated Headspace H.sub.2 S Average = 1020 ppmppm H.sub.2 S - Avg.Treatment 5.25% Hydrogenppm Active NaOCl Peroxide______________________________________10 790 91125 209 104550 11 911100 <15 649250 16 274______________________________________
______________________________________TEST #2Sulfur - Sample from Gulf Coast RefineryUntreated Headspace H.sub.2 S Average - 798 ppmSodium Perborate5% in H.sub.2 Oppm Active ppm H.sub.2 S - Average______________________________________10 82825 36350 174100 138______________________________________
______________________________________TEST #3Sulfur - Sample from Gulf Coast RefineryUntreated Headspace H.sub.2 S Average - 360 ppmppm H.sub.2 S - Avg.Treatment 12.5% ppm Active NaOCl______________________________________ 10 <50 20 <50 30 48 40 <50 50 <50 70 <50______________________________________
______________________________________TEST #4Sulfur - Reagent Grade Elemental SulfurUntreated Headspace H.sub.2 S Average = 320ppm H.sub.2 S - Avg.Treatment 12.5% ppm Active NaOCl______________________________________ 2 380 5 190 10 240 20 <50 30 60 60 <50______________________________________
The resulting pH of hypochlorite solutions is between 12 and 13. In all tests of hypochlorite, the ppm active shown in the above tables refers to the ppm added as concentrated sodium hypochlorite.
All experiments except for Test #4 were conducted with sulfur samples collected at a Gulf Coast Refinery. Although there was significant variation in the amount of H 2 S measured in the headspace of the untreated vials, the data shows that hypochlorite is effective at inhibiting the generation of hydrogen sulfide from molten sulfur. Additionally, a comparison of hydrogen peroxide and sodium hypochlorite in Test #1, showed that hydrogen peroxide, a known scavenger of hydrogen sulfide in waste water applications, was far less effective and efficient for preventing hydrogen sulfide evolution from molten sulfur. Another oxidant, sodium perborate, was evaluated in Test #2 and found to be far less effective at preventing headspace H 2 S compared to sodium hypochlorite. Results for sodium perborate and hydrogen peroxide indicate that those oxidants may be less selective than hypochlorite as oxidants of hydrogen sulfide in a sulfur matrix.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of the invention will be obvious to those skilled in the art. The appended claims and this invention 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 for inhibiting hydrogen sulfite evolution from molten sulfur is disclosed. The method involves adding a hypohalide to molten sulfur containing hydrogen sulfite. The hypohalide, such as hypochlorite, hyprobromite, and their sodium or calcium salts inhibit the evolution of hydrogen sulfite from molten sulfur. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division and continuation-in-part of pending application Ser. No. 09/854,255 filed May 14, 2001, and entitled “Light Plug With Storage Compartment.”
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] This invention relates to electrical plugs and receptacles and more particularly to a storage compartment formed with or attached to the plug or receptacle.
[0003] Many electrical devices are supplied with a multitude of replacement components. This is especially true of strings of Christmas Lights. These light strings are generally comprised of approximately one hundred lamps wired in series. The lamps vary in size, voltage and color. One manufacturer's lamps are not necessarily interchangeable with another manufacturer's lamps. Furthermore the lamp voltages, bases and sockets are not necessarily the same from manufacturer to manufacturer. Bulbs have different voltages, types of glass bottoms to prevent twisting and different plastic bases that may or may not fit and some will fit but are loose so arcing can be a problem. Some manufacturers furnish spare parts in a plastic bag packaged with a new light string, but the user has no way to keep the spare parts with the light string.
[0004] The fuses used to protect each string of lamps are also not necessarily interchangeable from string to string as the amperage of each string may vary from manufacturer to manufacturer. For example the one ampere fuse from a fifty light string and the three ampere fuse from a one hundred light string are not interchangeable.
[0005] Christmas Lights are commonly purchased a few strings at a time. At the time of original purchase, each string of Christmas Lights is normally supplied with spare lamps, flashers and spare fuses. These are selected to match the original string of lamps so that the user has the proper replacement parts. Having and using the proper replacement parts is not only a convenience, it is a matter of safety. It is common that the replacement parts are placed in a plastic bag that is packed with the string of lights. The bag may be left loose in the package or may be stapled or taped to the light string. Each manufacturer has its own set of spare fuses and lamps resulting in the user collecting numerous bags of spare parts. Generally the user takes the spare parts bag and puts it away. The bag is often lost, misplaced or otherwise can't be located when the parts are needed. If the user finds the place where the numerous bags of spare parts are kept, the user usually cannot identify which bag of spare parts is used for a given string of lights.
[0006] Some people merely throw the entire string of lights away if a bulb bums out. This is expensive, wasteful and is inconvenient to keep replacing an entire light string when one lamp bums out. Leaving the burned lamp in its socket increases the voltage to other lamps in the string resulting in shortening the life of the other lamps and exacerbates the problem. Equally important, the user may just go through his spares until he finds one that fits, which can lead to other problems, such as the wrong voltage or loose connections.
[0007] The manufacturer may also supply special tools or items such as a bulb remover designed for use with the Christmas Lights. The problem with this is the same as the replacement bulbs; the tool can be easily lost. Another problem is that these special bulb removing tools are always sold separately and have not been provided with the light set in the current marketplace.
[0008] Applicant's invention solves the problem of losing or misplacing the spare parts provided with a string of Christmas Lights. A storage compartment is provided as a part of the light string. It can be molded as a part of the plug or receptacle on an end of the light string, or it can be an add-on compartment for existing plugs, receptacles or light-string wires. The compartment can be opened from the top, side or surface end to allow access to the interior of the compartment. The compartment is designed to accommodate the extra lamps and fuses normally supplied in a plastic bag. The compartment can also provide access to an easy-to-store bulb remover, or the bulb remover can be formed as a part of the compartment.
[0009] Thus, it is a primary object of the present invention to provide a decorative light string with an integral or attached storage compartment for spare components such as spare lamps and fuses.
[0010] Another object is to provide a decorative light string having an electrical plug or receptacle with a storage compartment in which the storage compartment has integrally formed therein a lamp-removing tool. The advantage of this is that it eliminates the need for a separate tool that may be easily lost.
[0011] Another object is to provide a decorative light string having an integral or attached storage compartment that can be economically and efficiently manufactured.
[0012] Yet another object is to have readily available the proper replacement components for a decorative light string, to minimize the possibility of the user selecting and using the wrong replacement component, such as an improperly sized fuse which creates a safety hazard.
[0013] These and other objects and advantages will be apparent to those skilled in the art from the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective view of a decorative light string embodying the invention.
[0015] [0015]FIG. 2 is a top view of the electrical plug included in the light string of FIG. 1.
[0016] [0016]FIG. 3 as a left end view of the electrical plug of FIGS. 1 and 2.
[0017] [0017]FIG. 4 is a side elevation view of the electrical plug of FIGS. 1 and 2.
[0018] [0018]FIG. 5 is a left end view of a first alternative embodiment of an electrical plug in which a semi-circular lamp remover is formed in the body of the plug.
[0019] [0019]FIG. 6 is a left end view of a second alternative embodiment of an electrical plug in which the body of the plug and the cover form a circular lamp remover.
[0020] [0020]FIG. 7 is a left end view of a third alternative embodiment of an electrical plug in which the cover is slidably retained in channels on the body of the plug.
[0021] [0021]FIG. 8 is a side elevation view of a fourth alternative embodiment of an electrical plug in which the compartment is a separate component that is attached to a conventional electrical plug.
[0022] [0022]FIG. 9 is a side elevation view of another alternative embodiment in which the compartment is attached to a receptacle instead of a plug.
[0023] [0023]FIG. 10 is a plan view of another alternative embodiment of a storage compartment that can be attached to a plug, receptacle or wires of a light string.
[0024] [0024]FIG. 11 is a plan view of a modified version of the embodiment of FIG. 10 in which the storage compartment accommodates two tiers of replacement components.
[0025] [0025]FIG. 12 is a side elevation of the storage compartment of FIG. 11 and a light-string plug to which the storage compartment is attachable.
[0026] [0026]FIG. 13 is a bottom perspective view of the storage compartment shown in FIG. 12.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] Turning to FIG. 1, there is illustrated an electrical plug 10 molded of an electrically non-conductive material such as plastic or a rubber compound. There are electrical prongs 12 that engage a socket. Alternatively the electrical plug can be formed as a receptacle 11 (FIG. 9) on the female end or socket end of an electrical cord. There are two or more, commonly three, electrical wires 14 that connect to the prongs 12 or, in the case of a female plug, to the receptacles in the socket. Throughout this application the term “electrical plug” shall also mean an “electrical socket”. The electrical wires 14 have a plurality of electrical sockets 16 connected to them. In the case of Christmas Lights, the electrical connection is generally a series connection. Each socket 16 has a lamp 18 mounted in it. There may be thirty-five to one hundred fifty lights in a string of Christmas Lights. The lamps are commonly 2.5 or 3.5 volts each and may be made of various colors for decoration.
[0028] As seen in FIGS. 1 and 2, the molded plug 10 has a pair of opposed sidewalls 20 , 22 , a front wall 24 and a rear wall 26 . Alternatively the molded plug may be formed of other configurations such as a dome, cylinder or circle. Within the confines of the walls 20 - 26 is a compartment 28 . The compartment 28 has a bottom 30 . There is a cover 32 that closes the top of the compartment 28 . The cover 32 is attached to the sidewall 20 by means of a molded or living hinge 34 . The living hinge 34 can be formed at the same time that the electrical plug 10 is molded. This minimizes the cost and number of components necessary to attach the cover 32 to the sidewall 20 . The cover 32 can be made of clear plastic or colored plastic or rubber, depending on the needs and desires of the manufacturer and user. The compartment is dimensioned to hold several spare lamps 36 , spare fuses 38 and a bulb pulling tool.
[0029] The cover 32 can also be provided with a set of raised domes or bubbles that are used to indicate light bulb voltage, amperage or other information relating to the bulbs or fuses. By depressing the appropriate domes or bubbles, the user has a visual indication of the bulbs or fuses to buy for replacement items. Additional information such as the number of lights in a string, the length of the string, the date purchased or other such indications can also be added to the cover by similar indicia. Alternatively, the voltage, amperage or other important information can be molded into the plug 10 , the cover 32 or bottom 30 when the parts are formed. This is a safety feature so that the user always knows what size lamps and fuses he or she should be using with a string of lights.
[0030] In order to keep the cover 32 in a secure closed position on the compartment 28 , there is provided a latch means 40 on the top of the side wall 22 . The latch can be a molded piece of rubber that engages an edge of the cover 32 opposite the living hinge. Instead of a latch, a magnetic strip may be added to the top of the sidewall 22 and a complementary magnetic strip on the edge of the cover 32 . Other closure devices could be utilized as known in the art. If desired, the cover may be made water-tight to keep moisture from entering the compartment 28 and possibly damaging the spare lamps 36 or fuses 38 .
[0031] As described above, there is provided a compartment 28 that is capable of storing spare lamps 36 and spare fuses 38 that is integral with the molded electrical plug 10 . The spare components are readily accessible when needed. The user merely opens the cover 28 , removes the needed spare, and closes the cover. There is no searching for the whereabouts of the spare parts bag or worrying about installing a wrong lamp or fuse. The current system of supplying the spare parts in a bag that is stapled to the wires between two of the bulbs also presents another safety issue. The staple can pierce the insulation and wire or can scratch the wire or the person removing the staple.
[0032] In FIG. 5, there is an alternative embodiment in which a semi-circular recess 42 is formed in the front wall 24 . The semi-circular recess 42 forms an opening 44 that creates a lamp remover tool to remove burned out lamps from their respective sockets. The diameter of the opening 44 is substantially the same as the diameter of the base of the lamp 18 . This allows the base of a burned out lamp 18 to be inserted into the opening 44 when the cover is opened. The cover is closed and held down by the user. This securely holds the lamp in the opening 44 . The user then pulls the socket 16 away from the lamp 18 . Optionally the recess 42 may have a metal insert 46 placed around its edge if the material forming the front wall 24 is not strong enough to withstand the force necessary to remove the burned out lamp. The recess is illustrated in the front wall 24 but can also be formed in the rear wall 26 . A small piece of flexible material can also be formed on the cover or as part of the front wall 24 to partially or completely cover the opening 44 . This keeps the spare lamps or fuses from falling out through the opening 44 .
[0033] [0033]FIG. 6 illustrates another alternative embodiment. The cover 28 is formed with a semi-circular dome 48 that aligns with the semi-circular recess 42 in the front wall 24 . The aligned dome 48 and recess 42 form a circular opening 50 . The dimension should be slightly smaller than the diameter of the socket 16 . When a burned out lamp 18 is inserted into the opening 50 , the user holds the socket 16 in place. The lamp 18 is then pulled out from the socket 16 . There is optionally provided a flexible webbed material 52 that has a plurality slits emanating from the center of the opening 50 toward the circumference of the opening 50 . This provides a covered opening that is easily penetrated by a lamp 18 when it is inserted into the opening 50 . The webbed material 52 can be easily formed with the cover 32 and front wall 24 .
[0034] [0034]FIG. 7 illustrates another alternative embodiment in which the cover 32 is attached to the molded plug 10 by a different means. Instead of using a molded hinge 34 , the cover 32 is held within a pair of U-shaped channels 54 , 56 extending along the top of the sidewalls 20 , 22 . The U-shaped channels 54 , 56 retain the edges of the cover 32 so that the cover can be removed from the compartment 28 by sliding the cover 32 horizontally along the top of the compartment 28 . The same types of lamp removers as described in the alternative embodiments shown in FIGS. 5 and 6 can be used with the embodiment shown in FIG. 7.
[0035] [0035]FIG. 8 illustrates another alternative embodiment in which a compartment 58 is formed as a separate stand-alone element. The compartment 58 can have the same features as the previously described compartment 28 such as different closure means and alternative lamp removal devices. However the compartment 58 has one or more open slots 60 at its bottom. The slots 60 receive plastic closure devices 62 such as conventionally used to secure bundles of wires together. These wire ties 62 securely hold the compartment 58 to the molded electrical plug 10 . Other means such as clips or clamps can be used to attach the compartment 58 to the plug 10 . Such alternative fastening means will be apparent to those skilled in the art. In this manner the compartments 58 can be added to existing Christmas Light strings.
[0036] [0036]FIG. 9 illustrates another alternative embodiment in which the plug 10 is replaced by a receptacle 11 having electrically conductive socket receiving slots 13 to receive the electrical prongs 12 . The compartment 58 is otherwise the same as described in FIG. 8 above. The compartment 58 is shown holding a bulb puller or bulb removing tool 68 . Any of the plugs 10 described herein can be replaced by a receptacle 11 with all other features of the compartment remaining intact.
[0037] [0037]FIG. 10 illustrates a modified storage compartment 70 that provides sub-compartments for more organized storage of different types of replacement components. The entire storage compartment shown in FIG. 10 is preferably formed as a single molded plastic part. Three yokes 71 , 72 and 73 extend upwardly from the bottom wall 74 of the compartment 70 to receive the tips of three replacement lamps 75 , 76 and 77 , respectively. The open upper end of each of the yokes 71 - 73 forms an opening that is slightly smaller than the minimum cross-sectional dimension of the lamp, and then flares out in the central portion of the yoke to approximately match the minimum cross-sectional dimension of the lamp. As a lamp is pressed down into the open end of the yoke, the two arms of the yoke are forced slightly apart to allow the lamp to enter, and then the arms spring back to capture the lamp within the yoke as the lamp enters the wider central portion of the opening in the yoke.
[0038] Near the right-hand side of the compartment as viewed in FIG. 10, a post 78 extends upwardly from the bottom wall 74 to capture a replacement fuse 79 against the adjacent sidewall 80 of the compartment 70 . The side of the post 78 facing the sidewall 80 is undercut slightly beneath its free end to capture the fuse 79 after it has been pressed down into the space between the post 78 and the sidewall 80 , deflecting the resilient post 78 slightly away from the sidewall 80 in the process.
[0039] The space between the post 78 and the end yoke 73 is utilized to store a lamp base 81 inserted between the post 78 and a second post 82 extending upward from the bottom wall 74 . The second post 82 positions the lamp base 81 between the fuse 78 and the lamp 77 .
[0040] The storage compartment of FIG. 10 can be provided with any of the different types of closures described above, such as a lid attached to one sidewall of the compartment by a living hinge. Alternatively, a plug or receptacle attached to an end of the light string may be provided with depending L-shaped flanges that mesh with corresponding exterior grooves in a pair of opposed sidewalls of the compartment so that the plug or receptacle serves as a closure for the storage compartment. A simple latch may be provided to prevent the compartment from sliding off the flanges.
[0041] FIGS. 11 - 13 illustrate a modified storage compartment 90 that is dimensioned to receive two tiers of replacement components. The thickest components are the lamp bases 91 and 92 , which are much smaller at their lower ends than at their upper ends. Thus, as can be seen in FIGS. 11 and 12, they are stored with their small ends overlapping, so that the depth of the storage compartment need be increased by only about 50% to receive the two overlapping bases 91 and 92 . This increase in depth is sufficient to accommodate two tiers of lamps and fuses.
[0042] As can be seen in FIGS. 12 and 13, the storage compartment 90 is provided with two plastic prongs 93 and 94 formed as an integral part of the storage compartment and adapted to fit into the socket of a standard socket 95 on the end of a light string. Thus, the storage compartment 90 can be removably attached to a light string by simply plugging it into the socket typically provided on one end of a light string. In addition, as can be seen in FIG. 13, the plastic prongs 93 and 94 form notches 93 a and 94 a so that the prongs can be removably attached to the wires 96 and 97 of a light string. Each of the notches 93 a and 94 a has a narrow throat 93 b or 94 b at its open end to hold the storage compartment 90 captive on the wires 96 , 97 after the prongs 93 , 94 have been pressed onto the wires.
[0043] Thus there has been described a that has a storage compartment for safely and securely storing spare components such as lamps and fuses. Furthermore the storage compartment may include an integrally formed lamp remover. Although the invention has been described in conjunction with certain specific embodiments, it will be understood that alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims. | A string of decorative lights comprises a plurality of elongated electrical conductors having multiple electrical lamps connected thereto at intervals along the lengths of the conductors, a small storage compartment for storing spare components for use in the light string, a movable closure for opening and closing the storage compartment to permit access to the spare components stored therein, and to closing the compartment during storage. The storage compartment is attached to the string of decorative lights so that the spare components stored therein are conveniently accessible when needed to replace a component in the light string. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to surgical instruments and, in particular to acetabular reamers.
[0002] An acetabular reamer having a reamer head is used in hip replacement surgery for re-forming the hip socket, or acetabulum, in preparation for implanting a prosthetic component, such as an acetabular cup or socket. To insure a proper fit of the prosthetic device, the deteriorated or diseased bone and cartilage needs to be cut or shaved away to healthy bone tissue so that the reamed acetabulum matches the contours of the prosthetic to be fitted.
[0003] In a typical hip replacement procedure, including an acetabular implant, a surgeon makes an incision in the hip area, displaces the existing hip joint, shapes the acetabulum with the reamer to receive a metallic or plastic prosthetic socket, inserts the prosthetic socket, replaces the ball of the femur with a prosthetic ball, and inserts the prosthetic ball into the prosthetic socket to complete the operation.
[0004] Typically, a reamer head is comprised of a continuous exterior surface that requires a large incision in the skin of the patient in order to place the reamer head adjacent the socket to be reamed. Such a reamer is shown in U.S. Pat. Nos. 5,658,290, 6,106,536 and 6,702,819. Unfortunately, the size of the incision, effects the time that is required for recovery of the operation with a larger size incision increasing the recovery time. In addition, a larger incision also makes the patient more susceptible to infection and increases the time frame that disease may be introduced into the body via the incision.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to surgical instruments and implants. In one aspect of the present invention, a rotary surgical reamer assembly for moving bone and tissue from a bone joint include a dome and a body. The dome may include an exterior and an interior as well as a plurality of cutting sites disposed on the exterior and a plurality of apertures adjacent to the cutting sites. The body preferably includes a base, a ridge and at least one column connecting the base to the ridge. In one aspect of the present invention, the dome is attached to the ridge.
[0006] The assembly also preferably includes a circumferential ridge having an exterior and interior, a first edge, a second edge and an opening extending from the first edge to the second edge. The circumferential ring includes a plurality of cutting sites disposed on the exterior and a plurality of apertures adjacent to the cutting sites. The first edge of the circumferential ring is adjacent to the dome and the second edge of the circumferential ring is adjacent to the base of the body. Preferably, the exterior of the dome and the exterior of the circumferential ring form a substantially continuous wall.
[0007] In one aspect of the present invention, the dome and the circumferential ring are part-spherical and in combination form a substantially hemispherical shape. The dome may include a pole further comprising a polar axis passing through the pole. The exterior of the dome and the exterior of the circumferential ring are preferably substantially curvilinear relative to the polar axis.
[0008] In one aspect, the interior of the circumferential ring may include a first portion rectilinear relative to the polar axis such that when the circumferential ring is disposed on the body, the first portion engages the at least one column to thereby prevent rotation of the circumferential ring relative to the body.
[0009] The dome may be remote from the base of the body at a sufficient distance to permit the dome and the body to be placed through an incision concurrently without causing the cutting sites of the dome to engage soft tissue surrounding the incision, as compared to when the circumferential ring and the body are passed through the incision concurrently where the cutting sites would contact the soft tissue surrounding the incision.
[0010] In one aspect of the present invention, a method of removing bone and soft tissue from a bone joint may include providing a first portion of a surgical reamer. The first portion having a first cutting surface for removing bone and soft tissue. The method also comprising providing a second portion of a surgical reamer that also includes cutting surfaces for removing bone and soft tissue. After making an incision at a portion of a body to allow access to a bone joint, the first portion is placed through the incision and subsequently the second portion is place through the incision and into the vicinity of the bone joint. Once the first portion and second portion are placed within the vicinity of the bone joint, they are assembled together such that the first cutting surface and the second cutting surface form a substantially single cutting surface.
[0011] In one aspect of the present invention, a method of removing bone and soft tissue from a bone joint includes making an incision into the skin of a patient to allow access to a desired location. The incision has dimensions that permit a first portion and a second portion of a reamer to pass through the incision and into the desired location, without a cutting surface of the first portion or second portion coming into contact with the skin surrounding the incision. The method also includes assembling the first portion of the reamer to the second portion of the reamer wherein the resulting assembly has overall dimensions larger than the dimensions of the incision such that if the resulting assembly was passed through the incision, the cutting surface of either the first portion or the second portion would come in contact with the skin surrounding the incision.
[0012] In another aspect of the present invention, an orthopedic implant is provided having a core with an interior surface, an exterior surface, a first end and an apex. The core also includes an engagement element. The implant further includes a ring having an interior surface, an exterior surface, a first edge, a second edge and an opening extending from the first edge to the second edge. The ring also having an engagement element, which corresponds to the engagement element of the core. The opening of the ring being sized to receive the core such that the apex of the core may be passed through the opening until the first end of the core is adjacent to the first end of the ring. When the first end of the core is adjacent to the first end of the ring, the engagement element of the core may be mated with the engagement element of the ring to thereby lock the core to the ring. In one embodiment the orthopedic implant described above is an acetabular shell implant.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates one embodiment of an acetabular reamer assembly according to the present invention;
[0014] FIG. 2 is a side view of a first component of the acetabular reamer assembly shown in FIG. 1 ;
[0015] FIG. 3 is a top view of the first component shown in FIG. 2 ;
[0016] FIG. 4 is a bottom view of the first component shown in FIG. 2 ;
[0017] FIG. 5 is a side view of second component of the acetabular reamer shown in FIG. 1 ;
[0018] FIG. 6 is a top view of the second component shown in FIG. 5 ;
[0019] FIG. 7 illustrates the second component of FIG. 5 being inserted into a patient;
[0020] FIG. 8 illustrates another aspect of the present invention relating for a two-part first component;
[0021] FIG. 9 illustrates an embodiment of an acetabulum shell according to the present invention.
DETAILED DESCRIPTION
[0022] The present invention relates to a surgical reamer assembly in the form of an acetabular reamer assembly 10 as shown in FIG. 1 . An acetabular reamer assembly 10 is generally useful for removing bone and tissue from a joint socket when performing reconstructive surgery, to facilitate the installation of a prosthetic device or to repair the damaged bone.
[0023] In one aspect of the present invention, the acetabular reamer assembly 10 preferably includes a first component having a body (not shown in FIG. 1 ), coupled to a dome 12 and a second component comprising a ring 14 . The dome 12 and the ring 14 in combination define the cutting surface of the acetabular reamer assembly 10 . A handle 16 is attached to the body and preferably extends transversely from the dome 12 as will be described below. The adjustment handle 16 may include a drive shaft 17 having a drive end 19 that is attached to a rotational driver such as a surgical drill (not shown). The surgical drill provides rotational movement to the drive shaft 17 , which in turn causes the dome 12 and the ring 14 to rotate. Such surgical drills are known to those in the art as for example surgical drills included in U.S. Patent Publication Nos. 2004/0087958, 2004/0153080, and 2005/0216022, the disclosures of which are hereby incorporated by reference herein.
[0024] With reference to FIGS. 2-4 , various aspects of the dome 12 will now be described. The dome 12 is preferably formed from stainless steel and includes an exterior surface 20 and an interior surface 22 . A plurality of cutting sites 24 is disposed along the exterior surface 20 of the dome 12 . The cutting sites 24 may comprise a plurality of cupped cutters distributed along the exterior surface 20 and oriented to face a rotational cutting direction, as known in the art. An aperture 26 , extending from the exterior surface 20 to the interior surface 22 may be positioned next to each cutting site 24 . The apertures 26 enable any material cut by the cutting sites 24 to pass from the exterior surface 20 of the dome 12 through the aperture and into a void below the dome. The cutting sites 24 preferably have sharp edges that extend beyond the exterior surface 20 of the dome 12 . The cutting sites 24 may be thought of as a plurality of grating holes, having a raised sharpened edge on one side of the hole facing the cutting direction for cutting and removal of bone in the acetabular region.
[0025] The dome 12 preferably has an arcuate shape similar to a portion of a sphere that includes an apex of the sphere. Thus, as shown in FIG. 2 , the dome 12 has an apex 21 and a bottom ridge 23 opposite the apex. A polar axis 30 passes through the apex of the dome 12 and a center of the dome. The arcuate dome 12 extends outwardly in a direction towards the equator of the sphere from the apex 21 . The dome has a maximum diameter L extending from a first point along the bottom ridge 23 to a second point along the ridge, the first point being 180° away from the second point along the bottom ridge but on the opposite side (180° along the circumference). In the preferred embodiment the spherical dome extends about 30° latitude with respect to an equator at approximately 90° from the apex 21 .
[0026] The dome 12 may be permanently or temporarily affixed to the main frame body 13 . In one aspect of the present invention, the main frame body 13 includes a base 42 , a ridge 44 , remote from the base, and a plurality of connecting walls such as columns 46 extending from the base to the ridge. As shown in FIG. 3 , the preferred base 42 is generally circular and similarly, as shown in FIGS. 3 and 4 , the ridge 44 is also circular. Both the base 42 and the ridge 44 , preferably extend about axis 30 , which also passes through a center of body 13 , such that base 42 and ridge 44 are concentric with one another. The ridge 44 preferably has a maximum diameter that is substantially equal to the maximum diameter L of the dome 12 . However, the base 42 has a maximum diameter L′ that is greater than the maximum diameter L of the dome 12 . The lengths all being measured from a first point along a circumference of the particular element to a second point along the circumference but 180° away from the first point.
[0027] Also as shown in FIG. 4 , a cross-bar system 45 is provided within an internal void 47 of the body 13 . The cross-bar system 45 includes a first bar 50 and a second bar 52 , which enable the handle 16 to be attached to the body 13 . As shown in the figure, the first bar 50 extends from a point along the edge of the ridge 44 through the center of the device, as defined by axis 30 to an opposite edge of the ridge. The second bar 52 , similarly extends from one edge of the ridge 44 to an opposite edge of the ridge and also passes through the center. Thus, the first bar 50 and the second bar 52 are preferably perpendicular to one another.
[0028] Another aspect of the present invention is ring 14 , shown in FIGS. 5 and 6 . Similar to dome 12 , ring 14 includes an interior surface 60 , exterior surface 62 and is formed from stainless steel. Also similar to dome surface 12 , ring 14 includes a plurality of cutting sites 24 A disposed along its exterior surface 62 and a plurality of apertures 26 A positioned adjacent the cutting sites. The apertures 26 A extend from the exterior surface 62 to the interior surface 60 of the ring and allow material cut by the cutting sites 26 A to pass from the exterior surface 62 of the ring to a void within the center of the ring. The ring 14 is preferably arcuate and concaved relative to axis 30 at least along its exterior surface 62 . The ring 14 also includes a first circular edge 64 having a first diameter D and a second circular edge 66 having a second diameter D′ remote from the first circular edge. The edges 64 and 66 define the boundaries of ring 14 . In a preferred embodiment, the maximum diameter L of the ridge 44 of the body has a dimension that is slightly less the dimension of the first diameter D of the first circular edge 64 . And the maximum diameter of the base 42 has a dimension that is slightly larger than the dimension of the second diameter D′ of the second circular edge 66 . The first circular edge 64 and the second circular edge 66 are preferably parallel to one another with the outer surface of the ring being part-spherical.
[0029] The ring 14 is situated about axis 30 and includes an opening 70 extending from the first edge 64 to the second circular edge 66 . In one preferred embodiment, the opening 70 has a larger diameter adjacent to second circular edge 66 than its diameter adjacent to first circular edge 64 .
[0030] As shown in FIG. 5 in shadow, the interior surface 60 of the ring 14 preferably includes at least one wall 71 that is perpendicular to first circular edge 64 or at least rectilinear to the edge. When the dome 12 and particularly the body 13 are assembled to the ring 14 , the wall 71 interacts with at least one column 46 to thereby prevent the ring 14 from rotating about the body, as will be described below.
[0031] In a method of assembling the acetabular reamer assembly 10 , the dome 12 is attached to the body 13 , either integrally or modularly such as being held on by screws or a taper lock. The dome 12 may also be snap-fitted to the body 13 or each element may have a structure that corresponds to the other structure, which permits engagement between the two elements but does not permit rotation between the two. The ring 14 is placed over the dome 12 with the apex 21 of the dome being received within the opening 70 of the ring adjacent to second circular edge 66 . The dome 12 and body 13 are continually translated through the opening 70 until the entire dome 12 extends outwardly past opening 70 adjacent first circular edge 64 . With the dome 12 positioned atop of the first circular edge 64 of the ring 14 , most of the body 13 is retained within opening 70 of ring 14 . But the ridge 44 of the body 13 is adjacent the first circular edge 64 of the ring 14 and the second circular edge 66 of the ring 14 is adjacent base 42 of the body. Since the base 42 has a larger maximum diameter L′ than the length of the second diameter D′, the body 13 can not pass entirely though the opening 70 . When assembled together, the dome 12 and ring 14 form a hemispherical body having a plurality of cutting sites 24 and 24 A and a plurality of apertures 26 and 26 A extending about their respective exterior surfaces, as shown in FIG. 1 . The second circular edge 66 is approximately equivalent to an equator of a sphere.
[0032] In this configuration, the acetabular reamer assembly 10 is ready to be employed to ream out an acetabulum such that an acetabular shell may be positioned correctly during reconstructive surgery.
[0033] In order to prevent the ring 14 from being able to rotate about the body 13 when the acetabular reamer assembly is employed and more specifically when a force causes the ring 14 and the dome 12 to rotate about axis 30 , an engaging mechanism may be provided as alluded to before. For instance, when assembling the ring 14 and the dome 12 together, the wall 71 of the ring 14 may be aligned with one of the columns 46 such that these two linear elements confront each other. Since the wall 71 and the column 46 are parallel or at least rectilinear to axis 30 , and are proximate one another when the acetabular reamer assembly is assembled, once coupled together, they do not permit the ring 14 to rotate about the body 13 of the acetabular reamer assembly 10 . Therefore, when the acetabular reamer assembly 10 is employed and a rotational force is applied to the body 13 via a surgical rotary hand piece, the ring 14 , and dome 12 also rotate simultaneously. The engagement mechanism prevents unwanted motion of the ring 14 relative to the body 13 .
[0034] In a method of use, the ring 14 and dome 12 are placed through an incision in the skin of a patient separately. After a surgeon determines an incision location on the patient, he next slices the skin to create the incision I, as shown in FIG. 7 . The ring 14 is then placed sideways through the incision. A sideways orientation of the ring 14 refers to an orientation wherein the plane of the first edge 64 and the plane of the second edge 66 are more parallel to the longitudinal direction of the incision I, than they are perpendicular, as shown in FIG. 7 . Once the ring 14 has been positioned in-situ, the ring is rotated such that the opening 70 and more specifically the second circular edge 66 of the ring faces the incision opening. Since the ring 14 , when orientated sideways, has a relatively narrow width, the size of the incision may be smaller than usually required to insert an integral cutting surface of a conventional acetabular reamer.
[0035] Next, the dome 12 and body 13 , which are already assembled together, are translated through the incision I. As with the ring 14 , during introduction through the incision I the plane of the base of the dome/body are oriented sideways with a plane that is tangential to the apex 21 of the dome and the base 42 of the body being more parallel to the longitudinal direction of the incision I, than they are perpendicular. When translating the dome/body 12 , 13 through the incision the base 42 may be used to pry the walls of the incision I apart in order to enlarge the incision opening. Since the skin is generally flexible, this can be accomplished without any further tearing of the skin. Once again, because the dome/body 12 , 13 only has cutting sites 24 along one portion of the combination component, i.e., dome 12 and body 13 , and more specifically does not have cutting sites proximate the base 42 of the body, the size of the incision required to place the dome/body component in-situ is smaller than the size of an incision required to place a reamer having a continuous hemispherical cutting surface. This prevents the cutters from damaging the soft tissue.
[0036] Thus, since the acetabular reamer assembly 10 is positioned within the body in two stages, and specifically the cutting sites 24 , 24 A are separately inserted, the incision I may by smaller than required for conventional hemispherical reamers. This is because conventional hemispherical reamers include a continuous exterior surface with cutting sites. As the conventional reamer is inserted through an incision, the incision must be sufficiently wide to prevent the skin from being cut by the cutting sites. This is particularly problematic where a cross section of the reamer is at its largest diameter such as at a position nearest the base of the reamer. This is because as the reamer is inserted sideways, the incision must be long enough to receive the maximum diameter of the reamer but also wide enough to receive the width of the reamer. Thereby requiring a relatively large incision.
[0037] The present invention avoids this by dissecting the cutting sites 24 , 24 A into two distinct halves, the dome 12 and the ring 14 . When oriented sideways, the ring 14 may have a maximum diameter that is equal to the diameter of a conventional hemispherical reamer also oriented sideways but the width of the ring is less. The combination of the dome 12 and body 13 , when oriented sideways, has a width equal to the width of a conventional reamer but a maximum diameter that is less. And since the combination of the dome 12 and body 13 does not include cutting sites positioned proximate the end of the body that is remote from the dome, to insert the dome/body 12 , 13 , the base 42 of the body maybe placed against the skin positioned adjacent a longitudinal side of the incision I. The body may then be used to pry open the flexible skin such that the dome/body 12 , 13 may be inserted therethrough. Because all of the cutting sites 24 are proximate only the ends of only one side of the incision, the likelihood that the cutting sites may contact the skin is reduced. Plus the requirement of greatly stretching the skin or having a larger incision is eliminated, as compared to an incision required for conventional hemispherical reamers. This configuration enables the dome/body 12 , 13 to be received through an incision while minimizing the risk that a cutting site will tear the skin around an incision.
[0038] Once the dome/body 12 , 13 are placed in-situ, they are rotated such that the apex 21 of the dome is aligned with the opening 70 of the ring 14 . Also, if an engagement member is provided such as discussed above, it may be correctly aligned. For instance, a column 46 of the body may be aligned with the wall 71 of the ring 14 . The dome/body 12 , 13 is translated through the opening 70 until the entire dome 12 extends outwardly from the opening with the bottom ridge 23 of the dome positioned adjacent the first circular edge 64 of the ring. The wall 71 and column 46 may not only prevent unwanted movement between the ring 14 and body 12 but may also provide a key-way system, that only permits the components to be coupled together in a specific spatial relationship. In other words, the ring 14 and body 13 can not be coupled together unless the wall 71 and a column 46 are aligned.
[0039] Once the elements are assembled together and the handle 16 is coupled to the cross-bar system (the handle is preferably coupled to the body during insertion of the dome and the body), a rotary power device may be connected to the handle so as to provide rotational movement to the handle 16 and subsequently to the dome 12 and ring 14 .
[0040] As the dome 12 and ring 14 rotate about axis 30 , the cutting sites 24 , 24 A are brought into proximity of the bone and soft tissue to be reamed to thereby begin the process of creating a cavity in the bone.
[0041] In another aspect of the present invention, as already alluded to, the dome 12 may be coupled to the body 13 in a removable manner. Thus, as shown in FIG. 8 , the dome 12 is shown disassembled from the body 13 . To fit the two elements together, the bottom ridge 23 of the dome may be removably attached or permanently attached to ridge 44 of the body 13 such as by snap fitting, welding, using various catch-mechanisms known to those in the art or the like.
[0042] Although the present invention has been described in conjunction with an acetubular reamer assembly, the concept of the invention may also be adapted for other purposes. For instance, an acetabulum implant shell 110 may be dissected in half to form a core 112 and a ring 114 , as shown in FIG. 9 . The core includes an interior surface 116 , an exterior surface 118 , an apex 117 and a circular edge 119 . Similarly, the ring 114 includes an interior surface 120 , an exterior surface 122 and an opening 124 extending from a first circular edge 126 of the ring to a second circular edge 128 . As with the acetabular reamer assembly 10 , the components of the acetabulum shell implant 110 may be inserted in a two-step process. This reduces the size of the incision required for inserting the shell, as compared to unitary shells.
[0043] In one method, after the acetabulum has been reamed, the ring 114 is inserted through an incision and placed adjacent the acetabulum. Next, the core 12 is inserted through the incision and subsequently through the opening 124 of the ring 114 . The core 112 is translated entirely through the opening 124 until the circular edge 119 of the core 112 is adjacent the first circular edge 126 of the ring 114 . In addition, the exterior surface 118 of the core 112 is positioned adjacent the acetabulum. Preferably, the interior surfaces, 116 , 124 of the core 112 and ring 114 form a substantially smooth and continuous surface such that a prosthesis placed adjacent the interior surfaces can angulate and rotate smoothly against the surfaces.
[0044] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | A modular part-spherical acetabular reamer including a first part-spherical element having an outer surface including a pole and a portion extending from the pole toward an equator of the reamer to a point intermediate the pole and the equator. The reamer also includes a second part-spherical element having an outer surface extending from the intermediate point towards the equator. Further, the reamer includes means for releasably coupling the first and second portions to form the modular part-spherical reamer. | 0 |
RELATED PATENT APPLICATION
[0001] This application is a Continuation-In-Part of U.S. patent application Ser. No. 10/092,852, filed on Mar. 5, 2002.
FIELD OF THE INVENTION
[0002] This invention relates generally to collapsible structures and more particularly to portable tents that are constructed to be easily constructed and collapsed.
BACKGROUND OF THE INVENTION
[0003] A variety of portable tents and similar collapsible structures have heretofore been known, includint those described in U.S. Pat. Nos. 6,209,557 Zheng), 5,038,812 (Norman), 5,467,794 (Zheng) and 5,560,385 (Zheng). These portable tents and similar collapsible structures may be used by children or adults for temporary shelter, camping, as beach cabanas, play houses, etc.
[0004] The ease with which portable tents or other collapsible structures may be constructed and collapsed is a significant factor that determines their desirability for use in applications that require rapid orfrequent construction and collapsing or easy portability, such as when these collapsible structures are used as beach cabanas, temporary play houses or while hiking, backpacking, rock climbing, etc.
[0005] Also, two or more portable tents or other collapsible structures are sometimes used in conjunction with one another and, in at least some applications, it may be desirable to connect two or more portable tents or other collapsible structures to one another to facilitate easy passage of humans, animals or objects from the interior of one structure to the interior of another structure.
[0006] Although the portable tents and similar collapsible structures have included a number of different designs, no one prior design is believed to be optimal and their remains a need in the art for the development of new and different portable tents and similar collapsible structures that are useable in new ways or are more easily collapsed/constructed or more easily portable than those of the prior art.
SUMMARY OF THE INVENTION
[0007] The present invention provides a collapsible structure (e.g., a tent, cabana, play hose, etc.) that generally comprises a plurality of pole members, a flexible covering disposed on the pole members, a plurality of strut members that are connected to the pole members and a hub assembly having upper and lower hub members, the hub assembly being attached to the pole members and the strut members. The structure is alternately disposable in a) a constructed configuration wherein the lower hub member is in abutment with the upper hub member and the flexible covering is drawn taut between the pole members and b) a collapsed configuration wherein the lower hub member is a spaced distance below the upper hub member, the pole members are closer together than they are when the structure is in its constructed configuration and the flexible covering is loosely disposed between the pole members.
[0008] Further in accordance with the invention, the strut members may be configured to exert an upward bias on the hub assembly when the structure is in its constructed configuration, thereby holding the hub members in substantially fixed vertical positions relative to one another and preventing the structure form inadvertently collapsing during use. When downward pressure is applied to the hub assembly, the upward bias of the strut memebrs is overcome, thereby releasing the hub assembly, allowing the upper and lower hub members to separate from one another and allowing the structure to assume its collapsed configuration.
[0009] Still further in accordance with the invention, the hub assembly may incorporate or be provided with locking structure(s) which mechanically lock the upper and lower hub members together when the structure is in its constructed configuration. These locating structures may be unlocked when it is desired to convert the structure to its collapsed configurations, thereby allowing the upper and lower hub members to move apart from one another and allowing the structure to assume the desired collapsed configuration.
[0010] Still further in accordance with the present invention, there are provided systems for attaching a plurality of collapsible structures of the forgoing type (or of any other type) to one another to form a multiple-structure assembly comprising a plurality of collapsible structures that are interconnects or linked to one another. Openings are formed in the individual collapsible structures and tunnel members are attachable to those openings so as to link the individual structures together and to provide enclosed or partially enclosed passageways between the individual collapsible structures that make up the multiple-structure assembly.
[0011] Still further in accordance with the present invention, collapsible structures of the forgoing type (or of any other type) may be provided with decorative markings or decorative items to impart entertaining or desired appearance(s) to the structure. For example, collapsible structures my have the appearance of a character (e.g., an animal or cartoon character). The decorative markings may be situated such that a door or flap which provides for passage into and out of the collapsible structure is positioned within an opening of the decorative object (e.g., the mouth of an animal or fish, the opening of a cave or volcano, etc.), thereby giving rise to the appearance that children or other users of the structure are passing into the opening of the decorative object as the enter the collapsible structure. In multi-unit embodiments, the decorative markings formed on each individual unit of the multi-unit assembly may fit together to give rise to a single decorative object (e.g. an elongate animal such as a snake or eel).
[0012] Further aspects and elements of the present invention will be appreciable to those of skill in the art upon reading the detailed descriptions of embodiments set forth herebelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a perspective view of a collapsible structure of the present invention in its fully constructed state.
[0014] [0014]FIG. 2 is a perspective view of the collapsible structure of FIG. 1 in its collapsed state, immediately after removal from its optional carrying case.
[0015] [0015]FIG. 3 is a perspective view of the collapsible structure of FIG. 2 in a partially constructed yet still partially collapsed state.
[0016] [0016]FIG. 4 is an enlarged view of portion 4 - 4 of FIG. 3.
[0017] [0017]FIG. 5 is an enlarged view of portion 5 - 5 of FIG. 3.
[0018] [0018]FIG. 6 is a perspective view of the top portion of the collapsible structure of FIGS. 1-5 in a nearly fully constructed state.
[0019] [0019]FIG. 7 is a perspective view of the top portion of the collapsible structure of FIGS. 1-5 in its fully constructed state.
[0020] [0020]FIG. 8 is sectional view taken vertically through the upper and lower hub members of the upper assembly of the collapsible structure shown in FIG. 1.
[0021] [0021]FIG. 9 is anothersectional viewtaken verticallythrough the upperand lower hub members of the upper assembly of the collapsible structure shown in FIG. 1.
[0022] [0022]FIG. 10 is a sectional view taken vertically through the upper and lower hub members of the upper assembly of the collapsible structure shown in FIG. 1 while in its locked in its constructed configuration.
[0023] [0023]FIG. 11 is a sectional view taken vertically through the upper and lower hub members of the upper assembly of the collapsible structure shown in FIG. 1 after downward pressure has been applied to the upper hub member so as to cause the lower hub member to separate from the upper hub member and causing the structure to begin to transition from its constructed configuration to its collapsed configuration.
[0024] [0024]FIG. 12 is a collection of perspective views of multiple unit embodiments oc the persent invention with and without decorative markings formed thereon.
[0025] [0025]FIG. 13 is a diagram of an alternative hub assembly that is useable in embodiments where structure is locked in its constructed configuration with the internal angle between a longitudinal axis projected through each the strut member and an axis projected through the center of the hub member (e.g., a vertical axis) is less than or equal to 90 degrees when the structure is in its fully constructed state.
[0026] [0026]FIG. 14 is a diagram of another alternative hub assembly that is useable in embodiments where structure is locked in its constructed configuration with the internal angle between a longitudinal axis projected through each the strut member and an axis projected through the center of the hub member (e.g., a vertical axis) is greater than 90 degrees when the structure is in its fully constructed state.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0027] The following detailed description is provided for the purpose of describing only selected embodiments or examples of the invention and is not intended to describe all possible embodiments and examples of the invention.
[0028] [0028]FIGS. 1 and 12 show an examples of a collapsible structures 10 of the present invention in their fully constructed configurations. As shown in FIG. 1, each collapsible structure 10 generally comprises a) a support frame formed of a plurality of pole members 14 , a plurality of strut members 60 and upper and lower hub members 38 , 32 and b) a flexible covering 22 formed of woven nylon, plastic sheet or similar material. As shown in FIG. 12, flexible covering 22 has a flap opening 21 , such flap 21 being securable in a closed position by a zipper 23 .
[0029] Optionally, as shown in FIG. 1, a removable panel 24 may be formed in the flexible cover 20 to and such removable panel 24 may be secured to the flexible cover by a zipper 25 .. When the removable panel 24 is removed and opening is formed in the flexible cover 22 of the collapsible structure 10 . As shown in FIG. 12, and optional tunnel members 60 may be used in conjunction with two of the collapsible structures 10 that have optional removable panels 24 to form a multi-unit collapsible structure. The optional total member 60 preferably comprises a to the formed of flexible material such as woven by a line, plastic sheet or other suitable material. Zippers may be formed around the either end of the tunnel member 60 and may be mated or meshed with the portions of the zippers 25 that remainin on the flexible covers 22 of the collapsible structures 10 after their optional removable panels 44 have been removed. In this manner, one end of a tunnel member 60 may be connected to an opening formed in one collapsible structure 10 and the other end of that tunnel member may be connected to an opening formed in another collapsible structure 10 , thereby forming a multi-unit collapsible structure wherein the tunnel member 60 acts as a passageway between two collapsible structures 10 . Although the embodiments shown in FIG. 12 utilize only two collapsible structures 10 , it will be appreciated that more than one removable panel 24 may be formed in some collapsible structures 10 and three or more of the collapsible structures 10 may be joined by tunnel members 60 to form multi-unit collapsible structures of this invention that incorporate more than two of the individual collapsible structures 10 of the type shown in FIG. 1.
[0030] Also, and shown in FIG. 12, decorative markings 62 may be formed on the flexible covers 22 and/or on the optional tunnel members 60 to impart a desired appearance. These optional decorative markings 62 may be used on single-unit or multi-unit collapsible structures 10 of this invention and may be particularly desirable when the collapsible structures 10 are intended for use as children's beach cabanas, children's playhouses, doll houses or otherwise for the entertainment of children. In these types of applications, it may be desirable for the decorative markings 62 to impart the appearance of an insect or animal. In this regard, the decorative markings 62 may be in the nature of facial features such as eyes, nose and mouth and the opened mouth of the creature may appear around the entry flap 21 of a collapsible structure 10 to give the appearance of entering through the mouth of the creature as a child passes through the entry flap 21 .
[0031] The collapsible structures 10 of the present invention may be easily constructed and easily collapsed and folded to a stowable configuration. When in their fully collapsed states, the collapsible structures may be inserted in two caring cases or bags. A desired carrying case (not shown) comprises a light weight, woven nylon case that has carrying handles and a zipper for opening and closing the carrying case.
[0032] To fully appreciate the manner in which the collapsible structure 10 may be constructed and collapsed, it is helpful to consider and understand the components, design and function of the support. structure and the manner in which the flexible cover 22 is disposed upon the support structure. The support structure generally comprises a plurality of pole members 14 , a plurality of strut members 16 , a hub assembly 29 comprising an upper hub member 38 , a lower hub member 32 and an actuator 30 . The pole members 14 extend through elongate receiving channels 15 formed in the corners of the flexible cover 22 and the bottom ends of the pole members 14 are inserted into tabs 19 that are attached to and extend from the bottoms of the corners of the flexible cover 22 . Each tab preferably comprises a pocket formed of durable fabric and having an opening in its top edge such that the bottom end of a pole member 14 may be received within the pocket as shown in FIG. 5. When the structure 10 is collapsed, as shown in FIGS. 2 and 3, the pole members 14 are substantially straight, the upper and lower hub members 38 , 32 are separated and spaced apart, and the flexible cover 22 is loosely disposed. Also, hinged joints 20 , as shown in FIG. 4, are formed in the pole members 14 approximately midway along their length. When the hinged joints 20 are extended as shown in FIG. 3, they reside within the receiving channels 15 of the cover 22 between notches or cut out areas 66 formed in the fabric that defines the channels 15 . These hinged joints 20 may be folded over in the manner shown in FIG. 2 to further collapse the structure 10 . The presence of the notches or cut away areas 66 facilitates such folding of the pole members 14 at their hinged joints 20 by preventing the fabric of the cover 22 that forms the channels 15 from bunching or binding the hinged joints 20 .
[0033] The process of converting the collapsible structure 10 from its collapsed configuration shown in FIG. 2 to its constructed configuration shown in FIG. 1 begins with unfolding of the hinged joints 20 to convert the fully collapsed structure shown in FIG. 2 to a partially collapsed states as shown in FIG. 3. Thereafter, with the bottom ends of the pole members 14 inserted into their receiving tabs 19 , the user may grasp the free ends of the two cords 34 , pulling them in opposite, horizontal, outward directions as illustrated in FIG. 6. The cords 34 are knotted within the lower hub member 32 as shown in FIG. 8. Thus, as the cords 34 are pulled outwardly, the lower hub member 32 will be drawn upwardly toward the upper hub member 38 such that the upper projecting portion 40 of the lower hub member 32 will be received within a bore or concavity 39 formed in the upper hub member 38 , and the upper and lower hub members 38 , 32 will be in abutting contact with one another. Also, as shown in FIG. 10, when the lower hub member 32 reaches its uppermost position in full abutment with the upper hub member 38 , the inner ends IE of strut members 16 may be slightly elevated above the outer ends OE of the strut members 16 and such upward slanting of the strut members will serve to exert a biasing force in the upward direction against the lower hub member holding it in abutting contact with the upper hub member 30 even afterthe user releases the cords 34 . Also, as the hub members 38 , 32 are pulled into abutting contact with each other, the pole members 14 will bow to an arcuate configuration, giving the fully constructed structure 10 the configuration shown in FIG. 1.
[0034] When it is desired to return the structure to its collapsed state, the user may simply push downwardly on the actuator knob 30 to flex the upper assembly 12 and poles 14 downwardly to a position where the inner ends IE of the strut members 16 are now lower than the outer ends OE of those strut members 16 . This results in a loss of the upward bias on the lower hub member 32 and allows the lower hub member 32 to separate from the upper hub member 30 , as shown in FIG. 11. The structure may then be picked up vertically by the actuator knob 30 without constraining or preventing free retraction of the cords 34 and the structure will assume the partially collapsed configuration shown in FIG. 3. Thereafter, the hinged joints 20 may be folded over to place the structure 10 in its fully collapsed state as shown in FIG. 2. The fully collapsed structure may then be placed in an optional carrying case (not shown) or otherwise carried or transported with ease.
[0035] As shown in FIGS. 10 and 11, when the hub assembly 29 is vertically situated, a hub axis, which in the drawings is shown as a vertical axis VA, is projectable through the center of upper and lower hub members 38 , 32 . Also, a strut axis SA is projectable through each of the strut members 16 . An internal angle A is definable between the strut axis SA and the vertical axis VA. When the structure 10 is locked in the constructed configuration shown in FIG. 10, angle A is more than 90 degrees and the outer ends OE of the strut members 16 are lower than or below the inner ends IE of the strut members 16 . When the structure 10 is in the unlocked configuration shown in FIG. 11(e.g., as it is being collapsed or constructed), angle A is less than 90 degrees and the outer ends OE of the strut members 16 are above or higher than the inner ends IE of the strut members.
[0036] In alternative embodiments, such as those shown in FIGS. 13 and 14, alternative hub assemblies 29 a , 29 b may be utilized to mechanically or frictionally lock the structure 10 in its constructed configuration without requiring angle A to be more than 90 degrees and without requiring the outer ends OE of the strut members 16 to be above or higher than their inner ends IE.
[0037] [0037]FIG. 13 shows one side of an alternative hub assembly 29 a that is useable in embodiments where the internal angle A between the strut axis SA and the vertical axis VA is less than or equal to 90° when the structure is in its fully opened or fully constructed configuration. In this alternative hub assembly 29 a , one or more downwardly extending legs G are formed on actuator cap 30 a and the actuator cap 30 a is at least partially rotatable, as indicated by the labeled arrows shown on FIG. 13. Receiving slots A are formed in legs G and protruding keys B are slidably received within slots A to stabilize and guide the up and down motion of actuator knob 30 a . The corner surface C of each leg G contacts a protruding key D formed on the lower hub member 32 a . A side slot E is also formed on a lower portion of leg G to receive another key member F that protrudes from the lower hub member 32 a. When it is desired to convert the structure from its open or constructed configuration to its collapsed configuration, the actuator cap 30 is turned in the counter-clockwise direction to the position shown in FIG. 13, wherein key B resides within slot A adjacent to but not within locking side slot AS, and key F resides adjacent to but not within slot E. The actuator cap 30 a is pressed downwardly, causing corner surface C to exert downward force on lower hub 32 a , causing lower hub member 32 a to separate from upper hub member 38 a , and allowing the structure to assume its collapsed configuration. When it is desired to convert the structure from its collapsed configuration to its open or constructed configuration, the various elements of the structure will be manipulated into the general configuration sheon in FIG. 1 with the hub assembly 29 a once again in the configuration shown in FIG. 13. Thereafter, the actuator cap 30 a is turned in the clockwise direction. This causes key B to slide into locking side slot AS, and key F to slide into slot E, thereby locking the upper and lower hub members 38 a , 32 a in fixed vertical positions relative to one another and preventing the structure from inadvertently collapsing during use.
[0038] [0038]FIG. 14 shows one side of another alternative hub assembly 29 b that is useable in embodiments where, when the structure is in its fully opened or fully constructed state, the internal angle A between the strut axis SA and the vertical axis VA is greater than 90°. In this alternative hub assembly 29 b , one or more downwardly extending legs G′ are formed on actuator cap 30 b . When the user presses downwardly on the actuator cap 30 b , the legs G′ extend downwardly into abutment with flange h of lower hub member 32 b . Slots A′ are formed in the legs G′ and protruding keys B′ are slidably received within slots A, thereby guiding the up and down motion of actuator knob 30 b.
[0039] Although exemplary embodiments of the invention have been shown and described, many changes, modifications and substitutions may be made bythose having ordinary skill in the art without necessarily departing from the spirit and scope of this invention. Specifically, elements or attributes described in connection with one embodiment may also be used in connection with another embodiment provided that the inclusion or use of such element or attribute would not render the embodiment in which it is incorporated unuseable or otherwise undesirable for an intended application. Accordingly, all such additions, deletions, modifications and variations to the above-described embodiments are to be included within the scope of the following claims. | A collapsible structure comprising a collapsible support structure having a flexible covering disposed thereon. The support structure comprises a plurality of pole members that emanate from an upper assembly. The upper assembly has first and second hub members that, when brought into abutting contact with each other, cause the structure to assume a fully constructed configuration but when separated from each other allow the structure to become collapsed. In many embodiments, the structure can be converted from its constructed configuration to its collapsed configuration substantially with the use of a single hand. In some embodiments, 2 or more of the collapsible structures may be joined together to form a multi-unit structure. These collapsible structures may include decorative markings on the flexible cover, especially in embodiments intended for use by or entertainment of children. | 4 |
FIELD OF THE INVENTION
The present invention relates to a monitor support structure for angle adjustment, and more particularly to a monitor support structure that provides the steady support effect and disperses the supported weight effectively.
BACKGROUND OF THE INVENTION
The monitor support structure must be angle-adjustable, frontward/backward adjustable, and leftward/rightward adjustable, besides providing the basic support function. With the gradual improvement in high-tech product, the traditional CRT monitor is gradually replaced by the LCD monitor. The LCD monitor has certain volume and weight even if it is thin and light and occupies smaller space. Therefore, the user must apply a certain amount of force for adjusting the angle of the support structure.
Furthermore, there exists a tendency to provide the LCD monitor with a bigger screen size, which makes the LCD monitor heavier. As a result, the purpose of the present invention is to provide a monitor support structure with better support torque and make it suitable for all view angles.
SUMMARY OF THE INVENTION
It is a main object of the present invention to provide a monitor support structure for adjusting the tilt angle of a LCD monitor. The elastic devices provide the elastic force for pulling the support arm downward so as to share the weight of the article. Besides, the linking rod can balance the weight of the article for steadily supporting the article.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational diagram of the present invention.
FIG. 2 is partially exploded diagram of present invention.
FIG. 3 is exploded diagram showing the support arm and pivotal connecting unit of the present invention.
FIG. 4 is a first partially, perspective diagram showing the assembled pivotal connecting unit and support arm of the present invention.
FIG. 5 is a second partially, perspective diagram showing the assembled pivotal connecting unit and support arm of the present invention.
FIG. 6 is a perspective diagram showing the internal structure of the support arm of the present invention.
FIG. 7 is a schematic diagram showing the operation status of the linking rod of the present invention.
FIG. 8 is schematic diagram showing the utilization status of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 , 2 , 3 , and 8 , a monitor support structure of the present invention generally comprises a clamping unit 1 , a rotatable arm 2 , a support arm 3 , a pivotal connecting unit 4 , a linking rod 5 , and a shiftable unit 6 .
In the present invention, the clamping unit 1 can be fixed on a tabletop 7 so as to allow the monitor support structure, which is constructed of the clamping unit 1 , the rotatable arm 2 , the support arm 3 , the pivotal connecting unit 4 , the linking rod 5 , and the shiftable unit 6 , to hold and support a LCD monitor 8 . The aforesaid clamping unit 1 has a support pillar 11 pivotally connecting to one end of the rotatable arm 2 . The rotatable arm 2 is leftward and rightward rotatable. A pivot unit 21 is extended from the other end of the rotatable arm 2 , and pivotally fixed between two bottom plates 43 , which are located on one side of the pivotal connecting unit 4 .
The pivotal connecting unit 4 has a shaft hole 41 , a penetrated guide slot 42 for holding a shaft 46 , a penetrated hole 48 , and a pair of hooking ears 44 on the other side of the pivotal connecting unit 4 . After penetration, the shaft 46 is sealed and fixed by a plug cover 461 . Besides, the pivotal connecting unit 4 is connectedly assembled to the support arm 3 .
The support arm 3 is a bar-shaped unit, and the support arm 3 is covered with a cover 36 . The support arm 3 has a chamber for orderly holding, for example, signal and power cables of the LCD monitor 8 . The support arm 3 has two clamping plates 32 bilaterally on the bottom for coupling with the pivotal connecting unit 4 . The support arm 3 further has two lateral plates 31 having respective symmetric long slots 311 on the respective upper portions. The lateral plates 31 have respective fixing units 312 closely under respective long slots 311 for fixing respective first ends of a pair of elastic devices 47 . One of the clamping plates 32 , which is located on the bottom of the support arm 3 , has a center hole 321 , a pin hole 322 , and several positioning holes 323 on the inner surface. In addition, the other clamping plate 32 has a center hole 321 , a slotted hole 324 , and several positioning holes 323 on the inner surface. A pair of friction devices 37 is disposed between the clamping plates 32 to touch the pivotal connecting unit 4 , thereby avoiding the attrition between the support arm 3 and the pivotal connecting unit 4 . Thus, the support arm 3 and the pivotal connecting unit 4 are smoothly pivotally rotatable. Each friction device 37 has a shaft hole 371 , a pin hole 372 , and several pins 373 .
Referring to FIGS. 2 through 6 , the assembly between the support arm 3 and the pivotal connecting unit 4 is shown. Each of the friction devices 37 is located between the clamping plate 32 and the pivotal connecting unit 4 . The pins 373 of the friction device 37 can be inserted into and coupled with the positioning holes 323 . The shaft hole 41 of the pivotal connecting unit 4 , the center holes 321 of the clamping plates 32 , and the shaft holes 371 of the friction devices 37 are penetrated through by a threaded rod 34 . Next, a screw nut 341 is screwed onto the threaded rod 34 for pivotally fixing the pivotal connecting unit 4 , the clamping plates 32 , and the friction devices 37 together. The center hole 321 of each of the clamping plates 32 is covered with a coupling cover 35 . The pin hole 322 of the clamping plate 32 , the pin holes 372 of the friction devices 37 , and the guide slot 42 of the pivotal connecting unit 4 are penetrated through by the shaft 46 , wherein one end of the shaft 46 is held in the slotted hole 324 of one of the clamping plates 32 . In addition, the other end of the shaft 46 is held in the pin hole 322 of the other clamping plate 32 , and covered with the plug cover 461 .
Besides, the penetrated hole 48 is formed on the pivotal connecting unit 4 above the shaft hole 41 for holding a shaft rod 49 , wherein first ends of the elastic devices 47 are fixed respectively on the fixing units 312 of the lateral plates 31 and second ends of the elastic devices 47 are respectively fixed on the both ends of the shaft rod 49 .
Moreover, the pivotal connecting unit 4 has the hooking ears 44 on rearward for holding a second shaft sleeve 52 that locates on one end of the linking rod 5 . The second shaft sleeve 52 is fixed on the hooking ears 44 by shaft assemblies 45 . The linking rod 5 has a first shaft sleeve 51 on the other end, wherein this first shaft sleeve 51 is held in the long slots 311 of the lateral plates 31 of the support arm 3 by respective screw assemblies 33 . In addition, two elastic sheets 331 are disposed between the first shaft sleeve 51 and the long slots 311 , respectively, for adjusting the tightness between the linking rod 5 and the screw assemblies 33 that screw thereon.
Two wing plates 313 are coupled with the respective upper ends of the respective lateral plates 31 of the support arm 3 , and connected to a joint unit 62 that couples with a mounting frame 61 of the shiftable unit 6 . The LCD monitor 8 is mounted on the shiftable unit 6 such that the LCD monitor 8 is leftward and rightward rotatable.
FIGS. 1 and 8 illustrate the assembled structure of the present invention. If there is a need to adjust the LCD monitor 8 to the optimum operation angle, as shown in FIGS. 2 and 7 , the user can shift the support arm 3 upward or downward to adjust the tilt angle. Because the pivotal connecting unit 4 is pivotally fixed on the rotatable arm 2 , the rotation of the clamping plates 32 of the support arm 3 including the friction devices 37 that couple thereto allows the movement of the shaft 46 in the guide slot 42 . Therefore, the tilt angle of the support arm 3 is changed by the movement of the shaft 46 . In addition, the linking rod 5 is upward or downward shiftable within a sliding slot 361 of the cover 36 such that the first shaft sleeve 51 of the linking rod 5 is shiftable within the long slots 311 of the support arm 3 . Besides, the movement of the support arm 3 provides the elastic devices 47 with the elastic force, which pulls the support arm 3 downward for sharing the weight of the LCD monitor 8 . After the adjustment is completed, the linking rod 5 can be tightly positioned by the screw assemblies 33 so as to provide the support arm 3 with the reliable tilt angle. Besides, the shiftable unit 6 that couples with the support arm 3 further allows the LCD monitor 8 to make the leftward and rightward movement.
While the preferred embodiment of the invention has been set forth for the purpose of disclosure, modifications of the disclosed embodiment of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments, which do not depart from the spirit and scope of the invention. | A monitor support structure generally comprises a clamping unit, a rotatable arm, a support arm, a pivotal connecting unit, a linking rod, and a shiftable unit. The clamping unit is provided for fixing so as to allow the monitor support structure to hold and support an article. The pivotal connecting unit allows the support arm to shift upward or downward for adjusting the tilt angle of the article. Besides, the elastic devices provide the elastic force for pulling the support arm downward so as to share the weight of the article. Moreover, the linking rod can balance the weight of the article for steadily supporting the article. | 5 |
RELATED APPLICATION
This application is a continuation application of Ser. No. 09/864,022 filed May 23, 2001, now U.S. Pat. No. 6,379,756, which in turn is a divisional application of Ser. No. 09/556,133, filed Apr. 20, 2000 now U.S. Pat. No. 6,264,788, which in turn is a divisional application of Ser. No. 09/094,451, filed Jun. 10, 1998, now U.S. Pat. No. 6,106,737 issued Aug. 22, 2000, which is a divisional application of application Ser. No. 08/424,127, filed Apr. 19, 1995, issued as U.S. Pat. No. 5,900,103 on May 4, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plasma treatment method by which substrates such as semiconductor wafers are etched or sputtered under plasma atmosphere. It also relates to a plasma treatment apparatus for the same.
2. Description of the Related Art
Recently, semiconductor devices are more and more highly integrated and the plasma treatment is therefore asked to have a finer workability in their making course. In order to achieve such a finer workability, the process chamber must be decompressed to a greater extent, plasma density must be kept higher and the treatment must have a higher selectivity. In the case of the conventional plasma treatment methods, however, high frequency voltage becomes higher as output is made larger, and ion energy, therefore, becomes stronger than needed. The semiconductor wafer becomes susceptible to damage, accordingly. Further, the process chamber is kept about 250 mTorr in the case of the conventional methods and when the degree of vacuum in the process chamber is made higher (or the internal pressure in the chamber is made smaller), plasma cannot be kept stable and its density cannot be made high.
SUMMARY OF THE INVENTION
When gases are made plasma, the action of ions in the plasma becomes different, depending upon frequencies of high frequency power. In short, ion energy and plasma density can be controlled independently of the other when high frequency power having two different frequencies is applied to process gases. However, ions (loaded particles) easily run from plasma to the wafer at a frequency band, but it becomes difficult for them to run from the plasma sheath to the wafer at another frequency band (or transit frequency zone). The so-called follow-up of ions becomes unstable.
Particularly molecular gases change their dissociation, depending upon various conditions (such as kinds of gas, flow rate, high frequency power applying conditions and internal pressure and temperature in the process chamber), and the follow-up of ions in the plasma sheath changes in response to this changing dissociation. Further, the follow-up of ions at the transit frequency zone also depends upon their volume (or mass). Particularly in the case of molecular gases used in etching and CVD, the dissociation of gas molecules progresses to an extent greater than needed when electron temperature becomes high with a little increase of high frequency power, and the behavior of ions in the plasma sheath changes accordingly. Plasma properties such as ion current density become thus unstable and the plasma treatment becomes uneven, thereby causing the productivity to be lowered.
When the frequency of high frequency power is only made high to increase plasma density, the dissociation of gas molecules progresses to the extent greater than needed. It is therefore desirable that the plasma density is raised not to depend upon whether the frequency is high or low.
An object of the present invention is therefore to provide plasma treatment method and apparatus capable of controlling both of the dissociation of gas molecules and the follow-up of ions and also capable of promoting the incidence of ions onto a substrate to be treated.
Another object of the present invention is to provide plasma treatment method and apparatus capable of raising the plasma density with smaller high frequency power not to damage the substrate to be treated.
According to the present invention, there can be provided a plasma treatment method of plasma-treating a substrate to be treated under decompressed atmosphere comprising exhausting a process chamber; mounting the substrate an a lower electrode; supplying plasma generating gas to the substrate on the lower electrode through an upper electrode; applying high frequency power having a first frequency f 1 , lower than the lower limit of ion transit frequencies characteristic of process gas, to the lower electrode; and applying high frequency power having a second frequency, higher than the upper limit of ion transit frequencies characteristic of process gas, to the upper electrode, whereby a plasma generates in the process chamber and activated species influence the substrate to be treated.
It is preferable that the first frequency f 1 is set lower than 5 MHz, more preferably in a range of 100 kHz-1 MHz. It is also preferable that the second frequency f 2 is set higher than 10 MHz, more preferably in a range of 10 MHz-100 MHz.
High frequency power having the frequency lower than the lower limit of ion transit frequencies is applied to the lower electrode. Therefore, the follow-up of ions becomes more excellent and ions can be sore efficiently accelerated with a smaller power. In addition, both of ion and electron currents change more smoothly. Further, the follow-up of ions does not depend upon kinds of ion. The plasma treatment can be thus made more stable even when the degree in the process chamber and the rate of gases mixed change. On the other hand, high frequency power having the frequency higher than the upper limit of ion transit frequencies is applied to the upper electrode. Therefore, ions can be left free from frequencies of their transit frequency zone to thereby enable more stable plasma to be generated.
Ion transit frequency zones of process gases used by the plasma treatment in the process, such as etching, CVD and sputtering, of making semiconductor devices are almost all in the range of 1 MHz-10 MHz.
Impedances including such capacitive components that the impedance relative to high frequency power becomes smaller than several kΩ and that the impedance relative to relatively low frequency power becomes larger than several Ω are arranged in series between the upper electrode and its matching circuit and between them and the ground. Current is thus made easier to flow to raise the plasma density and ion control.
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 in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention and, together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a block diagram showing the plasma etching apparatus according to an embodiment of the present invention;
FIG. 2 is a flow chart showing the plasma etching method according to an embodiment of the present invention;
FIG. 3 shows a waveform of frequency applied to an upper (or second) electrode;
FIG. 4 shows a waveform of frequency applied to a lower (or first) electrode (or suscepter);
FIG. 5 is a graph showing transit frequency zones of various gases;
FIG. 6 is a block diagram showing the plasma etching apparatus according to another embodiment of the present invention;
FIG. 7 is a block diagram showing the plasma etching apparatus according to a further embodiment of the present invention;
FIG. 8 is a block diagram showing the plasma etching apparatus according to a still further embodiment of the present invention;
FIG. 9 is a vertically-sectioned view showing a housing and a ring member of the plasma etching apparatus;
FIG. 10 is a vertically-sectioned view showing the ring member being cleaned;
FIG. 11 is a vertically-sectioned view showing the ring member being cleaned;
FIG. 12 is a perspective view showing an upper shower electrode and a semiconductor wafer dismantled;
FIG. 13 is a block diagram showing the plasma etching apparatus according to a still further embodiment of the present invention;
FIG. 14 is a vertically-sectioned view showing the plasma etching apparatus when the suscepter is lowered;
FIG. 15 is a vertically-sectioned view showing the plasma etching apparatus when the suscepter is lifted;
FIG. 16 is a partly-sectioned view showing a wafer carry-in and -out gate and a baffle member;
FIG. 17 is a partly-sectioned view showing the wafer carry-in and -out gate and another baffle member;
FIG. 18 is a block diagram showing the plasma etching apparatus according to a still further embodiment of the present invention;
FIG. 19 is a perspective view showing a cover for the upper shower electrode;
FIG. 20 is a perspective view showing another cover for the upper shower electrode;
FIG. 21 is a vertically-sectioned view showing the cover for the upper shower electrode;
FIG. 22 is a plan view showing the cover for the upper shower electrode;
FIG. 23 shows how the cover is attached to the upper shower electrode;
FIG. 24 shows how the cover is detached from the upper shower electrode;
FIG. 25 is a sectional view showing the cover being cleaned;
FIG. 26 is a sectional view showing a further cover;
FIG. 27 is a sectional view showing a still further cover;
FIG. 28 is a sectional view showing a still further cover;
FIG. 29 is a block diagram showing a magnetron plasma etching apparatus in which plasma is being generated;
FIG. 30 is a perspective view showing a baffle member arranged on the side of the suscepter;
FIG. 31 is a vertically-sectioned view showing a hole formed in the baffle member;
FIG. 32 is a vertically-sectioned view showing another hole formed in the another baffle member;
FIG. 33 shows plasma generated in the conventional apparatus;
FIG. 34 is intended to explain the relation of the process chamber to magnetic field generated by a permanent magnet;
FIG. 35 is a block diagram showing the plasma etching apparatus according to a still further embodiment of the present invention;
FIG. 36 is a block diagram showing the inside of a vaporizer;
FIG. 37 is a sectional view showing another vaporizer;
FIG. 38 is a sectional view showing a further vaporizer;
FIG. 39 is a perspective view showing a still further vaporizer;
FIG. 40 is a sectional view showing a pipe in which plural kinds of gas are mixed;
FIG. 41 is a block diagram showing a plasma CVD apparatus provided with the vaporizer;
FIG. 42 is a sectional view showing the inside of the conventional vaporizer; and
FIG. 43 is a graph showing the change of gas flow rate at the initial stage of gas supply.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some embodiments of the present invention will be described with reference to the accompanying drawings. Referring to FIGS. 1 through 5, a first embodiment will be described.
A process chamber 2 of an etching treatment apparatus 1 is assembled by alumite-processed aluminium plates. It is earthed and a suscepter 5 insulated by an insulating plate 3 is arranged in it. The suscepter 5 is supported by its bottom through the insulating plate 3 and a support 4 .
A coolant chamber 6 is formed in the suscepter support 4 . It is communicated with a coolant supply supply (not shown) through inlet and outlet pipes 7 and 8 and coolant such as liquid nitrogen is circulated between it and the coolant supply supply.
An internal passage 9 is formed in a suscepter assembly which comprises the insulating plate 3 , the support 4 , the suscepter 5 and an electrostatic chuck 11 , and heat exchanger gas such as helium gas is supplied from a gas supply supply (not shown) to the underside of a wafer W through it.
The top center portion of the suscepter 5 is swelled and the electrostatic chuck 11 , same in shape as the wafer W, is mounted on the swelled portion of the suscepter 5 . A conductive layer 12 of the electrostatic chuck 11 is sandwiched between two sheets of high molecular polyimide film. It is connected to a 1.5 kV DC high voltage power supply 13 arranged outside the process chamber 2 .
A focus ring 14 is arranged on the top of the suscepter 5 along the outer rim thereof, enclosing the wafer W. It is made of insulating material not to draw reactive ions.
An upper electrode 21 is opposed to the top of the suscepter assembly. Its electrode plate 24 is made of SiC or amorphous carbon and its support member 25 is made by an alumite-process aluminium plate. Its underside is separated from the wafer W on the suscepter assembly by about 15-20 mm. It is supported by the top of the process chamber 2 through an insulating member 22 . A plurality of apertures 23 are formed in its underside.
A gas inlet 26 is formed in the center of the support 25 and a gas inlet pipe 27 is connected to it. A gas supply pipe 28 is connected to the gas inlet pipe 27 . The gas supply pipe 28 is divided into three which are communicated with process gas supply sources 35 , 36 and 37 , respectively. The first one is communicated with the CF 4 gas supply source 35 through a valve 29 and a mass flow controller 32 . The second one with the O 2 gas supply supply 36 through a valve 30 and a mass flow controller 33 . The third one with the N 2 gas supply supply 37 through valve 31 and a mass flow controller 34 .
An exhaust pipe 41 is connected to the bottom of the process chamber 2 . An exhaust pipe 44 is also connected to the bottom of an adjacent load lock chamber 43 . Both of them are communicated with a common exhaust mechanism 45 which is provided with a turbo molecular pump and the like. The load lock chamber 43 is connected to the process chamber 2 through a gate valve 42 . A carrier arm mechanism 46 is arranged in the load lock chamber 43 to carry the wafers W one by one between the process chamber 2 and the load lock chamber 43 .
A high frequency power applier means for generating plasma in the process chamber 2 will be described.
A first oscillator 51 serves to oscillate high frequency signal having a frequency of 800 kHz. A circuit extending from the oscillator 51 to the lower electrode (or suscepter) 5 includes a phase controller 52 , an amplifier 53 , a matching unit 54 , a switch SW 1 and a feeder rod 55 . The amplifier 53 is an RF generator and the matching unit 54 includes a decoupling capacitor. The switch SW 1 is connected to the feeder rod 55 . A capacitance 56 is arranged on an earthed circuit of the feeder rod 55 . The phase controller 52 houses a bypass circuit (not shown) and a changeover switch (not shown) therein to enable signal to be sent from the first oscillator 51 to the amplifier 53 through the bypass circuit. High frequency signal oscillated is applied to the suscepter 5 through the phase controller 52 , the amplifier 53 , the matching unit 54 and feeder rod 55 .
On the other hand, a second oscillator 61 serves to oscillate high frequency signal having a frequency of 27 MHz. A circuit extending from the oscillator 61 to the upper (or shower) electrode 21 includes an amplitude modulator 62 , an amplifier 63 , a matching unit 64 , a switch SW 2 and a feeder rod 65 . The amplitude modulator 62 is connected to a signal circuit of the second oscillator 61 and also to that of the first oscillator 51 . It houses a bypass circuit (not shown) and a changeover switch (not shown) in it to enable signal to be sent from it to the amplifier 63 through the bypass circuit. The amplifier 63 is an RP generator and the matching unit 64 includes a decoupling capacitor. The switch SW 2 is connected to the feeder rod 65 . A capacitance 66 and an inductance 67 are arranged on an earthed circuit of the feeder rod 65 . High frequency signal oscillated is applied to the upper electrode 21 through the amplitude modulator 62 , the amplifier 63 , the matching unit 64 and the feeder rod 65 . High frequency signal having the frequency of 800 kHZ can also be applied, as modulated wave, to the amplitude modulator 62 .
The reason why the earthed circuit of the feeder rod 55 includes no inductance resides in that the electrostatic chuck 11 , the gas passage 9 , the coolant chamber 6 , lifter pins (not shown) and the like are included in the lower electrode signal transmission circuit, that the feeder rod 55 itself is long, and that the suscepter 5 itself has large inductance accordingly.
The amplifiers 51 and 64 are arranged independently of the other. Therefore, voltages applied to the upper electrode 21 and the suscepter 5 can be changed independently of the other.
Referring to FIG. 2, it will be described how silicon oxide film (SiO 2 ) on the silicon wafer W is plasma-etched.
Both of the load lock chamber 43 and the process chamber 2 are exhausted to substantially same internal pressure. The gate valve 42 is opened and the wafer W is carried from the load lock chamber 43 into the process chamber 2 (step S 1 ). The gate valve 42 is is closed and the process chamber 2 is further exhausted to set its internal pressure in a range of 10-250 mTorr (step S 2 ).
The valves 29 and 30 are opened, and CF 4 and O 2 gases are introduced into the process chamber 2 . Their flow rates are controlled and they are mixed at a predetermined rate. The (CF 4 +O 2 ) mixed gases are supplied to the wafer W through apertures 23 of the upper shower electrode 21 (step S 3 ). When the internal pressure in the chamber 2 becomes stable at about 1 Pa, high frequency voltages are applied to the upper and lower electrodes 21 and 5 to generate plasma between them.
Frequencies of high frequency power applied to the upper and lower electrodes 21 and 5 to generate plasma are controlled as follows (step S 4 ).
The switches SW 1 and SW 2 are opened to disconnect (OFF) the capacitance 56 from the feeder rod 55 and the capacitance 66 and the inductance 67 from the feeder rod 65 . When the oscillators 61 , 51 , the amplitude modulator 62 and the amplifiers 63 , 53 are made operative under this state, high frequency power having a certain waveform is applied to the upper electrode 21 . High frequency power having a frequency same as or higher than the higher one of upper ion transit frequencies characteristic of CF 4 and O 2 gases is applied to the upper electrode 21 . High frequency power having a waveform shown in FIG. 3, for example, is applied to the upper electrode 21 . Plasma is thus generated.
On the other hand, high frequency power having a certain waveform is applied to the lower electrode 5 by the oscillator 51 . High frequency power having a frequency same as or lower than the lower one of ion transit frequencies characteristic of CF 4 and O 2 gases is applied to the lower electrode 5 . High frequency power having a waveform shown in FIG. 4, for example, is applied to the lower electrode. Ions in plasma are thus accelerated and drawn to the wafer W, passing through the plasma sheath, to thereby act on the wafer W.
The high frequency by which plasma is generated has the waveform shown in FIG. 3 in this case. Therefore, the dissociation of gases introduced into the process chamber 2 is not advanced to an extent greater than needed. In addition, the frequency of 800 kHz by which ions in plasma are accelerated and drawn to the wafer W can be controlled in phase by the phase controller 52 . Ions can be thus drawn to the wafer W before the dissociation of gases progresses to the extent greater than needed. When ions most suitable for etching are generated, therefore, they can be made incident onto the wafer W. When they are caused to act on the wafer W while cooling it, therefore, anisotropic etching having a high aspect rate can be realized.
The phase control of the high frequency power (frequency: 800 kHz) applied to the lower electrode may be based on a state under which the dissociation of gases does not progress to the extent greater than needed or a state under which the dissociation of gases progresses to the final stage, they are then combined again and become radicals suitable for etching.
Further, it may be arranged that a dummy wafer DW is used and that the treatment is carried out while confirming the extent to which the phase of the high frequency 800 kHs is shifted. The timing at which the phase of the high frequency 800 kHz is shifted may be previously set in this case, depending upon kinds of process gases, etching, coating and the like.
When the end point of anisotropic etching is detected (step S 5 ), exhaust, process gas introducing and plasma control steps S 6 , S 7 and S 8 are successively carried out to isotropically etch film on the wafer W. The exhaust step S 6 is substantially same as the above-described one S 2 . At the process gas introducing step S 7 , C 4 F 8 , CHF 3 , Ar and CO gases, for example, different from those at the above-described step S 3 , are supplied to the process chamber 2 .
At the plasma control step S 8 , plasma is controlled substantially as seen at the above-described step S 4 . When the end point of isotropic etching is detected (step S 9 ), the applying of the high frequency power is stopped and the process chamber 2 is exhausted while supplying nitrogen gas into it (step S 10 ). The gate valve 42 is opened and the wafer W is carried from the process chamber 2 into the load lock chamber 43 (step S 11 ).
Referring to FIG. 5, the plasma control steps S 4 and S 8 will be described in more detail.
FIG. 5 is a graph showing ion transit frequency zones characteristic of three kinds of gages A, B and C, in which frequencies are plotted on the vertical axis. An ion transit frequency zone Az of gas A extends from an upper end Au to a lower end Al, an ion transit frequency zone Bz of gas B from an upper end Bu to a lower end Bl, and an ion transit frequency zone Cz of gas C from an upper end Cu to a lower end Cl. CHF 3 or CO gas is cited as gas A. Ar gas is cited as gas B. CF 4 , C 4 F 8 or O 2 gas is cited as gas C. At least one or more gases selected from the group consisting of CF 4 , C 4 F 8 , CHF 3 , Ar, O 2 and CO gases are used as process gas. In short, process gas may be one of them or one of mixed gases (CH 3 +Ar+O 2 ), (CHF 3 +CO+O 2 ), (C 4 F 8 +Ar+O 2 ), (C 4 F 8 +CO+Ar+O 2 ) and (CF 4 +CHF 3 ).
When mixed gases of A, B and C are used as process gas, the high frequency power applied to the upper electrode has a frequency higher than the highest one Bu of upper ion transit frequencies Au, Bu and Cu and the high frequency power applied to the lower electrode has a frequency lower than the lowest one Cl of lower ion transit frequencies Al, Bl and Cl.
Another etching treatment method conducted using the above-described etching treatment apparatus 1 will be described
The switches SW 1 and SW 2 are closed or turned on to connect the signal transmission circuits to their earthed circuits. High frequency signal (frequency: 800 kHz) is amplified directly by the amplifier 53 , bypassing the phase controller 52 , and applied to the suscepter 5 through the matching unit 54 . On the other hand, high frequency signal (frequency: 27 MHz) is amplified directly by the amplifier 63 , bypassing the amplitude modulator 62 , and applied to the upper electrode 21 via the matching unit 64 and the feeder rod 65 .
Conventionally, the matching unit arranged on the side of the suscepter is matched relative to the high frequency of 800 kHz but it becomes high in impedance relative to the high frequency of 27 MHz applied from the upper electrode, thereby making it difficult for the high frequency applied from the upper electrode to flow to the suscepter. Plasma is thus scattered, so that the plasma density decreases.
In the apparatus 1 , however, the capacitance 56 is arranged between the feeder rod and the ground. A DC resonance circuit can be thus formed relative to the high frequency applied from the upper electrode. When the value of the capacitance 56 is adjusted, considering the constant of a distributed constant circuit, therefore, composite impedance can be made smaller than several Ω to thereby make it easy for the high frequency applied from the upper electrode to flow to the suscepter 5 . Therefore, current density can be raised and plasma density thus attained can also be raised.
On the other hand, the capacitance 66 and the inductance 67 are attached to the feeder rod 65 arranged on the side of the upper electrode 21 . Therefore, a DC resonance circuit is also provided relative to the high frequency of 800 kHz, thereby making it easy for the high frequency 800 kHz applied to the side of the suscepter 5 to flow to the upper electrode 21 . The incidence of ions in plasma onto the wafer W is promoted accordingly.
Although high frequency power having the frequency 27 MHz has been applied to the upper electrode 21 and high frequency power having the frequency 800 kHz to the lower electrode 5 in the above-described embodiment, other frequencies may be set, depending upon kinds of process gas.
It is desirable that high frequency power applied to the lower electrode 5 has a frequency lower than the inherent lower ion transit frequency or lower than 1 MHz and that high frequency power applied to the upper electrode 21 has a frequency higher than the inherent upper ion transit frequency or higher than 10 MHz. When so arranged, ions are more efficiently accelerated with a smaller high frequency power and the follow-up of ions in the plasma sheath to bias frequencies becomes stable even when the rate of gases mixed and the degree of vacuum in the process chamber are a little changed. Therefore, ions can be made incident onto the wafer without scattering in the plasma sheath, thereby enabling a finer work to be achieved at high speed.
According to the present invention, the follow-up of ions is more excellent due to the high frequency power applied to he first electrode and they can be more efficiently accelerated with a smaller power. In addition, plasma itself can be kept stable. A more stable treatment can be thus realized even when the degree of vacuum in the process chamber and the rate of gases mixed change.
Further, when the dissociation is controlled not to progress to the extent greater than needed and the phase of the high frequency power applied to the first electrode is also controlled, ions or radicals needed for the treatment can be created at a desired timing and they can be made incident onto the wafer. Anisotropic etching treatment having a high aspect rate can be thus attained. In addition, damage applied to the wafers can be reduced. Further, plasma density can be made high without raising the high frequency power and its frequency, and ion control can be made easier.
A second embodiment will be described referring to FIG. 6 . Same components as those in the above-described first embodiment will be mentioned only when needed.
An etching treatment apparatus 100 has, as high frequency power applier means, two high frequency power supplies 141 , 151 and a transformer 142 . The primary side of the transformer 142 is connected to the first power supply 141 and then earthed. Its secondary side is connected to both of the upper and lower electrodes 21 and 105 . A first low pass filter 144 is arranged between the secondary side and the upper electrode 21 and a second low pass filter 145 between the secondary side and the lower electrode 105 . The first power supply 141 serves to apply high frequency power having the relatively low frequency such as 380 kHz to the electrodes 105 and 21 . When silicon oxide (SiO 2 ) film is to be etched, it is optimum that a frequency f 0 of high frequency power applied from the first power supply 141 is 380 kHz and when polysilicon (poly-Si) film is to be etched, it is preferably in a range of 10 kHz-5 MHz.
The transformer 142 has a controller 143 , by which the power of the first power supply 141 is distributed to both electrodes 105 and 21 at an optional rate. For example, 400 W of full power 1000 W can be applied to the suscepter 105 and 600 W to the upper electrode 21 . In addition, high frequency powers whose phases are shifted from each other by 180° are applied to the suscepter 105 and the upper electrode 21 .
The second power supply 151 serves to apply high frequency power having the high frequency such as 13.56, for example, to the upper electrode 21 . It is connected to the upper electrode 21 via a capacitor 152 and then earthed. This plasma generating circuit is called P mode one. It is optimum that a frequency f 1 of high frequency power applied from it is 13.56 MHz, preferably in a range of 10-100 MHz.
It will be described how silicon oxide film (SiO 2 ) on the silicon wafer W is etched by the above-described etching apparatus 100 .
The wafer w is mounted on the suscepter 105 and sucked and held there by the electrostatic chuck 11 . The process chamber 102 is exhausted while introducing CF 4 gas into it. After its internal pressure reaches about 10 mTorr, high frequency power of 13.56 MHz is applied from the second power supply 151 to the upper electrode 21 to make CF 4 gas into plasma and dissociate gas molecules between the upper electrode 21 and the suscepter 105 . On the other hand, high frequency power of 380 kHz is applied from the first power supply 141 to the upper and lower electrodes 21 and 105 . Ions and radicals such as fluoric ones in plasma-like gas molecules are thus drawn to the suscepter 105 , thereby enabling silicon oxide film on the wafer to be etched.
The generating and keeping of plasma itself are attained in this case by the high frequency power having a higher frequency and applied from the second power supply 151 . Stable and high density plasma can be thus created. In addition, activated species in this plasma are controlled by the high frequency power of 380 kHz applied to the upper and lower electrodes 21 and 105 . Therefore, a more highly selective etching can be applied to the wafer W. Ions cannot follow up to the high frequency power which has the frequency of 13.56 MHz and by which plasma is generated. Even when the output of the power supply 151 is made large to generate high density plasma, however, the wafers W cannot be damaged.
The first and second low pass filters 144 and 145 are arranged on the secondary circuit of the transformer 142 . This prevents the high frequency power having the frequency of 13.56 MHz and applied from the second power supply 151 from entering into the secondary circuit of the transformer 142 . Therefore, the high frequency power having the frequency of 13.56 MHz does not interfere with the one having the frequency of 380 kHz, thereby making plasma stable. Blocking capacitors may be used instead of the low pass filters 144 and 145 . Although high frequency powers have been continuously applied to the electrodes in the above case, modulation power which becomes strong and weak periodically may be applied to the electrodes 21 and 105 .
A third apparatus 200 will be described with reference to FIG. 7 . Same components as those in the above-described first and second embodiments will be mentioned only when needed.
A high frequency power circuit of this apparatus 200 is different from that of the second embodiment in the following points: A suscepter 205 of the apparatus 200 is not earthed; no low pass filter is arranged on 5 the secondary circuit of a transformer 275 ; and a second transformer 282 is arranged on the circuit of a second power supply 281 .
The second power supply 281 serves to generate high frequency power of 3 MHz. It is connected to the primary side of the transformer 282 , whose secondary side are connected to upper and lower electrodes 21 and 205 . A controller 293 which controls the distribution of power is also attached to the secondary side of the transformer 282 .
It will be described how the etching treatment is carried out by the apparatus 200 .
High frequency powers of 3 MHz whose phases are shifted from each other by 180° are applied from the power supply 281 to the suscepter 205 and the upper electrode 21 to generate plasma between them. At the same time, high frequency powers of 380 kHz whose phases are shifted from each other by 180° are applied from a power supply 274 to them. Ions in plasma generated are thus accelerated to enter into the wafer W.
Further, the two high frequency power supplies 274 and 281 in the third apparatus are arranged independently of the other. In short, they are of the power split type. Therefore, they do not interfere with each other, thereby enabling a more stable etching treatment to be realized.
Furthermore, high frequency powers are supplied from the two power supplies 274 and 281 to both of upper and lower electrodes 21 and 205 , respectively. The flow of current can be thus concentrated on a narrow area between the upper 21 and the lower electrode 205 . As the result, a high density plasma can be generated and the efficiency of controlling ions in plasma can be raised.
A fourth embodiment will be described, referring to FIGS. 8 through 12. Same components as those in the above-described embodiments will be mentioned only when needed.
As shown in FIG. 8, an etching apparatus 300 has a cylindrical or rectangular column-like air-tight chamber 302 . A top lid 303 is connected to the side wall of the process chamber 302 by hinges 304 . Temperature adjuster means such as a heater 306 is arranged in a suscepter 305 to adjust the treated face of a treated substrate W to a desired temperature. The heater 306 is made, for example, by inserting a conductive resistance heating unit such as tungsten into an insulating sintered body made of aluminium nitride. Current is supplied to this resistant heating unit through a filter 310 to control the temperature of the wafer W in such a way that the treated face of the wafer W is raised to a predetermined temperature.
A high frequency power supply 319 is connected to the suscepter 305 through a blocking capacitor 318 . When the wafer W is to be etched, the high frequency power of 13.56 MHz is applied from the power supply 319 to the suscepter 305 .
The suscepter 305 is supported by a shaft 321 of a lifter mechanism 320 . When the shaft 321 of the lifter mechanism 320 is extended and retreated, the suscepter 305 is moved up and down. A bellows 322 is attached to the lower end of the suscepter 305 not to leak gases in the process chamber 302 outside.
Reaction products deposit in the process chamber 302 . A ring 325 is freely detachably attached to the outer circumference of the suscepter 305 . It is made preferably of PTFE (teflon), PFA, polyimide or PBI (polybenzoimidazole). It may also be made of such a resin that has insulation in a temperature range of common temperature −500° C. or of such a metal like aluminium that has insulating film on its surface. A baffle plate 326 is made integral to it. A plurality of holes 328 are formed in the baffle plate 326 . They are intended to adjust the flow of gases in the process chamber 302 , to make its exhaust uniform, and to make a pressure difference between the treatment space and a space downstream the flow of gases. A top portion 327 of the ring 325 is bent inwards, extending adjacent to the electro-static chuck 11 , to make the top of the suscepter 305 exposed as small as possible.
An upper electrode 330 is arranged above the suscepter 305 . When the etching treatment is to be carried out, the suscepter 305 is lifted to adjust the interval between the suscepter 305 and the upper electrode 330 . The upper electrode 330 is made hollow and a gas supply pipe 332 is connected to this hollow portion 331 to introduce CF 4 gas and others from a process gas supply supply 333 into the hollow portion 331 through a mass flow controller (MFC) 334 . A diffusion plate 335 is arranged in the hollow portion 331 to promote the uniform diffusion or scattering of process gases. Further, a process gas introducing section 337 having a plurality of apertures 336 is arranged under the diffusion plate 335 . An exhaust opening 340 which is communicated with an exhaust system provided with a vacuum pump and others is formed in the side wall of the process chamber 302 at the lower portion thereof to exhaust the process chamber 302 to an internal pressure of 0.5 Torr, for example.
When the wafer W is etched in the process chamber 302 , reaction products are caused and they adhere to the ring 325 and the baffle plate 326 , leaving the outer circumference of the suscepter 305 substantially free from them. When the etching treatment is finished, the wafer W is carried out of the process chamber 302 into the load lock chamber 43 . A next new wafer W is then carried from the load lock chamber 43 into the process chamber 302 and etched in it. When this etching treatment is repeated many times, a lot of reaction products adhere to the ring 325 .
As shown in FIG. 9, the top lid 303 of the process chamber 302 is opened and the ring 325 is detached from the suscepter 305 . Reaction products are then removed from the ring 325 by cleaning.
The time at which the ring 325 must be cleaned is determined as follows:
the number of particles adhering to the wafer W which has been treated by the apparatus 300 is counted and when it becomes larger than a predetermined value;
the number of particles scattering in the atmosphere exhausted from the apparatus 300 and/or at least in one or more areas in the exhaust pipe is counted and when it becomes larger than a predetermined value;
when predetermined sheets of the wafer W have been treated in the apparatus 300 ; and
when the total of hours during which plasma has been generated or the plasma treatment has been carried out reaches a predetermined value.
Dry or wet cleaning is used. The dry cleaning is carried out in such a way that ClF 3 , CF 4 or NF 3 gas is blown to the ring 325 which is left attached to the suscepter 305 or which is detached from the suscepter 305 and left outside the process chamber 302 , as shown in FIG. 10 .
On the other hand, the wet cleaning is carried out in such a way that the ring 325 to which reaction products have adhered is immersed in cleaning liquid 351 in a container 350 , as shown in FIG. 11 . IPA (isopropyl alcohol), water or fluorophosphoric acid is used as cleaning liquid 351 . The ring 325 from which reaction products have been removed by the dry or wet cleaning is again attached to the suscepter 305 and the plasma treatment is then repeated.
When the wafers W are to be etched, plural rings 325 are previously prepared relative to one suscepter 305 . If so, cleaned one can be attached to the suscepter 305 while cleaning the other.
The dry or wet cleaning can be appropriately used to remove reaction products from the ring 325 . When the dry cleaning is compared with the wet one, however, the former is easier in carrying out it but its cleaning is more incomplete. To the contrary, the latter is more excellent in cleaning the ring 325 but its work is relatively more troublesome. Therefore, it is desirable that the wet cleaning is periodically inserted while regularly carrying out the dry cleaning.
The baffle plate will be described referring to FIGS. 12 and 13.
As shown in FIG. 12, It is preferable that an effective diameter D 1 is set not larger than a diameter D 2 . The effective diameter D 1 represents a diameter of that area where the process gas jetting apertures 336 are present, and the diameter D 2 denotes that of the wafer W in this case. When the effective diameter D 1 is set in this manner, a high efficient etching can be attained in the process chamber 302 . It is the most preferable that the effective diameter D 1 is set to occupy about 90% of the diameter D 2 .
Providing that the underside 338 of the upper electrode has a diameter D 3 , the effective diameter D 1 , the diameter D 2 and the diameter D 3 meet the following inequality (1).
D 1 <D 2 <D 3 (1)
When the ring the whole of which is made of insulating material is used as it is, the effective area of the lower electrode becomes substantially smaller than that of the upper electrode, thereby making plasma uneven. This problem can be solved when the effective area of the lower electrode is made same as that of the upper electrode or when it is made larger than that of the upper electrode.
As shown in FIG. 13, the baffle plate 326 is made integral to the ring 325 . It is divided into a portion 360 equal to the diameter D 4 and another portion 361 larger than it, and the inner portion 360 is made of metal such as aluminium and stainless steel while the outer portion 361 of PTPE (teflon), PPA, polyimide, PBI (polybenzoimidazole), other insulating resin or alumite-processed aluminium.
The diameter D 4 is made same as or larger than the diameter D 3 . At least the inner portion 360 of the baffle plate 326 is positioned just under the upper electrode 330 . The ring 326 is divided into an upper half 363 and a lower half 364 , sandwiching an insulator 362 between them. The upper half 363 is made of metal such as aluminium and stainless steel and it is made integral to the inner portion 360 of the baffle plate 326 . A power supply 319 which serves to apply high frequency power to the suscepter 305 is connected to these inner portion 360 of the baffle plate 326 and upper half 363 of the ring 325 by a lead 367 via a blocking capacitor 318 . At least those portions (the inner portion 360 of the baffle plate and the upper half 363 of the ring) which are positioned just under the upper electrode 330 are made same in potential. In order to make it easy to exchange the ring 325 , it is preferable that the lead 367 is connected to the upper half 363 of the ring or the inner portion 360 of the baffle plate 326 by an easily-detached socket 368 . A lower suscepter 365 is insulated from the upper one 305 by an insulating layer 366 . The lower half 364 of the ring is also therefore insulated from the upper half 363 thereof by the insulator 362 .
When at least that portion of the baffle plate 326 which is positioned just under the upper electrode 330 is made same in potential as the suscepter 305 , as described above, plasma can be made uniform.
Referring to FIGS. 14 and 15, it will be described how the side opening 41 of the process chamber 302 through which the wafer W is carried in and out is opened and closed as the suscepter is moved up and down.
The ring 325 provided with the baffle plate 326 encloses the suscepter 305 . The lifter means 320 is arranged under the process chamber 302 and the suscepter 305 is supported by the shaft 321 of the lifter means 320 .
When the suscepter 305 is moved down, as shown in FIG. 14, the baffle plate 326 is positioned lower than the side opening 41 . When it is moved up, as shown in FIG. 15, the baffle plate 326 is positioned higher than the side opening 41 .
When the suscepter 305 is moved down and the baffle plate 326 is positioned lower than the side opening 41 , therefore, the wafer W can be freely carried in and out of the process chamber 302 through the side opening 41 . When the baffle plate 326 is positioned higher than the side opening 41 at the time of etching treatment, however, the side opening 41 is shielded from the process space between the upper and the lower electrode, thereby preventing plasma from entering into the side opening 41 .
As shown in FIG. 16, it may be arranged that a shielding plate 370 is attached to the outer circumference of the baffle plate 326 and that the side opening 41 is closed by the shielding plate 370 when the suscepter 305 is moved up. Particularly, the side opening 41 is too narrow for hands to be inserted. Therefore, inert gas may be supplied, as purge gas, into a clearance 371 between the shielding plate 370 and the inner face of the process chamber 302 not to cause process gases to enter into the side opening 41 . Similarly, purge gas may also be supplied into a clearance 372 between the wafer-mounted stage 305 and the upper half 363 of the ring 325 .
The side opening 41 may be closed by a shielding plate 373 attached to the outer circumference of the baffle plate 326 , as shown in FIG. 17, when the baffle plate 326 is lifted half the side opening 41 .
Referring to FIGS. 18 through 28, the cleaning of a fifth CVD apparatus will be described. Same components as those in the above-described embodiments will be mentioned only when needed.
A CVD apparatus 500 has a process chamber 502 which can be exhausted vacuum. A top lid 503 is connected to the side wall of the process chamber 502 by hinges 505 . A shower head 506 is formed in the center portion of the top lid 503 at the underside thereof. A process gas supply pipe 507 is connected to the top of the shower head 506 to introduce mixed gases (SiH 4 +H 2 ) from a process gas supply 508 into the shower head 506 through a mass flow controller (MFC) 510 . A plurality of gas jetting apertures 511 are formed in the bottom of the shower head 506 and process gases are supplied to the wafer W through these apertures 511 .
An exhaust pipe 516 which is communicated with a vacuum pump 515 is connected to the side wall of the process chamber at the lower portion thereof. A laser counter 517 which serves to count the number of particles contained in the gas exhausted from the process chamber 502 is attached to the exhaust pipe 516 . The process char 502 is decompressed to about 10 −6 Torr by the exhaust means 515 .
The process char 502 has a bottom plate 521 supported by a substantially cylindrical support 520 and cooling water chambers 522 are formed in the bottom plate 521 to circulate cooling water supplied through a cooling water pipe 523 through them.
A suscepter 525 is mounted on the bottom plate 521 through a heater 526 and these heater 526 and the wafer-mounted stage 525 are enclosed by a heat insulating wall 527 . The heat insulating wall 527 has a mirror-finished surface to reflect heat radiated from around. The heater 526 is heated to a predetermined temperature or 400-2000° C. by voltage applied from an AC power supply (not shown). The wafer W on the stage 525 is heated to 800° C. or more by the heater 526 .
An electrostatic chuck 530 is arranged on the top of the wafer-mounted stage 525 . It comprises polyimide resin films 531 , 532 and a conductive film 533 . A variable DC voltage supply (not shown) is connected to the conductive film 533 .
A detector section 538 of a temperature sensor 537 is embedded in the suscepter 525 to successively detect is temperature in the wafer-mounted stage 525 . The power of the AC power supply which is supplied to the heater 526 is controlled responsive to signal applied from the temperature sensor 537 . A lifter 541 is connected to the suscepter 525 through a member 543 to move it up and down. Those portions of a support plate 546 through which support poles 544 and 545 are passed are provided with bellows 547 and 548 to keep the process chamber 502 air-tight.
A cover 560 is freely detachably attached to the shower head 506 . It is made of material of the PTFE (teflon) group, PPA, polyimide, PBI (polybenzoimidazole) or polybenzoazole, which are insulators and heat resistant. In the case of the plasma CVD apparatus, the wafer-mounted stage 525 is heated to about 350-400° C. at the time of plasma process and in the case of the heat CVD apparatus, it is usually heated higher than 650° C. or to about 800° C. The cover 560 is therefore made of such a material that can resist this radiation heat.
As shown in FIG. 19, a large-diameter opening 563 is formed in a bottom 561 of the cover 560 . When the cover 560 is attached to the shower head 506 , the gas jetting apertures 511 of the shower head 506 appear in the opening 563 .
As shown in FIG. 20, a plurality of apertures 565 may also be formed in the cover 560 . These apertures 565 are aligned with those of the shower head 506 in this case.
As shown in FIG. 21, recesses 570 may be formed in the outer circumference of the shower head 506 while claws 571 are formed on an inner circumference 562 of the cover 506 , as shown in FIG. 22 . The claws 571 are fitted into recesses 570 in this case while elastically deforming the cover 560 . The three claws 571 are arranged on the inner circumference 562 of the cover 560 at a same interval, as shown in FIG. 22 .
As shown in FIG. 23, the cover 560 may be attached to the shower head 506 in such a way that bolts 575 are screwed into recesses 573 of the shower head 506 through a cover side 562 .
It will be described how upper electrode cover is cleaned.
When mixed gases (SiH 4 +H 2 ), for example, are introduced into the process chamber 502 to form film on the wafer W, reaction products adhere to the upper electrode cover 560 . As shown in FIG. 24, the top lid 503 is opened and the cover 560 is detached from the shower head 506 . The cover 560 is then immersed in cleaning liquid 581 in a container 580 (wet cleaning). Or the dry cleaning may be conducted in such a way that cleaning gas such as ClF 3 , CF 4 or NF 3 gas is introduced into the process chamber 502 while keeping the cover 560 attached to the shower head 506 .
The time at which the cleaning must be conducted is determined as follows. The number of particles contained in the gas exhausted through the exhaust pipe 516 is counted by the counter 517 and when it becomes larger than a limit value, the cleaning of the cover 560 must be started.
As shown in FIG. 26, the underside of the top lid 503 may be covered by a cover 585 , in addition to the shower head 506 . Or the inner face of the process chamber 502 may be covered by a cover 586 , in addition to the shower head 506 , as shown in FIG. 27 . An opening 587 is formed in the cover 586 in this case, corresponding to the side opening 41 of the process chamber 502 . Or a cover 590 having a curved bottom 591 may be used, as shown in FIG. 28 .
A sixth embodiment will be described referring to FIGS. 29 through 34. Same components as those in the above-described embodiments will be mentioned only when needed.
As shown in FIG. 29, a magnetron type plasma etching apparatus 600 has a rotary magnet 627 above a process chamber 602 . Upper and lower electrodes 624 and 603 are opposed in the process chamber 602 . Process gases are introduced from a gas supply supply 629 to the space between the upper and the lower electrode through an MFC 630 . The rotary magnet 627 serves to stir plasma generated between both of the electrodes 603 and 624 .
A suscepter assembly comprises an insulating plate 604 , a cooling block 605 , a heater block 606 , an electrostatic chuck 608 and a focus ring 612 . A conductive film 608 c of the electrostatic chuck 608 is connected to a filter 610 and a variable DC high voltage supply 611 by a lead 609 . The filter 610 is intended to cut high frequencies. An internal passage 613 is formed in the cooling block 605 and liquid nitrogen is circulated between it and a coolant supply supply (not shown) through pipes 614 and 615 . A gas passage 616 is opened at tops of the suscepter 603 , the heater 617 and the cooling block 605 , passing through the suscepter assembly. The base end of the gas passage 616 is communicated with a heat exchanger gas supply supply (not shown) to supply heat exchanger gas such as helium gas to the underside of the wafer W through it. The heater block 606 is arranged between the suscepter 603 and the cooling block 605 . It is shaped like a band-like ring and it is several mm thick. It is a resistant heating unit. It is connected to a filter 619 and a power supply 620 .
Inner and outer pipes 621 a and 521 b are connected to the suscepter 603 and the process chamber 602 . They are conductive double pipes, the outer one 621 a of which is earthed and the inner one 621 b of which is connected to a high frequency power supply 623 via a blocking capacitor 622 . The high frequency power supply 623 has an oscillator for oscillating the high frequency of 13.56 MHz. Inert gas is introduced from a gas supply supply (not shown) into a clearance between the inner 621 a and the outer pipe 621 b and also into the inner pipe 621 b.
Except the upper electrode, the inner faces of the top of the process chamber 602 is covered by an insulating protection layer 625 , 3 mm or more thick. Similarly, the inner face of its side wall is covered by an insulating protection layer 626 , 3 mm or more thick.
In the conventional magnetron type plasma etching apparatus, the flow of electrons tends to gather near the inner wall of the process chamber, as shown in FIG. 34 . The flow of plasma is thus irradiated in a direction W, that is, to the side wall of the process chamber, thereby damaging it. In the above-described apparatus 600 , however, the side wall of the process chamber 602 is covered by the insulating protection layer 626 so that it can be protected.
Process gas supply and exhaust lines or systems of the apparatus 600 will be described.
A process gas supply pipe 628 is connected to the side wall of the process chamber 602 at the upper portion thereof and CF 4 gas is introduced from a process gas supply 629 into the process chamber 602 through it. An exhaust pipe 633 is also connected to the side wall of the process chamber 602 at the lower portion thereof to exhaust the process chamber 602 by an exhaust means 631 , which is provided with a vacuum pump. A valve 632 is attached to the exhaust pipe 633 .
As shown in FIG. 30, a baffle plate 635 is arranged between the outer circumference of the suscepter 603 and the inner wall of the process chamber 602 . Plural holes 634 are formed in the baffle plate 635 to adjust the flow of exhausted air or gas.
As shown in FIG. 31, each hole 634 is tilted. Therefore, the conductance of gas rises when it passes through the holes 634 and the gradient of electric field becomes gentle accordingly. This prevents discharge from being caused in the holes 634 and plasma from flowing inward under the baffle plate 635 .
As shown in FIG. 32, holes 634 a, 634 b, 634 c and 634 d each having a same pitch may be formed in plural baffle plates 635 a, 635 b, 635 c and 635 d to form a step-like exhaust hole 634 A. This exhaust hole 634 A can be formed when the baffle plates 635 a, 635 b, 635 c and 635 d are placed one upon the others in such a way that the holes 634 a, 634 b, 634 c and 634 d are a little shifted from their adjacent ones. When these exhaust holes 634 A are formed, abnormal discharges in plasma generation can be more effectively prevented.
In the conventional apparatus, each hole 692 in the baffle plate extends only vertical, as shown in FIG. 33 . These holes 692 allow plasma to flow inward under the baffle plate and abnormal discharges such as sparkles to be caused in them, thereby causing metal contamination and articles. In the apparatus 600 , however, the holes 634 are directed toward the exhaust opening 633 . The reduction of exhaust speed can be thus prevented. When the direction in which the turbo-pump 631 is driven in made reverse to the flow of exhausted gas, that is, when it is made anticlockwise in a case where exhausted gas flows clockwise, the speed of exhausted gas can be raise to a further extent.
A seventh embodiment will be described referring to FIGS. 35 through 43. TEOS gas is used to form film on the wafer W in this seventh plasma CVD apparatus. Same components as those in the above-described embodiments will be mentioned only when needed.
The plasma CVD apparatus 700 has a cylindrical or rectangular process chamber 710 , in which a suscepter 712 is arranged to hold a wafer W on it. It is made of conductive material such as aluminium and it is insulated from the wail of the process chamber 710 by an insulating member 714 . A heater 716 which is connected to a power supply 718 is embedded in it. The wafer W on it is heated to about 300° C. (or film forming temperature) by the heater 716 . The process chamber is of the cold wall type in this case, but it may be of the hot wall type. The process chamber of the hot wall type can prevent gas from being condensed and stuck.
The electrostatic chuck 11 is arranged on the suscepter 712 . Its conductive film 12 is sandwiched between two sheets of film made of polybensoimidazole resin. A variable DC high voltage power supply 722 is connected to the conductive film 12 . A focus ring 724 is arranged on the suscepter 712 along the outer rim thereof.
A high frequency power supply 728 is connected to the suscepter 712 via a matching capacitor 726 to apply high frequency power having a frequency of 13.56 MHz or 40.68 MHz to the suscepter 712 .
An upper electrode 730 serves as a plasma generator electrode and also as a process gas introducing passage. It is a hollow aluminium-made electrode and a plurality of apertures 730 a are formed in its bottom. It has a heater (not shown) connected to a power supply 731 . It can be thus heated to about 150° C. by the heater.
A process gas supply line or system provided with a vaporizer (VAPO) 732 will be described referring to FIGS. 35 and 36.
Liquid TEOS is stored in a container 734 . At the film forming process, a liquid mass flow controller (LMFC) 736 is controlled by a controller 758 to control the flow rate of liquid TEOS supplied from the container 734 to the vaporizer 732 .
As shown in FIG. 36, a porous and conductive heating unit 744 is housed in a housing 742 of the vaporizer 732 . The housing 742 has an inlet 738 and an outlet 740 . The inlet 738 is communicated with the liquid supply side of the container 734 . The outlet 740 is communicated with the hollow portion of the upper electrode 730 .
The heating unit 744 is made of sintered ceramics in which conductive material such as carbon is contained, and it is porous. It is preferably excellent in workability and in heat and chemical resistance. Terminals 747 are attached to it and current is supplied from a power supply 746 to it through them. When current is supplied to it, it is resistance-heated to about 150° C. Further, vibrators 748 are embedded in the housing 742 , sandwiching the heating unit 744 between them. It is preferable that they are supersonic ones. The power supply 746 for the heating unit 744 and a power supply (not shown) for the vibrators 748 are controlled by the controller 758 .
It will be described how the vaporizer 732 is operated.
When liquid TEOS is supplied from the container 734 to the vaporizer 732 , it enters into holes in the porous heating unit 744 and it is heated and vaporized. Because its contact area with the porous heating unit 744 becomes extremely large, its vaporized efficiency becomes remarkably higher, as compared with the conventional vaporizers.
Further, vibration is transmitted from vibrators 748 to liquid TEOS caught by the heating unit 744 and in its holes. Heat transfer face and liquid vibrations are thus caused. Therefore, the border layer between the heat transfer face of each hole In the heating unit 744 and liquid TEOS, that is, the heat resistance layer is made thinner. As the result, convection heat transmission is promoted to further raise the vaporized efficiency of liquid TEOS.
According to the vaporizer in this case, gas-like TEOS is moved by pressure difference caused between the inlet 738 and the outlet 740 and thus introduced into the process chamber 710 without using any carrier gas.
A bypass 750 and a stop valve 752 may be attached to the passage extending from the outlet 740 of the vaporizer, as shown in FIG. 35 . The bypass 750 is communicated with a clean-up unit (not shown) via a bypass valve 754 . The clean-up unit has a burner and others to remove unnecessary gas components. Further, a sensor 756 is also attached to the passage extending from the outlet 740 to detect whether or not liquid TEOS is completely vaporized and whether or not gases are mixed at a correct rate. Detection signal Is sent from the sensor 756 to the controller 758 .
The operation of the above-described CVD apparatus 700 will be described.
The wafer W is carried into the process chamber 710 which has been decompressed to about 1×10 −4 —several Torr, and it is mounted on the suscepter 712 . It is then heated to 300° C., for example, by the heater 716 . While preparing the process chamber 710 in this manner, liquid TEOS is vaporized by the vaporizer 732 . High frequency power is applied from the high frequency power supply 728 to the lower electrode 712 to generate reactive plasma in the process chamber. Activated species in plasma reach the treated face of the wafer W to thereby from P-TEOS (plasma-tetraethylorthosilicate) film, for example, on it.
Other vaporizers will be described referring to FIGS. 37 through 41.
As shown in FIG. 37, a vaporizer 732 A may be made integral to an upper electrode 730 A of a process chamber 710 A. It is attached integral to the upper electrode 730 A at the upper portion thereof with an intermediate chamber 770 formed under it. Its housing 742 A has a gas outlet side 774 in which a plurality of apertures 772 are formed.
A gas pipe 776 is communicated with the intermediate chamber 770 in the upper electrode 730 A to introduce second gas such as oxygen and inert gases is into it. A bypass 750 A extends from that portion of the upper electrode 730 A which is opposed to the gas pipe 776 to exhaust unnecessary gas from the upper electrode 730 A. Further, plates 780 a, 780 b and 780 c in which a plurality of apertures 778 a, 778 b and 778 c are formed are arranged in the lower portion of the intermediate chamber 770 with an interval interposed between them.
As shown in FIGS. 38 and 39, a liquid passage 782 is formed in a heating unit 744 B in the case of a vaporizer 732 B. It includes a center passage 782 a and passages 782 b radically branching from the center passage 782 a. When it is formed in the heating unit 744 B in this manner, it enables liquid to be uniformly distributed in the whole of the porous heating unit 744 B, thereby raising gas vaporized efficiency to a further extent.
After liquid is vaporized by a vaporizer 738 C, two or more gases may be mixed, as shown in FIG. 40. A second gas supply opening 784 is arranged downstream the vaporizer 738 C and second gas component such as oxygen and inert gases is supplied through it. A gas mixing duct 786 extends downstream it and a bypass 750 C having a bypass valve 754 C, and a stop valve 752 C are further arranged in the lower portion of the gas mixing duct 786 . A strip-like mer 788 is housed in the gas mixing duct 786 to form a spiral passage 790 in it. First and second gas components are fully mixed, while passing through the spiral passage 790 , and they reach a point at which the bypass 750 branches from the passage extending to the side of the process chamber.
In addition to TEOS (tetraethylorthosilicate), trichlorsilane (SiHCl 3 ), silicon tetrachloride (SiCl 4 ), pentaethoxytantalum (PEOTa: Ta(OC 2 H 5 ) 5 ), pentamethoxytantalum (PMOTa: Ta(OCH 3 ) 5 ), tetrasopropoxytitanium (Ti(i-OC 3 H 7 ) 4 ), tetradimethylaminotitanium (TDMAT: Ti(N(CH 3 ) 2 ) 4 ), tetraxisdiethylaminatitanium (TDEAT: Ti(N(C 2 H 5 ) 2 ) 4 ), titanium tetrachloride (TiCl 4 ), Cu(HFA) 2 and Cu(DPM) 2 may be used as liquid material to be vaporized. Further, Ba(DPM) 2 /THF and Sr(DPM) 2 /THF may be used as thin ferroelectric film forming material. Water (H 2 O), ethanol (C 2 H 5 OH), tetrahydrofuran (THP: C 4 H 8 O) and dimethylaluminiumhydride (DMAH: (CH 3 ) 2 AlH) may also be used.
A vaporizer 819 may be attached to a batch type horizontal plasma CVD apparatus 800 , as shown in FIG. 41 . This CVD apparatus 800 includes a process chamber 814 provided with an exhaust opening 810 and a process gas supply section 812 , a wafer boat 816 and a heater means 818 . Connected to the process gas supply section 812 are a process gas supply line or system having a liquid container 815 , a liquid mass flow controller 817 and a vaporizer 819 . This vaporizer 819 is substantially same in arrangement as the above-described one 732 .
As shown in FIG. 42, a conventional vaporizer 701 has a housing 702 which is kept under atmospheric pressure and which is filled with a plurality of heat transmitting balls 703 each being made of material, excellent in heat transmission. These heat transmitting balls 703 are heated higher than the boiling point of liquid material by an external heater means (not shown) to vaporize liquid material introduced from below. Carrier gas is introduced into the vaporizer 701 to carry vaporized process gases.
In the conventional vaporizer 701 , however, gas flow rate becomes excessive at the initial stage of gas supply, that is, overshooting is caused. FIG. 43 is a graph showing how gas flow rates attained by the conventional and our vaporizers change at the initial stage of gas supply, in which time lapse is plotted on the horizontal axis and gas flow rates on the vertical axis. A curve P represents results obtained by the conventional vaporizer and another curve Q those obtained by our present vaporizer. As apparent from FIG. 43, gas flow rate overshoots a predetermined one V 1 , in the case of the conventional vaporizer, after the lapse of 10-20 seconds since the supply of gas is started. In the above-described vaporizer used by the present invention, however, it reaches the predetermined flow rate V 1 without overshooting it.
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, representative devices, and illustrated examples 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. | An apparatus for treating a substrate which includes a chamber and an opening formed in the chamber allowing the substrate to be conveyed into the chamber or taken out thereof. The chamber, also, includes a detachable baffle plate that fits around an electrode. For treatment to commence, the substrate is placed on the electrode and the chamber is exhausted of or supplied with gases. The electrode is then vertically lifted together with the baffle plate and the baffle plate is moved either to a position that is higher in level than an upper end of the opening of the chamber or to a position that is lower in level than a lower end of the opening of the chamber. This allows the baffle plate to shield a region near the opening of the chamber from a treatment region and allows reaction products to be adhered to the baffle plate. | 8 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates in general to suppressing electric and electromagnetic interference and more specifically to preventing interference from affecting electronic circuitry that controls an operation such as the air mixture of gasoline in a catalytic converter of an automobile.
2. Description of the Prior Art
Due to stringent limitations on air pollution, automobile exhaust is strictly controlled in order to minimize pollutant levels. A catalytic converter is used to cleanse exhaust gases. The efficiency of the catalytic converter is heavily dependent upon a strictly controlled air/gasoline mixture. Several parameters are considered and manipulated by a computer which then acts to adjust the air/gas ratio and minimize pollutant levels. Typically, electromagnetic sensors, piezo-resistant sensors, Hall effect sensors, CTN type probes, and oxygen probes are used to collect data. The data is sent to a calculating device, such as a computer, where the data is processed and used to drive the ignition and fuel injection of the engine.
Because an electronic computer is used to manipulate the data collected by the various sensors, it is subject to electric and electromagnetic interference that may affect the results generated by the computer, adversely affecting the efficiency of the catalytic converter. The very probes used to collect the data necessary for the computer to operate create interference signals that upset the accuracy of the calculating device. Interferences from the environment external to the vehicle also upset the accuracy of the calculating device. The external interferences can also interfere with the sensors and probes as data is collected, adversely affecting the individual component as it attempts to collect data.
The interference signals disturb the engine's performance, resulting in inefficient fuel consumption and pollution. Currently there is no solution to the problem other than replacing components, which results in high operating costs for the user and high warranty costs for the manufacturer.
Electrical signals are subject to contamination from interference generated by many different sources. The signal can be filtered, or treated, in an attempt to minimize the "noise" generated by interfering signals and isolate the "useful" signal. Interference that is within the same frequency band as the "useful" signal is more difficult to treat. U.S. Pat. No. 4,081,740 to Teratani et al. discloses a capacitor connected between a voltage divider line and ground, distinct from the chassis ground. The capacitor absorbs high frequency noises appearing over the voltage divider line and ground, yet does not address amplitude differences that occur in noise interference. Likewise, U.S. Pat. No. 3,256,487 to Sinninger and French Patent No. 93-06391, which was filed in the United States, disclose a device that acts to maximize the noise to signal ratio of a system by injecting a phase opposition signal against the interference signal, which would be disastrous if used in the asymmetric system of an automotive vehicle. Injecting a phase opposition signal would double the effect of the interference voltage rather than cancel out its effects as in the present invention. The interference suppression system as taught by Sinninger requires that the phase relationship of the interference signals be different from each other, ideally 180° out of phase. Likewise, in French Patent No. 93-06391 discloses a filtering device including two light emitting diodes in parallel, and a processing device that injects a phase-opposition current on the ground parts of the machine to eliminate higher-amplitude interference. The teachings of French Patent No. 93-06391 are not only opposite the teachings of the present invention, but are functionally impossible. The processing device of the French patent is a capacitor. A capacitor cannot process amplitude, and the diodes disclosed do not filter. And as discussed above, injecting a current in phase opposition effectively doubles the interference signal rather than cancels it out.
In automotive systems, there are many components that come together and operate as a complete assembly. Individually, each of these components must meet an electromagnetic compatibility (EMC) standard. However, when the individual components are combined, the assembly may not meet the EMC standard. In addition, automotive manufacturers rely on the metallic parts of the car body as a ground, when in fact they are not. The "ground" of the car body is subject to interference generated by galvanic coupling, or conduction of current through one or several impedances that are common to two or more pieces of electrical equipment. All conductors have an inherent impedance, which is mostly negligible at low frequencies. However, harmonic currents will develop harmonic voltages through an impedance that increases as frequency increases. The harmonic voltages interfere with the "useful" signal, adversely affecting the efficiency of the catalytic converter. Magnetic and capacitive coupling can also interfere with the "useful" signal.
What is needed is a simple and cost effective device which adequately neutralizes the effect of an interference signal on an asymmetric system.
SUMMARY OF THE INVENTION
The electromagnetic interference suppression device of the present invention reduces the severity of electromagnetic interference with the operation of a catalytic converter. The electromagnetic interference suppression device utilizes an antenna to develop a voltage that is ideally equal to the interference voltage developed from interference signals.
The device of the present invention utilizes a tuned circuit having two opposing diodes, a capacitor and an inductor, mounted in series with each other, to create a voltage that approximates the interference voltage as closely as possible, neutralizing its effect on an asymmetric system.
It is an object of the present invention to neutralize the effect of an interference signal on an asymmetric system.
It is another object of the present invention to control the level of polluting emissions from automotive exhaust systems.
It is yet another object of the present invention to prevent inefficiencies in the operation of an automotive catalytic converter.
It is yet another object of the present invention to lessen the severity of electromagnetic interference.
It is still a further object of the present invention to enhance the operation of a vehicles computer control of vehicle emissions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a symmetric system including a probe, a pair of twisted conductors, and an amplifier;
FIG. 2 is a graphical representation of an interference voltage on the symmetric system of FIG. 1;
FIG. 3 is a schematic of an asymmetric system including a probe, two conductors, and an amplifier;
FIG. 4 is a graphical representation of an interference voltage on the asymmetric system of FIG. 3;
FIG. 5 is a schematic of an asymmetric system depicting the location of the interference suppressing device of the present invention; and
FIG. 6 is a schematic of the interference suppressing device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
It is generally known in the prior art that the best way to prevent electrical disturbances from affecting electrical controls is to employ a symmetric control system, as used in aerospace technology. A symmetric system is ideal within any range of frequencies. A symmetric system as shown in FIG. 1 includes a sensor 1, a pair of twisted conductors C1 and C2, and an amplifier 2 having a gain G. Referring to FIG. 2, a voltage induced by an interference signal Vp1 and Vp2, will have the same amplitude and phase on both conductors C1 and C2 of FIG. 1. An output voltage Vs is shown in FIG. 2. Each of the two conductors C1 and C2 shown in FIG. 1 has an inherent impedance. The amplifier inputs are E1 and E2. The voltage signal Vs will have the opposite sign on each conductor. Therefore,
when
Vs=G(E1-E2) (1)
we have:
E1-(-E1)=E1+E1 (2)
or
Vs=2E1×G (3)
The interference signal,
Vp1-(Vp2)=Vp1-Vp2 (4)
If
Vp1=Vp2 (5)
then the interference signal output voltage will be zero. Unfortunately the elementary rules of symmetry are not employed in the automotive industry, primarily for cost reasons.
An asymmetric system that is used in automotive technology is best shown in FIG. 3. In an asymmetric system, individual conductors 11 and 12 are used as opposed to the pair of conductors C1 and C2 used in a symmetric system. One of the conductors 11 of an asymmetric system is attached to a source 1, and the other conductor 12 is attached directly to the system ground G. As discussed above, the "ground" used in the automotive industry is the metal parts of the vehicle's body and not an actual ground, giving rise to potential interference.
In an asymmetric system, a transient, or interference signal, created by the sensor 1 will occur only on one conductor 11, whose amplitude is then magnified by the gain G of the amplifier 2. This is shown schematically in FIG. 4. Referring to FIG. 3, a voltage V1 is applied to input E1. The voltage at E2 is zero. Therefore, using formula (1) from above:
Vs=G(E1-E2) (6)
or
E1-E2=(V1-0) (7)
If an interference voltage Vp1 is induced on the conductor 11, the voltage at input E1 would be:
E1=V1+Vp1 (8)
where
E2=V2=0 (9)
and
E1-E2=V1+Vp1 (10)
In this example, the voltage at Vs would be:
Vs=G(V1+Vp1) (11)
whereby the interference voltage Vp1 passes through and is magnified by the gain of the amplifier.
The present invention minimizes the effect of an interference voltage Vp1 induced by an interference signal at the amplifier 2 by introducing a signal Vp2 that is closely matched to the interference voltage Vp1, thereby reducing the effect of the interference signal and simulating a symmetric system. The objective in an ideal world is for Vp2 to equal Vp1. However, in a real world, ideal values are not always possible, and slight variations are present for unknown reasons. A person of ordinary skill in the art is aware of the difficulty in arriving at a value of Vp2 that is exactly equal to Vp1. The value of Vp2 should match as closely as possible the value of Vp1. The closer Vp2 matches Vp1, the greater the reduction in the effect of the interference signal. Referring to FIG. 5, the suppressing device 10 of the present invention is attached to the ground conductor 12. The suppressing device 10 introduces a voltage Vp2 that is equal to the interference voltage Vp1 that occurs on the conductor 11 to input E1.
Therefore, using the formula (2) from above:
E1-E2=(V1+Vp1)-(V2+Vp2) (12)
since
Vp1=Vp2 (13)
E1-E2=V1-V2 (14)
and since the conductor 12 is attached directly to ground,
V2=0 (15)
and
E1-E2=V1. (16)
The circuit is void of the interference signal.
Referring now to FIG. 6 the suppressing device 10 of the present invention is generally shown. The device 10 includes an antenna 20, two opposing diodes 31 and 32, a capacitor 40, and an inductor 50. The antenna 20 has been tuned to a pass-band within the frequency spectrum of the interference signals. The tuning has been performed empirically from the results of exhaust gas analysis. A catalytic converter in good operating condition yields the following gas analysis results:
CO: 0
CO 2 : 15.6
HC: 0
O 2 : 0 to 0.03
NOX: 0
Any vehicle which does not show this gas analysis has been affected by an interference signal.
The tuned circuit can be changed and tuned to the interference amplitudes by means of the two opposing diodes 31 and 32, which act in a capacitive manner for lower frequency interferences. The opposing diodes 31 and 32 are effective only to a certain predetermined frequency. For larger amplitude interferences, the diodes 31 and 32 will behave resistively. In such cases, the tuning frequency of the suppressing device 10 of the present invention 10 is controlled by the capacitor 40. The pass-band of the suppressing device 10 will increase in width as the interference voltage Vp1 rises. The inductance is detected at the inductor 50, and the whole system creates a current which passes through an impedance (Z) as shown in FIG. 5, creating a voltage Vp2 across the ground conductor 12 whose value is as close as possible to the interference voltage Vp1 across the conductor 11 as shown in 1 FIG. 5. The voltages Vp1 and Vp2 effectively cancel each other out, and the asymmetric system simulates the efficiency of a symmetric system. The interference voltage Vp1 has no effect on the output of the amplifier and subsequently no effect on the data that is sent to the computer for processing.
The suppressing device of the present invention allows an asymmetric system to simulate the efficiency of a symmetric system. The present invention is most effective within the range of 50 kHz to 3 MHz. The severity of electromagnetic interference is reduced, enhancing the computer controlled operation of the vehicle. The calculating device will efficiently control the level of polluting emissions from the exhaust system by avoiding interference signals that would affect the operation of the catalytic converter.
While a specific embodiment of the invention has been described, it will be clear that variations in the details of the preferred embodiment may be made without departing from the scope of the invention as described in the appended claims. | An electromagnetic and/or electric interference suppression device that reduces the severity of electromagnetic and/or electric interference of an asymmetric system. The suppression device utilizes an antenna to develop a voltage that is ideally equal to the interference voltage developed from interference signals. A tuned circuit having two opposing diodes, a capacitor, and an inductor mounted in series with each other, to create a voltage that approximates as closely as possible the interference voltage, neutralizing its effect on an asymmetric system. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION DATA
[0001] Priority is claimed under 35 U.S.C. §119(e) to U.S. Provisional Application No. 60/929,990, filed on Jul. 20, 2007, which is incorporated by reference herein; this application is a continuation-in-part of application Ser. No. 12/146,068 filed on Jun. 25, 2008 also entitled “Resistance System for Fitness Equipment.”
FIELD OF THE INVENTION
[0002] The present invention generally relates to fitness equipment and, more particularly, to a system for altering the resistance in an exercise device.
BACKGROUND OF THE INVENTION
[0003] Increased convenience and efficiency are hallmarks of value in many products. Fitness equipment is no different. Resistance type fitness equipment has repeatedly been shown to provide numerous benefits including increased bone density, increased lean tissue mass and also some cardiovascular benefits. A desirable aspect of fitness equipment is the ability to change the resistance. Users need to increase resistance as they progress in an exercise program thereby the machine must be able to provide a variability in resistance settings. Ease of use and the ability to quickly change resistance are important in that some exercise programs require resistance changes with minimal down time. General ease of operation is always desirable but in fitness equipment and especially resistance or strength equipment it is highly desirable.
[0004] It should therefore be appreciated that there is a need for an adjustable resistance setting device that allows for actuation of a dial or other actuation system to simply, easily and reliably change the resistance settings in an exercise device. The present invention fulfills this need and others.
SUMMARY OF THE INVENTION
[0005] The present invention provides a resistance system for fitness equipment. This includes a frame, a resistance source coupled to a resistance block, a support disk movably mounted to the frame and adapted to enable selective engagement with the resistance block. A carriage may be provided that is movably mounted to the frame and coupled to the resistance source and a transmission member with a first end coupled to the carriage and a second end adapted to be engaged by a user. The transmission member can be rigid or a pliable member and in one embodiment it may be coupled to a lower portion of the carriage. The second end of the transmission member may be engaged by the user directly as by use of a handle mounted to the end of the transmission member or indirectly as would be the case when the transmission member mounts to a secondary system such as a gearbox or other transmission, of which the user engages. In another embodiment of the invention the carriage may include a handle or other user interface so that the carriage is moved directly by the user.
[0006] The resistance source of the resistance system may be a device selected from the group including a weight block, an elastic cord, a spring, a pneumatic cylinder or a hydraulic cylinder. The resistance source may be a single element or comprised of a plurality of resistance elements. The plurality of resistance elements may include at least one element with the resistance capacity of twice that of another resistance element. The plurality of resistance elements may include an element with twice the resistance capacity relative to the lowest resistance capacity element and every other resistance element has twice the resistance capacity of the next lower capacity resistance element.
[0007] The resistance block of the resistance system for exercise may include a load support adapted to be received by a disk lip on the support disk. In addition, the resistance system may further include a plurality of support disks on a common shaft, the shaft rotatably mounted to the frame.
[0008] In another form of the invention a method of exercise is also disclosed. This method includes providing the device as stated above and the steps of moving the support disk to engage a resistance block with the support disk and then actuating the carriage with respect to the frame so as to displace a portion of the resistance source. This provides a resistance to movement of the carriage at the user interface.
[0009] For the purposes of summarizing the invention and the advantages achieved over the prior art, certain advantages of the invention have been described herein. Of course, it is to be understood that not necessarily all such advantages can be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention can be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
[0010] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following description of the preferred embodiments and drawings, the invention not being limited to any particular preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Embodiments of the present invention will now be described, by way of example only, with reference to the following drawings, in which:
[0012] FIG. 1 is an isometric front view of a base of an exercise device incorporating a resistance system in accordance with the present invention.
[0013] FIG. 2 is a detail of the top section of the base of an exercise device of FIG. 1 along line 2 - 2 .
[0014] FIG. 3 is a front view of the base of the exercise device of FIG. 1 .
[0015] FIG. 4 is a detail of the top portion of the device shown in FIG. 3 along line 4 - 4 .
[0016] FIG. 5 is a front isometric view of the device of FIG. 1 shown with the covers removed.
[0017] FIG. 6 is a detail of the top, center portion of the device shown in FIG. 5 along line 6 - 6 .
[0018] FIG. 7 is a top view of the exercise device of FIG. 1
[0019] FIG. 8 is a sectioned view of the exercise device in FIG. 7 sectioned along line 8 - 8 .
[0020] FIG. 9 is an isometric view of the support disk assembly of the exercise device of FIG. 1 .
[0021] FIG. 10 is an isometric view of a resistance block of the exercise device of FIG. 1
[0022] FIG. 11 is a detail view of the top portion of the resistance block of FIG. 10 along line 11 - 11 .
[0023] FIG. 12 is a front view of the dial knob of FIG. 1 , with a dial face showing an example of the resistance settings.
[0024] FIG. 13 is an isometric front view of a variation of the exercise device of FIG. 1 with the elastic cords removed and replaced with a weight system.
[0025] FIG. 14 is an isometric rear view of the exercise device of FIG. 13 .
[0026] FIG. 15 is a front isometric view of the exercise device of FIG. 13 shown in use when the system is actuated.
[0027] FIG. 16 is a rear isometric view of the exercise device shown in FIG. 15 with the rear block cover in place.
[0028] FIG. 17 is a front isometric view of a variation of the exercise device shown in FIG. 1 with a pin-in-disk system.
[0029] FIG. 18 is a detail view of the pin-in-disk system shown in FIG. 17 along line 18 - 18 .
[0030] FIG. 19 is a detail view of a single disk and a modified resistance block as shown in FIG. 18 along line 19 - 19 .
[0031] FIG. 20 is an isometric view of the pin-in-disk assembly as shown in FIG. 17 .
[0032] FIG. 21 is a detail view of a portion of a disk shown in FIG. 20 along line 21 - 21 .
[0033] FIG. 22 is a front isometric view of a modified resistance block adapted for use with the pin-in-disk system of FIG. 17 .
[0034] FIG. 23 is a detail view of the top portion of the resistance block of FIG. 22 along line 23 - 23 .
[0035] FIG. 24 is a break out isometric view of an embodiment of the invention in which the disk assembly is mounted on the movable carriage.
DETAILED DESCRIPTION OF THE INVENTION
[0036] With reference to the figures, and particularly to FIGS. 1-12 , there is shown a first embodiment of a base of an exercise device 20 . In this embodiment, device 20 includes a frame 22 and two rails 24 . The rails 24 enable proper tracking of the carriage 26 relative to the frame 22 . In this embodiment this is accomplished by four carriage rollers 28 mounted to each of four corners of the carriage 26 and rolling on the rails 24 . The specifics of this tracking system are not considered critical to the novelty of the invention. It is understood that this is one embodiment of this assembly but other methods such as linear bearings, linear slides and glide bushings could also be used without taking away from the spirit of the invention.
[0037] Two bearings 30 are supported on the frame 22 and more clearly shown in FIGS. 2 and 4 . These bearings 30 provide a means for movable support of a support disk assembly 32 on the frame 22 . In this embodiment the support disk assembly 32 is comprised of five support disks, each with at least one disk lip 34 . A first disk 36 includes a plurality of disk lips 34 spaced about the perimeter of the disk 36 . The purpose of each disk lip 34 is to engage with a portion of a resistance block 38 . When the disk lip 34 engages a block lip 40 , that resistance block 38 is supported by the frame 22 through the support disk assembly 32 . A carriage 26 can be displaced down by applying tension to a cable 42 . A resistance against this movement is provided by resistance cords 44 secured to a resistance block 38 , in which the disk lip 34 and block lip 40 are engaged. Any resistance blocks 38 in which their respective disk lip 34 is not engaged with a block lip 40 will be allowed to freely move down with the carriage 26 when tension is placed on the cable 42 . The cords 44 that are not supported by a disk lip 34 will not be elongated and therefore not add any tension to the cable 42 , as can be also seen in FIGS. 5 and 6 .
[0038] In FIG. 3 a front view of the mechanism is shown. The support disk assembly 32 includes five disks, each with a corresponding resistance block 38 and cord. In this embodiment the resistance cords 44 are configured according to the formula: T N =(T N−1 )*2. As an example, if T 1 =F, then T 2 =T 1 *2 and T 3 =T 2 *2 and so on, where T 1 through T N are the tensions generated by elastic properties of the associated cords 44 . The lowest tension (F) is represented by T 1 . Each higher tension is represented by the following higher numbers, in this case T 2 , T 3 through T 5 . Each higher resistance cord (T 2 , T 3 , etc) provides twice the tension of the cord of the preceding lower tension (i.e. T 3 =T 2 *2). This provides a system with 2 N number of increments or (2 N −1) number of increments when not counting zero resistance, where “N” is the number of cords and the value of the increments is the value of T 1 (or F). For example, a four
[0000] TABLE 1 T 1 (10 lbs) T 2 (20 lbs) T 3 (40 lbs) T 4 (80 lbs) Total Force — — — — 0 10 — — — 10 — 20 — — 20 10 20 — — 30 — — 40 — 40 10 — 40 — 50 — 20 40 — 60 10 20 40 — 70 — — — 80 80 10 — — 80 90 — 20 — 80 100 10 20 — 80 110 — — 40 80 120 10 — 40 80 130 — 20 40 80 140 10 20 40 80 150
cord system with 10 pounds as the first cord would have 15 increments (2 4 −1=15) or 16 increments counting zero. One example of the cords and loads are presented in Table 1.
[0039] With every increase in the number of cords the total number (including zero tension) of load combinations doubles. With 5 cords there are 2 5 or 32 combinations. With six cords counting zero there are 26 or 64 combinations. Whatever increment value is chosen to start (T 1 ) will be the tension or force increment. For example if T 1 =5 pounds, then the range would be 0 to 75 pounds with four cords in this arrangement. If T 1 =20 pounds then the sixteen increments of resistance would be 0 to 300 pounds. By adding one 160 pound cord as the fifth (T 5 ) to the previously mentioned four cord system with ten pound increments, the range would be 0 to 310 pounds with thirty-two different settings in ten-pound increments. In the system as described, a great deal of variety and range in resistance can be achieved with a small number of resistance cords. This system is disclosed with resistance cords only, but the same system can be used with a number of resistance sources including weights, springs, pneumatic and hydraulic cylinders, or any spring material and configuration which allows for the storage of mechanical energy stretching, bending, twisting or other physical deformation.
[0040] The disks of the assembly 32 in FIGS. 3 and 4 are positioned with the associated highest resistance cord 46 nearest the center of the carriage 26 . This is desirable in that it minimizes the load in the tracking system of the carriage 26 but is not mandatory to the function of the invention. The fifth disk 48 has a common shaft 50 with the first disk 36 . Likewise the second disk 52 , third disk 54 and fourth disk 56 are also continuous with the shaft 50 . A shaft gear 58 is also continuous with the shaft 50 , thereby movement of the shaft gear 58 results in rotation of the shaft 50 and all the disks ( 36 , 48 , 52 , 54 and 56 ). In this embodiment a knob gear 60 is provided that drives the shaft gear 58 . This is done to allow access to the knob 82 at the front of the device 20 . The location and for that matter, the presence of the shaft gear 58 and knob gear 60 are not mandatory but provided here as one embodiment of the invention. Another embodiment eliminates the shaft gear 58 and knob gear 60 and may provide a knob 82 on one or both ends of the shaft 50 , so that the user may rotate the shaft 50 directly. In a comparable manner, a drive system such as an electric motor, may be attached directly to the shaft 50 or any gear 58 . In this way the shaft 50 can be actuated by the push of a button somewhere on the machine or even remotely by wired or wireless connection including radio frequency (RF), infrared or any other communication known in the art. Any method of rotating the disks ( 36 , 48 , 52 , 54 and 56 ) can be used to accomplish selection of the desired resistance.
[0041] In this embodiment the resistance blocks 38 are similar in construction in each position and adjacent to each disk ( 36 , 48 , 52 , 54 and 56 ). Each resistance block 38 is attached to a resistance cord. As previously noted, the heaviest cord 46 is associated with the fifth disk 48 . The lightest cord, cord one 62 , is associated with the first disk 36 , cord two 64 is associated with the second disk 52 , cord three 66 with the third disk 54 and cord four 68 with the fourth disk 56 . Each of the cords ( 46 , 62 , 64 , 66 and 68 ) is secured to the carriage 26 at the bottom rail 70 . Orientation of the support disk assembly 32 provides selective engagement of any or all of the resistance blocks 38 and associated cords ( 46 , 62 , 64 , 66 and 68 ) to the frame through the disks ( 36 , 48 , 52 , 54 and 56 ). Power is transferred to the carriage 26 by the user through the cable 42 . In this embodiment the resistance block cover 72 provides additional movable support of the resistance blocks 38 as they are guided by the slots 74 . This is one of any number of structural elements that may be used to guide the blocks 38 as they travel relative to the frame 22 .
[0042] More detail of the device 20 is shown in FIGS. 5 and 6 in which the resistance block covers 72 (front and back) have been removed. In this view, the carriage 26 is shown with the carriage recoil bar 76 positioned under the block rail 78 or any other portion of the resistance block 38 . When a resistance block 38 is not engaged with the associated disk ( 36 , 48 , 52 , 54 or 56 ), that resistance block 38 will move down with the carriage 26 as actuated by the cable 42 . These non-engaged resistance blocks 38 will be supported by the carriage recoil bar 76 and therefore be moved back up to the disk assembly 32 when the tension is decreased from the cable 42 and the carriage moves back to its original or non-tensioned position. An optional recoil cord (not shown in this figure) may be used to pull the carriage back to the top (starting position as shown here) if no cords are used.
[0043] The engagement of the fifth disk 48 with the associated resistance block 38 is illustrated in FIG. 6 . Each disk ( 36 , 48 , 52 , 54 and 56 ) includes a disk lip 34 that enables selective engagement with the block lip 40 of the resistance block 38 . The disks ( 48 , 56 , etc.) are moved in this embodiment by actuation of the knob 82 , which is mounted to the knob gear 60 . The knob gear 60 is in this embodiment is a beveled gear that mates with the shaft gear 58 that is continuous with the shaft 50 . Thereby actuation of the knob 82 in a clockwise direction 84 causes rotation of the support disk assembly 32 in a clockwise direction 86 when viewed from the right of the machine 20 as is indicated by the arrows ( 84 and 86 ). Rotation of the shaft 50 , and therefore the combination of disks ( 36 , 48 , 52 , 54 and 56 ) such that any of the associated disk lips 34 engage with their respective block lips 40 of the resistance blocks 38 , that block 38 (or combination of multiple blocks 38 ) will have one end of the cord 44 that is secured to that particular block 38 fixed to the frame 22 by way of the disk assembly 32 . In this embodiment the cable 42 is coupled to the carriage 26 at the opposite end relative to the blocks 38 . Also secured to this end of the carriage 26 , are the end of the cords 44 which are opposite to the end of the cords 44 where the blocks 38 are located. The resistance to movement of the carriage 26 by way of the cable 42 is proportionate to which blocks 38 , and therefore which cords 44 , have their blocks 38 held by engagement with the disk assembly 32 .
[0044] A top view of the device 20 is shown in FIG. 7 illustrating the position of the section line 8 - 8 . This partial section view is shown in FIG. 8 with the resistance block covers 72 removed for clarity. In this view it can be seen that the resistance blocks 38 are selectively engaged with the disks ( 36 , 52 , 48 , 56 and 54 ), which are positioned adjacent to each block 38 . The blocks 38 are mounted to the appropriate cords ( 62 , 64 , 46 , 68 and 66 ) by a crimp 88 that may be positioned through a hole in a block bracket 90 . The block bracket 90 is fastened to the resistance block 38 by a pin 92 or similar fastening device. The opposite end of each cord ( 62 , 64 , 46 , 68 and 66 ) is fastened to the end of the bottom rail 70 of the carriage 26 by a second crimp 94 . The cable 42 may also be mounted to the bottom rail 70 by a cable crimp 96 , thus enabling displacement of the carriage 26 from the support disk assembly 32 by tension applied to the cable 42 . Any resistance blocks 38 which are secured to the adjacent disk of the support disk assembly 32 will maintain the upper position of the associated cords ( 62 , 64 , 46 , 68 and 66 ) relative to the frame 22 while the lower end of that cord will move away from the support disk assembly 32 , stretching those cords and providing resistance to movement of the carriage 26 . It is understood that the invention may be positioned in any number of orientations relative to the user. This is only one version where the blocks 38 move in a vertical plane and are initially positioned near the upper portion of the frame 22 . Varying the combination of cords ( 62 , 64 , 46 , 68 and 66 ) as per their selective engagement with their respective disks ( 36 , 52 , 48 , 56 and 54 ) will vary the force in the cable 42 similar to that noted in Table 1, only as shown here with twice the number of variations or thirty-two settings for five cords rather than sixteen settings for four cords as previously noted.
[0045] The support disk assembly 32 of this embodiment is shown in FIG. 9 . In this embodiment each disk has at least one disk lip 34 . The first disk 36 has sixteen disk lips 34 , the second disk 52 has eight disk lips 34 , the third disk 54 has four lips and the fourth disk 56 has two lips 34 . The fifth disk 48 is shown to have one disk lip 34 that covers substantially half of the perimeter of the disk 48 . Each of the disks is coupled to the shaft 50 for rotation therewith. This may be a molded part or a series of metal parts that are welded or assembled of this or other materials to create this assembly 32 . The shaft gear 58 is also securely mounted to the shaft 50 by any method known in the art.
[0046] A variation to the invention as presented in FIG. 9 is to provide a series of disks that are similar in the size and general construction of the disk lip 34 but with the initial gap 98 positioned out of phase and in a set order. By doing this, resistance cords can be sequentially added with a set rotational displacement of the support disk assembly 32 . In this variation and all forms of the invention, the resistance cords ( 62 , 64 , 46 , 68 and 66 ) may be one tension or provided in different tensions. Also the disk portions may be half disks, quarter disks or any other portion of a full disk. Or, instead of disks, a wheel structure may be used with a hub and spokes supporting a rim. And, the rim could be annular or segmented with a rim portion at the end of each spoke.
[0047] A resistance block 38 is shown in FIG. 10 with more detail in FIG. 1l . In this embodiment, the block 38 may include a block rail 78 which is a protrusion or other structural feature that allows guided communication with the slots 74 in the resistance block cover 72 ( FIG. 3 ). This optional structure 78 may have many numbers of variations in size, structure and orientation to the block 38 . The block lip 40 on the upper portion of the block 38 is adapted to receive the disk lip 34 to offer support to the resistance block 38 or to allow the resistance block 38 to pass through the gaps 98 between the disk lips 34 . In this embodiment the disk lips 34 include a disk flange 100 that is positioned adjacent to the wall 102 of the resistance block 38 . A block flange 104 may be used to provide stable support of the resistance block 38 under load when supported on a disk of the support disk assembly 32 . It is understood that many variations to the disk lips 34 and block lips 40 can be made. Inserts and detents can be added to the disk assembly 32 to provide more secure indexing of the components and reduce the likelihood of inadvertent movement relative to one another when one or more of the cords ( 62 , 64 , 46 , 68 and 66 ) are stretched and therefore the system is under load.
[0048] A typical application of the display 106 is shown in FIG. 12 . The knob 82 is positioned central to an indication display 108 . The indication display 108 includes a plurality of indexing graphics such as tick marks 110 and some if not all of the load increments noted in text 112 . Movement of the knob 82 to any position will be noted by a tick mark 110 . That actuation rotates the shaft 50 of the support disk assembly 32 altering the engagement of the disks ( 36 , 52 , 48 , 56 and 54 ) with the resistance blocks 38 and associated cords ( 62 , 64 , 46 , 68 and 66 ), thus altering the tension in the cable 42 as to be overcome by the user.
[0049] As previously noted, in an alternative embodiment the knob 82 may be mounted directly to the shaft 50 of the support disk assembly 32 on one or both ends of the shaft 50 . This eliminates the need for the gears ( 58 and 60 ) and in some situations could be desirable while maintaining the function as described herein.
[0050] Indexing of the knob 82 , and therefore the support disk assembly 32 to be properly positioned can be accomplished in a number of methods. A spring loaded washer with an indent for every position (in this embodiment thirty-two positions) can be positioned under the knob 82 or at any place on the support disk assembly 32 . In this embodiment the gears ( 58 and 60 ) have 32 teeth so a flexible element offering interference, such as a leaf spring, can be positioned to allow movement of the assembly 32 , but guide it to settle at any one of the 32 settings, as opposed to settling between two settings (tick marks 110 ). It is understood that the detail of the load increments, methods of indexing and graphic design can change without altering the spirit of the invention.
[0051] With reference to FIGS. 13 and 14 , the device 20 ′ is shown employing an alternate resistance system. In this embodiment the resistance cords 44 have been replaced with the weight blocks 114 . The carriage 26 ′ has been slightly modified to include a series of pulleys 116 mounted at the lower end. A weight cable 118 connects the individual weight blocks 114 to the carriage 26 ′ by way of the respective pulley 116 . A recoil spring 120 connects the bottom of the carriage 26 ′ to the top of the frame 22 at the spring bracket 122 . This spring 120 provides lift to the carriage 26 ′ to bias it toward the elevated position shown so that the top of the modified resistance blocks 38 ′ are properly located so as to enable selective engagement with the support disk assembly 32 as previously described. In this position shown, the system is at rest, with no tension in the cable 42 .
[0052] In FIGS. 15 and 16 the device 20 ′ of the previous figures is shown in one example of an activated state, where tension has been applied to the cable 42 to cause the carriage 26 ′ to be displaced down toward the bottom of the frame 22 . This action increases the distance between the pulleys 116 at the bottom of the engaged modified resistance blocks 38 ″ and the bottom frame member 124 of the carriage 26 ′ for only those engaged resistance blocks 38 ″ that are attached to their respective disks of the disk assembly 32 . The unengaged modified resistance blocks 38 ′ are not attached to their respective disks of the disk assembly 32 and follow with the carriage 26 ′ as it moves away from the disk assembly 32 , as they may be supported by the bottom frame member 124 . This bottom frame member 124 is analogous in function to the carriage recoil bar 76 ( FIG. 5 ) in that it supports the unengaged resistance blocks 38 ′. When the carriage 26 ′ is drawn down by the tension applied to the cable 42 , any pulley 116 that remains elevated displaces the respective weight block 114 up by way of the respective tight weight cable 118 . The slacked weight cables 118 ′ attached to weight blocks 114 that are not elevated, go slack in this process. Orientation of the disk assembly 32 selects which resistance blocks 38 ′ remain elevated and which move with the carriage, thereby altering the combination of which of the weight blocks 114 are elevated and which are not elevated when the carriage 26 ′ is moved. The combination of the mass of the weight blocks 114 lifted at any time determines the tension in the cable 42 .
[0053] In these views, the weight blocks 114 are shown to be different sizes. This allows for a different amount of resistance settings. For example, if the weight block number one 126 with the greatest mass is twice that of weight block number two 128 , which has twice the mass of weight block number three 130 and this continues for weight block number four 132 being twice the mass of weight block number five 134 , the sequence of resistance combinations noted with the cords can also be achieved with this combination of weight blocks 114 . This is not mandatory for the function of the device 20 ′, but in some cases it may be desirable to provide the greatest number of resistance combinations in equal increasing increments with the least number of weight blocks.
[0054] Another embodiment of the invention is shown in FIGS. 17-19 . Here the device 20 ″ is shown with a cord resistance as compared to the weight blocks, but both forms of resistance could be used in this embodiment. The variation is in the modified disk assembly 32 ′. A detail of the modified disk assembly 32 ′ is shown in FIG. 18 and a detail of the interaction of the pin-in-disk system disk 136 is illustrated in FIG. 19 . Referring to the drawings, the disk assembly 32 ′ has been altered to include a substantially flat plate 138 with one or more pins 140 protruding from one or both sides of the plate 138 . In this embodiment the pins 140 extend from both sides of the plate 138 , as this is considered more desirable for load bearing characteristics as opposed to a cantilevered load on only one side. In some situations for clearance or assembly considerations, it may be desirable to have the pins 140 extend from only one side of the plate 138 . That will be considered an understood variation of the disclosed invention.
[0055] The pin 140 is similar to the disk lip 34 of the previous embodiment of the invention 20 . In this case the pin 140 provides the supportive surface necessary to engage with a recess in the block lip 40 ′. The curved surface of the pin 140 may provide a built in “self centering” or indexing feature that also helps prevent unintentional removal of the pin 140 from the block lip 40 ′. More detail of this engagement is shown in the following figures.
[0056] With reference to FIGS. 20-23 , the pin-in-disk system disk assembly 32 ′ and the resistance block 38 ′″ are shown in detail. The disk assembly 32 ′ includes one or more plates 138 which are each mounted to the shaft 50 . Each plate 138 includes one or more pins 140 that extend from a surface of the plate 138 . As a common and economical form of manufacturing, the plates 138 can be constructed of steel, aluminum, plastics or like material with holes for the shaft 50 and the pins 140 . The shaft 50 , pins 140 or any combination can be press fit or positioned and welded or otherwise fastened into the proper configuration, or they may be molded or casted as one part. As previously noted, a shaft gear 58 can also be positioned on the shaft 50 to enable rotational actuation of the disk assembly 32 ′. In all embodiments, the shaft gear 58 is used only if the orientation of the shaft 50 is desired to be different from the orientation of the axis of the knob 82 . A knob 82 can also be placed on one or both ends of the shaft 50 and this gear 58 would then be eliminated.
[0057] The resistance block 38 ′″ is similar in construction to the previously noted embodiments of the invention with, in this embodiment, a modification to the upper section including the block lip 40 ′. In this embodiment, the block lip 40 ′ includes a center recess 142 adapted to accept the edge of the disk 138 and adjacent pin 140 to pass there through. If a pin 140 is positioned within the center recess 142 and the block 38 ′″ is displaced, the pin 140 will be received by the upper structure of the block lip 40 ′ and secured to the disk assembly 32 ′ by the pin 140 .
[0058] The shape of the contact area 144 of the block lip 40 ′ is shown to be concave. This is to provide a self centering feature of the pin 140 when engaged with the block lip 40 ′. The dimensions of many aspects of the block lip 40 ′ are subject to design variation. The displacement of the center of the contact area 144 relative to the adjacent outside edges of the block lip 40 ′ provides an obstruction to disassociation of the pin 140 , and therefore the disk assembly 32 ′, relative to the block 38 ′″ when a load is applied to the block 38 ′″. This feature helps “lock” the position of the disk assembly 32 ′ when it is in a loaded (cords tensioned, weight blocks lifted, or any other tension system engaged) condition thereby helps to reduce the likelihood of a weight block 38 ′″ (for example) from falling when loaded. This system can be incorporated in some form in all embodiments of the invention.
[0059] Another variation of the invention is shown in FIG. 24 . In this form, the carriage 26 ″ is shown slightly displaced as is the case when the cable 42 is slightly tensioned. As noted earlier, the orientation of the carriage 26 ″ in all embodiments of the invention can be varied. When resistance cords ( 62 , 64 , 46 , 68 and 66 ), as shown here, are used as a resistance source, or any other non-gravity based resistance source, the orientation relative to gravity makes no difference and though the carriage 26 ″ is shown to actuate in a vertical plane, it is understood that this is not necessary to the function of the invention and is shown here as one example of that embodiment.
[0060] Given the foregoing, in this embodiment, the carriage 26 ″ is guided by four carriage rollers 28 that articulate with a rounded edge of the vertical members 146 of the frame 22 ′. The round edges of the vertical members 146 are similar to the rails 24 of FIG. 1 in that they provide a guided support surface for the carriage 26 ″ by way of the carriage rollers 28 . In this embodiment relative to the previous is, in this view, the disk assembly 32 is rotatably mounted to the carriage 26 ″. As the cable 42 is actuated by the handle 148 and pulled over the pulley 150 , the carriage 26 ″, with the disk assembly 32 , moves vertically. The cords ( 62 , 64 , 46 , 68 and 66 ) have one end secured to the slide blocks 38 , as previously disclosed, and the other end is secured to the bottom frame member 152 by the crimps 94 . A break out of the bottom frame member 152 shows the crimp 94 on the highest resistance cord 46 . The rest of the cords ( 62 , 64 , 68 and 66 ) would have a similar fastening system to keep one end stationary with respect to the frame 22 ′
[0061] As noted, the carriage 26 ″ is slightly actuated and therefore the cords ( 62 , 64 , 46 , 68 and 66 ) are slightly tensioned as would be the case if all five slide blocks 38 are supported by the associated disks of the disk assembly 32 and the cable 42 is tensioned by pulling on the handle 148 . The cable 42 is secured to the carriage 26 ″ at the cross bar 154 . When the tension in the cable 42 is relaxed and the carriage 26 ″ is lowered, the slide blocks 38 are supported on the recoil bar 76 ′. In this embodiment the recoil bar 76 ′ is mounted to the frame 22 ′, but still offers support for the slide blocks 38 when the system is at rest (no tension in the cable 42 ) and also for any slide block 38 and associated cord ( 62 , 64 , 46 , 68 and 66 ) that is not engaged with the associated disk of the disk assembly 32 when the carriage 26 ″ is actuated. As before, the recoil bar 76 ′ provides sustained positioning of the slide blocks 38 that are not engaged during movement of the carriage 26 ″ and in doing so allows for selective engagement when the carriage 26 ″ is returned to its resting position.
[0062] In all embodiments of the invention as shown and described herein, a rotary mounted engagement mechanism (disk assembly 32 ) is used to selectively engage one or more blocks 38 and their respective forms of resistance, including a cord 44 ( FIGS. 1-8 ) or other elastic element or a weight block 114 ( FIGS. 13-16 ). The engagement mechanism (disk assembly 32 ) is rotatably mounted to the frame ( FIGS. 1-8 and 13 - 17 ) or rotatably mounted to the carriage ( FIG. 24 ). In either case the disk assembly 32 enables the blocks 38 to be “directly” engaged or disengaged in a non-sequential order. For the purposes of this disclosure the term “sequential” is defined as “in order from a first end to a second end”. Therefore “direct” or “non-sequential” engagement of the block 38 mounted to the (middle positioned) heaviest cord 46 with the fifth disk 48 in FIG. 8 is done “directly” without the necessity of any portion of the disk assembly 32 passing through any of the adjacent blocks 38 . This direct engagement is therefore “non-sequential” in that no portion of the disk assembly 32 must first pass through or engage the adjacent blocks 38 before the block 38 associated with the desired cord 46 is reached. The direct engagement is accomplished by the existence of a disk ( 48 for example) that is unique to each block 38 . This direct engagement reduces the probability of inadvertent engagement of a portion of the engagement mechanism with a block 38 not desired to be engaged when using a sequential engagement mechanism. The disk assembly 32 may be actuated as one structure, thereby providing all the combinations of resistances noted herein by the movement of one element. This provides efficiency and ease of use.
[0063] The foregoing detailed description of the present invention is provided for purposes of illustration and it is not intended to be exhaustive or to limit the invention to the particular embodiments shown. The embodiments may provide different capabilities and benefits, depending on the configuration used to implement key features of the invention. | A resistance system for fitness equipment includes a frame, a resistance source such as an elastic cord, coil or any other type of spring, weight, pneumatic or hydraulic cylinders. The resistance source is mounted to a resistance block with a load support. A support disk is provided that is movably mounted to the frame and adapted to enable selective engagement with the load support. A transmission member, including a pliable member such as a cable, belt or other member, is coupled to the resistance source. Movement of the support disk enables selective engagement of the resistance source. In this way one or more individual resistance sources can be selectively engaged or disengaged to vary the resistance to the user by actuation of a dial or other actuator as directed by the user. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a variable cam phaser for an internal combustion engine.
JP 3-53447 B2 discloses a variable cam phaser for the angular adjustment of a camshaft with respect to a drive wheel. By means of this variable cam phaser, the angular adjustment is effected by an annular piston. The annular piston has inner and outer splines of varying lead. The annular piston is slidably mounted in a hydraulic cylinder and defines in the hydraulic cylinder a fluid chamber. The piston is biased by a return spring. The annular piston is axially movable. This movement of the annular piston in the cylinder causes the drive and driven members to undergo relative angular displacement in a direction corresponding to the direction of movement of the annular piston. The cam phaser further includes valve means for pressurizing the fluid chamber for displacing the annular piston in one direction against the return spring or depressurizing said fluid chamber for allowing said return spring to displace the annular piston in the opposite direction and thereby controlling the relative angular position of the drive and driven members. The annular piston is subject to the bias of the return spring via a control sleeve so that the control sleeve follows the axial movement of the annular piston. The control sleeve has an axial bore which constitutes an inlet or an outlet always open to the fluid chamber. The control sleeve has an inner peripheral wall formed with an inner circumferential groove communicating with the axial bore. The inner peripheral wall of the control sleeve defines a space communicating with a drainage. The driven member has an inner circumferential transfer groove and bores connecting the transfer groove to a source of fluid pressure. The transfer groove is wide enough to maintain fluid flow communication with a radial bore extending through the control sleeve during axial movement of the annular piston. This radial bore terminates in a port, namely, a supply port, with which the inner peripheral wall of the control sleeve is formed. The valve means includes a spool slidably mounted in the control sleeve. The spool has a circumferential groove adjacent a land. The circumferential groove of the spool is kept in communication with the supply port to receive fluid pressure, while the land covers the inner circumferential groove of the control sleeve. Shifting the spool in one direction causes the land to uncovers the inner circumferential groove of the control sleeve to communicate with the supply port of the control sleeve via the circumferential groove of the spool, pressurizing the fluid chamber and thereby displacing the annular piston and the control sleeve against the return spring. This displacement continues until the inner circumferential groove of the control sleeve is covered by the land of the spool again. Subsequently, shifting the spool in the opposite direction causes the land to uncover the inner circumferential groove to communicate with the drain space, depressurizing the fluid chamber and thereby allowing the return spring to displace the annular piston and the control sleeve in the opposute direction until the inner circumferential groove of the control sleeve is covered again. In this manner the annular piston can take any position corresponding to a position taken by the spool.
An object of the present invention is to provide an alternative to the variable cam phaser of the above kind.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a variable cam phaser comprising drive and driven members, coupling means for drivingly connecting said drive and driven members in driving relation, said coupling means including means for enabling said drive and driven members to be relatively angularly adjustable while maintaining the driving relation therebetween, said enabling means including a hydraulic cylinder, a piston slidably mounted for movement in said hydraulic cylinder, said piston defining in said cylinder a fluid chamber, and a return spring biasing said piston toward said fluid chamber, the movement of said piston in said cylinder causing said drive and driven members to undergo relative angular displacement in a direction corresponding to the direction of movement of said piston, and valve means for pressurizing said fluid chamber for displacing said piston in one direction against said return spring and depressurizing said fluid chamber for allowing said return spring to displace said piston in the opposite direction and thereby controlling the relative angular position of said drive and driven members,
wherein
there are provided an inlet which is always open to said fluid chamber and a plurality of outlets for venting said cylinder, said plurality of outlets including a first outlet which is always open to said fluid chamber and at least one second outlet for venting said hydraulic cylinder,
said valve means has a first end position wherein said first outlet is vented to depressurize said fluid chamber, allowing said piston to take one extreme position thereof under the bias of said return spring, said piston in said one extreme position thereof blocking flow communication between said fluid chamber and said second outlet,
said valve means has a second end position wherein said first and second outlets are closed to pressurize said fluid chamber, displacing said piston against said return spring to the opposite extreme position thereof, said piston in said the opposite extreme position thereof opening flow communication between said fluid chamber and said second outlet,
said valve means has an intermediate position wherein said first outlet is closed and said second outlet is vented,
moving said valve means from said first end position thereof to said intermediate position thereof pressurizes said fluid chamber, displacing said piston against said return spring until said piston regulates discharge of hydraulic fluid from said fluid chamber through said second outlet to establish an equilibrium state wherein pressure within said fluid chamber balances with said return spring,
moving said valve means from said second end position thereof to said intermediate position thereof depressurizes said fluid chamber, allowing said return spring to displace said piston until said pistion regulates discharge of hydraulic fluid from said fluid chamber through said second outlet to establish said equilibrium state.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a logitudinal section of a first embodiment of a variable cam phaser according to the present invention, the variable cam phaser having a valve in a first end position thereof;
FIG. 2 is an axial end evelation of a shaft adapted to be secured to a camshaft for unitary rotation therewith;
FIG. 3 is an axial end elevation of a bushing adapted to be secured to the camshaft together with the shaft of FIG. 2 for unitary rotation therewith;
FIG. 4 is an axial end elevation of a piston;
FIG. 5 is a section taken through the line A--A of FIG. 4;
FIG. 6 is a fragementary enlarged view showing a portion of the bottom half of FIG. 1;
FIG. 7 is a similar view to FIG. 1 showing position of parts when the valve is in a first intermediate position;
FIG. 8 is a similar view to FIG. 1 showing position of parts when the valve is in a second intermediate position thereof;
FIG. 9 is a similar view to FIG. 1 showing position of parts when the valve in in a third intermediate position thereof;
FIG. 10 is a similar view to FIG. 1 showing position of parts when the valve is in a second end position thereof;
FIG. 11 is an axial section of an altermative form to the shaft used in FIG. 1;
FIG. 12 is a fragmentary view of FIG. 1 illustrating a modified annular piston;
FIG. 13 is a similar view to FIG. 5 showing the modified piston;
FIG. 14 is a similar view of FIG. 12 showing an altermative modification of annular piston;
FIG. 15 is a fragmentary view of FIG. 1 showing a modified inner slide;
FIG. 16 is a similar view to FIG. 15 showing an alternative modification of inner slide;
FIG. 17 is a similar view to FIG. 15 showing still another alternative of inner slide;
FIG. 18 is a similar view to FIG. 1 showing the detail of oil supply;
FIG. 19 is a similar view to FIG. 18 showing a modification of oil supply;
FIG. 20 is a similar view to FIG. 1 showing another embodiment;
FIG. 21 is a similar view to FIG. 1 showing still another embodiment;
FIG. 22 is a section taken though the line A--A of FIG. 21;
FIG. 23 is a section taken through the line B--B of FIG. 22;
FIG. 24 is a secion taken through the line C--C of FIG. 22;
FIG. 25 is a longitudinal section of a cylindrical bushing;
FIG. 26 is an end view of a stub shaft; and
FIGS. 27, 28, 29 and 30 are views of corresponding to FIGS. 7, 8, 9 and 10, respectively.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the reference numeral 10 generally indicates an internal combustion engine of a type having a camshaft 12 driven by a crankshaft, not shown. The camshaft 12, shown in phantom line, carries a plurality of cams (not shown) for actuating cylinder valves (not shown) of the engine in known manner. In this embodiment, the cylinder valves are intake valves although they may be exhaust valves. The camshaft 12 is supported by a bearing bracket, not shown, that is carried by the engine cylinder in known manner. The reference numeral 14 indicates an oil pump directly driven by the crankshaft. The reference numeral 16 indicates an oil pan.
On the front, driven, end of the camshaft 12, there is a phaser adjuster or variable cam phaser (VCP) 18 that includes a sprocket 20. The sprocket 20 comprises a drive member with a peripheral drive portion, i.e., wheel 22, that is toothed and drivingly engaged by a chain, not shown, for rotatably driving the sprocket 20 about an axis 24that is co-axial with the camshaft 12. Within the wheel 22 is a radially extending hub 26. The rear hub 26 abuts on a front part 28 of the camshaft 12. This part 28 of the camshaft 12 forms a journal shaft and a centering pin for the wheel 22. A cylindrical body 30 has at a rear end a flange 32 secured to the radially extending 26 by a plurality of bolts 34 and extending forwardly from the radially extending hub 26. The cylindrical body 30 has at a front end thereof a cover 36. The cover 36 has a peripheral edge fixedly retained by the cylindrical body 30. The cover 36 has a central opening 38. The cylindrical body 30 has an internal helical spline 40.
The VCP 18 further includes a stub shaft 42 (see also FIG. 2) having at one end a reduced diameter journal 44 extending through the central opening and rotatably supported supported the cover 36. The stub shaft 42 further includes an external helical spline 46 adjacent the other end. This end is secured through a central opening 48 to the front end of the camshaft 12 by a bolt 50 with a key projection 52 extending from the front end of the camshaft 12 received in a groove 54 of the stub shaft 42 to maintain a fixed drive relationship between the stub shaft 42 and the camshaft 12.
The facing splines 40 and 46 have opposite and, preferrably equal leads (or helix angles) to provide for phasing action. Between and engagingboth splines 40 and 46 are two axially-spaced annular slides, called for convenience, an outer slide 56 and an inner slide 56, the latter being closer to the radially extending sprocket hub 26. Both slides 56 and 58 have inner and outer helical splines drivingly mated with the splines 46 and 40 of the sub shaft 42 and cylindrical body 30, respectively.
The splines are mis-aligned so that, when the slides 56 and 58 are urged inwardly towards one another, they engage opposite sides of the mated splines 46 and 40 and thus take up the lash that would otherwise occur in transferring drive torque between the sprocket 20 and stub shaft 42. The slides 56 and 58 are urged, i.e., biased, towards one another by angularly spaced pins 60 press-fitted in the inner slide 58 and having heads 62 compressing springs 64 in recesses 66 on the far side of the outer slides 56.
An annular cylinder 68 is defined between the outer cylindrical body 30 and stub shaft 42. The annular cylinder 68 has one end closed and the opposte end disposed adjacent the splines 46 and 40. An annular piston 70 (see FIGS. 4 and 5) is slidably disposed in the cylinder 68 and between the outside face of the outer slide 56 and the cover 36. An oil seal 72 is received in a circumferential groove 74 of the piston 70 (see also FIG. 5). Owing to this oil seal 72, the piston 70 together with the adjacent walls of the cylindrical body 30 and stub shaft 42 and the adjacent wall of the cover 36 define an annular chamber 76 within the cylinder 68. As readily seen from FIGS. 4 and 5, the annular piston 70 has near the outer periphery thereof four equi-angularly spaced seats 78 adapted to abut the adjacent wall of the cover 36.
The annular piston 70 and slides 56, 58 assembly is urged in a direction compressing the annular chamber 76 by a coil return spring 80 that extends between an end of a recess 82 in the inner slide 58 and an inner face of the sprocket radially extending hub 26.
Referring back to FIG. 1, the inner slide 58 has at one end splined and at the other end a radially extending circumferential protrusion 84 slidably engaging the adjacent inner wall of the cylindrical body 30. This protrusion 84 serves as a guide to ensure smooth axial movement of the piston 70 and slides 56, 58 assembly. Smooth axial movement of the piston and slides assembly is effective to reduce oil leak path through a clearance between the outer wall of the stub shaft 42 and the inner peripheral wall 86 of the annular piston 70. However, there exist oil leak paths through the valleys of the splines of the outer and inner slides 56 and 58 and the mating external and internal splines 46 and 40. In order to discharge oil having past through the leak paths, the sprocket radially extending hub 26 has drain holes 88.
The stub shaft 42 has a bore 90 receiving a cylindrical bushing 92 (see also FIG. 3). The bushing 92 has one end closed. The closed end of the bushing 92 is secured through a central opening 94 to a front face of a radially extending hub 96 of the stub shaft 42 by the bolt 50 with a dowel pin 98 received in openings 100 and 102 of the bushing 92 and stub shaft 42 to maintain a fixed drive relation between the stub shaft 42 and bushing 92. The bolt 50 has a head 104 and a shank 106 extending through a central opening 108 defined by the radially extending hub 96 of the stub shaft 42 with an annular clearance between the shank 106 and the radially extending hub 96. This annular clearance is connected through a schematically illustrated passage 110 with an oil gallery 112. As readilly seen from FIGS. 1 and 3, the bushing 92 is recessed at 114 over the whole axial dimension of thereof to define together with the adjacent cylindrical wall of the bore 90 an axially extending passage 116. The closed end of the bushing 92 has a face in firm engagement with the adjacent wall of the radially extending hub 96 of the stub shaft 42 and a radial groove 118 recessed from this face. The radial groove 118 extends from the central opening 94 to the recessed portion 114. A radial passage 120 is formed by this radial groove 118 and connects the axial passage 116 with the annular clearance around the shank 106 of the bolt 50. The outer open end of the cylindrical bushing 92 is rotatably supported by a central boss 122 of an end plug 124 which is secured to the cover 36 by fasteners 126. The end plug 124 has an annular groove 128 with which the outwre end of the axial passage 116 communicates. The cover 36 has a bore 130 which constitutes an inlet orifice to the annular cylinder 68 and which is always open to the annular chamber 76. This bore 130 is open to the annular bore 128.
The end plug 124 has drain holes 132 for discharging oil from a cylindrical bore 134 defined by the bushing 92. A valve in the form of a slide 136 is slidably mounted within the bushing 92 and has axial through passages 138 for allowing free flow paths therethrough. The slide 136 is secured to a rod 140 which extends forwardly and outwardly through the end plug 124. The slide 136 is biased in a direction toward the end plug 124 by a return spring 142 that extends between the slide 136 and a recess 144 of the head 104 of the bolt 50. The rod 140 is drivingly connected to an actuator including a stepper motor, not shown, to urge the rod 140 to move the slide 136 from a first end position as illustrated in FIG. 1 to a second end position as illustrated in FIG. 10 and vice versa. Further, the rod 140 can move the slide 136 to any one of three intermediate positions, namely a first intermediate position as illustrated in FIG. 7, a second intermediate position as illustrated in FIG. 8 and a third intermediate position as illustrated in FIG. 9.
Referring to FIGS. 1, 2 and 6, the stub shaft 42 has four outlets 146, 148, 150 and 152 axially spaced one after another for venting the cylinder 68. Each outlet is constituted by eight circumferentially spaced bores (see FIG. 2). Similarly, the bushing 32 has four valve ports 154, 156, 158 and 160 axially spaced one after another. Each valve port is constituted by eight circumferentially spaced openings (see FIG. 3). The four outlets 154, 156, 158 and 160 are aligned with the corresponding valve ports 154, 156, 158 and 160, respectively. In other words, the eight circumferentially spaced bores of each outlet are aligned with the eight circumferentially spaced valve openings of the corresponding one of the valve ports.
Alternatively, each outlet may be constituted by a circumferentially extending slit as shown in FIG. 11. FIG. 11 shows a modified stub shaft 170 which is substantially the same as the sub shaft 42 except the fact that each of four outlets 146, 148, 150 and 152 is constituted by a circumferentially extending slit. In this case, each of the corresponding valve ports 154, 156, 158 and 160 is constituted by a circumferentially extending slit.
In operation of the VCP 18, when the slide 136 is in the first end position as illustrated in FIG. 1, the slide 136 uncovers and thus open all of the valve ports 154, 156, 158 and 160 to the cylindrical bore 134, thereby venting not only the outlet 146 which is always open to the annular chamber 76, but also the other three outlets 148, 150 and 152, thereby to depressurize the annular chamber 76. The return spring 80 is thus able to maintain the piston 70 and slides 56, 58 assembly to ist extreme outer position against the cover 36 whereby the volume of the annular chamber 76 is held at a minimum. In this position, the camshaft 12 is maintained by the slides 56, 58 in a retarded phase relation with the sprocket 20 for operation of the actuated engine intake valves under desired retarded timing conditions. In this position, oil supplied to the annular chamber 76 via the inlet orifice 130 is discharged through the outlet 146 and valve port 154 to the cylindrical bore 134 and through axial passages 138 of the slide 136 and drain holes 132 of the end plug 124 to the outside of the VCP 18. The oil discharged from the end plug 124 returns to the oil pan 16. It is seen from FIG. 1 that fluid communication between the other outlets 148, 150 and 152 and annular chamber 76 is blocked by the piston 70.
When the engine operating conditions call for fully advanced vaslve timing, the rod 140 is urged to move the slide 136 against the return spring 142 from the first end position to the second end position as illustrated in FIG. 10. In this position, the slide 136 covers all of the valve ports to close all of the outlets 146, 148, 150 and 152, thereby pressurizing the annular chamber 76 and displacing the piston 70 and slides 56, 58 assembly against the return spring 80 to the extreme inner position against the sprocket radially extending hub 26. Because of the opposite lead of the internal and external splines 40 and 46, the inward motion of the piston 70 and slides 56, 58 assembly advances the timing or phase angle of the camshaft 12 relative to the sprocket 20 so that the timing of the associated engine cylinder valves is likewise advanced. In this position, there is no discharge of oil from the annular chamber 76.
A return to the retarded timing when called for is accomplished by moving the slide 136 back to the first end position as illustrated in FIG. 1. The spring 80 then returns the piston 70 and slides 56, 58 assembly to its initial retarded position (see FIG. 1) adjacent the cover 36.
In addition to this phase-changing function, the slides 56, 58 are also the means through which all torque is transferred from the sprocket to the camshaft 12 and vice versa via their helical splines and the mating splines 40 and 46.
When the engine operating conditions call for less retarded valve timing, the rod 140 is urged to move the slide 136 to a desired one of three intermediate positions as illustrated in FIGS. 7, 8 and 9 against the return spring 80.
Let us now consider the case when the rod 140 is urged to move the slide 136 from the first end position (see FIG. 1) to the first intermediate position (see FIG. 7). In this position, the slide 136 covers the valve port 154 and thus closes the outlet 146, thereby pressurizing the annular chamber 76 and displacing the piston 70 and slides 56, 58 assembly against the spring 80. This movement of the piston 70 uncovers the outlet 148 communicating with the valve port 156 that is left open to the cylidrical bore 134, allowing discharge of oil through this outlet 148 and causing a drop of pressure within the annular chamber 76. The opening degree of the outlet 148 is controlled by the front edge of the inner peripheral wall of the annular piston 70. If this drop of pressure causes an excessive reduction of pressure within the annular chamber 76, the return spring 80 returns the piston 70 to reduce the opening degree of the outlet 148. In this manner, the piston 70 regulates discharge flow of oil through the outlet 148 to develop a pressure within the anular chamber 76 which is high enough to balance with the return spring 80. If this state is accomplished, the front edge of the inner peripheral wall of the annular piston 70 takes a position falling in a narrow window limited by leading and trailing edges of the outlet 148. The distance between the leading and trailing edges is the axial dimension or diameter of the outlet 148. In this position as illustrated in FIG. 7, the discharged oil from the annular chamber 76 passes through the outlet 148 and valve port 156 into the cylindrical bore 134.
Let us consider the case when the rod 140 is urged to move the slide 136 from the intermediate position just described above to another intermediate position as illustrated in FIG. 8. In this position, the slide 136 covers the valve port 156 in addition to the valve port 154 and thus closes the outlet 148 in addition to the outlet 146, thereby pressurizing the annular chamber 76 and displacing the piston 70 and slides 56, 58 assembly further against the spring 80. This further movement of the piston 70 uncovers the outlet 150 communicating with the valve port 158 that is left open to the cylindrical bore 134, allowing discharge of oil through this outlet 150 and causing a drop of pressure within the annular chamber 76. In the same manner as described, the piston 70 regulates discharge flow of oil through the outlet 150 to develop a pressure within the anular chamber 76 which is high enough to balance with the return spring 80. If this equilibrium state is accomplished, the front edge of the inner peripheral wall of the annular piston 70 takes a position falling in a narrow window limited by leading and trailing edges of the outlet 150. In this position as illustrated in FIG. 8, the discharged oil from the annular chamber 76 passes through the outlet 150 and valve port 158 into the cylindrical bore 134.
Let us consider the case when the rod 140 is urged to move the slide 136 from the intermediate position as illustrated in FIG. 8 to still another intermediate position as illustrated in FIG. 9. In this position, the slide 136 covers the valve port 158 in addition to the valve ports 154 and 156 and thus closes the outlet 150 in addition to the outlets 146 and 148, thereby pressurizing the annular chamber 76 and displacing the piston 70 and slides 56, 58 assembly further against the spring 80. This further movement of the piston 70 uncovers the outlet 152 communicating with the valve port 160 that is left open to the cylindrical bore 134, allowing discharge of oil through this outlet 152 and causing a drop of pressure within the annular chamber 76. In the same manner as described, the piston 70 regulates discharge flow of oil through the outlet 152 to develop a pressure within the anular chamber 76 which is high enough to balance with the return spring 80. If this equilibrium state is accomplished, the front edge of the inner peripheral wall of the annular piston 70 takes a position falling in a narrow window limited by leading and trailing edges of the outlet 152. In this position as illustrated in FIG. 9, the discharged oil from the annular chamber 76 passes through the outlet 152 and valve port 160 into the cylindrical bore 134.
Let us consider the case when the rod 140 is urged to move the slide 136 from the intermediate position as illustrated in FIG. 9 to the second end position as illustrated in FIG. 10. In this position, the slide 136 covers all of the valve port 154, 156, 158 and 160 and thus closes all of the outlets 154, 156, 158 and 160, thereby pressurizing the annular chamber 76 to a maximum and displacing the piston 70 and slides 56, 58 assembly against the spring 80. This further movement of the piston 70 fully uncovers the outlet 152 communicating with the valve port 160. This valve port 160 is covered by the slide 136. In this position as illustrated in FIG. 10, there is no discharge of oil from the annular chamber 76.
In the above described manner, the timing or phase angle of the camshaft 12 relative to the sprocket 20 can be varied in a descrete manner between the most advanced condition as illustrated in FIG. 10 and the most retarded condition as illustrated in FIG. 1.
A return to retarded timing as represented by one of intermediate positions as illustrated in FIGS. 7, 8 and 9 is accomplished by moving the slide 136 toward the cover 36 to the desired intermediate position. This movement of the slide 136 allows discharge of oil from the annular chamber 76 to depressurize same, allowing the spring 80 returns the piston 70 and slides 56, 58 assembly until the equilibrium state between the pressure of the annular chamber 76 and spring 80 is established.
Referring to FIG. 6, the preferred relation between the outlets 148, 150 and 152 and their associated vaslve ports 156, 158 and 160 is explained. As explained before, the distance a of each of these outlets 148, 150 and 152 between the leading and trailing edges thereof determines the width of the narrow window within which the front edge of the inner peripheral wall of the annular piston 70 moves to hold the equilibrimum state. In order to narrow the window, it is preferrable to set the distance or diameter a of each of the outlets 148, 150 and 152 smaller than the corresponding distance or diameter b of the associated valve ports 156, 158 and 160.
As shown in slightly exaggerated manner in FIG. 6, the size of the outlet 146 which is always open to the annular chamber 76 is larger than the size of each of the other outlets 148, 150 and 152. The size of the outlet 146 is determined to ensure enough discharge of oil from the annular chamber 76 to hold the pressure of the annular chamber sufficiently below a pressure level that balances with the return spring 80, thereby to hold the piston 90 and slides 56, 58 assembly in the position as illustrated in FIGS. 10 or 6.
FIGS. 12 and 13 show a modification to the annular piston 70. The modified annular piston 174 is formed with a cutout 176 at the outer or front edge of the inner peripheral wall thereof and has an annular seal 178 which slidably engages adjacent cylindrical wall of the stub shaft 42. In this case, the seal 178 functions to regulate flow of discharge oil from the annular chamber 76.
Although in the modification, the seal 178 located at the outer edge of the inner peripheral wall of the annular piston 174. The location of the seal is not limited to this example. The seal 178 may be recived in a groove 180 disposed between the outer and inner edges of the inner peripheral wall of the annular piston 182.
The provision of the seal 178 is found to be effective in holding the associated piston 174 or 182 in desired appropriate position during operation.
Referring to FIG. 15, it is now explained how pressure build-up due to the leaked oil. In operation, owing to centrifugal force the leaked oil is thrown outwardly against the external spline 40, causing pressurfe build-up within a space 184 partly defined by the protrusion 84. If this pressure is appliked to the protrusion 84, the inner slide 58 is urged toward the sprocket radially extending hub 26. This phanemena is not desired. Thus, the inner slide 58 has holes 186 connecting the space 184 to the recess 82 receiving the return spring 80.
FIG. 16 shows a variation to FIG. 15. According to this variation, the protrusion 84 has circumferentially spaced cutouts 188 to provide drain paths.
FIG. 17 shows another variation to FIG. 15. According to this variation, an inner slide 190 without such protrusion is proposed. This inner slide 190 is an alternative to the inner slide 58.
According to the VCP 18 previously described, oil is discharged outwardly from the drain holes 132 of the end plug 124. In order to reduce the amount of oil discharged out of the VCP 18, a relief valve 18 is provided to keep the pressure at which the oil is supplied to the VCP 18 from the oil gallery 112 at a level high enough to move the annular piston 70 as shown in FIG. 18. In order to further reduce the amount of oil discharged out of the VCP 18, there is provided a solenoid operated shut off valve 202 between the oil gallery 112 and relief valve 200. The solenoid operated shut off valve 202 blocks flow communication between the oil gallery 112 and VCP 18 when the engine operating condition calls for the most retarded valve timing and thus the VCP 18 is to take the position as illustrated in FIG. 1.
Oil resulting from regulation of pressure at the pressure relief valve 200 returns immediately to the oil pan 16 and there is no supply of oil from the oil gallery when the engine operating condiktions call for the most retarded valve timing. Thus, sufficient amount of oil is retained in the oil pan 16 and oil gallery 112 for distribution to portions to be lubricated.
FIG. 20 shows an embodiment of the invention for use with a timing belt drive.
A variable cam phaser (VCP) 300 is mounted on the front end of a camshaft 302. The VCP 300 includes a pulley 304 having an outer toothed wheel 306 driven by the timing belt, not shown. The wheel 306 is connected to a cylindrical body 30 in a similar manner to that shown in FIG. 1. A bolt 308 secures a bushing 92 and a srub shaft 42 to the camshaft 302 in a manner similar to that shown in FIG. 1. An end plug 310 is secured to a cover 36 in a manner similar to that shown in FIG. 1. In FIG. 20, the same reference numerals as used in FIG. 1 are used to designate like or similar parts or portions. Thus detailed description is thereby omitted.
The end plug 310 is different from the end plug 124 shown in FIG. 1. The end plug 310 carries an oil seal 312 for preventing oil leak through clearance around a rod 140 and has no drain holes (see drain holes 132 in FIG. 1). In order to discharge oil from a cylindrical bore 134 defined by the bushing 92, the bolt 308 has an axial through central bore 314 having one end opening to the cylindrical bore 134 and the opposite inner end opening to a central axial bore 316 of the camshaft 302. The camshaft 302 further has a radial drain passage 316 having an inner end opening to the axial bore 316 and an outer end opening to the inside of the engine casing. Owing to this path, oil discharged from the cylindrical bore 134 returns to an oil pan 16 through the axial bore 314 of the bolt 308, bore 316 of the camshaft 302 and radial passage 318.
FIG. 21 shows another embodiment of VCP 330 which includes a sprocket 332 with a radially extending hub 334, a cylindrical body 336, a cover 338, a stub shaft 340, a cylindrical bushing 342, a bolt 344, four slides 344, 346, 348 & 350 (see also FIG. 22), an annular cylinder 352, an annular piston 354, an annular chamber 356, a return spring 358 for the piston 354, a valve slide 360 with a rod 362, and a return spring 364 for the valve slide 360 which, although slightly differing form, are the dunctional equivalents of the corresponding parts of the FIG. 1 embodiment. FIG. 12 differs in that the cylindrical bushing 342 has an end press fitted to the stub shaft 340 and fixedly retains at a front end the cover 338. The cover 338 rotatably receives an outer end the cylindrical body 336. As best seen in FIG. 25, the bushing 342 has four outlets 366, 368, 370 and 372 which function alo as valve ports and thus are functional equivalents to the outlets 146, 148, 150, 152 and their associated valve ports 154, 156, 158 and 160, respectively. The stub shaft 340 cooperates with the front end of the associated camshaft 374 to define an inlet orifice 376 which is always open to the annular chamber 356. Supply of oil to this inlet orifice 376 is schematically illustrated.
As different from FIG. 1 embodiment, the cylindrical body 336 and the stub shaft 340 have no helical splines.
In FIG. 21 embodiment, the cylindrical body 336 has diameterically opposed inwardly extending guides 378 and 380, the stub shaft 340 is fixedly coupled with a ring 382 with two diameterically opposed radially extending hubs 384 and 386. The radially extending hub 384 is disposed between the guides 378 and 380, while the other radially extending hub 386 is disposed between the guides 380 and 378. The slide 344 is disposed between and drivingly mated with the guide 378 and the radially extending hub 384. The slide 346 is disposed between and drivingly mated with the radially extending hub 384 and guide 380. The slide 348 is disposed between and drivingly mated with the guide 380 and radially extending hub 386. The slide 350 is disposed between and drivingly masted with the radially extending hub 386 and guide 378. As best seen in FIG. 23, the slide 344 is mounted to the annular piston 354 by a pin 388 and resiliently biased against the annular piston 354 by a spring 390. The slide 344 has an inlined surface 392 drivingly mated with an inclined edge 394 of the radially extending hub 384. In a similar manner to the slide 344, the slide 348 is mounted to the annular piston 354 by a pin, not shown, and resiliently biased against the annular piston 354 by a spring, not shown, and has an inclined surface drivingly mated with an inclined edge of the radially extending hub 386. As best seen in FIG. 24, the slide 350 is mounted to the annular piston 354 by a pin 398 and resiliently biased against the annular piston 354 by a spring 400. The slide 350 has an inlined surface 402 drivingly mated with an inclined edge 404 of the radially extending hub 386. In a similar manner to the slide 350, the slide 346 is mounted to the annular piston 354 by a pin, not shown, and resiliently biased against the annular piston 354 by a spring, not shown, and has an inclined surface 406 drivingly mated with an inclined edge 408 of the radially extending hub 384.
As will be readily understood from FIGS. 21, 22, 23 and 24, axial movement of the annular piston 354 imparts torque to the stub shaft 340 via the radially extending hubs 384 and 386 of the ring 382 and thus changes the phase angle of the camshaft 374 relative to the sprocket 332.
In addition to the phase-changing function, the slides 344, 346, 348 and 350 are also the measn through which all torque is transferred from the sprocket 332 to the camshaft 374 and vice versa.
The VCP 330 has five positions as illustrated in FIGS. 21, 27, 28, 29 and 30 which, although slightly differeing form, correspond to the operative positions of FIG. 1 embodiment as illustrated in FIGS. 1, 7, 8, 9 and 10. | A variable cam phaser (VCP) is disclosed in various modifications. The VCP includes a piston responsive to pressure in a fluid chamber having an inlet orifice and a plurality of outlets including a first outlet and a plurality of second outlets. A valve slide is movable to cover said second outlets one after another to pressurize the fluid chamber to displace the piston against a return spring. Outer and inner splined slides are drivingly mated with an internal helical spline of a cylindrical body secured to a sprocket and an external helical spline of a stub shaft secured to a camshaft. The splined slides are disposed between the piston and the return spring. Thus, movement of the piston and splined slides assembly in response to pressurization or depressurization of the fluid chamber advances or retards the valve timing or phase angle of the camshaft relative to the sprocket. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is claiming priority of Korean Patent Application No. 10-2002-0063541 dated Oct. 17, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of compressing bell sounds using recorded sounds and voice memos (hereinafter, referred to ‘sounds’) in mobile terminals and, more particularly, to a method of compressing sounds in mobile terminals, which compresses pulse code modulation (PCM) code generated by sampling sounds, using Lempel Ziv Welch (LZW) compression technique by applying a differential method.
2. Description of the Related Art
Generally, mobile terminals use Musical Instrument Digital Interface (MIDI) or recorded bell sounds in order to inform users of phone calls. MIDI bell sounds have been developing from existing mono-poly sounds to poly-poly sounds, and the recorded bell sounds use recorded music or voice to satisfy personal taste. Also, mobile terminals store voices so as to store details of the calling during on the line or to leave a memo during call waiting.
Presently, a method of storing sounds including bell sounds and voice memos used in mobile terminals uses a method of storing sounds using Adaptive Differential Pulse Code Modulation (ADPCM) compression algorithm without using sounds coder/decoder (CODEC) for supporting high tone quality provided by mobile terminals. Such ADPCM compression algorithm can reduce a storage space by about half level, but it cannot resist a degradation of tone quality.
In the existing method of storing sounds, voices are stored by transforming data sampled into PCM using ADPCM. PCM algorithm has been disclosed in International Telecommunications Union-Telecommunication Standardization Sector (ITU-T) G.711 Recommendations and ADPCM algorithm has been disclosed in ITU-T G.721 Recommendations.
The sounds storage method using the existing ADPCM described above has been improved, but it still has problems in that memories are excessively consumed and original sounds cannot be restored as they are because the method uses compression technique causing damage of source data.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and an object of the present invention is to provide a method of compressing sounds, which increases compression efficiency by transforming input data to be suitable for LZW compression algorithm through applying differential method to PCM code generated by sampling sounds.
In order to achieve at least the above objects, in whole or in parts, there is provided a method of compressing sounds in mobile terminals, including: initializing differential code corresponding to difference between adjacent PCM codes among PCM codes generated by sampling input sounds, in a dictionary table; sequentially reading PCM codes generated by sampling actually inputted input sounds, transforming the PCM codes into corresponding differential codes initialized in the dictionary table, and outputting the differential codes; and registering the outputted differential codes in a dictionary through dictionary generation algorithm.
Preferably, in initializing the differential codes in the dictionary table, the differential codes are 6-bit differential codes and the number of the differential codes is 64.
Preferably, said sequentially reading the PCM codes, transforming the PCM codes into differential codes, and outputting the differential codes includes: producing differential code variables that are differences between previously read PCM code and presently read PCM code; and differently outputting the differential codes according to the produced differential code variables' values.
Preferably, in said differently outputting the differential codes according to the produced differential code variables' values, if the produced differential code variables' values are in a certain range, the differential code variables are outputted as they are, on the other hand, if the produced differential code variables' values are not in the certain range, the differential code variables are transformed and outputted.
Preferably, the certain range is a range that the produced differential code variables' values are equal to or more than 0 and less than 31.
Preferably, if the produced differential code variables' values are not in the certain range, the differential code variables are classified again according to the values of differential code variables, and the corresponding differential code variables are transformed in different manners according to the classified values and outputted.
BRIEF DESCRIPTION OF THE FIGURES
The above and other objects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a flow chart of processes for sound compression in mobile terminals according to one preferred embodiment of the present invention;
FIG. 2 is a flow chart of differencing process illustrated in FIG. 1 ;
FIG. 3 is a flow chart of dictionary generation function in the compressing process illustrated in FIG. 1 ;
FIG. 4 illustrates output bit string of code word according to one preferred embodiment of the present invention;
FIG. 5 illustrates a structure of code word table of sound data according to one preferred embodiment of the present invention;
FIG. 6 illustrates the probability of PCM code of sampling sound data according to one preferred embodiment of the present invention; and
FIG. 7 illustrates the probability of differential code according to one preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a flow chart of processes for sound compression in mobile terminals according to one preferred embodiment of the present invention, whose first process is to initialize 64 code words for 6-bit differential code in a dictionary table (S 110 ).
That is to say, as a result of analysis of PCM code obtained by sampling the recorded sounds in order to construct a code word required for sounds compression, the difference between neighboring PCM codes (the absolute value of a certain value obtained by subtracting one PCM code from neighboring PCM code) is less than 32, so that only 64 code words that may be generated are stored in the dictionary table as differential codes, and code word variable (C1), which indicates the next code word to be registered, is initialized as the number of N5 (N5=65), which is initial dictionary entry number.
Then, the stored PCM codes are sequentially read one by one (S 120 ). The read PCM codes are processed with differencing so as to be mapped into 64 differential codes initialized in the dictionary table (S 130 ). The differential codes after differencing are outputted to a function of compression (S 140 ).
According to the function of compression, the differential codes are compressed by using dictionary generation algorithm and the compressed code words are outputted and stored in a memory. At this time, the dictionary generation algorithm generates dictionary trees suitable for the differential codes.
The steps (S 120 , S 130 and S 140 ) are repeated until all the PCM codes obtained by sampling are read (S 150 ).
Then, when the differencing and compressing of all the PCM codes are completed, a flush is finally conducted (S 160 ). According to a storage method in a memory, data is stored by 8-bit or 16-bit. Since the number of bits of compressed data is variable, final data stored in a memory may not correspond to 8-bit or 16-bit. Thus, bits left are filled with 0 and the above process is called ‘flush’.
Respective processes of sound compression will be described in detail with reference to the drawings.
FIG. 2 is a flow chart of a process for differencing the PCM codes (S 130 ).
Referring to FIG. 2 , the corresponding differencing process is to transform 8-bit PCM code into 6-bit differential code, wherein PCM code previously read (old) is subtracted by PCM code presently read (cur) so as to obtain the differential value of PCM code, and the subtracted value is stored in differential code variable (temp) (S 201 ).
Then, it is checked whether or not the value of differential code variable is within a range of initialized differential codes so as to map input sounds into 64 differential codes initialized in the dictionary table, using the differential code variable.
For example, if the value of differential code variable ranges from 0 to 31 (31 is not included) (S 202 ), the corresponding differential code variable is outputted as a differential code because the corresponding code variable is a differential code initialized in the dictionary table (S 203 ). And, if the value ranges from −32 to 0 (0 is not included) (S 204 ), 6-bit complement for 2 of differential code variable is outputted as differential code (S 205 ).
However, when the value of differential code variable exceeds the range of differential code initialized in the dictionary table, differential code variable goes through a certain processing. When the value of differential code variable ranges from −160 to −32 (−160 is not included) (S 206 ), differential code 32 is outputted in order to indicate that the value of differential code variable is less than −32 and, then, an absolute value of the corresponding differential code variable divided by 2 is outputted as differential code (S 207 and S 208 ).
When differential code variable ranges from 31 to 159 (159 is not included) (S 209 ), differential code 31 is outputted in order to indicate that the corresponding differential code variable exceeds 31 and, then, a value of the corresponding differential code variable divided by 2 is outputted as differential code (S 210 and S 211 ).
FIG. 3 is a flow chart showing a step (S 140 ) of compressing differential code transformed by the differencing process, using dictionary generation algorithm. A dictionary generated for compressing differential code can be previously generated upon fabricating mobile terminals or upon initially storing sounds.
Referring to FIG. 3 , a case where a character string is not added to the dictionary is one where the character string exceeds the maximum number (N7) of character string (S 301 ) or where the character string is previously registered in the dictionary (S 302 ). The character string is allocated to a new code word C1 except upon the above two cases (S 303 ).
Then, new code word C1 increases by 1 so as to be allocated to the code word of character string to be generated next (S 304 ). When the increased C1 is equal to or more than the number of code word (N2) (S 305 ), the number of N5, initial dictionary entry number, is allocated to the C1 (S 306 ). The steps (S 304 to S 306 ) are repeated until a node allocated to the C1 is a leaf node indicating last character of the character string in the dictionary tree, or a node that is not used (C1=NULL) (S 307 ).
Where the node allocated to the C1 is a leaf node or the node that is not used, C1 is deleted from the dictionary tree in order for new code word of the character string to be allocated (S 308 ).
When the compression has been completed through the above steps, generated code word is outputted and stored in a memory. To reduce the size of compressed code word, a process is conducted as follows. That is to say, in order to obtain accurate character string when decompressing the compressed code word, the corresponding code word is outputted as to satisfy the following equations.
( C 1+ lim )≦2 ┌log 2 (C1+1)┐ −1 [equation 1]
lim=C 3 −C 1−1 [equation 2]
C 3=2 ┌ log 2 (C1+1)┐ [equation 3]
where C1 is the number of code word presently allocated, lim means a limit value capable of reducing bits, and ┌log 2 (C1+1)┐ means minimum integer larger than log 2 (C1+1) . Accordingly, when code word is changed into bit string, if the code word is smaller than a predetermined limit value lim, it is outputted as ┌log 2 (C1+1)┐−1 bit, and if the code word is larger than a limit value, it is outputted as ┌log 2 (C1+1)┐ bit.
For example, as shown in FIG. 4 , since lim=(1024-750-1)=273, when C1 is 750. Code words ranging 0 to 273 upon being compressed are coded by 9 bits and outputted, and code words ranging 274 to 749 are coded by 10 bits after adding 274 to respective code words and are outputted.
When decompressed, code word bits are read by 9 bits. If the read value is smaller than 274, the value itself is taken as a code word, on the other hand, if the value is larger than 274, code word bits are read again by 10 bits and a certain value subtracting 274 from the read value is taken as a code word.
FIG. 5 illustrates a structure of the dictionary table according to one preferred embodiment of the present invention. The code words ranging 0 to 63 are defined as differential code, code words ranging 64 to 127 as 7-bit coding area, code words ranging 128 to 255 as 8-bit coding area, and finally code words ranging 2048 to 4095 as 12-bit coding area.
In order to evaluate performance of the method of compressing sounds according to the present invention, compression algorithm is implemented using C language and tested. For sound data, actual human voice is recorded at 8000 samples per second (64 Kbps) and used.
FIG. 6 illustrates the probability of PCM code of sampling sound data, and FIG. 7 illustrates the probability of differential code, which records difference based on data from FIG. 6 .
Compressibility of sounds according to the present invention is obtained by dividing the size of sounds data before compression by the size of sounds data after compression. With the result of this, samples 1 to 4 have compressibility of 3.00, 3.66, 3.35, and 2.5, respectively and average value of 3.13.
As described above, the present invention can reduce the number of kinds of code word, a parameter which heightens performance of LZW compression algorithm, by applying differential method to PCM code generated by sampling sounds and can enhance sound compression efficiency by increasing the number of repeated character string.
Although preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | A method of compressing sounds in mobile terminals according to the present invention transforms pulse code modulations (PCM) codes, which are source data of bell sounds using recorded sounds or voice memos and are generated by sampling the sounds, through applying a differential method and, then, compresses the PCM codes using Lempel Ziv Welch (LZW) compresses technique, thus reducing a storage space required for storing bell sounds using sounds or voice memos in mobile terminals. According to the present invention, compression efficiency is maximized upon using LZW algorithm by transforming PCM code through applying differential method, thereby increasing restoration efficiency of original sounds and heightening compression efficiency by about 50%, compared with the existing compression storage method using ADPCM. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Section 371 International Application No. PCT/AT2013/000127, filed Aug. 1, 2013, which was published in the German language on Feb. 6, 2014, under International Publication No. WO 2014/019004 A2 and the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an ironing device for holding a textile portion of a textile piece for a process of washing the textile piece and a process of drying the textile piece. The ironing device comprises at least two opposite stretching surface elements closable by a biasing device. The biasing device clamps the textile portion introduced between the stretching surface elements and extending in parallel with the stretching surface between the stretching surface elements by application of a biasing force. The textile portion is held, without displacement, in the extension surface of the stretching surface relative to the stretching surface elements.
[0003] The invention also comprises a method comprising a process of washing the textile piece and a process of drying the textile piece.
[0004] German Patent No. DE 1919730, and U.S. Pat. Nos. 3,868,835 and 3,664,159 disclose devices for washing of, among other things, non-iron clothes. Since it is not an aim with non-iron clothes to clamp a textile portion by a device part, those documents do not contain any reference thereto.
[0005] Furthermore, French Patent Nos. FR 2721625 and FR 2092259 do not disclose any device for clamping a textile portion as part of the washing and drying device.
[0006] The device described in European Patent No. EP 2209936 also does not comprise any device parts for clamping a textile portion.
[0007] German Patent No. DE10065336 discloses a washing and drying device for textiles, wherein the textiles are brought into a defined position by stretching devices and/or steam dolls for the washing process and/or drying process. The use of stretching devices and steam dolls is space-intensive.
[0008] The devices disclosed in German Patent No. DE 2035540 or in U.S. Patent Application Publication No. 2004/0112095 are based on suspending the textiles to be cleaned within the device.
[0009] U.S. Pat. No. 5,305,484 and International Patent Application Publication No. WO 2009057177 disclose tensioning means for bringing the textile into a defined shape during a washing and drying process by the device described in U.S. Pat. No. 5,305,484.
[0010] International Patent Application Publication Nos. WO 2006134364 and WO 02052087 mention means for receiving the textiles to be cleaned, but no means for clamping the textile portion to be cleaned are explicitly mentioned.
[0011] Like the above documents, U.S. Pat. Nos. 3,114,919 and 3,664,159, and WO 0205087 also do not disclose any device for keeping the textile piece in the desired shape by stretching devices during the drying process.
BRIEF SUMMARY OF THE INVENTION
[0012] It is an object of the invention discussed herein to provide a method for washing a textile piece in a way that no subsequent ironing of the textile piece is necessary, as well as providing devices required for this purpose. As used in the present disclosure, a textile piece is a textile piece requiring no ironing, wherein the textile piece comprises a textile portion to be defined by a user that is substantially smooth and has no creases or crumples. The invention discussed herein can optionally also comprise the creation of desired pleats within the textile portion. Another object of the invention discussed herein is to provide a device for holding the textile piece during the drying process, the device having an effect similar to applying an iron according to the state of the art.
[0013] According to an embodiment of the invention this is achieved by using the ironing device of the present invention during the washing process and/or drying process of the textile piece. The ironing device includes stretching surface elements having e a stretching surface with a surface extension at least as big as the textile portion. The textile portion corresponds to a defined smooth desired area to be produced from the textile piece, and optionally includes a desired pleat. The textile portion is introducible between the stretching surface elements in the shape to be produced. The ironing device includes a nozzle for applying a fluid and/or a detergent to the textile portion to clean the textile portion or for applying air to the textile portion to smoothly dry it.
[0014] A textile portion can, for example, be the collar of a shirt, which is defined by its edges and a seam. A textile portion can be a part of a sleeve, part of which is on the one hand defined by the sleeve seam, on the other hand by the half pleat of the sleeve opposite the sleeve seam. Analogous to the latter example, the textile portion can be part of a pair of trousers.
[0015] For producing a smooth textile portion, the textile portion is arranged in parallel with the stretching surface elements, after which the ironing device is closed by the biasing device by activating a biasing force, such that the stretching surface elements hold the textile portion in a clamping fashion. The biasing force depends on the size and/or weight, in particular wet weight, of the textile piece, so that the textile portion is supported without displacement, including during the washing process or the drying process. The frictional forces between the textile portion and the stretching surface activated by the biasing force should be chosen to be higher than forces such as the weight of the textile piece, which could cause a displacement of the textile portion. The effect of the stretching device on the textile portion during the drying process corresponds approximately to that of an iron applied to the textile portion.
[0016] The textile portion may comprise a desired pleat. For producing a desired pleat via the ironing device, the textile portion is introduced between the stretching surface elements in two layers, wherein the desired pleat to be produced is arranged between the stretching surface elements.
[0017] The textile portion is to be introduced into the ironing device in a manner similar to the shape that the textile portion is to have after the washing and/or drying process. The ironing device prevents the textile portion from receiving and assuming a different shape during the washing process and/or drying process.
[0018] In some embodiments, the nozzle is coupled to an inlet such that a fluid and/or detergent can be applied to the textile portion for cleaning the textile portion. The inlet extends through a stretching surface element of the ironing device.
[0019] The inlet can be coupled to a pumping device for applying the fluid and/or the detergent with overpressure.
[0020] In some embodiments, the nozzle is oriented so that the fluid and/or detergent applied to the textile portion, or the jet formed by the fluid and/or detergent and oriented by the nozzle, hits the textile portion at an angle of 90°, so that the fluid and/or detergent can penetrate the fabric of the textile portion. In some embodiments, the nozzle creates a jet from the fluid and/or detergent streaming through the nozzle, so that the fluid/and or detergent can penetrate the fabric of the textile portion.
[0021] The nozzle can also comprise means for enriching the fluid and/or detergent with air, in particular oxygen, or other gas mixtures, so that the cleaning effect of the fluid and/or detergent according to the state of the art is increased.
[0022] In some embodiments, the nozzle can also be oriented so that the jet formed from the fluid and/or detergent hits the textile portion at an acute angle differing from 90°, in order to optionally remove solid dirt from the textile portion by splitting it off.
[0023] The nozzle can be formed so that air is applied to the textile portion through the nozzle for drying the textile portion, which displaces water adhering thereto.
[0024] In some embodiments, the ironing device may include a plurality of nozzles, which are distributed over the stretching surface elements.
[0025] In some embodiments, the ironing device may include a discharge device for removing the fluid and/or detergent from the textile portion.
[0026] The discharge device is coupled to an outlet, which extends through a stretching surface element of the ironing device. The outlet is coupled to a suction device, so that fluid and/or detergent between the stretching surface elements can be exhausted.
[0027] In some embodiments, the ironing device may comprise several discharge devices distributed over the stretching surface element.
[0028] A nozzle and a suction device may be arranged along an axis as well as offset from the axis in opposite areas of the stretching surface elements.
[0029] In one possible embodiment, the nozzle or the discharge device is used as a nozzle during the washing process and as a discharge device during the drying process. The nozzle or discharge device are formed so that on the one hand the fluid and/or detergent can be applied to the textile portion, and on the other hand they can be removed therefrom, wherein the pumping device is controllable to create overpressure or under-pressure, respectively.
[0030] The inlet and outlet may be coupled to each other, wherein a pumping device is arranged at the coupling point, which on the one hand creates overpressure in the nozzle area, and on the other hand creates under-pressure in the discharge device area. The fluid and/or detergent applied to the textile portion via the nozzle is discharged from the textile portion as a fluid and/or detergent enriched in dirt through the discharge device arranged at the opposite side of the textile portion. Together with the inlet and the outlet, the nozzle and the discharge device provide a cycle.
[0031] The stretching surface may be formed as a surface preventing sliding of the textile portion clamped between the stretching surface elements relative to the ironing device, wherein the stretching surface and the textile portion have a high adhesive friction number and a high sliding friction number when in contact.
[0032] Furthermore, another aspect of the invention relates to a method for cleaning and/or drying a textile piece having a textile portion. The textile piece is held by the ironing device according to the above description, wherein the textile piece held by clamping of the textile portion in the ironing device is led through a washing area and optionally a drying area.
[0033] According to an aspect of the method of the present invention, the textile portion is brought into a defined shape by introduction into the ironing device, which shape is maintained during the washing process and/or drying process via the ironing device. The defined shape may be a substantially smooth surface, optionally including a desired pleat.
[0034] Ironing of the textile portion after the washing and/or drying process is omitted.
[0035] Via a movement of the ironing device, the textile piece to be cleaned and/or dried is conveyed into a washing unit and/or drying unit.
[0036] The washing unit generally comprises a container filled with a fluid and/or detergent, wherein the textile piece is moved relative to the fluid and/or detergent. The latter can be achieved by moving the textile piece through a controlled movement of the ironing device or by moving the fluid and/or detergent. Movement of the fluid and/or detergent may, for example, be achieved via a rotating drum according to the state of the art.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0037] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0038] In the drawings:
[0039] FIG. 1 is a side view of an ironing device, according to a first embodiment of the invention;
[0040] FIG. 2 is a top view of the ironing device of FIG. 1 ;
[0041] FIG. 3 is a perspective schematic representation of a device for implementing a washing process and/or drying process of a textile piece by using the ironing device of FIG. 1 .
[0042] FIG. 4 is an isometric cutaway view of the device of FIG. 3 .
[0043] FIG. 5 is a perspective view of an ironing device, according to a second embodiment of the invention;
[0044] FIG. 6 is a sectional view of the ironing device of FIG. 5 ; and
[0045] FIG. 7 is a further sectional view of the ironing device of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0046] FIG. 1 shows a side view of an ironing device according to a first embodiment of the invention, for holding a textile portion 1 of a textile piece 2 for a process of washing the textile piece 2 and/or for a process of drying the textile piece 2 . The textile portion 1 corresponds to a defined smooth desired surface to be produced of the textile piece 2 , optionally comprising a desired pleat. The ironing device comprises at least two opposite, closable stretching surface elements 4 . The stretching surface elements 4 each have a stretching surface 5 with a surface extension at least as big as the textile portion 1 . FIG. 1 shows a stretching surface element 4 in an opened position 6 . In the opened position 6 , a user can easily place the textile portion 1 in the area between the stretching surface elements 4 .
[0047] After placing the textile portion 1 in the area between the stretching surface elements 4 , a stretching surface element 4 is moved from the opened position 6 into a closed position 7 . The ironing device comprises a biasing device 8 , through which the textile portion 1 introduced between the stretching surface elements 4 and extending parallel to the stretching surface 5 is clamped therebetween, by application of a biasing force 9 , and held without displacement relative to the stretching surface elements 4 .
[0048] The ironing device further comprises at least one nozzle 12 for applying water, air and/or a detergent to the textile portion 1 . The nozzle 12 is coupled to an inlet (not shown in FIGS. 1 and 2 ), wherein the nozzle 12 and the inlet extent in their longitudinal directions through a stretching surface element 4 . In the device shown in FIG. 1 , the nozzle 12 is oriented so that a jet formed by nozzle 12 consisting of a fluid, detergent and/or air is oriented to the clamped textile portion 1 at an angle of approximately 90°. The nozzle 12 is coupled to a pumping device, not shown in FIG. 1 , for creating overpressure.
[0049] The ironing device further comprises a discharge device (not shown) for removing the fluid and/or the detergent from the textile portion. The discharge device is coupled to an outlet (not shown), wherein the discharge device and the outlet extend in their longitudinal directions through the stretching surface element 4 . The discharge device is coupled to a pumping device (not shown), for creating under-pressure.
[0050] The stretching surface 5 is formed as a surface preventing sliding of the textile portion 1 clamped between the stretching surface elements 4 , relative to the ironing device. The stretching surface 5 and the textile portion 1 have a high adhesive friction number and a high sliding friction number when in contact and subject to the biasing force 9 .
[0051] The ironing device further comprises a holding device 10 , through which the ironing device is temporarily introduced into a console 11 and held there during the process of introducing the textile portion 1 between the stretching surface elements 4 . The holding device 10 is also utilized in a subsequent process for mounting the ironing device in a device for implementing the washing process and/or drying process, so that the ironing device and the textile piece 2 held by the ironing device are movable from, e.g., a washing unit to a drying unit.
[0052] The console 11 is part of a placing device shown in FIG. 1 , which further comprises a support 16 , in which the console 11 is provided, and a table 17 , which is only partly shown in FIG. 1 . The textile piece 2 is placed on the table 17 to clamp it into the ironing device. For easier use of the ironing device, the table 17 is spaced apart from the support 16 .
[0053] The console 11 and the support 16 are located outside of the device shown in the other Figs. for implementing the method of the present invention.
[0054] FIG. 2 shows a top view of the device illustrated in FIG. 1 .
[0055] FIG. 3 shows a device for implementing a washing process and/or drying process of a textile piece comprising a textile portion clamped into the ironing device.
[0056] The textile piece 2 clamped in the ironing device is introduced into the device via a delivery opening 18 . The ironing device is mounted to a conveying unit 19 via the holding device 10 . The conveying unit 19 moves the ironing device, including the textile piece 2 to be cleaned, to the washing unit 20 . Inside the washing unit 20 , the textile piece 2 is at least partially moved into a trough 21 filled with a fluid and/or detergent, via a controlled movement of the ironing device. During the washing process, the textile portion 1 clamped by the stretching surface elements 4 is cleaned by the fluid and/or detergent, which are applied to the textile portion 1 through the nozzle 12 .
[0057] Afterwards, the textile portion 2 is moved into a drying unit 22 via a controlled movement of the ironing device. The drying unit 22 comprises a drying chamber with a height larger than the length of the suspended textile portion 1 to be cleaned. During the drying process, the textile portion 1 clamped by the stretching surface elements 4 is dried by air applied to the textile portion 1 via the discharge device and/or the nozzle 12 .
[0058] FIG. 4 shows a cutaway view of the device illustrated in FIG. 3 . For reasons of clarity, the delivery opening 18 is not shown in FIG. 4 .
[0059] The textile pieces 2 are held by clamping the textile portions 1 in the ironing device. The ironing device is coupled to the conveying unit 19 via the holding device 10 .
[0060] The textile pieces 2 suspended in FIG. 4 are in a pre-washing unit 23 upstream of the washing unit 20 . In the pre-washing unit 23 , the textile pieces 2 are sprayed with a fluid and/or a detergent via spraying nozzles 24 .
[0061] Via the conveying unit 19 , the textile pieces 2 are, optionally in combination with the spraying via the spraying nozzles 24 in the pre-washing unit 23 , introduced into the washing unit 20 . In the washing unit 20 , the textile pieces 2 are immersed in a trough 21 and lifted out of the trough 21 . This process can be repeated until the textile piece 2 is clean.
[0062] The clean textile pieces 2 are then, by a movement of the ironing device, moved into the drying unit 22 . Before the partial process of drying the textile pieces 2 , the textile piece 2 is sprayed with cold water in the drying unit 22 for rinsing the textile piece 2 according to the state of the art. The cold water is applied to the textile piece 2 through cold-water nozzles 26 arranged in the top area of the drying unit 22 .
[0063] Drying of the textile piece 2 is achieved by hot-air nozzles 25 , from which hot air is applied to the textile piece 2 . The hot-air nozzles 25 are arranged in the side areas of the drying unit 22 . Drying of the textile piece 2 via hot air is done according to the state of the art.
[0064] Finally, the textile piece 2 is moved to the removal opening 27 .
[0065] FIGS. 5-7 show an ironing device in accordance with a second embodiment. The ironing device comprises three stretching surface elements 4 , through which two textile portions 1 of a textile piece 2 are stretched in a clamped manner. For applying the biasing force 9 acting as clamping force, the ironing device comprises a biasing device 8 .
[0066] In addition, the ironing device comprises a holding device 10 , which is engaged with the guiding unit 27 of the conveying unit 19 . Via the guiding unit 27 , a fluid and/or detergent is introduced into the holding unit 10 . Alternatively, the introduced fluid and/or detergent is released into the chamber via the nozzles 12 arranged in the holding device 10 , which achieves wetting of the textile piece 2 . Alternatively, part of the introduced fluid and/or detergent is also applied directly to the textile portion through the nozzles 12 arranged in the stretching surface elements 4 .
[0067] FIGS. 6 and 7 show isometric views of the ironing device illustrated in FIG. 5 comprising three stretching surface elements 4 , between which two textile portions 1 are stretched in a clamped manner. The three stretching surface elements 4 are connected adjustably to one another via the biasing device 8 , wherein the biasing force 9 is also applied through the biasing device 8 .
[0068] FIG. 6 shows the ironing device with stretching surface elements 4 in an opened position 6 and in a closed position 7 . The positions are predefined by the mode of action of the biasing device 8 .
[0069] FIG. 7 shows the ironing device with stretching surface elements 4 in a closed position 7 . A fluid and/or a detergent is introduced into the holding device 10 , with a substantially spherical shape, through the guiding unit 27 , which is part of the conveying unit 19 and is engaged with the holding device 10 .
[0070] The central element 4 of the three stretching surface elements 4 comprises a fluid channel 28 , which extends from the holding device 10 to nozzles 12 arranged in the two stretching surfaces 5 of the central stretching surface element 4 . After exiting the nozzles 12 , the fluid and/or detergent contacts the textile portion 1 .
[0071] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. | A device for holding a textile area of a textile piece is provided, for a process of washing and/or drying the textile piece. The device includes at least two opposing clamping surface elements which can be closed by means of a pre-clamping device. The pre-clamping device grips the textile area introduced between the clamping surface elements and extended parallel to the clamping surface, by application of a pre-clamping force between the clamping surface elements. The textile area can be held immovably in the extension surface of the clamping surface relative to the clamping surface elements. The clamping surface elements have a clamping surface with a surface area at least as large as the textile area. The device includes a nozzle for application of a fluid and/or a washing agent to the textile area for washing the textile area or for application of air to the textile area for smoothing drying. | 3 |
BACKGROUND
[0001] A person may have an account with a store or a business. For example, a person may have a mobile phone account with a mobile phone service provider or a bank account with a bank. The person may desire to go into a store and discuss the account with a store representative (e.g., a store employee). However, to access the account, the person may be required to verbally give authentication information (e.g., an account password) to the store representative in the presence of other customers at the store. Accordingly, another customer may overhear the person's password causing security or privacy issues.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a diagram of an overview of an example implementation described herein;
[0003] FIG. 2 is a diagram of an example environment in which systems and/or methods described herein may be implemented;
[0004] FIG. 3 is a diagram of example components of a device that corresponds to one or more devices of FIG. 2 ;
[0005] FIG. 4 is a flowchart of an example process for creating an account;
[0006] FIG. 5 is a flowchart of an example process for transmitting an authentication message from a user device to a terminal device;
[0007] FIG. 6 is a diagram of an example implementation relating to the process shown in FIG. 5 ;
[0008] FIG. 7 is a flowchart of an example process for transmitting an authentication message from a user device to a terminal device; and
[0009] FIG. 8 is a diagram of an example implementation relating to the process shown in FIG. 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] The following detailed description of example implementations refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.
[0011] A person verbally giving account information to a store representative may create privacy or security concerns. For example, other people in the store may overhear the password. Implementations described herein may improve privacy and/or security by allowing a person at a store to verify the person is an authorized user of an account using a person's mobile device to transmit authentication information to the store representative in a manner that may not be intercepted by other customers.
[0012] FIG. 1 is a diagram of an overview of an example implementation 100 described herein. Assume a customer enters a store and requests to speak with a store representative about an account. The customer may provide an account identifier to the store representative identifying the account.
[0013] The store representative may use a terminal device at the store to transmit a request to a server device to start a session used to authenticate that the customer is authorized to access the account. The server device may receive the request and may create the session, and associate the session with a session identification (ID). The server device may transmit the session ID to the terminal device.
[0014] The terminal device may receive the session ID and display the session ID. The store representative may provide the session ID to the customer. For example, the store representative may verbally tell the customer the session ID or allow the customer to read the session ID displayed by the terminal device.
[0015] The customer may input the session ID and authentication information (e.g., a password) into a user device. The user device may transmit the session ID and the authentication information to the server. Additionally, or alternatively, the user device may store the authentication information preprogrammed to be provided with the session ID when triggered by the customer.
[0016] The server device may receive the session ID and the authentication information from the user device. The server device may transmit the authentication information to the terminal device based on the session ID. The terminal device may receive the authentication information and determine whether the customer is authorized to discuss the account.
[0017] In this way, a person may provide a store representative with authentication information for an account without other customers in the store overhearing or intercepting the authentication information.
[0018] FIG. 2 is a diagram of an example environment 200 in which systems and/or methods described herein may be implemented. As shown in FIG. 2 , environment 200 may include a user device 210 , a server device 220 , a terminal device 230 , and/or a network 240 .
[0019] User device 210 may include a device capable of receiving, processing, and providing information. For example, user device 210 may include a mobile phone (e.g., a smart phone, a radiotelephone, etc.), a computing device (e.g., a laptop computer, a tablet computer, a handheld computer, etc.), or a similar device. In some implementations, user device 210 may include a communication interface that allows user device 210 to receive information from and/or transmit information to server device 220 and/or another device in environment 200 . User device 210 may store and execute an application for authenticating a user.
[0020] Server device 220 may include one or more devices capable of processing and/or routing information. In some implementations, server device 220 may include a communication interface that allows server device 220 to receive information from and/or transmit information to other devices in environment 200 .
[0021] Terminal device 230 may include a device capable of receiving, processing, and providing information. For example, terminal device 230 may include a mobile phone (e.g., a smart phone, a radiotelephone, etc.), a computing device (e.g., a desktop computer, a laptop computer, a tablet computer, a handheld computer, etc.), or a similar device. In some implementations, terminal device 230 may include a communication interface that allows terminal device 230 to receive information from and/or transmit information to other devices in environment 200 . Terminal device 230 may be located at a store. The store may be any place of business (e.g., a bank, a phone company store, a cable company store, a clothing store, a department store, an office, etc.).
[0022] Network 240 may include one or more wired and/or wireless networks. For example, network 240 may include a cellular network, a public land mobile network (“PLMN”), a second generation (“2G”) network, a third generation (“3G”) network, a fourth generation (“4G”) network, a fifth generation (“5G”) network, a long term evolution (“LTE”) network, and/or a similar type of network. Additionally, or alternatively, network 270 may include a local area network (“LAN”), a wide area network (“WAN”), a metropolitan area network (“MAN”), a telephone network (e.g., the Public Switched Telephone Network (“PSTN”)), an ad hoc network, an intranet, the Internet, a fiber optic-based network, and/or a combination of these or other types of networks.
[0023] The number of devices and/or networks shown in FIG. 2 is provided for explanatory purposes. In practice, there may be additional devices and/or networks, fewer devices and/or networks, different devices and/or networks, or differently arranged devices and/or networks than those shown in FIG. 2 . Furthermore, two or more devices shown in FIG. 2 may be implemented within a single device, or a single device shown in FIG. 2 may be implemented as multiple, distributed devices. Additionally, one or more of the devices of environment 200 may perform one or more functions described as being performed by another one or more devices of environment 200 . Devices of environment 200 may interconnect via wired connections, wireless connections, or a combination of wired and wireless connections.
[0024] FIG. 3 is a diagram of example components of a device 300 that corresponds to one or more devices of FIG. 2 . Device 300 may correspond to user device 210 , server device 220 , and/or terminal device 230 . Additionally, or alternatively, user device 210 , server device 220 , and/or terminal device 230 may include one or more devices 300 and/or one or more components of device 300 .
[0025] As illustrated in FIG. 3 , device 300 may include a bus 310 , a processor 320 , a memory 330 , an input component 340 , an output component 350 , and/or a communication interface 360 .
[0026] Bus 310 may include a path that permits communication among the components of device 300 . Processor 320 may include a processor (e.g., a central processing unit, a graphics processing unit, an accelerated processing unit), a microprocessor, and/or another type of processing component (e.g., a field-programmable gate array (“FPGA”), an application-specific integrated circuit (“ASIC”), etc.) that interprets and/or executes instructions. Memory 330 may include a random access memory (“RAM”), a read only memory (“ROM”), and/or another type of dynamic or static storage device (e.g., a flash, magnetic, or optical memory) that stores information and/or instructions for use by processor 320 .
[0027] Input component 340 may include a component that permits a user to input information to device 300 (e.g., a touch screen display, a keyboard, a keypad, a mouse, a button, a switch, etc.). Input component 340 may also include a sensor for sensing information. For example, input component 340 may include a global positioning system (GPS) device for sensing a location of device 300 .
[0028] Output component 350 may include a component that outputs information from device 300 (e.g., a display, a speaker, one or more light-emitting diodes (“LEDs”), etc.).
[0029] Communication interface 360 may include a transceiver-like component, such as a transceiver and/or a separate receiver and transmitter that enables device 300 to communicate with other devices, such as via a wired connection, a wireless connection, or a combination of wired and wireless connections. For example, communication interface 360 may include an Ethernet interface, an optical interface, a coaxial interface, an infrared interface, a radio frequency (“RF”) interface, a universal serial bus (“USB”) interface, or the like.
[0030] Device 300 may perform various operations described herein. Device 300 may perform these operations in response to processor 320 executing software instructions included in a computer-readable medium, such as memory 330 . A computer-readable medium is defined as a non-transitory memory device. A memory device includes memory space within a single storage device or memory space spread across multiple storage devices.
[0031] Software instructions may be read into memory 330 from another computer-readable medium or from another device via communication interface 360 . When executed, software instructions stored in memory 330 may cause processor 320 to perform one or more processes described herein. Additionally, or alternatively, hardwired circuitry may be used in place of or in combination with software instructions to perform one or more processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.
[0032] The number of components shown in FIG. 3 is provided for explanatory purposes. In practice, device 300 may include additional components, fewer components, different components, or differently arranged components than those shown in FIG. 3 .
[0033] FIG. 4 is a flowchart of an example process 400 for creating an account. In some implementations, one or more process blocks of FIG. 4 may be performed by server device 220 . Additionally, or alternatively, one or more process blocks of FIG. 4 may be performed by another device or a group of devices separate from or including server device 220 .
[0034] As shown in FIG. 4 , process 400 may include creating an account (block 410 ). For example, server device 220 may create the account.
[0035] Server device 220 may create the account by generating an entry in an account data structure for the account. Server device 220 may store the entry in the account data structure stored in a memory of server device 220 and/or another device. Server device 220 may generate the account based on receiving a request from user device 210 , terminal device 230 , and/or another device.
[0036] As further shown in FIG. 4 , process 400 may include obtaining account ID information (block 420 ). For example, server device 220 may obtain account ID information.
[0037] The account ID information may include an account identifier for the account (e.g., an account number, a mobile phone number for the account, etc.). Server device 220 may obtain the account identifier by generating the account identifier. The account identifier may include a string of characters of any length.
[0038] The account ID information may include contact information for a person authorized to use the account. For example, the account ID information may include an address, a phone number, an email address, or the like. A person may input the contact information into user device 210 , terminal device 230 , and/or another device, which may transmit the contact information to server device 220 . Server device 220 may obtain the contact information by receiving the contact information from user device 210 , terminal device 230 , and/or another device.
[0039] As further shown in FIG. 4 , process 400 may include obtaining account authentication information (block 430 ). For example, server device 220 may obtain the account authentication information.
[0040] The account authentication information may be information used to authenticate a person before accessing an account (e.g., a password). The account authentication information may be a string of characters of any length. A person may input the account authentication information into user device 210 , terminal device 230 , and/or another device, which may transmit the account authentication information to server device 220 . Server device 220 may obtain the account authentication information by receiving the account authentication information from user device 210 , terminal device 230 , and/or another device.
[0041] As further shown in FIG. 4 , process 400 may include obtaining account content (block 440 ). For example, server device 220 may obtain the account content.
[0042] The account content may be any information associated with a service provided by a store. For example, the account may be a bank account and the account content may include financial information. The account may be a phone account and the account content may include information about data usage. The account content may also include billing information and/or payment information for the account. Server device 220 may obtain the account content by receiving the account content form user device 210 , terminal device 230 , and/or another device. Additionally, or alternatively, server device 220 may obtain the account content by generating the account content.
[0043] As further shown in FIG. 4 , process 400 may include storing the account ID information, the account authentication information, and the account content for the account (block 450 ). For example, server device 220 may store the account ID information, the authentication information, and the account content in the account data structure stored in a memory of server device 220 and/or another device.
[0044] While a series of blocks has been described with regard to FIG. 4 , the blocks and/or the order of the blocks may be modified in some implementations. Additionally, or alternatively, non-dependent blocks may be performed in parallel.
[0045] FIG. 5 is a flowchart of an example process 500 for transmitting an authentication message from user device 210 to terminal device 230 . In some implementations, one or more process blocks of FIG. 5 may be performed by server device 220 . Additionally, or alternatively, one or more process blocks of FIG. 5 may be performed by another device or a group of devices separate from or including server device 220 .
[0046] As shown in FIG. 5 , process 500 may include receiving a request from terminal device 230 to start a session to authenticate a person (block 510 ). For example, server device 220 may receive the request from terminal device 230 to start a session.
[0047] A person may come into a store and desire to discuss or manage an account with a store representative. The store representative may ask the person to verbally provide account ID information identifying the account. The account ID information may be any information identifying the account. For example, the account ID information may be an account ID, contact information associated with the account (e.g., a phone number, an email address, a name, an address, etc.), a username associated with the account, or the like.
[0048] The store representative may have to verify that the person is authorized to access the account before discussing the account with the person. Accordingly, the store representative may use terminal device 230 at the store to transmit a request to server device 220 to start a session to authenticate the person at the store. The request may include information identifying terminal device 230 (e.g., an IP address for terminal device 230 ). Additionally, or alternatively, the request may include the account ID information identifying the account. Server device 220 may receive the request transmitted by terminal device 230 .
[0049] As shown in FIG. 5 , process 500 may include creating a session associated with terminal device 230 , a session ID, and/or a location ID (block 520 ). For example, server device 220 may create the session.
[0050] Server device 220 may create the session by establishing an interactive information interchange between server device 220 and terminal device 230 . Additionally, or alternatively, the session may be associated with an entry in a data structure identifying terminal device 230 .
[0051] In some implementations, the session may be associated with a session ID identifying the session and a location ID identifying a location of terminal device 230 .
[0052] The session ID may be a string of characters of any length. For example, the session ID may include numbers, letters, symbols, and/or other characters. In some implementations, the session ID may have a length that may be easily input by a user. For example, the session ID may have a length of five or fewer characters. The session ID may uniquely identify an active session (e.g., a session that has not been terminated) from among all stores. Additionally, or alternatively, the session ID may uniquely identify a session at the store where terminal device 230 is located. In other words, a session associated with a terminal device 230 at a different store may have a same session ID (but be associated with a different location ID).
[0053] Server device 220 may obtain the session ID by generating the session ID. For example, server device 220 may generate a random string of characters as the session ID. Additionally, or alternatively, terminal device 230 may generate the session ID and transmit the session ID to server device 230 . In this case, server device 220 may obtain the session ID by receiving the session ID from terminal device 230 with the request to start the session. For example, the store representative may input an employee identifier identifying the representative (e.g., an employee name and/or an employee number) into terminal device 230 as the session ID.
[0054] The location ID may identify a location associated with terminal device 230 . For example, the location ID may represent a store where terminal device 230 is located. Each store may be associated with a location ID and each store may include multiple terminal devices 230 . The location ID may be a string of characters of any length. For example, the location ID may include numbers, letter, symbols, and/or other characters. In some implementations, the location ID may have a length that may be easily input by a user and still uniquely identify a store. For example, the location ID may have a length of five or fewer characters.
[0055] Server device 220 may obtain the location ID from a terminal device data structure included in a memory of server device 220 and/or of another device based on the terminal device information included in the request. For example, the terminal device data structure may associate a location ID with terminal device 230 . Additionally, or alternatively, terminal device 230 may store the location ID and transmit the location ID to server device 220 . In this case, server device 220 may receive the location ID from terminal device 230 with the request to start the session.
[0056] In some implementations, the session may be associated with account ID information identifying the account the person at the store desires to discuss. For example, if the request to start the session includes the account ID information, the account ID information may be associated with the session.
[0057] As shown in FIG. 5 , process 500 may include transmitting the session ID and/or the location ID to terminal device 230 (block 530 ). For example, server device 220 may transmit the session ID and/or the location ID to terminal device 230 .
[0058] In some implementations, server device 220 may have generated the session ID. Accordingly, server device 220 may transmit the session ID to terminal device 230 . Additionally, or alternatively, the terminal device 230 may have generated the session ID and transmitted the session ID to server device 220 . Accordingly, server device 220 may not have to transmit the session ID to terminal device 230 because terminal device 230 already has the session ID.
[0059] Terminal device 230 may display the session ID and the store representative may read the session ID. The store representative may provide the session ID to the person desiring to access the account (e.g., the store representative may verbally provide the session ID to the person and/or allow the person to read the session ID displayed on terminal device 230 ).
[0060] In some implementations, server device 220 may have obtained the location ID from the terminal device data structure. Accordingly, server device 220 may transmit the location ID to terminal device 230 . Additionally, or alternatively, the terminal device 230 may store the location ID and may have transmitted the location ID to server device 220 . Accordingly, server device 220 may not have to transmit the location ID to terminal device 230 because terminal device 230 already has the location ID.
[0061] Terminal device 230 may display the location ID and the store representative may read the location ID. The store representative may provide the location ID to the person desiring to access the account (e.g., the store representative may verbally provide the location ID to the person and/or allow the person to read the location ID displayed on terminal device 230 ).
[0062] As shown in FIG. 5 , process 500 may include receiving the session ID, location information, and authentication information from user device 210 operated by the person (block 540 ). For example, server device 220 may receive the session ID, the location information, and/or the authentication information from user device 210 .
[0063] The person at the store may execute an application on user device 210 that communicates with server device 220 . The application may be a store application installed and executed on user device 210 for authentication in a store. The person may input the session ID received from the store representative into user device 210 using the application. Accordingly, user device 210 may obtain the session ID via user input.
[0064] In some implementations, the person may input the location information into user device 210 by inputting the location ID received from the store representative into user device 210 using the application. Accordingly, user device 210 may receive the location information via user input. Additionally, or alternatively, the location information may be a GPS location obtained from a GPS sensor included in user device 210 .
[0065] User device 210 may obtain the authentication information by the person at the store inputting the authentication information into the application. Additionally, or alternatively, the application may already store the authentication information and provide the authentication information to user device 210 . The authentication information may be a string of characters of any length. For example, the authentication information may be a password associated with the account.
[0066] In some implementations, server device 220 may receive account ID information identifying the account from user device 210 . User device 210 may obtain the account ID information by the person at the store inputting the account ID information into the application. Additionally, or alternatively, the application may store the account ID information and provide the account ID information to user device 210 .
[0067] User device 210 may transmit the obtained session ID, location information, authentication information, and/or account ID information to server device 220 using the application. Server device 220 may receive the session ID, the location information, the authentication information, and/or the account ID information from user device 210 .
[0068] As shown in FIG. 5 , process 500 may include identifying the session based on the session ID and the location information (block 550 ). For example, server device 220 may identify the session.
[0069] Server device 220 may identify the location ID based on the location information. For example, the location information may include the location ID. Additionally, or alternatively, the location information may indicate a GPS location. Server device 220 may use the GPS location to determine a store at the location and a location ID associated with the store.
[0070] Thus, server device 220 may determine a session associated with the session ID and/or the location ID and identify terminal device 230 associated with the session. In some implementations, the location ID may not be needed to identify the session. For example, the session ID may uniquely identify the session from among sessions for all terminal devices 230 at all stores. Additionally, or alternatively, the session ID may uniquely identify the session from among sessions for terminal devices 230 at a same store. In such a case, the location ID may be used to identify the store and the session ID may be used to identify a specific session associated with a terminal device 230 at the store.
[0071] As shown in FIG. 5 , process 500 may include generating an authentication message based on the authentication information (block 560 ). For example, server device 220 may generate the authentication message.
[0072] The authentication message may include the authentication information. For example, the authentication message may include the password input by the person at the store.
[0073] Additionally, or alternatively, server device 220 may use the authentication information to authenticate the user. For example, server device 220 may have received account ID information from user device 210 and/or terminal device 230 . Server device 220 may access the account in the account data structure using the account ID information (e.g., an account ID, contact information associated with account, etc.) and determine whether the authentication information received from user device 210 (e.g., a password) matches the account authentication information. Server device 220 may generate an authentication result indicating whether the user of user device 210 is an authorized user of the account. Accordingly, the authentication message may include the authentication result (e.g., “authentication successful” or “authentication failed”).
[0074] Server device 220 may determine whether the session between the server device 220 and terminal device 230 is still active or has been terminated. For example, server device 220 may determine whether the interactive information interchange between server device 220 and terminal device 230 has been terminated. Additionally, or alternatively, server device 220 may determine whether the entry for the session in the data structure has been deleted. If the session is still active, server device 220 may generate the authentication message. If the session has been terminated, server device 220 may stop process 500 and not generate the authentication message.
[0075] As shown in FIG. 5 , process 500 may include transmitting the authentication message to terminal device 230 (block 570 ). For example, server device 220 may transmit the authentication message to terminal device 230 .
[0076] Terminal device 230 may receive the authentication message form server device 220 and display the authentication message. In some implementations, the authentication message may include the authentication information. In some implementations, the displayed authentication information may be masked to prevent the store representative and/or others from seeing the authentication information. The store representative may determine if the person at the store is authorized to access the account by checking whether the displayed authentication information (e.g., a password) matches the account authentication information for the account the person is trying to access. Additionally, or alternatively, the authentication message may include the authentication result generated by server device 220 . Accordingly, the store representative may determine whether the person at the store is authorized to access the account by reading the authentication result displayed by terminal device 230 .
[0077] As shown in FIG. 5 , process 500 may include terminating the session (block 580 ). For example, server device 220 may terminate the session.
[0078] Server device 220 may terminate the session by terminating the interactive information interchange between server device 220 and terminal device 230 associated with the session ID. Additionally, or alternatively, server device 220 may terminate the session by deleting an entry for the session in a data structure.
[0079] In some implementations, server device 220 may terminate the session based on receiving a termination message from terminal device 230 instructing server device 220 to terminate the session. Additionally, or alternatively, server device 220 may terminate the session based on a same terminal device 230 sending a request for a new session.
[0080] In some implementations, server device 220 may terminate the session based on a message from user device 210 . For example, the application on user device 210 may transmit a GPS location to server device 220 during the session. If the GPS location indicates user device 210 has left the store where terminal device 230 is located, server device 220 may terminate the session.
[0081] The session ID associated with the session may be reused for a new session once the session has been terminated.
[0082] While a series of blocks has been described with regard to FIG. 5 , the blocks and/or the order of the blocks may be modified in some implementations. Additionally, or alternatively, non-dependent blocks may be performed in parallel.
[0083] FIG. 6 is a diagram of an example implementation 600 relating to process 500 shown in FIG. 5 . Assume a person brings user device 610 into a store and desires to discuss an account with a store representative. The store representative may obtain an account ID from the person. The store representative may use terminal device 630 to transmit a request to a server device to start a session to authenticate that the person is authorized to discuss the account.
[0084] The server device may receive the request and create a session. The session may be associated with terminal device 630 . Additionally, the server device may generate a session code (e.g., a session ID) for the session (e.g., “8173”). The session code may be different than any other session code that is currently being used for another terminal device 630 at the store, but may be the same as a session ID associated with a terminal device 630 at another store. The server device may associate a store code (e.g., a location ID) for the store where terminal device 630 is located with the session. The server device may transmit the session ID to terminal device 630 . The server device may also transmit the store code to terminal device 630 (e.g., “7482”).
[0085] Terminal device 630 may receive the session code and the store code and display the session code and the store code. The store representative may convey the session code and the store code to the person at the store.
[0086] The person may input the store code and the session code into user device 610 . The person may also input a password (e.g., “6172”), for the account, into user device 610 . User device 610 may transmit the store code, the session code, and the password to the server device. The server device may identify the session associated with terminal device 630 based on the store code and the session code. The server device may transmit the password to terminal device 630 and terminal device 630 may use the password to authenticate the person at the store.
[0087] FIG. 7 is a flowchart of an example process 700 for transmitting an authentication message from user device 210 to terminal device 230 . In some implementations, one or more process blocks of FIG. 7 may be performed by server device 220 . Additionally, or alternatively, one or more process blocks of FIG. 7 may be performed by another device or a group of devices separate from or including server device 220 .
[0088] As shown in FIG. 7 , process 700 may include receiving a request from terminal device 230 to start a session to authenticate a user (block 710 ). For example, server device 220 may receive the request from terminal device 230 to start a session.
[0089] The store representative may have to verify that the person is authorized to access the account before discussing the account with the person. Accordingly, the store representative may use terminal device 230 at the store to transmit a request to server device 220 to start a session to verify that the person at the store is authorized to access the account. The request may include a terminal device ID identifying terminal device 230 and/or the store representative that sent the request. Server device 220 may receive the request transmitted by terminal device 230 .
[0090] As shown in FIG. 7 , process 700 may include creating a session for terminal device 230 associated with the terminal device ID (block 720 ). For example, server device 220 may create the session.
[0091] Server device 220 may create the session by establishing an interactive information interchange between server device 220 and terminal device 230 . Additionally, or alternatively, the session may be an entry in a data structure identifying terminal device 230 . The session may be associated with the terminal device ID.
[0092] As shown in FIG. 7 , process 700 may further include providing store information to user device 210 (block 730 ). For example, server device 220 may provide the store information to user device 210 .
[0093] The person at the store may execute an application on user device 210 . The application on user device 210 may prompt the person at the store to select the store from a list of stores. Additionally, or alternatively, the application may select a store based on a GPS location of user device 210 . The application may send information identifying the selected store to server device 220 . Server device 220 may receive the information identifying the selected store. Server device 220 may store a data structure including store information about multiple stores. The store information may include terminal device information about terminal devices 230 at each store and store representatives at each store. Server device 220 may obtain the store information about the selected store from the data structure and provide the store information about the selected store to user device 210 . In some implementations, the store information may indicate which terminal device 230 and/or store representatives have an active session with server device 220 . Additionally, or alternatively, server device 220 may only provide information about terminal devices 230 and/or store representatives that have an active session with server device 220 . Furthermore, the store information transmitted to user device 210 may include a terminal device ID for each terminal device 230 and/or store representative in the selected store.
[0094] As shown in FIG. 7 , process 700 may further include receiving terminal device information, included in the store information, and authentication information for user device 210 (block 740 ). For example, server device 220 may receive the terminal device information and the authentication information from user device 210 .
[0095] User device 210 may receive the store information and display the store information to the person at the store. For example, user device 210 may display a list of store representatives that work at the store and/or a list of terminal devices 230 in the store. The user may select a store representative from the list and/or a terminal device 230 from the list. Additionally, or alternatively, user device 210 may display a virtual representation of the store indicating the location of terminal devices 230 in the store. Accordingly, the person may select terminal device 230 based on a location of the terminal device 230 in the store as shown in the virtual representation. User device 210 may generate and provide terminal device information about the selected terminal device 230 and/or store representative to server device 220 and server device 220 may receive the terminal device information. The terminal device information may include a terminal device ID for the selected terminal device 230 and/or store representative.
[0096] The application on user device 210 may prompt the person to input authentication information. Accordingly, user device 210 may obtain the authentication information by the person at the store inputting the authentication information into the application. Additionally, or alternatively, the application may store the authentication information and provide the authentication information to user device 210 . The authentication information may be a string of characters of any length. For example, the authentication information may be a password associated with the account. User device 210 may transmit the authentication information to server device 220 . Server device 220 may receive the authentication information from user device 210 .
[0097] As shown in FIG. 7 , process 700 may further include identifying the session based on the terminal device information (block 750 ). For example, server device 220 may identify the session.
[0098] Server device 220 may identify the session based on the terminal device information. For example, the terminal device information may include the terminal device ID associated with the session. Additionally, or alternatively, server device 220 may use the terminal device information to look up a terminal device ID in the data structure.
[0099] Thus, server device 220 may determine a session associated with the terminal device ID and identify terminal device 230 associated with the session.
[0100] As shown in FIG. 7 , process 700 may include generating an authentication message based on the authentication information (block 760 ). For example, server device 220 may generate the authentication message.
[0101] The authentication message may include the authentication information. For example, the authentication message may include the password input by the person at the store. In some implementations, server device 220 may encrypt the authentication information.
[0102] Additionally, or alternatively, server device 220 may use the authentication information to authenticate the user. For example, server device 220 may have received account ID information from user device 210 and/or terminal device 230 . Server device 220 may access the account in the account data structure using the account ID information (e.g., an account ID, contact information associated with account, etc.) and determine whether the authentication information received from user device 210 (e.g., a password) matches the account authentication information for the account. Server device 220 may generate an authentication result indicating whether the user of user device 210 is an authorized user of the account. Accordingly, the authentication message may include the authentication result (e.g., “authentication successful” or “authentication failed”).
[0103] Server device 220 may determine whether the session between the server device 220 and terminal device 230 is still active or has been terminated. For example, server device 220 may determine whether the interactive information interchange between server device 220 and terminal device 230 has been terminated. Additionally, or alternatively, server device 220 may determine whether the entry for the session in the data structure has been deleted. If the session is still active, server device 220 may generate the authentication message. If the session has been terminated, server device 220 may stop process 500 and not generate the authentication message.
[0104] As shown in FIG. 7 , process 700 may include transmitting the authentication message to terminal device 230 (block 770 ). For example, server device 220 may transmit the authentication message to terminal device 230 .
[0105] Terminal device 230 may receive the authentication message from server device 220 and display the authentication message. In some implementations, the authentication message may include the authentication information. The store representative, via terminal device 230 , may determine if the person at the store is authorized to access the account by checking whether the displayed authentication information (e.g., password) matches account authentication information for the account the person is trying to access. Additionally, or alternatively, the authentication message may include the authentication result generated by server device 220 . Accordingly, the store representative may determine whether the person at the store is authorized to access the account by reading the authentication result displayed by terminal device 230 .
[0106] As shown in FIG. 7 , process 700 may include terminating the session (block 780 ). For example, server device 220 may terminate the session.
[0107] Server device 220 may terminate the session by terminating the interactive information interchange between server device 220 and terminal device 230 associated with the terminal device ID. Additionally, or alternatively, server device 220 may terminate the session by deleting an entry for the session in a data structure.
[0108] In some implementations, server device 220 may terminate the session based on receiving a termination message from terminal device 230 instructing server device 220 to terminate the session. Additionally, or alternatively, server device 220 may terminate the session based on the same terminal device 230 sending a request for a new session.
[0109] In some implementations, server device 220 may terminate the session based on a message from user device 210 . For example, the application on user device 210 may transmit a GPS location to server device 220 during the session. If the GPS location indicates user device 210 has left the store including terminal device 230 , server device 220 may terminate the session.
[0110] While a series of blocks has been described with regard to FIG. 7 , the blocks and/or the order of the blocks may be modified in some implementations. Additionally, or alternatively, non-dependent blocks may be performed in parallel.
[0111] FIG. 8 is a diagram of an example implementation 800 relating to process 700 shown in FIG. 7 . Assume a person brings user device 810 into a store and desires to discuss an account with a store representative. The store representative may obtain an account ID (e.g., a phone number associated with the account) from the person. The store representative may use terminal device 830 to transmit a request to a server device to start a session to authenticate that the person is authorized to discuss the account. The request may include the account ID and information identifying the store representative.
[0112] The server device may receive the request from the terminal device and start a session. The session may be associated with terminal device 830 that sent the request, the information identifying the store representative, and the account ID.
[0113] The store representative may instruct the person at the store to use user device 810 to execute an application used for authentication. The person may execute the application on user device 810 . The application may detect a location of user device 810 using a GPS device on user device 810 . The application may determine that a store in Chicago is associated with the location. The application may cause user device 810 to display information about the Chicago store. For example, the application may cause user device 810 to display a list of names for store representatives that work at the store in Chicago. The person may input a selection of a name (e.g., Emily Johnson). The application may store authentication information in a memory of user device 810 and/or prompt the person to input the authentication information. The application may obtain the authentication from the memory or from a user input. User device 810 may transmit the information identifying the selected store representative and the authentication information to the server device.
[0114] The server device may receive the information identifying the selected store representative and the authentication information. The server device may determine a session based on the selected store representative. For example, a store representative may only be associated with one active session at a time. The server device may obtain the account ID associated with the session and obtain account authentication information for the account. The server device may compare the authentication information received from user device 810 with the account authentication information to generate an authentication result. For example, the authentication result may indicate that authentication is successful because the authentication information received form user device 810 matches the account authentication information. The server device may generate an authentication message including the authentication result and transmit the authentication message to terminal device 830 .
[0115] Terminal device 830 may receive the authentication message from the server device. Terminal device 830 may display a message “authentication successful” indicating that the person at the store is authorized to access the account.
[0116] Implementations described herein may improve privacy and/or security by allowing a person at a store to verify the person is an authorized user of an account using a person's mobile device to transmit authentication information to authenticate the person in a manner that may not be overheard or seen by other people at the store.
[0117] The foregoing disclosure provides illustration and description, but is not intended to be exhaustive or to limit the implementations to the precise form disclosed. Modifications and variations are possible in light of the above disclosure or may be acquired from practice of the implementations.
[0118] To the extent the aforementioned implementations collect, store, or employ personal information provided by individuals, it should be understood that such information shall be used in accordance with all applicable laws concerning protection of personal information. Additionally, the collection, storage, and use of such information may be subject to consent of the individual to such activity, for example, through “opt-in” or “opt-out” processes as may be appropriate for the situation and type of information. Storage and use of personal information may be in an appropriately secure manner reflective of the type of information, for example, through various encryption and anonymization techniques for particularly sensitive information.
[0119] As used herein, the term “component” is intended to be broadly construed as hardware, firmware, or a combination of hardware and software.
[0120] Certain user interfaces have been described herein. In some implementations, the user interfaces may be customizable by a user or a device. Additionally, or alternatively, the user interfaces may be pre-configured to a standard configuration, a specific configuration based on a type of device on which the user interfaces are displayed, or a set of configurations based on capabilities and/or specifications associated with a device on which the user interfaces are displayed.
[0121] It will be apparent that systems and/or methods, as described herein, may be implemented in many different forms of software, firmware, and hardware in the implementations illustrated in the figures. The actual software code or specialized control hardware used to implement these systems and/or methods is not limiting of the implementations. Thus, the operation and behavior of the systems and/or methods were described without reference to the specific software code—it being understood that software and control hardware can be designed to implement the systems and/or methods based on the description herein.
[0122] Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of possible implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. Although each dependent claim listed below may directly depend on only one claim, the disclosure of possible implementations includes each dependent claim in combination with every other claim in the claim set.
[0123] No element, act, or instruction used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items, and may be used interchangeably with “one or more.” Where only one item is intended, the term “one” or similar language is used. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. | A device receives a request from a terminal device to start a session to authenticate a person associated with an account. The device creates the session. The session is associated with the terminal device. The device receives session information and authentication information from a user device operated by the person. The device determines the session based on the session information and generates an authentication message based on the authentication information. The device transmits the authentication message to the terminal device associated with the session to authenticate that the person is associated with the account. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from Provisional U.S. Patent Application No. 60/928,617, filed May 10, 2007, the full disclosure of which is hereby incorporated by reference in their entirety for all purposes.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not applicable.
FIELD OF THE INVENTION
[0003] The invention is in the field of reducing autofluorescence background noise.
BACKGROUND OF THE INVENTION
[0004] Typical fluorescence based optical analysis of analytical reactions employs reactants or other reagents in the reaction of interest that bear a fluorescent moiety, such as a labeling group, where the detection of that moiety is indicative of a particular reaction result or condition. For example, reactions may be engineered to produce a change in the amount, location, spectrum, or other characteristic upon occurrence of a reaction of interest.
[0005] During analysis, an excitation light source is directed through an optical system or train at the reaction to excite fluorescence from the fluorescent moiety. The emitted fluorescence is then collected by the optical train and directed toward a detection system, which quantifies, records, and/or processes the signal data from the fluorescence. Fluorescence-based systems are generally desired for their high signal levels deriving from the high quantum efficiency of the available fluorescent dye moieties. Because of these high signal levels, relatively low levels of the materials are generally required in order to observe a fluorescent signal.
[0006] Notwithstanding the great benefits of fluorescent reaction systems, the application of these systems does have some drawbacks particularly when used in extremely low signal level reactions, e.g., low concentration or even single molecule detection systems. In particular, these systems often have a number of components that can potentially generate amounts of background signal, e.g., detected signal that does not emanate from the fluorescent species of interest, when illuminated with relatively high intensity radiation. This background signal can contribute to signal noise levels, and potentially overwhelm relatively low reaction derived signals or make more difficult the identification of signal events, e.g., increases, decreases, pulses etc., of fluorescent signal associated with the reactions being observed.
[0007] Background signal, or noise, can derive from a number of sources, including, for example, fluorescent signals from non targeted reaction regions, fluorescence from targeted reaction regions but that derive from non-relevant sources, such as non-specific reactions or associations, such as dye or label molecules that have nonspecifically adsorbed to surfaces, prevalence or build up of labeled reaction products, other fluorescent reaction components, contaminants, and the like. Other sources of background signals in fluorescent systems include signal noise that derives from the use of relatively high-intensity excitation radiation in conjunction with sensitive light detection. Such noise sources include those that derive from errant light entering the detection system that may come from inappropriately filtered or blocked excitation radiation, and/or contaminating ambient light sources that may impact the overall system. Other sources of signal noise resulting from the application of high intensity excitation illumination derives from the auto-fluorescence of the various components of the system when subjected to such illumination, as well as Raman scattering of the excitation illumination. The contribution of this systemic fluorescence is generally referred to herein as autofluorescence background noise (ABN).
[0008] It would be therefore desirable to provide methods, components and systems in which background signal, such as autofluorescence background noise, was minimized. This is particularly the case in relatively low signal level reactions, such as single molecule fluorescence detection methods and systems. The present invention meets these and other needs.
SUMMARY OF THE INVENTION
[0009] The invention provides methods and systems that have improved abilities to monitor fluorescent signals from analytical reactions by virtue of having reduced levels of background signal noise that derives from autofluorescence created within one or more components of the overall system.
[0010] In a first aspect, the invention provides systems for monitoring a plurality of discrete fluorescent signals from a substrate. The systems include a substrate onto which a plurality of discrete fluorescent signal sources has been disposed, an excitation illumination source, and a detector for detecting fluorescent signals from the plurality of fluorescent signal sources. In addition, the systems include an optical train positioned to simultaneously direct excitation illumination from the excitation illumination source to each of the plurality of discrete fluorescent signal sources on the substrate and direct fluorescent signals from the plurality of fluorescent signal sources to the detector. The optical train of the systems comprises an objective lens focused in a first focal plane at the substrate for simultaneously collecting fluorescent signals from the plurality of fluorescent signal sources on the substrate, a first focusing lens for receiving the fluorescent signals from the objective lens and focusing the fluorescent signals in a second focal plane, and a confocal filter placed within the second focal plane to filter fluorescent signals from the substrate that are not within the first focal plane.
[0011] Optionally, the systems for monitoring a plurality of discrete fluorescent signals from a substrate can include a substrate that comprises first and second opposing surfaces that is positioned such that the first surface of the substrate is more proximal to the optical train than the second surface, and such that the first focal plane is substantially coplanar with the second surface. The systems can optionally include an optical train that simultaneously directs excitation radiation at and collects fluorescent signals from at least 100 discrete fluorescent signal sources, at least 500 discrete fluorescent signal sources, at least 1000 discrete signal sources, or at least 5000 discrete signal sources. The systems can optionally include an optical train that comprises a microlens array and/or a diffractive optical element to simultaneously direct excitation illumination at the plurality of discrete fluorescent signal sources on the substrate.
[0012] Each of the plurality of discrete signal sources in the systems described above can optionally comprise a reaction region, e.g., an optically confined region on the substrate, into which a complex comprising a nucleic acid polymerase, a template sequence, and a primer sequence, and at least one fluorescently labeled nucleotide has been disposed. Optionally, the optically confined regions can comprise zero mode waveguides.
[0013] The invention also provides second set of systems for monitoring a plurality of discrete fluorescent signals from a substrate, which includes a substrate onto which a plurality of discrete fluorescent signal sources has been disposed, an excitation illumination source, and a detector for detecting fluorescent signals from the plurality of fluorescent signal sources. In addition, the second set of systems of monitoring a plurality of discrete fluorescent signals from a substrate includes an optical train that is positioned to direct excitation illumination from the excitation illumination source to each of the plurality of discrete fluorescent signal sources on the substrate in a targeted illumination pattern. In addition, the optical train directs fluorescent signals from the plurality of fluorescent signal sources to the detector.
[0014] Optionally, the optical train in the second set systems for monitoring a plurality of discrete fluorescent signals from a substrate can comprise a microlens array and/or a diffractive optical element to direct excitation radiation to each of the plurality of discrete fluorescent signal sources in a targeted illumination pattern. The diffractive optical element can optionally be configured to direct excitation radiation to at least 100 discrete fluorescent signal sources, at least 500 discrete fluorescent signal sources, at least 1000 discrete fluorescent signal sources, or at least 5000 discrete fluorescent signal sources in a targeted illumination pattern.
[0015] In the second set systems for monitoring a plurality of discrete fluorescent signals from a substrate, each of the plurality of discrete signal sources can optionally comprise a reaction region, e.g., an optically confined region on the substrate, into which a complex comprising a nucleic acid polymerase, a template sequence, and a primer sequence, and at least one fluorescently labeled nucleotide has been disposed. The optically confined regions can optionally comprise zero mode waveguides.
[0016] In a related aspect, the invention provides methods of reducing fluorescence background signals in detecting fluorescent signals from a substrate that comprises a plurality of fluorescent signal sources. The methods include directing excitation radiation simultaneously at a plurality of fluorescent signal sources on a substrate in a first focal plane, collecting fluorescent signals simultaneously from the plurality of fluorescent signal sources, filtering the fluorescent signals to reduce fluorescence not in the first focal plane to provide filtered fluorescent signals, and detecting the filtered fluorescent signals. The filtering step in the methods can optionally comprise confocally filtering the fluorescent signals to provide filtered fluorescent signals.
[0017] The invention also provides methods of detecting fluorescent signals from a plurality of discrete fluorescent signal sources on a substrate. These methods include providing a substrate onto which a plurality of discrete fluorescent signal sources has disposed, directing excitation illumination at the substrate in a targeted illumination pattern, and detecting fluorescent signals from each of the plurality of discrete fluorescent signal sources. The step of directing excitation at the substrate in a targeted illumination pattern can optionally comprise passing the excitation illumination through a microlens array and/or a diffractive optical element. The targeted illumination pattern can optionally comprise at least 100 discrete illumination spots positioned to be incident upon at least 100 discrete fluorescent signal sources, at least 500 discrete illumination spots positioned to be incident upon at least 500 discrete fluorescent signal sources, at least 1000 discrete illumination spots positioned to be incident upon at least 1000 discrete fluorescent signal sources, or at least 5000 discrete illumination spots positioned to be incident upon at least 5000 discrete fluorescent signal sources.
[0018] In addition, the invention provides three sets of methods of monitoring fluorescent signals from a source of fluorescent signals. In the first set, the methods include providing a fluorescent signal detection system that comprises a substrate comprising a plurality of discrete fluorescent signal sources, providing a source of excitation illumination, providing a fluorescent signal detector, and providing an optical train for directing excitation illumination from the source of excitation illumination to the substrate and for directing fluorescent signals from the substrate to the fluorescent signal detector. In this set of methods, at least one optical component in the optical train is photobleached so as to reduce a level of autofluorescence produced by the at least one optical component in response to passing excitation illumination therethrough.
[0019] The second set of methods of monitoring fluorescent signals from a source of fluorescent signals includes providing a substrate onto which a plurality of discrete fluorescent signal sources have been disposed, directing excitation illumination at the substrate in a targeted illumination pattern to excite fluorescent signals from the fluorescent signal sources, collecting the fluorescent signals from the plurality of discrete fluorescent signal sources illuminated with the targeted illumination pattern, confocally filtering the fluorescent emissions, and separately detecting the fluorescent emissions from the discrete fluorescent signal sources.
[0020] The third set of methods of monitoring fluorescent signals from a source of fluorescent signals includes providing an excitation illumination source, providing a substrate onto which at least a first fluorescent signal source has been disposed, and providing an optical train comprising optical components that is positioned to direct excitation illumination from the illumination source to the at least first fluorescent signal source and for transmitting fluorescent signals from the at least first fluorescent signal source to a detector. The third set of methods includes photobleaching at least one of the optical components to reduce an amount of autofluorescence produced by the at least one optical component in response to the excitation illumination, directing excitation illumination through the at least one optical component and at the at least first fluorescent signal source, and detecting fluorescent signals from the at least first fluorescent signal source. In the third set of methods, the fluorescent signals can optionally be confocally filtered prior to being detected.
[0021] Relatedly, the invention provides systems for detecting fluorescent signals from a plurality of signal sources on a substrate. These systems include a source of excitation illumination, a detection system, and an optical train positioned to direct excitation illumination from the source of excitation illumination to the plurality of signal sources on the substrate and transmit emitted fluorescence from the plurality of fluorescent signal sources to the detector. The optical train in these systems includes an objective lens that has a ratio of excitation illumination to autofluorescence of greater than 1×10 −10 .
[0022] Those of skill in the art will appreciate that that the methods provided by the invention, e.g., for detecting a plurality of discrete fluorescent signals from a plurality of discrete locations on a substrate, for reducing fluorescence background signals in detecting fluorescent signals from a substrate that comprises a plurality of fluorescent signal sources, and/or for monitoring fluorescent signals from a source of fluorescent signals, can be used alone or in combination and can be used in combination with any one or more of the systems described herein. In addition to the foregoing, the invention is also directed to the use of any of the foregoing systems and/or methods in a variety of analytical operations.
BRIEF DESCRIPTION OF THE FIGURES
[0023] FIG. 1 provides a schematic overview of a fluorescence detection system.
[0024] FIG. 2 shows a plot of fluorescent signals as a function of the number of illumination lines applied to a given fluorescently spotted substrate, showing increasing background fluorescence levels with increasing illumination.
[0025] FIG. 3 provides an example of a microlens array for use in the present invention.
[0026] FIG. 4 shows an image of diffractive optical element (“DOE”) and the illumination pattern generated when light is passed through the DOE.
[0027] FIG. 5 provides a schematic of an optical train incorporating a confocal mask.
[0028] FIG. 6 shows a comparison plot of autofluorescence of a fluorescent detection system in the absence and presence of a confocal mask in the system, to filter out of focus autofluorescence components.
[0029] FIG. 7 is a comparative plot of autofluorescence imaged at a discrete detector location in the absence of a confocal mask, and in the presence of confocal slits of decreasing cross sectional dimensions.
DETAILED DESCRIPTION OF THE INVENTION
I. General Discussion of Invention
[0030] The present invention generally provides methods, processes and systems for monitoring fluorescent signals associated with reactions of interest, but in which background signal levels and particularly autofluorescence background noise of system components, is reduced.
[0031] The methods, processes and systems of the invention are particularly suited to the detection of fluorescent signals from signal sources, e.g., reaction regions, on substantially planar substrates, and particularly for detection of relatively low levels of fluorescent signals from such reaction regions, where signal background has a greater potential for negative impact.
[0032] For ease of discussion, the present invention is described in terms of its application to arrays of single molecule reaction regions on planar substrates from which fluorescent signals emanate, which signals are indicative of a particular reaction occurring within such reaction regions. Though described in terms of such single molecule arrays, it will be appreciated that the invention, as a whole, or in part, will have broader applicability and may be employed in a number of different applications, such as in detection of fluorescent signals from other array formats, e.g., spotted arrays, arrays of fluidic channels, conduits or the like, or detection of fluorescent signals from multiwell plate formats, fluorescent bar-coding techniques, and the like.
[0033] One exemplary analytical system or process in which the invention is applied is in a single molecule DNA sequencing operation in which an immobilized complex of DNA polymerase, DNA template and primer are monitored to detect incorporation of nucleotides or nucleotide analogs that bear fluorescent detectable groups. See, e.g., U.S. Pat. Nos. 7,033,764, 7,052,847, 7,056,661, and 7,056,676, the disclosures of which are incorporated herein by reference in their entirety for all purposes. Typically, large numbers of complexes are provided immobilized upon transparent substrates, e.g., glass, quartz, fused silica, or the like, and positioned such that individual complexes are optically resolvable when associated with a fluorescent labeling group or molecule, such as a labeled nucleotide or nucleotide analog.
[0034] In preferred aspects, the individual complexes may be provided within an optically confined space, such as a zero mode waveguide, where the substrate comprises an array of zero mode waveguides housing individual complexes. In this aspect, an excitation light source is directed through a transparent substrate at an immobilized complex within a zero mode waveguide core. Due to the cross-sectional dimension of the waveguide core in the nanometer range, e.g., from about 20 to about 200 nm, the excitation light is unable to propagate through the core, and evanescent decay of the excitation light results in an illumination volume that only extends a very short distance into the core. As such, an illumination volume that contains one or a few complexes results. Zero mode waveguides and their application in sequencing and other analyses are described in, e.g., U.S. Pat. Nos. 6,917,726, 7,013,054, and 7,181,122, the full disclosures of which are incorporated herein by reference in their entirety for all purposes.
[0035] Other approaches to optical confinement may also be employed. For example, total internal reflectance fluorescence microscopy may be used to confine the illumination to near the surface of a substrate. This provides a similar confining effect as the zero mode waveguide, but does so without providing a structural confinement as well. Still other optical confinement techniques may generally be applied, such as those described in U.S. Pat. Nos. 7,033,764, 7,052,847, 7,056,661, and 7,056,676, previously incorporated herein by reference.
[0036] In order to optimize the throughput of the sequencing process, multiple different reactions represented in multiple waveguide cores in individual arrays are illuminated and observed simultaneously.
[0037] The above described arrays are typically interrogated using a fluorescence detection system that directs excitation radiation at the various reaction regions in the array and collects and records the fluorescent signals emitted from those regions. A simplified schematic illustration of these systems is shown in FIG. 1 . As shown, the system 100 includes a substrate 102 that includes a plurality of discrete sources of fluorescent signals, e.g., an array of zero mode waveguides 104 . An excitation illumination source, e.g., laser 106 , is provided in the system and is positioned to direct excitation radiation at the various fluorescent signal sources. This is typically done by directing excitation radiation at or through appropriate optical components, e.g., dichroic 108 and objective lens 110 , that direct the excitation radiation at the substrate 102 , and particularly the signal sources 104 . Emitted fluorescent signals from the sources 104 are then collected by the optical components, e.g., objective 110 , and passed through additional optical elements, e.g., dichroic 108 , prism 112 and lens 114 , until they are directed to and impinge upon an optical detection system, e.g., detector array 116 . The signals are then detected by detector array 116 , and the data from that detection is transmitted to an appropriate data processing unit, e.g., computer 118 , where the data is subjected to interpretation, analysis, and ultimately presented in a user ready format, e.g., on display 120 , or printout 122 , from printer 124 .
[0038] With respect to the exemplary sequencing systems described above, sources of autofluorescence background noise can typically include the components of the optical train through which the excitation radiation is directed, including the objective lens 110 or lenses, the dichroic filter(s) 108 , and any other optical components, i.e., filters, lenses, etc., through which the excitation radiation passes. Also contributing to this autofluorescence background noise are components of the substrate upon which the monitored sequencing reactions are occurring, which, in the case of zero mode waveguide arrays for example, include the underlying transparent substrate that is typically comprised of glass, quartz or fused silica, as well as the cladding layer that is disposed upon the substrate, typically a metal layer such as aluminum.
[0039] In general, the present invention provides both preventive and remedial approaches to reducing impacts of autofluorescence background noise, in the context of analyses that employ illuminated reactions. Restated, in a first general preventive aspect, the invention is directed to processes and systems that have a reduced level of autofluorescence background noise that is created and that might be ultimately detected by the system. In the additional or alternative remedial aspects, the invention provides methods and systems in which any autofluorescence background noise that is created, is filtered, blocked or masked substantially or in part from detection by the system. As will be appreciated, in many cases, both preventative and remedial approaches may be used in combination to reduce autofluorescence background noise.
II Preventive Measures
[0040] In a first aspect, the present invention reduces the level of autofluorescence background noise generation by preventing or reducing the production of that background noise in the first instance. In particular, this aspect of the invention is directed to providing illumination of the optical signal source or sources in a way that reduces or minimizes the generation of such autofluorescence background noise.
[0041] In accordance with one aspect of the invention, the reduction in autofluorescence creation is accomplished by reducing the amount of illumination input into the system and/or directed at the substrate, e.g., by providing highly targeted illumination of only the locations that are desired to be illuminated, and preventing illumination elsewhere in the array or system. By using highly targeted illumination, one simultaneously reduces the area of the substrate that might give rise to autofluorescence, and reduces the overall amount of input illumination radiation required to be input into the system, as such input illumination is more efficiently applied.
[0042] In particular, the amount of illumination power required to be applied to the system increases with the number of signal sources that are required to be illuminated. For example, in a zero mode waveguide array that is configured in a gridded format of rows and/or columns of waveguides, multiple waveguides are generally illuminated using a linear illumination format (See, e.g., International Patent Application Nos. US2007/003570 and US2007/003804, which are incorporated herein by reference in their entirety for all purposes). Multiple rows and/or columns are then illuminated with multiple illumination lines.
[0043] As shown in FIG. 2 , as the number of illumination lines increases, it results in a linear increase in the amount of autofluorescence emanating from the system. In particular, FIG. 2 shows a plot of fluorescent signals emanating from a spotted array of Alexa488 fluorescent dye spots on a fused silica slide. As can be seen, as more illumination lines are applied to the array, the baseline fluorescence level attributable to autofluorescence background noise increases linearly with the number of illumination lines. Further, it has been demonstrated that this autofluorescence background noise derives not only from the substrate, but also from the other optical components of the system, such as the objective lens and dichroic filter(s).
[0044] Accordingly, in a first aspect, the invention reduces the amount of autofluorescence background noise by reducing the amount of excitation illumination put into the system, while still producing the desired fluorescent signals. In general, providing the same or similar levels of excitation illumination at desired locations, e.g., on the substrate, while reducing overall applied excitation illumination in the system, is accomplished through more efficient use of applied illumination by targeting that illumination only to the desired locations. In particular, by targeting illumination only at the relevant locations, e.g., primarily at only the waveguides on an array, one can reduce the amount of power required to be directed into the system to accomplish the desired level of illumination and at the substrate, yielding a consequent reduction in the amount of autofluorescence background noise that is generated at either of the substrate or those optical components through which such illumination power is directed. Additionally, because less of the substrate is being illuminated by virtue of the targeted nature of the illumination, less of the substrate will be capable of contributing to the autofluorescence background noise.
[0045] Targeting illumination to each of an array of point targets such as zero mode waveguides, can be accomplished by a number of methods. For example, in a first aspect, excitation radiation may be directed through a microlens array in conjunction with the objective lens, in order to generate spot illumination for each of a number of array locations. In particular, a lens array can be used that would generate a gridded array of illumination spots that would be focused upon a gridded array of signal sources, such as zero mode waveguides, on a substrate. An example of a microlens array is shown in FIG. 3 , panel A. In particular, shown is an SEM image of the array. Panel B of FIG. 3 illustrates the illumination pattern from the microlens array used in conjunction with the objective lens of the system. As will be appreciated, the lens array is fabricated so as to be able to focus illumination spots on the same pitch and position as the locations on the array that are desired to be illuminated.
[0046] In an alternative aspect, a plurality of illumination spots for targeted illumination of signal sources may be generated by passing excitation illumination through one or more diffractive optical elements (“DOE”) upstream of the objective lens. In particular, DOEs can be fabricated to provide complex illumination patterns, including arrays of large numbers of illumination spots that can, in turn, be focused upon large numbers of discrete targets.
[0047] For example, as shown in FIG. 4 , a DOE Phase mask, as shown in Panel A, can generate a highly targeted illumination pattern, such as that shown in panel B, which provides targeted illumination of relatively large numbers of discrete locations on a substrate, simultaneously. In particular, the DOE equipped optical system can generally separately illuminate at least 100 discrete signal sources, e.g., zero mode waveguides, simultaneously and in a targeted illumination pattern. In preferred aspects, the DOE may be used to simultaneously illuminate at least 500 discrete signal sources, and in more preferred aspects, illuminate at least 1000, at least 5000, or at least 10,000 or more discrete signal sources simultaneously, and in a targeted illumination pattern, e.g., without substantially illuminating other portions of a substrate such as the space between adjacent signal sources preferably between adjacent illumination spots.
[0048] Several approaches can be used to design and fabricate a DOE for use in the present invention. The purpose here is to evenly divide the single laser beam into a large number of discrete new beams, e.g., up to 5000 or more new beams, each with 1/5000 of the energy of the original beam, and each of the 5000 “beamlets” traveling in a different direction. By way of example, the DOE design requirement is to evenly space the beamlets in angles (the 2 angles are referred to herein as θ x and θ y ). By analogy, if one provides a diffraction grating that provides equal amplitude to the different orders, and illuminates it with a laser beam, it will result in a row of illuminated dots, corresponding to discrete beams each traveling at a unique angle after they impinge on the grating. If a second similar grating is placed adjacent to the first but rotated by 90 degrees, it will provide a 2 dimensional grid of beamlets, each traveling with a unique θ x and θ y . If the 2 gratings are identical, a square grid will result, but if the 2 gratings have different period, a rectangular grid will result.
[0049] As will be appreciated, the DOE (and the Microlens Array) will divide the light into numerous beams that are propagating at unique angles. In a preferred illumination scheme the DOE is combined with the objective lens in a planned way, such that the objective lens will perform a fourier transform on all of the beamlets. In this fourier transform, angle information is converted into special information at the image plane of the objective. After the beamlets pass through the objective, each unique θ x and θ y will correspond to a unique x,y location in the image plane of the objective. The objective properties must be known in order to correctly design the DOE or microlens. The formula for the fourier transform is given by:
[0000] ( x,y )=EFL×Tangent(θ x ,θ y ),
[0050] where EFL is the Effective Focal Length of the objective.
[0051] There are several different approaches to producing a DOE that will meet the needs of the invention. For example, one approach is through the use of a phase mask that is pixelated such that each pixel will retard the incident photons by a programmed amount. This phase retardation can again be achieved in different ways. For example, one preferred approach uses thickness of the glass element. For example, the phase mask might include a ½ inch square piece of SiO 2 . Material is etched away from the top surface of the SiO 2 plate to, e.g., 64 different etch depths. This is referred to as a 64-level grey scale pattern. The final phase mask then is comprised of a pixelated grid where each pixel is etched to a particular depth. The range of etch depths corresponds to a full 2π of phase difference. Restated, a photon which impinges on a pixel with the minimum etch depth (no etching) will experience exactly 2π additional phase evolution compared to a photon which strikes a maximum etch depth (thinnest part of the SiO 2 ). The pixelated pattern etched into the DOE is repeated periodically, with the result that the lateral position of the laser beam impinging on the mask is unimportant.
[0052] As will be appreciated, the actual phase evolution for the DOE is a function of the optical wavelength of the light being transmitted through it, so DOE devices will generally be provided for a specific wavelength of excitation illumination.
[0053] By targeted illumination or targeted illumination pattern, in accordance with the foregoing, is meant that the illumination directed at the substrate is primarily incident upon the desired locations, rather than other portions of the substrate. For example, as alluded to above, where one desires to interrogate a number of discrete locations on a substrate for fluorescent signals, using targeted illumination would include directing discrete illumination spots at each of a plurality of the different discrete locations. Such targeted illumination is in contrast to illumination patterns that illuminate multiple locations with a single illumination spot or line, in flood or linear illumination profiles. Again, as noted above, targeting illumination provides the cumulative benefits of reducing the required amount of illumination input into the system, and illuminating less area of the substrate, both of which contribute to the problem of autofluorescence background noise.
[0054] In particular, targeted illumination, as used herein, can be defined from a number of approaches. For example, in a first aspect, a targeted illumination pattern refers to a pattern of illuminating a plurality of discrete signal sources, reaction regions or the like, with a plurality of discrete illumination spots. While such targeted illumination may include ratios of illumination spots to discrete signal sources that are less than 1, i.e., 0.1, 0.25, or 0.5 (corresponding to one illumination spot for 10 signal sources, 4 signal sources and 2 signal sources, respectively) in particularly preferred aspects, the ratio will be 1 (e.g., one spot for one signal source, i.e., a waveguide).
[0055] Alternatively, as a goal of targeted illumination in the context of the present invention is to reduce autofluorescence from excessive illumination, targeted illumination denotes illumination where a substantial percentage of the illumination that is incident upon the substrate is incident upon the desired signal source(s) as opposed to being incident on other portions of the substrate. Accounting for the often small size of signal sources, e.g., in the case of nanoscale zero mode waveguides, as well as the tolerance in direction of illumination by optical systems, such targeted illumination will typically result in at least 5% of the illumination incident upon the overall substrate being incident upon the discrete signal sources themselves. This corresponds to 95% or less wasted illumination that is incident elsewhere. In preferred aspects, that percentage is improved such at least 10%, 20% or in highly targeted illumination patterns, at least 50% of the illumination incident upon the substrate is incident upon the discrete signal sources. Conversely, the amount of illumination incident upon other portions of the substrate is less than 90%, less than 80% or in highly targeted aspects, less than 50%. Determination of this percentage is typically a routine matter of dividing the area of a substrate that is occupied by the relevant signal discrete source divided by the area of total illumination, multiplied by 100, where a region is deemed “illuminated” for purposes of this determination if it exceeds a threshold level of detectable illumination from the illumination source, e.g., 5% of that at the maximum point of a given illumination spot of the same substrate.
[0056] In still a further aspect, targeted illumination may be identified through the amount of laser power required to illuminate discrete signal sources vs. illuminating such signal sources using a single flooding illumination profile, e.g., that simultaneously illuminates an entire area in which the plurality of discrete sources is located, as well as the space between such sources. Preferably, the efficiency in targeted illumination over such flood illumination will result in the use of 20% less laser power, preferably 30% less laser power, more preferably more than 50% less laser power, and in some cases more than 75%, 90% or even 99% less laser power to achieve the same illumination intensity at the desired locations, e.g., the signal sources. As will be appreciated, the smaller the discrete illumination spot size, e.g., the more targeted the illumination, the greater the susceptibility of the system to alignment and drift issues, and calibration efforts will need to be increased.
[0057] In addition to the advantages of reduced autofluorescence, as set forth above, targeted illumination also provides benefits in terms of reduced laser power input into the system which consequently reduces the level of laser induced heating of reaction regions.
[0058] In another preventive approach, an overall optical system or one or more components through which the excitation illumination passes, may be treated to reduce the amount of autofluorescence background noise generated by the system components. By way of example, in an overall optical system, e.g., as schematically illustrated in FIG. 1 , illumination may be applied to the system that results in a photobleaching of some or all of the elements of the various components that are fluorescing under normal illumination conditions. Typically, this will require an elevated illumination level relative to the normal analytical illumination conditions of the system. Photobleaching of the optical components may be carried out by exposing the optical train to illumination that is greater in one or both of intensity or power and duration. Either or both of these parameters may be from 2×, 5×10× or even greater than that employed under conventional analysis conditions. For example, exposure of the optical train to the excitation illumination for a prolonged period, e.g., greater than 10 minutes, preferably greater than 20 minutes, more preferably greater than 50 minutes, and in some cases greater than 200 or even 500 minutes, can yield substantial decreases in autofluorescence background noise emanating from the system components. In one particular exemplary application, a 20 mW, 488 nm laser can be used to illuminate the overall system for upwards of 20 hours in order to significantly reduce autofluorescence from the components of such system. FIG. 6 shows a plot of autofluorescence counts in a system illuminated with a 20 mW 488 nm laser, following exposure of the optical train to ‘burn in’ illumination from a 7.5 mW laser at 488 nm from 0 to 1000 minutes, followed by illumination from a 162 mW laser at 488 nm from 1000 to 4600 minutes. Alternatively or additionally, other illumination sources may be employed to photobleach the optical components, including, e.g., lasers of differing wavelengths, mercury lamps, or the like. As will be appreciated, the photobleaching of the optical components may be carried out at a targeted illumination profile, e.g., a relatively narrow wavelength range such as 488 nm laser illumination, or it may be carried out under a broader spectrum illumination, depending upon the nature of the components to be photobleached and the underlying cause of the autofluorescence.
[0059] In other preventive approaches to autofluorescence mitigation, the present invention also utilizes optical elements in the optical train or the overall system that are less susceptible to generating autofluorescence background noise. In particular, it has been determined that a substantial amount of autofluorescence from more complex optical systems derives from coatings applied to the optical components of the system, such as the coatings applied to dichroic filters and objective lenses. As a result, it will be appreciated that additional gains in the reduction of autofluorescence can be obtained through the selection of appropriate optical components, e.g., that have reduced autofluorescence. For example, in selecting an objective lens, it will typically be desirable to utilize an objective that provides a reasonably low ratio of autofluorescence to illumination, as determined on a photon count ratio. For example, in the case of a variety of objective lenses, this ratio has been determined at, e.g., 1.5×10 −10 and 3.2×10 −10 for Olympus model objective lenses UIS2Fluorite 60× Air objective and 40× Air Objective, respectively. Conversely, objectives that have been selected or treated to have reduced autofluorescence will typically have a ratio that is greater than this, e.g., greater than 1×10 −10 . By way of example, an Olympus model UIS1 APO 60× Air Objective provided a ratio of 6×10 −11 following a photobleaching exposure as described above.
[0060] As noted above, selection of components to fall within the desired levels of autofluorescence will in many cases select for components that have fewer or no applied coating layers, or that have coating layers that are selected to have lower autofluorescence characteristics under the particular applied illumination conditions. Of particular relevance to the instant aspect is the selection of dichroic filters that have been selected to have lower autofluorescence deriving from their coatings, either through selection of coating materials or use of thinner coating layers.
III. Prevention of Detection of Autofluorescence
[0061] In an alternative or additional aspect, the invention is directed to a remedial approach to background signal levels, e.g., that reduce the amount of background signal or autofluorescence that is detected or detectable by the system. Typically, this aspect of the invention is directed to filtering signals that are derived from the signal sources or arrays in such a way that highly relevant signals, e.g., those from the signal sources and not from irrelevant regions, are detected by the system. As will be appreciated, this aspect of the invention may be applied alone, or in combination with the preventive measures set forth above, in order to maximize the reduction of the impact of background signal levels.
[0062] In the context of one aspect of the invention, it has been determined that a large amount of the autofluorescence background noise constitutes “out of focus” fluorescence, or fluorescence that is not within the focal plane of the system when analyzing a given reaction region or regions. For example, autofluorescence that derives from the substrate portion of the overall systems of the invention, e.g., substrate 102 in FIG. 1 , derives from locations in the substrate that are outside of the focal plane of the optical system. In particular, where the optical system is focused upon the back surface of the substrate, the autofluorescence that derives from the entirety of the thickness of the substrate, from the cladding layer above the back surface of the substrate, or from other points not within the focal plane of the system, will generally be out of focus. Likewise, autofluorescence from optical components of the system that are subjected to excitation illumination also are typically not within the focal plane of the instrument. Such components include, for example and with reference to FIG. 1 , objective lens 110 , and dichroic 108 . Because these components transmit the full excitation illumination, they are more prone to emitting autofluorescence. However, the majority of this autofluorescence will be out of the focal plane of the system.
[0063] Accordingly, in at least one aspect, the invention employs a spatial filter component to filter out autofluorescence that is out of the focal plane of the objective lens. One example of such a spatial filter includes a confocal mask or filter placed in the optical train. An example of an optical train including such a confocal filter is schematically illustrated in FIG. 5 . As shown, an objective lens 502 is positioned adjacent to a substrate, such as zero mode waveguide array 504 having the reaction regions of interest disposed upon it, so as to collect signals emanating from the substrate, as well as any autofluorescence that emanates from the substrate. The collected fluorescence is then focused through a first focusing lens 506 . A confocal mask 508 is placed in the focal plane of the first focusing lens 506 . Spatially filtered fluorescence that is passed by the confocal mask is then refocused through a second focusing lens 510 and passed through the remainder of the optical train. As shown, this includes a wedge prism 512 to spatially separate spectral components of the fluorescence, and third focusing lens 514 , that focuses the image of the fluorescence derived from the focal plane of the objective 502 , onto a detector, such as EMCCD 516 . By placing the confocal mask in the focal plane of the first focusing lens 506 , autofluorescence components that are out of the focal plane of the objective lens (and thus not focused by the focusing lens at the confocal mask 508 ) will be blocked or filtered, and only fluorescence that is in the focal plane, e.g., fluorescent signals and any autofluorescence that exists in the focal plane, will be passed and imaged upon the detector 516 , and detected. In comparative experiments, autofluorescence background signals were reduced approximately 3 fold through the incorporation of a confocal mask, in both two and three laser systems.
[0064] FIG. 6 provides an illustration of the effects of out of focus autofluorescence as well as the benefits of a confocal mask in reducing such autofluorescence. In particular, FIG. 6 shows a plot of autofluorescence levels as a function of the location of the image of the autofluorescence on an EMCCD detector, from a substrate that was illuminated with four illumination lines at 488 nm. As shown, the upper plot 602 corresponds to autofluorescence image from 4 illumination lines, but in the absence of a confocal mask filtering the out of focus components. The 4 peaks ( 604 - 610 ) correspond to the elevated autofluorescence at the illumination lines on the substrate while the baseline corresponds to the overall global autofluorescence across the remainder of the substrate. By contrast, inclusion of a confocal mask provides a substantial reduction in the amount of the out of focus autofluorescence from the system. In particular, the lower plot 612 , reflects the confocally filtered traces through a number of different slit sizes, where each aggregate peak ( 614 - 648 ) corresponds to the position of the slits in the confocal masks used. As can be seen, peaks 628 - 634 correspond to the location of the illumination lines, and as such have a higher amount of in focus autofluorescence. The remaining peaks also represent autofluorescence that is in the focal plane and thus not filtered by the confocal mask. FIG. 7 shows an expanded view of the various plots with illumination at 633 nm, with the upper plot reflecting an unfiltered level of autofluorescence imaged at a given position on the detector, while the lower plots reflect the autofluorescence at the same position but filtered using confocal masks having slit sizes of 60 nm, 55 nm, 50 nm, 45 nm, 40 nm, and 30 nm. The decreasing size of the autofluorescence peak is correlated to the reduction in the dimensions of the slit in the confocal mask used.
[0065] Notwithstanding this in focus component, it can be easily seen that the provision of the confocal mask provides a significant reduction in the overall autofluorescence that is detected (as indicated by the area under each of the two plots). As noted, the confocal mask used in the example shown in FIG. 6 employed confocal slits for a linear illumination profile. It will be appreciated that alternative mask configurations may be employed as well, such as the use of arrayed pin holes in the confocal mask, in order to provide arrayed spot or targeted illumination as discussed elsewhere herein.
[0066] Other additional approaches to reduction of generated autofluorescence include spectral filtering of autofluorescence noise, through the incorporation of appropriate filters within the optical train, and particularly the collection aspects of the optical train. It has been observed that a substantial amount of autofluorescence signal in a typical illumination profile, e.g., in a wavelength range of from about 720 nm to about 1000 nm, falls within spectral ranges that do not overlap with desired detection ranges, e.g., from about 500 nm to about 720 nm. As such, elimination of at least a portion of autofluorescence noise may be accomplished by incorporating optical filters that block light outside of the desired range, e.g., long or short pass filters that block light of a wavelength greater than about 720 nm or less than about 500 nm. Such filters are generally made to order from optical component suppliers, including, e.g., Semrock, Inc., Rochester N.Y., Barr Associates, Inc., Westford, Mass., Chroma Technology Corp., Rockingham Vt.
[0067] Although described in some detail for purposes of illustration, it will be readily appreciated that a number of variations known or appreciated by those of skill in the art may be practiced within the scope of present invention. To the extent not already expressly incorporated herein, all published references and patent documents referred to in this disclosure are incorporated herein by reference in their entirety for all purposes. | Mitigative and remedial approaches to reduction of autofluorescence background noise are applied in analytical systems that rely upon sensitive measurement of fluorescent signals from arrays of fluorescent signal sources. Such systems are for particular use in fluorescence based sequencing by incorporation systems that rely upon small numbers or individual fluorescent molecules in detecting incorporation of nucleotides in primer extension reactions | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dye compositions and the use thereof, more particularly to navy blue reactive dye compositions and the use thereof for dyeing cellulose materials.
2. Description of Related Art
Reactive dyestuffs generally refer to dyestuff molecules containing reactive functional groups that react with fiber. The reactive functional groups can react to the hydroxyl group of cellulose fiber or the amide, imino and carboxylic acid group in animal and polyamide synthetic fibers. Thus, with the covalent bonding between the dyestuffs and fibers, the purpose of dying is achieved. For example, U.S. Pat. No. 4,703,112, U.S. Pat. No. 5,484,899, and GB. Pat. No. 1,353,899 disclosed fiber reactive dyestuffs, which are applied by exhaustion, printing or continuous dyeing.
The reactive dyestuffs for dyeing or printing cellulose fibers or cellulose containing fibers need the properties of leveling, reproducibility, solubility, fastness etc to a particularly high quality.
However, the reactive dyestuffs available presently are short of a navy blue dye having superior light fastness such that the dyed material shows a poor light fastness. Take the blue dyestuffs for example, it is known that anthraquinone dyestuff is excellent in various fastness properties, nevertheless, anthraquinone dyestuff is hard to achieve in matching middle or dark colors for it has a brighter color than others.
The present invention provides dye compositions that have both excellent light fastness and superior perspiration-light fastness through the combination of anthraquinone dyestuff with other dyestuffs. In addition to the various fastness properties that already exist, the dye compositions of the present invention are economic in dyeing middle to dark colors.
SUMMARY OF THE INVENTION
The present invention provides a dye composition, which has both excellent light fastness and perspiration-light fastness. The dye compositions are economic in dyeing middle to dark colors and can achieve various fastness properties. When combined with red and yellow dyestuffs that also have good light fastness, the composition containing the three primary colors not only overcomes the problems of color fading and discoloration, but also exhibits outstanding light fastness and perspiration-light fastness.
The dye composition of the present invention includes:
(a) a blue anthraquinone dye of the following formula (I):
wherein Y is —CH═CH 2 , —CH 2 CH 2 Cl, or —CH 2 CH 2 OSO 3 H; and
(b) a gray-black azo dye of the following formula (II):
wherein Y is defined as the above.
The present invention also provides a method for dyeing or printing fiber materials containing hydroxyl or amino groups, in particular for cellulose fiber materials, which use a solution containing a dye composition aforementioned to dyeing fiber materials, wherein said cellulose fiber material is cotton.
The dye compositions of the present invention are suitable for dyeing and printing materials that contain either cellulose fibers, such as cotton, artificial cotton, linen, and artificial linen, or synthetic polyamide, such as wool, silk, and nylon. The materials obtained through utilizing the dye compositions above-mentioned show excellent properties, especially in light fastness and perspiration-light fastness.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The dye compositions of the present invention combining with red and yellow dyestuffs form a three-primary-color composition, which overcomes the color fading and discoloration problems, and exhibits outstanding properties of light fastness and perspiration-light fastness.
wherein Y′ is —CH═CH 2 or —CH 2 CH 2 OSO 3 H. Most preferably it is the blue anthraquinone dye of the following formula (I-1)
The synthesis of formula (II) may refer to UK Patent No. 1,162,144. Preferably the compound of formula (II) is the gray-black azo dye of the following formula (IIa)
wherein Y is —CH═CH 2 , —CH 2 CH 2 Cl, or —CH 2 CH 2 OSO 3 H. More preferably it is the gray-black azo dye of the following formula (IIb)
wherein Y′ is —CH═CH 2 or —CH 2 CH 2 OSO 3 H. Most preferably it is the gray-black azo dye of the following formula (II-1)
The compositions of the present invention can be prepared in several ways. For example, the dye components can be prepared separately and then mixed together to make powder, granular and liquid forms, or a number of individual dyes may be mixed according to the dyeing recipes in a dyehouse. The dye mixtures of the present invention can be prepared, for example, by mixing the individual dyes. The mixing process is carried out, for example, in a suitable mill, such as a ball mill or a pin mill, or kneaders or mixers.
If necessary, the dye composition of the present invention may contain inorganic salts (e.g. sodium chloride, potassium chloride and sodium sulfate), dispersants (e.g. β-naphthalenesulfonic acid-formaldehyde condensation products, methylnaphthalenesulfonic acid-formaldehyde condensation products, acetylaminonaphthol based compounds, etc.), non-dusting agents (e.g. di-2-ethylhexyl terephthalate, etc.), pH buffering agents (e.g. sodium acetate, sodium phosphate, etc.), water softeners (e.g. polyphosphate, etc.), well-known dyeing assistants, etc.
The form of the dye composition of the present invention is not critical. The dye composition can be powders, granules or liquids form.
For the convenience of description, the compounds are depicted as free acids in the specification. When the dyestuffs of the present invention are manufactured, purified or used, they exist in the form of water soluble salts, especially alkaline metallic salts, such as sodium salts, lithium salts, potassium salts or ammonium salts.
The dye compositions of the present invention can be used to dye a wide range of fiber materials, especially for cellulose fiber materials. These dye compositions can also be used to dye natural cellulose fibers and regenerated cellulose fibers, such as cotton, linen, jute, ramie, mucilage rayon, as well as cellulose based fibers.
The dyeing by using the dye compositions of the present invention can be any generally used process. Take exhaustion dyeing for example, it utilizes either inorganic neutral salts such as sodium sulfate anhydride and sodium chloride, or acid chelating agents such as sodium carbonate and sodium hydroxide, or both of them. The amount of inorganic neutral salts or base is not of concern, and can be added once or separately. In addition to that, it is optional to add traditionally used dyeing assistants, such as leveling agents and retarding agents. The temperature of dyeing ranges from 40° C. to 90° C., and preferably 50° C. to 70° C.
A cold batch-up dyeing method firstly carried out pad-dyeing by using inorganic neutral salts such as sodium sulfate anhydride and sodium chloride, and acid chelating agents such as sodium silicate and sodium hydroxide, and then the materials were rolled up to start dyeing.
Continuous dyeing is single batch-up dyeing, which mixes a well-known acid chelating agent such as sodium carbonate or sodium bicarbonate with a pad-dyeing liquor, and pad-dyeing is carried out. After that, the dyed materials are dried or evaporated to fix the color, and then the dyed materials are treated with well-known inorganic neutral salts such as sodium sulfate anhydride and sodium chloride, and acid chelating agents such as sodium hydroxide or sodium silicate. Preferably, the treated materials are dried or evaporated again by common methods to finally fix the color.
Among textile printing methods, a one-way printing method utilizes a printing paste containing an acid chelating agent such as sodium bicarbonate to print the materials, thereafter the printed materials are dried or evaporated to fix the color. However, a two-phase printing method includes printing by printing paste and fixing color by soaking the printed materials in high temperature (90° C. or above) solution containing inorganic neutral salts (like sodium chloride) and acid chelating agents (like sodium hydroxide or sodium silicate). The dyeing methods of the present invention are not restricted to the aforementioned methods.
The dye compositions of the present invention not only have excellent fixative ability and build up, but are also provided with good properties in darkness of colors, levelness, cleaning, solubility, and exhausting and fixative extent. Therefore, exhaustion dyeing at a low temperature and pad dyeing can be carried out in a short period of time. The dyed products are highly fixative and minimally damaged after soap cleaning.
The dye composition of the present invention exhibits superior hue and excellent cellulose-dyestuff combination stability in dyeing cellulose fiber materials, no matter the dyeing environment is acid or base. Besides, the dyed cellulose fiber materials have good properties of light fastness, perspiration-light fastness, and wet fastness, e.g. clean fastness, water fastness, sea water fastness, cross-dyeing fastness, and perspiration fastness, as well as fastness of wrinkling, ironing, and friction. Therefore, it is a valuable reactive navy blue dye for cellulose fibers in the dyeing industry. The dye compositions have the materials dyed with excellent properties and resulted in outstanding light fastness and perspiration-light fastness. Owing to the change of the demand of the market, the general reactive dyestuff will not meet the requirements of the extremely light color and mélange market any more. The dye compositions of the present invention exhibit better perspiration-light fastness in light color, and particularly in mélange of extremely light color, which leads to fit in with the requirements and expectations of market.
Many examples have been used to illustrate the present invention. The examples sited below should not be taken as a limit to the scope of the invention. In these examples, the compounds are represented in the form of dissolved acid. However, in practice, they will exist as alkali salts for mixing and salts for dyeing.
In the following examples, quantities are given as parts by weight (%) if there is no indication. The relationship between weight parts and volume parts are the same as that between kilogram and liter.
EXAMPLE 1
The blue anthraquinone dye of formula (I) (55 weight parts) and the gray-black azo dye of formula (II) (45 weight parts) were prepared, which were then mixed completely to form a dye composition.
EXAMPLE 2-3
The preparation methods of Examples 2 and 3 were the same as Example 1, except the ratios of raw material were different, which are listed in table 1 below.
TABLE 1
Example
Dye of formula (I-1)
Dye of formula (II-1)
Example 2
30 parts
70 parts
Example 3
70 parts
30 parts
COMPARATIVE EXAMPLE 1-4
Compare the dyeing properties of the dye compositions of the present invention with the prior dyestuffs, which have large sales volume and wide purpose in the marketplace, like reactive black B, reactive blue BRF, or reactive navy blue FBN.
The preparation methods of Comparative examples 1 to 4 were the same as Example 1, except the kinds of raw materials and the ratios of each raw material were different, which are listed in table 2 below.
TABLE 2
Dye of
Dye of
Reactive
formula
formula
Reactive
Reactive
Navy Blue
Example
(I-1)
(II-1)
Black B
Blue BRF
FBN
Comparative
60 parts
—
40 parts
—
—
example 1
Comparative
—
—
40 parts
60 parts
—
example 2
Comparative
—
100 parts
—
—
—
example 3
Comparative
—
—
—
—
100 parts
example 4
The dye of comparative Example 3 is fully composed of the dye of formula (II-1) in order to show the dyeing properties without the existence of the dye of formula (I-1). Besides, use of reactive navy blue FBN acts as the dye of Comparative example 4 to demonstrate the perspiration-light fastness of the present invention in ultra-light color mixing.
TESTING EXAMPLE 1
Light Fastness Testing by Exhaustion Dyeing
The light fastness of each dye composition of Example 1 and Comparative example 1-4 was tested. Also their mixtures composed of the three primary colors, i.e. yellow, red, and blue, were tested. The detailed description is as the following.
First, three dye liquors were prepared, wherein each respectively had a concentration of 0.1%, 0.5%, and 1.0% on the weight of the fabric (o.w.f). After that, inorganic neutral salt was added, and then dyeing of the un-mercerized cloths made of pure cotton was started. The un-mercerized cotton cloths were soaked in the dye liquors. At the same time, dyeing of the dyestuffs was started at 60° C. and then the dyestuffs started diffusing to adhere the cloths with the aid of a horizontal shaker, which is followed by adding an alkali agent that made the dyestuffs react with fiber completely to achieve firm adherence. The resulting dyed cloths were water cleaned, soap washed, and tumble-dried to form finished products.
The obtained products aforementioned were tested in a light fastness machine, in which the samples and blue color labels were put and illuminated by a Xenon-Arc Lamp Light (ISO 105-B02), wherein the blue color labels were classified into eight degrees, i.e. L1 to L8. When the color fading of DE=1.7±0.3 occurred on the sample, the illuminating of the samples was stopped. The results are summarized in table 3 below.
TABLE 3
Concentration of
Degree of
Example
dye liquors (o.w.f)
color labels
Example 1
0.1%
4
0.5%
4-5
1.0%
5-6
Comparative example 1
0.1%
3
0.5%
3-4
1.0%
4
Comparative example 2
0.1%
2-3
0.5%
2-3
1.0%
3
Comparative example 3
0.1%
3-4
0.5%
4
1.0%
5
Comparative example 4
0.1%
3
0.5%
3-4
1.0%
4
Currently, the red dyestuff-Everzol Red LF-2BL™ (Everlight Chemical Inc., Taiwan, ROC) and the yellow dyestuff-Everzol Yellow 3RS™ (Everlight Chemical Inc., Taiwan, ROC) have large sales volumes and wide purposes in the marketplace, and are the main products for color mixing. In the present invention, Everzol Red LF-2BL™ (Everlight Chemical Inc., Taiwan, ROC) and Everzol Yellow 3RS™(Everlight Chemical Inc., Taiwan, ROC) were chosen to be mixed with the navy blue dye compositions of the present invention to show the performance of color mixing of the three primary colors, i.e., yellow, red, and blue of the present invention. The resulted are listed in table 4.
TABLE 4
The composition of dye
mixture composed of
three primary colors
Concentration of
Degree of color
(yellow, red, and blue)
dye liquors (o.w.f)
labels
{circle around (1)}Example 1
0.1%
4-5
{circle around (2)}Everzol Red LF-2BL ™
0.5%
5-6
{circle around (3)}Everzol Yellow 3RS ™
1.0%
6
After the illuminating testing, the cloths were measured by a DATA MATCH computer metering system to find the difference of dyeing degree and color fading. The higher degree of dyeing and the lesser extent of color fading are preferred. Under high energy illumination, the light fastness of the dye composition of example 1, i.e. the dye composition of the present invention, is above degree 5, which proves that the dye compositions of the present invention have a high degree of dyeing, a low extent of color fading, and good light fastness. Also, among the color mixing compositions containing the yellow, red, and blue dyes, the light fastness of the composition containing the dye of example 1 attains degree 5, which shows that the dye composition of the present invention has higher degree of dyeing, a lesser extent of color fading, and better light fastness than the existing art.
TESTING EXAMPLE 2
Perspiration-Light Fastness Testing by Exhaustion Dyeing
The dyeing steps were the same as testing example 1, except that the dyed cloths were soaked in artificial perspiration solution (ISO-105-E04), in which the acid solution and alkali solution are prepared as listed in table 5 below.
TABLE 5
Artificial perspiration solution (ISO-105-E04)
Acid solution
Alkali solution
C 6 H 9 O 2 N 3 .HCl.H 2 O
0.5 g/l
C 6 H 9 O 2 N 3 .HCl.H 2 O
0.5 g/l
NaCl
5.0 g/l
NaCl
5.0 g/l
NaH 2 PO 4 .2H 2 O
2.2 g/l
Na 2 HPO 4 .2H 2 O
2.5 g/l
Adjusting pH to 5.5
Adjusting pH to 8.0
After the dyed cloths were fully moistened in the artificial perspiration solution, the pick up of the dyed cloths was controlled to be 100%, and then the Xenon-Arc Lamp Light (ISO 105-B02) illuminating test was proceeded with. The eight-degree blue labels and cloth samples were put into the light fastness machine together to be illuminated, wherein the cloth samples were illuminated from L1 to L8. The illuminations were stopped when a color fading of DE=1.7±0.3 occurred on the cloth samples. The results are summarized in tables 6 and 7 below.
TABLE 6
Acid perspiration light
Alkali perspiration light
Concentration of dye
Concentration of dye
liquors (o.w.f)
liquors (o.w.f)
0.1%
0.5%
1.0%
0.1%
0.5%
1.0%
Example 1
3-4
4
5
2-3
3
3-4
Comparative
2-3
3
3-4
1-2
2
2-3
example 1
Comparative
2
2
2-3
1-2
1-2
2
example 2
Comparative
3
3-4
4-5
2
2
2-3
example 3
Comparative
3
3
3-4
2
2
2-3
example 4
TABLE 7
Acid Perspiration
Alkali Perspiration
Color mixing composition
Light
Light
composed of the three
Concentration of
Concentration of dye
primary colors-yellow, red,
dye liquors (o.w.f)
liquors (o.w.f)
and blue
0.1%
0.5%
1.0%
0.1%
0.5%
1.0%
{circle around (1)}Example 1
4-5
5
5
4
4
4-5
{circle around (2)}Everzol Red LF-2BL ™
{circle around (3)}Everzol Yellow 3RS ™
The samples dyed by the above-mentioned Example 1, Comparative examples 1 to 4, and mixture compositions of the three primary colors, i.e. yellow, red, and blue, were illuminated by light and then the difference of dyeing ability and the extent of color fading were compared by using the DATA MATCH computer metering system. The higher degree of dyeing and the lesser extent of color fading are preferred. By illuminating at a high energy level, the perspiration-light fastness of the dye composition of example 1, i.e. the dye composition of the present invention, is above degree 3, which means that the dye composition of the present invention has a higher degree of dyeing, a lesser extent of color fading, and a better perspiration-light fastness compared to prior arts. Also, among the color mixing compositions composed of dyes of the three primary colors, i.e. yellow, red, and blue, the perspiration-light fastness of the composition containing the dye of example 1 achieved degree 4, which revealed that the dye composition of the present invention has higher degree of dyeing, a lesser extent of color fading, and a better perspiration-light fastness than the prior art.
TESTING EXAMPLE 3
Perspiration-Light Fastness Testing by Using the Cold Printed Batch-Up (C.P.B.) Dyeing Method
The dye composition of example 1 was further proceeded with cold printed batch-up dyeing. Similarly, the C.P.B dyeing test was carried out by using the single color dye and the mixing color dyes composed of the three primary colors, i.e. yellow, red, and blue. The preparing method and the results will be described in the following description.
First, four dye liquors were prepared, wherein each of dye liquor respectively had a concentration of 5, 10, 20, and 40 g/l, and a volume of 80 ml, which was followed by adding 20 ml of an alkali solution and high-speed mixing. The amounts of the alkali solutions are listed in the following table 8.
TABLE 8
Concentration of dye liquor, g/l
Amount of alkali solution
1-20
20-40
40-70
70
NaOH(38° B'e), ml/l
15
20
25
30
Na2SiO3(48° B'e), g/l
100
The mercerized cotton twill was dyed with the above-mentioned dye liquors, wherein the twill was soaked in the dye liquors to achieve the adhesion and diffusion of the dyestuffs. The pick up of the mercerized cotton twill was controlled to be 70% and the temperature of dye liquors was controlled to be 25° C. After that, pad-dye in a printed dyeing testing machine was carried out, and then the pad-dyed cloths were rolled up at room temperature for 4 hours. Afterwards, the dyed cloths were water cleaned, soap washed, and tumble-dried to become finished products.
The dyed materials were soaked individually in an artificial perspiration solution prepared as listed in table 5. After the dyed materials were completely damped, the Xenon-Arc Lamp Light (ISO 105-B02) illumination test was proceeded with at a controlled pick up of 100%. The eight-degree blue labels and dyed samples were illuminated in a light fastness machine, wherein the blue labels were classified into degrees ranging from L1 to L8. When the color fading of DE=1.7±0.3 occurred on the samples, illuminating of the samples was stopped. The results are summarized in tables 9 and 10 below.
TABLE 9
Acid
Alkali
perspiration light
perspiration light
Concentration of
Concentration of
dye liquors (g/l)
dye liquors (g/l)
5
10
20
5
10
20
Example 1
4-5
5
5-6
3-4
4
5
TABLE 10
Acid Perspiration
Alkali Perspiration
Color mixing composition
Light
Light
composed of the three
Concentration of
Concentration of
primary colors-yellow,
dye liquors (g/l)
dye liquors (g/l)
red, and blue
10
20
40
10
20
40
{circle around (1)}Example 1
4-5
5
5
4
5
5
{circle around (2)}Everzol Red LF-2BL ™
{circle around (3)}Everzol Yellow 3RS ™
The cloth samples dyed by the above-mentioned example 1 and mixture compositions of the three primary colors, i.e. yellow, red, and blue, were soaked in artificial perspiration solutions, and tested by illuminating using the DATA MATCH computer metering system in order to compare the difference of dyeing ability and the extent of color fading. The higher degree of dyeing and the lesser extent of color fading are preferred. By illuminating at a high energy level, the perspiration-light fastness of the dye composition of example 1, i.e. the dye composition of the present invention, is above degree 4, which means that the dye composition of the present invention has a higher degree of dyeing, a lesser extent of color fading, and better perspiration-light fastness than the prior art. Also, among the color mixing compositions composed of dyes of the three primary colors, i.e. yellow, red, and blue, the perspiration-light fastness of the composition containing the dye of example 1 was above degree 5, which exhibited that the dye composition of the present invention has a higher degree of dyeing, a lesser extent of color fading, and a better perspiration-light fastness than the prior art.
Generally speaking, the color matching of the dyestuffs is through mixing of the three primary colors, i.e. yellow, red, and blue. In particular, for the color matching of the middle to dark colors, the navy blue component faded and changed quite obviously after exposure to light in the prior art due to the lower light fastness of the navy blue component comparing with that of yellow and red ones. The dye compositions of the present invention have improved the light fastness of the navy blue dyestuff. In particularly, the ultra-light color collocated by the dye compositions of the present invention, the red dyestuff-Everzol Red LF-2BL™ (Everlight Chemical Inc., Taiwan, ROC), and the yellow dyestuff-Everzol Yellow 3RS™ (Everlight Chemical Inc., Taiwan, ROC) is qualified to have less variation in color after exposure to light. Besides, the color fading of the sample having the ultra-light color above-mentioned is the same as its variation in color. As the dye compositions of the present invention are used with the red dyestuff-Everzol Red LF-2BL™ (Everlight Chemical Inc., Taiwan, ROC) and the yellow dyestuff-Everzol Yellow 3RS™ (Everlight Chemical Inc., Taiwan, ROC), the dye mixture not only achieves a fastness above 4, but also exhibits the outstanding properties of the present invention as well as the higher efficiency thereof.
The testing results of Examples 2 and 3 of the present invention in the tests referring to testing Examples 1 to 3 above-mentioned are also compatible with those of Example 1.
The dye compositions of the present invention are suitable for common uses and have excellent properties. They can be applied to cellulose fibers by general dyeing methods, such as exhaustion dyeing, printed-dyeing, or continuous dyeing that are commonly used in the dyeing of reactive dyestuffs
The dye compositions of the present invention are water-soluble dyestuffs that have a highly commercial value. The dye compositions of the present invention can manufacture dyed materials that exhibit excellent properties in all aspects, especially in cleaning, darkness of colors, levelness, light fastness, and perspiration-light fastness.
Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed. | A dye composition is disclosed, which comprises a blue anthraquinone dye of the following formula (I)
wherein Y is —CH═CH 2 , —CH 2 CH 2 Cl or —CH 2 CH 2 OSO 3 H; and a gray-black azo dye of the following formula (II)
wherein Y is defined as the above. The dye compositions of the present invention have good stability and build-up property. The dye compositions are suitable for dyeing and printing materials that contain either cellulose fibers, such as cotton, artificial cotton, linen, and artificial linen, or synthetic polyamide, such as wool, silk, and nylon. The materials obtained through treatment with the dye compositions aforementioned show excellent properties, especially in wash-off, level-dyeing, build-up, light fastness and perspiration-light fastness. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates in general to certain new and useful improvements in ladder stabilizing apparatus and more particularly, to an improved ladder stabilizing apparatus which is adjustably positionable so as to obtain an optimum stabilizing position and is also adjustably positionable to removably receive a ladder.
[0003] 2. Brief Description of Related Art
[0004] Ladders are frequently used in a variety of occupations such as roofing occupations, construction work, television antenna installation and the like. There are frequent needs for a homeowner to even use a ladder for access to a roof structure of a house or other building for a variety of maintenance or repair purposes.
[0005] Presently, and while there have been several proposals for prior art ladder stabilizing apparatus, there is no effective apparatus which will stabilize a ladder against a lateral shifting movement or tipping movement in an arcuate path away from the building itself. As would be anticipated, there is a large number of accidents, sometimes resulting in vary substantial injury and death occurring from parties using ladders and where the ladder either slips from the building, tips arcuately away from the building or shifts laterally with respect to the building. As a result, those individuals who frequently use ladders also encounter higher insurance premiums because of the potential for injury.
[0006] There are various governmental requirements for ladder manufacturers and ladder users which are designed to improve safety and reduce possibilities of accidents and injuries arising from the slippage of a ladder or falling of f a ladder. One of these requirements is to adhere the top of the ladder to a portion of the roof of the building. Typically, this involves the tying of the ladder with a rope to some fixed structure on the building. However, the rope itself presents a hazard in that the party using the ladder can literally trip over the rope if he or she is not careful, thereby resulting in severe accidents, particularly if that party should fall off of the roof.
[0007] There are a large number of ladder stabilizing apparatus of various types which have been proposed for holding a ladder relative to a building structure in order to preclude any slidable movement of the ladder or tipping of the ladder which could thereby not only damage the ladder, and perhaps the building structure, but cause serious injury to a user thereof. Most of the prior art ladder stabilizing apparatus usually rely upon some means to physically secure the ladder to a side wall of a building and hence, they are complex, time consuming and difficult to use.
[0008] Representative of prior art used for securing a ladder to a side wall of a building is U.S. Pat. No. 2,903,086, to Chubbs, for ladder attachment. The Chubbs patent includes an attachment which has an appearance somewhat similar to the device of the instant application, as hereinafter described. However, Chubbs relies upon an elongate bar or frame having a pair of outwardly extending arms which engage a side wall of a building. In effect, the forces applied to the building are almost all horizontal in nature. Contrariwise, the device of the present invention, as hereinafter described, applies a substantial vertical force so as to actually stabilize the apparatus against the building and on the building.
[0009] There are other U.S. patents which also teach of securing a ladder to a side wall of a building. Representative of one of these systems is U.S. Pat. No. 3,713,510 to O'Dell. This apparatus requires securement to the wall of the building before it can actually be used and therefore, suffers the disadvantages mentioned above.
[0010] There are several ladder stabilizing apparatus which have arms which are designed to engage a vertically disposed wall of the building and thereby attempt to preclude lateral displacement of the ladder. Representative of this type of structure is U.S. Pat. No. 5,113,973 to Southern. However, it can be observed that this type of device does not actually preclude a lateral shifting movement of the ladder and has no means whatsoever to preclude a tipping of the ladder away from the building.
[0011] Other ladder stabilizing apparatus employ some means for engaging a roof structure or otherwise, a portion of a building having a generally upwardly presented surface. However, and here again, these apparatus do not actually secure the ladder. Representative of this type of stabilizing apparatus is U.S. Pat. No. 5,180,032 to Hidalgo and U.S. Pat. No. 4,949,810 to Dwinell. In each of these references, there is nothing to physically hold the ladder to the building itself.
[0012] Accordingly, there has been a need for a ladder stabilizing apparatus which will stabilize a ladder with respect to a building structure against a lateral shifting movement to the side or a tipping movement in a arcuate path away from the building.
OBJECTS OF THE INVENTION
[0013] It is, therefore, one of the primary objects of the present invention to provide a ladder stabilizing apparatus which prevents sidewise lateral movement of a ladder with respect to a building structure and an arcuate tipping movement of a ladder away from the building structure.
[0014] It is another object of the present invention to provide a ladder stabilizing apparatus of the type stated which provides for adjustable engagement of a ladder in order to accommodate different sizes and types of ladders.
[0015] It is a further object of the present invention to provide a ladder stabilizing apparatus of the type stated which includes adjustably positionable arms in order to engage a generally upwardly presented surface of a portion of a roof structure on a building.
[0016] It is an additional object of the present invention to provide a ladder stabilizing apparatus of the type stated which can be folded up and stored in a small compact area.
[0017] It is also an object of the prevent invention to provide a ladder stabilizing apparatus of the type stated which applies a substantial downward force vector to a roof by a pair of spaced-apart arms extending from a frame secured to the ladder, and essentially with only a small horizontal force applied to the building to thereby firmly stabilize a ladder.
[0018] It is another salient object of the present invention to provide a ladder stabilizing apparatus of the type stated which can be manufactured at a relatively low cost and which is highly safe and reliable in operation.
[0019] With the above and other objects in view, my invention resides in the novel features of form, construction, arrangement and combination of parts presently described and pointed out in the claims.
BRIEF SUMMARY OF THE INVENTION
[0020] The present invention relates to a ladder stabilizing apparatus which is adapted to stabilize a ladder with respect to a building structure against sidewise lateral movement and to also stabilize the ladder with respect to an arcuate tipping movement away from the building structure. The ladder stabilizing apparatus of the present invention is also adjustable in various ways in order to conform to the size or shape of a generally upwardly presented portion of a roof on a building structure, or otherwise to accommodate ladders of differing sizes.
[0021] The ladder stabilizing apparatus of the present invention, at least in general terms, comprises a main frame. A means for releasably coupling the frame to the side rails of a ladder is also provided, and this holds the frame to the ladder. The frame is further provided with a pair of laterally spaced apart arms adapted to extend outwardly from the frame and engage the generally upwardly presented surface on the building structure. In addition, means is provided on the frame for adjustably positioning the arms relative to the ladder in order to obtain a desired amount of stabilization relative to the building structure and the angle of the ladder relative to the building structure.
[0022] A pair of brackets also extend outwardly from the frame and constitute a means for coupling the frame to the side rails of the ladder. These brackets have generally U-shaped sections which extend around the exterior surfaces of the side rails of the ladder. Moreover, the positioning of the brackets relative to one another is adjustable so as to accommodate ladders of differing sizes. Moreover, the relative size of the bracket can be changed for accommodating ladder rails having differing sizes.
[0023] As indicated previously, the arms of the frame extend outwardly from the frame. More preferably, they extend rearwardly to engage the generally upwardly presented surface on the building structure. The arms are adjustably positionable laterally relative to the side rails of the ladder in order to adjust the amount of space between each of the arms.
[0024] The main frame of the ladder stabilizing apparatus is also pivotal relative to the vertical orientation of the ladder itself such that the main frame can be positioned at an angle relative to a true horizontal position. In this way, the arms can be used to secure the ladder to an eave or a rake of an angulated roof with a position of optimum stabilizing.
[0025] In many cases, the roof structure or other upwardly presented surface of the building against which the ladder is used is not truly flat and horizontally disposed. For example, in many roof structures, dormers exist and these dormers have angularly disposed roof walls. However, they have a substantial horizontal component, and to this extent, they are considered generally upwardly presented surfaces. Thus, the roof may have an orientation which is angularly displaced from a vertical plane toward a horizontal plane, i.e., 15° to 45° or more away from a horizonal plane. Accordingly, and in the context of the present invention, a generally upwardly presented surface does not necessarily refer to a roof or other upwardly presented surface which is absolutely horizontal.
[0026] The ladder stabilizing apparatus of this invention has, as a principle advantage, the fact that it is actually constructed so as to apply a substantial downward force vector to a building. It is actually this downward force vector which stabilizes the ladder against a sidewards tipping movement, particularly when a sidewards or lateral force is applied to the ladder. One of the serious problems in the use of ladders is that, if weight is not properly distributed on the ladder, it can tend to tip to one side or the other. When a user of the ladder climbs on the ladder, a downward force is literally applied to the roof of the building. This is due to the fact that the roof is frequently canted and the ladder is always located at an angle relative to the building, that is, it is canted relative to the building. Thus, with this substantial vertical force vector, the outwardly extending arms on the stabilizing apparatus engage the roof, and are effectively held against any tipping movement. In other words, if one should attempt to impose a force on one of the lateral sides of the ladder, that force is imposed on the roof's structure, and the ladder will not tip laterally. This is a dramatic and unobvious advantage of the stabilizing apparatus of the present invention.
[0027] This invention possesses many other advantages and has other purposes which will be made more fully apparent from a consideration of the forms in which it may be embodied. One of the forms of this apparatus and, for that matter, the associated method, is more fully described in the following description, and more fully illustrated in the accompanying drawings. However, it is to be understood that these drawings and the following detailed description are, set forth for purposes of illustrating and describing the general principles of the invention and are not to be taken in a limiting sense.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Having thus described the invention, reference will now be made to the accompanying drawings in which:
[0029] [0029]FIG. 1 is a perspective view of one embodiment of the ladder stabilizing apparatus constructed in accordance with and embodying the present invention;
[0030] [0030]FIG. 2 is a vertical sectional view taken along line 2 - 2 of FIG. 1;
[0031] [0031]FIG. 3 is a fragmentary perspective view showing a rear side of the ladder stabilizing apparatus of FIG. 1;
[0032] [0032]FIG. 4 is a perspective view of a slightly modified form of the ladder stabilizing apparatus constructed in accordance with and embodying the present invention;
[0033] [0033]FIG. 5 is a top plan view of the ladder stabilizing apparatus of FIG. 4;
[0034] [0034]FIG. 6 is a rear elevational view of the ladder stabilizing apparatus of FIG. 4;
[0035] [0035]FIG. 7 is a side elevational view of the ladder stabilizing apparatus of FIGS. 4 - 6 ;
[0036] [0036]FIG. 8 is an opposite side elevational view and showing the positioning of a ladder and an individual relative to the ladder using the ladder stabilizing apparatus of the present invention;
[0037] [0037]FIG. 9 is an enlarged top plan view of one form of ladder stabilizing apparatus constructed in accordance with and embodying the present invention;
[0038] [0038]FIG. 10 is a side elevational view of the ladder stabilizing apparatus of FIG. 9;
[0039] [0039]FIG. 11 is a perspective view of a further modified form of ladder stabilizing apparatus constructed in accordance with and embodying the present invention;
[0040] [0040]FIG. 12 is an end elevational view of the ladder stabilizing apparatus of FIG. 11 showing a folding of one of the arms relative to the frame of the apparatus;
[0041] [0041]FIG. 13 is an exploded fragmentary perspective view showing the mounting of the arm relative to the frame in the apparatus of FIGS. 11 and 12;
[0042] [0042]FIG. 14 is a front elevational view of a ladder with the ladder stabilizing apparatus employed relative to the rake of a roof;
[0043] [0043]FIG. 15 is a fragmentary front elevational view, similar to FIG. 14, and showing a different angulated position of the ladder stabilizing apparatus relative to the rake of the roof and to the ladder; and
[0044] [0044]FIG. 16 is a perspective view showing the use of the ladder stabilizing apparatus with feet mounted on the ends of the arms thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0045] Referring now in more detail and by reference characters to the drawings which illustrate several practical embodiments of the present invention, A 1 designates a ladder stabilizing apparatus, having a main frame 20 which is shown in FIG. 1 as releasibly supporting a ladder 22 , the latter of which is shown in phantom lines in FIG. 1.
[0046] The ladder with which the ladder stabilizing apparatus A of the present invention will be used generally conventional in construction and comprised of a pair of side rails 24 which are connected by horizontally extending rungs 26 extending therebetween. Some of the ladders with which the invention can be used are the so-called “telescopic” ladders of the type illustrated in FIG. 8, and as hereinafter described. Nevertheless, these telescopic ladder constructions still have a pair of spaced apart side rails connected by rungs.
[0047] The main frame 20 of the ladder stabilizing apparatus A 1 is comprised of a first frame section 30 and having an elongate leg 32 and which is generally of tubular construction. Extending outwardly from the right-hand end of the leg 32 is a telescopically adjustable leg 33 forming part of a second frame section 34 and which terminates in an integrally formed perpendicularly arranged, rearwardly struck arm 35 which is adapted to engage a generally upwardly presented surface on a building structure. The main frame 20 also comprises a second leg 36 extending outwardly from the opposite side of the elongate leg 32 and which also forms part of the second frame section 34 . In like manner, the leg 36 has a rearwardly struck arm 40 adapted for engagement with a generally upwardly presented surface of a building structure.
[0048] Due to the fact that the arms and the legs 33 and 36 are telescopically positionable with respect to the leg 32 , the pair of arms 35 and 40 are adjustably positionable relative to one another. Thus, the distance between the two arms 352 leg and 40 can be shortened or lengthened, as desired. Moreover, and by reference to FIG. 2, it can be seen that the legs 33 and 36 and hence the leg 32 is also located at a somewhat acute angle relative to a true perpendicular line. In other words, the legs 33 and 36 are inclined relative to a vertical direction due to the fact that the ladder itself is actually angularly positioned relative to a building structure. The angle of the legs 33 and 36 is approximately the same as the angle of the ladder 22 relative to a wall of a building structure, e.g. 15-18 degrees.
[0049] Each of the legs 33 and 36 are telescopically shiftable with respect to the main elongate leg 32 and extend inwardly into the leg 32 when retracted and can be pulled outwardly therefrom, such as to the position as shown in FIG. 1. In this way, a desired distance between the two arms 35 and 40 can be achieved for maximum stabilization, as aforesaid. Furthermore, and in order to hold the pair of legs 33 and 36 in the extended position, the elongate leg 32 may be provided with releasable push button latches 38 , as shown in FIG. 1, and which are provided on each of the opposite ends of the leg 32 . These push button latches 38 may function such that when depressed, as for example by a thumb, the legs 33 and 38 can be shifted inwardly or outwardly. When released, the legs will lock in a selected position. Otherwise, apertures could be formed in the leg 32 and alignable with like apertures in the legs 33 and 36 for receipt of releasable locking pins or the like.
[0050] The ladder stabilizing apparatus A 1 of the present invention also includes a pair of forwardly extended brackets 42 . Each of these brackets 42 have a generally U-shaped construction as shown in top plan view and moreover, are provided with reversely bent tabs 44 facing one another as shown in FIG. 3, and thereby provide slots 46 to receive the side rails 24 of the ladder. In this respect, and by reference to FIG. 1, it can be observed that the side rails 24 of the ladder which are generally of a rectangular shape in cross section, will fit within the rectangular recess 48 .
[0051] The position of the pair of brackets 42 , relative to one another can be changed by an adjustable positioning means 50 as best shown in FIG. 3 of the drawings. In this case, the adjustable positioning means 50 comprises bolts 52 having externally threaded sections which extent rearwardly from each of the brackets 42 , as shown. Large locking nuts 54 are threaded on these bolts 52 for retentively holding the brackets 42 in a locked position. Moreover, the bolts 52 extend through elongate slots 56 formed in the legs 32 and 38 . In this way, the distance between the brackets 42 relative to one another can be either lengthened or shorted, as may be desired. Moreover, this is convenient for purposes of mounting the ladder stabilizing apparatus.
[0052] It should be understood that the leg 38 may necessarily be provided with an elongate slot (not shown) but somewhat in alignment with the slot 56 in order to accommodate the bolts 52 if required. Furthermore, and while the adjustable positioning means is shown as including a bolt and locking nut, other forms of adjustable positioning means which would lock the brackets 42 releasibly but in a fixed position could also be employed.
[0053] FIGS. 4 - 10 of the drawings illustrate another modified form of ladder stabilizing apparatus A 2 constructed in accordance with and embodying the present invention. The ladder stabilizing apparatus A 2 comprises a frame 60 which is generally of L-shaped construction, as shown in FIG. 4 and comprises a horizontal leg 62 and a vertically disposed leg 64 . In this embodiment, a somewhat U-shaped retainer arm assembly 66 is welded to the L-shaped frame 60 and comprises a pair of laterally spaced apart arms 68 , as best shown in FIGS. 4 and 5 of the drawings. In this embodiment, the arms 68 engage the generally upwardly presented surface of the roof or other portion of the building.
[0054] The generally U-shaped retainer arm assembly 66 is shown in the embodiment in FIGS. 4 - 10 as being welded or otherwise rigidly secured to the L-shaped frame 60 . However, it should be understood that the U-shaped retainer arm assembly 66 could be secured to the frame 60 in such a manner that it is adjustably positionable at a desired angle relative to the frame 60 in order to accommodate different angles of the generally upwardly presented surface of the roof structure or other portion of a building structure.
[0055] The ladder stabilizing apparatus A 2 also has a pair of forwardly extending brackets 70 which are also of a general U-shaped construction, having reversely bent tabs 72 as best shown in FIGS. 4 and 5. In this way, the brackets 70 will accommodate the side rails of a ladder much in the same manner as the brackets 42 . The brackets 70 , however, unlike the brackets 42 , may be adjustable in their longitudinal dimension. The brackets 70 comprise a first bracket section 74 and a second bracket section 76 which are positionable relative to one another. The bracket section 74 is rigidly welded or otherwise rigidly secured to an arm 78 which is in turn secured to the L-shaped frame as hereinafter described. Another arm 80 is threadedly adjustably positionable relative to the arm 78 as shown in FIG. 5 and is also welded or otherwise secured to the bracket section 76 , again as best shown in FIGS. 4 and 5 of the drawings. Thus, by rotating a bolt 82 extending between the arms 78 and 80 which are tubular and internally threaded, it is possible to adjustably position the overall dimension between the bracket sections 74 and 76 as well as to adjustably position the overall dimension between each of the brackets 70 .
[0056] The brackets 70 are also provided with an adjustable positioning means 84 as best shown in FIGS. 5, 7 and 8 of the drawings. The adjustable positioning means is essentially identical to that adjustable positioning means 50 used in the ladder stabilizing apparatus A 1 and is therefore neither illustrated nor described in any further detail in this embodiment.
[0057] The ladder stabilizing apparatus A 2 offers the additional advantage that the brackets 70 can accommodate differing sizes of ladder rails. Moreover, it should be understood that the brackets of the ladder stabilizing apparatus A 2 could be used on the ladder stabilizing apparatus A 1 .
[0058] FIGS. 11 - 13 illustrate a further modified form of ladder stabilizing apparatus A 3 . The ladder stabilizing apparatus A 3 also comprises a frame 90 having a first frame leg 92 and a second telescopically located second frame leg 94 which operate much in the same manner as the frame legs 32 and 38 . In this respect, arms 96 and 98 are mounted on the ends of the legs in a manner hereinafter described, and can be adjustably positioned at a selective distance therebetween.
[0059] Also mounted on the frame leg 92 is a pair of outwardly extending brackets 100 which are substantially identical to the brackets 70 used in the ladder stabilizing apparatus A 2 . In this respect, the brackets 100 are also adjustably sizeable in order to accommodate the side rails of a ladder.
[0060] The arms 96 and 98 are respectively mounted to the outer ends of the legs 92 and 94 , respectively, by a hinge mechanism 102 , the details of construction of which is more fully illustrated in FIG. 13 of the drawings. The hinge mechanism 102 comprises a pair of vertically spaced apart hinge plates 104 and 106 with one of the arms, e.g., the arm 98 , fitted therebetween, as shown in FIG. 13. The hinge plates 104 and 106 are secured to the outer end of the leg 94 by means of spring pins 108 . The arm 98 is pivotally mounted on the end of the leg 94 by means of a rivet-type hinge pin 110 . Thus, and in accordance with this construction, it can be seen that the arm 98 can be folded inwardly and lie in juxtaposed relationship to the rearwardly presented face of the leg 94 .
[0061] When the arm 98 is located in the extended position as shown in FIG. 11, it can be locked in that position by means of an additional locking pin 112 inserted through the hinge plates 104 and 106 and the arm 98 .
[0062] The arms 96 and 98 can also be provided with vertically arranged screw holes 114 for accommodating wood screws or like screws 116 as shown in FIG. 11. In this way, the ladder stabilizing apparatus could be secured to the roof for a temporary period of time, as for example, when the ladder is used in movie locations and the like.
[0063] It should be understood that the arm 96 could be hingedly locked to the leg 92 with the same hinge mechanism 102 , as described in connection with the hinged mounting of the arm 98 with respect to the leg 96 . Moreover, it can be seen that by use of the hinge mechanism 102 , it is possible to fold the arms 96 and 98 in juxtaposed relationship to and against the rearwardly presented surface of the legs 92 and 94 , respectively, to thereby provide a small compact unit. Moreover, the brackets 100 can be easily removed from the frame for purposes of storage and/or transport.
[0064] One of the important aspects of the present invention is the fact that the angular position of the main frame 32 can be altered relative to the position of the ladder and the position of the roof of the structure against which the ladder is used. As indicated previously, the overall position of the brackets 70 can be adjusted relative to one another due to the fact that the bolts 50 move in elongate slots 54 . This mounting of the brackets 70 to the main frame 32 , however, also allows the brackets to be pivoted at an angle relative to the main frame. In essentially all cases, the ladder will be positioned in a generally upright orientation with respect to a building. Typically, the ladder is positioned so that it assumes an angle of roughly fifteen degrees to eighteen degrees with respect to a true vertical direction when leaning against a building. More specifically, the ladder is used with a recommended angle of about fifteen to sixteen degrees relative to a vertical direction.
[0065] The brackets 70 of the ladder stabilizing apparatus also allow the brackets to be rotated relative to the main frame so that the brackets allow the rails of the ladder to assume a true vertical orientation as shown in FIG. 14. However, this also allows the main frame 32 to be positioned at an angle relative to the rails of the ladder. Thus, and by reference to FIG. 14, it can be observed that one of the arms, such as the left-hand arm 68 is positioned above a rake 120 of a roof and the right-hand arm 68 is located under the rake of the roof. In this way, the left-hand arm 68 precludes the ladder from tipping to the right and the right-hand arm 68 precludes the ladder from tipping to the left. Thus, the ladder will be effectively locked into place on the rake of the roof.
[0066] Heretofore, most governmental standards precluded the use of positioning a ladder against the rake of a roof because of the attendant danger of the ladder tipping to one side or the other. The ladder stabilizing apparatus of the present invention overcomes that problem in that the ladder can now be effectively and safely used with the rake of a roof as well as with the eave of a roof.
[0067] [0067]FIG. 15 is a view similar to FIG. 14 and showing the potential use of the ladder stabilizing apparatus in a different position relative to the rake of the roof and relative to the ladder. This positioning merely shows the universal possibilities of locating the ladder stabilizing apparatus relative to a supporting structure in order to obtain optimum use thereof.
[0068] [0068]FIG. 16 is a fragmentary perspective view showing the use of the ladder stabilizing apparatus against the eave of a pitched roof and in a position of optimum stabilizing therefore. In this case, it can be seen that the ladder stabilizing apparatus is secured to the ladder in a position such that the arms are generally horizontally disposed.
[0069] [0069]FIG. 16 also shows in dotted lines a potential position of the ladder stabilizing apparatus where the arms are generally parallel to the pitch of the roof. This ladder position does not necessarily provide any significant stabilization and would normally be avoided. However, when the ladder stabilizing apparatus does assume the position as shown in the solid lines of FIG. 16, full stabilization is achieved. However, in order to prevent any possibility of sliding movement, and further to avoid damage to the roof's structure, rubber feet 122 are mounted on the ends of each of the arms.
[0070] The ladder stabilizing apparatus of the present invention is also versatile in its assembly with regard to a conventional ladder. The ladder stabilizing apparatus is adaptable for use with a variety of different sized ladders, including for example, commercial ladders and household use ladders. It can also be mounted when the ladder is already located in a position of use or before the ladder is located in a position of use. Thus, the user of the ladder stabilizing apparatus can position a ladder against a portion of a building and thereafter install the ladder stabilizing apparatus directly on the ladder from the upper end thereof. This ladder stabilizing apparatus is particularly effective with the so-called “extendable ladders”.
[0071] Thus, there has been illustrated and described a unique ladder stabilizing apparatus which fulfills all of the objects and advantages which have been sought therefor. It should be understood that many changes, modifications, variations and other uses and applications will become apparent to those skilled in the art after considering this specification and the accompanying drawings. Therefore, any and 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. | A ladder stabilizing apparatus for holding a ladder in a fixed position against a building structure. The ladder stabilizing apparatus includes a frame having arms adapted to engage and rest upon an upwardly presented surface of a building structure. The position of the arms relative to the ladder held by the stabilizing apparatus is adjustable, such that they can extend outwardly or be retracted inwardly with respect to the position of the ladder. Further, the angle of the frame relative to the ladder can be adjusted so as to engage the eave or the rake of a roof which is other than a flat roof. A substantial downward force, which may have a horizontal force vector no greater then the downward force, is applied to the building, and particularly the roof of the building using a lateral force is applied to the ladder while using the stabilizing apparatus of the invention. A pair of adjustably positionable brackets are mounted on the frame and are sized to engage and extend around each of the side rails of the ladder. | 4 |
This application is a division of application Ser. No. 08/466,424 filed Jun. 6, 1995, now U.S. Pat. No. 5,700,686.
FIELD OF THE INVENTION
This invention relates to compositions and methods for reducing or preventing the backstaining of blue indigo dye onto denim during the stonewashing of denim fabric and garments utilizing cellulase enzymes.
BACKGROUND OF THE INVENTION
Denim is a woven cotton cloth wherein the warp thread has been dyed, usually blue, with the dye, indigo. One desirable characteristic of indigo-dyed denim cloth is the look created by the alternating blue and white threads of the warp and weft yarns, which upon normal wear and tear gives denim a white on blue appearance. A popular look for denim is the stonewashed look. This stonewashed look consists of a generally lighter blue color than unwashed denim with localized areas, particularly around the seams, of even lighter color. Stonewashed material often has a softer texture and maintains the desirable white on blue contrast. Traditionally, stonewashing has been performed by laundering the denim material in the presence of pumice stone, which results in fabric having a faded or worn appearance and the desired white on blue contrast described above.
Enzymes, particularly cellulases, are currently used in processing denim. In particular, cellulases are used to give denim a stonewashed appearance without the need for as high a loading of the pumice stones that are used in traditional stonewashing. This processing method is referred to herein as enzymatic "stonewashing", even if no stones are present in the washer. Use of enzymes to stonewash has become increasingly popular because use of stones has several disadvantages. For example, stones used in the process cause wear and tear on the machinery, environmental waste problems due to the grit produced and result in high labor costs associated with the manual removal of the stones from the machines and the pockets of garments. Consequently, reduction or elimination of stones in the wash may be desirable.
Contrary to the use of pumice stones, enzymes (particularly cellulases) are safe for the machine, result in little or no waste problem and drastically reduce labor costs. Therefore, it may be beneficial to use enzymes for stonewashing. However, even though the use of enzymes such as cellulase may be beneficial as compared to stones, there are some problems associated with the use of enzymes for this purpose. For example, one problem with some cellulases, such as cellulases from the wood-rotting fungus Trichoderma, is what could be described as a "redeposition" or "backstaining" (both terms used interchangeably herein) of some of the dye back onto the fabric during the enzymatic stonewashing process. Such redeposition or backstaining leads to a blue coloration on the white denim threads, resulting in less contrast between the blue and white threads and abrasion points (i.e., a blue on blue look rather than the preferred white on blue). See American Dyestuff Reporter, Sept. 1990, pp. 24-28.
Redeposition or backstaining is objectionable to some users. For example, even though Trichoderma cellulases exhibit a much higher specific activity on denim material than Humicola cellulases, cellulases from Humicola are often preferred because of their lower level of backstaining. This is so, even though the much higher potency of Trichoderma cellulase permits the use of smaller quantities of enzyme to achieve a higher degree of abrasion in significantly shorter processing times.
The problem of redeposition of dye during stonewashing has been a concern of denim processors. Previous attempts to address the problem with Trichodermna cellulase compositions include addition of extra anti-redeposition chemicals, such as surfactants or other agents, into the cellulase wash to help disperse the loosened indigo dye and reduce redeposition. In addition, denim processors have tried using cellulases with less specific activity on denim, along with extra rinsings. This results in additional chemical costs and longer processing times. Another method attempting to address the redeposition problem includes adding a mild bleaching agent or stain removing agent in the process. This method affects the final shade of the garment and increases processing time.
While these methods aid to some limited degree in the reduction of redeposition, the methods are not entirely satisfactory and some objectionable backstaining remains. Use of enzymes and stones together may be advantageous in decreasing the degree of redeposition; however, it leaves the processor with some of the problems associated with the use of stones alone.
Another method, as described by Clarkson et al in PCT Publication No. WO 94/29426 (hereafter "Clarkson et al"), has been to include an added protease enzyme in the stone washing treatment. It was found that the treatment of denim with a composition comprising a redepositing cellulase and an added protease improves the contrast between white and blue threads and reduces dye redeposition. Acting in the washing machine, the proteases are somehow thought to prevent the cellulase proteins from binding the colored particles back onto the surface of the denim, and yet, when used in moderation, they do not have a severe adverse effect on the resultant abraded look caused by the action of the cellulase. This method, while providing some advantages, is costly and requires careful control because proteases, by their very nature, tend to destroy cellulase enzymes. The practitioner must strike a balance between the desirable proteolytic effect on reducing backstaining and the undesirable proteolytic effect on reducing the activity of the cellulase.
In the process of Clarkson et al, the protease is used essentially as a stain remover or staining inhibitor and must be included in the washing process. Clarkson et al teach three options; (1) add the protease directly to the washer with the cellulase enzyme, (2) add the protease to the rinse cycle after a cellulase treatment, or (3) blend the protease with the cellulase prior to washing. Relative to the basic process of adding the protease and cellulase together, adding the protease to the rinse cycle avoids significant proteolytic attack on the cellulase, but it has the disadvantage of adding an extra processing step. Pre-blending the cellulose and protease, on the other hand, makes for a simple easy-to-use formulation, but results in a difficult balance between the desirable proteolytic effect on stain removal and the undesirable proteolytic effect on destroying cellulose activity. For example, a highly active protease may completely destroy the cellulase enzyme during the normal time it takes for storage and shipping. This shelf stability problem can be managed but requires; (1) selection of a protease that has good anti-staining power, but can digest cellulase to, at most a limited extent, (subtilisins, which are not highly active against cellulase but are well known as potent stain removers are a preferred choice), and (2) a pre-incubation of the selected protease and cellulase at an elevated temperature to ensure that what proteolytic attack there is on the cellulase is taken to completion and that a commercial formulation will be stable during storage and shipping.
The action of stronger proteases, particularly the protease papain on Trichoderma cellulases, has been investigated extensively. It has been found that limited amounts of papain digestion can split the core domains of Trichoderma cellobiohydrolases apart from their natural binding domains. This has the effect of essentially eliminating any measurable activity these enzymes have against crystalline cellulose such as Avicel or cotton while still preserving their activity against soluble substrates such as β-glucan. As a result, prior workers concluded that the natural binding domain plays a critical role in enabling the cellobiohydrolase enzyme's attack on crystalline cellulose. The extent of treatment needed for papain to completely eliminate CBH activity on crystalline cellulose was roughly 0.1 to 0.5 grams of papain protein per gram of cellulase protein, all multiplied by the treatment time in minutes (g min/g), that is, weight ratio of protease protein to cellulase protein multiplied by the treatment time.
Based on the shortcomings of previously attempted methods for reducing or preventing redeposition, there is a need for more easily controlled and more cost effective methods to address the issue of redeposition or backstaining of dye during stonewash treatment.
Accordingly, it would be desirable to find an enzymatic composition or method that would be cost effective, have good shelf stability, high potency, and not include a redepositing or backstaining cellulase.
SUMMARY OF THE INVENTION
The inventors of the present invention ("the inventors") have found that washing cotton indigo-dyed denim with a low backstaining cellulase enzyme composition made by subjecting a Trichoderma cellulase that contains both cellobiohydrolase and endoglucanase enzymes to a limited proteolysis (i.e., a limited protease treatment) and subsequent removal of the added protease is an improvement over the use of a redepositing cellulase preparation or one that includes both a cellulase and a protease. The denim produced by treatment with such a composition unexpectedly has a reduced level of dye redeposition and hence good contrast between blue and white threads on the denim. The composition is shelf stable, requires significantly less protease than previous methods, and has a surprisingly low level of redeposition even though the "backstain inhibiting composition" (i.e., the protease) taught to be required by Clarkson et al is not present. The inventors have also provided methods to recover and recycle protease so that this expensive ingredient can be reused. In the denim washing process, a small percentage of surface active chemical surfactant may optionally be added to the compositions or methods described herein. If a surface active agent is added, it may be added either with the cellulase in the wash or as an after treatment rinse. In addition, the denim washing process may be carried out with or without stones added to the compositions described herein.
DETAILED DESCRIPTION OF THE INVENTION
Denim that is stonewashed with a Trichoderma cellulase enzyme composition that has been subjected to a limited protease treatment and subsequent purification to remove the protease shows a dramatic reduction in the level of backstaining and a visible increase in the contrast between white and blue threads. While the inventors do not wish to be held to any particular theory, one possible explanation for the apparently contradictory observations that, on the one hand protease is required in the washer (Clarkson et al) and that, on the other hand it need not be present (this invention), is that there are two separate and distinct mechanisms by which proteases may affect backstaining in a denim washing processes.
The first mechanism is that described by Clarkson et al, where the protease simply acts as a stain removing agent in the washer. This mechanism is consistent with Clarkson's findings that proteases can remove redeposited dye even after it has stained the white denim in a prior cellulase treatment. It is also consistent with the well known use of proteases as stain removers in detergent systems. Not surprisingly, the dye-based stains created by cellulase proteins can be removed by one of the well known approaches for treating stains related to proteins: proteases.
Under this first mechanism, however, those skilled in the art would not expect proteases to be able to mitigate against backstaining in the washer if they are never put in the washer. To explain the inventors' surprising finding that proteases seem to be able to do just that, the inventors suggest that there is a second mechanism that is more subtle and less obvious than the first. In particular, the inventors believe that a limited-protease treatment changes the mode of action of cellulase enzymes causing them to make small, easily dispersed particles that do not backstain. While it has been reported that proteases can render the cellobiohydrolase components present in the Trichoderma cellulase enzyme complex inactive against crystalline cellulose by cleaving off their natural cellulose binding domains, the inventors hypothesize that such a treatment may still leave the cellobiohydrolase enzymes capable of making small nicks in the cellulose which are not detectable on their own but, when used in combination with other components in the Trichoderma cellulase enzyme complex, i.e. the endoglucanases, lead to substantial abrasion in a denim washing environment. The inventors further suggest that, because the modified cellobiohydrolases do not have binding domains, their action against crystalline cellulose is likely to be less localized and more evenly distributed on the denim fibers than under treatment with the intact Trichoderma cellulase. For intact Trichoderma cellulase enzymes, their highly localized mode of action could lead to relatively large particles being released from the main body of the cellulose as the enzymes cut directly through large parts of the fiber. By contrast, the more distributed pattern of action of protease-treated Trichoderma cellulase compositions might lead to smaller, more easily dispersable particles being broken loose from the main body of the cellulose in an environment: where there is a significant amount of shear or mixing. As a result, there would be less backstaining.
This second mechanism, although unrecognized, was probably playing a minor role in the combined cellulase and protease treatments described by Clarkson. It went unrecognized because prior workers focused on exploiting the more obvious use of protease to remove stains in the washer. It was not fully exploited because, if one is planning to make a single commercial enzyme composition containing both cellulase and protease enzymes, it is difficult to operate the proteolysis reaction effectively. In Clarkson's own words, there is a difficult tradeoff and one must "balance between the proteolytic effect on reducing backstaining and the proteolytic effect on reducing abrasion". Thus, to make a combined cellulase/protease enzyme composition that can be added directly to a washer, those skilled in the art would certainly want to avoid the use of proteases like papain which are known to destroy activity on crystalline cellulose in favor of ones more known for their anti-staining properties in detergents, e.g. subtilisin.
Surprisingly, the inventors have found that better overall results are achieved by (1) abandoning the benefits of this first "anti-staining" mechanism (i.e. by removing the protease from the enzyme preparation and thereby the denim washing), and (2) taking advantage of this change to modify the conditions of the proteolytic reaction to get a stronger and more aggressive treatment and thereby maximize the impact of the previously unrecognized second mechanism. In all, the new compositions resulting from this approach permit superior and more cost effective washing of denim.
Prior to discussing this invention in further detail, the following terms will be defined.
The term "Trichoderma cellulase composition" comprises at least one or more of the cellobiohydrolase (CBH) enzymes, and one or more of the endoglucanase (EG) enzymes produced by the fungal microorganism Trichoderma sp. When the composition is produced by a naturally occurring Trichoderma microorganism, and each of these components is found at the ratio naturally produced by the microorganism, the composition is sometimes referred to herein as a "complete or natural Trichoderma cellulase composition."
It is contemplated that the Trichoderma cellulase compositions of the present invention may also refer to any cellulase composition containing both a cellobiohydrolase and endoglucanase that is obtained from a Trichoderma sp. that has been genetically modified so as to overproduce, underproduce or not produce one or more of the CBH, and/or EG components of cellulase. These endoglucanases and cellobiohydrolases may include not only enzymes that are a part of the natural Trichoderma cellulase enzyme composition, but also such modified cellulase compositions as truncated cellulase proteins comprising either the binding domain or the core domain of the CBHs or EGs, or a portion or derivative thereof. Other examples of modified cellulase compositions may include alterations in the degree of glycosylation, or substitution(s) of amino acid(s) in the primary structure of the cellulases or truncated cellulases. It is also contemplated that any natural or modified versions of natural Trichoderma cellulases, such as those outlined above, shall be considered Trichoderma cellulase compositions even if they are produced in a genetically modified host microorganism other than Trichoderma.
The term "protease-treated Trichoderma cellulase" refers to a Trichoderma cellulase composition in which a significant fraction of the CBH core domains have had their CBH binding domains cleaved off, for example with treatment by an added protease enzyme. The protease-treated Trichoderma cellulase compositions should not, however, have any significant incremental or residual active protease over the amount which is produced naturally by the microorganism. Such an incremental amount should, for example, be less than 0.1% of the total amount of protein in the cellulase enzyme composition.
It is contemplated that the protease-treated cellulase compositions of the present invention may include both preparations where an added protease enzyme is used to cleave the CBH core and binding domains as well as modified cellulase compositions where the CBH core domain is produced directly without its binding domain by a genetically modified microorganism. In all cases, though, a protease-treated Trichoderma cellulase composition should contain endoglucanase activity as well as CBH core protein.
The methods of the present invention comprise contacting denim to be partially or wholly enzymatically stonewashed with a protease treated Trichoderma cellulase composition in an amount sufficient to achieve the desired level of dye removal from the garment. The use of such an enzyme will result in a garment with excellent contrast between blue and white threads and a low level of backstaining. The enzyme itself will have good stability and be in no danger of significant protease degradation.
In one embodiment of this invention, the protease-treated Trichoderma cellulase composition is produced by contacting a Trichoderma cellulase composition with an added protease enzyme wherein the extent of treatment, as defined by the weight ratio of protease protein to cellulase protein multiplied by the average treatment time, is in the range between 1.0 g min/g and 10,000 g min/g. The protease is then removed from the cellulase using a chromatographic separation. In a further embodiment of this invention, this protease treated Trichoderma cellulase composition is added to a washing machine with indigo dyed denim and used to created an abraded appearance with a high contrast between the blue and white fibers of the denim.
Cellulase Enzymes
Trichoderma cellulase compositions are typically produced in submerged culture of the fungus Trichoderma and methods for their production and recovery are well documented in the literature and widely known to those skilled in the art.
Commercial sources for these enzymes include Iogen Corporation, Genencor International, Novo Nordisk, Gist-Brocades, Sigma Chemicals, and Enzyme Development Corporation.
One of the preferred Trichoderma cellulase compositions of this invention is that produced by strains of the fungus Trichoderma longibrachiatum in which the relative concentrations of the enzymes CBH1, CBH2, EG1, EG2, and EG3 are all essentially consistent with what is found in a complete or natural Trichoderma cellulase composition.
Commercial cellulase preparations are not 100% cellulase protein and often include fillers, buffers, stabilizers and other ingredients. Total cellulase protein can be measured by various assay methods known in the art. The assay preferably used herein is the commercially available Biorad Coomassie Blue Protein assay sold by the Biorad Company, Los Angeles, using highly purified cellulase protein as the standard.
Added Protease
Proteases are available from several sources including microbial, plant, and animal sources and are well documented in the literature. Some important microbial proteolytic sources include Bacillus licheniformis, Bacillus subtilis, and Aspergillus oryzae.
Important sources of plant proteases include papaya for papain, and pineapples for bromelain. Proteases suitable for the invention include serine, cysteine, aspartic acid and metallo proteases. One of the preferred proteases is the cysteine protease papain.
Proteases are readily available commercially from firms such as Sigma Chemicals in a number of different forms including as liquid solutions, powders, or as insoluble enzymes attached to solid supports. In a preferred embodiment of this invention, the protease papain is used in a liquid suspension.
Commercial protease preparations are not 100% protease protein and often include fillers, buffers, stabilizers and other ingredients. Total protease protein can be measured by various assay methods known in the art. The assay preferably used herein is the commercially available Biorad Coomassie Blue Protein assay sold by the Biorad Company, Los Angeles.
Protease Treatment
The limited protease treatment of this invention comprises contacting a liquid Trichoderma cellulase composition with an added protease under controlled reaction conditions for a defined period of time. One skilled in the art will recognize that the appropriate extent of treatment will depend upon the temperature, pH, concentration chosen to prepare the mixture and on the specific activity of the protease enzyme that has been selected and will further recognize that routine testing procedures can be used to select an optimum set of process conditions for a given cellulase composition and added protease.
In a preferred embodiment, the limited-protease treatment is carried out at an elevated temperature between 20° C. and 60° C. and more preferably between 30° C. and 50° C. In the most preferred embodiment, a temperature of about 37° C. is employed.
In a preferred embodiment, the limited protease treatment is carried out at a pH between 3.0 and 8.0 and more preferably between 4 and 7. In the most preferred embodiment, the pH is between 4 and 5.
In a preferred embodiment, the limited protease treatment is carried out with a concentration of cellulase protein between 5 and 250 g/l and more preferably between 50 and 200 g/l. In the most preferred embodiment, the cellulase protein concentration is about 100 g/l.
In a preferred embodiment, the limited protease treatment time is between 5 minutes and four weeks and more preferably between 1 and 120 hours. In the most preferred embodiment, where the protease is papain, the treatment time is about 24 to 48 hours.
In a preferred embodiment, the extent of treatment, as defined by the weight ratio of protease protein to cellulase protein multiplied by the average treatment time, is in the range between 1.0 g min/g and 10,000 g min/g and more preferably between 10 and 1,000 g min/g. In the most preferred embodiment, where the protease is papain, the extent of treatment is in the range of about 200 g min/g. Under these preferred conditions, this means that the concentration of the papain is about 14 gm/liter.
One preferred method of following the progress of a proteolysis reaction is to use the filter paper carboxymethylcellulose (CMC) assays which measure respectively filter paper units (FPUs) and carboxymethylcellulose units (CMCUs) of cellulase activity (Ghose, 1987). Preferably the protease treatment would be run to an extent that the cellulase loses at least 5% of its initial activity as measured in filter paper units and not more than 50% of its initial activity as measured in CMC units. Even more preferably, the cellulase should be treated to an extent that it loses at least 10% of its initial cellulase activity as measured in FPUs and maintains substantially between 70% and 100% of its initial activity as measured in CMCUs. Even more preferably, the cellulase should be treated to an extent that it loses about 50% of its initial cellulase activity as measured in EPUs and less than 10% of its initial activity as measured in CMCUs.
Protease Removal and Recovery
The method of this invention further requires that the proteolytic reaction be stopped when it has reached the desired extent of treatment such that no significant amounts of exogenous protease contaminate the protease-treated Trichoderma cellulase enzyme composition of this invention. The reaction can be stopped, for example, by chilling or by adjusting the pH. The added protease can then be separated from the cellulase complex. One skilled in the art will recognize that there are a number of means to selectively remove added protease from a Trichoderma cellulase enzyme composition including chromatographic separation, selective precipitation, ultra-filtration, or filtration (if an insoluble enzyme on a solid support is used). The appropriate method of removal will depend upon the specific nature and form of the protease that has been selected for the treatment.
A preferred method of accomplishing this separation is to bind a dissolved protease to a solid material and then wash the cellulase away from it. One such binding medium used herein is a commercially available cation exchange resin, S-Sepharose, sold by Pharmacia Biotech, Uppsala, Sweden, which will bind many commercial protease enzymes when contacted with a solution of cellulase and protease at a pH below 6.0. A preferred method of using S-Sepharose, which is applicable for removing the protease papain from a Trichoderma cellulase enzyme preparation, is to dialyse a mixture of cellulase and protease to a conductivity of 3,000 μ-S or less and then pass it over an S-Sepharose resin at a pH of between 4.5 and 5.0 and a temperature below 20° C.
In a preferred embodiment, the protease is recovered and reused on another batch of Trichoderma cellulase. One preferred method of recovering the protease is to bind it to an S-Sepharose resin at a pH of between 4.5 and 5.0 and a temperature below 20° C. The S-Sepharose resin can bind approximately 100 gm/l of the protease papain. The cellulase/papain mixture is passed over the resin and when the resin is fully loaded with papain, it is washed with softened water to remove any contaminating cellulase and then washed with a 1 M sodium chloride solution to desorb the papain. The papain solution is then dialysed to remove excess salt and is then ready for reuse. During this recovery operation it is important to maintain a reducing environment because papain is subject to a reversible oxidative inactivation.
Product Formulation
The cellulase compositions of this invention may also comprise various adjuvants has known to those skilled in the art. For example, a surfactant (anionic or nonionic) compatible with the cellulase composition would be useful in the compositions of the present invention. Preferable surfactants are nonionic, such as the polyoxyethylated alcohols found in the TRITON® series of surfactants (octylphenoxypolyethoxyethanol nonionic surfactants) which are commercially available from Union Carbide. It should be noted that inclusion of a surfactant may further improve the relative contrast between white and blue threads and reduce the amount of dye redeposition. Other materials can also be used with or placed in the composition as desired, including stones, fillers, solvents, buffers, enzyme stabilizers, pH control agents, enzyme activators, builders, other anti-redeposition agents and the like. The enzyme composition may be formulated as a solid product wherein the solid may be granular, spray dried or agglomerated. Alternatively, the enzyme composition may be formulated as a liquid, gel, or a paste product. A liquid preparation is preferred herein.
Denim Washing
The washing of denim to create a "stone washed" appearance can substantially be accomplished by using a stone or a stone free process in which the denim or denim garments are mechanically agitated in a washing machine with an aqueous composition containing the protease-treated Trichoderma cellulase compositions. The amount of the composition used to treat denim would depend on the concentration of cellulase protein in the cellulase composition, the amount of denim substrate in the washer, and the desired amount of stonewash effect, and other well-known parameters to those skilled in the art. The preferred amount of the protease-treated Trichoderma cellulase composition is generally between 500 and 200,000 CMC units of enzyme per kg of denim and more preferably between about 5,000 and 100,000 CMC units per kg of denim.
In a preferred embodiment, the denim washing treatment is carried out at an elevated temperature between 30° C. and 70° C. and more preferably between 45° C. and 55° C.
In a preferred embodiment, the denim washing treatment is carried out at a pH between 4.0 and 7.5 and more preferably between 4.5 and 6.5. In the most preferred embodiment, the pH for the denim treatment is about 6.0.
In addition to the cellulase composition, the denim washing step may also use a variety of other processing aids. For example, a surfactant (anionic or nonionic) compatible with the cellulase composition would be useful to be added to the washer in the methods of the present invention. Preferable surfactants are nonionic, such as the polyoxyethylated alcohols found in the TRITON® series of surfactants (octylphenoxypolyethoxyethanol nonionic surfactants) which are commercially available from Union Carbide. It should be noted that inclusion of a surfactant may further improve the relative contrast between white and blue threads and reduce the amount of dye redeposition. Other materials can also be used with or placed in the washer as desired, including stones, fillers, solvents, buffers, enzyme stabilizers, pH control agents, enzyme activators, builders, other anti-redeposition agents and the like.
EXAMPLES
The above specification provides a discussion of the compositions of the invention and methods of making and using the compositions in the "stone-washing" of fabric clothing items. The following Examples provide specific details with respect to the compositions and methods of the invention. Other choices of added protease and cellulase, as well as wash conditions such as concentration, measurement, pH, temperature, and the like, will be evident to those skilled in the art based on the teachings herein.
Example 1: Preparation of a Protease Treated Trichoderma Cellulase Composition
Approximately 600 liters of a natural Trichoderma cellulase preparation was produced by the fermentation of Trichoderma longibrachiatum and dialysed to a conductivity of 450 μ-S. While this product was not stabilized or preserved, it is available in a stabilized and preserved form as Iogen Cellulase from logen Corporation. A substantially similar material can be prepared by simply dialysing Iogen Cellulase to remove stabilizers and preservatives. It was then concentrated to a volume of 500 liters by ultrafiltration. The resulting dialysed product has a protein concentration of 140 gm/l and an endoglucanase activity of 1599 CMC units/ml using the method of Ghose (1987). 150 liters of the preparation was removed and the remaining preparation was then mixed with 150 liters of soft water and 40 kg of Biocon papain powder available from Quest International (Product number 5x98490) and having a protein concentration of 105 g/kg and an activity of 1,000 milk clotting units (MCU)/mg of papain powder as specified by Quest International. The pH was adjusted to 4.8 using sodium benzoate and the mixture was incubated at roughly 35° C. to 40° C. for 42 hours. The resulting extent of treatment was approximately 216 g min/g. 49% of the initial cellulase activity was lost during this protease treatment as measured in FPUs and less than 10% as measured in CMCUs. The mixture was then chilled to roughly 20° C. over a period of one hour. The mixture was then clarified on a diatamaceous earth precoated plate and frame filter. With rinse water, the preparation was diluted to a volume of roughly 960 liters. Protease was removed from the protease and cellulase mixture by passing the preparation over an S-Sepharose cation exchange resin according to the instructions of the resin manufacturer (Pharmacia Technical Manual 18-1022-19 "Ion Exchange Chromatography: Principles and Methods", 1991). S-Sepharose was first equilibrated to pH 4.7 with acetate buffer; subsequently, the protease/cellulase mixture was loaded to the resin to the extent of approximately 13 g papain protein per liter of packed resin. The resin was washed with pH 4.7 acetate buffer. The combined effluents from the column loading and washing phases consisted of pure papain-free cellulase: the activity of papain in the cellulase was below detection limits based on activity against azo-casein. The S-Sepharose bound papain was subsequently recovered by passing 1.0 M sodium chloride, pH 4.8, over the resin. The volume of the protease-treated Trichoderma cellulase preparation was about 2,700 liters. The resulting protease-treated Trichoderma cellulase preparation was preserved by adjusting its pH to 4.0 and adding sodium benzoate to 0.5%. This composition was then concentrated by ultrafiltration and stabilized conventionally ("Enzyme Applications", Encyclopedia of Chemical Technology, Vol. 9, Fourth Edition, 1994) to a final concentration of approximately 1,800 CMC units/ml.
Example 2: Denim Washing With a Protease Treated Trichoderma Cellulase Compostion
A 35 lb. UniMac Washer/Extractor machine was used. Approximately 5.1 kg of desized denim garment was placed in the machine. The denim consisted of 3 sewn pant legs, of 30 cm. length and 5 one meter square pieces of Swift 14 oz. #37628 denim, and 3 sewn pant legs of 30 cm. length of Swift 12 oz. #25113 denim, all made by Swift, Drummondville, Quebec. The denim was desized by treating for 15 minutes at 70° C. with 30 g of Rapidase UC alpha-amylase enzyme, available from Gist-Brocades. The machine was filled with 51 liters of hot water and brought to 50° C. The liquor ratio was 10:1 (weight of liquor to weight of garments). The liquor was buffered to pH 6.0 with 300 grams of 85% phosphoric acid and 114 grams of sodium hydroxide pellets.
The machine was agitated for 1 minute to disperse the buffer and establish the temperature. At this point, 70 ml of the protease-treated cellulase preparation of Example 1 was added to the machine. The garments were washed at 47 RPM for 60 minutes. After this, the bath was dropped.
The bath was then filled with 50° C. water and 2 g/L of soda ash was added to adjust the pH up to 9.0 to 11.0 to destroy the cellulase activity. The machine was agitated for 10 minutes and then the bath was dropped. The garments were then rinsed with cold water for 5 minutes and hot water for 30 seconds. This was followed by two 10-minute rinses at 50° C., then the bath was dropped and spun down. The garments were then dried in a standard household dryer for 30 minutes. The garments were then removed from the dryer and ironed without steam.
Brightness readings were taken off the denim using an Elrephro brightness meter. The brightness readings of the #37628 pant leg were used to estimate net dye removal and were converted to net amount of indigo dye removal from the fabric by comparing with samples of known indigo content. Results are reported as a percent of the indigo in unwashed denim. The brightness readings of the #25113 pant leg were used to estimate degree of backstaining and were converted to net amount of indigo dye redeposited onto the fabric by comparing with samples of known indigo content. Results are reported as a percent of the indigo in unwashed denim.
The procedure was repeated with 88 ml of Iogen Cellulase, a standard redepositing cellulase enzyme. The results were as shown in Table 1.
TABLE 1______________________________________Comparison of protease treated and non treated Trichoderma cellulase. Net Dye Release Backstaining______________________________________Protease treated Cellulase 19.2% 2.8%Iogen Cellulase 21.4% 8.3%______________________________________
As is apparent from Table 1 for roughly the same degree of dye removal, denim exposed to the protease-treated cellulase exhibits much less backstaining than the redepositing cellulase.
Example 3: Denim Washing With Added Surfactant
Using the procedures described in Example 2 except as noted, the following enzymes were used in washing the denim:
a. 80 ml of protease-treated Trichoderma cellulase from Example 1, used as in Example 2.
b. 80 ml of protease-treated Trichoderma cellulase from Example 1, used as in Example 2 except that 40 ppm of TRITON® X100 was added to the washer at the start of the cellulase washing.
c. 80 ml of protease-treated Trichoderma cellulase from Example 1, used as in Example 2 except that 80 ppm of TRITON® X100 was added to the washer at the start of the cellulase washing.
d. 80 ml of protease-treated Trichoderma cellulase from Example 1, used as in Example 2 except that 160 ppm of TRITON® X100 was added to the washer at the start of the cellulase washing.
TABLE 2______________________________________Demonstration of the effect of added surfactant. Net Dye Release Backstaining______________________________________Protease treated Cellulase 21.46% 2.81%(0 ppm TRITON ® X100)Protease treated Cellulase 21.09% 2.29%(40 ppm TRITON ® X100)Protease treated Cellulase 20.08% 2.22%(80 ppm TRITON ® X100)Protease treated Cellulase 17.72% 2.09%(160 ppm TRITON ® X100)______________________________________
As Table 2 demonstrates, the addition of surfactant further reduces backstaining without significant loss of net dye release.
Example 4: Comparative Denim Washing Results
Using the procedures described in Example 2, the following enzymes were used in the washing denim:
a. Protease-treated cellulase from Example 1 and tested in Example 2.
b. Following the protocols of Clarkson et al, Iogen Cellulase (which consists of 142 mg/ml of protein) was added as the redepositing Trichoderma cellulase and respectively 0.02 ml, 0.10 ml, 0.5 ml, 2.5 ml, and 12.5 ml of Rapidase WSL-2 subtilisin, available from Gist-Brocades, was added as the protease. This protease consists of 110 mg/ml of protein. The amount of Iogen Cellulase used was 88 ml, except for the run with 12.5 ml protease, which had 78 ml cellulase. The levels of protease addition were respectively 0.02%, 0.08%, 0.40%, 2.0% and 10% of weight of subtilisin protein to weight of cellulase protein. The minimum desirable level taught by Clarkson et al was 0.1%. As suggested by Clarkson et al, the pH in the washer was adjusted to 5.0 with 152 g glacial acetic acid and 55 g sodium hydroxide pellets. All of the other procedures were as in Example 2.
The results are listed in Table 3 and show that the protease-treated Trichoderma cellulase composition gave denim a much lower level of backstaining than the method of Clarkson et al. While the results contradict the Clarkson et al teaching of the need for protease in the wash, they do support their teachings that when cellulase and protease are added together to the washing machine, the backstaining is significantly decreased with more than 0.1% protease relative to cellulase present.
TABLE 3______________________________________Comparison of non-redepositing cellulase enzyme compositions. Net Dye Release Backstaining______________________________________Protease treated Cellulase 19.2% 2.8%Clarkson et al (0.02%) 23.8% 13.6%Clarkson et al (0.08%) 24.7% 9.7%Clarkson et al (0.4%) 28.4% 6.1%Clarkson et al (2.0%) 24.8% 6.2%Clarkson et al (10.0%) 23.6% 7.1%______________________________________
Example 5: Further Preparation of Protease Treated Trichoderma Cellulase Compositions
Approximately 1,000 liters of a natural Trichoderma cellulase preparation was produced by the fermentation of Trichoderma longibrachiatum and dialysed to a conductivity of 310 μS. While this product was not stabilized or preserved, it is available in a stabilized and preserved form as logen Cellulase from logen Corporation. A substantially similar material can be prepared by simply dialysing Iogen Cellulase to remove stabilizers and preservatives. It was then concentrated to a volume of 725 liters by ultrafiltration. The resulting dialysed product had a protein, concentration of 98 gm/l and an endoglucanase activity of 1325 CMC units/ml using the method of Ghose (1987). 375 liters of the preparation was removed and the remaining preparation was then mixed with 150 liters of soft water and 15.75 kg of "Folexco Papain 300 MCU" available from Folexco Incorporated and having a concentration of active papain protein estimated at 32 g/kg and an estimated activity of 300 milk clotting units (MCU)/mg of papain powder. The pH was adjusted to 4.8 using sodium benzoate and the mixture was incubated at roughly 35° C. to 50° C. for 27 hours. The resulting extent of treatment was approximately 24 g min/g. The inventors estimate that roughly 20% of the FPU activity and none of the CMCU activity was lost during this protease treatment. The mixture was then chilled to roughly 10° C. over a period of two hours. The mixture was then clarified on a diatamaceous earth precoated plate and frame filter. With rinse water, the preparation was diluted to a volume of roughly 800 liters. Protease was removed from the protease and cellulase mixture by passing the preparation over an S-Sepharose cation exchange resin according to the instructions of the resin manufacturer (Pharmacia Technical Manual 18-1022-19 "Ion Exchange Chromatography: Principles and Methods", 1991). S-Sepharose was first equilibrated to pH 4.7 with acetate buffer; subsequently, the protease/cellulase mixture was loaded to the resin to the extent of approximately 5 g papain protein per liter of packed resin. The resin was washed with pH 4.7 acetate buffer. The combined effluents from the column loading and washing phases consisted of pure, papain-free cellulase: the activity of papain in the cellulase was below detection limits based or activity against azo-casein. The Sepharose bound papain was subsequently recovered by passing 1.0 M soduim chloride, pH 4.8, over the resin. The volume of the protease treated Trichoderma cellulase preparation was about 1,600 liters. The resulting protease treated Trichoderma cellulase preparation was preserved by adjusting its pH to 4.0 and adding sodium benzoate to 0.5%. This composition was then concentrated by ultrafiltration and stabilized conventionally ("Enzyme Applications", Encyclopedia of Chemical Technology, Vol. 9, Fourth Edition, 1994) to a final concentration of approximately 2,000 CMC units/ml.
Example 6: Denim Washing With Protease-Treated Trichoderma Cellulase Compositions
Using the procedures described in Example 2 except as noted, the following enzymes were used in washing denim:
a. 86 ml of protease-treated Trichoderma cellulase from Example 5, used as in Example 2.
b. 70 ml of protease-treated Trichoderma cellulase from Example 1 as tested in Example 2.
c. 88 ml of Iogen Cellulase as described and tested in Example 2.
The results are listed in Table 4 and demonstrate that the lower levels of papain treatment employed in Example 5 (24 g min/g) do not give quite so good performance as the more harsh treatments of Example 1 (216 g min/g).
TABLE 4______________________________________Comparison of protease treated and non treated Trichoderma cellulase. Net Dye Release Backstaining______________________________________Protease treated Cellulase (Example 5) 18.0% 3.8%Protease treated Cellulase (Example 1) 19.2% 2.8%Iogen Cellulase 21.4% 8.3%______________________________________
Example 7: Comparative Denim Washing Results
Using the procedures described in Example 2, the following enzymes were used in washing denim:
a. Protease-treated cellulase from Example 1 and tested in Example 2.
b. 80 ml of protease-treated Trichoderna cellulase from Example 1, as tested in Example 3 with 40 ppm of TRITON® X100 added to the washer at the start of the cellulase washing.
c. Euro L, a commercial cellulase product of Genencor International that we believe contains protease enzyme, a redepositing Trichoderma cellulase and a surfactant, was added at an amount of 100 ml. As per the manufacturers suggestion, the pH was adjusted to 5.5 with 150 g of glacial acetic acid and 85 g of sodium hydroxide pellets. All other procedures were as in Example 2.
d. Euro L was added to the washer at an amount of 100 ml. 40 ppm of TRITON® X100 was also added to the washer at the start of the cellulase washing. As per the manufacturers suggestion, the pH was adjusted to 5.5 with 150 g of glacial acetic acid and 85 g of sodium hydroxide pellets. All other procedures were as in Example 2.
e. Denimax L, a commercial product of Novo Nordisk that we believe contains low-backstaining enzyme image by Humicola insolens was added at an amount of 250 ml. As per the manufacturer's suggestion, the pH was adjusted to 6.5 with 297 g of phosphoric acid and 125 g of sodium hydroxide pellets. All other procedures were as in Example 2.
f. Denimax L was added to the washer at an amount of 250 ml. 44 ppm of TRITON® X100 was also added to the washer at the start of the cellulase washing. As per the manufacturer's suggestion, the pH was adjusted to 6.5 with 297 g of phosphoric acid and 125 g of sodium hydroxide pellets. All other procedures were as in Example 2.
The results are listed in Table 3 and show that, for similar dye release, the protease-treated Trichoderma cellulase composition gives denim a lower level of backstaining than the Euro L or the Denimax L. This good performance of the protease treated Trichoderma cellulase without surfactant relative to Euro L is achieved even though Euro L contains performance enhancing surfactants. The low potency of the Humicola insolens cellulase is evident from the fact that 2 to 3-fold more Denimax L was required to fade the denim than with the other enzymes.
TABLE 3______________________________________Comparison of non-redepositing cellulase enzyme compositions. Net Dye Release Backstaining______________________________________Protease treated Cellulase 19.2% 2.8%Protease treated Cellulase 21.09% 2.29%(40 ppm TRITON ® X100)Euro L 19.9% 3.4%Euro L (40 ppm TRITON ® X100) 21.44% 3.35%Denimax L 19.6% 3.6%Denimax L (40 ppm TRITON ® X100) 18.17% 3.32%______________________________________
While preferred embodiments of our invention have been shown and described, the invention is to be defined solely by the scope of the appended claims. | During the enzymatic "stone washing" of a denim fabric and/or garments, an undesirable redeposition of blue dye often occurs on the surfaces of the denim. The invention relates to a means of overcoming this problem using an enzyme composition comprised of Trichoderma endoglucanases and Trichoderma cellobiohydrolases that has been partially digested by a protease enzyme to separate its core and binding domains. The use of this composition reduces the redeposition of the blue dye and hence improves the stone washing process relative to using a redepositing or backstaining cellulase. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Patent Application No. 62/102,228 filed Jan. 12, 2015, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Designing a vehicle requires a balance between form and function with every decision requiring a compromise; fuel economy vs. acceleration, understeering vs. oversteering, efficiency vs. safety. There are even conflicts between different aspects of the same objective. For example, a reduction in pillar thickness would decrease blind spots, however, narrower pillars cannot be made as strong as thicker pillars and airbags require pillars of a particular thickness. There is therefore a safety conflict between preventing accidents and protecting individuals in case of an accident.
[0003] A blind spot is any area that cannot be seen due to an obstruction within a field of view. Blind spots may occur in front of the driver when the A-pillar (also called the windshield pillar), side-view mirror, and interior rear-view mirrors block a driver's view of the road. Front end blind spots are frequently influenced by the distance between the driver and the pillar, the thickness of the pillar, the angle of the pillar in a vertical plane side view, the angle of the pillar in a vertical plane front view, the form of the pillar (straight or arc-form), the angle of the windshield, the height of the driver in relation to the dashboard, and the speed of the opposite car. Behind the driver there are additional pillars, headrests, passengers, and cargo that may reduce rear and side visibility. While side view mirrors provide some assistance in reducing lateral blind spots, most mirrors have a blind-spot between the area lateral to the side-view mirror's field and behind the driver's direct lateral vision so that at some point an adjacent vehicle disappears from the viewing range of the mirror. There is a similar blind spot on the passenger's side of the vehicle. These blind spots can be between half a car length to a car length behind the front of the car creating a hazard when turning, merging, or changing lanes.
[0004] While technological solutions such as back-up cameras and active blind spot monitoring have been introduced, there are still more than 800,000 blind-spot-related accidents every year according to the National Highway Traffic Safety Administration. There is therefore an unmet need for an alternate means of eliminating blind spots.
BRIEF SUMMARY
[0005] Provided herein is a means for decreasing or eliminating blind spots in a motor vehicle. One or more cameras are placed on an exterior portion of the vehicle or an interior portion of a vehicle facing through a transparent surface such as the on the back of the rear view mirror. Captured images are displayed on flexible electronic displays placed on surfaces of the interior of the passenger compartment. A microprocessor in communication with one or more of the cameras and one or more of the display screens continuously processes images received from the camera(s) and transmits the images from the camera(s) to the designated flexible electronic screen on the interior of the passenger compartment. In some embodiments, the flexible electronic screens display the images taken immediately exterior of the motorized vehicle corresponding to the interior placement of the flexible electronic screen in real time allowing for a consistent view between the images on the flexible electronic screens and a transparent surface adjacent to the flexible electronic screens such as a window. The cameras may take images sequentially or substantially simultaneously. In some embodiments, images are recorded continuously. In other embodiments, images may be recorded and/or displayed intermittently.
[0006] Each of the cameras placed on the vehicle comprises a lens and a sensor. Each camera may have the same or different types of lens and each group of cameras in a particular location may have the same or different types of lenses such as, but not limited to, an infrared lens, standard lens, medium telephoto lens, a wide angle lens, telephoto and/or other specialist lens.
[0007] In some embodiments, images taken by a plurality of cameras may be combined using an overlapping capture region to form a single image. The images may be taken substantially simultaneously or at different times.
[0008] While any flexible electronic screen may be used to display the images, in some embodiments, the flexible screen is an active-matrix organic light-emitting diode (AMOLED) screen. In other embodiments, the flexible screen is an OLED screen.
[0009] In some embodiments, the flexible electronic display(s) attached to the interior of the passenger compartment of a motorized vehicle may be perforated at one or more points allowing for them to break away in the event of an airbag deployment.
[0010] These and other embodiments, features and potential advantages will become apparent with reference to the following description.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.
[0012] FIG. 1 is an exterior view of a vehicle depicting a blind spot eliminator.
[0013] FIG. 2 is an exterior of a vehicle showing an embodiment of a blind spot eliminator.
[0014] FIG. 3 depicts an exterior view of an embodiment of a car with a blind spot eliminator system.
[0015] FIG. 4 is an interior of a vehicle showing an embodiment of a blind spot eliminator.
[0016] FIG. 5 is a system diagram of an embodiment of a blind spot eliminator.
[0017] FIG. 6 is an action flow diagram of an embodiment of a blind spot eliminator.
[0018] FIG. 7 is a flow chart of an embodiment of a blind spot eliminator.
[0019] FIG. 8 is a system diagram of a system for analyzing blind spots.
[0020] FIG. 9 is an action flow diagram of a system for analyzing blind spots.
[0021] FIG. 10 is a flow chart of an embodiment of a system for analyzing blind spots.
[0022] FIG. 11 is a figure an embodiment of a blind spot eliminator system.
[0023] FIG. 12 is a system diagram of an embodiment of a blind spot eliminator.
[0024] FIG. 13 is an action flow diagram of an embodiment of a blind spot eliminator.
[0025] FIG. 14 is a flow chart of an embodiment of a blind spot eliminator.
[0026] FIG. 15 is a figure depicting an embodiment of a display.
DETAILED DESCRIPTION
Glossary
[0027] “AMOLED” in this context refers to Active-Matrix Organic Light-Emitting Diode.
[0028] “Blind Spot” in this context refers to an area around the vehicle that cannot be directly observed by the driver while at the controls.
[0029] “BRIEF” in this context refers to Binary Robust Independent Elementary Features (BRIEF) keypoint descriptor algorithm.
[0030] “Bundle adjustment” in this context refers to simultaneously refining the 3D coordinates describing the scene geometry as well as the parameters of the relative motion and the optical characteristics of the camera(s) employed to acquire the images according to an optimality criterion involving the corresponding image projections of all points.
[0031] “Composting” in this context refers to combining visual elements from separate sources into single images, often to create the illusion that all those elements are parts of the same scene.
[0032] “Decoder” in this context refers to an electronic device that converts a coded signal into one that can be used by other equipment.
[0033] “Encoder” in this context refers to a device, circuit, transducer, software program, algorithm or person that converts information from one format or code to another for the purposes of standardization, speed, secrecy, security or compressions. In some embodiments the terms encoder and multiplexer may be used interchangeably.
[0034] “FAST” in this context refers to Features from Accelerated Segment Test keypoint detection.
[0035] “Flexible electronic display” in this context refers to a display capable of being bent, turned, or forced from a substantially straight line or form without breaking and without compromising the display quality associated with well known, non-flexible LCD or LED display panel.
[0036] “Global optimization” in this context refers to finding the absolutely best set of parameters to optimize an objective function.
[0037] “Harris Corner Detector (Harris)” in this context refers to a means of using a normalized cross-correlation of intensity values to match features between images.
[0038] “HEVC” in this context refers to High Efficiency Video Coding.
[0039] “Image registration” in this context refers to the determination of a geometrical transformation that aligns points in one view of an object with corresponding points in another view of that object or another object.
[0040] “Multiplexer” in this context refers to a device allowing one or more low-speed analog or digital input signals to be selected, combined and transmitted at a higher speed on a single shared medium or within a single shared device.
[0041] “ORB” in this context refers to Oriented FAST and Rotated BRIEF (ORB), a very fast binary descriptor based on Binary Robust Independent Elementary Features (BRIEF) key point descriptor.
[0042] “Photo-stitching” in this context refers to combining a series of images to form a larger image or a panoramic photo.
[0043] “PROSAC” in this context refers to the progressive sample consensus (PROSAC) algorithm which exploits the linear ordering defined on the set of correspondences by a similarity function used in establishing tentative correspondences.
[0044] “RANSAC” in this context refers to random sample consensus (RANSAC), an iterative method to estimate parameters of a mathematical model from a set of observed data which contains outliers.
[0045] “SIFT” in this context refers to Scale-Invariant Feature Transform (SIFT), an algorithm in computer vision to detect and describe local features in images.
[0046] “SURF” in this context refers to Speeded Up Robust Features (SURF). SURF uses an integral image for fast local gradient computations on an image.
[0047] “Thin Film” in this context refers to a layer of material ranging from fractions of a nanometer (monolayer) to several micrometers in thickness.
[0048] “Video compression format” in this context refers to a content representation format for storage or transmission of digital video content.
DESCRIPTION
[0049] Described herein is a means for reducing and/or eliminating blind spots in vehicles through the use of flexible electronic display material and exterior or interior cameras. While the motorized vehicle shown in the figures is a passenger sedan, it may also be a pickup truck, SUV, tractor trailer, bus or other motorized vehicle.
[0050] Blind spots are generally viewed as being rear quarter blind spots, areas towards the rear of the vehicle on both sides. However, they are also present at an acute angle intersection, while entering a left side or right side lane change, during a back-up maneuver, or while performing curbside parking/exiting. The use of a flexible electronic delay combined with exterior cameras may allow vehicle designers and engineers to create stronger, more rigid modes of transport by decreasing the need for windows, further increasing the safety of the vehicle.
[0051] In order to reduce and/or eliminate blind spots in vehicles, a plurality of cameras are mounted on the exterior of a vehicle or on the interior of a vehicle in areas that cause obstructions, such as the back of the rear view mirror. The cameras may protrude, may be flush mounted, or may be sunken into the side of the vehicle. In some embodiments the cameras may be placed on the exterior of the vehicle's support pillars. In additional embodiments, the cameras may be placed on the exterior casing of a car's mirrors. In further embodiments they may be placed below the exterior door latch. In yet another embodiment, they may be placed behind the mirror surface of side view mirrors, allowing for images to be taken through the glass of the mirror. In other embodiments, they may be placed all over the car. The cameras may be placed in a straight vertical line, a horizontal line, scattered, or placed in any other useful pattern for maximizing a driver's view. In some embodiments, the cameras may be placed at multiple sites on the vehicle, for example on a plurality of vehicle pillars. The passenger and driver sides of the vehicle may have the same or different numbers of cameras and/or camera placement. In some embodiments, there may be one camera per support pillar, i.e. generally four cameras on the driver side and four cameras on the passenger side of the vehicle.
[0052] Cameras may be placed on the exterior of a car so that the fields of view are independent or overlapping. In some embodiments, some fields of view may overlap while other views are independent (non-overlapping). In some embodiments, the fields of view may overlap by ⅛, ¼, ⅓, ½, ⅔, ¾ or any fraction thereof. In additional embodiments, the fields of view may overlap by about 10-50%, 10-15%, 15-20%, 10-30%, 20-30%, or less. In other embodiments, the field of view of the cameras does not overlap, but are directly adjacent to one another in a horizontal and/or vertical line. In additional embodiments, some of the fields of view may overlap and others may be adjacent to one another. In some embodiments there may be secondary cameras which are only used when the primary camera fails to capture an image whether through damage, wear and tear, obstruction of the primary cameras, or difficult light situations. Such images from the secondary cameras may be combined with or displayed in place of the primary camera images.
[0053] While any type of camera may be used, the vehicle mounted cameras as used herein generally comprise a lens and a sensor. Each camera may use any type of lens desired, including, but not limited to, wide angle, infrared, ultra-wide angle, macro, stereoscopic lens, swivel lenses, shift lenses, movable lenses, standard lens, medium telephoto lens, telephoto and/or other specialist lens. Each camera may have the same or different types of lenses from other cameras on the same pillar, used in combination with one another, or other cameras on the vehicle. The cameras may each independently have varifocal or fixed lens. Given the differences in the size and point of view of each driver and the size and angle of support pillars on different vehicles, in some embodiments the angle of view and focal point of one or more cameras may be adjustable to suit the driver's preferences.
[0054] At times, exterior conditions may be such that an accurate image cannot be captured, for example in situations of low light, because of dirt or other debris on the camera lens, or other reasons for insufficient data capture. In such instances, a warning may be displayed or sounded to alert the driver that the image is not sufficiently detailed for human discernment in a particular direction or on a particular display surface. In some embodiments, a low-lux parameter can be set to optimize viewing. For example, the camera gain and exposure may be adjusted automatically to a pre-set value or to achieve a target brightness specified by the driver. In some embodiments, the luminance of captured frames is used to adjust the camera exposure and/or gain of subsequent frames. In other embodiments, the ideal limit of the exposure in normal operating conditions may be set between the exposure settings for normal and low light conditions allowing for a minimization of motion blur. The ideal limit may be pre-set or may be adjustable, allowing the driver to optimize the lighting level at which the camera will switch to night mode.
[0055] The images from two or more cameras are processed using one or more microprocessors substantially simultaneously. In some embodiments, the images may be processed through an image signal processor or sent directly to a multiplexer or data selector. The image signal processor corrects any distortion of image data and outputs a distortion-corrected image. In some embodiments, the image signal processor receives image data from a frame buffer. The frame buffer may store all image data or only the image data needed for image distortion corrections. Selective storage allows for increased availability of space in the buffer for image storage. In some embodiments, the images are split upon reaching the screen through the use of a demultiplexer into the original multiple images which are then displayed on a screen mounted in the passenger compartment of the car. In other embodiments, the images of a single camera are sent to a single display.
[0056] In some embodiments, the images from the camera are analyzed to determine an overlapping capture region. The images are then stitched together using the overlapping capture region. For example, a first camera may take a first image and a second camera may take a second image. The first camera and second camera are positioned on the exterior of a vehicle such that a portion of the first image and a portion of the second image overlap. The first and second camera may or may not be on the same pillar or section of the vehicle. The first image and the second image are then stitched together to form a single image which is then projected on the flexible electronic screen on the interior of the pillar. In some embodiments, there is provided a non-transitory computer readable medium storing a computer program comprising instructions configured to, working with at least one processor, cause at least the following to be performed: analyzing first and second images, the first being captured by a first camera and the second image being captured by a second camera, wherein at least one position on the first and second images, at which the analysis of the first and second images is initiated depends upon at least one contextual characteristic (correspondence relationship) identified by a feature matching algorithm such as, but not limited to, SIFT, SURF, Harris, Fast, PCA-SIFT, ORB and the like; determining, from the analysis of the first and second images, an overlapping capture region for the first camera and the second camera, for example using RANSC or PROSAC algorithms; and stitching the first and second images together using the overlapping capture region. Images from two, three, four, five, six or more cameras on may be combined to form a single image in any processing and integration order. Overlapping regions of the images may be captured by two or more cameras. For example, camera one may have an overlapping region with camera two. Camera two may also have an overlapping region with camera three, but camera three does not share an overlapping region with camera one.
[0057] Images may be processed for appropriate display on the flexible electronic display, allowing for correction of the aspect ration while maintaining good resolution. In some embodiments, the images may be processed to adjust the size of the image displayed. The processing may alter the size of the image displayed in order to obtain the clearest image with the least distortion. The image may be increased or decreased in size depending on the amount of distortion. In some embodiments, the image size may be adjusted by the vehicle operator. In other embodiments, the image size may be pre-set by the manufacturer. In some embodiments, images may be processed such that the images present a constant view between surfaces displaying the images and transparent surfaces such as a window or another display.
[0058] In some embodiments, multiple images of the same scene are combined into an accurate 3D reconstruction using bundle adjustment. A globally consistent set of alignment parameters that minimize the misregistration between all pairs of images are identified. Initial estimates of the 3D location of features are computed along with information regarding the camera locations on the vehicle. An iterative algorithm is then applied to compute optimal values for the 3D reconstruction of the scene and camera positions by minimizing the log-likelihood of the overall feature projection errors using a least-squares algorithm. The images are then composted based on the shape of the projection surface.
[0059] Images taken by two or more cameras are processed, transmitted using a video compression format, and displayed real-time on one or more flexible electronic displays on the inside of the passenger compartment of the vehicle. Any video compression format can be used including, but not limited to, advanced video coding, high efficiency video coding, Dirac, VC-1, Real Video, VP8, VP9 or any other generally used compression format. The flexible electronic display may be any type of flexible display of 10 mm thickness or less generally used including, but not limited to, an organic light emitting diode (OLED), active matrix light emitting diode, super AMOLED, Super AMOLED Plus, HD Super AMOLED, HD Super AMOLED Plus, Full HD Super AMOLED Plus, WQ HD Super AMOLED, and WQXGA Super AMOLED. In some embodiments, the flexible electronic display may have a backplane of polymers, plastic, metal, or flexible glass such as, but not limtied to, polyimide film, flexible Thin-Film Field Effect Transistor (TFT), polymer organic semiconductor, small molecule organic semiconductor (OSC), metal oxide, organic thin film transistors, or any other suitable substrate. In some embodiments, the flexible display may be about 5 mm or less, about 3 mm or less, about 1 mm or less, about 0.5 mm or less, about 0.25 mm or less, about 0.2 mm or less, about 0.18 mm or less, about 0.15 mm or less, 0.1 mm or less or any subset thereof. While a flexible electronic display with any appropriate amount of flexibility may be used, in some embodiments, the flexible electronic display may bend through at least about 10° from the center of the screen, about 15°, about 20°, about 25°, about 30°, about 40°, about 50°, about 75°, about 100°, about 120°, about 130°, about 140°, about 150°, about 170° about 180°, about 220°, about 250°, about 300°, about 360° or any fraction thereof. In other embodiments, the amount of flexibility may be defined by the curvature radius such as, but not limited to, a curvature radius of at least about 3 mm, about 5 mm, about 7 mm, about 7.5 mm, about 10 mm, about 15 mm, about 20 mm, about 50 mm, about 100 mm, about 300 mm, about 400 mm, about 500 mm, about 600 mm, about 700 mm, about 800 mm, about 1000 mm or any other desired curvature radius.
[0060] Flexible electornic displays may be placed throughout the interior of the passenger compartment of a vehicle. In some embodiments, the flexible electronic display is on the dashboard. In other embodiments, the flexible electronic display is attached to all or part of the interior of the car creating the illusion that the driver and/or the passengers of the vehicle can see directly through the vehicle's walls. For example, where the B pillar is located on the driver side of the car, images taken from the exterior of the B pillar may be displayed on the interior of the B pillar. In some embodiments, flexible electronic displays may be placed on the pillars. In other embodiments, the flexible electronic display may be applied to one or more non-transparent surfaces in the interior of a vehicle including, but not limited to, the pillars, the interior mirror access cover, the roof, the doors, the headrests, the interior or any other non-transparent surface in the interior of a vehicle. In further embodiments, the flexible electronic display may be applied to transparent and/or non-transparent surfaces in the interior of a vehicle. In other embodiments, the flexible electronic displays are placed on any surface that may interfere with a driver's view of objects or events occurring outside of the vehicle. In some embodiments, multiple flexible electronic displays may be applied in a vertical and/or horizontal line to provide the desired display size. In additional embodiments, such as in an articulated vehicle, the flexible electronic display may be applied to the interior of the driver's cab, including behind the driver such that the driver has a view of the exterior of the articulated vehicle. In further embodiments, a single display may be placed on each pillar. In yet another embodiment, a series of displays may be applied in an horizontal or vertical line such that each camera is linked to a single display, but displays as a whole may be combined to display a greater view than would be possible from an individual camera. In additional embodiments, the flexible electronic displays may be used to display images other than those from the cameras on the exterior of the vehicles. For example, the displays may be used to present traffic information, alerts, still images, pre-formatted video and the like.
[0061] Most cars have air bags or air curtains in one or more of the vehicle pillars. In some embodiments, flexible electronic displays may be designed to break away when an air bag deploys. For example, in some embodiments, the flexible electronic display screen may be affixed to a pillar containing an air bag. One or more of the attachment points of the flexible electronic display screen may be scored or otherwise perforated allowing the flexible electronic display to detach from the vehicle pillar along at least one edge in the event of an air bag deployment. In some embodiments, the flexible electronic display may be attached using tabs or attachment mechanisms located behind the fascia of the vehicle pillar. The flexible electronic display may be perforated along the tabs behind the fascia. In other embodiments, the flexible electronic display may be perforated on the surface of the fascia or at any other useful place on the display suitable to prevent the display from interfering with airbag deployment. For example, in some embodiments, the flexible display may be perforated down and/or across the middle with each side or corner anchored to the pillar thereby minimizing the size, force and/or addition of any additional projectiles in an accident. The flexible electronic display may be attached to the vehicle pillar using any type of attachment means or attachment device including, but not limited to, automotive industrial adhesives, fascia or pillar lining clips, screws, brads, rivets, or other types of suitable adhesives or fastening mechanisms.
[0062] The images displayed on the flexible electronic display may be of a fixed perspective or may alter depending on the point of view of the driver. In some embodiments, a sensor may determine the driver's head position and alter the display correspondingly. For example, if a driver looks over their left shoulder, the display may change to reflect what the driver would see at that angle, i.e. to the left and back and not what is directly outside of the car on the left hand side. In other embodiments, the angle of the camera may alter based on the position of the steering wheel.
DRAWINGS
[0063] Referring to FIG. 1 , a vehicle 118 has a plurality of pillars. Pillars are the vertical or near vertical supports of an automobile's window area. The vehicle 118 has an A pillar 102 , a B pillar 104 , a C pillar 106 and a D pillar 108 . Each pillar may have mounted thereon one or more cameras 110 , 112 , 114 and 116 respectively. The number of cameras on a particular pillar may be the same or different as the number of cameras on any other pillar. In some embodiments, the cameras be placed on other parts of the vehicle such as the doors, the bumpers, or any other part of the vehicle where a blind spot may be an issue mitigated by use of a camera view.
[0064] Referring to FIG. 2 , a vehicle 216 has a plurality of pillars. Pillars are the vertical or near vertical supports of an automobile's window area. The vehicle 216 has an A pillar 202 , a B pillar 204 , a C pillar 206 , and a D pillar 208 . Each pillar may have mounted thereon one or more cameras 110 , 112 and 114 respectively. The number of cameras on a particular pillar may be the same or different as the number of cameras on any other pillar. In some embodiments, the cameras be placed on other parts of the vehicle such as the doors, the bumpers, or any other part of the vehicle where a blind spot may be an issue mitigated by use of a camera view.
[0065] Referring to FIG. 3 , a vehicle 322 has a plurality of pillars. Pillars are the vertical or near vertical supports of an automobile's window area. The vehicle 322 has an A pillar 302 , a B pillar 304 , a C pillar 306 and a D pillar 308 . Each pillar may have mounted thereon one or more cameras 310 , 314 , 318 and 320 respectively. The number of cameras on a particular pillar may be the same or different as the number of cameras on any other pillar. Additional cameras may be placed on alternate parts of the vehicle such as below the door handles at 312 and 316 or on any other part of the of the vehicles where a blind spot may be an issue mitigated by the use of a camera view.
[0066] Referring to FIG. 4 , in the interior of a vehicle 402 pillar B 404 and pillar C 406 are covered with one or more flexible electronic screens 408 and 410 respectively allowing the driver and the passengers to view objects exterior of the vehicle such as the truck 412 which are partially or completely obstructed by blind spots of the vehicle.
[0067] FIG. 5 is a system diagram of an embodiment of a blind spot eliminator. FIG. 6 is an action flow diagram of an embodiment of a blind spot eliminator. FIG. 7 is a flow chart of an embodiment of a blind spot eliminator.
[0068] The system comprises camera lens 502 , sensor 504 , image signal processor 506 , codec 508 , multiplexer 510 , demultiplexer 512 , and flexible electronic display 514 . The sensor 504 receives a focused light signal from the camera lens 502 and in response captures an image from the exterior of the vehicle ( 702 ). The image signal processor 506 receives an image transfer signal from the sensor 504 and in response corrects distortion of the image data ( 704 ). The codec 508 receives an image transfer signal from the image signal processor 506 and in response compresses the video ( 706 ). The multiplexer 510 receives a video transfer signal from the codec 508 and in response combines multiple inputs into a single data stream ( 708 ). The demultiplexer 512 receives a video transfer signal from the multiplexer 510 and in response splits the single data stream into the original multiple signals ( 710 ). The flexible electronic display 514 receives an individual video file signal from the demultiplexer 512 and in response displays the image ( 712 ).
[0069] FIG. 8 is a system diagram of a system for analyzing blind spots. FIG. 9 is an action flow diagram of a system for analyzing blind spots. FIG. 10 is a flow chart of an embodiment of a system for analyzing blind spots.
[0070] The system comprises camera lens 802 , sensor 804 , analyzer 806 , processor 808 , video compressor 810 , and flexible electronic screen 812 . The sensor 804 receives a focused light signal from the camera lens 802 and in response captures an image ( 1002 ). The analyzer 806 receives an image transfer signal from the sensor 804 and in response analyzes images for overlapping regions ( 1004 ). The processor 808 receives an image transfer signal from the analyzer 806 and in response stitches the images together ( 1006 ). The video compressor 810 receives a stitched images signal from the processor 808 and in response compresses the video using a video compression codec such as a high efficiency video coding ( 1008 ). The flexible electronic screen 812 receives a decoded video signal from the video compressor 810 and in response displays the video on the flexible electronic screen ( 1010 ).
[0071] Referring to FIG. 11 , the system comprises camera lens A 1102 and camera lens B 1104 , though n camera lens may be used, sensor A 1106 and sensor B 1108 , or as many sensors as there are camera lenses, a codec 1110 , a multiplexer/demultiplexer 1112 , and flexible electronic display A 1114 and flexible electronic display B 1116 though any number of flexible electronic displays may be used. The sensors A and B receive a focused light signal from the respective camera lens A and B and the image is recorded. The images are then transferred to the codec 1110 for processing and the resulting video is transferred to a multiplexer/demultiplexer and then distributed to the correct flexible electronic display such that each electronic display shows images taken immediately exterior of the car at the position of the interior electronic display.
[0072] FIG. 12 is a system diagram of an embodiment of a blind spot eliminator. FIG. 13 is an action flow diagram of an embodiment of a blind spot eliminator. FIG. 14 is a flow chart of an embodiment of a blind spot eliminator.
[0073] The system comprises camera lens 1202 , sensor 1204 , video compression 1206 , flexible electronic display 1208 , and photo-stitching 1210 . The sensor 1204 receives a focused light signal from the camera lens 1202 and in response captures an image ( 1402 ). The photo-stitching 1210 receives an image transfer signal from the sensor 1204 and in response assembles captured images into a video ( 1406 ). The video compression 1206 receives a video transfer signal from the photo-stitching 1210 and in response compresses the video using a video compression codec such as high efficiency video coding ( 1408 ). The flexible electronic display 1208 receives a decoded video signal from the video compression 1206 and in response displays the integrated images shot from the exterior of the vehicle ( 1404 ).
[0074] Referring to FIG. 15 , a flexible electronic display screen 1502 shaped to fit vehicle pillars is scored along an edge 1520 . The flexible electronic display screen 1502 is attached to a longitudinal edge of a pillar using attachment tabs 1508 , 1510 and 1512 which wrap behind the fascia of the vehicle pillars and are attached to either the fascia or the pillar. The attachment tabs 1508 , 1510 , and 1512 may be attached using any type of adhesive or fastener. In some embodiments, the attachment tabs are attached at attachment points 1514 , 1516 and 1518 respectively. At 1522 , the opposite edge from the scored edge 1520 , the flexible electronic display screen 1502 is attached to the opposite longitudinal edge of a pillar from the point of attachment for the attachment tabs 1508 , 1510 and 1518 . The opposite edge 1522 may be attached to the fascia and/or the vehicle pillar through a plurality of attachment points 1524 . The display is attached to the video processor at a connection point, integrated circuit or flex cable 1526 .
[0075] It will be readily understood that the components of the system as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Elements of embodiments described above may be embodied in hardware, firmware and/or software. While exemplary embodiments revealed herein may only describe one of these forms, it is to be understood that one skilled in the art would be able to effectuate these elements in any of these forms while resting within the scope of the present invention.
[0076] Embodiments of a blind spot elimination system have been described. The following claims are directed to said embodiments, but do not preempt blind spot elimination in the abstract. Those having skill in the art will recognize numerous other approaches to blind spot elimination are possible and/or utilized commercially, precluding any possibility of preemption in the abstract. However, the claimed system improves, in one or more specific ways, the operation of a machine system for blind spot elimination, and thus distinguishes from other approaches to the same problem/process in how its physical arrangement of a machine system determines the system's operation and ultimate effects on the material environment. | A means for decreasing or eliminating blind spots through the combination of a flexible electronic display and exterior cameras which allow the user to see if anything is occupying a traditional blind spot. Information received from the exterior cameras is combined through the use of photo-stitching allowing for presentation of a wider range of view than that presented by a single camera and providing the perception that the viewer is able to directly view spaces near the car that are in a blind spot such as cars in adjacent lanes near the rear quarter of the car and items that are too low to see. | 7 |
FIELD OF THE INVENTION
This invention relates to a power converter with full DC galvanic isolation between its input and output circuitry and, in particular, to a power converter having circuitry on its input side to estimate signal conditions on its output side.
BACKGROUND OF THE INVENTION
Power converters typically are required by imposed safety requirements to provide full DC galvanic isolation between the input source common return circuit and the output load common return circuit. This full DC galvanic isolation is normally provided by use of a power transformer which blocks DC current flow between the primary and secondary circuitry (e.g., in galvanic isolation there is no DC current path across the isolation barrier). Power converters typically also require the output signals to be regulated. That is, the output voltage and/or current must somehow be sensed and made to fall within some boundary limit of specified values. To achieve this, without breaching the DC galvanic isolation provided by the power transformer, commonly requires a secondary to primary feedback path including an opto-isolator, signal transformer or some other isolating signal means, to provide the desired galvanic isolation between input and output.
The regulating circuitry is normally divided into circuitry at both the primary and secondary sides of the converter. The secondary side circuitry senses the output signal to be regulated and the primary side circuitry controls a power switch to achieve the desired regulation. The division of the regulating circuitry between input and output and the galvanic isolating devices required in the feedback path increases the parts count of the converter and increases its size and expense. It is desirable to reduce the parts count to enhance circuit reliability. It is also desirable to reduce both cost and circuit size in many applications. Among existing methods that eliminate the need for a separate isolating feedback path are the techniques of implicit primary side sensing and post secondary regulation.
Post secondary regulation, implies an added power processing module subsequent to the power converter itself. It adds complexity to the overall system and significantly increases the system parts count. It additionally detracts from the power system efficiency since it uses a separate power processing module in tandem with the primary power converter and the overall efficiency is the product of the two individual efficiencies.
Implicit sensing on the primary side of the converter need not significantly impact the efficiency of the power processing system and it may be implemented within integrated circuitry that combines it with other control functions of the converters. One well known method of implementing implicit sensing is to add a tertiary winding to the power transformer to enable sensing of a signal related to the output signal of the converter. A typical implicit sensing arrangement in a flyback type power converter senses a voltage from a tertiary winding on the power transformer. This voltage is sensed without compromising the DC galvanic isolation between input and output. However, the regulation based on this sensed voltage tends to be inaccurate since the tertiary winding voltage is not necessarily directly proportional to the output load voltage. Estimated voltages derived from this tertiary winding are inaccurate since estimated currents tend to be a constant while the actual output load currents vary.
Implicit sensing of output voltages and currents is typically dependent on static estimating circuit arrangements that do not accurately reflect the dynamic nature of the power converters output signals. Such arrangements tend to be relatively inaccurate in estimating the output signals at the primary side. Neither output currents nor output voltages are reflected accurately in these arrangements. Regulation accuracy using these implicit sensing schemes is typically 10% to 20% and is functional only over a very limited range of load current. To be effective and achieve accurate regulation, an implicit sensing scheme at the input must accurately reproduce the signal conditions at the output of the converter.
SUMMARY OF THE INVENTION
A method of, and apparatus for estimating the output signals of a power converter, having DC galvanic isolation between the input and output, observes the voltage and current on the primary side of the converter as reflected through a tertiary winding or influenced through the primary winding of the power transformer and applies error corrections thereto to accurately replicate the actual output voltage and/or current signals. These corrections are arrived at by compensating for operational differences between input and output circuitry and by emulating, on the primary side, the output side circuitry that causes the differences between the actual output signal and the reflected signal. The resulting replicated signal is applied to primary side feedback control circuitry, in lieu of the actual output signal, and used to regulate the output of the power converter.
In a particular embodiment of the estimating circuitry the diode current of the estimating circuit is adjusted by an input/output voltage ratio to make it more accurately proportional to the output rectifier current. The estimating circuitry compensates for the differing duty ratios of the power switch and the rectifying diode and hence, increases the accuracy of the estimated output current. The resistance of the estimating circuitry is also made to be proportional to the resistance of the output circuitry on the secondary side to improve accuracy. The reflected output voltage may also be extracted from the primary winding eliminating the need for an added tertiary winding.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block schematic of a power converter with DC galvanic isolation between its input and output circuitry and utilizing primary side implicit voltage sensing;
FIG. 2 is a schematic of a power converter of the prior art as defined by the block diagram of FIG. 1 and having implicit voltage sensing derived from a tertiary winding and using a static load replication;
FIG. 3 is a schematic of a power converter embodying principles of the invention and having implicit voltage sensing derived from a tertiary winding and having implicit current sensing to achieve dynamic load replication;
FIG. 4 is a schematic of primary side estimator circuitry of the power converter deriving information from the primary winding of the power transformer;
FIG. 5 is a schematic of the primary side current estimating circuitry with duty ratio correction to more accurately estimate an output load current;
FIG. 6 is a graph of a voltage waveform, of a primary winding of a flyback power converter;
FIG. 7 is a schematic of a current correcting divider using duty ratio correction to more accurately estimate an output load current.
DETAILED DESCRIPTION
A power converter is shown in block schematic form in FIG. 1. As shown it encompasses both the prior art schematic of FIG. 2 and the power converter circuitry of the remaining figures embodying the principles of the invention. The power converter shown in FIG. 1 has a primary side circuit 103 and a secondary side circuit 104 galvanically isolated from each other by the power transformer 105. Input power is applied to the input lead 101 and chopped by the power processing switch 102 and applied to a primary winding 108 of the power transformer 105. The transformed signal at the secondary winding 106 of the power transformer 105 is rectified and filtered by the rectifier and filter circuit denoted by the block 107. Its output is applied to a load 109. A signal representative of the output voltage and/or output current is sensed on the primary side of the converter by the sense and estimator circuit 111. This sense and estimator circuit 111 may be connected to a tertiary winding of the power transformer or connected to sense a signal of the primary winding 108. Explicit techniques of sensing are disclosed herein below. The sensed signal is converted to a replica of the output by the sense and estimator circuit 111 and is used by a control circuit 112 to control a duty cycle or on/off ratio of the power switches of the power processing switch 102.
The power converter of FIG. 2 includes estimator circuitry operative to replicate the output circuit signals on the primary side of the power converter. Input power is applied, via the input terminal 201, to the primary winding 209 of the power transformer 210. The input power is pulse width modulated by the FET power switch 205. Its switching action and duty ratio is controlled by the switch control circuit 207.
The signal of the primary winding is transformed and applied by the secondary winding 211 to the rectifying diode 212. A lumped resistor 215 represents the combined impedance of the output circuitry presented to the secondary winding 211. The power converter of FIG. 2 operates in a flyback mode in which the conduction of the power switch 205 is out of phase with the conduction of the rectifying diode 212. In a typical flyback converter, the power switch and rectifying diodes have conducting intervals of significantly different durations.
The signal rectified by diode 212 is applied to a filter capacitor 231 and to a load 235 to be energized. Voltage at the load 235 is regulated by controlling a duty ratio of the power switch 205. A switch control circuit 207 driving the power switch 205 determines this duty ratio in response to an estimated voltage generated by the estimator circuit 250 which is connected to a tertiary winding 208 of the power transformer 210.
Estimator circuit 250 includes a resistor 251, a diode 252, a capacitor 253 and a static load 254. Resistor 251 has a resistance value comprising the winding resistance of the tertiary winding 208 plus the body resistance of the diode 252.
This implicit sensing arrangement, shown in FIG. 2, uses a static estimated load 254 while in practice the actual loads of a power converter tend to vary considerably. As a result of this and other considerations discussed above, the simulated load current in the estimator circuit 250 does not track the load current supplied by the converter and thus the estimated output voltage does not necessarily accurately represent the actual output voltage of the converter. An actual 5 volt power converter circuit in this schematical embodiment could be expected to have a regulation of no better than 10% to 20% over a narrow load current range.
The above discussed limitations of the estimator circuit of FIG. 2 are overcome in the estimator circuit disclosed in FIG. 3. The converter circuit of FIG. 3 discloses an implicit voltage sensing scheme with a dynamic surrogate load in the estimator circuit that accurately tracks the output load current.
Input power is applied to the primary winding 309 of the transformer 310, via lead 301. The quantum of power applied to the winding 309 is controlled by the modulating action of the FET power switch 305 under the control of control circuit 306. The output power is supplied from the secondary winding 311, through the rectifying diode 312 to a load 313.
A feedback signal for controlling the output voltage is derived from a tertiary winding 308 of the power transformer 310. The voltage of the tertiary winding 308 is applied to an estimator circuit 350 which replicates the action of the output circuitry at the output of the secondary winding 311. The estimator circuit 350 includes a resistor 351, a diode 352, a capacitor 353 and a dynamic load 375. The resistor 351(R est ) is proportional to the resistance 315(R sec ) by the load current scaling factor m. Where:
R.sub.est =m×R.sub.sec.
A transconductance circuit 375 is connected to resistor 374 to sense the current through power switch 305. It is operative to control the current output (i est ) of the diode 352 to be a value proportional to the actual current (i rect ) of the rectifying diode 312 by the factor m. Where:
i.sub.rect =i.sub.est ×m.
An embodiment of an improved estimator circuit is shown in the flyback converter shown in FIG. 4. This particular arrangement uses primary side sensing circuitry that relies only on the primary winding for sensing a voltage representative of the secondary winding voltage (v sec ) and hence, eliminates the need for a tertiary winding on the power transformer. In this illustrative flyback converter, voltage is sensed across the primary winding at node 401(v IN ) and at node 403(v PRI ). Node 403 is common to the primary winding 409 and to the drain 411 of the FET 410. The voltage (v PRI ) at the drain 411, as sensed by lead 417, may be represented by the expression:
v.sub.PRI =N×v.sub.SEC +V.sub.IN.
Two voltage dividers including the resistors 431 and 432 and the resistors 421 and 422, respectively, adjust the sensed primary winding voltage to account for the turns ratio N:1 of the power transformer 405. The voltages sensed at the center nodes of the voltage dividers are coupled through op amps 423 and 433, respectively to the summing circuit 435 which subtracts the v IN related voltage on lead 424 from the v PRI related voltage on lead 439 and produces an estimate of the output voltage on lead 419. The output of the amplifier 433 is coupled to lead 439 by a diode 434 and a resistor 437 proportionate to the output circuit resistance 473, modified by the load current scaling factor m, which includes the power transformer turns ratio N and to a capacitor 434 also proportional to the output capacitor 443 by the load current scaling factor.
The current through the diode 434 and resistor 437 is an estimate of the secondary current flowing through diode 470 and is derived from the primary current flowing through the FET 410. The source current of FET 410 flows through a resistor 415 and is sensed by a current sense circuit 475. The sensed current on lead 477, as well as the estimated output voltage on lead 419 and the input voltage on lead 401, is applied to the current sense circuit 475 to derive a proportional replica of the output rectifier current on lead 476. The ratio of the estimated voltage and input voltage is processed by current sense circuit 475 to compensate for a difference in conduction duty cycles of FET 410 and the output rectifying diode 470.
A critical factor in estimating the load current on the primary side of an isolated power converter is the differing conduction duty ratios of the power switch and the rectifying diode. A typical example of the differing conduction duty ratios in a flyback converter may be seen in FIG. 6 which is a graph of a flyback converter primary winding transformer voltage. As shown, the primary winding voltage duration 601, responsive to the power switch conduction interval, can differ considerably from the winding voltage duration 602, responsive to the rectifying diode conduction. It is also apparent that these currents flow at differing times, with the primary current unavailable when the reflected output voltage is available to the implicit primary sensing circuitry.
A primary side implicit current sensing arrangement that accurately compensates for the differing duty cycle ratios and which may comprise the circuitry of the current sensing circuit of FIG. 4 is shown in FIG. 5. The current is sensed at the source 515 of the FET switch 510 and is coupled by a current lead 516 to a current sensing amplifier 517. The output of the current sensing amplifier 517 is applied to a current averaging circuit 518 which determines an average value for the output of the current sensing amplifier. The current averaging circuit 518 converts the sensed FET current into a DC current before applying it to the subsequent duty ratio divider circuit 520. The duty ratio divider circuit 520 modifies the estimated output current to accommodate the differing conduction duty ratios of the rectifying diode and the FET power switch. These differing duty ratios are derived by comparing the input and output voltages. Where:
<i.sub.RECT >=<i.sub.PRI >×(V.sub.IN /V.sub.OUT).
Where <i PRI > is the average sensed FET current and <i RECT > is the average rectifier current of the output which is substantially equal to the load current and is used to represent the surrogate load current in the primary estimator circuitry. The input voltage is applied to the duty ratio divider 520 at input lead 521 and a representation of the output voltage, which may comprise the estimated output voltage or if necessitated by circuit operating conditions, a reference voltage equal to or proportionate to the desired output voltage V out is applied to the duty ratio divider 520 at input lead 522.
A schematic of a duty ratio divider circuit operative to apply corrections to the rough first estimate of the output load current is shown in FIG. 7. The divider circuit includes two controlled current paths to receive input and estimated output voltages and convert them to proportional currents. These currents together with the primary current value generate the estimated value of the output load current. A first input 701 is connected to receive the estimated output voltage or a nominal reference output voltage and a second input 702 is connected to receive the input voltage. The representative output voltage at lead 701 applied to resistor 731 controls the controlled current sources 703 and 705. The input voltage at lead 702 applied to resistor 732 controls the controlled current sources 704 and 706. The current sensed at the primary winding side of the converter is modified to reflect the load current scaling factor and applied to the diode connected transistor 712, via the lead 711, which is connected to a logarithmic adder circuit 714 comprising diode connected transistors 712, 713, 722 and 723. The two controlled current sources 703 and 705 are connected to source and sink respectively, the logarithmic element diode connected transistor 713. Similarly, the two controlled current sources 704 and 706 are connected to source and sink the logarithmic element diode connected transistor 722. The collector of transistor 723 is connected to an output lead 725 and provides the estimated load current.
In operation the summed voltage across diode connected transistors 712, 713 and 722, which is proportional to the logarithms of the currents through these transistors, controls the voltage across the base-emitter junction of transistor 723 and, hence, controls the estimated output current generated at the output 725. The relevant voltage summing equation is:
V.sub.723 =V.sub.712 -V.sub.713 +V.sub.722
logI.sub.725 =logI.sub.711 -log(V.sub.701 /R)+log(V.sub.702 /R)
and hence,
I.sub.725 =I.sub.711 ×(V.sub.702 /V.sub.701).
The detailed circuitry of controlled current sources 705, 704, 705 and 706 is well known in the art. Such circuitry may comprise current mirror circuits responsive to control amplifier circuits. The amplifier circuits are in turn responsive to the input and representative output voltages. It is not believed necessary to disclose this circuitry in detail since suitable circuits for this function may be readily devised by those skilled in the art. | A method of and apparatus for monitoring the output signals of a power converter, having galvanic isolation between the input and output, observes the voltage and current on the primary side of the converter as reflected through a tertiary winding or influenced through the primary winding of the power transformer and applies error corrections thereto to replicate the output signal. These corrections are arrived at by compensating for operational differences between input and output circuitry and by emulating, on the primary side, the output side circuitry that causes the differences between the output signal and the reflected signal, and the conditions to which the output side circuitry is subjected. The resulting replicated signal is applied to feedback control circuitry, in lieu of the actual output signal, and used to regulate the output of the power converter. | 7 |
[0001] This application claims priority under 35 USC 119(e) based on provisional patent application No. 60/453,203 filed on Mar. 11, 2003.
FIELD OF THE INVENTION
[0002] The present invention is directed to a cleaning composition, and in particular, to a composition containing a terpene, hydrogen peroxide, and a reduced amount of surfactant.
BACKGROUND ART
[0003] In the prior art, hydrogen peroxide is a desirable component of cleaning preparations. However, it is also an unstable compound, and its use in a cleaning composition requires fine tuning in order that the composition remain stable over time, and that hydrogen peroxide does not break down.
[0004] One such composition is disclosed in U.S. Pat. No. 6,316,399 to Melikyan et al. This patent discloses a composition combining a terpene such as D-limonene and hydrogen peroxide and a number of surfactants. The aim of this patent is to provide a composition that has high stability over long periods of time. This aim is accomplished by using a terpene, an anti-oxidant, two anionic surfactants, a nonionic surfactant, hydrogen peroxide, and Deionized water. One of the anionic surfactants acts as an emulsifier, and a cleaning surfactant, whereas the other anionic surfactant acts as a wetting agent, surface tension reducer, and hydrotrope.
[0005] While the composition of the Melikyan et al. patent is described as having stability, it suffers from a high loading of surfactants. The loadings tend to leave a sticky residue on the material being treated and this stickiness contributes to resoiling of the treated area.
[0006] Thus, a need exists to provide improved hydrogen peroxide-containing cleaning compositions which are both stable over long periods of time, and do not cause rapid resoiling of the areas treated with the composition.
[0007] The present invention responds to this need by the discovery of a cleaning composition that is both stable and is more resistant to resoiling by virtue of a lower surfactant loading.
SUMMARY OF THE INVENTION
[0008] It is a first object of the present invention to provide an improved cleaning composition that uses a terpene such as D-limonene or orange oil.
[0009] Another object of the invention is a method of using the composition in a variety of strengths.
[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 improved cleaning composition consisting essentially of a terpene in an amount ranging between 0.01-30.0% by weight; an anti-oxidant in a finite amount between zero and 4.0% by weight; a water soluble co-solvent between zero and up to 10.0% by weight; a single anionic surfactant, either an alkali metal salt of a linear alkylbenzene sulfonic acid in an amount corresponding to 1.2 parts per 1.0 part of the terpene component, or an alkali metal salt of an alkyl sulfonate in an amount of 0.8 parts per 1.0 part of the terpene component; a non-ionic surfactant in an amount between 0.5 and 7.0% by weight; hydrogen peroxide in an amount between 2.0-75.0% by weight, wherein the hydrogen peroxide amount is based on a solution of 35% concentration; a thickener from zero and up to 5.0% by weight; and the balance deionized water.
[0012] The single anionic surfactant can be either the alkali metal salt of a linear alkylbenzene sulfonic acid or the alkali metal salt of an alkyl sulfonate. When using the alkali metal salt of a linear alkylbenzene sulfonic acid, it is preferably an isopropylamine salt of a linear alkylbenzene sulfonic acid. When using the alkali metal salt of an alkyl sulfonate, it is preferably sodium 1-octane sulfonate.
[0013] The terpene is preferably an orange oil or D-limonene. When using a co-solvent, a glycol ether such as ethylene glycol monobutyl ether can be used in effective amounts. The nonionic surfactant is preferably an alcohol ethoxylate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present invention is an improvement in cleaning compositions using a terpene and hydrogen peroxide. The inventor has discovered that a stable and effective composition can be made by the use of a single anionic surfactant in combination with a nonionic surfactant, an anti-oxidant, a terpene, hydrogen peroxide, and deionized water. In certain formulations, due to a high amount of hydrogen peroxide, the deionized water component may be zero. The formulation can also employ an additional solvent and a thickener.
[0015] The following table outlines the components of the composition, in terms of weight percent of the compositional solution.
TABLE 1 range in weight percent of component based on entire solution weight as shown in Johnson Components formulation a terpene 1 , 0.01-30.0% including D-limonene and orange oils an anti-oxidant 2 a finite amount between zero and 4.0% a water soluble co- zero and up to 10.0% solvent 3 one anionic 1.2 parts of the A-type surfactant only, to 1.0 part of the either an A type or terpene component or B type anionic 0.8 parts of the B-type surfactant 4 to 1.0 part of the terpene component non-ionic 0.5-7.0% surfactant 5 hydrogen peroxide 2.0-75.0% (35%) a thickener 6 zero and up to 5.0% deionized water balance to make 100%
[0016] More details of the surfactants is as follows:
[0017] One of the Type A or B Anionic Surfactants
[0018] One preferred surfactant as Type A is an isopropylamine salt of the linear alkylbenzene sulfonic acid. A preferred Type B anionic surfactant is sodium 1-octane sulfonate.
[0019] One commercial formulation of the Type A surfactant listed above is BIOSOFT-411. This type A surfactant is available from a number of suppliers, e.g. Stepan, and is also sold under a different trade name but still identified as a match with BIOSOFT-411. Likewise, one commercial formulations of the Type B surfactant is Bioterge PAS-8S and this is available from one or more suppliers, either under this trade name or under another trade name known to be an equivalent to Bioterge PAS-8S.
[0020] Nonionic Surfactant
[0021] The nonionic surfactant can have its number of carbon atoms vary, with a preferred range being between 10-15 carbon atoms. A preferred HLB value is 13.1. In this regard, one commercial formulation for this type of surfactant is Neodol 25-9, which is available from a number of suppliers, whose identities can be obtained by using the world wide web. Other commercial formulations under different trade names are also available as an equivalent to Neodol 25-9.
[0022] A key aspect of the invention is the ability to use a single anionic surfactant to maintain the stability of the composition, as opposed to having first and second anionic surfactants as is required in the Melikyan et al. patent.
[0023] While Table 1 above outlines the limits of the invention, specific formulations are detailed below in TABLE 2.
TABLE 2 component wt. % deionized water 55.36 58.17 93.06 93.59 0.00 0.00 49.89 93.89 94.11 92.69 anti-oxidant 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 glycol ether 0.00 0.00 0.00 0.00 0.00 0.00 7.00 0.58 0.58 0.58 D-limonene 7.08 7.08 1.32 1.32 7.08 7.08 6.58 0.55 0.55 0.55 Biosoft-411 8.55 0.00 1.60 0.00 8.55 0.00 7.95 0.66 0.00 0.66 Bioterge PAS-8S 0.00 5.74 0.00 1.07 00.0 5.74 0.00 0.00 0.44 0.00 Neodol 25-9 6.41 6.44 0.00 1.07 6.41 6.41 5.96 0.50 0.50 0.50 thickener 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.00 1.00 hydrogen 22.6 22.6 2.80 2.80 72.2 72.2 22.6 2.80 2.80 4.00 peroxide (35%)
[0024] It should also be understood that this disclosure incorporates by reference the Melikyan et al. patent discussed above. In this regard, the Melikyan patent discloses a number of different concentration levels for different uses in Table 2 thereof, and any of the uses would be applicable with any of the inventive formulations encompassed by Table 1 or the specifics ones of Table 2 of the instant application.
[0025] As noted in the Table 1 and 2 above, the hydrogen peroxide is preferred in a 35% concentration.
[0026] The thickener is an optional component of the formulation as is the co-solvent. A preferred co-solvent is a glycol ether, more preferably an ethylene glycol monobutyl ether or an equivalent thereto, since these types are effective in removing organic and petroleum soils as a result of the ether linkage.
[0027] The cleaning composition can be used virtually for any cleaning use, either for the consumer or in the industrial area. The uses include those known uses disclosed in Table 2 of the Melikyan patent, and any other known uses where cleaning, degreasing, odor and/or mildew elimination, disinfection, and stain removal are needed.
[0028] As such an invention has been disclosed in terms of preferred embodiments thereof, which fulfills each and every one of the objects of the invention as set forth above, and provides an improved cleaning composition.
[0029] 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 cleaning composition uses a terpene such as D-limonene or orange oil, a nonionic surfactant, a single anionic surfactant, an anti-oxidant, hydrogen peroxide, and the balance deionized water. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for reducing the likelihood of shoulder dislocations or subluxations occuring during athletic activity and, in particular is directed to apparatus to be worn by an athlete equipped with a standard shoulder pad assembly.
In athletic endeavors, the human body is frequently called on to perform certain motions which are not always those with which the musculo-skeletal structure of the body is comfortable. These motions, when repeatedly performed can result in a weakening of the supporting structure surrounding the joint. When a difficult motion is undertaken to an extreme, the joint undergoes a full dislocation. This situation requires a reduction of the joint to restore it to its normal condition. Each time a joint undergoes a full dislocation, the easier it is to have the situation repeat itself. This overall weakening also takes place in the case of partial dislocations where the received bone partially leaves the socket and thereafter returns to the proper position.
While certain joints in the human body are characterized by a deep socket, for example the socket formed in the pelvic bone to receive the head of the femur, there are other joints of the body which are designed for mobility rather than stability. These joints are characterized by relatively shallow socket. One such joint is the shoulder wherein the shallow socket (glenoid fossa) of the scapula receives the head of the humerus or upper arm bone. In athletics, this type of shallow-socket joint is frequently subjected to a motion, which coupled with an external force applied by either a competitor or contact with the ground, results in a partial dislocation or subluxation of the joint.
In the shallow glenohumeral shoulder joint, the mechanism of injury is typically an external rotation of the arm coupled with abduction or movement away from the body by the arm. The shoulder joint need not undergo a full dislocation, but often suffers a partial dislocation where the humerus or arm bone slides part way out of the joint and then moves back into place. As it is repeated, the tendency for it to occur again is greatly increased.
In contact sports such as football and hockey, the participants are equipped with a shoulder pad assembly. These pads cushion impact, but do little or nothing to prevent partial dislocations or subluxations of the shoulder. Consequently, athletes may have their upper torso wrapped with an elastic bandage prior to "putting on the pads." The Shoulder Spica is a well-known wrap that has been used to support the shoulder joint while still permitting use of the arm. The wrap is characterized by wrapping the upper arm and then taking the free end thereof across the chest, under the opposite arm, and behind the back. Three or more upper torso wraps are taken about the chest and back and down the upper arm. The free end is taped which decreases its effectiveness during an athletic workout or game since the wrap tends to loosen with use. Furthermore, the bulkiness of the wrap tends to reduce the field of other motions frequently limiting overall performance. To change the wrap is time-consuming. It requires the over-lying equipment to be removed since no adjustment can be made to the player without repeating the wrapping process.
As a substitute for the Shoulder Spica wrap, mechanical shoulder braces have been designed to assist football players in preventing shoulder subluxation. The braces provide motion inhibiting results when strapped to the torso. Hinged joints of the brace control the movement of the shoulder. These braces are cumbersome and quite expensive. Generally, they are beyond the budgetary abilities of most schools. Furthermore, the range of motion limitations of the brace provide freedom of movement up to the limit with no indication provided to the wearer of when the limit is about to be reached, i.e. no proprioceptive feedback is provided to the wearer. Consequently, the effectiveness of the athlete is reduced when the limit is abruptly reached.
A substitute for the mechanical brace with its hinged joint is the use of a fabric vest and attached half sleeve. Straps across the back and chest are used as stops to limit abduction while the cuff or half-sleeve on the upper arm serve to maintain the combination in position on the torso. The vest-sleeve combination establish limits to abductive movements, i.e. movements away from the central axis of the body, but does not provide any significant control of arm rotation. As a result, severe external rotation of the humerus in relation to the scapula can occur and subluxation is still a cause for concern.
Any device worn to reduce the chance of subluxation of the shoulder requires that resistance to external rotation and abduction be provided but to enhance the effectiveness to the wearer requires that the athlete be able to sense when the limits are being reached. An athlete sensing that he is approaching a limitation on permissible movement can alter his other movements so as to achieve his performance goal. The use of rigid confining harnesses alone or in combination with the fixed length tether of the fabric vest do establish a limit to movement, but fail to provide the athlete with notice that he is about to reach his limit. Without warning of the limit, hockey and lacrosse players raising their stick, or the football receiver extending his arms for the football do not have sufficient time to react and adjust. Thus, the existing orthotic devices decrease performance levels of the wearers.
Accordingly, an object of the present invention is the provision of an improved shoulder brace to reduce the possibility of subluxation. The invention is designed to indicate to the wearer when abduction and external rotation are approaching the limit for this individual so that overall movement can be adjusted to compensate. In addition, the present athletic brace is applied in combination with the conventional shoulder pad assembly when the assembly is in place. Consequently, individual adjustment can be made without requiring the wearer to shed pads and all.
SUMMARY OF THE INVENTION
The present invention is concerned with an athletic brace to be used in combination with a shoulder pad assembly in order to reduce the possibility of a shoulder subluxation while facilitating movement of the upper arm during athletic activities. In particular, the athletic shoulder brace includes an elongated elastic member to be wrapped about the upper arm of the wearer. The elastic member is similar to the elastic wrap utilized by athletic trainers in providing joint support. The elastic member has first and second ends with an engaging means affixed to the member proximate to its first end.
When the elongated elastic member is wrapped about upper arm of the wearer, the engaging means which may be an insert of hooked material, such as that used in the hook and eye fasteners widely used in clothing and containers, engages the adjacent surface of the elastic member to provide a secure initial wrap about the upper arm. The elastic member is further wrapped about the upper arm in an internal wrap in which the first end is brought underneath the arm and then around the back of the arm and over it. The free or second end extends toward the center of the chest.
The second end of the elastic member is provided with attachment means which can be secured to the conventional athletic shoulder pad assembly at a location inwardly spaced from the shoulder. Typically, the attachment means is interlaced using the lashing provided at the front portion of the shoulder pad assembly. The wrapping of the first end about the upper arm then results in a portion of the elastic member extending across the adjacent portion of the chest of the wearer. Since the second end is attached to the shoulder pad assembly, an abduction movement of the upper arm encounters increasing resistance as the elastic member is subjected to tension. In addition, external rotation, i.e. away from the body, of the arm also encounters the increasing opposing force due to tension of the elastic member.
The limits on combined abduction and rotational movement of the upper arm are established when the wrap is made about the upper arm of the wearer. Since the member is elastic, the wearer feels the forces exerted thereby in opposition to his proposed movement. Thus, the wearer is continually made aware of the fact that he is approaching a limitation to his permitted movement well before reaching the point where subluxation of the shoulder is a distinct possibility, should he continue movement of this type. Thus, the athlete engaged in competitive activity can make adjustment for the fact that he is about to encounter a limit to his movement and alter his position or body attitude accordingly. The prospect of the receiver of the football extending his arms and having movement toward the path of the ball abruptly limited without warning is not present.
Furthermore, the placement of the present invention on the wearer takes place after he has been outfitted with all the undergarments and paddings, but just prior to the placement of the identifying shirt which constitutes his outer layer. Adjustments can be affected merely by removing the outer garment from the player and rewrapping the upper arm to adjust the tension of the elastic member when the arm is not extended.
Further features and advantages of the invention will become more readily apparent from the following description of a particular embodiment when viewed in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective showing a shoulder pad assembly and the subject matter of the invention when detached therefrom.
FIG. 2 is a partial view in perspective showing the engaging means affixed proximate the first end.
FIG. 3 is a partial front view of the human torso illustrating the movements to be controlled.
FIGS. 4(a) and 4(b) show the wrapping of the elastic member about the upper arm of the wearer.
FIG. 4(c) shows the combination of the present invention with a conventional shoulder pad assembly positioned for use.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a typical shoulder pad assembly 11 is shown without the lashing that secures the frontal protectors 14 to one another. In use, the assembly is slipped over the head of the wearer so that the protective extensions 12 reside on and over the shoulders of the wearer. The frontal protectors 14 extend downwardly providing a degree of protection for the clavicle. Each frontal protector is provided with a tab section 16 containing a plurality of spaced grommets 15. When positioned to be comfortable, the lashing is drawn tight and tied. Typically, the lashing is never removed from the grommets after use, but is merely loosened to enable the wearer to remove the assembly over his head.
The athletic brace to be worn in combination with the shoulder pad assembly 11 is shown in FIG. 1 in an extended position. The brace comprises an elongated elastic member 20 having opposing ends. The elastic member has a free end which is provided with a first engaging means 22 and a second engaging means 21 spaced inwardly therefrom. As will later be described, this portion of the elastic member 20 is wrapped about the upper arm of the wearer.
The opposing end of the elastic member is provided with a plurality of spaced grommets 15 at second end 27. The grommets are spaced so that they will substantially register with grommets 15 on the tab 16 of the shoulder pad assembly. In practice, the lashing used for the shoulder pad assembly secures the second end 27 to the adjacent tab 16. The second end 27 is secured by fabric extensions 26 which are coupled to a plurality of individual release means 24. The release means are detachable into male and female components by finger pressure exerted on their side. The other end of the release means is affixed by fabric extensions 26 to a flap 25 which is folded back upon the elastic member to provide a double thickness termination.
The elongated elastic member may be fabricated from the elastic wrap material used by athletic trainers today so that it has elasticity in all directions and is capable of being conformably wrapped on the upper arm of the wearer.
As shown in FIG. 2, the spaced engaging means 21 and 22 are formed on the same side of the elastic member with one located fairly close to the free end, and the other inwardly spaced therefrom. Since many of the elastic wraps are made from a ribbed fabric that has a rough surface that exposes threads, the engaging means in the embodiment shown are patches of hook material such as used in the common hook-eye fasteners found in multiple uses with containers, clothing and footwear and the like. It is recognized that other fasteners can be used if desired. The location of the patches forming the engaging means is not particularly critical since they are designed to engage the adjacent surface of the portion of the elastic member and thus both are placed on the same surface of the elastic member.
The function served by the engaging means is more clearly shown in FIGS. 4(a) and 4(b) wherein the wrapping about the upper arm is shown. In FIG. 4(a), a single wrap about the arm is shown made in an internal wrap wherein the wrap begins toward the axis of the body and continues around the back of the arm. The wrap has not been drawn tight to show the relative position of the engaging means. In the case of the single wrap as shown in FIG. 4(a), only one of the engaging means contacts the elastic member. In FIG. 4(b), the wearer has received a double internal wrap and the engaging means 21 and 22 provide a more secure wrap that is less likely to move during use. Normally, the wrap is made under some tension, but not enough to restrict blood flow in the arm of the user. In FIG. 4(b), it is to be noted that the second end 27 has been removed with the three release means being decoupled from their adjacent parts. This is to illustrate how readily the elastic member can be decoupled by use of the release means from the second end 27 and the shoulder pad assembly. This feature permits the wearer to be rewrapped without requiring other equipment to be removed.
The affixation of the present invention to the shoulder pad assembly is shown in FIG. 4(c) wherein the elongated elastic member is shown wrapped about the upper arm in an internal rotation wrap below the protective extension 12 of the shoulder pad assembly. The elastic member 20 extends across the adjacent portion of the chest of the wearer and overlies the first frontal protector with the second end 27 being affixed to the opposing frontal protector by lashing 18 drawn through the grommets 15. The male portions 28 and female portions of the release means 24 are inserted and locked and the athletic brace is in position to both support the shoulder joint and protect against subluxation.
The movements of the upper arm 31 that are known to promote subluxation of the shoulder 32 are shown in FIG. 3 wherein the abductive movement of the arm upward and away from the central axis of the body is shown by the arrow. In addition, the external rotation or movement of the humerous in its socket outwardly away from the torso is shown by the circular arrow on the dashed line of the arm in its abducted position. The combination of these two movements greatly increases the tendency of the humerous to move out of the socket in the scapula. These partial dislocations are commonly referred to as subluxations and their repeated occurrences enhance the likelihood that they will recur.
When the wearer is provided with the present invention as shown in FIG. 4(c), the abductive movement away from the body and the external rotation both encounter the opposing or restoring force of the elastic member 20. Thus, the wearer is ever-conscious of the fact that there will be a movement limitation determined by the present invention. He is alerted to the fact that during competition, this limit is likely to be encountered. As he makes one or both of the two movements being controlled, the increasing resistance encountered from the elastic member should indicate to the athlete that he has to change his body position in order to complete his assigned task. The limits are established by the initial tension provided to the elastic member, by the position of the wrap on the upper arm and the number of turns thereof. The engaging means fixes the length of the elastic member once the wrap of the upper arm is made. In the event that there should be an adjustment necessary or replacement of the elastic member during competition, the athlete need not remove his shoulder pads. The release means 24 is provided to allow the elastic member to be detached, replaced or rewrapped as desired. Access to the assembly is provided merely by removal of the identifying shirt of the athlete.
The use of a flexible and accessible bracing system does not encumber the athlete as is the case with rigid brace assemblies or preventer staps worn with vests and the like. This invention is found to have been successful in decreasing the chances of subluxation, especially in the case of wide receivers in football. The present athletic brace is relatively inexpensive to manufacture and comfortable for the wearer. At the conclusion of the athletic activity, the wearer need only decouple the release means so that the wrap is separated from the second end 27. In practice, the second end 27 is left with the individual shoulder pad assembly. No assistance is necessary to remove the present invention from the wearer.
While the above description has referred to a particular embodiment of the invention, it is to be recognized that many modifications and variations may be made therein without departing from the scope of the invention as claimed. | An athletic brace to be worn with conventional shoulder pads for reducing the chance of subluxation of the shoulder which includes a wide elastic member that is internally wrapped about the upper arm and brought across the chest for attachment to the front of the shoulder pads. The elastic member tends to limit both abduction and external rotation of the upper arm of the user thereby reducing the chance of the athlete reaching the point that tends to stress the glenohumeral joint to the point of subluxation or dislocation. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates, in general, to an electromagnetic wave-shielding coating material and, more particularly, to an electromagnetic wave-shielding coating material which paints are mixed with electroconductive polymers, so that may be superior in both paintability and electromagnetic wave shielding activity.
With a great technical advance in the electronics field, electronic appliances, which are indispensable for daily life, become better and better in performance and function. In addition, electronic appliances are also developed in dimension with an inclination to lightness and slimness. In this regard, cases of electronic appliances are changed into plastics, which are light and comfortable to carry. Whereas being light, strong, and easy to mold, plastics, however, are restricted in their uses owing to their nonconductivity. One of the most serious problems that plastics have results from electromagnetic waves. In general, plastic itself cannot shield electromagnetic waves. If they do not cope with electromagnetic waves, plastics, however graceful in appearance or convenient in use they may be, cannot be used for the fear of the malfunction of the electronic appliances.
In an effort to solve such problems, there have been developed various techniques for shielding electromagnetic waves. At present, the shielding of electromagnetic waves is conducted by use of, for example, plating, electroconductive paints, vacuum deposition, and electroconductive polymers. Of them, plating is most prevalently used because the other methods show significant disadvantages over the plating method.
For example, electroconductive polymers are relatively poor in shielding ability, vacuum deposition requires expensive facilities, and electroconductive polymers are restricted in their materials. For these reasons, a plating method is prevalently used now. However, the plating method is disadvantageous in that plating materials are expensive.
An electromagnetic wave consists of vibrating electric and magnetic fields which move with the same phase at a given time. The electric field, determined by the intensity of charges, is shielded by any of electroconductive materials while the magnetic field, depending on the motion of charges, is penetrative of all materials. In particular, electric fields are known to be more harmful to the body than are electric fields.
Electromagnetic waves are generated by electric and electromagnetic apparatuses, such as household appliances, wireless communication systems, control systems, power systems, high frequency-generating instruments, lighting instruments, and the like, and power lines. In recent, the most serious artificial noise is sourced from digital systems, including computers.
Electromagnetic waves cause various dysfunctions in the body although they are not the same in severity. Recently, active research has been directed to the protection of the body from electromagnetic waves.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to overcome the above problems encountered in prior arts and to provide a coating material which is able to effectively shield electromagnetic waves with a broad band of frequencies and be coated onto cases of various electromagnetic apparatuses, thereby protecting the body from electromagnetic wave pollutions.
In addition, it is another object of the present invention to provide an antistatic coating material.
In accordance with an embodiment of the present invention, there is provided an electromagnetic wave-shielding coating material, comprising polyaniline (ES) with a solid content of 1-50%, a matrix polymer with a solid content of 1-50%, and additives at a predetermined amount.
In one version of this embodiment, the matrix polymer is selected from the group consisting of a vinyl emulsion and an acrylic emulsion. In another version of this embodiment, the additives comprise a wetting agent, a coalescing agent, a freeze/thaw stabilizer, a defoamer, a thickner or mixtures thereof.
In accordance with another embodiment of the present invention, there is provided an electromagnetic wave-shielding coating material, prepared by mixing polyaniline (ES, 100%), an acrylic resin and additives at predetermined amounts and adding the mixture with a hardener and a mixed solvent at predetermined amounts just before use.
In one version of this embodiment, the additives comprise a dispersion agent, a defoamer, a leveling agent, a UV stabilizer, a UV absorber, a catalyst or mixtures thereof. In another version, a hardener is further added.
DETAILED DESCRIPTION OF THE INVENTION
One of the hottest electromagnetic wave issues is that the body is damaged when being exposed to weak electromagnetic waves with low frequencies for a long period of time. As for the harmfulness of strong electromagnetic waves, it is scientifically verified. Recent legislation, in response to electromagnetic wave concerns, has been enacted to prescribe maximal exposure limits for the protection of the body.
It is reported that, when the body is exposed to electromagnetic waves of low frequencies for a long period of time, currents are induced in the body to incur an imbalance in concentration between various intracellular and extracellular ions such as Na + , K + , Cl − and so on, affecting hormone secretion and immune cells.
An electromagnetic wave, as mentioned previously, consists of electric and magnetic fields. The intensity of an electric field is determined by the magnitude of a potential while the intensity of a magnetic field is determined by the magnitude of a current. An electric field is greatly shielded by a highly conductive material whereas a magnetic field is difficult to shield because it can be shielded only by special alloys which are very highly magnetic. When exposed to electric fields, the body may suffer from a thermal disease such as eczema as a current flows through the body. On the other hand, magnetic fields are found to penetrate into the body to affect the iron molecules in blood. Electromagnetic waves are more harmful to blood corpuscles, which proliferate rapidly, the genital organs, lymphatic glands and children.
Examples of the symptoms that electromagnetic waves may cause include languidness, insomnia, nervousness, headache, reduction in the secretion of melatonin responsible for sound sleep, and pulse decrease. In addition, recent reports have argued that electromagnetic waves may cause diseases such as leukemia lymph cancer, brain cancer, central nerve cancer, breast cancer, dementia, abortion, and deformed child parturition. Besides, many other diseases are reported to be caused by electromagnetic waves.
Much effort has been made to prevent the evils of electromagnetic waves. In result, many electromagnetic shielding products are developed. Especially, in accordance with the present invention, developed is an electromagnetic wave-shielding coating material which itself is resistant to electromagnetic waves.
In general, coating materials are used for printing and exemplified by varnish and paints. Undercoating materials have the function of anti-corrosion. Medium and finishing coating materials are to provide resistance against external conditions for targeted materials. Usually, such coating materials are composed of pigments, resins and organic solvents.
Suitable for use in the purpose are benzene, toluene, xylene, methylethyl ketone, methylisobutyl ketone, and combinations thereof.
The present invention is directed to a coating material for shielding electromagnetic waves, comprising polyaniline with a solid content of 1-50%, which is an electroconductive polymer having self-resistance to electromagnetic waves, a matrix polymer with a solid content of 1-50%, and additives at predetermined amounts.
As the matrix polymer for the coating material for shielding electromagnetic waves, a vinyl emulsion or an acrylic emulsion resin is available.
As for the additives suitable in the present invention, they comprise a wetting agent, a coalescing agent, a freeze/thawing stabilizer, a defoamer, and/or a thickner.
The wetting agent is selected from the group consisting of polyoxyethylene nonylphenyl ether (ethylene oxide: 4-10 mol), polyoxyethylene octylphenyl ether (ethylene oxide: 5-10 mol), ditridecyl sodium sulfosuccinate, polyethyleneglycol laurate (HLB=6-15) and mixtures thereof.
The coalescing agent is selected from the group consisting of 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, butyl carbitol acetate, butyl cellosolve, butyl cellosolve acetate, diethyleneglycol butyl ether acetate, and mixtures thereof.
The freeze/thaw stabilizer is selected from the group consisting of propylene glycol, ethylene glycol, 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, and mixtures thereof.
The defoamer is selected from the group consisting of PEG-2 tallowate, isooctylalcohol, disodium tallow sulfosuccinamate, and mixtures thereof.
The thickner is selected from the group consisting of modified hydroxyethylcellulose, polymer hydroxyethylcellulose, acrylic acid ester copolymer, ammonium polyacrylate, and mixtures thereof.
In accordance with the present invention, the coating material for shielding electromagnetic waves is prepared by mixing polyaniline (ES, 100%), an acrylic resin and additives at predetermined amounts and adding the mixture with a hardener and a mixed solvent just before use.
Examples of the additives available in the present invention include a dispersion agent, a defoamer, a leveling agent, a UV stabilizer, a UV absorber and a catalyst. Additionally, a hardener may be used.
The dispersion agent is selected from the group consisting of a polyester modified methylalkylpolysiloxane copolymer, sulfosuccinic acid ester, an ethylene/acrylic acid copolymer, and mixtures thereof.
The defoamer is selected from the group consisting of methylalkylsiloxane, a sodium salt of an acrylic acid copolymer, and a mixture thereof.
The leveling agent is selected from the group consisting of polyacrylate, a polyester modified methylalkylpolysiloxane copolymer, and a mixture thereof.
The UV stabilizer is a benzotriazole derivative (2-2′-hydroxy-3,5′-di-t-amylphenylbenzotriazole).
The UV absorber is selected from the group consisting of a benzophenone derivative, 2-2′-diethoxy acetophenone, and a mixture thereof.
The catalyst is selected from the group consisting of an organic tin compound, dibutyltinoxide, dibutyltindisulfide, stannous octoate, tetraisobutyltitanate, and mixtures thereof.
The hardener is selected from the group consisting of hexamethylene diisocyanate isocyanurate, hexamethylene diisocyanate biuret, heamethylene diisocyanate uredione, isophorone diisocyanate isocyanurate, and mixtures thereof.
Polyaniline, which plays a core role in shielding electromagnetic waves, is prepared from an aniline monomer (C 6 H 5 NH 2 ) as follows. Preferably, the aniline monomer is purified before use. In the preparation of polyaniline, ammonium peroxydisolfate to be used as an oxidant, H 2 SO 4 and NH 4 OH may be used without further purification.
(1) 40 ml of aniline is dissolved in 800 ml of a mixture of 80:20 1M-H 2 SO 4 :formic acid (v/v) and cooled to 0° C. Separately, 23 g of (NH 4 ) 2 S 2 O 8 is dissolved in 200 ml of 1M H 2 SO 4 and cooled to 0° C. Next, the aniline solution is added with the (NH 4 ) 2 S 2 O 8 solution for 2 minutes while being stirring with a magnet. Subsequently, the resulting mixed solution is allowed to react for 90 minutes while being stirred with a magnet. After completion of the reaction, the reaction product is filtered off through a filter.
(2) The filtrate obtained in step (1) is reacted at 0° C. for 90 minutes with a solution obtained by dissolving 23 g of (NH 4 ) 2 S 2 O 8 in a mixture of 80:20 1M H 2 SO 4 :formic acid (v/v) in a total volume of 1 liter without further adding aniline. After 90 minutes, the reaction product is filtered off through a filter.
(3) The filtrate obtained in step (2) is reacted at 0° C. for 90 minutes with a solution obtained by dissolving 23 g of (NH 4 ) 2 S 2 O 8 in a mixture of 80:20 1M H 2 SO 4 :formic acid (v/v) in a total volume of 1 liter without further adding aniline. After 90 minutes, the reaction product is filtered off through a filter.
(4) The filtrate obtained in step (3) is reacted at 0° C. for 90 minutes with a solution obtained by dissolving 23 g of (NH 4 ) 2 S 2 O 8 in a mixture of 80:20 1M H 2 SO 4 :formic acid (v/v) in a total volume of 1 liter without further adding aniline. After 90 minutes, the reaction product is filtered off through a filter.
(5) The solid material filtered through steps (1) to (4) is again added in a 1M HCl solution and stirred by use of a glass rod to give a suspension which is then stirred for 15 hours with the aid of a magnet and filtered through a filter.
Upon this filtration, the filtrate is washed with 1M HCl until it becomes completely colorless, so as to produce protonated polyaniline (ES, solid content 1-50%). The above-mentioned method can synthesize polyaniline at high production yields compared with conventional methods.
As described above, the polyaniline filtrate obtained after the synthesis of polyaniline is treated 3-5 times with oxidizing agents without additionally using aniline monomers to produce polyaniline superior in physicochemical properties such as electroconductivity and thermal stability.
The polyaniline according to the present invention has the following chemical structure:
Through the above-illustrated procedure, aniline monomers can be polymerized into polyaniline ranging, in molecular weight, from 30,000 to 50,000.
A better understanding of the present invention may be obtained in light of the following examples which are set forth to illustrate, but are not to be construed to limit the present invention.
EXAMPLE 1
A wetting agent, a coalescing agent, a freeze/thaw stabilizer, a defoamer, and a thickner were sufficiently mixed in deionized water as indicated in Table 1, below. The mixture was added with polyaniline and stirred at 1,000-2,000 rpm for about 30 minutes to give a homogeneous phase. Thoroughly mixing the homogeneous phase with a vinyl emulsion gave a coating material.
To be tested for physical properties requisite for an electromagnetic wave-shielding coating, the coating material was coated on a slate plate and naturally dried to give a coating 40 μm thick. The coating was measured for adhesive strength in accordance with “paint adhesiveness test of ISO 2409”, hardness in accordance with “pencil hardness of JIS K-5400”, and electromagnetic wave-shielding efficiency in accordance with “ASTM-D4935-89”. The results are given in Table 3, below.
EXAMPLE 2
A coating material was prepared in a similar manner to that of Example 1, except that an acrylic emulsion was used, instead of a vinyl emulsion. The physical properties were assayed in the same manner as in Example 1 and the results are given in Table 3, below.
EXAMPLE 3
A hydroxy group-containing acrylic resin, a dispersant, a defoamer, a leveling agent, a UV stabilizer, a UV absorber, and a catalyst were sufficiently mixed as indicated in Table 2, added with 10% by weight of polyaniline, and stirred for 30 minutes at 1,000-2,000 rpm to give a homogeneous phase. Just before use, this homogeneous phase was polyisocyanate resin and a mixed solvent to give a coating material.
To be tested for physical properties requisite for an electromagnetic wave-shielding coating, the coating material was painted over a plastic plate by spraying and naturally dried to give a coating 50 μm thick. The coating was measured for adhesive strength in accordance with “paint adhesiveness test of ISO 2409”, hardness in accordance with “pencil hardness of JIS K-5400”, and electromagnetic wave-shielding efficiency in accordance with “ASTM-D4935-89”. The results are given in Table 3, below.
EXAMPLE 4
A coating material was prepared in a similar manner to that of Example 3, except that the hydroxy group-containing acrylic emulsion was used at an amount less by 10% by weight than as in Example 3 while polyaniline was used at 20% by weight. The physical properties were assayed in the same manner as in Example 3 and the results are given in Table 3, below.
Comparative Example 1
A coating material was prepared in a similar manner to that of Example 1, except that polyaniline was not used and the vinyl emulsion was further added as much. The physical properties were assayed in the same manner as in Example 1 and the results are given in Table 3, below.
Comparative Example 2
A coating material was prepared in a similar manner to that of Example 2, except that polyaniline was not used and the acryl emulsion was further added as much. The physical properties were assayed in the same manner as in Example 2 and the results are given in Table 3, below.
Comparative Example 3
A coating material was prepared in a similar manner to that of Example 3, except that polyaniline was not used and the acryl resin was further added as much. The physical properties were assayed in the same manner as in Example 3 and the results are given in Table 3, below.
TABLE 1
(wt %)
Compar-
Compar-
ative
ative
Ex-
Ex-
Used
Example
Example
ample
ample
No
Material
1
2
1
2
Remarks
1
Deionized
12.5
12.5
12.5
12.5
Water
2
Igepal
2.0
2.0
2.0
2.0
Wetting
Agent
3
Texanol
1.0
1.0
1.0
1.0
Coalescing
Agent
4
Propylene
1.0
1.0
1.0
1.0
Freeze/Thaw
Glycol
Stabilizer
5
Nopalcol
0.5
0.5
0.5
0.5
Defoamer
1-TW
6
Natrosol
1.0
1.0
1.0
1.0
Thickener
Plus
7
Poly-
—
—
72.0
72.0
ES, Solid
aniline
Content:20%
8
Vinyl
82.0
—
10.0
—
Solid
Emulsion
Content:50%
9
Acrylic
—
82.0
—
10.0
Solid
Emulsion
Content:50%
Total
100
100
100
100
In Table 1, Igepal CO-610 (Rhodia Co.) is a brand name of polyoxyethylene nonlyphenyl ether (ethylene oxide: 7.7 mol), Texanol (Eastman Co.) a brand name of 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, Nopalcol 1-TW (Henkel Co.) a brand name of PEG-2 tallowate, and Natrosol plus (Hercules Co.) a brand name of a modified hydroxyethylcellulose polymer.
TABLE 2
(wt %)
Compar-
ative
Used
Example
Example
Example
No
Material
3
3
4
Remarks
1
Hydroxy
69.0
59.0
49.0
Solid Content:75%
Acrylic
Resin
2
BYK320
0.4
0.4
0.4
Dispersion Agent
3
BYK065
0.2
0.2
0.2
Defoamer
4
BYK355
0.4
0.4
0.4
Leveling Agent
5
Tinuvin
0.4
0.4
0.4
UV Stabilizer
328
6
Tinuvin
0.2
0.2
0.2
UV Absorber
292
7
Fascat
0.1
0.1
0.1
Catalyst
4231
8
Poly-
—
10.
20
Solid Content:
aniline
100%
9
Desmodur
18.2
18.2
18.2
Hardener
N-3600
10
Mixed
11.1
11.1
11.1
Xylene, Butyl
Solvent
Acetate
Total
100
100
100
In Table 2, BYK 320 (BYK-Chemie Co.) is a brand name of a polyester modified methylalkylpolysiloxane copolymer, BYK 065 (BYK-Chemie Co.) a brand name of methylalkylsiloxane, BYK 355 (BYK-Chemie Co.) a brand name of polyacrylate, Tinuvin 328 (Ciba-Geigy Co.) a brand name of 2-2′-hydroxy-3,5′-di-t-amylphenylbenzotriazole, Tinuvin 292 (Ciba-Geigy Co.) a brand name of a benzophenone derivative, Fascat 4231 (Elf Atochem Co) a brand name of an organic tin compound, and Desmodur N-3600 (Bayer Co.) a brand name of hexamethylene diisocyanate isocyanurate (NCO=23%).
TABLE 3
Compar-
Compar-
Compar-
ative
ative
ative
Example
Exampl
Exampl
Example
Example
Example
Example
1
2
3
1
2
3
4
Adhesive
80/100
79/100
100/100
84/100
82/100
100/100
100/100
Strength
Pencil
B
B
H
HB
HB
2H
2H
Hardness
EMI
—
—
—
18dB
17dB
20dB
25dB
Shielding
Effect
Taken together, the data obtained in above examples demonstrate that the electromagnetic wave-shielding coating materials according to the present invention superior in physical properties requisite for coating materials, such as adhesive strength and pencil hardness. Thus, the electromagnetic wave-shielding coating materials of the present invention can be easily applied to plastics as well as iron matrices and firmly adhere thereto without producing paint dust. Also, the electromagnetic wave-shielding coating materials can be well coated even on edge portions of cases of various electromagnetic appliances.
In addition, the electromagnetic wave-shielding coating materials of the present invention show excellent EMI shielding effects. Thus, when applied to surfaces various electromagnetic appliances, the coating materials can shield electric and magnetic fields of the electromagnetic waves generated from the electromagnetic appliances, thereby protecting the body therefrom. For example, the electromagnetic wave-shielding coating materials of the present invention can be used as paints for automobiles with the aim of preventing the electromagnetic wave interference, which is believed to cause burst-to-start. Also, the electromagnetic wave-shielding coating materials are effective in shielding electromagnetic waves from cellular phones, pagers, television monitors, computer monitors, etc.
Further, the electromagnetic wave-shielding coating materials of the present invention are so antistatic that the objects applied by the coating materials are not allowed to be charged.
As described hereinbefore, the electromagnetic wave-shielding coating materials, which are prepared by mixing a polymer, self-resistant to electromagnetic waves, with a paint matrix at suitable amounts, are effective in shielding electromagnetic waves radiating from various electromagnetic appliances in addition to being superior in coatability. The electromagnetic wave-shield coating materials are expected to prevent the burst-to-start phenomenon of automobiles, which is supposed to be attributed to electromagnetic wave interference. In addition, the electromagnetic wave-shielding coating materials of the present invention have an antistatic effect such that an object, when coated with the coating materials, cannot be charged on its surfaces.
The present invention has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be in the nature of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | Disclosed is an electromagnetic wave-shielding coating material which is superior in both paintability and a electromagnetic wave shielding activity. Also, the coating material is of antistatic activity. The coating material comprises polyaniline (ES) with a solid content of 1-50%, a matrix polymer with a solid content of 1-50%, and additives at a predetermined amount. Also disclosed is an electromagnetic wave-shielding coating material, which is prepared by mixing polyaniline (ES, 100%), an acrylic resin and additives at predetermined amounts and adding the mixture with a hardener and a mixed solvent at predetermined amounts just before use. The electromagnetic-shielding coating material is able to effectively shield electromagnetic waves with a broad band of frequencies and be coated onto cases of various electromagnetic apparatuses, thereby protecting the body from electromagnetic wave pollutions. | 7 |
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