description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
BACKGROUND
[0001] Wound healing is a complex process, and involves the regulation of numerous cellular functions including the interactions of fibroblasts/fibrocytes, osteoblasts, chondrocytes, endothelial cells, inflammatory cells, epithelial cells and smooth muscle cells, with the extracellular matrix. Normal healing results in scar formation in humans. However, it is well known that certain animals, and even the human fetus, are capable of regenerative healing of wounds which is indistinguishable from surrounding skin.
[0002] Although the intricate details of wound healing are still being discovered, the process follows along a typical time line having four phases:
[0003] Hemostasis Phase—This phase includes vasoconstriction lasting for the first 5-10 minutes after the injury.
[0004] Inflammation Phase—This phase includes vasodilation and a cellular response by inflammatory macrophages, neutrophils and fibroblasts. Neutrophils undergo cannbilaization to produce transforming growth factor beta-1 (TGF-β1), which stimulates production of type I collagen (the mature collagen present in nomal skin) and stimulates fibroblast to myofibroblasts mediated by hyaluronic acid and epidermal growth factor receptor (EGFR). Bacteria, foreign particles and damaged cells are removed from the wound. Vasodilation starts at about 10 minutes after the initial injury, and the cellular response typically starts 30 minutes after the initial injury. Keratinocytes detach from the basement membrane and migrate to cover the exposed wound and connective tissue, and the wound clot is replaced with epithelial cells and granulation tissue (type Ill collagen). Differentiating keratinocytes also produce TGF-β1. The cellular response may last 7 to 8 days.
[0005] Proliferation Phase—This phase includes re-epithelialization of the wound, fibroplasia, including collagen synthesis and wound contraction. During this phase skin cells multiply and spread, covering the wound. Re-epithelialization typically starts 24 hours after the injury. Fibroplasia typically starts in 3 to 4 days after the injury. Myofibroblasts (present in granulation tissue) express alpha-smooth muscle actin and are responsible for wound contraction, which typically starts 7 days after the injury.
[0006] Remodeling Phase—This phase includes scar/collagen remodeling. The newly formed collagen matrix becomes cross linked and organized starting about 3 weeks from wound initiation and lasting as long as 1 year.
[0007] Scar formation is a typical response for normal healing in humans. As compared with normal skin, a scar contains an overproduction of type III and type I collagens, and the mixture is disorganized. The scar itself is not very elastic and is of a different color than normal skin. The scar is also missing the layer of kertinocytes found on normal skin. Furthermore, depending on how deep was the original wound, the scar may be missing the normal underlying layers of muscle, fat, blood vessels, and many layers of the skin; these missing layers may result in the scar forming a depression compared to the level of the surrounding skin.
[0008] Some animals are capable of scar free healing. In axolotls, there is a substantial reduction in neutrophil infiltration and a relatively long delay in production of new extracellular matrix during scar free healing. Studies with athymic nude mice indicate that up-regulation in metalloproteinase-9 (MMP-9) throughout the remodeling phase may contribute to scar free healing. Matrix metalloproteinases (MMP's) are a family of zinc dependent enzymes capable of degradation of extracellular matrix and are vital to the remodeling of the matrix and migration of cells. During normal human wound healing, MMP-9 degrades the type IV collagen of the basement membrane allowing keratinocytes to detach from the basement membrane and migrate to cover the exposed wound and connective tissue.
[0009] Human oral healing of wounds results in little to no scar formation. Oral mucosal wounds show a robust early up-regulation of MMP-1, MMP-2 and MMP-9 at 3 days after the initial injury, as compared to skin wounds at 14 days after the initial injury. The human fetus, which also shows scar free healing, is surrounded by amniotic fluid which contains high molecular weight hyaluronic acid. High molecular weight hyaluronic acid is known to increase expression of MMP-2 and MMP-9. Although high molecular weight hyaluronic acid application at a wound site can reduce scarring, a scar is nevertheless still formed.
[0010] Resveratrol (trans-3,4′,5-trihydroxystilbene), a stilbenoid, is a grape polyphenol present in various plants, some food products, red wine and grapes. Resveratrol has anti-inflammatory, anti-carcinogenic and anti-oxidant properties, and has been extensively studied. Huge interest in resveratrol was created when it was discovered that it was able to active the SIRT1 gene, a gene implicated in the life span extension associate with calorie-restricted diets. However, resveratrol is poorly absorbed when consumed as a dietary supplement, and is subject to metabolic degradation, and beneficial effect have been difficult to observe in human clinical studies.
SUMMARY
[0011] In a first aspect, the present invention is a method for reducing scarring comprises applying into a wound a composition comprising resveratrol. The wound was formed at most one day before the applying, and no part of the skin surface of the wound is more than 3 cm from uninjured skin.
[0012] In a second aspect, the present invention is a composition for reducing scarring by applying into a wound which was formed at most one day before the applying, and in which no part of the skin surface of the wound is more than 3 cm from uninjured skin, the composition comprising resveratrol.
[0013] In a third aspect, the present invention is a use of resveratrol to prepare a composition for reducing scarring by applying into a wound, wherein the wound was formed at most one day before the applying, and no part of the skin surface of the wound is more than 3 cm from uninjured skin.
DETAILED DESCRIPTION
[0014] The present invention makes use of the discovery that compositions containing resveratrol, when applied into a wound soon after the initial injury, will greatly reduce scarring. In some cases, compositions containing resveratrol may even eliminate scarring altogether. Also discovered is that these effects of resveratrol may be enhanced when combined with one or more additional active agents.
[0015] It has been discovered that if a wound or incision is completely healed in less than 3 days, before fibroplasia begins, then no scar will be formed at the location of the wound or incision. Therefore composition containing resveratrol will allow for scar free healing when applied to wounds or incisions that do not have any injured or missing tissue which is more than 3 cm from uninjured tissue. Examples include almost all incisions purposefully created by a surgeon, because the surgeon is able to bring the edges of the skin at the location of the incision to well within 3 cm of each other. Preferably, no part of the skin surface of the wound is more than 3 cm from uninjured skin, more preferably no part of the skin surface of the wound is more than 2 cm from uninjured skin, even more preferably no part of the skin surface of the wound is more than 1 cm from uninjured skin, and most preferably no part of the skin surface of the wound is more than 0.5 cm from uninjured skin.
[0016] Compositions containing resveratrol, either as the sole active agent or in combination with other active agents, is preferably applied to a wound or incision at any time from prior to formation of a wound or incision up until at most one day after the formation of a wound or incision; more preferably prior to formation of a wound or incision, up until at most 1 hour after the formation of a wound or incision; and most preferably prior to formation of a wound or incision, up until at most 10 minutes after the formation of a wound or incision. Preferably, only a single application of a composition containing resveratrol is used. For example, a composition containing resveratrol may be applied topically to an incision site, or injected below an incision site, then the skin may be cut, optionally followed by closing the incision; for example the deep structures which have been cut under the skin may be tied down using VICRYL™ (polyglactin 910) sutures, and then skin sutured or sealed using DERMABOND ADVANCED™ topical skin adhesive or NEW-SKIN® liquid bandage. Alternatively, a composition containing resveratrol may be applied to the incision or wound after it is formed, followed by closing the wound or incision as described above.
[0017] Preferably, resveratrol is present in a composition at a concentration of at least 0.01 micromoles/liter, more preferably at a concentration of at least 0.10 micromoles/liter, and most preferably at a concentration of at least 0.50 micromoles/liter. Preferably, resveratrol is present in the composition at a concentration of at most 100 micromoles/liter, more preferably at most 40 micromoles/liter. Examples include 0.75, 0.80, 0.90, 1.0, 1.25, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.19, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.25, 3.5, 3.75, 4.0, 4.25, 4.5, 4.75, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 9.0, 10.0, 15.0, 20.0, 25.0, 30.0 and 35.0 micromoles/liter. Concentrations of resveratrol above 100 micromoles/liter appear to be cytotoxic to keratinocytes.
[0018] In some forms, such as gels and pastes, the delivery medium limits contact with the surrounding tissue, the surrounding tissue rapidly degrades the resveratrol, and the tissue itself will absorb the resveratrol, resulting in a much lower effective concentration of resveratrol. In those cases, the concentration of resveratrol may optionally be increased 10 fold. In those cases, preferably resveratrol is present in a composition at a concentration of at least 0.1 micromoles/liter, more preferably at a concentration of at least 1.0 micromoles/liter, and most preferably at a concentration of at least 5.0 micromoles/liter. Preferably, resveratrol is present in those compositions at a concentration of at most 1000 micromoles/liter, more preferably at most 400 micromoles/liter. Examples include 7.5, 8.0, 9.0, 10, 12.5, 15, 16, 17, 18, 19, 20, 21, 21.9, 22, 23, 24, 25, 26, 27, 28, 29, 30, 32.5, 35, 37.5, 40, 42.5, 45, 47.5, 50, 55, 60, 65, 70, 75, 80, 90, 100, 150, 200, 250, 300 and 350 micromoles/liter.
[0019] Resveratrol has a very low solubility in water, however only that portion which is dissolved in water will exert its effects. Furthermore, if the resveratrol is applied dissolved in a hydrophobic medium, it may slowly diffuse into the surrounding aqueous medium, and undesirably extend the effective application time. Therefore, it is preferable that the resveratrol be applied as a solution in an aqueous medium. For ease of application in a clinical setting, preferably the aqueous medium is a gel, paste, foam, suspension or thickened solution. Examples include aqueous compositions containing hydroxypropyl methylcellulose, high molecular weight hyaluronic acid, polyethylene glycol, agar, dextrin, pectin, trehalose, xanthan gum, polyoxyethylene alkyl ethers, chitosan, guar gum and sodium alginate. Other vehicles, adjuvants and excipients, which are hydrophilic or have hydrophilic moieties, and are compatible which application into wounds, may also be used. Other pharmaceutically acceptable adjuvant, excipients and vehicles may also be included.
[0020] Premeasured amounts of the compositions containing resveratrol may also be used. These are referred to as unit dosage forms, since each premeasured amount is intended to be used on a single patient for one or more application, all used at the same time. Examples include prefilled syringes, pouches, packets and tubes. Another example would be a tube or dispenser which may be used to form foam of its contents just prior to application, for example by shaking or using a foaming agent. A self-foaming tablet, which forms foam when placed into water, could also be used. The volume of material present in these unit dosage forms may be at least 0.1 to 100 ml, or 1 to 50 ml. including 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 35, 40 and 45 ml.
[0021] Other active agents may be included, such as other activators of SIRT1; HDAC2 (a class I histone deacetylase) inhibitors, such as trichostatin A; agents which stimulate the production of certain growth factors such as EGF, FGF-10 and IGF-1; luteolin; tretinoin (all-trans retinoic acid); and high molecular weight hyaluronic acid.
[0022] Although it is not known exactly how resveratrol reduces scarring, resveratrol does up-regulate and increase the expression of a variety of agents which are involved in wound healing. One possible explanation is that resveratrol causes the over-expression of MMP-9, interleukin-8 (IL-8) and SIRT1, and increases expression of EGFR on the keratinocyte membrane and nucleus. SIRT1 may then promote differentiation, motility and proliferation of keratinocytes, and deacetylation and inactivation of p53 protein thus inhibiting p53-dependent cell death from apoptosis in response to stress in human tenocytes (fibroblast-like tendon cells). SIRT1 may induce nitric oxide (NO) production, which inhibits class I HDAC 2 from blocking growth factors, including epithelial growth factor, keratinocyte growth factor 2, fibroblast growth factor 10 (FGF-10), and insulin-like growth factor 1 (IGF-1). SIRT1 may also decrease inflammation and apoptosis through a variety of mechanisms. IL-8 has a direct and profound stimulatory effect on the migration of keratinocytes, which is likely due via the PLC-gamma pathway, and furthermore IL-8 may recruit neutrophils. As noted above, MMP-9 degrades the type IV collagen of the basement membrane. EGFR may cause keratinocyte and fibroblast migration and may protect and repair tissue through nuclear DNA repair. Resveratrol may also inhibit NF-kB dependent proinflammatory and matrix degrading gene products induced by IL-1β and nicotinamide.
EXAMPLES
Example 1
In Vivo Application of Various Compositions Containing Resveratrol in a Rat Model
[0023] In this example, 15 Sprague Dawley Rats, 6-8 weeks old, will be placed randomly into 5 different groups, Study Groups 1-5, resulting in 3 animals per study group. An incision, 2 cm in length, will be made on both the right and left shoulder of each rat: the left side will be an untreated control, while the right side will be treated with the Compositions 1-5, with the Study Group number corresponding to the Composition number.
[0024] The Compositions 1-5 are: (1) 0.5 g resveratrol in 1.0 cc aqueous hydroxypropyl methyl cellulose gel (resveratrol concentration=2.19 micromoles/liter); (2) 0.5 g resveratrol in 1.0 cc aqueous high molecular weight hyaluronic acid gel (resveratrol concentration=2.19 micromoles/liter); (3) 0.5 g resveratrol and 0.5 g tretinoin in 1.0 cc aqueous hydroxypropyl methyl cellulose gel (resveratrol concentration =2.19 micromoles/liter); (4) 0.5 g resveratrol and 0.5 g luteolin in 1.0 cc aqueous hydroxypropyl methyl cellulose gel (resveratrol concentration=2.19 micromoles/liter); and (5) resveratrol powder.
[0025] After each incision is made, the resveratrol containing composition will be applied to the right incision just prior to closure using interrupted 5-0 nylon sutures. The left incision will also be closed using interrupted 5-0 nylon sutures. Each incision will be photographed and measurements will be taken, each day for 7 days. On the 4 th day, serum blood samples will be taken for systemic absorption assay. On the 7 th day, a punch biopsy will be taken from each test and control incision.
[0026] Since each skin flap of the incisions is very close together, when the composition containing resveratrol is applied soon after the incision is made, the incision on the right shoulder heals before fibroplasia begins, so no scar is formed. This is in contrast to the otherwise identical incision on the left side, where no resveratrol is applied, which displays a typical scar.
REFERENCES
[0000]
Ehrlich H, Krummel T: Regulation of wound healing from a connective tissue perspective. Wound Repair & Regeneration 1996, 4(2):203-210.
Leung A, Crombleholme T M, Keswani S G: Fetal wound healing: implictions for minimal scar formation. Curr Opin Pediatr 2012, Jun. 24(3): 371-8.
Manuel J, Gawronska-Kozak B: Matrix metalloproteinase 9 (MMP-9) is upregulated during scarless wound healing in athymic nude mice. Matrix Biology 2006, 25:505-514.
Seifert A W, Monaghan J, Voss S, Maden M: Skin regernation in adult axolotls: a blueprint for scar-free healing in vertebrates. PLoS One 2012, 7: 4
Polette M, Nawrocki-Raby B, Gilles C, Clavell C, Birembaut P: Tumor invasion and matrix metalloproteinases. Crit. Rev. Oncol Hematol 2004, 49:179-186.
Salo T, Makela M, Kylmaniemi M, Autio-Harmainen H, Larjava H: Expression of matrix metalloproteinase-2 and -9 during early human wound healing. Lab Invest 1994, February; 70(2):176-82.
Giannelis, G: Matrix metalloproteinases in scarless wound healing. Electronic Theses and Dissertations 2008 to 2011, July. (Available at hdl.handle.net/2429/36241).
Guo M S, Wu Y Y, Liang Z B: Hyaluronic acid increases MMP-2 and MMP-9 expressions in cultured trabecular meshwork cells from patients with primary open-angle glaucoma. Mol Vis 2012,18:11175-81.
Ndiaye M, Philippe C, Mukhtar H, Ahmad N: The grape antioxidant resveratrol for skin disorders: promise, prospects, and challenges. Arch Biochem Biophys 2011, Apr. 15:508(2): 164-70.
Gweon E, Kim S: Resveratrol induces MMP-9 and cell migration via the p38 kinase and PI-3K pathways in HT1080 human fibrosarcoma cells. Oncol Rep 2013, Feb. 29(2): 826-34.
Ghosh S, Liu B, Zhou Z: Resveratrol activates SIRT1 in a Lamin A-dependent manner. Cell Cycle 2013 Mar. 15; 12(6):872-6.
Blander G, Bhimavarapu A, Mammone T, Maes D, Elliston K, Reich C, Matsui M S, Buarente L, Loureiro J J. SIRT1 promotes differentiation of normal human keratinocytes. J Invest Dermatol 2009 January; 129(1):41-9.
Thompson N L, Flander K C, Smith J M, Ellingsworth L R, Roberts A B, Sporn M B. Expressions of transforming growth factor-beta 1 in specific cells and tissues of adult and neonatal mice. J Cell Biol. 1989:108:661-9.
Midgley A, Rogers M, Hallett M, Clayton A, Bowen T, Phillips A, Steadman R. Transforming growth factor-beta 1 (TGF-B1)-stimulated fibroblast to myofibroblast differentiation is mediated by hyaluronan (HA)-facilitated epidermal growth factor receptor (EGFR) and CD44 colocalisation in lipid rafts. J Biol Chem 2013 Apr. 15 [Epub ahead of print].
Busch F, Mobashieri A, Shayan P, Stahlmann R, Shakibaei M. Sirt-1 Is Required for the Inhibition of Apoptosis and Inflammatory Responses in Human Tenocytes. J Biol Chem 2012 Jul. 27; 287(31):25770-25781.
Spallotta F, Cencioni C, Straino S, Nanni S, Rosati J, Artuso S, Manni I Colussi C, Piaggio G, Martelli F, Valent S, Mai A, Caposgrassi M D, Faretti A, Gaetano C. A Nitric Oxide-dependent Cross-talk between Clas I and II Histone Deacetylases Accelerates Skin Repari. J Bio Chem. 2013 Apr 19; 288(16):11004-12.
Pastore S, Lulli D, Maurelli R, Dellambra E, DeLuca C, Korkina L G; Resveratrol induces long-lasting IL-8 expression and peculiar EGFR activation/distributio in human keratinocytes:mechanisms and implications for skin administration. PLoS One 2013:8(3):e59632.
Jiang W G, Sanders A J, Ruge F, Harding K G. Influence of interleukin-8(IL-8) and IL-8 receptors on the migration of human keratinocytes, the role of PLC-gamma and potential clinical implications. Exp The Med 2012 February; 3(2):231-236.
Steiger S, Harper J L. Neutrophil cannibalism triggers transforming growth factor betal production and self regulation of neutrophil inflammatory function in monosodium urate monohydrate crystal-induced inflammation in mice. Arthritis Rheum 2013 March: 65(3):815-23.
Holian O, Walter R J. Resveratrol inhibits the proliferation of normal human keratinocytes in vitro. J Cell Biochem Suppl 2001; Suppl 36:55-62.
Kim J J, Kim S J, Kim S Y, Park S H, Kim E C. The role of SIRT1 on angiogenic and odontogenic potential in human dental pulp cells. J Endod 2012 July; 38(7):899-906.
Williams L D, et al.; Safety studies conducted on high-purity trans-resveratrol in experimental animals. Food Chem Toxicol, 2009 September; 47(9):2170-82.
Polonini H C, et al. Photoprotective activity of resveratrol analogues. Bioorg Med Chem, 2013 Feb. 15; 21(4):964-8.
Hung C F, Lin Y K, Huang Z R, Fang J Y. Delivery of resveratrol, a red wine polyphenol, from solutions and hydrogels via the skin. Biol Pharm Bull. 2008 May; 31(5):955-62.
Alonso C, Marti M, Martinez V, Rubio L, Parra J L, Coderch L. Antioxidant cosmeto-textiles: skin assessment. Eur J Pharm Biopharm. 2013 May; 84(1):192-9. doi: 10.1016/j.ejpb.2012.12.004. Epub 2012 Dec. 20.
Machesney M, Tidman N, Waseem A, Kirby L, Leigh I. Activated keratinocytes in the epidermis of hypertrophic scars. Am J Pathol. 1998 May; 152(5):1133-41.
Fagone E, Conte E, Gili E, Fruciano M, Pistorio M P, Lo Furno D, Giuffrida R, Crimi N, Vancheri C. Resveratrol inhibits transforming growth factor-β-induced proliferation and differentiation of ex vivo human lung fibroblasts into myofibroblasts through ERK/Akt inhibition and PTEN restoration. Exp Lung Res. 2011 April; 37(3):162-74. doi: 10.3109/01902148.2010.524722. Epub 2011 Jan. 26.
Sheu S Y, Chen W S, Sun J S, Lin F H, Wu T. Biological characterization of oxidized hyaluronic acid/resveratrol hydrogel for cartilage tissue engineering. J Biomed Mater Res A. 2013 Apr. 18. doi: 10.1002/jbm.a.34653. [Epub ahead of print]
Fearmonti R, Bond J, Erdmann D, Levinson H. A review of scar scales and scar measuring devices. Eplasty. 2010 Jun. 21; 10:e43.
Busch F, Mobasheri A, Shayan P, Stahlmann R, Shakibaei M. Sirt-1 is required for the inhibition of apoptosis and inflammatory responses in human tenocytes. J Biol Chem. 2012 Jul. 27; 287(31):25770-81. doi: 10.1074/jbc.M112.355420. Epub 2012 Jun. 11.
Nayor D, Kiefer D. Living longer, Healthier Lives with Resveratrol. Le Magazine 2008 February (available at www.lef.org).
Resveratrol. en.wikipedia.org/wiki/Resveratrol (downloaded Jun. 21, 2013).
Amato et al. U.S. Pat. Pub., Publication no. US 2011/0245345 (Oct. 6, 2011).
McKay et al. U.S. Pat. Pub., Publication no. US 2011/0038965 (Feb. 17, 2011).
NEW-SKIN® Cover. Protect. Prevent. newskinproducts.com/products.aspx (downloaded Jun. 20, 2013). | A method for reducing scarring comprises applying into a wound a composition comprising resveratrol. The wound was formed at most one day before the applying, and no part of the skin surface of the wound is more than 3 cm from uninjured skin. | 0 |
CROSS REFERENCES TO RELATED APPLICATIONS
The present application is a continuation-in-part of, and claims the benefit under 35 USC 120 of my copending application U.S. Ser. No. 07/258,648 filed Oct. 17, 1988, now U.S. Pat. No. 4,995,968 dated Sept. 11, 1990.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT.
Research and development of the present invention and application have not been Federally-sponsored, and no rights are given under any Federal program.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to covers for trailer hitches, and more particularly to devices of the type intended to prevent injury to personnel working in the vicinity of a hitch, especially that resulting from inadvertent bumping of the hitch by a person's leg or knee.
2. Description of the Related Art Including Information Disclosed Under 37 CFR §§1.97-1.99
The hazards associated with existing trailer hitches are generally well known to anyone who has worked with them; all too often, the hitches are susceptible of being inadvertently bumped by one's kneecap or leg. The injury, while not necessarily serious, is usually most annoying and painful.
In an effort to avoid this, plastic or rubber covers have been designed, which go over the ball of the hitch when it is not being used. These covers consist essentially of a cup-like structure having a size which fits snugly over the ball. The material is generally rubber or plastic. Although these covers provide some degree of protection, the thickness of the material of which the cover is made is usually insufficient to absorb much of the shock of the bump. Also, in some cases the covers are difficult to install. Accordingly there has existed a need for improvement over the concept of employing a simple cup-like cover piece.
SUMMARY OF THE INVENTION
The above disadvantages and drawbacks of prior trailer hitch covers are obviated by the present invention, which has for one object the provision of a novel and improved cover which is extremely simple in its construction, and which provides significantly improved protection against inadvertent injury to personnel when a trailer is not connected to the hitch.
A related object of the invention is to provide an improved trailer hitch cover as above set forth, which can be readily applied and removed without the use of special tools or equipment.
Still another object of the invention is to provide an improved trailer hitch cover as above characterized, which is rugged, and which can be readily molded of plastic or rubber as a single piece, thereby keeping the manufacturing cost as low as possible.
Yet another object of the invention is to provide an improved trailer hitch cover of the kind indicated, which requires no assembly or skilled labor in its fabrication or use.
A still further object of the invention is to provide an improved trailer hitch cover as outlined above, which is adaptable, essentially without modification, to hitches of the box-end type as well as hitches of the kind incorporating a ball.
The above objects are accomplished, in one embodiment, by a cover for a trailer hitch comprising a base portion adapted to at least partially surround the hitch bar, an upstanding dome portion connected with the base portion and encircling the ball of the hitch, and wherein the dome portion has a side wall with a cross-sectional configuration that enables it to readily expand, if necessary, upon being press-fitted over the ball. A head-space is provided in the dome portion, above the area occupied by the ball, such that upon impact, the dome portion's upper wall can, with some resistance, yield inwardly prior to coming into contact with the ball, thereby minimizing injury to a person's knee, leg, arm, etc.
Preferably a single cover configuration can be employed with either ball-type or box-end type hitches, thus making the unit universal.
Other features and advantages will hereinafter appear.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the improved trailer hitch cover of the invention, illustrating in plan the top wall of the dome portion, and also the top wall of the base portion.
FIG. 2 is a bottom plan view of the cover of FIG. 1.
FIG. 3 is a section taken on the line 3--3 of FIG. 2; shown in dotted outline is a trailer hitch having a base portion and ball.
FIG. 4 is a front elevation of the cover, illustrating the cavity in the base portion for receiving the hitch bar.
FIG. 5 is a top plan view of a modified trailer hitch cover having one side of the base portion essentially completely open, constituting another embodiment of the invention.
FIG. 6 is a bottom plan view of the cover of FIG. 5.
FIG. 7 is a section taken on the line 7--7 of FIG. 6.
FIG. 8 is a rear elevation of the cover of FIGS. 5-7.
FIG. 9 is a fragmentary side elevational view of a further modified cover, incorporating a dome with multiple sealing or seating rings, and having a base configuration otherwise similar to the cover of FIGS. 5-8.
FIG. 10 is a bottom plan view of a further modified cover, constituted of foam rubber or rubber-like substance, constituting yet another embodiment of the invention.
FIG. 11 is a section taken on the line 11--11 of FIG. 10.
FIG. 12 is a fragmentary rear elevation similar to that of FIG. 4, of a still further modified cover, constituting yet another embodiment of the invention.
FIG. 13 is a fragmentary vertical section of the cover of FIG. 12.
FIG. 14 is a vertical section of a further modified hitch cover, constituting another embodiment of the invention, and
FIG. 15 is a side elevation of the hitch cover of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
By way of example, referring to FIGS. 1-4 and in accordance with the present invention there is provided a novel and improved cover for a trailer hitch, designated generally by the numeral 10. Shown dotted in FIG. 3 is a trailer hitch 11 of the type having a ball 12 and comprising a hitch bar 13 and connecting stem 14 which latter can take the form of a bolt or stud that is secured to the bar 13.
The cover 10 comprises a base portion 18 having a top wall 20 with an upper surface 22, side walls 24, 26 and 28, and a bottom wall 30, the base portion 18 being open at one side location to thereby define a cavity 32 of generally box-like configuration. Side walls 24 and 28 have re-entrant terminal portions 25 and 29, respectively.
Extending upwardly from the base portion 18 is a rounded dome portion 34, having an expandable side wall 36 and a top wall 38 which latter, in the illustrated example, is semi-spherical. According to the invention, the side wall 36 can have a polygonal cross-section; in the illustrated example this wall has eight sides, thereby enabling a limited expansion in radially outward directions when press-fitting the cover 10 over the ball 12 of the hitch 11.
An important feature of the invention is the provision of a well-defined enclosed, sealing head-space 40 between the lower surface 42 of the dome's top wall 38 and the upper surface 44 of the ball 12. Preferably the cover 10 is fabricated of resilient material such as polypropylene, and with the thickness shown, the wall 38 will be reasonably stiff but not rigid. Impact forces applied to the wall 38, as by bumping from a person's knee or leg, will cause limited inward movement of the wall 38 against its resilience and in many cases against the pressure of air trapped and sealed sin the head space 40. In effect, the provision of the head-space 40 thus causes impacts of the type noted to be cushioned, thereby minimizing the chance of injury to personnel.
This action relates to another feature of the invention involving the provision of an annular sealing seat 46 at the junction of the semi-spherical wall 38 and the side wall 36, whereby the head space 40 constitutes an essentially air-tight chamber with the upper surface 44 of the ball 12. Air trapped in the chamber 40 will inhibit complete yielding or collapse of the wall 38; instead, there will result a desirable cushioning effect, as noted above, and which is similar to the effect of depressing a localized area on an air-filled ball, such as a basketball or tennis ball.
Even if the seal between the seat 46 and ball 12 is not completely air-tight, the seat 46 nevertheless constitutes a stop or positioning seat or shoulder to prevent the top wall 18 from readily collapsing and coming into contact with the upper surface 44 of the ball 12.
Other forms of stop shoulders could be provided, such as a series of nibs (not shown) spaced circumstantially around the inner surface of the side wall, etc.
A further important aspect of the invention is the raised positioning of the wall 38, as defined by the distance between it and the top wall 20 of the base portion 18. The side wall 36 of the dome portion 34 maintains the head-space 40, since in order for the wall 38 to contact the upper surface 44 of the ball 12, at least part of the side wall 36 would have to buckle or collapse, which has been found to be unlikely.
As illustrated, the base portion 18 is open at one side, forming the cavity 32, in order to accept the hitch bar 13. By the present invention, the base portion 18 is made oversize with respect to the dimensions of the bar 13, and a series of projections or fins 48, 50 is provided on the inner surfaces of the top wall 20 and side walls 24, 26 and 28 respectively. The fins 48, 50 have the approximate dimensions illustrated, and define between them a series of spaces; the fins thus maintain both the top wall 20 and side walls 24, 26 and 28 in spaced relation with respect to the hitch bar 13.
The fins 48, 50 are preferably integral with the respective walls 20, 24, 26 and 28, and the spaces so formed provide a desirable cushioning if the walls are inadvertently bumped by personnel. Stated differently, the fins 48, 50 impart a controlled yieldability to the top wall 20 and side walls 24, 26 and 28, thereby minimizing possible injury from outside contact with these areas of the cover.
The fins 48, 50 extend inwardly as shown. Fins 50 on the side walls 24, 26 and 28 are vertical, and the fins 48 on the top wall 20 are horizontal; refer to FIGS. 2-4.
The friction of the fins 48, 50 on the bar 13 is effective in retaining the cover 10 in position, thereby minimizing the possibility of its becoming lost or misplaced.
Another embodiment of the invention is shown in FIGS. 5-8, wherein like reference numerals having the suffix "a" have been assigned to similar components. A modified cover 10a is provided, comprising a base portion 18a having a top wall 20a and side walls 24a, 26a, and 28a. The base portion 18a is open at one side location to thereby define the cavity 32a.
Extending upwardly from the base portion 18a is a rounded dome portion 34a having a generally cylindrical side wall 36a with a series of internal, vertical stiffening ribs 52, and a top wall 38a.
There is provided a well-defined enclosed, sealing headspace 40a between the lower surface of the top wall 38a and the upper surface of the ball 12 (not shown in FIGS. 5-8). Impact forces applied to the wall 38a as by bumping from a person's knee or leg, will cause limited inward movement of the wall against its resilience. The provision of the head-space thus causes such impacts to be cushioned, thereby minimizing the chance of injury to personnel.
As in the previous embodiment, the raised positioning of the wall 38a as defined by the distance between it and the top wall 20a of the base portion 18a maintains the head-space 40a.
By the invention, the base portion 18a is made oversize with respect to the dimensions of the bar 13, and a series of projections or fins 48a, 50a is provided on the inner surfaces of the top wall 20a and side walls 24a, 26a and 28a respectively. The fins have the approximate dimensions illustrated, and define between them a series of spaces; the fins thus maintain both the top wall 20a and side walls 24a, 26a and 30a in spaced relation with respect to the hitch bar 13.
The fins 48a and 50a extend inwardly as shown. Fins 50a on the side walls are vertical, and the fins 48a on the top wall are horizontal.
On the inner surface of the top wall 38a of the dome portion are two stiffening ribs 54 and 56, forming an "X". These provide the desired rigidity to this area.
The construction shown in FIGS. 5-8 has the distinct advantage of ease of molding, since there has been eliminated the bottom wall which existed in the first embodiment. Stripping of the cured article from the mold is thus facilitated.
Still another embodiment of the invention is illustrated in FIG. 9, wherein like reference numerals having the suffix "b" have been assigned to similar components. In this embodiment, there is provided a modified dome portion 34b, which may or may not be adapted for use with an integral base similar to that of FIGS. 5-8. In addition to the dome portion's top wall 38b, there is a generally cylindrical side wall 36b. By the invention, the inner surface of this side wall is provided with a series of vertically spaced annular ribs 58, any one of which is intended to form a seat or seal with the large diameter portion of the trailer hitch ball (12, FIG. 3). Regardless of the location of the ball 12 with respect to the hitch base, one or two of the ribs 58 will fit tightly against the ball, creating an air-lock in the chamber 40b, as in the first embodiment. The air-lock provides a cushioning effect to the dome portion 34b, by limiting the tendency for the top wall 38b thereof to collapse when impacted by forces external of the cover.
In other respects the embodiment of FIG. 9 can be similar to that of FIGS. 5-8.
Alternately, the construction of FIG. 9 could be employed without a base; instead, the construction would resemble an inverted cup with a lip which might or might not extend to and engage the hitch bar 13.
Still another embodiment of the invention is shown in FIGS. 10 and 11, illustrating a greatly simplified cover. Essentially the cover comprises an inverted cup 60 having a top wall 62 and a side wall 64. Preferably the cup 60 is constituted of foam rubber or foam rubber-like substance, and the side wall 64 of the cup is sufficiently thick to provide a cushion between the ball of the hitch and an object (i.e. a person's knee) which might impact on the cover 60 from its exterior. The inner diameter of the cup 60 is preferably made to fit snugly around the ball. The area of the side wall adjacent the lip of the cup can be thickened slightly, as shown in FIG. 11, to improve the retention.
Still another embodiment of the invention is shown in FIGS. 12 and 13, wherein like reference numerals having the suffix "c" have been assigned to similar components.
By the invention, there is applied to the inner surface of the top wall 20c and side walls 24c, 26c and 28c of the base portion 18c strips 66 and a cutout 68 of thin foam material in order to provide the desired cushioning. A single strip 66 can be wrapped along the inside of the three side walls 24c, 26c, and 28c, with a fourth piece 68 of foam material secured to the inside of the top wall 20c. Attachment can be made by means of suitable cement or glue, or alternately by employing adhesive-backed foam strips similar to those used for weatherstripping windows and doors in buildings or residences.
The dome structure associated with this base would typically be similar to that of FIGS. 1-4 or 5-8; accordingly details of these structures need not be repeated.
Another embodiment of the invention is illustrated in FIGS. 14 and 15, wherein like reference numerals having the suffix "d" have been assigned to similar components. A modified cover 10d is provided comprising a base portion 18d having a top wall 20d and side walls 24d, 26d and 28d. The base portion 18d is open at one side location as shown. The top wall 20d and side walls 24d, 26d, and 28d thus form a cavity 32d or channel-like enclosure means that overlies the upper surface of the hitch bar 13 and the side surfaces thereof. Extending upwardly from the base portion 18d is a rounded dome portion 34d having a generally cylindrical side wall 36d. There is provided a well-defined enclosed, sealing head-space 40d between the lower surface of the top wall 38d and the upper surface of the ball 12, as in FIG. 14.
The upstanding ball 12 of the hitch is seen to have a smooth and unbroken circumferential latitudinal zone 15, FIG. 14, and by the invention the side wall 36d of the dome has a generally annular sealing surface 41 for essentially air-tight sealing engagement by the ball 12 of the hitch at a location substantially at the said latitudinal zone 15, so as to form a yieldable air-tight head space between the trailer hitch ball 12 and the top wall 38d of the dome when the cover is installed. Impact forces applied to the wall 38d as by bumping from a person's knee or leg, will cause limited inward movement of the wall which are opposed by its resilience, as well as being opposed by the pressure seal formed between the wall 38d and ball 12. The provision of the head-space thus causes such impacts to be cushioned, thereby minimizing the chance of injury to personnel.
The dome and base portion are preferably constituted of resilient material, and can advantageously be made of either foam rubber or foamed plastic material. Preferably, the dome and base portion are molded as a single integral piece.
From the above it can be seen that I have provided novel and improved cover constructions which have important features that minimize injury from inadvertent contact with an exposed trailer hitch. The cover can be molded as a single piece, including the fins illustrated in the first two embodiments. It is adaptable for use with trailer hitches of the ball-type, or else it can be employed with a box-end type hitch in which the area inside the dome portion 34 (FIGS. 1-4) would be unoccupied. Accordingly the unit can be universal for a given hitch size.
The device is thus seen to represent a distinct advance and improvement over previously known covers of this kind.
Variations and modifications are possible without departing from the spirit of the invention.
Each and every one of the appended claims defines an aspect of the invention which is separate and distinct from all others, and accordingly it is intended that each claim be treated as such when examined in the light of the prior art devices in any determination of novelty or validity. | A cover for a trailer hitch, to prevent inadvertent injury to personnel when the hitch is not being used. An upstanding dome is provided for use with hitches of the type having a ball. The dome incircles the ball, and in addition provides a clearance space above the top of the ball, such that the cover can yield when jarred by the knee or leg of a person, thereby preventing injury. The cover has a base which is preferably oversize with respect to the dimensions of the hitch bar, and is provided with internal ribs or other cushinong structures that are yieldable. The ribs engage the surface of the bar such that when the cover is inadvertently bumped, the ribs yield, again preventing injury to the leg of a person. The cover also serves to protect parts of the hitch from corrosion. | 1 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for utilizing a cryogen including the manipulation, management and control of a cryogen. Cryogen can be utilized in the production of frozen and/or solidified small volumes of desired substances. The small volumes of solidified substances, also called pellets or granules in prior art, are hereinafter referred to as units.
The invention also relates to a method and apparatus for the manipulation, management, and control of the main body of the cryogen in combination with its internal currents.
BACKGROUND OF THE INVENTION
The desire for small volumes of substances, individually frozen or solidified has become greater as the technology has improved and the awareness and availability of such a product has increased. This demand includes food type products, bioactive products, chemical products, and in general any liquid, semi-liquid, semisolid or solid that may be desired to be frozen or solidified in small individual units. Small individual units do not demand the thawing of a large amount of product for utilization. Measurability, novelty, convenience, reduced waste, higher quality, ease of use, flowability, handling, minimizing cellular damage, and maximizing product efficacy are also advantages that industry is discovering with small frozen or solidified units. This demand has created a need for a product that has reasonable-consistency of size, shape and other physical characteristics.
In the field of bio-active products, small frozen or solidified units have significant advantages. The freezing process is very fast and results in minimal cellular and structural damage, which provides maintenance of the desired bioactive characteristics.
The rapid freezing minimizes cellular damage caused by the formation of ice crystals, normally associated with freezing. Bioactive-products are often freeze dried for storage. The characteristics of the units make them excellent for freeze drying. The more consistent the size and form of the units, the more favorable they are for a freeze drying process.
One of the advantages of a small volume of frozen or solidified product is that it can be made to flow like ball bearings (flowability). Thus, the handling of specific amounts of units that may vary with demand is possible. Agglomeration and deformed individual units inhibit the ability to flow as desired.
Measurement and utilization is also an important feature. If an average weight of the product is known, a specific amount can be utilized without thawing a larger block of product. The thawing of the desired amount of product is faster as a direct result of the relatively large surface area per unit of weight as compared to a frozen block of product. Many characteristics are improved significantly as a result of the rapid freezing or solidification of the small volume of liquids.
There is prior art in the field of production of frozen units by utilizing a cryogenic liquid. Much of the known art utilizes a particular cryogenic liquid, such as Liquid Nitrogen (LN2).
The main problem with the prior art is that the small volumes of substance are introduced into the cryogen with relatively little consideration of the manipulation and management of the cryogen itself. This results in the formation of random or poorly formed units. Creation of deformed units is commonly referred to as the “popcorn” effect. The units look like “popcorn” rather than smooth spheres.
Consistency of size, structure, texture and surface quality as well as control of agglomeration has not been able to be a manageable and controllable feature previously.
All of these variances result from the inability to control and manage the rapid heat transfer that occurs in the process. This rapid heat transfer results in remarkably violent gasification, which results from introduction of a relatively warm substance into the extremely cold cryogen. Gasification occurs at the interface between the cryogen and the forming units. Violent gasification results in cavitations at the surface of the cryogen resulting from the creation of gas bubbles, which can break the surface of the cryogen. Gas bubbles bursting at the surface of the cryogen can lead to incomplete and non-uniform immersion of the introduced substance into the cryogen. It also causes the units to violently interact. This violent interaction results in significant structural alterations of the units.
Agglomeration is also often a problem as the rapidly forming units often combine with other units resulting in multiple units combining and solidifying together. This agglomeration affects the flowability of the product as well as affecting other desired qualities
The relevant prior art is referenced as follows:
Canadian Patent # 937450:
This patent describes the deformation that would naturally occur when a small volume of liquid is entered into a body of cryogenic material.
Canadian Patent # 964921:
This art describes a small volume of liquid being introduced into an unmanaged and static body of cryogenic liquid.
Canadian Patent # 1217351 and U.S. Pat. No. 4,655,047:
This patent describes the improved formation frozen pellets. This patent describes the introduced liquid relative to speed into the body of cryogenic liquid.
Canadian Patent # 2013094 and U.S. Pat. No. 4,982,577:
This patent identifies the previous patents' lack of ability to control the exposure of the cryogenic liquid to external heat sources and thereby the subsequent waste of the cryogenic liquid. Although it establishes a good method of handling the liquid for the purposes of cost, it does not identify, mention or claim the benefits of a process of manipulation of the fluid dynamics of the cryogenic liquid to produce the ability to manage the characteristics of the introduced liquid as it solidifies.
U.S. Pat. No. 4,687,672:
This patent describes a freezing of large volume of product and its subsequent fracturing and grinding to produce a granular product.
U.S. Pat. No. 5,126,156:
This art describes a liquid being introduced into a cryogenic liquid without any reference to manipulation or management of the cryogenic liquid only referring to the removal of the pellets from the liquid after freezing and a screening process to extract only the pellets from the liquid via an auger in a similar fashion to Canadian patent 964921.
U.S. Pat. No. 6,000,229:
The art is basically a tub of cryogen with an introduction point of cryogen. In addition an auger for the removal of solidified pellets. There is not any attempt to manage the heat transfer, gasification or other destructive aspects.
Generally, the prior art in the field focuses on the actual small volume of liquid being introduced and the handling and removal of subsequently-frozen product from the liquid cryogen. The prior art typically does not identify or discuss what actually occurs within the body of the cryogen or any methods or apparatus for managing the heat transfer and gasification that directly affects the structure and formation of the pellet being produced.
OBJECTS OF THE INVENTION
The synergistic effects of the type of management of the present invention include but are not limited to:
a) The dispersion of gas produced by the heat transfer between the thermally different introduced substance and cryogen. b) The dispersion of the heat transfer between the introduced substance and cryogen into the general body of the cryogen. c) Maintaining a physical distance between individual units such that the destructive aspects of physical interactions are minimized.
This enables the improved management, control and determination of the desired characteristics of the individual units. The characteristics managed are the shape, size, surface texture, deformation, frozen satellites, fines, and agglomeration of the introduced units as they are frozen or solidified.
Accordingly, several objects and advantages of the present invention include the manipulation and subsequent management of the cryogen utilized in the solidification of a series and/or multiple units of small volumes of a substance introduced into the cryogen. In general practice the cryogen utilized may be Liquid Nitrogen (LN2) or other suitable low temperature liquid.
Accordingly a primary objective of the present invention is the creation of the synergistic effects resulting from a method and apparatus for the manipulation and management of both the general fluid body (Fluid Body Movement) as well as the internal fluid dynamics (Currents) of the cryogen. These synergistic effects are utilized to control the characteristics of the frozen unit resulting from the introduction of that unit into the body of cryogen, such as Liquid Nitrogen (LN2). The controlled characteristics may include the surface structure, agglomeration, fines, satellites, average size, roundness and the prevention of ice crystallization.
Another object of the present invention is the physical movement of an introduced unit out of the introduction area of subsequently introduced units as a result of the unit being carried by the flow of the LN2.
Another object of the present invention is the reduction of physical interaction of forming and formed units with each other thereby avoiding the obvious physical damage that the firmer formed unit would cause to the forming units.
Another object of the present invention is to facilitate the dispersion of the gasification resulting from the interface between the small introduced unit and the cryogen. This dispersed gasification also assists in the enhancement of currents within the body of the cryogen.
Another object of the heat and gasification dispersion resulting from operation of the present invention is faster heat transfer from the introduced units into the liquid cryogen, as a result of increased direct contact between the forming unit and the LN2.
Another object of gas dispersion resulting from operation of the present invention is the minimizing of physical damage done as a result of the violent gasification on the forming unit.
Another object of the invention is the ability to regulate properties of the units, including these characteristics of the solidified or frozen unit, as the market requires. Properties can range from “popcorn” type products with or without agglomeration to smooth sphere like units that are individual in nature and of primarily similar size and shape.
An additional object of the invention is the utilization of a recycling system to create the desired flow of the cryogen.
An additional object of the invention is the utilization of a sloped raceway of varying designs to maintain the flow of the cryogen.
Another object of the invention is the length of the raceway. The length of the raceway, from the point of introduction of units into the cryogen to the point of units/cryogen separation at the removal mechanism for said units, can be calculated utilizing cryogen flow speed and desired retention time of the units in the cryogen.
Another object of the invention is the encouragement or discouragement of the internal currents within the body of the cryogen as a result of the recycling process to assist in desired results.
Additional objects, advantages, and other novel features of the invention will be set forth in part in the description and scientific explanation that follows and in part will become apparent to those skilled in the art upon examination of the following or may discerned from the practice of the invention.
The prior art does not manipulate, manage or utilize any of the described factors that occur in the cryogen. Previous patents simply introduce a unit into a body of cryogen. The gasification of the LN2 is sufficiently violent that the introduced unit appears to float or levitate on top of the LN2 as a result of the lift power of the gasification. This occurs in spite of the fact that units, in general, are heavier than the LN2. The units at the surface or near the surface are a combination of individual units in all three stages of formation moving violently and randomly. With the violent gasification and the combination of all stages of formation in close proximity it can easily be understood by anyone skilled in the art why the deformation, damage, fragmentation and agglomeration and other characteristics result.
To achieve the foregoing and other objects and advantages, and in accordance with the purposes of the present invention as described herein, a method and apparatus for producing the desired synergistic effects by manipulation of both the body and internal fluid dynamics of the cryogen utilized in the production of a free flowing frozen or solidified product resulting from the introduction of small volumes of liquid called units into the body of liquid cryogen.
SUMMARY OF INVENTION
The cryogen, preferably Liquid Nitrogen (LN2), may be drawn from a reservoir or sump at the bottom of the apparatus, by a means to remove said cryogen from the reservoir, such as a recycling system. The recycling system may comprise one or more augers; however, other recycling methods could be utilized. One or more augers may be utilized depending upon desired results. Multiple augers can provide a greater recycling volume as well as increased internal currents. An apparatus which creates a suction effect, or another means to elevate the cryogen from the reservoir may be suitable.
The recycled LN2 may be moved substantially vertically or upwards from the sump by rotation of an auger. The upward motion of the cryogen may result in a bubbling spring effect when the cryogen begins to transition to horizontal flow. Also, there may be internal currents created within the body of the cryogen that are initially caused by the auger or other recycling system.
A cryogen auger (as example of pumping methodology) does not have to be completely vertical however the preferred arrangement for lift is an auger that is substantially vertical with a plurality of flutes to be machined at a preferred angle of about 14 degrees from center with a quantity of flute flights of between about 8 and 10 per auger. The flutes preferred spacing is about 2.5 inches apart. The most preferred condition is a substantially vertical auger with a flute angle of 14 degrees from center with a quantity of flute flights of 8 with a spacing between flutes of 2.5 inches. If it is decided to employ an auger angle other than substantially vertical all flute angles and quantity of flutes thereof can be adjusted accordingly to offset the other than substantially vertical condition to allow for similar lifting volume of the cryogen. Large numbers of flutes are possible but can result in added vibration.
The vertical movement of the cryogen can develop into a fundamentally horizontal movement as it flows away from this transition point. At the transition point, back currents created by a vertical flow may dissipate and before the introduction of the small volume of substances at the introduction point. Once the flow evolves to a fundamentally horizontal flow the currents created by the recycling system disperse any minor gasification that results, resulting in a reasonably smooth surface on the LN2. The initial slope of the raceway at the product/cryogen interface will assist in the management of the speed and depth of the body of LN2 at this juncture with the preferred slope being between about −5 degrees (upward slope) up to about +15 degrees downward slope from the horizontal and the most preferred slope being +5 degrees downward from the horizontal. The subsequent angle of travel along the raceway beyond the interface point is preferred to be about +5 to about +15 degrees downward slope with the most preferred at +7 degrees.
If the current is too strong for the desired results, a screen or baffles can be utilized in advance of the introduction point of the small volumes of liquid to slow down the internal currents.
The distance of the exit of the recycling system at the point of transition from vertical to horizontal flow to the introduction point of the small volume of desired substance may be of sufficient distance such that the vertically moving LN2 being recycled converts to horizontal flow, thereby allowing any back eddies created by the vertical flowing liquid changing to a horizontal flow to dissipate and settle and become a non-factor in the current of the cryogen. This distance may be a factor associated with the maximum flow that the recycling system is capable of creating.
Once the LN2 has achieved a smooth surface and a substantially mono-directional horizontal flow, a desired substance may be introduced into the cryogen via a nozzle either under pressure or by gravity feed. The substance that is introduced may be a stream, or as individual measured droplets in varying degrees of frequency or precision depending upon the desired production outcome required. The height of the nozzle above the introduction zone may be adjustable due to desired characteristics of units. Preferably, the nozzle may be at a height sufficient to limit disruptive current resulting from introduction of the substance. Also, preferably the introduction of the substance will not cause upward spray of the cryogen. The horizontal movement of the LN2 can move the forming unit out of the introduction zone where subsequent units may be continuously introduced into the cryogen.
The inherent and artificial currents in the LN2 may disperse the gasification created by the introduction of the small volumes of relatively warm substance into the cryogen. Dispersion of this violent gasification at a point away from the introduction zone may enhance the internal currents within cryogen.
The LN2 can be guided down a sloped raceway. The raceway is constructed in a variety of formats depending upon the desired effect, substance being frozen or solidified, and desired retention time. The raceway may have a stainless steel surface, such as a “mirror” finish applicable in stainless steel polishing in the pharmaceutical industry, or other applications where a smooth finish is utilized. Finishes are typically determined pursuant to the regulatory bodies governing such things for individual industries, such as the FDA. These surface finishes can facilitate cleaning and disinfection of the system when required. In industry, often when there is a change from one product type to another it is essential that substantially the entire previous product be removed and cleaned. This is particularly imperative with bio-active products. In addition the smoother the surface the less the frictional resistance of the surface becomes a parameter in the movement of the cryogen or the individual units.
The cross section shape of the raceway may be an expanded “U” shape in order to facilitate cleaning and disinfection after use of the equipment. However, the raceway may be enclosed, such as a tube. A “U” shape can minimize corners that would affect the desired currents and flow for the cryogen. The “U” shape may also minimize damming or conglomerations of the units as they proceed down the raceway.
One embodiment of a raceway may be a spiral raceway. The slope of the raceway can be a function of the desired speed of the body of LN2 that is desired. The length of the spiral can be a function of the desired retention time of the forming and formed units. The longer the raceway or spiral the greater the retention time of the units. The slope of the spiral may also be a function of the desired retention time of the units and the desired speed of the cryogen. A greater the slope of the spiral will increase the rate of flow of the cryogen through the spiral.
The spiral formation can present additional benefits in that the currents and flow may not develop the opportunity to stabilize as easily as they would in a linear raceway.
Another embodiment of a raceway may be a series of linear raceways. The linear raceways may have a similar expanded “U” shape, or may be enclosed in a tube form. The raceway can be made up of a series of cascading linear raceways, whereby a first linear raceway feeds into a receiving linear raceway running in a substantially different direction. This cascading of the cryogen from a first raceway into the receiving raceway may cause a general mixing of the cryogen and the units. This cascading effect may enhance the internal currents within the cryogen.
Again, the overall length of the embodiment of the linear raceway can be a function of desired retention time of the introduced units. A particular velocity of the cryogen and a specific length of raceway may result in different durations that the units are in the body of cryogen in advance of being removed by the extraction system.
The actual number of cascades utilized can be a function of the desired size of the equipment and the enhancement of the currents desired. However, the more cascades that are utilized the more that the internal currents may be enhanced.
A further embodiment of the present invention may be a linear raceway without any cascading or spiral action. Again, the slope and length of this design may be a function of desired speed and retention time of the units.
Upon exiting the raceway, the cryogen may travel through a moving screen or wire mesh belt. Preferably, the screen or wire mesh is of a conveyor belt style. The porous screen or mesh can be designed to allow the passage of the cryogen through it while removing the resultant solidified unit. The separation of the unit from the cryogen can be referred to as the removal point.
The escape of the gasification that has occurred in the cryogen may be via the same exit point as the units on the conveyor belt. Similarly, another advantage may be the utilization of heat transfer from the units to the gas as it escapes with the extraction of the units from the equipment.
Once passing through the screen or belt, the cryogen may be returned to the sump. There, the returned cryogen can be re-fed into the recycling system, and the process be made continuous.
EXAMPLES
In order to effectively describe the advantages of the invention, the physics and science of the introduction of a small volume of substance, preferably a liquid, semi-liquid, semisolid or solid, into a body of cryogen, such as LN2, is presented as follows.
Example 1
For this example water (H 2 0) will be utilized as the sample introduced liquid and Liquid Nitrogen (LN2) will be utilized as the cryogenic liquid.
DEFINITIONS AND STANDARDS UTILIZED
Temperatures will be presented in Kelvin (K), with a conversion to Celsius (C) and Fahrenheit (F).
1. “Freezing Point” of water (H 2 0)=273.15 K 2. 273.15 K=32 degrees F.=0 degrees C. 3. 1 degree Celsius=1 degree Kelvin 4. 1 gram (gm) of H 2 0=1 cubic centimeter (cc) of H 2 0 5. 1 cc.=1 cubic centimeter=1 gram of H 2 0 6. calories=1 calorie=the heat required to raise 1 gram of H 2 0 1 degree K 7. “Heat of Fusion” of H 2 0=79.7 cal/gm=79.7 cal/cc 8. “Vaporization Point” of Liquid Nitrogen (LN2)=77.4 K 9. “Heat of Vaporization” of LN2=2.7929 kJ/mol of LN2 10. 1 Mol of LN2=28.0134 gm. 11. 1 cal=4.184 joules 12. LN2=0.807 gm/cc=1.239 cc/gm. 13. 2.79 kJ/mol=23.83 cal/gm=29.526 cal/cc. 14. 1 cal converts 0.042 gm of LN2 to gas or 0.034 cc of LN2 to 5.91 cc of Nitrogen gas. 15. Expansion factor of LN2 liquid to a gas at vaporization temperature=174.6 volume of expansion.
When 1 gram (1 cc) of H 2 0 is introduced into a body of cryogen, being LN2, the heat transfer falls into three main categories:
1. The energy exchange in the lowering of the temperature of the introduced liquid to the point where a ‘Phase Change’ of the introduced H 2 0 occurs. 2. The energy exchange associated with the change of phase “Heat of Fusion” 273.15 K or 0 C or 32 F. 3. The energy exchange as the temperature of the units decreases to the desired exiting temperature, below 273.15 K, 0 C or 32 F.
Above the fusion temperature of water, or pre-solidification:
It requires 1 cal of energy release from the H 2 0 for each degree K of change above the “Fusion” temperature of the introduced water. Therefore it utilizes 0.0411 gm or 0.0339 cc of LN2 for each degree change with a subsequent gas release of 5.9134 cc of Nitrogen gas per degree of change of the H 2 0.
The physical properties of the introduced small volume of liquid may be very vulnerable during this stage as the unit retains its fluid properties, and hence, most susceptible to deformation, separation and fragmentation as well as agglomeration with previously introduced units and each other. As the crust is formed and solidification is initiated, any physical interaction may cause significant deformation of the forming unit, and possible agglomeration with other forming or formed units.
The Phase Change of the Introduced Liquid:
It requires 79.7 cal of heat exchange for the “Heat of Fusion” of the introduced product. Therefore this heat exchange vaporizes 79.7×0.0411 gm or 79.7×0.0339 cc of LN2. This result is the release of 471.28 cc of nitrogen gas.
In a practical application the “Heat of Fusion,” as well as the temperature at which the phase change occurs will vary depending upon the number of solids in the unit and the percentages of other liquids in the units such as lipids (fats), salts, spices, etc.
The physical properties of the forming unit at this stage can be vulnerable to a more limited extent. In a practical application the solidification may not occur as rapidly as in the H 2 0 example. The presence of oils, solids, etc. in the liquid will result in the product being plastic or soft for a greater range of temperature. This results in a product that can be sensitive to physical damage such as deformation, as well as agglomeration with other units until complete solidification occurs.
Below the Fusion Temperature, or Post-Solidification:
It requires 1 cal of energy release from the H 2 0 for each degree of change below the “Fusion” temperature of the introduced water. Therefore, it utilizes 0.0411 gm or 0.0339 cc of LN2 for each degree change with a subsequent gas release of 5.9134 cc of Nitrogen gas per degree of desired change.
The ability of the unit, when solidified, to transfer heat may increase once it is solidified.
The physical properties of the frozen or solidified fluid below the fusion temperature are essentially constant, and additional damage or deformation is minimal, if even evident. A benefit to dispersion of gas produced and maintenance of distance between forming units is during the forming, pre-solidification, stage of the units.
In a model where the water is introduced at 278.15K or 5 C or 41 F and the removal temperature is 165K that is −108 C or −162 F, the gas production per cc of introduced H 2 0 input is:
Stage 1=5 cal×5.91 cc/cal=29.6 cc of gas released
Stage 2=79.7 cal×5.91 cc/cal=471.28 cc of gas released
Stage 3=108 cal×5.91 cc/cal=638.62 cc of gas released
This is a total of 1139.5 cc of gas produced within the body structure of the LN2 per gram or cc of H 2 0 introduced. As evident by this example, rapid Nitrogen buildup, or violent gasification, can result from the introduction of the relatively hot units into the LN2. This violent gasification may have a significant affect upon the internal currents and movement of the units within the body of the LN2.
Escaped gas can be utilized for additional cooling when the units are removed from the equipment on the conveyor screen.
Once the basic structure of the unit has taken place, the gas release of the individual unit slows down and the unit then sinks into the body of the LN2. Without management, virtually all the damage that would have been done to the physical characteristics would have occurred.
In a production system there is also a steady state loss of LN2 due to the operation of the equipment. The LN2 will vaporize even without the introduction of external units. This gasification is approximately 5,500 cc or 5.5 liters or 0.2 cubic feet per minute.
A system producing 200 lbs/hr and operating at an LN2 flow rate of 50% of motor capacity for a single auger LN2 pump and producing a product of approximately 15% to 25% solids will result in the following: The equipment-caused gasification would be approximately 5,500 cc of gas per minute, while the gas production from introduced units would be 1,730,000 cc of gas per min.
Example 2
A production system processing approximately 90 kilograms or 200 lbs of output per hour will release in excess of 1,730 liters or 61 cubic feet of gas per minute. Over 95% of that gas would be released normally at the interface of the introduced units and the LN2. This substantial gas release at the introduction point can lead to many adverse formation conditions, such as those previously mentioned.
In a production example, actual units range in size depending upon the introduction nozzles utilized and the particular characteristics of the liquid, semi-liquid, semisolid or solid. The average size may be from about 0.1 cc to 0.5 cc in size, but not limited to these sizes. The size of the unit will not affect the amount of gasification; however, the speed of the heat transfer will increase as the total surface area per total weight of product increases.
It can also be easily seen by anyone skilled in the art that violent gasification does occur and occurs very quickly at the interface between a forming unit and the LN2. In addition this violent gasification would affect the movement and interaction of units in the body of the cryogen. This type of reaction explains the deformation, size variances, surface characteristics and agglomeration that are noted to occur in the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cutaway view of the apparatus of the present invention.
FIG. 2 is a cutaway view of the introduction point of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Having summarized various aspects of the present invention, reference will now be made in detail to the description of the invention as illustrated in the drawings and described in the scientific description. While the invention will be described in connection to these drawings and description, there is no attempt to limit the invention to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the invention as defined by the appended claims.
Reference is now made to FIG. 1 showing the apparatus of the present invention. Cryogenic liquid ( 10 ) may be stored in a sump ( 20 ), or reservoir, at the bottom gravitational location of the apparatus. The cryogen may be lifted to the entrance of the raceway ( 24 ) via one or more augers ( 22 ). Alternatively, an impellor-type pump may be used, to created vertical flow of cryogen up to the raceway ( 24 ). The cryogen may then transition from vertical movement to horizontal flow, and initiate its travel down a sloped raceway ( 28 ).
The slope of the raceway can be a factor in the management of cryogen movement in the preferred embodiments for the slope being as follows for the top of the raceway at the product/cryogen interface. The length of the raceway, from the point of introduction of units into the cryogen to the point of units/cryogen separation at the removal mechanism for said units, can be calculated utilizing cryogen flow speed and desired retention time of the units in the cryogen.
The preferred slope can range from about −5 degrees (upward slope) to about +15 degrees (downward slope) from horizontal. Most preferably the slope is +5 degrees (downward slope from horizontal). The raceway slope can be produced to be adjustable across a desired range. Beyond the product/cryogen interface the raceway slope is preferred at about +5 to about +15 degrees downward slope with the most preferred at +7 degrees.
The cryogen with units contained therein can pass though a moving screen conveyor belt ( 30 ) that removes the solidified units from the cryogen. The conveyor belt ( 30 ) may be made of a screen, a wire mesh, or any suitable porous material that will filter the solidified or frozen units from the cryogen. The cryogen may then return to the sump ( 20 ) where it is recycled again.
The pumping capacity of the auger can be in excess of the ability of the cryogen in the sump to keep the entrance full of cryogen. If this operational condition was created, cavitations in the cryogen may occur if the auger is run too fast thereby introducing gas into the auger process. Cavitations in the cryogen may result in the vertical flow not being consistent. Also, an embodiment of the recycling system that consists of two or more augers thereby enables an increased flow without causing the undesirable cavitations and subsequent flow inconsistency.
The cryogen auger (as example of pumping methodology) does not have to be completely vertical however the preferred arrangement for lift is as follows: The auger can be substantially vertical with a plurality of flutes to be machined at about a 14 degree angle from center with a quantity of flute flights of between about 8 and 10 per auger. The flutes preferred spacing is about 2.5 inches apart. The most preferred condition is a substantially vertical auger with a flute angle of 14 degrees from center with a quantity of flute flights of 8 per auger, with a spacing between flutes of 2.5 inches. If it is decided to employ an auger angle other than substantially vertical all flute angles and quantity of flutes thereof can be adjusted accordingly to offset the other than substantially vertical condition to allow for similar lifting volume of the cryogen. Large numbers of flutes are possible but can result in added vibration.
Reference is now made to FIG. 2 in which the flow transition point is depicted. The cryogen may be lifted by the auger to enter the raceway ( 24 ). Motion of the auger ( 22 ) may create a circular and vertical direction ( 34 ) of the cryogen. Upon exiting the recycling system at the top of the auger, the direction of the fluid body movement is vertical and circular. The flow may change to a fundamentally horizontal flow. The transition from vertical to horizontal flow may result in the production of back eddies and reverse currents ( 36 ). Back eddies and reverse currents ( 36 ) can result in a spring bubbling-effect up into a body of cryogen then flowing in a horizontal direction.
These back eddies and reverse currents can be allowed to settle out as the fluid converts to basically horizontal flow ( 38 ) in advance of the introduction point ( 42 ) of the small volumes of a desired substance, such as liquid, semi-liquid, semisolid or solid. Upon introduction into the cryogen, these small volumes may be referred to as units. In another embodiment, a control means ( 40 ) may be introduced at the flow transition point to decrease the intensity of the back eddies and reverse currents. The control means may be a barrier, screen, baffle or dam. In a further embodiment, the apparatus may be adapted to inject a time delay for flow transition. In this embodiment, the auger may rotate with slower speed, there may be a dam before the introduction zone, or a diffusion pool may be added after the introduction zone.
The length of the raceway can determine the retention time of the units as a function of desired exiting temperature or required time necessary to ensure solidification in the cryogen given a particular speed of motion. In some cases the depth or speed of the cryogen can be adjusted to adjust retention time. In such cases a baffle, screen or a dam is placed in the raceway after the introduction point. A dam obviously increases the depth of the cryogen. A baffle aids in the direction of flow of the cryogen and units. A screen aids in the control of the internal currents in the cryogen.
The recycling of the cryogen can maintain a constant circular flow as it travels down the raceway back to the sump and up again to the entrance to the raceway ( 24 ).
The small volumes of substance can be introduced to the cryogen flow via a series of introduction nozzles ( 44 ) that introduce the liquid by streaming, or as individual droplets, either by gravity feed or under pressure. Droplets ( 46 ) can be predefined in volume by a specialized pump or can be determined by the particular surface tension of the liquid and form a droplet that can be released like a drip from a dripping tap.
The number of nozzles utilized for the introduction of small volumes of liquid, are a function of the engineering of the total unit. Preferably, multiple nozzles may be utilized. The actual number of nozzles utilized is a function of the total volume of liquid that the system can sustain while still maintaining the desired results. In general, the faster the speed of individual units being introduced, the faster the lateral movement of the cryogen required in order to achieve the results desired. In addition to pure cryogen velocity the higher the number of individual units being introduced the greater the surface area of the introduction point required.
The introduction point ( 42 ) may be positioned downstream from the introduction of the recycled cryogen such that eddies and back currents may have time to settle and a consistent forward flow is achieved. However, the introduction point ( 42 ) may be the same position as the entrance point ( 35 ). The distance from the recycled cryogen entrance ( 35 ) to the introduction point ( 42 ) can be dependent upon the maximum flow capacity desired for the equipment. An example of a desired result at the introduction point is a reasonably smooth surface on the flowing cryogen.
Preferably, the distance between the nozzles is sufficiently distant such that the droplets or steams will not combine with each other before hitting the surface of the cryogen. Combination of droplets may also be a function of the height of the nozzles above the cryogen surface. Also, the nature of the product being processed can influence the combination of the droplets. The distance between nozzles, height above cryogen surface and nature of product being processed are variable and may be adjusted by user-designation.
When a droplet is introduced into a horizontally moving body of cryogen, the resulting unit may be moved away from the introduction point ( 42 ). The faster droplets are introduced, the faster the flow of cryogen that is required to move the unit out of the way of the next introduced unit. Preferably, the unit is transported immediately from the introduction zone by the horizontal cryogen flow, thereby reducing the interaction between droplets and unformed units. The speed of the process may be controlled partly by the volume of cryogen recycled, the speed of the recycling of the cryogen, and the slope of the raceway.
Another management tool is the distance that the droplet will pass through before coming into contact with the LN2. The distance of the droplet height or individual liquid unit height from the body of LN2 can be dependent upon the liquid product to be frozen and could range from very low to very high. The preferred variance is from about 4 inches to about 36 inches above the cryogen. Depending on the product makeup (i.e. solid contents, viscosity and surface tension) and the desired results one wishes to achieve (i.e. consistent shaped pellets of varying degrees or misshapen and agglomerated pellets (i.e. Popcorn shaped) or many other combinations including frozen splatter) the height variance can be substantial. Also, liquid product pumping capacity may require establishment as to not overburden the system with too much liquid to be frozen and hence compromise the results desired or efficiencies of a certain type and size of unit/equipment. Testing of these parameters can be established to correlate to the needs of a particular end user and hence management for said requirements can be forecasted and built in to satisfying the existing and future needs of a user.
The distance of drop or droplet combined with its size and mass will to an extent demand that a particular depth and speed of LN2 be available in order to inhibit the droplet from hitting the actual bottom of the raceway in advance of the droplet forming its initial crust.
This methodology results in the gasification created by a particular unit not being added to the gasification of the next unit. In addition, increased flow may prevent the physical interaction of units while they are very susceptible to physical damage, as they are remote from each other.
The violent gasification results in cavitations. Cavitations are individual bubbles that eventually break the surface of the cryogen. In effect the surface becomes covered with cavitations, which present a jagged surface to which the droplets contact. However, these cavitations can be remarkably destructive to droplets when they are introduced into the flow of cryogen. Maintenance of a smooth cryogen surface at the introduction area can be one of the essential parameters in managing the form and structure of the resultant units. This may be accomplished by maintaining a steady horizontal flow of cryogen.
As the heat is transferred from the units to the body of cryogen, the currents may move the actual cryogen molecules that are in the process of going through a change of phase or vaporization. Since the actual molecules that are absorbing heat are continually being moved away from the solidifying unit much of the gasification that would normally occur at the interface may be delayed or occur at a point away from the interface.
The internal currents, still active due to the recycling systems' motion, assist in the dispersion of the gas and heat from the interface. The gasification that occurs within the body of the cryogen can create additional currents that assist in the dispersion of subsequent gasification and heat. The movement of the gas bubbles through the fluid body of the cryogen enhances the existing currents and creates new ones. These currents can aid in the desired effect created by the currents. This can minimize physical damage as a result of the violent gasification. The movement of the gasification and heat away from the interface minimizes the normal encapsulation of the forming unit by the gasification. When a unit is encapsulated in gasification the speed of heat transfer is inhibited, as the gas does not absorb heat as quickly as the liquid cryogen absorbs heat. The result of minimizing encapsulation is that physical contact with the liquid cryogen is maximized, thereby maximizing heat transfer.
The newly forming units are physically moved out of the way of the next introduction of units as a result of this controlled lateral flow of cryogen, thereby minimizing the physical interaction of forming and formed units with each other. The continued flow down the sloped raceway can maintain this distance between the units. This may assist in controlling the agglomeration that would be expected to occur, as well as the physical interaction and resulting deformation or structural damage to the units that would result.
Depending upon the product and the management desired in general it is preferred that the cryogen flow be such that product is moved away from subsequent newly introduced product. However for some products minimal or substantial no flow of the cryogen may be advantageous. This is because even without any river type flow of the cryogen there is substantial currents and resulting movement thereof caused within the body of the cryogen as a result of the significant gasification that occurs at the interface between the introduced product and the cryogen. This substantial movement is over and above the great deal of movement that already occurs from the steady state gasification that occurs even without the introduction of the substance to be frozen.
The preferred rate of cryogen flow is relative to the individual liquid units to be frozen however for each product there can be established of a most preferred rate. This is ultimately accomplished through the testing of each individual liquid type product to be frozen and adjusting the parameter for cryogen flow accordingly to establish a most preferred rate. As well the amount of pumping capacity can vary with the size of each piece of equipment constructed and the number of pumping sources available. For some of what may be considered larger sized pieces of equipment produced (this is of course somewhat subjective to individual industry definition of larger scale) a preferred range for cryogen pumping capacity for example would be about 100 to about 150 liters of cryogen per minute into a river width of about 8 to 12 inches. A most preferred rate would be 120 liters per minute of pumping capacity with a river width of 10 inches. It is important to note that this technology is scaleable (small and large). For comparative purposes for smaller sized equipment than that as cited above the above ranges could be about 50% of those values (once again dependent upon industry definition and need). The cryogen depth can be managed to be within a preferred rate of from about 1 inch to about 3 inches deep by adjusting the cryogen flow rate and/or the horizontal slope of the tray and/or by introducing a downstream flood gate/dam or a narrowing of the raceway that will allow more or less cryogen to flow over it past its point of location depending upon the cryogen depth desired.
For example, a product of composition such as skim milk dropping simultaneously from approximately 48 nozzles from a height of between 20 and 25 inches into a flowing cryogen source moving along a 10″ trough at a +5 degree angle at the point of interface and then descending at a rate of approximately 2.5 feet per second for a time of approximately 20 seconds (residence time) will produce a consistent size and shape of pellet in a quantity of approximately 325 to 375 pounds per hour.
In specialized product situations, individual channels can be built in the raceway such that each nozzle utilized at the introduction point directs the droplets to follow a particular channel thereby stopping any horizontal interaction between units that were introduced at the same time.
When the gasification is removed remotely from the interface and mixed into the general body of the cryogen, the gasification can create additional random mini-currents within the body of the cryogen that assist in the general manipulation of the inherent currents and their subsequent effect as well as encouraging continued movement of the gasification.
This movement of the gasification away from the interface inhibits the initial floatation or levitation of droplets caused by the violent gasification ( 52 ), thereby minimizing the interaction of floating units that are randomly thrown around and have the possibility of hitting the sides of the raceway and/or each other.
The form of the raceway can also assist in this management and manipulation. A spiral raceway can continually change the direction of the flow of the cryogen thereby not allowing it to stabilize in a particular direction. A cascading raceway may cause the cryogen to cascade thereby enhancing internal currents and thereby fortifying random currents and flow. A linear raceway may allow the flow to stabilize.
The solidified units may be removed from the flow of cryogen via a conveyor belt screen with spacing in the screen such that the cryogen flows through the belt while the formed units do not flow through the belt. The belt may take the formed units to the exterior of the equipment where they are stored or utilized as desired. The exit of the cryogen gas due to evaporation or gasification from the equipment can be where the conveyor belt removes the solidified units. Therefore, the units after removal from the cryogen may be in an atmosphere of very cold gas. By adjusting the speed of the belt, the time that the units are exposed to this cold gas can be determined. There may be additional cooling of the units from this exposure to the expelled gas. | A method and apparatus for the manipulation and management process of cryogen such that it controls both the fluid body movement as well as internal currents within the cryogen. Small volumes of a desired substance introduced into this managed cryogen for the production of frozen or solidified pellets or granules are better managed as to shape, size, deformation, frozen satellites, fines and agglomeration and overall desired quality. These benefits result from the dispersion of the gas produced, as well as the heat transferred, resulting from the introduction of the relatively hot substance to the cryogen. The fluid body movement assists in maintaining a distance between the individual solidifying pellets or granules thereby minimizing deformation as a result of physical contact. The output characteristics and desired quality of the pellets can be more effectively controlled and managed, as desired. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority of DE 10 2011 084 658.1, filed Oct. 18, 2011, the priority of this application is hereby claimed and this application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a friction clutch device, in particular for a drive train of a motor vehicle which is driven internal combustion engine, having a rotational axis, a housing, at least one pressure plate which can be displaced in the direction of the rotational axis relative to the housing for an actuation, and a spring device for loading the at least one pressure plate.
2. Description of the Related Art
DE 10 2008 005 918 A1 has disclosed a friction clutch having a housing, a pressure plate and an energy store which can be stressed between the housing and the pressure plate and via, which the pressure plate can be loaded in the closing direction of the friction clutch. The energy store is formed by a disk spring. The disk spring is fastened to and supported on the housing via an abutment in the manner of a two-arm lever. The disk spring can be elastically stressed axially between the housing and the pressure plate, with the result that it loads said pressure plate in the direction of the friction linings of a clutch plate. In order to disengage the clutch, the disk spring has to be loaded in the region of the tips of the disk spring tongues.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a friction clutch that improves structurally and/or functionally over the prior art.
The object is achieved by a friction clutch device, in particular for a drive train of a motor vehicle which is driven by internal combustion engine, having a rotational axis, a housing, qt least one pressure plate which can be displaced in the direction of the rotational axis relative to the housing for an actuation, and a spring device for loading the at least one pressure plate, in which friction clutch device the spring device has a first element for generating a pressure force which acts on the at least one pressure plate, and a second element which is separate structurally from the first element for transmitting an actuating force.
The friction clutch device can have a single clutch. The friction clutch device can have a double clutch. The friction clutch device can have a dry clutch. The friction clutch device can have a single plate clutch. The friction clutch device can have a wet clutch. The friction clutch device can have a multiple plate clutch. The friction clutch device can be arranged in a drive train of a motor vehicle. The motor vehicle can be a commercial vehicle. The motor vehicle can be an agricultural utility vehicle, such as a tractor. The motor vehicle can have an internal combustion engine. The motor vehicle can have a transmission. The friction clutch device can be arranged between the internal combustion engine and the transmission. The friction clutch device can have an input part. The input part can be capable of being driven by the internal combustion engine. The friction clutch device can have at least one output part. The transmission can be capable of being driven with the aid of the at least one output part. The friction clutch device can make driving off and changing of a transmission gear ratio possible.
Starting from a completely disengaged actuating position, in which substantially no power transmission takes place between the input part and the at least one output part, and moving as far as a completely engaged actuating position, in which substantially complete power transmission takes place between the input part and the at least one output part, the friction clutch device can make an increasing power transmission possible in a manner which is dependent on the actuation, it being possible for power transmission to take place frictionally between the input part and the at least one output part. Conversely, starting from a completely engaged actuating position, in which substantially complete power transmission takes place between the input part and the at least one output part, and moving as far as a completely disengaged actuating position, in which substantially no power transmission takes place between the input part and the at least one output part, a decreasing power transmission can be made possible in a manner which is dependent on the actuation. A completely engaged actuating position can be a closed actuating position. A completely disengaged actuating position can be an open actuating position.
A double clutch can have a first output part and a second output part. With the aid of the double clutch, the input part on one side and the first output part and/or the second output part on the other side can be connected to one another or can be disconnected from one another. In addition, a power flow from the input part can be moved in a fading change from the first output part to the second output part and vice versa.
The at least one pressure plate can be connected fixedly to the housing so as to rotate with it. The friction clutch device can have a back-pressure plate. The backpressure plate can be connected fixedly to the housing so as to rotate with it. The back-pressure plate can be connected to the housing in an axially fixed manner. The pressure plate can be displaceable relative to the back-pressure plate. The friction clutch device can have two pressure plates. One of the two pressure plates can be an intermediate pressing plate. The intermediate pressing plate can be connected fixedly to the housing so as to rotate with it. The intermediate pressing plate can be capable of being displaceable axially with respect to the housing. The pressure plate can be displaceable relative to the intermediate pressing plate. A single clutch can have a pressure plate and a back-pressure plate. A double clutch can have a first pressure plate, a second pressure plate which is an intermediate pressing plate, and a back-pressure plate.
The friction clutch device can have at least one clutch plate. The input part of the friction clutch device can have the housing, the at least one pressure plate and the back-pressure plate. The at least one output part of the friction clutch device can have the at least one clutch plate. The at least one clutch plate can be capable of being clamped between the pressure plate and the back-pressure plate. The at least one clutch plate can be capable of being clamped between the first pressure plate and the second pressure plate which is an intermediate pressing plate. The at least one clutch plate can be capable of being clamped between the second pressure plate, which is an intermediate pressing plate, and the back-pressure plate. The at least one clutch plate can have friction linings. A lining suspension system can be arranged between the friction linings of the at least one clutch plate.
The spring device can load the at least one pressure plate in a prestressed manner in the engagement direction. The friction clutch device can have an automatically closing clutch. The spring device can load the at least one pressure plate in a prestressed manner in the disengagement direction. The friction clutch device can have an automatically opening clutch. The friction clutch device can have a push type clutch. The friction clutch device can have a pull type clutch.
An actuation of the friction clutch device can take place with the aid of an actuating device. The actuating device can act on the second element. The actuating device can have an actuating bearing, such as a disengagement bearing. The actuating bearing can act on a radially inner section of the second element. The actuating bearing can have an annular shape.
An actuation on a large diameter is made possible by way of the friction clutch device according to the invention. A greater transmission ratio can be realized. A pressing force can be increased. A greater wear reserve can be provided.
The first element can be a disk spring which acts between the housing and the at least one pressure plate. The disk spring can have no tongues or only very short tongues. A large amount of installation space is available for a force edge of the disk spring. The disk spring has an enlarged force edge. High pressing forces can therefore be generated. High stress peaks are avoided in the force edge. The disk spring has a long characteristic curve profile. The disk spring can be configured to be adapted largely independently of a transmission ratio of the friction clutch device.
Rivets can be arranged on the housing and the rivets can serve to center the disk spring. Starting from the housing, the rivets can be directed inwardly toward the disk spring. Instead of the rivets, the housing can have pin-shaped projections. The projections can be connected, for example screwed or welded, to the housing in a nonpositive, positive and/or material-to-material manner. The rivets can bear against a radially inner edge section of the disk spring. The disk spring can be secured against rotation with the aid of the rivets.
The friction clutch device can have an actuating device, and the second element can have at least one lever which acts between the actuating device and the at least one pressure plate. A transmission ratio of the friction clutch device in the case of an actuation is fixed with the aid of the at least one lever. The transmission ratio of the friction clutch device can be set largely independently of a pressing force.
Radially on the inner side, the at least one pressure plate can have a groove, into which the at least one lever engages. The at least one lever can engage at least virtually without play into the groove of the at least one pressure plate. There is therefore a secure connection between the at least one lever and the at least one pressure plate, both in the engagement direction and in the disengagement direction.
Rivets can be arranged on the housing, and the second element can be arranged on the rivets. The second element is held on the rivets and can pivot on the rivets in the case of an actuation.
The first element can act on the at least one pressure plate on a first diameter and the second element can act on said at least one pressure plate on a second diameter, and the first diameter can be greater than the second diameter. A large area and a favorable lever ratio are therefore available, in order to apply a high pressing force.
A resilient pivoting bearing element can be arranged between the first element and the second element. The pivoting bearing element can be an undulating wire ring. A play in the direction of the rotational axis of the friction clutch device can therefore be minimized. Vibrations, in particular in an unactuated state, can be damped.
Rivets with rivet heads can be arranged on the housing, and a pivoting bearing element can be arranged between the first element and the housing and a pivoting bearing element can be arranged between the second element and the rivet heads. The pivoting elements can be wire rings.
In summary and described in other words, the result of the invention is therefore, inter alia, a sheet metal cover single clutch with a disk spring and disengagement lever or disengagement lever spring and/or a tractor double clutch on the basis of a sheet metal cover single clutch with a disk spring which is riveted onto the cover.
The clutch can consist of a sheet metals cover single clutch. The disk spring can have no tongues or only very short tongues. The disk spring can be clamped between the cover and the pressure plate and can therefore generate a pressing force on a pressure plate. The disk spring can be centered on an outer edge of a force edge via the pressure plate and can be secured against rotation by the sheet metal cover, for example by rivet pins in the sheet metal cover. Securing against rotation can be omitted in the case of a disk spring without tongues. An actuation of the clutch can take place via disengagement lever/lever spring; the disengagement lever/the lever spring can bring about a transmission ratio of the clutch. The disengagement lever/lever spring can be positioned via rivets on the cover of the single clutch. The disengagement lever/lever spring can have a wire ring as pivot point. Said wire ring can be supported on the rivets. The disengagement lever/lever spring can engage without play into groove of the pressure plate and, in the case of an actuation of the clutch, the disengagement lever/the lever spring can ensure a requested lift as a result. A resilient element, for example an undulating wire ring, can be situated between the disengagement lever/lever spring and the disk spring, in the region of an inner force edge of the disk spring, which undulating wire ring prevents axial play and therefore vibrations of the disengagement lever/the lever spring in the unactuated state.
In the following text, one exemplary embodiment of the invention will be described in greater detail with reference to figures. Further features and advantages result from this description. Concrete features of this exemplary embodiment can represent general features of the invention. Features of this exemplary embodiment which are associated with other features can also represent individual, features of the invention.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For a better understanding of the invention, its operating advantages, specific objects attained by its use, reference should be had to descriptive matter in which there are described preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 shows a drive train of a motor vehicle having internal combustion engine, a clutch and a transmission, and
FIG. 2 shows a detailed view of a clutch having a housing, a pressure plate, a disk spring and a lever spring.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a drive train 100 of a motor vehicle having an internal combustion engine a clutch 104 and a transmission 106 . The internal combustion engine 102 serves to drive the motor vehicle. The motor vehicle is an agricultural utility vehicle, such as a tractor. The internal combustion engine has a rotational speed sensor 108 for determining an internal combustion engine rotational speed.
Starting from the internal combustion engine 102 , the clutch 104 is arranged so as to follow the internal combustion engine 102 in the drive power flow direction. The clutch 104 is a friction clutch. The clutch is a single clutch. The clutch 104 has an input part and an output part. The part of the clutch 104 is drive connected to the internal combustion engine 102 . The output part of the clutch 104 is drive connected to the transmission 106 . An actuating device 110 is provided for actuating the clutch 104 . A sensor 111 serves to determine an actuating state of the clutch 104 .
The transmission 106 is arranged so as to follow the clutch 104 in the drive power flow direction. The transmission 106 has a plurality of shiftable transmission stages. An actuating device 112 is provided for shifting the transmission stages. A sensor 114 serves to determine a set transmission stage. An output shaft of the transmission 106 is drive connected to a cardan shaft 116 . Drive wheels 120 , 122 of the motor vehicle can be driven with a differential 118 connected in between. A rotational speed sensor 124 is provided for detecting a drive wheel rotational speed.
The control device 126 is provided with input signals 128 , for example from the rotational speed sensor 108 , the sensor 111 , the sensor 114 and/or the rotational speed sensor control device 126 generates signals output signals, for example for actuating the internal combustion engine 102 , the actuating device 110 of the clutch 104 and/or the actuating device 112 of the transmission 106 .
FIG. 2 shows a detailed view of a clutch 200 , such as a clutch 104 according to FIG. 1 , having a housing 202 , a pressure plate 204 , a disk spring 206 and a lever spring 208 . The clutch 200 has an input part. The input part of the clutch 200 has the housing 200 , the pressure plate 204 and a back-pressure plate (not shown here). The back-pressure plate is connected fixedly to the housing 202 . The pressure plate 204 is connected to the housing 202 such that it can be displaced axially and is fixed to said housing 202 as to rotate with it. The clutch. 200 has an output part. The output part of the clutch 200 has a clutch plate 210 . The clutch plate 210 has friction linings. A lining spring is arranged between the friction linings. The clutch plate 210 can be clamped between the pressure plate 204 and the back-pressure plate. An actuation of the clutch 200 takes place way of axial displacement of the pressure plate 204 .
Rivets, such as 212 , are arranged on the housing 202 . The rivets 212 are arranged such that they are directed inwardly toward the pressure plate 204 . A plurality of rivets 212 are arranged such that they are distributed over the circumference of the clutch 200 . The rivets 212 are arranged such that they are distributed uniformly over the circumference of the clutch 200 . Openings for receiving the rivets 212 are provided in the housing 202 . The rivets 212 are held in the openings in each case by way of a rivet head, such as 214 .
The disk spring 206 has a shape in the manner of a flat ring. The disk spring 206 has a radially inner edge section 216 . The disk spring 206 has a radially outer edge section 218 . The disk spring 206 bears with its radially inner edge section 216 against the rivets 212 and is centered with respect to the rotational axis of the clutch 200 with the aid of the rivets 212 wire ring 220 for the pivotable mounting of the disk spring 206 is arranged in the direction of the rotational axis of the clutch 200 between the disk spring 206 , in particular the radially inner edge section 216 of the disk spring 206 , and the housing 202 .
The pressure plate 204 has a supporting section 222 . The supporting section 222 is configured as a support in the manner of a ring or a ring section which projects toward the disk spring 206 in the direction of the rotational axis of the clutch 200 . The disk spring 206 rests with its radially outer edge section 218 on the supporting section 222 of the pressure plate 204 .
The lever spring 208 has levers, such as 224 , which are directed in the radial direction. The levers 224 are connected to one another with the aid of a force edge. The levers 224 in each case have a radially inner lever end. 226 and a radially outer lever end 228 . The levers 224 are fastened to the rivets 212 . The levers 224 have openings for fastening to the rivets 212 . The rivets 212 have rivet heads, such as 230 , for fastening the lever spring 208 . The rivets 212 are arranged in the openings of the lever 224 . A wire ring 232 for pivotably mounting the lever spring 208 is arranged in the direction of the rotational axis of the clutch 200 between the lever spring 208 and the rivet heads 230 .
The pressure plate 204 has a receiving section 234 . The receiving section 234 is directed radially inwardly. The receiving section 234 has a groove-like shape. The receiving section 234 is configured so as to be continuous or interrupted in the circumferential direction. The receiving section 234 has bearing sections in the direction of the rotational axis of the clutch 200 . The levers 224 of the lever spring 208 are received with their radially out lever ends 228 in the receiving section 234 of the pressure plate 204 . The lever ends 228 bear against theearing sections of the receiving section 234 . The lever ends 228 are received without play.
An undulating wire ring 236 for pivotable mounting is arranged between the lever spring 208 and the disk spring 206 . With the aid of the wire ring 236 , the lever spring 208 and the disk spring are supported on one another in an elastically prestressed manner. The wire rings 220 , 234 , 236 bear against the rivets 212 and are centered with respect to the rotational axis of the clutch 200 with the aid of the rivets 212 .
A pressing force is applied to the pressure plate 204 substantially with the aid of the disk spring. The pressure plate 204 can be displaced with the aid of the disk spring 206 in order to actuate the clutch 200 . The clutch 200 is self-closing under the loading of the force of the disk spring 206 . On account of the force of the disk spring 206 , the clutch plate 210 is clamped between the pressure plate 204 and the back-pressure plate in the engaged state, and the input part and the output part of the clutch 200 are drive connected to one another.
In order to disengage the clutch 200 , the radially inner lever ends 226 of the levers 224 of the lever spring 208 are loaded. The levers 224 pivot about the pivoting bearings which are formed by way of the wire rings 232 , 236 . The pressure plate 204 raises up from the back-pressure plate counter to the force of the disk spring 206 , and a drive connection between the input part and the output part of the clutch 200 is disconnected. A first lever arm of the levers 224 is formed between an acting location of the actuating device, such as disengagement bearing, and the pivoting bearing. A second lever arm of the levers 224 is formed between the pivoting bearing and the bearing section of the receiving section 234 of the pressure plate 204 .
While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principle. | A friction clutch device, in particular for a drive train of a motor vehicle which is driven by internal, combustion engine, having a rotational axis, a housing, at least one pressure plate which can be displaced in the direction of the rotational axis relative to the housing for an actuation, and a spring device for loading the at least one pressure plate, in which friction clutch device the spring device has a first element for generating a pressure force which acts on the at least one pressure plate, and a second element which is separate structurally from the first element for transmitting an actuating force, in order to improve the friction clutch structurally and/or functionally. | 5 |
BACKGROUND
[0001] 1. Field of Endeavor
[0002] The present invention relates to materials and processes useful in treatment of mammalian bodies, and more specifically to materials which degrade over time in vivo and processes of their use.
[0003] 2. Brief Description of the Related Art
[0004] Resorbable materials have been part of the medical literature for quite a while. The most obvious example is resorbable “Gut” or Chromic Suture. A substantial body of work has been done to make a number of sutures resorbable; examples would include Vicryl, Poly-glycolic acid, and Polydioxanone which are synthesized to selectively hydrolyze and be resorbed by the body. Other examples of resorbable materials are staples or surgical clips used for ligation, poly-lactic acid screws used in orthopedic repairs, haemostatic materials such as starch, oxidized cellulose, or gel foam.
SUMMARY
[0005] One of numerous aspects of the present inventions includes a bioresorbable device comprising a first subcomponent formed of a first bioresorbable material, and a second subcomponent formed of a second bioresorbable material, wherein the first bioresorbable material and the second bioresorbable material are mutually selected to degrade in vivo at at least two different rates.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0006] In general terms, materials embodying principles of the present invention combine materials to provide for a structure which can have multiple resorption times frames depending on the end use of the product. The materials can be fabricated as a laminate, alloy, or composite providing the multiple resorption time frames.
[0007] For short term use, a single material, such as a sugar, starch, or other polysaccharide can be constructed utilizing a binder material such as polyethylene glycol, methyl cellulose, and/or hydroxy methyl cellulose, among many materials suitable for this use, to bind the starch particles together. This construction stays as an integral material until the binder absorbs sufficient water to swell and break apart. The starch is enzymatically degraded by the body in several days. These compressed starch materials are very strong under compressive loads but are not suitable for a tensile load.
[0008] In one use, a compressed starch is used to provide for the short term portion of the construction and an outer layer composed of poly-lactic acid, or polyglycolic acid, to provide a longer term construction that is suitable for tensile loading or as a snap fit piece. The starch would be degraded rather quickly, leaving the poly-lactic acid for longer term degradation.
[0009] An alternate embodiment uses a composite structure where a base polymer, such as polylactic acid, is used as a binder and sugar, starch, methyl cellulose, hydroxy methyl cellulose, or other polysaccharide is used as an aggregate. This construction would allow an initial rigid polymer to be introduced into the body and then, as the aggregate was dissolved into fluid, or enzymeatically degraded, the polylactic acid polymer would becomes substantially porous, quickly reducing its mechanical strength and allowing more rapid infusion of water for hydrolytic degradation. This construction could function short term in either tensile or compressive loading.
[0010] Another composite design would be a braided fiber such as resorbable suture that is placed into a beta glucan matrix. The beta glucan matrix provides a short term rigid piece and the fiber structure allows for tensile loading rather than just compressive loads.
[0011] Alternately, laminated designs, such as a chitosan construction over the fibers, could be used in place of the starch if a flexible member was needed.
[0012] Materials as described herein have numerous potential uses, including, but not limited to the following.
[0013] 1) Vascular closure devices as described in a co-pending U.S. Provisional Application filed on even date herewith, entitled Vascular Closure Devices, bearing attorney reference number 099-002P, by Fred Burbank and Michael Jones.
[0014] 3) Connectors for bypass grafts—these devices would be used to join the bypass graft (either artery or vein) to the host artery. Each end of the connector would be configured like the vascular closure device to bring the grafted artery into the main artery at an angle. The graft artery end would be placed over the guide and the fingers would slipped over the end of the artery, trapping it between the fingers and the guide.
[0015] 4) In-situ tissue scaffolds—these devices are used as support structures and allow tissue healing to generate along a scaffold minimizing cosmetic, defects after a surgical procedure. The construction of these devices requires that the device be very porous to allow for infiltration during the healing process. These devices could be used for bone growth, nerve repair, soft tissue repair and potentially as a substrate for cartilage repair.
[0016] 5) Temporary markers for biopsy sites—these devices are placed into biopsy sites and mark a lesion location after biopsy. During biopsies, such as breast biopsies, the target location is primarily identified by mammography as calcifications; once the biopsy is performed, the calcifications are mostly, if not completely, removed and thus not available to provide a location further intervention is required. This marker would be left behind to provide a visual or imageable location for subsequent therapy or surgery. The marker could be died with any of the FDA approved dyes/colorant used in sutures for use as a visual marker. The marker could optionally have surface porosity or surface bubbles which would make it identifiable from surrounding tissue on ultrasound. It could be labeled or contain a chelated gadolineum compound to be identifiable with MRI.
[0017] Materials as described herein can have numerous advantages over prior materials. A first advantage over the existing materials is that, instead of a single functional (i.e., degradation) time that each material provides, a blend of properties can be provided depending upon the need of the particular area in which the device made of the material is used. By mixing and blending the materials, numerous mechanical properties can be achieved, from short term rigidity to long term rigidity. Materials can be produced with immediate rigidity when dry for installation and then hydrate and soften, but have a fiber structure which will allows for tensile loading of the device.
[0018] With the blending or laminate construction, the longevity of the device in the body can vary. While the use of compressed starch is not new per se, it is easily degraded in the body in several days. If a device is needed in excess of several days, a longer term polymer, such as polylactic acid, can be added as an encapsulant or binder, using the starch or other polysaccharide as an aggregate similar to gravel in concrete. Although, in the case of the uses described herein, the aggregate is resorbed into the body, leaving a soft structure behind.
[0019] As used herein, the term “poly” means multiple repeating blocks of the monomer. For example, for a polyglycolic acid, the glycolide monomer is repeated numerous times. The molecular weight sufficient for a combination of mechanical and degradation properties is in the range of 10,000 to 20,000 Daltons. When the hydrolytic degradation produces chains with roughly 5,000 Daltons, the polymer is mobile within the body.
[0020] For a co-polymer such as poly lactide-co-glycolide, the chain of lactide molecules could be terminated by a single glycolide molecule, although in practice the ratio is more typically 90:10 (lactide:glycolide) to 20:80. Typically these become random copolymers with a wide range of inter-chain repeating units. This vastly decreases their longevity in the body as they do not form crystalline structures and hydrolytic degradation proceeds rapidly.
[0021] All materials listed herein would be representative and suitable for any genus to which each belongs. Their fabrication method may differ, but the fabricated unit should be functional regardless of the material.
EXAMPLES
[0022] I. A compressed composition of starch with 20% (by weight percent) methyl cellulose is mixed as a binder. This material, when compressed at about 40,000 to 50,000 psi, becomes a useable solid material that has very good compressive strength, but little tensile strength.
[0023] II. A moldable composition includes a 65/35 copolymer of poly-lactic and poly-glycolic acid mixed with a short-term filler, such as starch or other polysaccharide, to accelerate its decomposition in vivo.
[0024] III. A first implantable sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A second, co-implanted sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A third co-implanted sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A fourth, co-implanted sub-component is made from a compressed starch with 20% by weight methyl cellulose as a binder. This fourth sub-component will be resorbed in the body in about 4-7 days.
[0025] II. A first implantable sub-component is compression molded from a bioresorbable, hemostatic starch with 20% by weight methyl cellulose as a binder. A second, co-implanted sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A third, co-implanted sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A fourth, co-implanted sub-component is made from a compressed starch with 20% by weight methyl cellulose as a binder. This fourth sub-component will be resorbed in the body in about 4-7 days.
[0026] III. A first implantable sub-component is compression molded from a bioresorbable, hemostatic chitosan with 20% by weight methyl cellulose as a binder. A second, co-implanted sub-component arm is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A third, co-implanted sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A fourth, co-implanted sub-component is made from a compressed starch with 20% by weight methyl cellulose as a binder. This fourth sub-component will be resorbed in the body in about 4-7 days.
[0027] IV. A first implantable sub-component is formed from a freeze dried bioresorbable, hemostatic chitosan. A second, co-implanted sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A third, co-implanted sub-component is molded from a bioresorbable polymer such as 63/35 PLGA with resorption time of 6-8 weeks in vivo. A fourth, co-implanted sub-component is made from a compressed starch with 20% by weight methyl cellulose as a binder. This fourth sub-component will be resorbed in the body in about 4-7 days.
[0028] V. A first implantable sub-component is molded from a bioresorbable polymer composite containing 20 to 50% by weight starch in a 63/35 PLGA with resorption time of 4-6 weeks in vivo. A second, co-implanted sub-component is molded from a bioresorbable polymer composite containing 20 to 50% by weight starch in a 63/35 PLGA. A third, co-implanted sub-component is molded from a bioresorbable polymer composite containing 20 to 50% by weight starch in a 63/35 PLGA. A fourth, co-implanted sub-component is made from a compressed starch with 20% by weight methyl cellulose as a binder. This fourth sub-component will be resorbed in the body in about 4-7 days.
[0029] VI. A first implantable sub-component is molded from a bioresorbable polymer composite containing 20 to 50% by weight chitosan in a 63/35 PLGA with resorption time of 4-6 weeks in vivo. A second, co-implanted sub-component is molded from a bioresorbable polymer composite containing 20 to 50% by weight starch in a 63/35 PLGA. A third, co-implanted sub-component is molded from a bioresorbable polymer composite containing 20 to 50% by weight starch in a 63/35 PLGA. A fourth, co-implanted sub-component is made from a compressed starch with 20% by weight methyl cellulose as a binder. This fourth sub-component will be resorbed in the body in about 4-7 days.
[0030] VII. A first implantable sub-component is formed from a freeze dried bioresorbable composite, of 20 to 50% by weight starch in chitosan. A second, co-implanted sub-component is molded from a bioresorbable polymer composite of 20 to 50% starch in 63/35 PLGA with resorption time of 4-6 weeks in vivo. A third, co-implanted sub-component is molded from a bioresorbable polymer composite of 20 to 50% starch in 63/35 PLGA with resorption time of 4-6 weeks in vivo. A fourth, co-implanted sub-component is made from a compressed starch with 20% by weight methyl cellulose as a binder. This fourth sub-component will be resorbed in the body in about 4-7 days.
[0031] While the invention has been described in detail with reference to exemplary embodiments thereof, it will be apparent to one skilled in the art that various changes can be made, and equivalents employed, without departing from the scope of the invention. The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents. The entirety of each of the aforementioned documents is incorporated by reference herein. | Biodegradable materials are formed by mixing together two or more materials which have different resorption times and different mechanical characteristics. Devices formed of these materials can be used in mammals in numerous medical and surgical applications, including those for which the mechanical properties of the device, left in vivo, much change over time. | 0 |
BACKGROUND OF THE INVENTION
The present invention is directed to a monitoring system for determining the magnitudes of the equivalent voltage source impedance and the equivalent voltage source voltage on a telephone line and in particular to a monitoring system for determining and indicating the magnitudes of the equivalent voltage source impedance and the equivalent voltage source voltage in a telephone system of the type having telephone lines and a switching network, wherein operating voltage sources are maintained on the line to support telephone communication and wherein each line and the network combine to form an equivalent voltage source and an equivalent voltage source impedance.
In telephone systems harmful conditions may exist on the telephone lines which could interfere with or interrupt telephone communication. Such conditions may exist on the telephone lines themselves or within the switching network to which the telephone lines are coupled. Such harmful conditions could be foreign potentials due to non-current limited DC potentials or high AC potentials which are greater than or equal to 120 volts AC from the 60 hertz commercial power network. Irregular conditions which also could interfere with telephone communication can be the presence of relatively low resistance leakage paths to ground, or low resistance paths to ground due to relays within the switching network that have not disconnected at the proper time.
It is therefore advantageous to detect such harmful conditions to eliminate the problems which they cause before telephone service is interrupted. The present invention provides a means by which such harmful conditions may be detected by realizing that each telephone line and the network combine to form a Thevenin equivalent voltage source and equivalent voltage source impedance. By measuring the magnitudes of the equivalent voltage source voltage and the equivalent voltage source impedance, such harmful conditions may be detected. It would also be advantageous to perform such a measurement and to convert the result of the measurement to a digital format which is compatable with the network controllers utilized in such telephone systems.
It is therefore a general object of the present invention to provide a monitoring system for measuring and indicating the magnitudes of the equivalent source voltage and equivalent voltage source impedance on a telephone line to detect harmful conditions which may interrupt telephone service.
It is a more particular object of the present invention to provide a monitoring system which measures the magnitudes of the equivalent voltage source voltage and equivalent voltage source impedance on a telephone line and which assigns the measured magnitudes to a range within a number of predetermined ranges to thus form a comparison to determine if harmful conditions exist on the telephone lines.
It is a still further object of the present invention to provide a method for measuring the equivalent voltage source voltage magnitude and equivalent voltage source impedance magnitude to determine if harmful conditions exist on the telephone lines which may cause interruption of telephone service.
SUMMARY OF THE INVENTION
The present invention provides, in a telephone system of the type having telephone lines and a switching network, wherein operating voltage sources are maintained on the lines to support telephone communication and wherein each line and the network combine to form an equivalent voltage source and an equivalent voltage source impedance, a monitoring system for indicating the magnitudes of the equivalent voltage source impedance and the equivalent voltage source voltage. The monitoring system of the present invention comprises a voltage source coupled to a selected one of the lines and operable for providing a constant voltage in opposition to the equivalent source voltage, voltage sensing means coupled to the side of the voltage source opposite the selected line, control means for activating and causing the voltage source to provide the constant voltage for a predetermined period of time sufficient to cause a first steady state voltage to appear at the voltage sensing means and for deactivating the voltage source at the end of the predetermined period of time to cause a second steady state voltage to appear at the voltage sensing means and subtracting means coupled to the sensing means for determining the difference between the magnitudes of the first and second steady state voltages. The monitoring system additionally comprises ratio determining means coupled to the voltage sensing means and to the subtracting means for determining the ratio of the second steady state voltage to the difference between the magnitudes of the first and second steady state voltages and for providing an output voltage which is directly related to the ratio to thereby provide a direct indication of the magnitude of the equivalent source voltage and impedance indication means also coupled to the subtracting means for providing an output voltage which is inversely related to the difference determined by the subtracting means and directly related to the equivalent source impedance for providing a direct indication of the magnitude of the equivalent source impedance.
The present invention also provides a method for monitoring and indicating the magnitudes of the equivalent voltage source impedance and the equivalent voltage source voltage in a telephone system of the type having telephone lines and switching network, wherein operating voltage sources are maintained on the lines to support telephone communication and wherein each line and the network combine to form an equivalent voltage source and an equivalent voltage source impedance. The method of the present invention comprises applying a constant voltage to a selected line in opposition to the equivalent source voltage for a predetermined period of time sufficient to cause a first steady state voltage to appear on the line, terminating the application of the constant voltage until a second steady state voltage appears on the line, sensing the first and second steady state voltages, subtracting the first steady state voltage from the second steady state voltage, determining the ratio between the second steady state voltage to the difference voltage to thereby provide direct indication of the magnitude of the equivalent voltage source voltage, and determining the reciprocal of the difference voltage to provide a signal which is directly related to the equivalent source impedance and for providing a direct indication of the magnitude of the equivalent voltage source impedance.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings, in the several figures in which like reference numerals identify like elements, and in which:
FIG. 1 is a schematic representation partially in block form of a monitoring system embodying the present invention;
FIG. 2 shows typical waveforms which may be utilized for gaining a better understanding of the operation of the monitoring system of the present invention;
FIG. 3 is a circuit diagram of a monitoring system which embodies further aspects of the present invention;
FIG. 4 is a schematic circuit diagram of a portion of the monitoring systems of FIGS. 1 and 3; and
FIG. 5 is another schematic circuit diagram of another portion of the monitoring systems of FIGS. 1 and 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the portion of FIG. 1 to the left of the dashed line comprises the Thevenin equivalent circuit of a combined telephone line and its associated network. The Thevenin equivalent circuit comprises an equivalent voltage source 10, an equivalent voltage source impedance represented by resistor 11, and capacitor 12 which represents the distributed capacitance along the telephone line. It is shown in dashed lines to indicate that capacitor 12 is a distributed capacitance and not a discrete capacitor. As well known in the art, telephone lines comprise a line pair commonly referred to a Ring and Tip. As used herein, the term "telephone line" is intended to connote either Ring or Tip lines inasmuch as the monitoring system of the present invention is capable of acting upon either the Ring or Tip side independently. The Figures herein represent the invention in relation to only one of the Ring or Tip lines for simplicity and may be duplicated for servicing both Ring and Tip simultaneously but independently. The portion of FIG. 1 to the right of the dashed line comprises a monitoring system which embodys the present invention and comprises a switch 13 (S 1 ), a voltage source 14 (V g ), a voltage sensing means comprising resistor 15 (R 0 ), control means 16, subtracting means 17, sample and hold circuit 18, impedance indicating means comprising the 1/x function module 19, and ratio determining means comprising multiplying module 20.
The equivalent voltage source 10, equivalent voltage source impedance 11, and equivalent distributed capacitance 12, comprise the Thevenin equivalent and its associated switching network. The common junction of resistor 11 and distributed capacitance 12 is coupled to the line 21 which represents the telephone line to be monitored. The selection of the line to be monitored is under the control of a network controller of the type well known in the art which may set up the path within the chosen line and the switching network to complete a test telephone call. In so establishing the selected line, the line 21 is connected to switch 13 which is in turn coupled to voltage source 14. Voltage source 14 is coupled to subtracting means 17 which may preferrably be a difference amplifier having a positive input 22 and a negative input 23. Thus, output 24 of difference amplifier 17 will provide a signal whose magnitude is the difference between the voltage at input 22 and the voltage at input 23. Output 24 of difference amplifier 17 is coupled to the impedance indicating means which comprises a 1/x function module 19. For reasons to be described hereinafter, the output 25 of the 1/x module is proportional to the magnitude of the equivalent voltage source impedance which is utilized for a direct indication of the magnitude of the equivalent voltage source impedance.
The voltage source 14 is also coupled to resistor 15 which serves as a sensing means for sensing the steady state voltages which are produced on line 21 during the test measurement. Sensing means resistor 15 is also coupled to the sample and hold circuit 18 which in turn has an output 26 coupled to input 23 of difference amplifier 17. The sensing means resistor 15 is additionally coupled to the ratio determining means comprising multiplying module 20 at input 27 which has another input 28 coupled to the 1/x module 19 at output 25. Lastly, control means 16 is coupled to switch 13 for enabling the monitoring system and to voltage source 14 for causing it to provide a constant voltage in opposition to equivalent voltage source 10 for a predetermined time period. Control means 16 is also coupled to sample and hold circuit 18 for strobing information into the sample and hold circuit to be utilized during the determination of the magnitudes of the equivalent source voltage and the equivalent source voltage impedance.
The operation of the monitoring system of FIG. 1 may best be understood with reference to FIG. 2 in conjunction with reference to FIG. 1. The measurement takes place over a fixed finite time of T duration. At t 1 the measurement begins when control means 16 receives an enable test signal from the network control and provides an enable signal to switch 13 to cause switch 13 to connect the monitoring system to telephone line 21. At the same time, control means 16 provides voltage source 14 with an enable signal to activate and to cause voltage source 14 to provide a constant voltage (V O ) in opposition to equivalent source 10 for a predetermined period of time sufficient to cause a first steady state voltage (V A ) to appear at sensing means resistor 15. The predetermined period of time for this embodiment is selected to by T/2. At t 2 control means 16 provides a sample signal to sample and hold circuit 18 which then detects and stores the value of the first steady state voltage (V A ). At t 3 , when the sample signal terminates, the enable signal to the voltage source 14 from control means 16 terminates which causes voltage source 14 to be deactivated at the end of the predetermined period of time to cause a second steady state voltage (V B ) to appear at voltage sensing means transistor 15. The time duration between t 1 and t 3 is selected in order to allow the distributed capacitance 12 to be fully charged to the point where the voltage stored in sample and hold circuit 18 is a steady state voltage. After the source 14 has been deactivated for a selected period of time, approximately T/2, the second steady state voltage (V B ) will appear at input 22 of difference amplifier 17. At that time, t 4 , control means 16 provides sample and hold circuit 18 with a strobe input signal to cause it to transfer the value of the first steady state voltage (V A ) to the negative input 23 of difference amplifier 17. Just prior to termination of the strobe signal at t 5 , output 24 of difference amplifier 17 has provided a difference signal which represents the difference between the magnitudes of the second steady state voltage (V B ) and the first steady state voltage (V A ). At t 5 the system has all of the information which it requires in order to make the final determination as to the magnitudes of the equivalent source voltage 10 and the magnitude of the equivalent source voltage impedance 11.
To better understand the manner in which the difference voltage and the second steady state voltage are utilized for determining the magnitudes of the equivalent source voltage and equivalent source voltage impedance, the following algebraic equations may be utilized. For these equations resistor 11 will be represented as R s , resistor 15 will be referred to as R O , the value of the constant voltage provided by voltage source 15 will be referred to as V O , the value of the equivalent source voltage will be represented as V s , and the first and second steady state voltages will be referred to as V A and V B respectively.
The two levels of voltage are introduced into the network through the voltage source 14 because two independent conditions in a linear network allow solution of two simultaneous equations for the two unknowns V s and R s . The two conditions of voltages V 0 volts and 0 volts by voltage source 14 may be chosen arbitrarily to simplify hardware implementation. The algebraic solution proceeds as follows:
In general: ##STR1##
1. Let V = V A at V g = V O ,
then ##STR2##
2. Let V = V B at V g = 0,
then ##STR3##
The two equations can now be solved for V s and R s as functions of V A and V B (V O and R O are known constants). The solution is: ##STR4##
It is not desired to have the distributed capacitance 12 effect the solution. Therefore sufficient time is allowed for a capacitance 12 to charge or discharge during each half cycle of the measurement process.
The solutions to the equations can be simplified further as follows:
Let ΔV = V B - V A , then ##STR5##
It can be seen from the foregoing, that the magnitude of the equivalent voltage source impedance 11 is inversely proportional to the difference between the second steady state voltage and the first steady state voltage. All other parameters of the voltage source impedance relationship are known constants. Thus, the output signal at output 24 of difference amplifier 17 is a signal which is inversely proportional to the magnitude of the equivalent source voltage impedance. By coupling output 24 of difference amplifier 17 to the 1/x module, output 25 of module 19 will provide a signal which is directly proportional to the magnitude of the equivalent source impedance. By transferring this signal to suitable linear amplifier for multiplying it by a suitable constant, a direct indication of the equivalent source voltage impedance may be obtained.
Also as a result of the foregoing equations, it can be seen that the magnitude of the equivalent source voltage is directly proportional to the ratio of the second steady state voltage (V B ) and the difference between the second steady state voltage and the first steady state voltage. Because the 1/x module 19 provides the inverse of the difference between the steady state voltages, output 25 of module 19 is coupled to input 28 of multiplying module 20. The second steady state voltage term is provided at input 27 of multiplying module 20 by being coupled to a sensing means resistor 15. Thus, module 20 takes the second steady state voltage (V B ) and multiplies it by the inverse of the difference signal to obtain the ratio of the second steady state voltage V B to the difference voltage (V B - V A ). Therefore output 29 of module 28 may be coupled to a suitable amplifier for multiplying the resultant ratio signal by a suitable constant for obtaining a direct indication of the magnitude of the equivalent voltage source 10.
The embodiment of FIG. 1 provides analog values for the magnitude of the equivalent voltage source and the magnitude of the equivalent voltage source impedance. Often times, such analog values are not necessary and in fact it may be desirable to only know in which range of a plurality of predetermined ranges the magnitudes lie. To this extent, simple comparators may be utilized for establishing the predetermined ranges and for forming the natural discriminating functions to determine in which ranges the magnitudes of the equivalent voltage source voltage and equivalent source voltage impedance lie. FIG. 3 shows such an embodiment. As to those elements of FIG. 3 which find correspondence to elements in FIG. 1 the same reference numerals have been retained.
The embodiment of FIG. 3 generates the difference voltage (V B - V A ) and the value of the second steady state voltage (V B ) in an identical manner as the embodiment of FIG. 1 except that the embodiment of FIG. 3 includes an absolute value amplifier which rectifys the second steady state voltage and provides the absolute value of it.
In addition to switch 13, voltage source 14, sensing resistor 15, sample and hold 18, difference amplifier 17, and absolute value amplifier 30, FIG. 3 includes a first plurality of comparators 31 and 32, a second plurality of comparators 33 and 34, a like first set of voltage reference sources 35 and 36, and a like second plurality of voltage dividers 37 and 38.
Comparators 31 and 32 which comprise the first plurality of comparators have reference inputs 40 and 41 respectively each being coupled to a respective given one of the reference voltage sources 35 and 36. To that end, input 40 is coupled to reference voltage source 35 and input 41 is coupled to reference voltage source 36. Each of the reference voltage sources comprises a voltage divider coupled to a positive voltage source terminal 42 and arranged in a conventional well known manner. They establish the predetermined ranges of the equivalent voltage source impedances and each provides a different reference voltage or potential.
Each of comparators 31 and 32 has another input 43 and 44 respectively coupled to the subtracting means difference amplifier 17 for receiving the difference voltage which it generates at output 24. Should one of the comparators have a reference potential at its reference input which is less than the difference voltage (V B -V A ) it will provide a first signal which is a high logic level and should one of the comparators be coupled to a reference potential at its reference input which is greater than the difference voltage, it will provide a second signal which is a low logic level.
The reference voltages, inasmuch as the equivalent source voltage impedance is directly related to the inverse of the magnitude of the difference voltage establish the different ranges in which magnitude of the equivalent voltage source impedance may lie. For example, in operation, assuming that the reference voltage supplied by reference voltage source 35 is V rf1 and that the reference voltage supplied by reference voltage source 36 is V rf2 , and assuming that V rf1 is greater than V rf2 , should the difference voltage be greater than V rf1 , comparators 31 and 32 will both provide the first signal which is a high logic level which indicates that the equivalent voltage source impedance is less than R s1 . Should the difference voltage be less than V rf1 but greater than V rf2 , comparator 31 will provide the second signal which is a low logic level and comparator 32 will provide the first signal which is the high logic level which indicates that the magnitude of the equivalent source voltage impedance is less than R s2 but greater than R s1 . Lastly, should the difference voltage be less than V rf2 , both comparator 31 and comparator 32 will provide the second signal which is a low output level indicating that the magnitude of the equivalent voltage source impedance is greater than R s2 .
The control and interface logic 50 may include logic circuitry of the type well known in the art which is responsive to the first and second signals of comparators 31 and 32 to provide at outputs 51, 52 and 53 a discrete indication as to which range the magnitude of the equivalent voltage source impedance lies.
In a somewhat similar manner the magnitude of the equivalent source voltage may also be assigned to one of a given number of predetermined ranges. To this end, the monitoring system of FIG. 3 includes a second plurality of comparators comprising comparators 33 and 34. Each comparator of the second plurality includes a first input, comparator 33 having first input 54 and comparator 34 having first input 55. Inputs 54 and 55 are coupled to output 24 of difference amplifier 17 to receive the difference voltage therefrom. Each of the second plurality of comparators also has a second input, comparator 33 having second input 56 and comparator 34 having second input 57. The monitoring system of FIG. 3 also includes a like second plurality of voltage dividers comprising variable resistors 37 and 38. Input 56 of comparator 33 is coupled to resistor 37 and input 57 of comparator 34 is coupled to resistor 38. Resistors 37 and 38 are coupled on one side of the absolute value amplifier 30 for receiving the second steady state voltage (V B ) and having the other sides coupled to ground. Thus, each of the voltage dividers comprising resistors 37 and 38 provide a predetermined portion of the second steady state voltage to each of the second inputs 56 and 57 which herein may be referred to as reference inputs. In this manner, the ranges into which the magnitude of the equivalent voltage source voltage may lie are established.
Recalling for a moment that the magnitude of the equivalent source voltage is proportional to the ratio of the second steady state voltage (V B ) to the difference voltage (V B - V A ), the predetermined portions of the second steady state voltage applied to inputs 56 and 57 may be selected to establish thresholds by which the magnitude of the equivalent source voltage may be discriminated against for determining into which range of voltages the magnitude of the equivalent source voltage lies. Assuming for this preferred embodiment that resistor 38 provides input 57 with a lesser portion of the second steady state voltage than that provided to input 56 by resistor 37, three different voltage ranges may be established wherein the magnitude of the equivalent source voltage (V s ) is less than V s1 , is greater than V s1 but less than V s2 , and greater than V s2 .
The range in which the magnitude of the equivalent source voltage lies is determined as follows. If the magnitude of the second steady state voltage (V B ) is of a low enough level such that the reference voltages applied to inputs 56 and 57 of comparators 33 and 34 are less than the difference voltage, comparators 33 and 34 provide a first signal which is a high logic level indicating that the magnitude of the equivalent source voltage (V s ) is less than V s1 . If the magnitude of V B is such that input 57 of comparator 34 has a lower reference voltage than the difference voltage at input 55, and input 56 of comparator 33 has a reference voltage which is greater than the difference voltage at input 54, comparator 34 will provide the first signal and comparator 33 will provide a second signal which is a low logic level to indicate that the magnitude of the equivalent source voltage is in between V s1 and V s2 . In other words, the magnitude of the equivalent source voltage will be greater than V s1 but less than V s2 . Lastly, if V B is high enough such that inputs 57 and 56 are greater than the difference voltage at inputs 55 and 54, comparators 33 and 34 will both provide the second signal which is a low logic level to indicate that the magnitude of the equivalent source voltage is greater than V s1 .
Control and interface logic 50 which constitutes an indication means, as in the case for indicating the range in which the equivalent voltage source impedance lies, also has similar logic circuitry of the type well known in the art for providing at outputs 58, 59 and 60 a discrete indication as to which range the magnitude of the equivalent source voltage lies. Of course, the control and interface logic may be followed by additional logic circuitry which logically groups the various combinations of the impedance magnitude and voltage magnitude ranges.
As in the embodiment of FIG. 1, the monitoring system is controlled under the commands by the control and interface logic 50 which provides an enable signal over line 61 to switch 13 for connecting the monitoring system to the selected line. Also, an enable signal is generated on line 62 which is coupled to voltage source 14 for activating and causing it to provide the constant voltage in opposition to the equivalent source voltage (V s ) for the predetermined period of time sufficient to cause the first steady state voltage to appear at sensing means resistor 15. A sample signal is generated over line 63 which is coupled to sample and hold circuit 18 for causing the first steady state voltage to be stored in sample and hold circuit 18. After the first steady state voltage is sampled and stored, line 62 discontinues its enabling signal to voltage source 14 for terminating the application of the constant voltage to allow the second steady state voltage to appear at sensing resistor 15. At this point in time, the difference amplifier and comparators may be strobed to cause the difference voltage to appear at output 24 and to cause the comparators 31 through 34 to perform their comparisons for determining into which range the magnitudes of the equivalent source voltage and equivalent voltage source impedance lie. The control and interface logic 50 may be followed by an additional logic stage of the type well known in the art to logically combine the discrete voltage and impedance outputs 51 through 53 and 58 through 60 to form a logic combination. The resulting logic combination may then be compared to stored logic combinations in the network controller to determine if harmful conditions exist on the line.
FIG. 4 shows a circuit schematic diagram of a switch which may be utilized in the embodiments of FIGS. 1 and 3 for switch 13. It comprises a first diode-bridge comprising diodes 70 through 73, a second diode-bridge 74, transistors 75 and 76, capacitor 77, transformer 78, optical isolator 79 and resistors 80 through 83.
Diodes 70 and 71 have a common junction which is coupled to the telephone line 21. Diodes 72 and 73 have a common junction which is coupled to the voltage source 14 as indicated by the arrow of FIGS. 1 and 3. Transistor 75 has a collector 84 coupled to the common junction of diodes 70 and 72, an emitter 85 coupled to base 86 of transistor 76 and to the common junction of diodes 71 and 73 by resistor 80. Transistor 75 also has a base 87 coupled to collector 88 of transistor 76, to the common junction of diode 71 and 73 by resistor 81, and to the optical isolator 79 by resistor 82. Transistor 76 has an emitter 89 coupled to the common junction of diode 71 and 73.
The optical isolator 79 is coupled to the second diode-bridge 74 and to the control means via line 61 for example as illustrated in FIG. 3 for receiving its enable input from the control means. The second diode-bridge 74 is also coupled to the common junction of diode 71 and 73 by capacitor 77. Transformer 78 has a primary winding coupled on one side to a square-wave oscillator on line 90 and to a negative voltage supply at terminal 91. Transformer 78 also has a secondary 92 coupled across the second diode-bridge 74. Diode-bridge 74 is also directly coupled to the common junction of diodes 71 and 73 by line 93.
The switch 13 of FIG. 4 is implemented as a high-voltage bi-polar transistor in a diode-bridge configuration. One requirement is to have the switch 13 "floating" relative to ground. To satisfy this requirement, the bias voltage to turn transistor 75 on is supplied by transformer 78 which is driven by a square-wave oscillator source at line 90. The voltage at secondary 92 of transformer 78 is rectified by the second diode-bridge 74. This bias voltage is applied to the base of pass transistor 75 through the optical isolator 79 which is actuated by the control logic over enable input line 61.
The pass transistor 75 is configured for emitter degenerative feedback by transistor 76 so that transistor 75 may be current limited. This assures that no damaging surge currents will pass through the network contacts. As can be seen from FIG. 4, switch 13 is bi-lateral, that is to say it conducts current in either direction, because the line voltage may be either positive or negative.
Referring now to FIG. 5, there is shown a schematic circuit diagram of a voltage source 14 which may be utilized in practicing the embodiments of FIGS. 1 and 3. It comprises transistors 100 through 103, a diode bridge comprising diodes 104 through 107, diodes 108 and 109, zener diodes 110, 111 and 112, operational amplifier 113, optical isolator 114, transformer 115, capacitors 116, 117 and 118, and resistors 119 through 125.
Voltage source 14 has an output 126 which is coupled to switch 13 of either FIG. 1 or FIG. 3. Transistors 100 and 101 have emitters 127 and 128 respectively which are coupled together, to the common junction of diodes 108 and 109, to output 126, and to emitters 129 and 130 of transistors 103 and 102 respectively by resistors 119. Bases 131 and 132 of transistors 100 and 101 respectively are coupled together and to emitters 129 and 130 of transistors 103 and 102 respectively. Bases 133 and 134 of transistors 103 and 102 respectively are coupled together, to emitters 129 and 130 by resistor 120, and to the output 135 of operational amplifier 113 by resistor 121. Diode 108 is coupled across emitter 127 and collector 136 of transistor 100. Collector 136, collector 137, operational amplifier 113, capacitor 116, and diodes 104 and 105 are all coupled together on line 138. Diode 109 is coupled across emitter 128 and collector 139 of transistor 101. Collector 139, collector 140, operational amplifier 113, capacitor 117, and diodes 106 and 107 are all coupled together by line 141.
Operational amplifier 113 has a negative input 142 coupled to output 126 by resistor 125 and a positive input 143 which is coupled to the optical isolator 114 and to the common junction of capacitor 116, capacitor 117, and zener diode 112 by resistor 123. Input 143 is also coupled to the optical isolator by resistor 122.
Zener diode 112 has capacitor 118 coupled across it and is also coupled to the optical isolator 114 and to line 138 by resistor 124. As can be seen from the Figure, diodes 104 through 107 are configured in a diode-bridge configuration which is coupled to the center-tapped secondary 144 of transformer 115. Center tap 145 of transformer 115 is coupled to the sensing means resistor R O . The primary 146 of transformer 115 is coupled to a square-wave voltage oscillator at line 147 and to a negative power source at terminal 148. Center tap 145 is also coupled to zener diode 112.
The voltage source 14 of FIG. 5 is implemented as a servo-amplifier operating as a voltage follower. The output stage comprising transistors 100 through 103 is a totem-pole configuration to allow current flow as a source or sink. This is required to guarantee the correct sensing of the first and second steady state voltages because a constant voltage difference must be maintained in the series path for either direction of current flow. The amplifier may be better defined as a voltage follower with power gain that follows the voltage present at the positive terminal 43 of the operational amplifier 113. This constant voltage difference is 0 volts relative to R Oleg of the series circuit comprising transformer center tap 145 when the optically coupled isolator 114 is off (open circuit) or a fixed positive voltage (V O ) generated by zener diode 112 when the optically coupled isolator 114 is on. As in the case of switch 13, the voltage source 14 must be "floating" relative to ground. To this end, power is derived by transformer 115 for the amplifier from the square-wave oscillator source on line 147 which is rectified by the diode-bridge comprising diodes 104 through 107. The optically coupled isolator 114 is actuated by the control logic or control means over line 62 as represented in FIG. 3.
The present invention therefore provides a monitoring system for determining and indicating the magnitudes of the equivalent source voltage and equivalent voltage source impedance on a telephone line. The determination can be made such that an absolute or analog value is obtained or the magnitudes may be assigned to one of a number of predetermined ranges for translating the information into a digital format to be used by the network control logic in a telephone exchange. The monitoring system of the present invention may be duplicated for both the ring and tip side of the telephone line and the determinations may be performed independently for either the ring or the tip side of the line.
While a particular embodiment of the invention has been shown and described, modifications may be made, and it is intended in the appended claims to cover all such modifications as may fall within the true spirit and scope of the invention. | The disclosure relates to a monitoring system and method for determining the magnitude of the equivalent voltage source impedance and the magnitude of the equivalent voltage source voltage on a telephone line and switching network of a telephone system. The monitoring system measures the Thevenin source voltage and source impedance to ground on the line by applying two independent voltage conditions to the line and senses the resulting steady state voltages thereby produced in a sensing resistor. The magnitudes of the sensed steady state voltage are thereafter utilized for obtaining the Thevenin source voltage and source impedance magnitudes. | 7 |
This is a continuation-in-part of parent application Ser. No. 09/714,133, filed Nov. 14, 2000 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus for detection of accuracy of format of a web of corrugated board moved in a conveying direction and comprising a first and a second smooth liner; and at least one corrugated paper web disposed between the liners; several profiled patterns running in the conveying direction, namely lateral edges, and at least one lengthwise cut, which divides the web of corrugated board into partial webs, and/or at least one groove.
2. Background Art
Facilities for the manufacture of webs of corrugated board, in particular for the manufacture of single-faced webs of corrugated board which consist of a corrugated paper web and a liner, are generally known for instance from U.S. Pat. No. 5,632,850 or GB 2,305,675 A. In machines of the generic type, lots of conceivable malfunctions may cause the quality of the corrugated board not to correspond to standard production; for example the truth to format of a web of corrugated board i.e., the position of its lengthwise edges and/or the position of a groove and/or the position of a lengthwise cut may be out of order.
SUMMARY OF THE INVENTION
It is an object of the invention to embody an apparatus of the generic type for detection of the accuracy of format of the web of corrugated board to be possible.
According to the invention, this object is attained by the features which consist in that at least one sensor is provided for the detection of the position of at least two profiled patterns relative to each other, which sensor is in working connection with an evaluation equipment for determination of the distance of the at least two profiled patterns from each other. By detecting the accuracy of format of a web of corrugated board, it is possible continuously to detect and monitor the quality of the finished web of corrugated board and possibly to correct the quality by intervention in the manufacturing process or to cut out and eliminate faulty parts.
Further features, advantages and details of the invention will become apparent from the ensuing description of an exemplary embodiment of the invention, taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective diagrammatic illustration of a quality-detecting apparatus; and
FIG. 2 is a cross-sectional illustration of the quality-detecting apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 diagrammatically illustrate a web of corrugated board 1 , which comprises a first upper liner 2 and a second lower liner 3 —each of paper—and a corrugated paper web 4 disposed between the liners 2 , 3 and united there-with by gluing. In the course of its manufacture, the web of corrugated board 1 is located on a facility for the manufacture of corrugated board—seen in the conveying direction 5 —downstream of a grooving and longitudinal cutting arrangement as illustrated and specified for instance in U.S. Pat. No. 5,857,395, to which reference is made explicitly. In this arrangement, the upper liner 2 has been equipped with upper grooves 6 that run in the conveying direction 5 and the lower liner 3 has been equipped with lower grooves 7 a , 7 b that are allocated to the upper grooves 6 a , 6 b . Furthermore, in this arrangement, the web of corrugated board 1 has been provided with a lengthwise cut 8 running in the conveying direction 5 and dividing the web of corrugated board 1 into two partial webs 1 a , 1 b of a width a and d, respectively,
As seen in FIGS. 1 and 2, the web of corrugated board 1 , which has been divided into two partial webs 1 a, b , passes through a first quality-detecting apparatus 9 that has two laser sensors 10 , 11 disposed above and below the web of corrugated board 1 . They are synchronously displaceable crosswise of the conveying direction 5 and crosswise of the corrugated board 1 on guides 12 , 13 by means of drives (not shown), which is roughly outlined by the double-headed arrow 14 in FIG. 1 . The laser sensor 10 detects the distance a from the upper liner 2 ; the lower laser sensor 11 detects the distance b from the lower liner 3 . If the sensors 10 , 11 , upon crosswise displacement, move over the upper groove 6 a and 6 b , respectively, or the lower groove 7 a and 7 b , respectively, they detect any change in the distance a and b, respectively, which means they detect the position of the grooves 6 a , 6 b and 7 a , 7 b , respectively, crosswise of the conveying direction 5 . In the same way, they detect the position of the lengthwise cut 8 and the position of the lateral edges 18 , 19 . Detecting the grooves 6 a , 6 b , 7 a , 7 b and the lengthwise cut 8 and the lateral edges 25 , 26 helps determine whether their position relative to each other is correct.
The distances a and b found by the laser sensors 10 , 11 are fed to an evaluation equipment 15 . This is where the distance of the lateral edge 18 of the partial web 1 a from the lengthwise cut 8 i.e., the width c of the partial web 1 a , is determined. The distance of the lengthwise cut 8 from the lateral edge 19 of the partial web 1 b i.e., the width d thereof, is determined in the same way. Furthermore, the distance e of the grooves 6 a , 7 a from the lateral edge 18 and/or the distance f of The grooves 6 a , 7 a of the partial web 1 a from the lengthwise cut 8 is determined. The same applies to the distance g of tie grooves 6 , 7 b of the partial web 1 b from the lengthwise cut 8 and to the distance h of the grooves 6 b , 7 b from the lateral edge 19 of the partial web 1 b . A display unit 15 a may be allocated to the evaluation equipment 15 . Via a control equipment 16 , which is disposed downstream of the evaluation equipment 15 , the evaluated information on the position can then be employed for triggering the mentioned grooving and longitudinal cutting arrangement. Furthermore, the control equipment 16 triggers an electric motor 17 , for instance the driving motor of a cross cutter which is disposed downstream in the conveying direction 5 in the facility and by means of which a section of the web is cut out that has been detected as being out of order. Such a section is eliminated in a turnout that is disposed downstream of the cross cutter. These details too become apparent from U.S. Pat. No. 5,857,395 which has already been mentioned and which reference is made to explicitly. | An apparatus for detection of format accuracy of a web of corrugated board that comprises a first and second smooth liner and a corrugated paper web disposed there-between, is equipped with at least one sensor which detects grooves running in a conveying direction of the web of corrugated board, and/or a lengthwise cut, and/or lateral edges. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The application claims priority of provisional application No. 60/837,671 filed Aug. 14, 2006.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to adjustable supports for aircraft interior equipment, in particular supports for aircraft seating, tables and the like.
[0003] A need exists in many aircraft interiors for seats and tables to translate and/or rotate for passenger comfort. Many aircraft floor space plans require several degrees of motion to allow a bulky seat or coffee table to be moved in the tight confines of smaller business aircraft. Seats must often be movable toward or away from tables, desks and other seats, all without using up valuable floor space. Military aircraft often have a need to access multiple stations from a single seat. In each of these cases, however, a chosen locked position must securely support and protect the seat occupant for normal use, turbulence loads and hard landing loads.
[0004] U.S. Pat. No. 4,671,572 (hereinafter “the '572 patent”) discloses an adjustable chair having a chair post that is movable within a large aperture in the mounting frame. This arrangement allows the chair to be rotated and translated across the top of the chair mounting frame. The chair is fixed in a desired position by a friction brake that engages the underside of the chair mounting frame. A disadvantage of the chair disclosed in the '572 patent is the substantial volume and floor space occupied by the relatively bulky chair mounting frame. Additionally, the friction lock does not provide a positive locking feature to endure heavy side loads.
SUMMARY OF THE INVENTION
[0005] The present invention comprises a support for securing interior equipment such as seats and tables to a frame such as for securing an aircraft seat to the floor of an aircraft. According to an illustrative embodiment, the support comprises a base that is attached to the aircraft floor. The base supports a lower support thrust bearing. A lower link is attached at one end to the support bearing so that the link is capable of rotating about the base. The other end of the link has a bearing that supports a second, intermediate link so that the intermediate link rotates about the end of the lower link. The opposite end of the intermediate link has a bearing that supports the seat platform, which enables the seat platform to rotate about the end of the intermediate link. This arrangement of links allows the seat frame to be moved laterally in any direction and the seat frame to be rotated 360 degrees.
[0006] In the illustrative embodiment, the support is locked in position by means of locking pins that engage corresponding metering plates adjacent the support bearings. The locking pins are released by a common linkage that sequentially releases the seat rotation lock then simultaneously releases the rotation locks of the intermediate and lower links. The simultaneous release of the intermediate and lower locks is effected by a movable yoke that is attached to the intermediate link. Although the yoke is attached to the intermediate link, the mechanism does not bind the lower and intermediate links or the seat platform from rotating in the released position because each locking pin engages its corresponding metering plate at a contact point located substantially on the same axis as the support bearing immediately above. Thus the lower link rotation lock engages its metering plate substantially along the rotational axis defined by the bearing that supports the intermediate link and the intermediate link rotation lock engages its metering plate substantially along the rotational axis of the bearing that supports the seat platform. The locking and release mechanism thus permits full translation and rotation of the seat platform while providing for a solid, positive lock of the seat platform once the locks are engaged.
BRIEF DESCRIPTION OF THE DRAWING
[0007] The present invention will be better understood from a reading of the following detailed description, taken in conjunction with the accompanying drawing figures in which like references designate like elements and, in which:
[0008] FIG. 1 is a front perspective view of an illustrative embodiment of a seat platform incorporating features of the present invention;
[0009] FIG. 2 is a front perspective view of the illustrative seat platform in its forwardmost extended position;
[0010] FIG. 3 is a front perspective view of the illustrative seat platform in a partially extended position;
[0011] FIG. 4 is a front perspective view of the illustrative seat platform in a partially extended and rotated position;
[0012] FIG. 5 is an exploded perspective view of portions of the links and seat platform of the illustrative seat support;
[0013] FIG. 6 is a cross-sectional view of the illustrative seat support with the rotation locks in their fully engaged position;
[0014] FIG. 7 is a cross-sectional view of the illustrative seat support with the seat rotation lock disengaged;
[0015] FIG. 8 is a cross-sectional view of the illustrative seat support with the seat rotation and link rotation locks disengaged and the seat platform moved to its forwardmost extended position; and
[0016] FIG. 9 is a perspective view of the rotation lock actuator linkage.
DETAILED DESCRIPTION
[0017] The drawing figures are intended to illustrate to the general manner of construction and are not necessarily to scale. In the detailed description and in the drawing figures, specific illustrative examples are shown and herein described in detail. It should be understood, however, that the drawing figures and detailed description are not intended to limit the invention to the particular form disclosed, but are merely illustrative and intended to teach one of ordinary skill how to make and/or use the invention claimed herein and for setting forth the best mode for carrying out the invention.
[0018] With reference to the figures and in particular FIGS. 1-5 , seat support 10 comprises a base 12 a lower link 14 an intermediate link 16 and a seat platform 18 . Lower link 14 is supported at its fixed end 20 by a lower thrust collar assembly 22 consisting of a spigot flange 24 and a roller thrust bearing 26 . The flanged portion 28 of spigot flange 24 has a plurality of holes 30 formed therein to form a metering plate 32 , the function of which will be explained in greater detailed hereafter. A retainer assembly 34 consisting of a second roller thrust bearing 36 and a collar 38 retains lower link 14 to the spigot portion 40 of spigot flange 24 .
[0019] The free end 44 of lower link 14 supports the fixed end 42 of intermediate link 16 by means of an intermediate thrust collar assembly 46 attached to free end 44 of lower link 14 . Intermediate thrust collar assembly 46 includes a metering plate 32 a with a plurality of holes 30 a and is identical in construction to thrust collar assembly 22 and therefore will not be explained further herein. Intermediate link 16 is retained on intermediate thrust collar assembly 46 by a retainer assembly 48 , which is identical in construction and operation to retainer assembly 34 and therefore will not be explained in detail herein.
[0020] Seat platform 18 is secured to the free end 50 of intermediate link 16 by an upper thrust collar assembly 52 , which is attached to the free end 50 of intermediate link 16 . Upper thrust collar assembly 52 includes a metering plate 32 b having a plurality of holes 30 b and is identical in construction and operation as thrust collar assembly 22 and therefore will not be explained further herein. Seat platform 18 is retained to thrust collar assembly 52 by a retainer assembly 54 , which is identical in construction and operation to retainer assembly 34 .
[0021] As can be determined from the foregoing, the arrangement of bearings and links enable seat platform 18 to be located anywhere from directly over the centerline of the rotating joint defined by thrust collar assembly 22 as shown in FIG. 1 to a fully forward extended position as shown in FIG. 2 , to a partially forward position as shown in FIG. 3 , to a partially forward and rotated position as shown in FIG. 4 , or any number of intermediate, rotated and unrotated positions enabled by the two degrees of freedom inherent in the arrangement of links and rotating joints.
[0022] With further reference to FIGS. 6-9 , lower link 14 , intermediate link 16 and seat platform 18 are locked in position by seat locking pin 78 , intermediate locking pin 86 and lower locking pin 88 , each of which is spring-loaded to engage a corresponding hole 30 , 30 a , 30 b in metering plates 32 , 32 a , 32 b . Lower link 14 , intermediate link 16 and seat platform 18 are released for rotation/translation then locked into position by means of a locking and release mechanism 60 which consists of a handle 62 , an arm 64 an upper walking beam 66 , a push rod 68 , a lower walking beam 70 and a yoke 72 . Upper walking beam 66 is supported by upper axle 74 which rotates in corresponding recesses formed in control lever mount 76 ( FIGS. 1-4 ). As handle 62 is pulled upward, upper walking beam 66 simultaneously lifts seat locking pin 78 against its spring so that it disengages corresponding hole 30 b of metering plate 32 b . Simultaneously, upper walking beam 66 presses push rod 68 into socket 80 of lower walking beam 70 . As can be seen most clearly in FIGS. 6-7 , there is positive engagement between upper walking beam 66 and seat locking pin 78 so that lifting handle 62 causes seat locking pin 78 to immediately disengage metering plate 32 b to allow the seat to rotate. However, there is clearance between push rod 68 and the bottom of socket 80 of lower walking beam 70 . Therefore, lower walking beam 70 does not move immediately. As handle 62 is pulled further upward, however, push rod 68 engages the lower surface of socket 80 causing lower walking beam 70 to pivot about its lower axle 82 , which in turn lifts yoke 72 via link 84 .
[0023] Yoke 72 is constrained to move vertically under the urging of link 84 by means of rollers 90 , 92 mounted to saddles 94 , 96 each of which engage a corresponding track 98 and 100 formed in yoke 72 . As yoke 72 is lifted upward, it simultaneously lifts intermediate locking pin 86 and lower locking pin 88 to disengage pins 86 and 88 from corresponding holes 30 and 30 a of metering plates 32 and 32 a . With locking pins 86 sand 88 released, lower link 14 and intermediate link 16 are free to rotate about their respective thrust collar assemblies 22 and 46 , thereby enabling horizontal translation of seat platform 18 .
[0024] As noted hereinbefore, yoke 72 lifts intermediate locking pin 86 and lower locking pin 88 simultaneously so that each disengages its respective metering plate at the same time, however, in an alternative embodiment, yoke 72 disengages intermediate locking pin 86 and lower locking pin 88 sequentially. As can be seen most clearly in FIG. 8 , lower locking pin 88 engages metering plate 32 at a point that is located substantially on the axis of rotation 102 that is defined by intermediate thrust collar assembly 46 . Thus even with lower locking pin 88 engaged to metering plate 32 , intermediate link 16 can still rotate about intermediate thrust collar assembly 46 as long as intermediate locking pin 86 is disengaged. Intermediate link 16 simply pivots about lower locking pin 88 in its engaged position. Similarly, intermediate locking pin 86 engages metering plate 32 a at a point that lies substantially on the axis of rotation 104 defined by upper thrust collar assembly 52 . This enables seat platform 18 to rotate about upper thrust collar assembly 52 as long as seat locking pin 78 is disengaged from metering plate 32 b.
[0025] In the illustrative embodiment, lower locking pin 88 has a head portion 108 that rotates in a seat (not shown) in yoke 72 to enable yoke 72 , which is mounted to intermediate link 16 to freely rotate about engaged lower locking pin 88 . Alternatively, since lower locking pin is cylindrical in shape, it would be possible simply to allow lower locking pin 88 to rotate in hole 30 formed in metering plate 32 . Similarly, intermediate locking pin 86 has a head portion 110 that rotates in a seat formed in yoke 72 to enable seat platform 18 to rotate about engaged intermediate locking pin 86 . Because the illustrative seat support 10 has only two main links in addition to the seat platform, the longitudinal axis 106 of seat locking pin 78 is merely offset from axis 104 of upper thrust collar assembly 52 , there being no additional thrust collar assemblies mounted above.
[0026] As can be determined from the foregoing, the unique arrangement of links and the alignment of the locking pins with the axis of rotation of the thrust collar assemblies immediately above enables a common rigid linkage such as yoke 72 to positively disengage and engage the locking pins without impeding free rotation of lower link 14 , intermediate link 16 and seat platform 18 and without the use of flexible joints, cables or other cumbersome mechanisms.
[0027] Although certain illustrative embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the spirit and scope of the invention. For example, although in the illustrative embodiment the support is for securing a seat to an aircraft floor, the invention is equally capable of securing other interior equipment, such as a coffee table, to a vehicle frame. Additionally, although the illustrative embodiment has only two main links, a seat supported by three or more links is considered within the scope of the invention. Accordingly, it is intended that the invention shall be limited only to the extent required by the appended claims and the rules and principles of applicable law. | A equipment support for aircraft and the like comprises a base to which a lower link, an intermediate link, and a equipment platform are attached. The lower link rotates horizontally about the base. The intermediate link rotates horizontally about the end of the lower link and the equipment platform rotates horizontally about the end of the intermediate link. This arrangement gives the equipment platform the ability to assume an infinite number of lateral positions and 360 degrees of rotation. The equipment support is locked in position by means of locking pins that engage corresponding metering plates adjacent the support bearings. The locking pins are released by a common linkage that sequentially releases the equipment platform rotation lock then simultaneously releases the rotation locks of the intermediate and lower links. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to tools and more particularly to a tool having an arrangement for easily identifying a size thereof by different colors and other techniques.
2. Description of Related Art
Conventionally, a tool is classified by size of the metric system or the British system. It is typical for a user to visually identify the size of a tool. This is a time consuming process. Further, a user may not be able to easily locate and identify the correct size since both the size and the tool have the same color. For solving the above problem, a number of documents have been disclosed as detailed below.
A Taiwanese Patent Published No. 77,210,372 as shown in FIG. 1 disclosed a sleeve 10 having its size labeled in the metric system (or a sleeve 11 having its size labeled in the British system). An annular recess 101 is formed around the sleeve 10 and an annular recess 111 is formed around the sleeve 11 respectively. An annular band 102 of a first color is adhered on the recess 101 and an annular band 112 of a second color different from the first color is adhered on the recess 111 respectively. Thus, it is easy to distinguish the size of the metric system from the size of the British system. Further, band 102 of one size has a width different from that of the band of an adjacent size for being easily identified. However, width change technique is not practical because a user can hardly distinguish one size from an adjacent size due to very small width change therebetween. That is, width change can be observed only between a size and another distal size. Unfortunately, this is not necessary since a visual observation is sufficient. In fact, a correct size can be identified only by a visual observation on the color band by slowly turning the sleeve. Thus, the first prior art is not advantageous.
Another Taiwanese Patent Published No. 77,210,372A01 as shown in FIG. 2 is a continuation-in-part of the first prior art. The second prior art substantially has same structure as the first one. The characteristics of the second prior art are detailed below. For a sleeve 12 , an annular band 122 , having the same color as the color band 121 but having a width smaller than the color band 121 , is adhered on an annular recess above the color band 121 . Likewise, for a sleeve 13 , an annular band 132 , having the same color as the color band 131 but having a width smaller than the color band 131 , is adhered on an annular recess above the color band 131 . The provision of the color bands 122 and 132 aims at identifying odd and even numbered sizes of the metric system and ⅛″ and 1/16″ of the British system respectively. However, it is preferred to have a simple color band combination from a user's point of view. As such, the second prior art can cause confusion for an ordinary user. Thus, it is impractical. Moreover, it is important for a user to correctly identify the correct size. Unfortunately, the second prior art fails to achieve the above goal. In other words, it is unnecessary.
Still another Taiwanese Patent Published No. 92,205,833 is shown in FIG. 3 . It disclosed color bands 161 and 171 printed around metal sleeves 16 and 17 respectively. On the color band 161 a rectangular area 162 having a color 163 different from that of the band 161 is formed. As shown, a numeral 22 , as an example of the metric system, is formed on the area 162 . Likewise, on the color band 171 a rectangular area 172 having a color 173 different from that of the band 171 is formed. As shown, a numeral ⅞″, as an example of the British system, is formed on the area 172 . It is easy to distinguish the sleeve 16 of the metric system from the sleeve 17 of the British system since the band 161 has a color different from that of the band 171 . Next, it is possible of quickly, easily finding the area 162 (or 172 ) by identify the color 163 (or 173 ). This facilitates to read the correct size. However, such arrangement may be too complicated, resulting in an increase in the manufacturing cost. Thus, the need for improvement still exists.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a tool comprising an area disposed on an outer surface, the area being printed in one of two different first colors for identifying the tool as one labeled in either the British system or the metric system; and a numeral as a representation of a size of the tool disposed in the area, the numeral being a stencil so as to expose a metal color of the tool, wherein the numeral has a second color different from the first color of the area for providing a contrast of the numeral to other portions of both the area and the tool. By utilizing the present invention, it is possible of quickly identifying the correct size of the tool prior to use or storage.
It is another object of the present invention to provide a tool comprising an area disposed on an outer surface, the area being printed in one of two different first colors for identifying the tool as one labeled in either the British system or the metric system; and a numeral as a representation of a size of the tool disposed in the area, the numeral being a stencil and having a color different from the first color of the are printed therein so as to provide a contrast of the numeral to other portions of both the area and the tool. By utilizing the present invention, it is possible of quickly identifying the correct size of the tool.
It is still another object of the present invention to provide a tool comprising an enclosed embossment disposed on an outer surface, the embossment being printed in one of two different first colors for identifying the tool as one labeled in either the British system or the metric system; and a numeral as a representation of a size of the tool disposed in the area by printing, the numeral having a second color different from the first color of the embossment for providing a contrast of the numeral to other portions of both the area and the tool. By utilizing the present invention, it is possible of quickly identifying the correct size of the tool.
It is a further object of the present invention to provide a tool comprising an area disposed on an outer surface, the area being printed in one of two different first colors for identifying the tool as one labeled in either the British system or the metric system; a numeral as a representation of a size of the tool disposed in the area, the numeral having a second color different from the first color of the area for providing a contrast of the numeral to other portions of both the area and the tool; and a trademark being formed by cutting through the area or printing on the area, the trademark having a third color different from both the first color of the area and the second color. By utilizing the present invention, it is possible of quickly identifying the correct size of the tool and the trademark.
The above and other objects, features and advantages of the present invention will become apparent from the following detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of two typical examples of tool having an arrangement for easily identifying a size thereof according to first prior art;
FIG. 2 is a perspective view of two typical examples of tool having an arrangement for easily identifying a size thereof according to second prior art;
FIG. 3 is a perspective view of two typical examples of tool having an arrangement for easily identifying a size thereof according to third prior art;
FIG. 4 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a first preferred embodiment of the invention;
FIG. 5 is a detailed view of the areas in circles A and B in FIG. 4 ;
FIG. 6 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a second preferred embodiment of the invention;
FIG. 7 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a third preferred embodiment of the invention;
FIG. 8 is a detailed view of the areas in circles C and D in FIG. 7 ;
FIG. 9 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a fourth preferred embodiment of the invention;
FIG. 10 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a fifth preferred embodiment of the invention;
FIG. 11 is a detailed view of the areas in circles E and F in FIG. 10 ;
FIG. 12 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a sixth preferred embodiment of the invention;
FIG. 13 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a seventh preferred embodiment of the invention;
FIG. 14 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to an eighth preferred embodiment of the invention;
FIG. 15 is a detailed view of the areas in circles G and H in FIG. 14 ;
FIG. 16 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a ninth preferred embodiment of the invention;
FIG. 17 is a detailed view of the areas in circles I and J in FIG. 16 ;
FIG. 18 is a perspective view of two exemplary examples of tool having an arrangement for easily identifying a size thereof according to a tenth preferred embodiment of the invention; and
FIG. 19 is a detailed view of the area in circle K in FIG. 18 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 4 and 5 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a first preferred embodiment of the invention. A rectangular area 181 having a color different from that of the remaining portion of the sleeve 18 of the metric system is printed on an outer surface of the sleeve 18 . A numeral 182 (e.g., 22 as shown) is formed by cutting through the rectangular area 181 so as to form a stencil for exposing the color of the metal sleeve 18 and providing a contrast of the numeral 182 to other portions of the sleeve 18 . Likewise, A rectangular area 191 having a color different from that of the remaining portion of the sleeve 19 of the British system is printed on an outer surface of the sleeve 19 . A numeral 192 (e.g., ⅞″ as shown) is formed by cutting through the rectangular area 191 so as to form a stencil for exposing the color of the metal sleeve 19 and providing a contrast of the numeral 192 to other portions of the sleeve 19 . The rectangular areas 181 and 191 have different colors. As such, a user not only can easily distinguish the sleeve 18 of the metric system from the sleeve 19 of the British system but also can quickly identify the correct size (e.g., the numeral) prior to use or storage.
Referring to FIG. 6 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a second preferred embodiment of the invention. An annular recess 201 is formed around the sleeve 20 of the metric system. A rectangular area 202 having a color different from that of the remaining portion of the sleeve 20 is printed on a portion of the recess 201 . A numeral 203 (e.g., 22 as shown) is formed by cutting through the rectangular area 202 so as to form a stencil for exposing and providing a contrast of the numeral 203 to other portions of the sleeve 20 . Likewise, an annular recess 211 is formed around the sleeve 21 of the British system. A rectangular area 212 having a color different from that of the remaining portion of the sleeve 21 is printed on a portion of the recess 211 . A numeral 213 (e.g., ⅞″ as shown) is formed by cutting through the rectangular area 212 so as to form a stencil for exposing the color of the metal sleeve 21 and providing a contrast of the numeral 213 to other portions of the sleeve 21 . The rectangular areas 202 and 212 have different colors. This embodiment has the same advantages as the above one.
Referring to FIGS. 7 and 8 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a third preferred embodiment of the invention. A rectangular area 221 having a color different from that of the remaining portion of the sleeve 22 of the metric system is printed on an outer surface of the sleeve 22 . A numeral 222 (e.g., 22 as shown) is formed by cutting through the rectangular area 221 so as to form a stencil. Further, color different from the color of the rectangular area 221 is printed on the numeral 222 so as to provide a contrast of the numeral 222 to other portions of the sleeve 22 . Likewise, a rectangular area 231 having a color different from that of the remaining portion of the sleeve 23 of the British system is printed on an outer surface of the sleeve 23 . A numeral 232 (e.g., ⅞″ as shown) is formed by cutting through the rectangular area 231 so as to form a stencil. Further, color different from the color of the rectangular area 231 is printed on the numeral 232 so as to provide a contrast of the numeral 232 to other portions of the sleeve 23 . This embodiment has the same advantages as the above one.
Referring to FIG. 9 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a fourth preferred embodiment of the invention. An annular recess 241 is formed around the sleeve 24 of the metric system. A rectangular area 242 having a color different from that of the remaining portion of the sleeve 24 is printed on a portion of the recess 241 . A numeral 243 (e.g., 22 as shown) is formed by cutting through the rectangular area 242 so as to form a stencil. Further, color different from the color of the rectangular area 242 is printed on the numeral 243 so as to provide a contrast of the numeral 243 to other portions of the sleeve 24 . Likewise, an annular recess 251 is formed around the sleeve 25 of the British system. A rectangular area 252 having a color different from that of the remaining portion of the sleeve 25 is printed on a portion of the recess 251 . A numeral 253 (e.g., ⅞″ as shown) is formed by cutting through the rectangular area 252 so as to form a stencil. Further, color different from the color of the rectangular area 252 is printed on the numeral 253 so as to provide a contrast of the numeral 253 to other portions of the sleeve 25 . The rectangular areas 242 and 252 have different colors. This embodiment has the same advantages as the above one.
Referring to FIGS. 10 and 11 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a fifth preferred embodiment of the invention. A hollow rectangle 261 having a color different from that of the remaining portion of the sleeve 26 of the metric system is embossed on an outer surface of the sleeve 26 . A numeral 262 (e.g., 22 as shown) is printed within the rectangle 261 . The numeral 262 has a color different from that of the rectangle 261 and that of the sleeve 26 so as to provide a contrast of the numeral 262 to other portions of the sleeve 26 . Likewise, a hollow rectangle 271 having a color different from that of the remaining portion of the sleeve 27 of the British system is embossed on an outer surface of the sleeve 27 . A numeral 272 (e.g., ⅞″ as shown) is printed within the rectangle 271 . The numeral 272 has a color different from that of the rectangle 271 and that of the sleeve 27 so as to provide a contrast of the numeral 272 to other portions of the sleeve 27 . This embodiment has the same advantages as the above one.
Referring to FIG. 12 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a sixth preferred embodiment of the invention. An annular recess 281 is formed around the sleeve 28 of the metric system. A hollow rectangle 282 having a color different from that of the remaining portion of the sleeve 28 is embossed on a portion of the recess 281 . A numeral 283 (e.g., 22 as shown) is printed within the rectangle 282 . The numeral 283 has a color different from that of the rectangle 282 and that of the sleeve 28 so as to provide a contrast of the numeral 283 to other portions of the sleeve 28 . Likewise, an annular recess 291 is formed around the sleeve 29 of the British system. A hollow rectangle 292 having a color different from that of the remaining portion of the sleeve 29 is embossed on a portion of the recess 291 . A numeral 293 (e.g., ⅞″ as shown) is printed within the rectangle 292 . The numeral 293 has a color different from that of the rectangle 292 and that of the sleeve 29 so as to provide a contrast of the numeral 293 to other portions of the sleeve 29 . This embodiment has the same advantages as the above one.
Referring to FIG. 13 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a seventh preferred embodiment of the invention. A rectangular area 301 having a color different from that of the remaining portion of the sleeve 30 of the metric system is printed on an outer surface of the sleeve 30 . A numeral 302 (e.g., 22 as shown) is printed on the rectangular area 301 . The numeral 302 has a color different from that of the rectangular area 301 so as to provide a contrast of the numeral 302 to other portions of the sleeve 30 . Likewise, a rectangular area 311 having a color different from that of the remaining portion of the sleeve 31 of the British system is printed on an outer surface of the sleeve 31 . A numeral 312 (e.g., ⅞″ as shown) is printed on the rectangular area 311 . The numeral 312 has a color different from that of the rectangular area 311 and that of the sleeve 31 so as to provide a contrast of the numeral 312 to other portions of the sleeve 31 . This embodiment has the same advantages as the above one.
Referring to FIGS. 14 and 15 , there is shown a tool (e.g., combination box and open end wrench) having an arrangement for easily identifying a size thereof in accordance with an eighth preferred embodiment of the invention. A rectangular area 321 having a color different from that of the remaining portion of the wrench 32 of the metric system is printed on a handle of the wrench 32 . A numeral 322 (e.g., 22 as shown) is formed by cutting through the rectangular area 321 so as to form a stencil for exposing the color of the metal wrench 32 and providing a contrast of the numeral 322 to other portions of the wrench 32 . Likewise, a rectangular area 331 having a color different from that of the remaining portion of the wrench 33 of the British system is printed on a handle of the wrench 33 . A numeral 332 (e.g., ⅞″ as shown) is formed by cutting through the rectangular area 331 so as to form a stencil for exposing the color of the metal wrench 33 and providing a contrast of the numeral 332 to other portions of the wrench 33 . This embodiment has the same advantages as the above one.
Referring to FIGS. 16 and 17 , there is shown a tool (e.g., 6-point wrench) having an arrangement for easily identifying a size thereof in accordance with a ninth preferred embodiment of the invention. A rectangular area 341 having a color different from that of the remaining portion of the wrench 34 of the metric system is printed on a handle of the wrench 34 . A numeral 342 (e.g., 22 as shown) is formed by cutting through the rectangular area 341 so as to form a stencil for exposing the color of the metal wrench 34 and providing a contrast of the numeral 342 to other portions of the wrench 34 . Likewise, a rectangular area 351 having a color different from that of the remaining portion of the wrench 35 of the British system is printed on a handle of the wrench 35 . A numeral 352 (e.g., ⅞″ as shown) is formed by cutting through the rectangular area 351 so as to form a stencil for exposing the color of the metal wrench 35 and providing a contrast of the numeral 352 to other portions of the wrench 35 . This embodiment has the same advantages as the above one.
Referring to FIGS. 18 and 19 , there is shown a tool (e.g., sleeve) having an arrangement for easily identifying a size thereof in accordance with a tenth preferred embodiment of the invention. The tenth embodiment substantially has same structure and advantages as the first embodiment. The additional characteristic of the tenth embodiment is detailed below. Trademarks 183 and 193 are carved on left top corners of the rectangular areas 181 and 191 respectively for product distinguishing purpose.
While the invention herein disclosed has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims. | A tool comprises a surface area, the area being printed in one of two different first colors for identifying the tool as one labeled in either the British system or the metric system, and a numeral as a representation of a size of the tool disposed in the area, the numeral having a second color different from the first color of the area for providing a contrast of the numeral to other portions of both the area and the tool. The correct size of the tool thus can be quickly identified. Moreover, a number of embodiments are made possible. | 8 |
SECTOR OF THE TECHNIQUE
[0001] This invention concerns new products that result from the conjugation of flavenols with molecules that contain the thiol group. The new molecules are obtained from polyphenolic plant extracts rich in oligomeric and polymeric procyanidines and prodelfinidins. In this way, new products are generated with antioxidant properties and application as protective agents for the organism against disorders such as cancer, cardiovascular diseases and premature aging. The invention also refers to obtaining these new agents from waste materials from the agroalimentary industry. These waste materials are very complex mixtures and a simple and effective method of isolation and purification is described based on the physico-chemical characteristics of the new molecules.
[0002] Background of the invention and state of the art of the technique
[0003] Flavanols are members of a larger family of compounds called polyphenols. These contain more than one hydroxyl group (OH) bonded to the corresponding benzene ring. Oligomeric flavenols include procyanidines and prodelfinidines depending on whether these present two or three hydroxyl groups in the B ring of the flavenolic structure, respectively. FIG. 1 shows the general structure of procyanidines and prodelfinidins. Polyphenols and, more specifically, flavenols are present in all aerial parts of plants and are found in high concentrations in skin, bark and seeds. Sources rich in polyphenols are leaves of the tea plant, grape skin/pips and pine bark. The antioxidant/antitiradical action of polyphenols makes them useful as products for the prevention of diseases and health promotion. Body cells are constantly exposed to so-called reactive oxidant species (ROS) such as hydrogen peroxide (H 2 O 2 ), superoxide anion (O 2 ′), hydroxyl radical (OH′) and peroxide radicals (ROO′), which have the potential to cause cellular damage. For example, damage of genetic material (DNA) can cause mutations and cancer, and alterations in blood proteins (low-density lipoproteins, LDL) can lead to lipid accumulation and consequent blockage of arteries. In the skin, lipidic oxidation of the cell wall is related to changes in permeability which cause dryness and premature aging. Most ROS are produced during ordinary biological processes and the organism avoids these harmful effects using its own defense mechanisms (e.g. superoxide dysmutase, catalase and glutathione peroxidase against superoxide anion, hydrogen peroxide and organic peroxides, respectively). However, defense systems are not perfect and some of the reactive oxidant species can evade these. Moreover, some diseases, aging or external factors such as environmental pollution, tobacco and ultraviolet radiation can produce ROS levels that exceed the defense mechanisms' capacity. In these cases, an additional preventive action is required using exogenous antioxidants. For information about ROS, oxidative damage, defense mechanisms and the function of polyphenols and other antioxidants, see Diplock, A. T., Charleux, J. L., Crozier-Willi, G., Kok, F. J., Rice-Evans, C., Roberfroid, M., Stahl, W., Vina-Ribes, J., Br. J. Nutr., 80 Suppl 1, 77-112 (1998). Natural extracts of procyanidine have been described with antioxidant activity [Pietta, P., Simonetti, P., Mauri, P., J. Agr. Food Chem., 46 (11), 4487-4490 (1998); Masquellier, J., U.S. Pat. No. 4,698,360; Frangi, E., Bertani, M., Mustich, G., Tuccini, G., U.S. Pat. No. 5,484,594; Nafisi-Movaghar, K., Seroy, W. A., Svanoe, T. T., U.S. Pat. No. 5,912,363] and some of these are currently on the market.
[0004] Polyphenols also present other interesting activities, some of which are related with their adhesive/antiadhesive properties. Hence, polyphenols and especially oligomeric flavenols and glycosylated flavenols present antimicrobial activity at least partially due to inhibition of bacterial adhesion Walker, E. B., Mickelsen, R. A., Mickelsen, J., US5646178; Walker, E. B., Mickelsen, R. A., Mickelsen, J., US5650432; Hamada, S., Kontani, M., Hosono, H., Ono, H., Tanaka, T., Ooshima, T., Mitsunaga, T., Abe, I., FEMS Microbiol Lett., 143 (1), 35-40 (1996)]. Polyphenols and their derivatives are also used in the food industry as preservatives.
[0005] A large proportion of polyphenolic extracts on the market are mixtures of many species with different degrees of polymerization. It is not known for most products how the different components of mixtures are absorbed and distributed in the different systems and biological tissues. Often, some of the active molecules are lost due to their tendency to aggregate among themselves or with proteins, processes that cause their deactivation for example in the skin or the digestive system. Moreover, researchers found that not only polyphenols, especially oligomeric ones, have a general biological activity but also different fractions or individual species of oligomeres have differentiated biological potentials. Owing to the similarity of their physico-chemical properties, the individual compounds are difficult to purify. Moreover, normally the amount of a selected oligomeric compound in a complex mixture is small.
[0006] Thioacidolysis of procyanidines and prodelfinidines is used to establish the degree of polymerization of oligomeric mixtures [Rigaud, J., Perez-Ilzarbe, J., Ricardo da Silva, J. M., Cheynier, V., J. Chromatogr., 540, 401-405 (1991); Prieur, C., Rigaud, J., Cheynier, V., Moutounet, M., Phytochemistry, 36 (3), 781-784 (1994); Souquet, J.-M., Cheynier, V., Brossaud, F., Moutounet, M., Phytochemistry, 43 (2), 509-512 (1996), Souquet, J. M., Labarbe, B., LeGuerneve, C., Cheynier, V., Moutounet, M., J Agr. Food Chem., 48 (4), 1076-1080 (2000)]. Toluene-α-thiol is used as a source of thiols. Terminal flavan-3-ols are released as such while the internal polymer units are released as benzylthioethers in position 4 of the flavanolic system. The mixtures are studied by reverse phase high performance liquid chromatography, RP-HPLC). This method is useful from an analytical perspective. Applications have not been described for the resulting derivatives and also the breakdown product, toluene- -thiol, is toxic, irritant and lacrimogenous. The purification procedure only consists of reverse phase chromatography.
[0007] There is one example of cysteamine conjugates with an antioxidant molecule (tocopherol) [Pelle, E., Maes, D. H., U.S. Pat. No. 5,811,083]. Cysteamine is joined to tocopherol by an amide bond thus eliminating the amino function. Moreover, tocopherol is a different type of compound to flavan-3-ols. There are also examples of antioxidant compounds obtained by adding mercaptoethanol and alkylic chains to flavanols [Tanaka, T., Kusano, R., Kouno, I., Bioorg. Medicinal Chem. Letter, 8 (14), 1801-1806 (1998)]. These are derivatives that do not contain the amino group and have an amphyphylic character.
DESCRIPTION OF THE INVENTION
[0008] The present invention describes a new combination of a species that contains a thiol group and an amino group with species that include the flavan-3-ol system. It also describes a method to obtain and purify new products. The thiol is cysteamine and the polyphenolic part consists of different monomers derived from polymeric procyanidines and prodelfinidins. FIG. 2 shows the structures of the new conjugates. The polyphenol source can be any plant material that contains procyanadins and/or prodelfinidines regardless of their degree of polymerization. One aspect of the invention uses a byproduct of grape pressing as a source of polymeric polyphenols. After a simple thioacidolysis step, the new molecules are effectively isolated from the mixture by a process of cationic exchange, thanks to the amino group introduced with the cysteamine. Ulterior purification by reverse phase chromatography produces each of the active compounds. Flavanolic conjugates are dried at low pressure.
BRIEF DESCRIPTION OF THE FIGURES
[0009] [0009]FIG. 1. Monomeric and polymeric flavan-3-ol structures. A: Monomeric flavan-3-ols. B: Oligomeric and polymeric procyanidines and prodelfinidins. The arrows indicate possible polymerization positions. The bonded molecules can be monomeric or oligomeric flavanols. The bonds are established between the central type C ring and either of the two positions available in the A type rings.
[0010] [0010]FIG. 2. Structures of new aminoethyl derivatives of flavan-3-ols.
[0011] [0011]FIG. 3. Antioxidant efficacy of phenolic compounds in the DPPH assay. The absorbance (A) at 517 nm is a measure of the amount of free radical remaining in solution. (1−A/A 0 )×100 represents the percentage of DPPH that has reacted with the antioxidant. The amount of antioxidant expressed as micromoles per micromole of initial DPPH. to correct the possible day to day variation in the amount of initial DPPH. The initial concentration of DPPH. is calculated from the absorbance (A) and a calibration line. Each point represents the mean of three determinations.
□ Trolox ⋄ Epicatequina ◯ Aminoetiltioepicatequina 1 Δ Aminoetiltioepicatequina-3- O-galato III
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention describes the conjugation of polymeric polyphenols with cysteamine to produce products I-VI. The first source of oligomeric and polymeric flavenols is treated with water/ethanol to obtain the crude polyphenolic fraction. It is not necessary to carry out subsequent fractioninations since thioacidolysis works with the first extract. This does not exclude the use of other fractions of variable purity obtained from the first extract or during any other similar process. In the course of the present invention, aminoethyl derivatives I-VI have been generated from fractions of the first extract. After eliminating water and extraction solvents, the residue is suspended in methanol in the presence of hydrochloric acid and a suitable amount of cysteamine. The mixture is heated to 65° C. and after 15 min, is cooled and diluted with water. This diluted solution is directly loaded onto a cation-exhange column equilibrated at a slightly acid pH. The flavan-3-ols conjugated with cysteamine are retained by the resin while the rest of the material, i.e. monomeric flavan-3-ols, other polyphenols such as flavonols and phenolic acids, and other species such as sugars, are eliminated in the washing process. After, the derived products are recovered from the column in the presence of a suitable amount of salt (sodium chloride) and organic solvent by an efficient and simple procedure. The resulting mixture, which contains a much smaller amount of products than the crude reaction mixture, is submitted to another purification by reverse phase liquid chromatography followed by lyophilization to obtain each of the new molecules with a purity of over 99.5% by analytical HPLC.
[0013] The new molecules are potent antioxidants with an excellent capacity to capture free radicals. The conjugates are more efficient than Trolox (water-soluble analogue of Vitamin E) in the DPPH assay (1,1-diphenyl-2-picrylhydracil) [Brand-Williams, W., Cuvelier, M. E., Berset, C., Lebensm.-Wiss. u.-Technol., 28, 25-30 (1995)]. The conjugates are also more efficient than the corresponding non-derived species.
[0014] The method of the present invention includes a number of phases that are presented below separately to clarify the explanation.
[0015] Extraction phase
[0016] The first step in the preparation of the new conjugates is extraction of polyphenols from the first plant source. In one of the applications of the invention, polyphenols are extracted from the grape-pressing residue (skin, pips and lees) with water/ethanol (3:7) to give a crude C extract. The same procedure can be used with other sources such as the pods, skins/seeds of other species and leaves. Other extraction solvents miscible with water such as methanol and acetone can be used. In another application of the invention, the first crude extract (C) is fractionated by liquid/liquid distribution using ethyl acetate and water acidified with acetic acid. The mixture was separated into two layers, the organic layer (0, mainly ethyl acetate) and the aqueous layer (A, mainly water). The organic fraction 0 mainly contains monomeric flavan-3-ols ((+)-catechine, (−)-epicatechine, (−)-epicatechine-3-O-galate), oligomeric procyanidines and prodelfinidines and glycosylated flavonols. The aqueous fraction A mainly contains procyanidines and prodelfinidines with a high degree of polymerization and flavonols and other non-falvonolic species such as sugars. All the crude products and fractions are analyzed by reverse phase HPLC with elution by water mixtures and acetonitrile in the presence of 0.1% trifluoroacetic acid with detection at 214, 280 and 320 nm.
[0017] Thiolysis phase
[0018] The second step is thioacidolysis of the first extract and the fractions depending on the case. Several of the mixtures have been used for this purpose to i.e. the crude ethanolic extract C, the ethyl acetate fraction 0 and the aqueous fraction A obtained in the previous phase. It is of special interest for the present invention that the final products can be obtained efficiently regardless of the purity of the sources of procyanidins/prodelfinidins. All the starting mixtures in this phase are lyophilized before the hydrolysis treatment. The thiolysis reaction has been described to be complete in 10-15 min at 65° C. in the presence of 0.2 M hydrochloric acid in methanol and a surplus of thio, of approximately 1:50 (weight/weight). In the present invention, a ratio of reagents of only 1:5 has been used and the initial polymers were consumed in only 15 minutes. Formation of anthocyanines has not been detected, as revealed by the absence of signals in the analytical chromatogram register of HPLC at 525 nm. Majority conjugates in the mixture resulting from thiolysis are epicatechine thioethers (I), epicatechinegalate (III) y catechine (II), in order of abundance. Other minority products are derivatives of epigalocatechine (IV), epigalocatechinegalate (VI) and galocatechine (V). The configuration of compounds in position 4 of the C ring could correspond to either of two possibilities (4α, 4). In FIG. 2, the configuration in this carbon is expressed as 4.
[0019] Isolation and Purification
[0020] A crucial aspect of the present invention is isolation of the flavanol derivatives from the complex reaction mixtures. In this stage it is an important advantage to have introduced an amine group during formation of the conjugates. The new derivatives are retained electrostatically to a cationic exchange resin while the rest of the material is eliminated in the resin washing. This operation is important because it permits one to work with first extracts without requiring later fractionating. It is to little avail that these are useful in the previous phase if the following purification is ineffective. Isolation of the new products can be done in the presence of a wide range of materials of different physico-chemical nature, which, while they are not retained in the resin by a positive charge, are easily eliminated in the washing process. It must be emphasized that most potential compounds for use as crude mixtures are of a non-ionic or anionic nature (negative charge in the working pH). The purification of individual compounds from the thiolysis mixture is greatly facilitated with this step. This washing process using resin presents a high efficacy that is independent of the extract or fraction used in previous stages. The composition of the thiolysis mixtures presents some variations depending on the starting material used and the majority products are essentially the same in all cases.
[0021] Different cationic exchange resins can be used in this isolation or washing stage. The resins preferentially include a sulphonic group incorporated in a polmeric support. There are several types of support that can be used in this stage of the invention. These include agarose, co-polymers of styrene-divinylbenzene, polyether and methacrylate. All the resins mentioned are strong exchangers (the anion is a strong acid). However, the possibilities are not limited to these supports or to the anion exchanger, which can also be, for example, a carboxyl group (weak acid) incorporated to an insoluble support. Preferentially, the conjugates are isolated on strong exchangers SP Sepharose®, supplied by Amersham-Pharmacia Biotech and MacroPrep HighS®, supplied by BioRad. The resins, column packed, are equilibrated with sodium acetate buffer at pH 4.75 in the presence of a quantity of water-soluble solvent, selected from methanol, ethanol, acetonitrile and tetrahydrofurane. The crude products of thiolysis are loaded in the column after diluting the reaction mixture with water (dilution factor 1/5). After, the resin is washed with 10 column volumes of the buffer eluent/equilibrium solvent system. The conjugates with cysteine are eluted from the resin sequentially using acetate buffers that contain appropriate quantities of solvent and salt (NaCl). The procedure not only allows the conjugates to be isolated but also provides separation between some of them, facilitating the subsequent purification operations even more.
[0022] Each of the individual chemical species is purified extensively by preparative reverse phase HPLC, preferably in a 25×5 cm column packed with stationary phase VYDAC® C18 provided by The Separations Group. The solutions obtained after washing/isolation are diluted with water (dilution factor 1/3) and separately loaded in the column, previously equilibrated with triethylamine phosphate buffer pH 2.25. Each component is eluted from the column using the appropriate amount of acetonitrile in the equilibrated buffer. After, the pure products are desalinated by packing them in the same column and eluting with water/acetonitrile in the presence of 0.1% trifluoroacetic acid. The final preparations are obtained by lyophilization.
[0023] Antioxidant/Antiradical Power Assay
[0024] The new pure products are strong antioxidants/capturers of free radicals. FIG. 3 presents the results of the DPPH test (1,1-diphenyl-2-pycrylhydracil). The values of EC 50 (effective concentration 50) are calculated from the curves. EC 50 is the amount of antioxidant required to reduce the initial concentration to half (around 60 μM) of DPPH. This amount is expressed as micromoles antioxidant/micromoles initial DPPH. The EC 50 values for compounds relevant to the present invention are: Trolox (water-soluble analogue of Vitamin E), 0.26; (−)-epicatechine, 0.19, 4-(2-aminoethylthio)epicatechine I, 0.11; 4-(2-aminoethylthio)epicatechinegalate III, 0.11. According to the definition of EC 50 , the most effective compounds are those with the lowest effective concentration.
EXAMPLE
[0025] In one application of this invention, compound 1,4-(2-aminoethylthio)epicatechine is obtained by thioacidolysis of a water-soluble fraction (A). Fraction A contains a polyphenol concentration of 10 g/L, measured by the Folin-Ciocalteu method and expressed as equivalents in gallic acid. An aliquot of fraction A (80 mL, 0.8 g equivalents gallic acid) is evaporated under vacuum and suspended in methanol (80 mL). After, a solution of hydrochloric acid is added (HCl) 37% (1.72 mL) and cysteamine (4 g) in methanol (80 mL) and the mixture (160 mL) is maintained at 65° C. for 20 minutes and occasionally stirred. At the end of the reaction, water is added (640 mL) and the mixture is kept at 5° C.
[0026] Isolation of the aminoethylthioethers of the 3-flavanols is achieved by column cation exchange. The chromatographic column (1.6×10 cm, 20 mL bed volume), packed with HighLoad SP Sepharose® is equilibrated with 20 mM sodium acetate buffer, pH 4.75/acetonitrile(CH 3 CN) (9:1). The mixture (in aliquots of 120 mL) is loaded in the column and the underived material that does not contain the amino group is eluted with 10 bed volumes (200 mL) of equilibrated buffer. Compound I is eluted with a salt gradient (NaCl) (0 to 1 M) and a simultaneous gradient of CH 3 CN (10 to 20%) in 20 bed volumes (400 mL). The chromatographic process is repeated six times until all the thiolysis mixture has been exhausted. The fractions are analyzed by reverse phase HPLC in a C18 column and the eluents are mixtures of water/CH 3 CN in the presence of 0.1% trifluoroacetic acid. The fractions containing compound I are combined (650 mL for all the six loads) and diluted to 2.2 L with triethylamine phosphate buffer pH 2.25. The solution is loaded in a column prepacked with VYDAC® C18 (reverse phase) and compound I is eluted with a gradient of CH 3 CN (0 to 12%) in phosphate buffer of triethylamine pH 2.25 for 60 min. The compound 4-(2-aminoethylthio)epicatechine I elutes at a value of 5-6% CH 3 CN. The fractions that contain I are combined, diluted with water and desalinated using a fast gradient of CH 3 CN in 0.1% trifluoroacetic acid. The remaining solution (300 mL) is lyophilized to achieve a white solid (203 mg). The purity of the final product is higher than 99.5% by analytical HPLC with detection at 215 nm. Using mass spectroscopy with electrospray ionization, a molecular ion with 366.3 mass units is detected., when the theoretical ion for this structure is 366.1. The structure of I is confirmed by desulphuration with Raney nickel and comparison with a standard of (−)-epicatechine. The final product is also characterized by proton Nuclear Magnetic Resonance ( 1 H-NMR). Assignations (δ H ) to 300 MHz in (CD 3 ) 2 CO: 2.9-3.8 (4H, m, S—C H 2 —CH 2 —N); 4.02-4.07 (1H, 2 m, 3-H); 4.08-4.18 (2H, m, S—CH 2 —CH 2 —N H 2 ); 4.10-4.22 (1H, m,d J=2.1 Hz, 4-H); 5.12-5.23 (1H, 2 s, 2-H); 5.89 (1H, d J=2.4 Hz, 6-H); 6.07-6.09 (1H, 2 d, J=2.4 Hz each, 8-H); 6.83 (2H, m, 5′-H, 6′-H); 7.10 (1H, d J=2.1 Hz, 2′-H). Assignations ( H ) to 300 MHz en D 2 O: 2.64-3.26 (4H, 3 m, S—C H 2 —CH 2 —N); 3.77 (1H, s width, 3-H); 3.91 (1H, s width, 4-H); 5.11 (1H, s width, 2-H); 5.84 (1H, d width, 6-H); 5.89 (1H, d width, 8-H); 6.72 (2H, s width, 5′-H, 6′-H); 6.82 (1H, s width, 2′-H). Some multiplicities detected could be due to the existence of two products with 4α, 4 configuration. | The present invention refers to new products generated by the conjugation of flavanols with molecules that contain the thiol group. New molecules are obtained from polyphenolic plant extracts rich in oligomeric and polymeric procyanidines and prodelfinidins. In this way, new products are generated with antioxidant properties for application as protective agents for the organism against disorders such as cancer, cardiovascular diseases and premature aging. The invention also refers to obtaining these new agents from waste material generated by the agroalimentary industry. Since these waste materials are highly complex mixtures a simple and effective method is described to isolate and purify these, based on the physico-chemical characteristics of the new molecules. | 0 |
FIELD OF THE INVENTION
The present invention relates to a flange and more specifically to a modular flange system adaptable for use with various sized components such as gears and for use with an imaging member such as a photoreceptor that is used in electrostatographic imaging machines, devices, and processes, including digital and color systems.
BACKGROUND OF THE INVENTION
The xerographic imaging process includes charging a photoconductive member to a uniform potential, and then exposing a light image of an original document onto the surface of the photoreceptor. Exposing the charged photoreceptor to light selectively discharges areas of the surface while allowing other areas to remain unchanged, thereby creating an electrostatic latent image of the document on the surface of the photoconductive member. A developer material is then brought into contact with the surface of the photoreceptor to transform the latent image into a visible reproduction. The developer typically includes toner particles with an electrical polarity opposite that of the photoconductive member. A blank copy sheet is brought into contact with the photoreceptor and the toner particles are transferred thereto by electrostatic charging the sheet. The sheet is subsequently heated, thereby permanently affixing the reproduced image to the sheet. This results in a “hard copy” reproduction of the document or image. The photoconductive member is then cleaned to remove any charge and/or residual developing material from its surface to prepare it for subsequent imaging cycles.
Various imaging and photoreceptor systems are disclosed in U.S. Pat. Nos. 4,120,576; 4,386,839; 4,400,077; 4,561,763; 4,839,690; 4,914,478; 4,975,744; 5,052,090; 5,210,574; 5,357,321; 5,402,207; 5,461,464; 5,599,265; 5,630,196, 5,634,175; 5,752,136; 5,815,773; 5,893,203; and 6,104,896, the disclosures of which are incorporated by reference in their entireties.
The modularity of components is important for manufacturers of sophisticated electronic equipment such as electrostatographic imaging machines. Thus, a need remains for a modular flange system for use with mountable components to facilitate efficiency in manufacturing and in recycling. There is a need for a modular flange system which will accommodate modularity of components such as gears. The present invention advantageously provides such a flange system with common mounting features.
All documents cited herein, including the foregoing, are incorporated herein by reference in their entireties.
SUMMARY OF THE INVENTION
The present invention provides embodiments of a flange assembly with a modular mounting feature for removably securing a gear thereon. The embodiments facilitate easy assembly and reuse of components. Moreover, the embodiments allow installation of the component on the manufacturing line.
An aspect of the invention relates to a flange assembly including an imaging member and a flange. The imaging member includes a first end, a second end, an inside surface, and an outside surface. The flange includes a hub for securing to the imaging member and a protrusion for removably securing a component thereon. The hub has a length and fits inside the imaging member. The protrusion has a length and an outside surface and extends external to the imaging member.
In a further aspect, the invention relates to a flange assembly including an imaging member, at least one flange, and a least one fastening system. The imaging member extends between a first end and a second end and has an inside surface. The flange includes a hub and protrusion. The hub is for securing to the imaging member and the protrusion is for removably securing a component thereon. The hub of the flange interferencely fits inside the imaging member and the protrusion of the flange extends external to the imaging member. The fastening system is for a removably securing a component with the protrusion of the flange.
An additional aspect of the invention relates to a flange assembly in a marking device including a photoreceptor, at least one flange, and at least one gear. The photoreceptor extends between two ends and includes an inside surface. The photoreceptor is adapted to move in the marking device. The flange includes a hub and a protrusion. The hub of the flange interferencely fits inside the photoreceptor. The protrusion is for removably securing a gear thereon. The protrusion of the flange includes a periphery and extends external to the photoreceptor. The gear includes a diameter, a width, and a lumen therein, and is removably securable to the protrusion of the flange.
Another aspect of the invention relates to a process for using a modular flange including: inserting a hub of a flange in an end of an imaging member forming an imaging member flange assembly, the flange having a protrusion extending outside the imaging member; installing the imaging member and flange assembly in an imaging system; disposing an opening of a component over the protrusion; and removably securing the component to the protrusion using a fastening system. The process may further include: removing the component from the protrusion; and replacing the component with another component.
A further aspect of the invention relates to a xerographic apparatus including an imaging member, two flanges, and two gears. The imaging member extends between two ends and is adapted to move in the xerographic apparatus. Each flange includes a hub and a protrusion. The protrusion includes an outside surface. One of the hubs interferencely fits inside the imaging member at one end of the imaging member and the other one of the hubs interferencely fits inside the imaging member at the other end of the imaging member. The protrusion extends external to the imaging member at each of the two ends. Each gear includes a diameter, a width, and a lumen therein. The lumen includes an inside surface. The two gears are removably securable to the protrusion at the two ends. The protrusion and the gear cooperate and functionally engage the other at each of the two ends. One of the gears may transfers torque to the flange and the imaging member. The imaging member may be part of an imaging system.
Still other aspects and advantages of the present invention and methods of construction of the same will become readily apparent to those skilled in the art from the following detailed description, wherein embodiments are shown and described, simply by way of illustration. As will be realized, the invention is capable of other and different embodiments and methods of construction, and its several details are capable of modification and interchangeability in various obvious respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic view of the flange assembly of the present invention;
FIG. 2 is a schematic side view of assembly of FIG. 1;
FIG. 3 depicts a side view of assembly of FIG. 1;
FIG. 4 depicts a schematic view of an embodiment of the flange and gear of the present invention;
FIG. 5 depicts a schematic view of an embodiment of the flange and gear of the present invention.
FIG. 6 depicts a front view of the flange and gear of FIG. 5;
FIG. 7 depicts a schematic view of an embodiment of the flange and gear of the present invention;
FIG. 8 depicts a front view of the flange and gear of FIG. 7;
FIG. 9 depicts an embodiment of a fastening system used to hold the gear on the flange; and
FIG. 10 depicts an embodiment of a fastening system used to hold the gear on the flange.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
While the principles and embodiments of the present invention will be described in connection with an imaging apparatus, it should be understood that the present invention is not limited to that embodiment or to that application. Therefore, it should be understood that the principles of the present invention and embodiments extend to all alternatives, modifications, and equivalents thereof.
FIG. 1 illustrates an embodiment of a modular imaging member flange assembly 10 . FIGS. 2-3 illustrate a flange 12 , imaging member 14 , gear 24 , and a fastening system such as hooks 23 and a clip 28 to removably secure the gear 24 to the flange 12 . The flange 12 includes a member 16 which is disk shaped, a hub 18 which extends axially from one side of the member 16 , and a protrusion 20 which extends axially from the other side of the member 16 . The hub 18 has an outside surface 21 . The member 16 extends radially outside the hub 18 and the protrusion 20 . In embodiments, the protrusion is of sufficient mass and strength to mount and removably secure a component such as a gear thereon.
FIGS. 2 and 3 further illustrate assembly of the flange 12 into an imaging member, for example, a photoreceptor 14 . The flange is designed to allow the hub 18 to be pushed and inserted into the interior of the photoreceptor 14 . As the hub 18 is pushed into the photoreceptor 14 , the member 16 acts as a stop to prevent further insertion of the hub 18 into the photoreceptor 14 . The hub 18 is inserted into the interior of the photoreceptor 14 until the end of the photoreceptor 14 and a face of the member 16 are in contact. The surface 21 of the hub 18 intimately contacts the surface 22 of the photoreceptor 14 and there is generally indiscernible clearance between the surfaces 21 , 22 . In operation, there is indiscernible relative movement between the flange 12 and the photoreceptor 14 .
The contacting surfaces 21 , 22 provide resistance against a torque applied to the flange 18 and the photoreceptor 14 . The hub 18 withstands the inner radial compression load that is exerted upon it in the photoreceptor 14 . The coefficients of thermal expansion of the photoreceptor 14 and the flange may be matched so that the interference fit is maintained independent of the temperature. Prior to assembly of the hub 18 into the photoreceptor 14 , outside diameter D 5 of the hub 18 is slightly larger than the inside diameter D 3 of photoreceptor 14 . The hub 18 is forced into the inside of photoreceptor 14 such that the surface 21 firmly contacts the surface 22 of the photoreceptor 14 . The photoreceptor 14 expands slightly in the outward radial direction as the hub 18 is inserted. The relation of the outside diameter D 5 of the hub 18 in relation to the inside diameter D 3 of photoreceptor 14 should not cause the photoreceptor 14 to bulge and affect the total indicated runout (TIR) of the photoreceptor 14 . Hub 18 may be secured to photoreceptor 14 by interference fit as disclosed in U.S. Pat. Nos. 6,104,896 and 5,815,773, the disclosures of which are incorporated by reference in their entireties.
After the flange is mounted to the photoreceptor 14 , the gear may be placed over the protrusion. The clip 28 is then removably secured to the hooks 23 to prevent the gear from pulling off the protrusion in the direction of the axis x. A secondary gear (not shown) may be further associated with and mate with the teeth of the gear. A motor (not shown) may be used to rotate or drive the gear about axis x as indicated by arrow y. The flange may be mounted on one end or both ends of the photoreceptor 14 and the gear may be attached to one end or both ends of the photoreceptor 14 . The flange may further include a shaft 27 which extends through the photoreceptor 14 and mounts to an imaging system. Alternatively, an individual shaft 27 at each flange may be mounted to an imaging system.
FIG. 4 illustrates a flange 12 having a protrusion 120 with notch mounting system 122 . A gear 124 includes tabs 125 which fit in the notches of the protrusion 120 . The tabs 125 radially protrude into the opening of the gear 124 for a distance ranging from about 0.08 inch to about 0.20 inch; extend a width ranging from about 0.04 inch to about 0.8 inch; and have a thickness ranging from about 0.07 inch to about 0.18 inch. The tabs 125 may be about 0.005 inch to about 0.05 inch smaller, such as about 0.015 inch smaller than the notch for a generally secure fit. After the gear 124 is disposed over the protrusion 20 , a ring 128 may be secured over hooks 123 to removably secure the gear 124 .
FIGS. 5-6 illustrate various fastening systems for embodiments of the modular imaging member flange assembly 10 . In FIG. 5, a clip 228 is secured over hooks 23 to removably secure the gear 24 on the flange 12 . In FIG. 6, a clip 328 is secured over hooks 23 to removably secure the gear 24 on the flange 12 .
FIGS. 7-8 illustrate an embodiment of the invention with a flange including a notch mounting system 222 . The protrusion 220 may have a rectangular or oblong shape. The gear 224 includes tabs 225 in the opening that are sized to fit and cooperate with the notches. The tabs 225 may radially protrude into the opening of the gear 224 for a distance A ranging from about 0.08 inch to about 0.20 inch, extend a width B ranging from about 0.04 inch to about 0.9 inch, and have a thickness C ranging from about 0.07 inch to about 0.18 inch. In operation, the gear 224 fits securely over the protrusion 220 and the tabs 225 fit securely and slide smoothly into their respective notch of the protrusion 220 . The tabs 225 may be about 0.005 inch to about 0.05 inch smaller, such as about 0.015 inch smaller than the notch for a generally secure fit. As the gear 224 is pushed toward the member 16 and nears the face of the member 16 , the gear 224 is twisted an angle Θ ranging from about 3 degrees to about 40 degrees, such as about 15 degrees in a clockwise direction y, and the tabs 225 are rotated and further positioned in their respective notch of the protrusion 220 . Seating the tabs 229 in the notches prevents the gear 224 from moving in the axial x direction. The gear 224 is driven by a motor or mating gear in the clockwise direction y which keeps the gear 224 in a seated position on the protrusion 220 . Alternatively, the gear 224 and protrusion 220 may be designed such that the gear 224 is locked in a counterclockwise drive system.
FIGS. 9-10 illustrate an embodiment of the invention with a flange including a protrusion 320 that is circular and a notch mounting system 322 . The diameter of the protrusion 320 may range from about 0.40 inch to about 2.5 inches, such as about 0.50 inches. The gear 324 includes tabs 325 in the opening that are sized to fit and cooperate with the notches. The tabs 325 may radially protrude into the opening of the gear 324 for a distance A ranging from about 0.08 inch to about 0.20 inch, extend a width B ranging from about 0.04 inch to about 0.9 inch, and have a thickness C ranging from about 0.07 inch to about 0.18 inch. In operation, the gear 324 fits securely over the protrusion 320 and the tabs 325 fit securely and slide smoothly into their respective notch of the protrusion 320 . The tabs 325 may be about 0.005 inch to about 0.05 inch smaller, such as about 0.015 inch smaller than the notch for a generally secure fit. As the gear 324 is pushed toward the member 16 and nears the face of the member 16 , the gear 324 is twisted an angle Θ ranging from about 3 degrees to about 40 degrees, such as about 15 degrees in a clockwise direction y, and the tabs 325 are rotated and further positioned in their respective notch of the protrusion 320 . Seating the tabs 325 in the to notches prevents the gear 324 from moving in the axial x direction. The gear 324 is driven by a motor or mating gear in the clockwise direction which keeps the gear in a seated position on the protrusion 320 . Alternatively, the gear 324 may be designed such that the gear 324 is locked in a counterclockwise drive system.
Other sizes, variations and equivalents of the flange, gear, and fastening system for an imaging machine are also envisioned.
The gear may have teeth on its external periphery and include an opening therein that is about 0.005 inch to about 0.05 inch larger, such as about 0.015 inch larger than the outside periphery of the protrusion to which it is removably secured. The opening of the gear generally conforms to the shape of the outside periphery of the protrusion. The gear may be comprised of: polycarbonate; acrylonitrile butadiene styrene copolymer (ABS); nylon; or combinations thereof. The gear may be mounted over the protrusion and may be removably secured with various fastening systems. The gear may have a diameter ranging from about 0.9 inch to about 3.7 inches, such as about 1.30 inches, and a width ranging from about 0.08 inch to about 1 inch, such as about 0.40 inch.
Other flange and gear systems are also envisioned. For example, a gear may be removably secured to a flange at one or both ends of the photoreceptor 14 ; a gear may be removably secured to a flange at one end of the photoreceptor 14 and a cap or other fitting may be used at the other end of the photoreceptor 14 ; a stepped gear may be removably secured to a flange at one or both ends of the photoreceptor 14 ; and combinations thereof are envisioned. The gears may have various widths. Moreover, the gear may be formed in one-piece and include more than one distinct outside gear surface; the gear may be formed in one-piece with two distinct outside gear surfaces, with distinct diameters such as a stepped gear; and the gear may be formed in one-piece with two distinct outside gear surfaces spaced from the other, with the same diameter. Alternatively, multiple gears of the same or distinct diameter and various widths may be stacked together on a protrusion and used. The relation between the protrusion and the component should include a generally snug fit that allows removable securement therebetween and a fit which includes centricity and generally little slackness. The gear may be of a size sufficient to fit in an imaging machine and may be made of a material compatible with other mating gears.
Various dimensions of the flange are envisioned. The flange may have a length L ranging from about 0.5 inch to about 3 inches, such as about 1 inch. The hub 18 may have a length L 1 ranging from about 0.25 inch to about 2 inches, such as about 0.5 inch; an outside diameter D 5 ranging from about 0.64 inch to about 3.23 inches, such as about 1.124 inches; an inside diameter D 1 ranging from about 0.5 inch to about 2.9 inches, such as about 0.65 inch; and a thickness T ranging from about 0.15 inch to about 1.5 inches, such as about 0.60 inch. Alternatively, the interior of the hub 18 may be solid. The member 16 may have a length L 3 ranging from about 0.04 inch to about 0.1 inch, such as about 0.06 inch; and a diameter D 2 ranging from about 0.80 inch to about 3.50 inches, such as about 1.12 inches. The protrusion may extend from an end of the member 16 for a distance L 2 ranging from about 0.20 inch to about 1 inch, such as about 0.40 inch. The protrusion may have an irregular or a non-circular cross-sectional shape that is, for example, square, rectangular, or oblong shape. The protrusion may have a height ranging from about 0.25 inch to about 2.5 inches, such as about 1 inch, and a width ranging from about 0.25 inch to about 2.5 inches, such as about 0.5 inch.
The flange may be made by fabrication processes such as injection molding, machining, or reaction injection molding. The flange may be formed in one-piece using a mold. Alternatively, the hub 18 , the member 16 , and the protrusion may be fabricated separately and from the same or different materials and then joined together. The flange may be secured without adhesives to the photoreceptor 14 . The flange may have a modular mounting feature such as a protrusion that is common for a product line or photoreceptor line which requires a certain type of gear. The protrusion of the flange may be designed to be common for a certain size product or type of product.
The flange may be formed from a composite material including combinations of polycarbonate, polytetrafluorethylene (PTFE) and glass. For example, the flange may be comprised of: (a) polycarbonate; (b) a composite of polycarbonate and PTFE; or (c) a composite of polycarbonate, PTFE, and carbon fiber composite. In embodiments of the invention, the flange may be comprised of about 75% polycarbonate, about 15% PTFE, and about 10% glass. Other combinations of these materials may be used, and the invention is not limited to these particular embodiments. The flange may also be comprised of a composite material including a combination of plastic and a conductive material in an amount sufficient to form an electrical ground path between the photoreceptor 14 and the flange. The plastic has a generally high impact strength and a generally high softening temperature. Those skilled in the art will recognize that it is possible to substitute similar or equivalent material for those listed such as fiberglass, plastic, and numerous other materials instead of glass. Alternative fastening designs such as tabs on the protrusion and notches on the gear are also envisioned. Notches about the perimeter of the protrusion may be used to accept and removably secure a clip or ring fastener for maintaining the gear on the protrusion. In addition, a clip or ring and post or hook system may be used in conjunction with a notch and tab system.
Alternative fastening system designs such as tabs on the protrusion and notches on the gear are also envisioned. In addition, notches circumferentially about the perimeter of the protrusion may be used to accept and removably secure a clip or ring fastener for maintaining the gear on the protrusion. Moreover, a clip or ring and post or hook system may be used in conjunction with a notch and tab system.
Various embodiment sizes and dimensions of the photoreceptor 14 are envisioned. The photoreceptor 14 may have an inside diameter D 3 ranging from about 0.59 inch to about 3.22 inches, such as about 1.122 inches; an outside diameter D 4 ranging from about 0.65 inch to about 3.31 inches, such as about 1.18 inches, a wall thickness T 1 ranging from about 0.03 inch to about 0.05 inch, such as about 0.04 inch; and a length ranging from about 9.84 inches to about 39.37 inches, such as about 13.38 inches.
In operation, the flange provides torsional and axial support for photoreceptor 14 . The flange transfers the torsional force applied by the gear to the photoreceptor 14 . The photoreceptor 14 often operates under torsional loads of as much as 45 lbs-in. As the gear rotates, photoreceptor 14 rotates past a corona device (not shown) for charging of the photoreceptor 14 to a uniform electrostatic potential. A light image of an original document is then exposed onto the surface of photoreceptor 14 to selectively discharge areas of the surface which correspond to blank areas in the original image. A developer material is then brought into contact with the surface of the photoreceptor 14 to transform the latent image into a visible reproduction.
While this invention has been described in conjunction with various embodiments, it is evident that many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations and their equivalents. | A flange assembly having modular mounting features for receiving and removably securing a component such as a gear thereon. The flange assembly is for use with an imaging member such as a photoreceptor drum. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority under 35 U.S.C. §119(e) from: earlier filed U.S. Provisional Application Ser. No. 61/556,826, filed Nov. 8, 2011; earlier filed U.S. Provisional Application Ser. No. 61/563,774, filed Nov. 26, 2011; and earlier filed U.S. Provisional Application Ser. No. 61/564,248, filed Nov. 28, 2011, the entirety of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to the field of video compression, particularly video compression using High Efficiency Video Coding (HEVC) that employ block processing.
[0004] 2. Related Art
[0005] FIG. 1 depicts a content distribution system 100 comprising a coding system 110 and a decoding system 140 that can be used to transmit and receive HEVC data. In some embodiments, the coding system 110 can comprise an input interface 130 , a controller 111 , a counter 112 , a frame memory 113 , an encoding unit 114 , a transmitter buffer 115 and an output interface 135 . The decoding system 140 can comprise a receiver buffer 150 , a decoding unit 151 , a frame memory 152 and a controller 153 . The coding system 110 and the decoding system 140 can be coupled with each other via a transmission path which can carry a compressed bitstream 105 . The controller 111 of the coding system 110 can control the amount of data to be transmitted on the basis of the capacity of the receiver buffer 150 and can include other parameters such as the amount of data per a unit of time. The controller 111 can control the encoding unit 114 to prevent the occurrence of a failure of a received signal decoding operation of the decoding system 140 . The controller 111 can be a processor or include, by way of a non-limiting example, a microcomputer having a processor, a random access memory and a read only memory.
[0006] Source pictures 120 supplied from, by way of a non-limiting example, a content provider can include a video sequence of frames including source pictures in a video sequence. The source pictures 120 can be uncompressed or compressed. If the source pictures 120 are uncompressed, the coding system 110 can have an encoding function. If the source pictures 120 are compressed, the coding system 110 can have a transcoding function. Coding units can be derived from the source pictures utilizing the controller 111 . The frame memory 113 can have a first area that can be used for storing the incoming frames from the source pictures 120 and a second area that can be used for reading out the frames and outputting them to the encoding unit 114 . The controller 111 can output an area switching control signal 123 to the frame memory 113 . The area switching control signal 123 can indicate whether the first area or the second area is to be utilized.
[0007] The controller 111 can output an encoding control signal 124 to the encoding unit 114 . The encoding control signal 124 can cause the encoding unit 114 to start an encoding operation, such as preparing the Coding Units based on a source picture. In response to the encoding control signal 124 from the controller 111 , the encoding unit 114 can begin to read out the prepared Coding Units to a high-efficiency encoding process, such as a prediction coding process or a transform coding process which process the prepared Coding Units generating video compression data based on the source pictures associated with the Coding Units.
[0008] The encoding unit 114 can package the generated video compression data in a packetized elementary stream (PES) including video packets. The encoding unit 114 can map the video packets into an encoded video signal 122 using control information and a program time stamp (PTS) and the encoded video signal 122 can be transmitted to the transmitter buffer 115 .
[0009] The encoded video signal 122 , including the generated video compression data, can be stored in the transmitter buffer 115 . The information amount counter 112 can be incremented to indicate the total amount of data in the transmitter buffer 115 . As data is retrieved and removed from the buffer, the counter 112 can be decremented to reflect the amount of data in the transmitter buffer 115 . The occupied area information signal 126 can be transmitted to the counter 112 to indicate whether data from the encoding unit 114 has been added or removed from the transmitted buffer 115 so the counter 112 can be incremented or decremented. The controller 111 can control the production of video packets produced by the encoding unit 114 on the basis of the occupied area information 126 which can be communicated in order to anticipate, avoid, prevent, and/or detect an overflow or underflow from taking place in the transmitter buffer 115 .
[0010] The information amount counter 112 can be reset in response to a preset signal 128 generated and output by the controller 111 . After the information counter 112 is reset, it can count data output by the encoding unit 114 and obtain the amount of video compression data and/or video packets which have been generated. The information amount counter 112 can supply the controller 111 with an information amount signal 129 representative of the obtained amount of information. The controller 111 can control the encoding unit 114 so that there is no overflow at the transmitter buffer 115 .
[0011] In some embodiments, the decoding system 140 can comprise an input interface 170 , a receiver buffer 150 , a controller 153 , a frame memory 152 , a decoding unit 151 and an output interface 175 . The receiver buffer 150 of the decoding system 140 can temporarily store the compressed bitstream 105 , including the received video compression data and video packets based on the source pictures from the source pictures 120 . The decoding system 140 can read the control information and presentation time stamp information associated with video packets in the received data and output a frame number signal 163 which can be applied to the controller 153 . The controller 153 can supervise the counted number of frames at a predetermined interval. By way of a non-limiting example, the controller 153 can supervise the counted number of frames each time the decoding unit 151 completes a decoding operation.
[0012] In some embodiments, when the frame number signal 163 indicates the receiver buffer 150 is at a predetermined capacity, the controller 153 can output a decoding start signal 164 to the decoding unit 151 . When the frame number signal 163 indicates the receiver buffer 150 is at less than a predetermined capacity, the controller 153 can wait for the occurrence of a situation in which the counted number of frames becomes equal to the predetermined amount. The controller 153 can output the decoding start signal 164 when the situation occurs. By way of a non-limiting example, the controller 153 can output the decoding start signal 164 when the frame number signal 163 indicates the receiver buffer 150 is at the predetermined capacity. The encoded video packets and video compression data can be decoded in a monotonic order (i.e., increasing or decreasing) based on presentation time stamps associated with the encoded video packets.
[0013] In response to the decoding start signal 164 , the decoding unit 151 can decode data amounting to one picture associated with a frame and compressed video data associated with the picture associated with video packets from the receiver buffer 150 . The decoding unit 151 can write a decoded video signal 162 into the frame memory 152 . The frame memory 152 can have a first area into which the decoded video signal is written, and a second area used for reading out decoded pictures 160 to the output interface 175 .
[0014] In various embodiments, the coding system 110 can be incorporated or otherwise associated with a transcoder or an encoding apparatus at a headend and the decoding system 140 can be incorporated or otherwise associated with a downstream device, such as a mobile device, a set top box or a transcoder.
[0015] The coding system 110 and decoding system 140 can be utilized separately or together to encode and decode video data according to various coding formats, including High Efficiency Video Coding (HEVC). HEVC is a block based hybrid spatial and temporal predictive coding scheme. In HEVC, input images, such as video frames, can be divided into square blocks called Largest Coding Units (LCUs) 200 , as shown in FIG. 2 . LCUs 200 can each be as large as 128×128 pixels, unlike other coding schemes that break input images into macroblocks of 16×16 pixels. As shown in FIG. 3 , each LCU 200 can be partitioned by splitting the LCU 200 into four Coding Units (CUs) 202 . CUs 202 can be square blocks each a quarter size of the LCU 200 . Each CU 202 can be further split into four smaller CUs 202 each a quarter size of the larger CU 202 . By way of a non-limiting example, the CU 202 in the upper right corner of the LCU 200 depicted in FIG. 3 can be divided into four smaller CUs 202 . In some embodiments, these smaller CUs 202 can be further split into even smaller sized quarters, and this process of splitting CUs 202 into smaller CUs 202 can be completed multiple times.
[0016] With higher and higher video data density, what is needed are further improved ways to code the CUs so that large input images and/or macroblocks can be rapidly, efficiently and accurately encoded and decoded.
SUMMARY
[0017] The present invention provides an improved system for HEVC. In embodiments for the system, a method of determining binary codewords for transform coefficients in an efficient manner is provided. Codewords for the transform coefficients within transform units (TUs) that are subdivisions of the CUs 202 are used in encoding input images and/or macroblocks.
[0018] In one embodiment, a method is provided that comprises providing a transform unit including one or more subsets of transform coefficients, each transform coefficient having a quantized value, determining a symbol for each transform coefficient having a quantized value equal to or greater than a threshold value by subtracting the threshold value from the quantized value of the transform coefficient, providing a parameter variable set to an initial value of zero, converting each symbol into a binary codeword based on the current value of the parameter variable and the value of the symbol, and updating the value of the parameter variable with a new current value after each symbol has been converted, the new current value being based at least in part on the last value of the parameter variable and the value of the last converted symbol in the current or previous subset.
[0019] In another embodiment, the invention includes a method of determining binary codewords for transform coefficients that uses a look up table to determine the transform coefficients. The method comprises providing a transform unit comprising one or more subsets of transform coefficients, each transform coefficient having a quantized value, determining a symbol for each transform coefficient having a quantized value equal to or greater than a threshold value, by subtracting the threshold value from the quantized value of the transform coefficient, providing a parameter variable set to an initial value of zero, converting each symbol into a binary codeword based on the current value of the parameter variable and the value of the symbol, looking up a new current value from a table based on the last value of the parameter variable and the value of the last converted symbol, and replacing the value of the parameter variable with the new current value.
[0020] In another embodiment, the invention includes a method of determining binary codewords for transform coefficients that uses one or more mathematical conditions that can be performed using logic rather than requiring a look up table. The method comprises providing a transform unit comprising one or more subsets of transform coefficients, each transform coefficient having a quantized value, determining a symbol for each transform coefficient having a quantized value equal to or greater than a threshold value, by subtracting the threshold value from the quantized value of the transform coefficient, providing a parameter variable set to an initial value of zero, converting each symbol into a binary codeword based on the current value of the parameter variable and the value of the symbol, determining whether the last value of the parameter variable and the value of the last converted symbol together satisfy one or more conditions, and mathematically adding an integer of one to the last value of the parameter variable for each of the one or more conditions that is satisfied.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Further details of the present invention are explained with the help of the attached drawings in which:
[0022] FIG. 1 depicts an embodiment of a content distribution system.
[0023] FIG. 2 depicts an embodiment of an input image divided into Large Coding Units.
[0024] FIG. 3 depicts an embodiment of a Large Coding Unit divided into Coding Units.
[0025] FIG. 4 depicts a quadtree representation of a Large Coding Unit divided into Coding Units.
[0026] FIG. 5 depicts possible exemplary arrangements of Prediction Units within a Coding Unit.
[0027] FIG. 6 depicts a block diagram of an embodiment of a method for encoding and/or decoding a Prediction Unit.
[0028] FIG. 7 depicts an exemplary embodiment of a Coding Unit divided into Prediction Units and Transform Units.
[0029] FIG. 8 depicts an exemplary embodiment of a quadtree representation of a Coding Unit divided into Transform Units.
[0030] FIG. 9 depicts an embodiment of a method of performing context-based adaptive binary arithmetic coding.
[0031] FIG. 10 depicts an exemplary embodiment of a significance map.
[0032] FIG. 11 depicts an embodiment of a reverse zig-zag scan of transform coefficients within a Transform Unit and subsets of transform coefficients.
[0033] FIG. 12 depicts an embodiment of a method of obtaining coefficient levels and symbols for transform coefficients.
[0034] FIG. 13 depicts an embodiment of the scanning order of transform coefficients within subsets.
[0035] FIG. 14 depicts exemplary embodiments of maximum symbol values for associated parameter variables.
[0036] FIG. 15 depicts an exemplary embodiment of a table for converting symbols into binary codewords based on parameter variables.
[0037] FIG. 16 depicts an embodiment of a method for coding symbols and updating parameter variables.
[0038] FIG. 17 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of 2, 4, 13, 11, and 10.
[0039] FIG. 18 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of 3, 6, and 12.
[0040] FIG. 19 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of 2, 5, and 11.
[0041] FIG. 20 depicts an exemplary embodiment of a combination logic representation of conditions for conditional symbol thresholds of 2, 4, 13, 11, and 10.
[0042] FIG. 21 depicts an exemplary embodiment of a combination logic representation of conditions for conditional symbol thresholds of 3, 6, and 12.
[0043] FIG. 22 depicts exemplary code that can be used to update the parameter variable based on conditional symbol thresholds of 2, 5, and 11.
[0044] FIG. 23 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of A, B, and C.
[0045] FIG. 24 depicts an exemplary embodiment of a combination logic representation of conditions for conditional symbol thresholds of A, B, and C.
[0046] FIG. 25 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of 2, 4, and 12.
[0047] FIG. 26 depicts an exemplary embodiment of a combination logic representation of conditions for conditional symbol thresholds of 2, 4, and 12.
[0048] FIG. 27 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of 2, 4, and 13.
[0049] FIG. 28 depicts an exemplary embodiment of a combination logic representation of conditions for conditional symbol thresholds of 2, 4, and 13.
[0050] FIG. 29 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of 2, 4, and 11.
[0051] FIG. 30 depicts an exemplary embodiment of a combination logic representation of conditions for conditional symbol thresholds of 2, 4, and 11.
[0052] FIG. 31 depicts an exemplary embodiment of a low complexity updating table with conditional symbol thresholds of 2, 4, and 10.
[0053] FIG. 32 depicts an exemplary embodiment of a combination logic representation of conditions for conditional symbol thresholds of 2, 4, and 10.
[0054] FIG. 33 depicts an exemplary embodiment of computer hardware.
DETAILED DESCRIPTION
[0055] In HEVC, an input image, such as a video frame, is broken up into CUs that are then identified in code. The CUs are then further broken into sub-units that are coded as will be described subsequently.
[0056] Initially for the coding a quadtree data representation can be used to describe the partition of a LCU 200 . The quadtree representation can have nodes corresponding to the LCU 200 and CUs 202 . At each node of the quadtree representation, a flag “1” can be assigned if the LCU 200 or CU 202 is split into four CUs 202 . If the node is not split into CUs 202 , a flag “0” can be assigned. By way of a non-limiting example, the quadtree representation shown in FIG. 4 can describe the LCU partition shown in FIG. 3 , in which the LCU 200 is split into four CUs 202 , and the second CU 202 is split into four smaller CUs 202 . The binary data representation of the quadtree can be a CU split flag that can be coded and transmitted as overhead, along with other data such as a skip mode flag, merge mode flag, and the PU coding mode described subsequently. By way of a non-limiting example, the CU split flag quadtree representation shown in FIG. 4 can be coded as the binary data representation “10100.”
[0057] At each leaf of the quadtree, the final CUs 202 can be broken up into one or more blocks called prediction units (PUs) 204 . PUs 204 can be square or rectangular. A CU 202 with dimensions of 2N×2N can have one of the four exemplary arrangements of PUs 204 shown in FIG. 5 , with PUs 204 having dimensions of 2N×2N, 2N×N, N×2N, or N×N.
[0058] A PU can be obtained through spatial or temporal prediction. Temporal prediction is related to inter mode pictures. Spatial prediction relates to intra mode pictures. The PUs 204 of each CU 202 can, thus, be coded in either intra mode or inter mode. Features of coding relating to intra mode and inter mode pictures is described in the paragraphs to follow.
[0059] Intra mode coding can use data from the current input image, without referring to other images, to code an I picture. In intra mode the PUs 204 can be spatially predictive coded. Each PU 204 of a CU 202 can have its own spatial prediction direction. Spatial prediction directions can be horizontal, vertical, 45-degree diagonal, 135 degree diagonal, DC, planar, or any other direction. The spatial prediction direction for the PU 204 can be coded as a syntax element. In some embodiments, brightness information (Luma) and color information (Chroma) for the PU 204 can be predicted separately. In some embodiments, the number of Luma intra prediction modes for 4×4, 8×8, 16×16, 32×32, and 64×64 blocks can be 18, 35, 35, 35, and 4 respectively. In alternate embodiments, the number of Luma intra prediction modes for blocks of any size can be 35. An additional mode can used for the Chroma intra prediction mode. In some embodiments, the Chroma prediction mode can be called “IntraFromLuma.”
[0060] Inter mode coding can use data from the current input image and one or more reference images to code “P” pictures and/or “B” pictures. In some situations and/or embodiments, inter mode coding can result in higher compression than intra mode coding. In inter mode PUs 204 can be temporally predictive coded, such that each PU 204 of the CU 202 can have one or more motion vectors and one or more associated reference images. Temporal prediction can be performed through a motion estimation operation that searches for a best match prediction for the PU 204 over the associated reference images. The best match prediction can be described by the motion vectors and associated reference images. P pictures use data from the current input image and one or more previous reference images. B pictures use data from the current input image and both previous and subsequent reference images, and can have up to two motion vectors. The motion vectors and reference pictures can be coded in the HEVC bitstream. In some embodiments, the motion vectors can be coded as syntax elements “MV,” and the reference pictures can be coded as syntax elements “refIdx.” In some embodiments, inter mode coding can allow both spatial and temporal predictive coding.
[0061] FIG. 6 depicts a block diagram of how a PU 204 , x, can be encoded and/or decoded. At 606 a predicted PU 206 , x′, that is predicted by intra mode at 602 or inter mode at 604 , as described above, can be subtracted from the current PU 204 , x, to obtain a residual PU 208 , e. At 608 the residual PU 208 , e, can be transformed with a block transform into one or more transform units (TUs) 210 , E. Each TU 210 can comprise one or more transform coefficients 212 . In some embodiments, the block transform can be square. In alternate embodiments, the block transform can be non-square.
[0062] As shown in FIG. 7 , in HEVC, a set of block transforms of different sizes can be performed on a CU 202 , such that some PUs 204 can be divided into smaller TUs 210 and other PUs 204 can have TUs 210 the same size as the PU 204 . Division of CUs 202 and PUs 204 into TUs 210 can be shown by a quadtree representation. By way of a non-limiting example, the quadtree representation shown in FIG. 8 depicts the arrangement of TUs 210 within the CU 202 shown in FIG. 7 .
[0063] Referring back to FIG. 6 , at 610 the transform coefficients 212 of the TU 210 , E, can be quantized into one of a finite number of possible values. In some embodiments, this is a lossy operation in which data lost by quantization may not be recoverable. After the transform coefficients 212 have been quantized, at 612 the quantized transform coefficients 212 can be entropy coded, as discussed below, to obtain the final compression bits 214 .
[0064] At 614 the quantized transform coefficients 212 can be dequantized into dequantized transform coefficients 216 E′. At 616 the dequantized transform coefficients 216 E′ can then be inverse transformed to reconstruct the residual PU 218 , e′. At 618 the reconstructed residual PU 218 , e′, can then be added to a corresponding prediction PU 206 , x′, obtained through either spatial prediction at 602 or temporal prediction at 604 , to obtain a reconstructed PU 220 , x″. At 620 a deblocking filter can be used on reconstructed PUs 220 , x″, to reduce blocking artifacts. At 620 a sample adaptive offset process is also provided that can be conditionally performed to compensate the pixel value offset between reconstructed pixels and original pixels. Further, at 620 , an adaptive loop filter can be conditionally used on the reconstructed PUs 220 , x″, to reduce or minimize coding distortion between input and output images.
[0065] If the reconstructed image is a reference image that will be used for future temporal prediction in inter mode coding, the reconstructed images can be stored in a reference buffer 622 . Intra mode coded images can be a possible point where decoding can begin without needing additional reconstructed images.
[0066] HEVC can use entropy coding schemes during step 612 such as context-based adaptive binary arithmetic coding (CABAC). The coding process for CABAC is shown in FIG. 9 . At 902 , the position of the last significant transform coefficient of the transform units 210 can be coded. Referring back to FIG. 6 , the quantized transform coefficients are created by quantizing the TUs 210 . Transform coefficients 212 can be significant or insignificant. FIG. 10 shows a significance map 1002 of the transform coefficients 212 . Insignificant transform coefficients 212 can have a quantized value of zero, while significant transform coefficients 212 can have a quantized value of one or more. In some embodiments, significant transform coefficients 212 can also be known as non-zero quantized transform coefficients 212 . If a TU 210 comprises one or more significant transform coefficients 212 , the coordinates of the last significant transform coefficient 212 along a forward zig-zag coding scan from the top left corner of the TU 210 to the lower right corner of the TU 210 , as shown in FIG. 10 , can be coded. In alternate embodiments, the significant transform coefficients 212 can be scanned along an inverse wavefront scan, inverse horizontal scan, inverse vertical scan, or any other scan order. In some embodiments, these coordinates can be coded as the syntax elements “last_significant_coeff_y” and “last_significant_coeff_x.” By way of a non-limiting example, FIG. 10 depicts the position of the last significant transform 212 b within a TU 210 which is being coded in block 902 of FIG. 9 .
[0067] At block 904 in FIG. 9 , the significance map 1002 can be coded to indicate the positions of each of the significant transform coefficients 212 in the TU 210 . A significance map 1002 can comprise a binary element for each position in the TU 210 . The binary element can be coded as “0” to indicate that the transform coefficient 212 at that position is not significant. The binary element can be coded as “1” to indicate that the transform coefficient 212 at that position is significant.
[0068] FIG. 11 illustrates how the quantized transform coefficients 212 of the TUs 210 can be divided into groups. In some embodiments, the groups can be sub-blocks. Sub-blocks can be square blocks of 16 quantized transform coefficients 212 . In other embodiments, the groups can be subsets 1102 . Subsets 1102 can comprise 16 quantized transform coefficients 212 that are consecutive along the scan order of a backwards zig-zag scan, as shown in FIG. 11 . The first subset can be the subset 1102 that includes the last significant transform coefficient 212 b , regardless of where the last significant transform coefficient 212 b is within the subset. By way of a non-limiting example, the last significant transform coefficient 212 b can be the 14th transform coefficient 212 in the subset, followed by two insignificant transform coefficients.
[0069] In some situations and/or embodiments, there can be one or more groups of 16 quantized transform coefficients 212 that do not contain a significant transform coefficient along the reverse scan order prior to the group containing the last significant transform coefficient 212 b . In these situations and/or embodiments, the first subset can be the subset 1102 containing the last significant transform coefficient 212 b , and any groups before the first subset 1102 are not considered part of a subset 1102 . By way of a non-limiting example, in FIG. 11 , the first subset 1102 “Subset 0” is the second grouping of 16 transform coefficients 212 along the reverse zig-zap scan order, while the group of 16 transform coefficients 212 at the lower right corner of the TU 210 are not part of a subset 1102 because none of those transform coefficients 212 are significant. In some embodiments, the first subset 1102 can be denoted as “subset 0,” and additional subsets 1102 can be denoted as “subset 1,” “subset 2,” up to “subset N.” The last subset 1102 can be the subset 1102 with the DC transform coefficient 212 at position 0, 0 at the upper left corner of the TU 210 .
[0070] Referring back to FIG. 9 in the last block 906 , each quantized transform coefficient 212 can be coded into binary values to obtain final compression bits 214 shown in FIG. 6 , including coding for significant coefficient levels. During coding the absolute value of each quantized transform coefficient 212 can be coded separately from the sign of the quantized transform coefficient 212 . FIG. 12 illustrates coding steps that deal with taking an absolute value of the quantized transform coefficients. As shown in FIG. 12 , at 1202 the absolute value of each quantized transform coefficient 212 can be taken to enable obtaining the coefficient level 222 for that quantized transform coefficient 212 at block 1204 .
[0071] The coefficient levels 222 obtained at block 1204 that are expected to occur with a higher frequency can be coded before coefficient levels 222 that are expected to occur with lower frequencies. By way of a non-limiting example, in some embodiments coefficient levels 222 of 0, 1, or 2 can be expected to occur most frequently. Coding the coefficient levels 222 in three parts can identify the most frequently occurring coefficient levels 222 , leaving more complex calculations for the coefficient levels 222 that can be expected to occur less frequently. In some embodiments, this can be done by coding the coefficient levels 222 in three parts. First, the coefficient level 222 of a quantized transform coefficient 212 can be checked to determine whether it is greater than one. If the coefficient level 222 is greater than one, the coefficient level 222 can be checked to determine whether it is greater than two.
[0072] At 1206 in FIG. 12 , if the coefficient level 222 is greater than two, the coefficient level 222 can be subtracted by a threshold value 224 of three to obtain a symbol. By way of a non-limiting example, in some embodiments, the coefficient level 222 can be coded as three variables: “coeff_abs_level_greater1_flag,” “coeff_abs_level_greater2_flag,” and “coeff_abs_level_minus3.” For quantized transform coefficients 212 with a coefficient level 222 of two or more, “coeff_abs_level_greater1_flag” can be set to “1.” If “coeff_abs_level_greater1_flag” is set to “1” and the quantized transform coefficient 212 also has a coefficient level 222 of three or more, “coeff_abs_level_greater2_flag” can be set to “1.” If “coeff_abs_level_greater2_flag” is set to “1,” the threshold value 224 of three can be subtracted from the coefficient level 222 to get the quantized transform coefficient's symbol 226 , coded as “coeff_abs_level_minus3.” In alternate embodiments, the coefficient level 222 can be coded in a different number of parts, and/or the threshold value 224 can be an integer other than three.
[0073] For the quantized transform coefficients 212 that occur less frequently and have coefficient levels 222 of three or more as determined in the blocks of FIG. 12 , as determined in the blocks of FIG. 12 , the quantized transform coefficient's symbol 226 can be converted to a binary codeword 228 that can be part of the final compression bits 214 generated as shown in FIG. 6 .
[0074] FIG. 13 illustrates how each symbol 226 can be coded by scanning through each subset 1102 and converting each symbol 226 of the subset 1102 in order according to the value of the parameter variable 230 , and then moving to the symbols 226 of the next subset 1102 . The conversion to a binary codeword 228 can be performed with Truncated Rice code alone, or with a combination of Truncated Rice code and 0th order exponential-Golomb (Exp-Golomb) code. The Truncated Rice code can obtain a binary codeword 228 based a parameter variable 230 and the symbol 226 . A diagram showing this coding progression is shown in FIG. 13 for the subsets 0 and 1 along the zig-zag lines of FIG. 11 . In some embodiments, the current scanning position can be denoted by “n.”
[0075] Referring to FIG. 15 , the parameter variable 230 can be a global variable that can be updated as each symbol 226 is coded. The parameter variable 230 can control the flatness of the codeword distribution. In some embodiments, the parameter variable 230 can be any integer between 0 and N. By way of a non-limiting example, in some embodiments N can be 3, such that the parameter variable 230 can be 0, 1, 2, or 3. In some embodiments, the parameter variable 230 can be denoted as “cRiceParam” as illustrated in FIG. 15 as well as FIG. 14 .
[0076] Referring still to FIG. 14 , each parameter variable 230 can have an associated maximum symbol value 232 that denotes the truncation point for the Truncated Rice code. In some embodiments, the maximum symbol value 232 for a particular parameter variable 230 can be denoted as “cTRMax” 232 as illustrated in FIG. 14 which depicts an exemplary table of maximum symbol values 232 “cTRMax” for parameter variables 230 “cRiceParam.” The table of FIG. 14 is labeled as Table 1, as it provides a first listing cRiceParam values 230 relative to maximum value symbols cTRMax 232 . If the symbol 226 of FIG. 15 is less than or equal to the maximum symbol value 232 for the parameter variable 230 , the symbol 226 can be converted into a binary codeword 228 using only Truncated Rice code. If the symbol 226 is greater than the maximum symbol value 232 for the parameter variable 230 , the binary codeword 228 can be generated using a combination of the Truncated Rice code and Exp-Golomb code, with the Truncated Rice codeword for the maximum symbol value 232 being concatenated with the 0th order Exp-Golomb code for the symbol 226 minus the maximum symbol value 232 minus one. By way of a non-limiting example, FIG. 15 depicts an exemplary table of binary codewords 228 generated based on symbols 226 and parameter variables 230 . Since FIG. 15 provides a second table listing cRiceParam parameter variables 230 relative to other values, it is labeled as Table 2.
[0077] In some situations and/or embodiments, converting the symbol 226 according to Truncated Rice code with a lower parameter variable 230 can result in a binary codeword 228 having fewer bits than converting the same symbol 226 according to Truncated Rice code with a higher parameter variable 230 . By way of a non-limiting example, as shown by the table depicted in FIG. 15 , using a parameter variable 230 of 0 to convert a symbol 226 of 0 can result in the binary codeword 228 of “0” having 1 bit, while using the parameter variable 230 of 1 to convert the symbol 226 of 0 can result in the binary codeword 228 of “00” having 2 bits.
[0078] In other situations and/or embodiments, converting the symbol 226 according to Truncated Rice code with a higher parameter variable 230 can result in a binary codeword 228 having fewer bits than converting the same symbol 226 according to Truncated Rice code with a lower parameter variable 230 . By way of a non-limiting example, as shown in the table depicted in FIG. 14 , using a parameter variable 230 of 0 to convert a symbol 226 of 6 can result in the binary codeword 228 of “1111110” having 7 bits, while using the parameter variable 230 of 2 to convert the symbol 226 of 6 can result in the binary codeword 228 of “1010” having 4 bits.
[0079] FIG. 16 is a flow chart depicting a method for entropy coding the symbols 226 . At 1602 , for each TU 210 , the parameter variable 230 can be initially set to a value of zero. At 1604 the coding system 110 can move to the next symbol 226 . In some situations and/or embodiments, the next symbol 226 can be the first symbol 226 in the first subset 1102 as illustrated in FIG. 11 . At 1606 , the symbol 226 can be coded with Truncated Rice and/or Exp-Golomb code using the current value of the parameter variable 230 . At 1608 , the parameter variable 230 can be updated based on the last value of the parameter variable 230 and the value of the last symbol 226 that was coded. In some situations and/or embodiments, the updated value of the parameter variable 230 can be the same as the last value of the parameter variable 230 . In other situations and/or embodiments, the updated value of the parameter variable 230 can be greater than the last value of the parameter variable 230 . The parameter variable 230 can be updated based upon calculations or upon values derived from a table as described herein subsequently.
[0080] After the parameter variable 230 has been updated at 1608 , the coding system 110 can return to 1604 and move to the next symbol 226 . The next symbol 226 can be in the current subset 1102 or in the next subset 1102 . The next symbol 226 can then be coded at 1606 using the updated value of the parameter variable 230 and the process can repeat for all remaining symbols 226 in the TU 210 . In some embodiments, when symbols 226 in a subsequent subset 1102 are coded, the parameter variable 230 can be updated based on the last value of the parameter variable 230 from the previous subset 1102 , such that the parameter variable 230 is not reset to zero at the first symbol 226 of each subset 1102 . In alternate embodiments, the parameter variable 230 can be set to zero at the first symbol 226 of each subset 1102 .
[0081] Generally referring to FIG. 15 , Truncated Rice code with a smaller cRiceParam parameter value 230 can be preferred to code the symbols with smaller codewords, as they need fewer bits to represent. For example, if a symbol 226 has a value of 0, using Truncated Rice code with a cRiceParam parameter value 230 equal to 0, only 1 bit is needed, but 2, 3, or 4 bits are needed when the cRiceParam value is 2, 3, or 4, respectively. If a symbol has a value of 6, using Truncated Rice code with a cRiceParam value equal to 0, 7 bits are needed. But 5, 4, or 4 bits are needed when the cRiceParam value is 2, 3, or 4, respectively.
[0082] In one embodiment illustrated with the table of FIG. 17 , the cRiceParam 230 labeled with a variable coeff_level_minus3[n] is derived and updated based on a table as follows. For a TU subset, the cRiceParam 230 is initially set to 0, and is then updated based on the previous cRiceParam and the coeff_abs_level_minus3[n−1] according to the table of FIG. 17 . Because FIG. 17 shows a third table listing symbol values 226 relative to cRiceParam parameter values 230 , the table is labeled as Table 3. Subsequent tables showing a similar comparison will, likewise, be labeled consecutively.
[0083] Note that in conventional implementations, cRiceParam 230 is reset once per subset with initial “0” values. For a TU with more than one subset of 16 consecutive symbol coefficients 226 , the cRiceParam calculation for coeff_abs_level_minus3 can be reset to 0 for each subset, which favors smaller symbol value coding. Generally, inside each TU, starting from the last non-zero quantized transform coefficient, the absolute values of the non-zero quantized transform coefficients tend to get larger and larger. Therefore, resetting cRiceParam to 0 for each subset might not give optimal compression performance.
[0084] In FIG. 13 , each circle stands for a quantized transform coefficient and the number inside each circle is the value of coeff_abs_level_minus3. If it is “NA”, it means there is no syntax of coeff_abs_level_minus3 for that coefficient. Following the reverse scanning pattern, the values of coeff_abs_level_minus3 tend to get larger within each subset and also from subset to subset, as shown in the example of FIG. 13 . In the example, cRiceParam is set to 2 for “5” in subset 0, and with cRiceParam set to 2, the value of “5” is binarized into a codeword of “1001”, or 4 bits, as shown in Table 2 of FIG. 15 . In conventional implementations, cRiceParam is then reset to 0 in subset 1. Now, with the reset cRiceParam of 0, the same value of “5” in subset 1 is now binarized into a codeword of 111110, or 6 bits, as shown in Table 2. Clearly, this resetting process not only introduces additional checking operations, but also can possibly result in inferior coding performance.
[0085] Tables 4 and 5 as illustrated in respective FIGS. 18 and 19 depict alternate embodiments on an update table. For these and other embodiments, the cRiceParam parameters 230 are derived as follows. First, for a TU, cRiceParam is initially set to 0, and is then updated based on the previous cRiceParam and coeff_abs_level_minus3[n−1] according to a cRiceParam update table, such as Tables 4 and 5. In these embodiments, cRiceParam is only reset once per TU, and not per subset of a TU as indicated with respect to the embodiment using Table 3.
[0086] By not resetting the cRiceParam to 0 at each subset, the operations of resetting for each subset are saved and once the cRiceParam reaches 3, the symbols will always be binarized with the same set truncated rice codes (cRiceParam equals 3), which can reduce hardware complexity.
[0087] Note that Table 5 of FIG. 19 is generated from Table 2 of FIG. 15 by analyzing the number of bits needed for each symbol 226 with a different cRiceParam value 230 while assuming the next level value is statistically no smaller than the current level along a reverse scan. For example, if the current symbol 226 is 2 and the cRiceParam is 0, the chance that the next symbol is larger than 2 is high and applying Truncated Rice code with cRiceParam equal to 1 might reduce the number of bits. If the current symbol is 5 and cRiceParam is 1, the chance that the next symbol is larger than 5 is high and applying Truncated Rice code with cRiceParam equal to 2 might reduce the number of bits. If the current symbol is 11 and the cRiceParam is 2, the chance that the next symbol is larger than 11 is high and applying Truncated Rice code with cRiceParam equal to 3 might reduce the number of bits.
[0088] In some embodiments, updating the parameter variable 230 at 1608 , referring back to FIG. 16 , can be determined from a comparison equation rather than a table. In the comparison, it is determined whether both the last value of the parameter variable 230 and the value of the last coded symbol 226 meet one or more conditions 1702 , as illustrated in FIG. 20 . In some embodiments, the value of the last coded symbol 226 can be denoted as “coeff_abs_level_minus3[n−1]” as it was in Tables 3-5. The parameter variable 230 can be updated depending on which conditions 1702 are met, and the value of the current symbol 226 can then be coded based on the updated parameter variable 230 using Truncated Rice code and/or Exp-Golomb Code.
[0089] In some embodiments, each condition 1702 can comprise two parts, a conditional symbol threshold and a conditional parameter threshold. In these embodiments, the condition 1702 can be met if the value of the symbol 226 is equal to greater than the conditional symbol threshold and the parameter variable 230 is equal to or greater than the conditional parameter threshold. In alternate embodiments, each condition 1702 can have any number of parts or have any type of condition for either or both the symbol 226 and parameter variable 230 .
[0090] Since updating tables can need extra memory to store and fetch the data and the memory can require a lot of processor cycles, it can be preferable to use combination logics to perform the comparison in place of an updating table as the logic can use very few processor cycles. An example of the combination logic that determines the cRiceParam for updating in the place of Table 3 is shown in FIG. 20 . An example of combination logic for representing Table 4 is shown in FIG. 21 . An example of combination logic for representing Table 5 is shown in FIG. 22 .
[0091] In some embodiments, the possible outcomes of the conditions 1702 based on possible values of the parameter variable 230 and the last coded symbols 226 can be stored in memory as a low complexity update table 1704 as illustrated in the table of FIG. 17 as well as other subsequent figures. In these embodiments, the parameter variable 230 can be updated by performing a table lookup from the low complexity update table 1704 based on the last value of the parameter variable 230 and the value of the last coded symbol 226 .
[0092] In further embodiments, a low complexity level parameter updating table in CABAC can be provided that in some embodiments can operate more efficiently than previous tables and not require the logic illustrated in FIGS. 20-22 . For these low complexity level parameter updating tables, the following applies: (1) Inputs: Previous cRiceParam and coeff_abs_level_minus3[n−1]. (2) Outputs: cRiceParam. (3) Previous cRiceParam and cRiceParam could have a value of 0, 1, 2 or 3.
[0093] Further in this low complexity level parameter updating tables, the following further applies: (1) The parameter variable 230 can: remain the same when the value of the last coded symbol 226 is between 0 and A−1; (2) The parameter variable 230 can be set to one or remain at the last value of the parameter variable 230 , whichever is greater, when the symbol 226 is between A and B−1; (3) The parameter variable 230 can be set to two or remain at the last value of the parameter variable 230 , whichever is greater, when the symbol 226 is between B and C−1; or (4) The parameter variable 230 can be set to three when the symbol 226 is greater than C−1. The low complexity update table 1704 , labeled Table 6, for these conditions 1702 is depicted in FIG. 23 . The combination logic representation for Table 6 is depicted in FIG. 24 . The values of A, B, and C can be set to any desired values. In this exemplary embodiment, A, B, or C can be the conditional symbol threshold respectively, and the value of 0, 1, or 2 can be the parameter symbol threshold respectively.
[0094] A selection of non-limiting examples of update tables 1704 and their associated combination logic representations 1706 with particular values of A, B, and C, are depicted in FIGS. 19-31 . FIGS. 19 and 20 respectively depict an update table 1704 and combination logic representation for conditional symbol thresholds of 3, 6, and 13. FIGS. 29 and 30 respectively depict an update table 9 and combination logic representation for conditional symbol thresholds of 2, 4, and 11. FIGS. 31 and 32 respectively depict an update table 10 and combination logic representation for conditional symbol thresholds of 2, 4, and 10.
[0095] The execution of the sequences of instructions required to practice the embodiments may be performed by a computer system 3300 as shown in FIG. 20 . In an embodiment, execution of the sequences of instructions is performed by a single computer system 3300 . According to other embodiments, two or more computer systems 3300 coupled by a communication link 3315 may perform the sequence of instructions in coordination with one another. Although a description of only one computer system 3300 may be presented herein, it should be understood that any number of computer systems 3300 may be employed.
[0096] A computer system 3300 according to an embodiment will now be described with reference to FIG. 20 , which is a block diagram of the functional components of a computer system 3300 . As used herein, the term computer system 3300 is broadly used to describe any computing device that can store and independently run one or more programs.
[0097] The computer system 3300 may include a communication interface 3314 coupled to the bus 3306 . The communication interface 3314 provides two-way communication between computer systems 3300 . The communication interface 3314 of a respective computer system 3300 transmits and receives electrical, electromagnetic or optical signals that include data streams representing various types of signal information, e.g., instructions, messages and data. A communication link 3315 links one computer system 3300 with another computer system 3300 . For example, the communication link 3315 may be a LAN, an integrated services digital network (ISDN) card, a modem, or the Internet.
[0098] A computer system 3300 may transmit and receive messages, data, and instructions, including programs, i.e., application, code, through its respective communication link 3315 and communication interface 3314 . Received program code may be executed by the respective processor(s) 3307 as it is received, and/or stored in the storage device 3310 , or other associated non-volatile media, for later execution.
[0099] In an embodiment, the computer system 3300 operates in conjunction with a data storage system 3331 , e.g., a data storage system 3331 that contains a database 3332 that is readily accessible by the computer system 3300 . The computer system 3300 communicates with the data storage system 3331 through a data interface 3333 .
[0100] Computer system 3300 can include a bus 3306 or other communication mechanism for communicating the instructions, messages and data, collectively, information, and one or more processors 3307 coupled with the bus 3306 for processing information. Computer system 3300 also includes a main memory 3308 , such as a random access memory (RAM) or other dynamic storage device, coupled to the bus 3306 for storing dynamic data and instructions to be executed by the processor(s) 3307 . The computer system 3300 may further include a read only memory (ROM) 3309 or other static storage device coupled to the bus 3306 for storing static data and instructions for the processor(s) 3307 . A storage device 3310 , such as a magnetic disk or optical disk, may also be provided and coupled to the bus 3306 for storing data and instructions for the processor(s) 3307 .
[0101] A computer system 3300 may be coupled via the bus 3306 to a display device 3311 , such as an LCD screen. An input device 3312 , e.g., alphanumeric and other keys, is coupled to the bus 3306 for communicating information and command selections to the processor(s) 3307 .
[0102] According to one embodiment, an individual computer system 3300 performs specific operations by their respective processor(s) 3307 executing one or more sequences of one or more instructions contained in the main memory 3308 . Such instructions may be read into the main memory 3308 from another computer-usable medium, such as the ROM 3309 or the storage device 3310 . Execution of the sequences of instructions contained in the main memory 3308 causes the processor(s) 3307 to perform the processes described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions. Thus, embodiments are not limited to any specific combination of hardware circuitry and/or software.
[0103] Although the present invention has been described above with particularity, this was merely to teach one of ordinary skill in the art how to make and use the invention. Many additional modifications will fall within the scope of the invention, as that scope is defined by the following claims. | A system is provided for creating level parameter updating codewords for transform coefficients used for relating transform units (TUs) that divide up coding units (CUs) in a High Efficiency Video Coding (HEVC) system. The system provides binarization of the codewords and removes unnecessary operations to reduce system complexity and increase compression performance. The system generates transform coefficients that relate the TUs and begins by providing a parameter variable (cRiceParam) set to an initial value of zero. The parameter variable is then converted into a binary codeword based on the current value of the parameter variable and the value of a symbol and then updated with a new current value after each symbol has been converted. Updating can be provided with reference to table values or the values can be provided from combination logic. | 7 |
[0001] This application claims priority to Chinese Patent Application No. 201310258233.7 filed Jun. 26, 2013, which is incorporated by reference herein.
TECHNICAL FIELD
[0002] The invention relates to metal material field, in particular, a low-cost high-plasticity wrought magnesium alloy with both good strength and toughness and its preparation method.
BACKGROUND ART
[0003] Magnesium alloy has the merits of low density, high specific strength, and excellent electromagnetic shielding performance as well as good damping property and the like, and it has abundant magnesium resources in China. Nowadays, energy source becomes less and less, and people have an urgent desire to use magnesium alloy having a lower density in a large scale instead of structural materials having a higher density, so as to achieve energy saving and exhaust reduction. Hence, magnesium alloy has become the focus of research owing to the pursuit of light weight. However, there are not many types of existing developed commercial magnesium alloy. The solid solubility of tin in magnesium at the eutectic temperature of 561° C. is 14.48%, and it is obtained that the solid solubility at room temperature is only less than 1.00%, providing a wide variation range of solid solubility. It is possible to utilize the variation of solid solubility along with temperature to generate a precipitate which led to good dispersion strengthening contributions, so magnesium-tin systems have gained attention of many researchers in recent years.
[0004] WANG Huiyuan, et al. discloses a magnesium-tin-aluminum-strontium-manganese multi-component wrought magnesium alloy in a Chinese patent (publication No.: CN101985714a) entitled “a high-plasticity magnesium ally and its preparation method”, In this patent, a high-plasticity magnesium-tin-aluminum-manganese-strontium wrought magnesium alloy is prepared by the process of cast rolling or conventional casting followed by deformation, and comprises 0.10% to 3.00% by mass of tin, 0.10% to 6.00% by mass of aluminum, 0.01% to 2.00% by mass of manganese and 0.001% to 2.00% by mass strontium. With respect to the above alloy, the added amount of tin is relatively large, and the price of tin is higher than conventional alloying elements such as aluminum, leading to increase in cost of the alloy. In this project, the addition of strontium has no evident influence on the property of the alloy, but would increase the cost. In addition, strontium element is highly active and very combustible in air, thus addition of strontium to the magnesium alloy easily causes burning loss of the alloy during melting, going against control on the components.
DESCRIPTION OF THE INVENTION
[0005] The invention provides a wrought magnesium alloy and its preparation method, for the purpose of decreasing alloy cost and preventing burning loss during melting while ensuring high plasticity thereof.
[0006] The raw materials of the low-cost wrought magnesium alloy involved in the present invention comprise between 0.10% and 1.00% by mass of tin, between 0.10% and 3.00% by mass of aluminum, between 0.10% and 1.00% by mass of manganese, and commercially pure magnesium and inevitable impurities in balance, wherein the commercially pure magnesium, aluminum and tin all have a purity of 99.00% or more; and manganese is added in the form of 4% magnesium-manganese intermediate alloy.
[0007] Preferably, the aluminum is in an amount of 1.00% by mass, the tin is in an amount of 1.00% by mass, and the manganese is in an amount of 0.30% by mass.
[0008] The magnesium alloy is prepared by the steps of:
[0009] (1) smelting ingots: weighing out the raw materials according to the components, smelting pure magnesium and pure aluminum at a temperature between 720° C. and 740° C. under protection of a protective gas, increasing the temperature to 740° C. after all components are molten, adding tin that has been preheated to 150° C. and magnesium-manganese intermediate alloy that has been preheated to 300° C. to 400° C. after the temperature is stable, adding a refining agent and fully stirring for 3 min to 6 min, standing at 720° C. for 10 min to 20 min, removing the dross on the surface of the melting metal liquid, and casting at a temperature of 660° C. to iron mold preheated at 250-350° C.;
[0010] (2) homogenizing: covering the magnesium ingots obtained from the step (1) with graphite, homogenizing at 410° C. to 500° C. for 24 h, and subsequently water quenching to obtain homogenized samples;
[0011] (3) extruding: preheating the magnesium ingots homogenized in the step (2) at 250° C. to 350° C. for 2 h after turning of outer cylinder of the as-homogenized ingots, coating a magnesium alloy lubricant thereon, and extruding at 250° C. to 350° C. with an extrusion ratio of 20:1 to 80:1 at an extrusion speed of 0.50 to 3.00 m/min to obtain profiles; or preheating the magnesium ingots from the step (1) at 250° C. to 350° C. for 2 h after turning the outer cylinder, coating a magnesium alloy lubricant, and extruding at 250° C. to 350° C. (preferably controlled at 300° C.) with an extrusion ratio of 20:1 to 80:1 at an extrusion speed of 0.50 to 3.00 m/min.
[0012] The invention optimizes the alloy components based on the magnesium-tin-aluminum-manganese-strontium multi-component wrought magnesium alloy, and reduces the content of the alloying element tin that is more expensive without reducing the strength and plasticity of the alloy, so as to decrease the cost. The addition amount of tin is not more than 1.00% in the present invention, because the inventors found, by a great deal of investigation and magnesium-tin-aluminum ternary phase diagrams, the solid solubility of tin in magnesium at about 250° C. is almost zero, and when tin is added in an amount of less than 1.00%, a large quantity of small and dispersed Mg 2 Sn could be precipitated through extrusion at 250° C. as a second phase which could improve the strength of the alloy. Since the second phase of Mg 2 Sn generated by precipitation of tin and magnesium is precipitated from the wrought magnesium alloy in parallel to the base plane, so addition of excessive tin does not make much contribution to the strength. Moreover, it was found in combination with a great deal of experiments that when the addition amount of tin is more than 1.00%, the yield strength does not change evidently with the increase in the content of tin (e.g. example 6). In addition, for cast magnesium alloy, the strontium added has good effect on purifying melt and refining grains. However, strontium does not play an important role in refining the grains in wrought magnesium alloy, and the wrought magnesium alloy is mainly an alloy with fine grains obtained by the processing means such as extruding and rolling. On the other hand, since the content of tin in the system is not very high, and the Mg 2 Sn precipitated after deformation exhibits a small and dispersed morphology, addition of strontium as an alloying element would not have a large effect on improving the morphology of the precipitated phase. Therefore, addition of strontium in wrought magnesium alloy has no remarkable influence on the properties of the alloy, but increases the cost. Furthermore, it was found by comparison (example 7) that strontium-containing alloy tends to combust during smelting, thereby inducing deterioration of melt quality and finally causing decrease in the elongation. Consequently, the present invention achieves refinement of grains by extrusion at a relatively low temperature (such as 250-300° C., particularly 300° C.) and prepares a low-cost high-plasticity magnesium-tin-aluminum-manganese wrought magnesium alloy, without using strontium element that easily leads to burning loss of melt under the premise of not influencing the properties of the alloy.
PREFERRED EMBODIMENT OF THE INVENTION
EXAMPLES
Example 1
[0013] (1) The following components were weighed out according to weight percentage: tin 1.00%; aluminum 1.00%; manganese 0.30%; and magnesium in balance.
[0014] (2) Pure magnesium and pure aluminum were smelted at a temperature between 720° C. and 740° C. under protection of a protective gas, the temperature was increased to 740° C. after all components were molten, after the temperature was stable, tin that had been preheated to 150° C. and magnesium-manganese intermediate alloy that had been preheated to 300° C. were added. Subsequently, hexachloroethane was added as a refining agent, and the mixture was fully stirred for 3 min to 6 min. The resultant melt was allowed to stand at 720° C. for 20 min, the dross on the surface was removed, and the melt at a temperature of 660° C. was casted to an iron mold that had been preheated to 350° C. to obtain ingots.
[0015] (3) The magnesium ingots obtained were covered with graphite, homogenized at 420° C. for 24 h, and then water quenched to obtain homogenized samples.
[0016] (4) The magnesium ingots homogenized were preheated at 250° C. for 2 h after skin layer removing, coated with a magnesium alloy lubricant, and extruded at 250° C. with an extrusion ratio of 25:1 at an extrusion speed of 0.90 to 1.20 m/min to obtain rods. The obtained alloy has a tensile strength of 289 MPa, a yield strength of 255 MPa and an elongation of 21.0%.
Example 2
[0017] (1) The following components were weighed out according to weight percentage: tin 1.00%; aluminum 1.00%; manganese 0.30%; and magnesium in balance.
[0018] (2) Pure magnesium and pure aluminum were smelted at a temperature between 720° C. and 740° C. under protection of a protective gas, the temperature was increased to 740° C. after all components were molten, after the temperature was stable, tin that had been preheated to 150° C. and magnesium-manganese intermediate alloy that had been preheated to 400° C. were added. Subsequently, hexachloroethane was added as a refining agent, and the mixture was fully stirred for 3 min to 6 min. The resultant melt was allowed to stand at 720° C. for 10 min, the dross on the surface was removed, and the melt at a temperature of 660° C. was casted to an iron mold that had been preheated to 250° C. to obtain ingots.
[0019] (3) The magnesium ingots obtained were covered with graphite, homogenized at 420° C. for 24 h, and then water quenched to obtain homogenized samples.
[0020] (4) The magnesium ingots homogenized were preheated at 300° C. for 2 h after skin layer removing, coated with a magnesium alloy lubricant, and extruded at 300° C. with an extrusion ratio of 25:1 at an extrusion speed of 0.90 to 1.20 m/min to obtain rods. The obtained alloy has a tensile strength of 293 MPa, a yield strength of 260 MPa and an elongation of 21.0%.
Example 3
[0021] (1) The following components were weighed out according to weight percentage: tin 1.00%; aluminum 1.00%; manganese 0.30%; and magnesium in balance.
[0022] (2) Pure magnesium and pure aluminum were smelted at a temperature between 720° C. and 740° C. under protection of a protective gas, the temperature was increased to 740° C. after all components were molten, after the temperature was stable, tin that had been preheated to 150° C. and magnesium-manganese intermediate alloy that had been preheated to 350° C. were added. Subsequently, hexachloroethane was added as a refining agent, and the mixture was fully stirred for 3 min to 6 min. The resultant melt was allowed to stand at 720° C. for 15 min, the dross on the surface was removed, and the melt at a temperature of 660° C. was casted to an iron mold that had been preheated to 300° C. to obtain ingots.
[0023] (3) The cast magnesium ingots were preheated at 300° C. for 2 h after skin layer removing, coated with a magnesium alloy lubricant, and extruded at 300° C. with an extrusion ratio of 25:1 at an extrusion speed of 0.90 to 1.20 m/min to obtain rods. The obtained alloy has a tensile strength of 290 MPa, a yield strength of 262 MPa and an elongation of 20.0%.
Example 4
[0024] (1) The following components were weighed out according to weight percentage: tin 0.75%; aluminum 1.00%; manganese 0.30%; and magnesium in balance.
[0025] (2) Pure magnesium and pure aluminum were smelted at a temperature between 720° C. and 740° C. under protection of a protective gas, the temperature was increased to 740° C. after all components were molten, after the temperature was stable, tin that had been preheated to 150° C. and magnesium-manganese intermediate alloy that had been preheated to 350° C. were added. Subsequently, hexachloroethane was added as a refining agent, and the mixture was fully stirred for 3 min to 6 min. The resultant melt was allowed to stand at 720° C. for 18 min, the dross on the surface was removed, and the melt at a temperature of 660° C. was casted to an iron mold that had been preheated to 300° C. to obtain ingots.
[0026] (3) The magnesium ingots obtained were covered with graphite, homogenized at 420° C. for 24 h, and then water quenched to obtain homogenized samples.
[0027] (4) The magnesium ingots homogenized were preheated at 300° C. for 2 h after skin layer removing, coated with a magnesium alloy lubricant, and extruded at 300° C. with an extrusion ratio of 25:1 at an extrusion speed of 0.90 to 1.20 m/min to obtain rods. The obtained alloy has a tensile strength of 283 MPa, a yield strength of 230 MPa and an elongation of 20.0%.
Example 5
[0028] (1) The following components were weighed out according to weight percentage: tin 1.00%; aluminum 2.00%; manganese 0.30%; and magnesium in balance.
[0029] (2) Pure magnesium and pure aluminum were smelted at a temperature between 720° C. and 740° C. under protection of a protective gas, the temperature was increased to 740° C. after all components were molten, after the temperature was stable, tin that had been preheated to 150° C. and magnesium-manganese intermediate alloy that had been preheated to 350° C. were added. Subsequently, hexachloroethane was added as a refining agent, and the mixture was fully stirred for 3 min to 6 min. The resultant melt was allowed to stand at 720° C. for 20 min, the dross on the surface was removed, and the melt at a temperature of 660° C. was casted to an iron mold that had been preheated to 300° C. to obtain ingots.
[0030] (3) The magnesium ingots obtained were covered with graphite, homogenized at 420° C. for 24 h, and then water quenched to obtain homogenized samples.
[0031] (4) The magnesium ingots homogenized were preheated at 300° C. for 2 h after skin layer removing, coated with a magnesium alloy lubricant, and extruded at 300° C. with an extrusion ratio of 25:1 at an extrusion speed of 0.90 to 1.20 m/min to obtain rods. The obtained alloy has a tensile strength of 280 MPa, a yield strength of 210 MPa and an elongation of 21.6%.
Comparative Example 6
[0032] (1) The following components were weighed out according to weight percentage: tin 3.00%; aluminum 1.00%; manganese 0.30%; and magnesium in balance.
[0033] (2) Pure magnesium and pure aluminum were smelted at a temperature between 720° C. and 740° C. under protection of a protective gas, the temperature was increased to 740° C. after all components were molten, after the temperature was stable, tin that had been preheated to 150° C. and magnesium-manganese intermediate alloy that had been preheated to 300° C. to 400° C. were added. Subsequently, hexachloroethane was added as a refining agent, and the mixture was fully stirred for 3 min to 6 min. The resultant melt was allowed to stand at 720° C. for 10 min to 20 min, the dross on the surface was removed, and the melt at a temperature of 660° C. was casted to an iron mold that had been preheated to 250° C. to 350° C. to obtain ingots.
[0034] (3) The magnesium ingots obtained were covered with graphite, homogenized at 420° C. for 24 h, and then water quenched to obtain homogenized samples.
[0035] (4) The magnesium ingots homogenized were preheated at 300° C. for 2 h after skin layer removing, coated with a magnesium alloy lubricant, and extruded at 300° C. with an extrusion ratio of 25:1 at an extrusion speed of 0.90 to 1.20 m/min to obtain rods. The obtained alloy has a tensile strength of 288 MPa, a yield strength of 253 MPa and an elongation of 20.0%.
Comparative Example 7
[0036] (1) The following components were weighed out according to weight percentage: tin 1.00%; aluminum 3.00%; manganese 0.30%; strontium 0.30% and magnesium in balance.
[0037] (2) Pure magnesium and pure aluminum were smelted at a temperature between 720° C. and 740° C. under protection of a protective gas, the temperature was increased to 740° C. after all components were molten, after the temperature was stable, tin that had been preheated to 150° C. as well as magnesium-manganese intermediate alloy and magnesium-strontium intermediate alloy that had been preheated to 300° C. to 400° C. were added. Subsequently, hexachloroethane was added as a refining agent, and the mixture was fully stirred for 3 min to 6 min. The resultant melt was allowed to stand at 720° C. for 10 min to 20 min, the dross on the surface was removed, and the melt at a temperature of 660° C. was casted to an iron mold that had been preheated to 250° C. to 350° C. to obtain ingots.
[0038] (3) The magnesium ingots obtained were covered with graphite, homogenized at 420° C. for 24 h, and then water quenched to obtain homogenized samples.
[0039] (4) The magnesium ingots homogenized were preheated at 300° C. for 2 h after skin layer removing, coated with a magnesium alloy lubricant, and extruded at 300° C. with an extrusion ratio of 25:1 at an extrusion speed of 0.90 to 1.20 m/min to obtain rods. The obtained alloy has a tensile strength of 295 MPa, a yield strength of 205 MPa and an elongation of 17.5%.
[0040] In each of the above examples, the protective gas is a mixture of sulfur hexafluoride and carbon dioxide, which comprises carbon dioxide supplemented with 0.5%-1.5% of sulfur hexafluoride. | The invention belongs to magnesium alloy design field, and relates to a low-cost high-plasticity wrought magnesium alloy. The magnesium alloy is made from the raw materials with components as follows: between 0.10% and 1.00% by mass of tin, between 0.10% and 3.00% by mass of aluminum, between 0.10% and 1.00% by mass of manganese, and commercially pure magnesium and inevitable impurities in balance. The magnesium alloy is prepared by the steps of: melting magnesium and aluminum, adding tin and then adding microalloyed element manganese, stirring, refining, casting to form ingots followed by homogenized heat treatment, and extruding to obtain a corresponding profile; or directly extruding to obtain a corresponding profile without homogenization. The invention is characterized by controlling the content of the high-cost raw material tin through using the raw material aluminum that is low in cost and low in melting point to obtain a low-cost high-plasticity wrought magnesium alloy. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 10/642,402, filed Aug. 15, 2003. The aforementioned related patent application is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to a wellbore completion. More particularly, the invention relates to placing sensors in a wellbore. Still more particularly, the invention relates to placing fiber optic sensor line in a wellbore.
[0004] 2. Description of the Related Art
[0005] During the past 10 years decline rates have doubled while at the same time, reservoirs are becoming more complex. Consequently, the aggressive development and installation of new technologies have become essential, such as intelligent well technology. Since downhole measurements play a critical role in the management of oil and gas reservoirs, intelligent well technology has come to the forefront. But like many new technologies, successful and reliable development of intelligent well techniques has been a challenge to design.
[0006] Prior to the introduction of permanently deployed in-well reservoir-monitoring systems, the only viable method to obtain downhole information was through the use of intervention-based logging techniques. Interventions would be conducted periodically to measure a variety of parameters, including pressure, temperature and flow. Although well logs provide valuable information, an inherently costly and risky well-intervention operation is required. As a result, wells were typically logged infrequently. The lack of timely data often compromised the ability of the operator to optimize production.
[0007] A new down-hole technology to better monitor and control production without intervention would represent a significant value to the industry. However, the challenge was to develop a cost-effective and reliable solution to integrate permanent-monitoring systems with flow control systems to deliver intelligent wells. Using a permanent monitoring system, intelligent wells have the capability to obtain a wide variety of measurements that make it easier to characterize oil and gas reservoirs. These measurements are designed to locate and track fluid fronts within the reservoir and for seismic interrogation of the rock strata within the reservoir. Additionally, intelligent completion systems are being developed to determine the types of fluids being produced prior to and after completion. Using permanent remote sensing and fiber optics, an analyzer can monitor the well's performance and production abnormalities can be detected earlier in the life cycle of the well, which can be corrected before becoming a major problem.
[0008] One challenge facing the progress of intelligent completion systems is the development of an efficient and a cost effective method of deploying fiber optic line in the wellbore. In the past several years, various deployment techniques have been developed. For example, a method for installing fiber optic line in a well is disclosed in U.S. Pat. No. 5,804,713. In this deployment technique, a conduit is wrapped around a string of production tubing prior to placing into the well. The conduit includes at least one sensor location defined by a turn in the conduit. After the string of production tubing is placed in the well, a pump is connected to an upper end of the conduit to provide a fluid to facilitate the placement of the fiber optic line in the conduit. Thereafter, the fiber optic line is introduced into the conduit and subsequently pumped through the conduit until it reaches the at least one sensor location. Using this technique for deploying fiber optic line in the wellbore presents various drawbacks. For example, a low viscosity fluid must be maintained at particular flow rate in order to locate the fiber optic line at a specific sensor location. In another example, a load is created on the fiber optic line as it is pumped through the conduit, thereby resulting in possible damage of the fiber optic line.
[0009] Another deployment technique for inserting a fiber optic line in a duct is disclosed in U.S. Pat. No. 6,116,578. In this deployment technique, a source of fiber optic line is positioned adjacent the wellbore having a pressure housing apparatus at the surface thereof. Thereafter, the fiber optic line is inserted through the pressure housing apparatus and subsequently into a tube by means of an expandable polymer foam mixture under pressure. As the polymer foam mixture expands, the foam adheres to the surface of the fiber optic line creating a viscous drag against the fiber optic line in the direction of pressure flow. The fiber optic line is subsequently urged through the duct to a predetermined location in the wellbore. Using this technique for deploying fiber optic line in the wellbore presents various drawbacks. For example, additional complex equipment, such as the pressure housing apparatus, is required to place the fiber optic line into the wellbore. In another example, the foam coating on the fiber optic line may not adequately protect the fiber optic line from mechanical forces generated during deployment into the duct, thereby resulting in possible damage of the fiber optic line. Furthermore, this deployment technique is complex and expensive.
[0010] A need therefore exists for a cost effective method of placing a fiber optic line in a wellbore. There is a further need for a method that protects the fiber optic line from damage during the deployment operation. Furthermore, there is a need for a method of placing a fiber optic line in a wellbore that does not depend on a specific flow rate or a specific viscosity fluid.
SUMMARY OF THE INVENTION
[0011] The present invention generally relates to a method and an apparatus for placing fiber optic sensor line in a wellbore. In one aspect, a method for placing a line in a wellbore is provided. The method includes providing a tubular in the wellbore, the tubular having a first conduit operatively attached thereto, whereby the first conduit extends substantially the entire length of the tubular. The method further includes aligning the first conduit with a second conduit operatively attached to a downhole component and forming a hydraulic connection between the first conduit and the second conduit thereby completing a passageway therethrough. Additionally, the method includes urging the line through the passageway.
[0012] In another aspect, a method for placing a sensor line in a wellbore is provided. The method includes placing a tubular in the wellbore, the tubular having a first conduit operatively attached thereto, whereby the first conduit extends substantially the entire length of the tubular. The method further includes pushing a fiber in metal tubing through the first conduit.
[0013] In yet another aspect, an assembly for an intelligent well is provided. The assembly includes a tubular having a first conduit operatively attached thereto and a fiber in metal tubing deployable in the first conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope for the invention may admit to other equally effective embodiments.
[0015] FIG. 1 is a cross-sectional view illustrating a wellbore with a gravel pack disposed at a lower end thereof.
[0016] FIG. 2 is a cross-sectional view illustrating a lower control line operatively attached to a screen tubular.
[0017] FIG. 3 is a cross-sectional view illustrating a string of production tubing disposed in the wellbore.
[0018] FIG. 4 is an enlarged view illustrating a hydraulic connection between an upper control line and the lower control line.
[0019] FIG. 5 is an isometric view illustrating a sensor line for use with the present invention.
[0020] FIG. 6 is a cross-sectional view illustrating the sensor line mechanically disposed in a passageway.
[0021] FIG. 7 is a cross-sectional view illustrating the sensor line hydraulically disposed in the passageway.
[0022] FIG. 8 is a cross-sectional view illustrating the sensor line connected to a data collection box.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Embodiments of the present invention generally provide a method and an apparatus for placement of a sensor arrangement in a well, such as fiber optic sensor, to monitor various characteristics of the well. For ease of explanation, the invention will be described generally in relation to a cased vertical wellbore with a sand screen and a gravel pack disposed at the lower end thereof. It is to be understood, however, that the invention may be employed in a wellbore without either a sand screen or a gravel pack. Furthermore, the invention may be employed in a horizontal wellbore or a diverging wellbore.
[0024] FIG. 1 is a cross-sectional view illustrating a wellbore 100 with a gravel pack 150 disposed at a lower end thereof. As depicted, the wellbore 100 is lined with a string of casing 105 . The casing 105 provides support to the wellbore 100 and facilitates the isolation of certain areas of the wellbore 100 adjacent hydrocarbon bearing formations. The casing 105 typically extends down the wellbore 100 from the surface of the well to a designated depth. An annular area is thus defined between the outside of the casing 105 and the earth formation. This annular area is filled with cement to permanently set the casing 105 in the wellbore 100 and to facilitate the isolation of production zones and fluids at different depths within the wellbore 100 . It should be noted, however, the present invention may also be employed in an uncased wellbore, which is referred to as an open hole completion.
[0025] As illustrated, the gravel pack 150 is disposed at the lower end of the casing 105 . The gravel pack 150 provides a means of controlling sand production. Preferably, the gravel pack 150 includes a large amount of gravel 155 (i.e., “sand”) placed around the exterior of a slotted, perforated, or other type liner or screen tubular 160 . Typically, the screen tubular 160 is attached to a lower end of the casing 105 by a packer arrangement 165 . The gravel 155 serves as a filter to help assure that formation fines and sand do not migrate with the produced fluids into the screen tubular 160 .
[0026] During a typical gravel pack completion operation, a tool (not shown) disposed at a lower end of a work or production tubing string (not shown) places the screen tubular 160 and the packer arrangement 165 in the wellbore 100 . Generally, the tool includes a production packer and a cross-over. Thereafter, gravel 155 is mixed with a carrier fluid to form a slurry and then pumped down the tubing through the cross-over into an annulus formed between the screen tubular 160 and the wellbore 100 . Subsequently, the carrier fluid in the slurry leaks off into the formation and/or through the screen tubular 160 while the gravel 155 remains in the annulus. As a result, the gravel 155 is deposited in the annulus around the screen tubular 160 where it forms the gravel pack 150 .
[0027] In the embodiment illustrated in FIG. 1 , a lower control line 175 is operatively attached to an outer surface of the screen tubular 160 by a connection means well-known in the art, such as clips, straps, or restraining members prior to deployment into the wellbore 100 . Generally, the lower control line 175 is tubular that is constructed and arranged to accommodate a sensor line (not shown) therein and extends substantially the entire outer length of the screen tubular 160 . In an alternative embodiment, the lower control line 175 may be operatively attached to an interior surface of the screen tubular 160 . In this embodiment, the lower control line 175 is substantially protected during deployment and placement of the screen tubular 160 . In either case, the lower control line 175 includes a conduit end 180 at an upper end thereof and a check valve 240 disposed at a lower end thereof.
[0028] FIG. 2 is a cross-sectional view illustrating the lower control line 175 operatively attached to the screen tubular 160 . As shown, the lower control line 175 is disposed adjacent the screen tubular 160 . The lower control line 175 may be secured to the screen tubular by a connection means known in the art, such as clips, straps, or restraining members.
[0029] FIG. 3 is a cross-sectional view illustrating a string of production tubing 185 disposed in the wellbore 100 . Prior to disposing the production tubing 185 into the wellbore 100 , a upper control line 190 is operatively attached to a outer surface thereof by a connection means well-known in the art, such as clips, straps, or restraining members. Similar to lower control line 175 , the upper control line 190 is constructed and arranged to accommodate a sensor line (not shown) therein. Typically, the upper control line 190 extends substantially the entire outer length of the production tubing 185 . In an alternative embodiment, the upper control line 190 may be disposed to an interior surface of the production tubing 185 . In this embodiment, the upper control line 190 is substantially protected during deployment and placement of the production tubing 185 . In either case, the upper control line 190 includes a hydraulic connect end 195 that mates with the upper conduit end 180 on the lower control line 175 .
[0030] As the production tubing 185 is lowered into the wellbore 100 , it is orientated by a means well-known in the art to substantially align the upper control line 190 with the lower control line 175 . For example, the production tubing 185 may include an orientation member (not shown) located proximal the lower end thereof and the screen tubular 160 may include a seat (not shown) disposed at an upper end thereof. The seat includes edges that slope downward toward a keyway (not shown) formed in the seat. The keyway is constructed and arranged to receive the orientation member on the production tubing 185 . As the production tubing 185 is lowered, the orientation member contacts the sloped edges on the seat and is guided into the keyway, thereby rotationally orientating the production tubing 185 relative to the screen tubular 160 .
[0031] Preferably, the production tubing 185 is lowered until the hydraulic connect end 195 substantially contacts the upper conduit end 180 . At this time, the connection between the upper control line 190 and the lower control line 175 creates a passageway 210 that extends from the surface of the wellbore 100 to the lower end of the screen tubular 160 . Prior to inserting a sensor therein, the passageway 210 is cleaned by pumping fluid therethrough to remove any sand or other accumulated wellbore material. After the passageway 210 is cleaned, the check valve 240 prevents further material from accumulating in the passageway 210 from the lower end of the wellbore 100 . Alternatively, a u-tube arrangement (not shown) could be employed in place of the check valve 240 to prevent further material from accumulating in the passageway 210 .
[0032] FIG. 4 is an enlarged view illustrating the hydraulic connection between the upper control line 190 and the lower control line 175 . As shown, the hydraulic connect end 195 has been aligned with the upper conduit end 180 . As further shown, a plurality of seals 205 in the hydraulic connect end 195 contact the conduit end 180 to create a fluid tight seal therebetween.
[0033] FIG. 5 is an isometric view illustrating a sensor line 200 for use with the present invention. Preferably, the sensor line 200 consists of a fiber in metal tube (“FIMT”), which includes a plurality of optical fibers 215 encased in a metal tube 220 , such as steel or aluminum tube. The metal tube 220 is constructed and arranged to protect the fibers 215 from a harmful wellbore environment that may include a high concentration of hydrogen, water, or other corrosive wellbore fluid. Additionally, the metal tube 220 protects the fibers 215 from mechanical forces generated during the deployment of the sensor line 200 , which could damage the fibers 215 . Preferably, a gel (not shown) is inserted into the metal tube 220 along with the fibers 215 for additional protection from humidity, and to protect the fibers 215 from the attack of hydrogen that may darken the fibers 215 causing a decrease in optical performance. In an alternative embodiment, the sensor line 200 consists of a plurality of optical fibers 215 encased in a protective polymer sheath (not shown), such as Teflon, Ryton, or PEEK. In this embodiment, the protective sheath may include an integral cup-shaped contours molded into the sheath to facilitate pumping the sensor line 200 down the control lines 190 , 175 . In some embodiments, the sensor line 200 may include electrical lines, hydraulic lines, fiber optic lines, or a combination thereof.
[0034] FIG. 6 is a cross-sectional view illustrating the sensor line 200 mechanically disposed in the passageway 210 . Preferably, the sensor line 200 is placed at the surface of the wellbore 100 on a roll for ease of transport and to facilitate the placement of the sensor line 200 into the wellbore 100 . Thereafter, a leading edge of the sensor line 200 is introduced into the passageway 210 at the top of the upper control line 190 . Then, the sensor line 200 is urged by a mechanical force through the entire passageway 210 consisting of the upper control line 190 , hydraulic connect 195 , and the lower control line 175 . Preferably, the mechanical force is generated by a gripping mechanism (not shown) or by another means well-known in the art that physically pushes the sensor line 200 through the passageway 210 until the leading edge of the sensor line 200 reaches a predetermined location proximate the check valve 240 . Typically, an increase in pressure in the passageway 210 indicates that the leading edge has reached the predetermined location. Alternatively, the length of sensor line 200 inserted in the passageway 210 is monitored and compared to the relative length of the passageway 210 to provide a visual indicator that the leading edge has reached the predetermined location.
[0035] FIG. 7 is a cross-sectional view illustrating the sensor line 200 hydraulically disposed in the passageway 210 . In this embodiment, a plurality of flow cups 230 are operatively attached to the sensor line 200 prior to inserting the leading edge into the passageway 210 . The plurality of flow cups 230 are constructed and arranged to facilitate the movement of the sensor line 200 through the passageway 210 . Typically, the flow cups 230 are fabricated from a flexible watertight material, such as elastomer. The flow cups 230 are spaced on the sensor line 200 in such a manner to increase the hydraulic deployment force created by a fluid that is pumped through the passageway 210 .
[0036] Typically, a fluid pump 225 is disposed at the surface of the wellbore 100 to pump fluid through the passageway 210 . Preferably, the fluid pump 225 is connected to the top of the passageway 210 by a connection hose 245 . After the sensor line 200 and the flow cups 230 are introduced into the top of the passageway 210 , the fluid pump 225 urges fluid through the connection hose 245 into the passageway 210 . As the fluid contacts the flow cups 230 , a hydraulic force is created to urge the sensor line 200 through the passageway 210 . Preferably, the fluid pump 225 continues to introduce fluid into the passageway 210 until the leading edge of the sensor line 200 reaches the predetermined location proximate the check valve 240 . Thereafter, the fluid flow is stopped and the hose 245 is disconnected from the passageway 210 .
[0037] FIG. 8 is a cross-sectional view illustrating the sensor line 200 connected to a data collection box 235 . Generally, the data collection box 235 collects data measured by the sensor line 200 at various locations in the wellbore 100 . Such data may include temperature, seismic, pressure, and flow measurements. In one embodiment, the sensor line 200 is used for distributed temperature sensing (“DTS”), whereby the data collection box 235 compiles temperature measurements at specific locations along the length of the sensor line 200 . More specifically, DTS is a technique that measures the temperature distribution along the plurality of optical fibers 215 .
[0038] Generally, a measurement is taken along the optical fiber 215 by launching a short pulse from a laser into the fiber 215 . As the pulse propagates along the fiber 215 it will be attenuated or weakened by absorption and scattering. The scattered light will be sent out in all directions and some will be scattered backward within the fiber's core and this radiation will propagate back to a transmitter end where it can be detected. The scattered light has several spectral components most of which consists of Rayleigh scattered light that is often used for optical fiber attenuation measurements. The wavelength of Rayleigh light is the same as for the launched laser light.
[0039] DTS uses a process where light is scattered at a slightly different wavelength than the launched wavelength. The process is referred to as Raman scattering which is temperature dependent. Generally, a time delay between the launch of the short pulse from the laser into the fiber 215 and its subsequent return indicates the location from which the scatter signal is coming. By measuring the strength of the Raman scattered signal as a function of the time delay, it is possible to determine the temperature at any point along the fiber 215 . In other words, the measurement of the Raman scattered signal relative to the time delay indicates the temperature along the length of the sensor line 200 .
[0040] In another embodiment, the sensor line 200 may include fiber optic sensors (not shown) which utilize strain sensitive Bragg grating (not shown) formed in a core of one or more optical fibers 215 . The fiber optic sensors may be combination pressure and temperature (P/T) sensors, similar to those described in detail in commonly-owned U.S. Pat. No. 5,892,860, entitled “Multi-Parameter Fiber Optic Sensor For Use In Harsh Environments”, issued Apr. 6, 1999 and incorporated herein by reference. Further, for some embodiments, the sensor line 200 may utilize a fiber optic differential pressure sensor (not shown), velocity sensor (not shown) or speed of sound sensor (not shown) similar to those described in commonly-owned U.S. Pat. No. 6,354,147, entitled “Fluid Parameter Measurement In Pipes Using Acoustic Pressures”, issued Mar. 12, 2002 and incorporated herein by reference. Bragg grating-based sensors are suitable for use in very hostile and remote environments, such as found downhole in wellbores.
[0041] In operation, a tubular is placed in a wellbore. The tubular having a first conduit operatively attached thereto, whereby the first conduit extends substantially the entire length of the tubular. Thereafter, the first conduit is aligned with a second conduit operatively attached to a downhole component, such as a sand screen. Next the first conduit and the second conduit are attached to form a hydraulic connection therebetween and thus creating a passageway therethrough. Subsequently, a sensor line, such as a fiber in metal tube, is urged through the passageway.
[0042] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | The present invention generally relates to a method and an apparatus for placing fiber optic control line in a wellbore. In one aspect, a method for placing a line in a wellbore is provided. The method includes providing a tubular in the wellbore, the tubular having a first conduit operatively attached thereto, whereby the first conduit extends substantially the entire length of the tubular. The method further includes aligning the first conduit with a second conduit operatively attached to a downhole component and forming a hydraulic connection between the first conduit and the second conduit thereby completing a passageway therethrough. Additionally, the method includes urging the line through the passageway. In another aspect, a method for placing a control line in a wellbore is provided. In yet another aspect, an assembly for an intelligent well is provided. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/979,505, filed Dec. 28, 2010, the content of which is hereby incorporated by reference in its entirety.
BACKGROUND
The present invention relates to shared memory, and more specifically, to managing shared data objects to provide visibility to shared memory between separate processes running the same processor.
Java is an example of a platform independent programming language that is used to build enterprise-level applications. With WebSphere Application Server for z/Series, a logical application server can be made up of multiple Java virtual machines (JVMs), each executing in a different address space. These address spaces are called servant regions (SRs), each containing one JVM. If a SR abends, another SR can take over the incoming requests in a multiple SR environment.
WebSphere Application server for z/Series distributed environment concepts to create and manage application servers. Each application server includes multiple address spaces that represent a single logical application server. At a minimum, one application server includes one control region (CR) and one SR. Additional SRs can be added, with the number of SRs limited by the physical memory available on the system. The main responsibility of the CR is to handle the incoming connections from the clients and dispatch the request to the SRs. The SR is the component of an application server where the actual application runs and transactions are processed in a JVM.
Currently in WebSphere for z/Series, a request is received from a client application by the CR and passed to the CR for processing. Upon processing of the request, a response is sent back to the CR for output to the client application. During the course of this processing several copies of data need to be made. When information is passed from the CR to the SR, a physical copy is made to allow visibility of the request to the SR. Similarly, on the response path the response is copied from the SR to the CR in order to allow the CR to have visibility to the response.
SUMMARY
An embodiment includes a method for sharing data between computer processes. The method includes executing a plurality of independent processes on an application server, the processes including a first process and a second process. A shared memory utilized by the plurality of independent processes is provided. A single copy of the data and metadata are stored in the shared memory. The metadata includes an address of the data. The first process initiates the storing of the data in the shared memory. An address of the metadata is transferred from the first process to the second process to notify the second process about the data. The second process determines the address of the shared memory by reading the metadata. The data in the shared memory is accessed by the second process.
Additional features and advantages are realized through the techniques of the present invention.
Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with the advantages and the features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The forgoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a computing system for implementing shared address spaces in accordance with an embodiment;
FIG. 2 illustrates an application server in accordance with an embodiment;
FIG. 3 illustrates a more detailed view of one embodiment of the application server of FIG. 2 ;
FIG. 4 illustrates a process flow for creating shared memory objects in accordance with an embodiment;
FIG. 5 illustrates contents of shared memory objects in accordance with an embodiment;
FIG. 6 illustrates a process flow for processing a request in accordance with an embodiment;
FIG. 7 illustrates a process flow for processing a response in accordance with an embodiment; and
FIG. 8 illustrates contents of a shared memory object in accordance with an alternate embodiment.
DETAILED DESCRIPTION
An embodiment provides visibility to shared memory between separate regions (or separate processes) executing on the same processor. In an embodiment, two regions, such as a control region (CR) and a servant region (SR) create shared memory objects (SMOs) for storing buffers (e.g., Java direct byte buffers). The created buffers are used for pointing to locations of data that is shared between the two regions. In an embodiment, a buffer pointing to a shared memory space storing data is created in one region (e.g., a Java virtual machine or “JVM”) of an application server. The data is shared with the second region by communicating the address of the buffer to the second region (or JVM) of the application server. The second region then creates a second buffer for storing the pointer to the shared memory space that stores the data. The second region accesses the data in the shared memory space via the second buffer. Embodiments described herein avoid the extra storage overhead of maintaining two copies of the data. In addition, embodiments avoid the processing expense of copying the information.
Embodiments are described herein in terms of Java and WebSphere for z/Series as example environments. It will be appreciated by those skilled in the art, that embodiments are not limited to Java and WebSphere for z/Series, and that embodiments apply to any platform independent software code environment that implements data sharing between multiple regions (or multiple processes) executing on the same processor.
Turning now to FIG. 1 , a block diagram of a system 100 upon which the processes to provide visibility to shared data may be implemented in accordance with an embodiment will now be described. The system 100 of FIG. 1 includes a host system 102 in communication with client systems 104 via one or more network(s) 106 . Host system 102 may be implemented using one or more servers operating in response to a computer program stored in a storage medium accessible by the server(s). The host system 102 may operate as a network server (e.g., a web server) to communicate with one or more client systems 104 . The host system 102 may handle sending and receiving information to and from client systems 104 and may perform associated tasks.
The host system 102 also operates as an application server 110 . In accordance with an embodiment, the host system 102 executes one or more computer programs to provide a Java application server for executing one or more processes. These one or more computer programs are referred to collectively herein as an application server 110 . Alternatively, a portion of the functionality of the application server 110 may be implemented via the client systems 104 .
Application server activities may be shared by the client systems 104 and the host system 102 by providing an application (e.g., java applet) to the client systems 104 . Alternatively, client systems 104 may include stand-alone software applications for performing a portion of the processing described herein. In yet further embodiments, the application sever functions may be built in to a web browser application executing on the client systems 104 (not shown).
As previously described, it is understood that separate servers may be utilized to implement the network server functions. Alternatively, the network server may be implemented by a single server executing computer programs to perform the requisite functions described with respect to host system 102 .
Client systems 104 may be coupled to host system 102 via one or more network(s) 106 . Each of the client systems 104 may be implemented using a general-purpose computer executing a computer program for carrying out some of the processes described herein. The client systems 104 may be personal computers (e.g., a lap top, a personal digital assistant) or host-attached terminals. For purposes of illustration, client systems 104 are operated by end users executing programs that generate requests that are received at the application server 110 . In addition, the programs may also receive responses generated by processes executing on the application server 110 .
In exemplary embodiments, the system 100 shown in FIG. 1 includes a storage device 108 . Storage device 108 is in communication with host system 102 and may be implemented using a variety of devices for storing electronic information. It is understood that the storage device 108 may be implemented using memory contained in the host system 102 or it may be a separate physical device, e.g., as shown in FIG. 1 . The storage device 108 is logically addressable as a consolidated data source across a distributed environment that includes network(s) 106 . Information stored in the storage device 108 may be retrieved and manipulated via the host system 102 and authorized users of client systems 104 . The storage device 108 may house shared data objects (e.g., request shared memory objects, response shared memory objects, and memory block shared memory objects), as well as application data for applications executing on the host system 102 , among other information desired by the service provider of host system 102 . These features are described further herein. In an exemplary embodiment, the host system 102 operates as a database server and coordinates access to application data including data stored on storage device 108 .
Network 106 may be any type of known network including, but not limited to, a wide area network (WAN), a local area network (LAN), a global network (e.g. Internet), a virtual private network (VPN), and an intranet. The network 106 may be implemented using a wireless network or any kind of physical network implementation known in the art. Client systems 104 may be coupled to the host system 102 through multiple networks (e.g., intranet and Internet) so that not all client systems 104 are coupled to the host system 102 through the same network. One or more of the client systems 104 and the host system 102 may be connected to the network(s) 106 in a wireless fashion.
FIG. 2 illustrates application server 110 in accordance with an embodiment that supports a WebSphere for z/Series environment. The application server 110 shown in FIG. 2 is executing one control region (CR) 202 and four servant regions (SRs) 204 . The CR 202 is in communication with each SR 204 via a cross memory channel. The cross memory channel is utilized to transfer requests and responses between the CR 202 and the SRs 204 .
As used herein, the term “shared memory object” or “SMO” refers to memory accessible by two or more regions executing on an application server. Data stored in an SMO may be written to and read from by two or more processes executing in different regions on the application server.
FIG. 3 illustrates a more detailed view of an embodiment of the application server of FIG. 2 . The embodiment shown in FIG. 2 includes one CR 202 , two SRs 204 , one request shared memory object (SMO) 310 , two response SMOs 312 (one for each SR 204 ) and one memory block SMO 304 . As used herein, the term “memory block” refers to one or more memory cells in a memory that are accessed as a unit. The size and physical location of the memory cells that make up a block can vary and are implementation specific. As shown in FIG. 3 , the CR 202 is in communication with the SRs 204 via a cross memory channel (Xmem). In addition, the CR 202 includes pointers to (e.g., an address) to the request SMO 310 and to the two response SMOs 312 . As shown in FIG. 3 , the request SMO 310 includes one allocated direct byte buffer (DBB) 306 that is pointing to a memory block 302 A in the memory block SMO 304 . Also as shown in FIG. 3 , response SMO 312 A includes one allocated response DBB 308 that is pointing to the same memory block 302 A in the memory block SMO 304 . Thus, the control region 202 and servant region 204 A are sharing access to memory block 302 A.
Though shown as separate blocks in FIG. 3 , one or all of the request SMO 310 and the response SMOs 312 may be implemented as memory blocks 302 in the memory block SMO 304 . In an embodiment, each memory block 302 is pointed to by at most one response DBB 308 from an SR 204 response SMO 312 .
FIG. 4 illustrates a process flow for creating SMOs in accordance with an embodiment. In an embodiment, the process flow is executed on the application server 110 . The process depicted in FIG. 4 assumes that the memory block SMO 304 has already been allocated. At block 402 , a CR 202 requests a SMO (e.g., from an operating system) for storing a request buffer(s). The operating system allocates the requested SMO (typically in the order of megabytes of size) and, at block 404 the CR 202 receives the address of the SMO. Thus, a request SMO 310 is allocated and available for use by the CR 202 . At block 406 , the CR 202 sends the address of the request SMO 310 to each of the SRs 204 to identify the request SMO 310 as a shared address space in the SR 204 . At block 408 , each SR 204 allocates a SMO for use as a response SMO 312 . The operating system allocates the requested SMO and, at block 410 each SR 204 sends the address of its response SMO 312 to the CR 202 to identify it as a shared address space in the CR 202 .
FIG. 5 illustrates contents of shared memory objects in accordance with an embodiment. The direct byte buffer 502 includes an address 504 and a length 506 (i.e., metadata about the memory block 302 ). The address 504 is the address of the memory block 302 in the memory block SMO 304 , and the length 506 is the size of the memory block 302 (e.g., in number of cells, in number of pages, etc.). Thus, the direct byte buffer 502 contains metadata that points to the location of the memory block 302 in the memory block SMO 304 that contains the shared data. Also shown in FIG. 5 is an embodiment of a memory block 302 that includes header information (e.g., a region indicator 508 and an in-use indicator 510 ) and a returned storage 512 . The region indicator 508 identifies which region (e.g., a CR, a SR) created the memory block 302 , and the in-use indicator identifies whether a region is currently using the memory block 302 . The returned storage 512 is the data portion of the memory block 302 .
FIG. 6 illustrates a process flow for processing a request in accordance with an embodiment. At block 602 , a request from a client application executing on a client system 104 is received at the application server 110 (e.g., a WebSphere application server) via the network 106 (e.g., a TCP/IP connection). At block 604 , the CR 202 obtains a memory block 302 from the memory block SMO 304 to store the request data. At block 606 , the CR 202 creates a request DBB 306 in the request SMO 310 to store the address of the memory block 302 that stores the request data. The new request DBB 306 is passed to the JVM of the CR 202 for any processing/routing required on the CR 202 . At block 608 , the CR 202 transfers the address of the request DBB 306 to the SR 204 that will be handling the request. By transferring the address of the request DBB 306 to SR 204 , the CR 202 is notifying the SR 204 about the existence of the request data in the memory block 302 . In an embodiment, a Java cross memory channel is used to transfer the address of the request DBB 306 to the SR 204 . At block 610 , the SR 204 reads the address of the request DBB 306 (e.g., the metadata) and creates a response DBB 308 to point to the address received from the CR 202 . Thus, the response DBB 308 contains the address of the shared memory block 302 . At block 612 , the SR 204 uses the response DBB 308 to access and process the request.
FIG. 7 illustrates a process flow for processing a response in accordance with an embodiment. At block 702 , a SR 204 creates a response, and at block 704 , the SR 204 obtains a memory block 302 from the memory block SMO 304 to store the response data. At block 706 , the SR 204 creates a response DBB 308 in the response SMO 312 to store the address of the memory block 302 that stores the response data. At block 708 , the SR 204 transfers the address of the response DBB 308 to the CR 202 that will be handling the request. By transferring the address of the response DBB 308 to the CR 202 , the SR 204 is notifying the CR 202 about the existence of the response data in the memory block 302 . At block 710 , the CR 202 reads the address of the response DBB 308 (e.g., the metadata) and creates a request DBB 306 to point to the address received from the SR 204 . At block 712 , the CR 202 passes the request DBB 306 to the JVM executing on the CR 202 for processing.
FIG. 8 illustrates contents of a shared memory object in accordance with an alternate embodiment. As shown in FIG. 8 , memory blocks 802 , 804 in a memory block SMO 806 can vary in size.
In an embodiment, when a DBB is destroyed (or deleted), the header of the memory block 302 is checked. If the header indicates that the region that allocated the memory block 302 (as indicated by the region indicator 508 ) matches the current region and memory block is no longer in use by the shared address space (as indicated by the in-use indicator 510 ), then this memory block is released and managed in an embodiment by chaining and/or pooling code. If the memory block 302 is still in use, the memory block 302 is added to a “deleted” list to be checked the next time a delete occurs. If the header indicates the region allocated does not match the current region, the in-user indicator 510 for the memory block 302 is updated to indicate that the memory block 302 is no longer in use by the shared address space so that when the next delete occurs in the allocating region, the memory block 302 will be released.
In an embodiment, the memory blocks 302 and DBBs taken from the SMOs are pooled/chained upon release. Because of the nature of the usage of DBB, it is desirable for chains of unused blocks to be maintained for several common sizes of buffers (i.e., 1 k, 4 k, 8 k, 16 k, 32 k, etc.). For blocks that are larger than the largest common size, these blocks will not be pooled, however they will be returned directly to the SMO that they were obtained from. In an embodiment, each SMO contains a list of “next available blocks” as well as “remaining area” within the SMO. New blocks may be obtained from either one of these areas.
In the case of “large” requested blocks these are preferentially taken from the next available blocks from the smallest available block. If allocated from the remaining area, these are taken from the end of the remaining are rather than the front of the remaining area. They are taken from the end of the remaining area since large blocks are not pooled and thus, are more likely to be combinable with other areas when returned to the SMO. That is, when a large block is returned, the chain of “next available blocks” is checked to see if any existing block may be combined with the newly returned block.
Technical effects and benefits include avoiding the extra storage overhead of maintaining two copies of shared data. Additional benefits include avoiding the processing expense of copying the information.
The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof.
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized to store instructions for execution of methods disclosed herein or to cause a computing device to perform the methods disclosed herein. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
The diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but 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 without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and 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. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. | Managing shared data objects to share data between computer processes, including a method for executing a plurality of independent processes on an application server, the processes including a first process and a second process. A shared memory utilized by the plurality of independent processes is provided. A single copy of the data and metadata are stored in the shared memory. The metadata includes an address of the data. The first process initiates the storing of the data in the shared memory. An address of the metadata is transferred from the first process to the second process to notify the second process about the data. The second process determines the address of the shared memory by reading the metadata. The data in the shared memory is accessed by the second process. | 6 |
[0001] This application claims priority to provisional application Ser. No. 60/300,281, filed on Jun. 22, 2001.
FIELD OF THE INVENTION
[0002] This invention relates to a composition and method for reducing cholesterol absorption and serum cholesterol in humans. It represents an improvement in that the material also contains a spray drying adjunct such as maltodextrin.
BACKGROUND OF THE INVENTION
[0003] Phytosterols are plant sterols structurally similar to cholesterol that have been known for many years to reduce cholesterol absorption and serum cholesterol levels while not being absorbed themselves. Lowering of circulating cholesterol and low density lipoprotein cholesterol is an important part of a strategy to prevent and treat cardiovascular disease and especially coronary heart disease. Cholesterol absorption is a critical component of whole body cholesterol metabolism. Cholesterol derived from the diet and also from endogenous biliary secretion enters the intestine, and approximately 50% of the mixed intestinal load is absorbed, Bosner, M. S., Ostlund, R. E., Jr., Osofisan, O., Grosklos, J., Fritschle, C., Lange, L. G 1993. The failure to absorb cholesterol quantitatively is therefore a key mechanism for the elimination of cholesterol from the body.
[0004] Drugs commonly used to treat high cholesterol levels have little or no effect on cholesterol absorption. For example, the potent new hydroxymethylglutaryl coenzyme A reductase inhibitors have a primary action to reduce cholesterol synthesis rather than increase cholesterol elimination. Bile acid sequestrants such as the ion:exchange resin cholestyramine act within the intestine but do not bind cholesterol and may actually increase cholesterol absorption when given chronically. McNamara, D. J., N. O. Davidson, P. Samuel, and E. H. Ahrens, Jr. 1980, Cholesterol absorption in man: effect of administration of clofibrate and/or cholestyramine. J. Lipid Res. 21:1058-1064. Although orally-administered neomycin reduces cholesterol absorption effectively, it is toxic and has the disadvantage of requiring chronic administration of a potent antibiotic, Samuel, P. 1979. Treatment of hypercholesterolemia with neomycinatime for reappraisal. N. Engl. J. Med. 301:595597. The drug Cytellin.RTM., an aqueous suspension of mixed phytosterols, was produced by Eli Lilly Co. for treatment of elevated cholesterol, but it has not been sold since 1985. As seen, it is apparent that new inhibitors of cholesterol absorption would complement currently-available treatment for high serum cholesterol.
[0005] Since phytosterols are natural products which are non-toxic and byproducts of food processing, they may be important in the treatment of individuals with mildly-increased serum cholesterol, or for the general population in food products or dietary supplements. The use of phytosterols could reduce the need for systematically-absorbed drugs.
[0006] Despite their potential attractiveness, the usefulness of phytosterols has been limited by small and erratic effectiveness and a large dosage requirement. For example, doses of 5-18 g sitosterol/day reduced serum cholesterol by 16-20%. Farquhar, J. W. and M. Sokolow, 1958. A dose-response study showed that 3-9 g/day of powdered sitosterol was needed to decrease serum cholesterol levels by 12%. Lees, A. M., H. Y. I. Mok, R. S. Lees, M. A. McCluskey, and S. M. Grundy. 1977. Plant sterols as cholesterol lowering agents: clinical trials in patents with hypercholesterolemia and studies of sterol balance, Atherosclerosis 28:325-338. To reduce the amount needed, recent experiments have used sitostanol instead of sitosterol because it appears to be more potent than other phytosterols and is non-absorbable, Sugano, J., H. Morioka, and I. Ikeda. (1977) A comparison of hypocholesterolemic activity of .beta.-sitosterol and .beta.sitostanol in rats. J. Nutr. 107:2011-2019. In subjects with severe hypercholesterolemia sitostanol at 1.5 g/day reduced serum cholesterol by 15%, Heinemann, T., O. Leiss, and K. von Bergmann (1986) Effect of low dose sitostanol on serum cholesterol in patients with hypercholesterolemia. Atherosclerosis 61:219-223. However, sitostanol at 3 g/day had no effect in subjects with moderate hypercholesterolemia. Denke, M. A. (1995), Lack of efficacy of low dose sitostanol therapy as an adjunct to a cholesterol-lowering diet in men with moderate hypercholesterolemia. Am. J. Clin. Nutr. 61:392-396.
[0007] Several investigators have proposed ways to increase the solubility or bioavailability of phytosterols in order to make them more useful. Based on studies in rats and the finding that phytosterol esters are much more soluble in oil than the free sterols, it has been proposed to use phytosterol esters in oil to lower cholesterol absorption, Mattson, F. H., R. A. Volpenhein, and B. A. Erickson (1977), Effect of plant sterol esters on the absorption of dietary cholesterol. J. Nutr. 107:11391146. U.S. Pat. No. 5,502,045 describes the use of sitostanol ester in oil for the treatment of hypercholesterolemia in humans. It was found that 2.8 g sitostanol/day given as sitostanol ester in margarine reduced LDL cholesterol by 16%. Miettinen, T. A., P. Puska, H. Gylling, H. Vanhanen, and E. Vartiainen (1995), Reduction of serum cholesterol with sitostanolester margarine in a mildly hypercholesterolemic population. N. England J. Med. 333:13081312. However, the use of sitostanol ester dissolved in dietary fat has the disadvantage of requiring the administration of 2350 g/day of dietary fat and of being 21% less effective at reducing cholesterol absorption in humans compared to the unesterified sterol. Mattson, F. H., S. M. Grundy, and J. R. Crouse, (1982), Optimizing the effect of plant sterols on cholesterol absorption in man. Am. J. Clin. Nutr. 35:697-700.
[0008] Other workers have investigated ways to improve the usefulness of unesterified phytosterols. in International Patent Publication WO 95/00158 a complex of sitosterol and the unabsorbable dietary fiber pectin reduced serum cholesterol by 16.4% when given to hypercholesterolemic humans in a dose of 2.1 g/day. However, no measurements of an effect on cholesterol absorption were made, and the complex was only about 50% soluble even at strongly alkaline pH, suggesting that the bioavailability of the sitosterol component was limited.
[0009] U.S. Pat. No. 5,244,887 describes the use of stanols including sitostanol in food additives to reduce cholesterol absorption. In U.S. Pat. No. 5,244,887, for preparation of the additives, sitostanol is dissolved with an edible solubilizing agent such as triglyceride, an antioxidant such as tocopherol, and a dispersant such as lecithin, polysorbate 80, or sodium lauryl sulfate. However, no data were given to guide one in the selection of the most effective components and their amounts or specific methods of preparation. Effectiveness in reducing cholesterol absorption was also not determined. The preferred embodiment consisted of 25% by weight stanols in vegetable oil, but the solubility of sterols in oil is only 2%.
[0010] U.S. Pat. No. 5,118,671 describes the production of sitosterol-lecithin complexes for pharmaceutical use but does not consider oral use for cholesterol lowering.
[0011] Cholesterol is absorbed from an intestinal micellar phase containing bile salts and phospholipids which is in equilibrium with an oil phase inside the intestine. Delivery of phytosterol as a solid powder or aqueous suspension is not preferred because of the limited rate and extent of solubility in intestinal liquid phases. Esterification of the phytosterol with delivery through the oil phase of foods is an alternative route but has the disadvantage of use of edible oils as the carrier.
[0012] U.S. Pat. Nos. 5,932,562 and 6,063,776 provide a delivery system for plant sterols, particularly sitostanol, which avoids an oil phase and which provides bioavailable sitostanol at a level which reduces cholesterol absorption as much as 37%, while at the same time using an excellent taste emulsifier in as low amounts as possible.
[0013] U.S. Pat. Nos. 5,932,562 and 6,063,776 also provide a water soluble composition which provides the sitostanol, not dissolved in fat, but rather combined with a preferred emulsifier (Sodium Stearoyl 2-lactylate) (SSL) in an aqueous vesicular complex which can enter directly into the intestinal micellar phase and is therefore highly bioavailable.
[0014] U.S. Pat. Nos. 5,932,562 and 6,063,776 also provide a composition of preferred enhanced solubility that contains a plant sterol, preferably sitostanol mixed with an emulsifier even better than phospholipids, namely SSL, which has water solubility in excess of 90%.
[0015] U.S. Pat. Nos. 5,932,562 and 6,063,776 also provide a method for reducing cholesterol absorption from food products containing cholesterol by mixing finely divided water soluble powder of an aqueous homogeneous micellar mix of sitostanol and SSL with a food product which is to be ingested.
[0016] U.S. Pat. Nos. 5,932,562 and 6,063,776 also provide a method of manufacturing a dry, finely divided water soluble powder which contains a plant sterol, preferably sitostanol, and lecithin, which is highly water soluble, so that when in contact with an aqueous system it will provide an aqueous vesicular complex which can enter directly into the intestinal micellar phase to inhibit cholesterol absorption.
[0017] It is an objective of the present invention to provide improved processing and other characteristics to the composition of U.S. Pat. Nos. 5,932,562 and 6,063,776 by the addition of a spray drying adjunct such as starches or hydrolyzed starches, and in a preferred embodiment maltodextrin, which provides additional benefits of improving the characteristics of the sterol/lecithin composition in food and beverage applications.
[0018] The method and manner of achieving each of the above objectives, as well as others, will become apparent from the detailed description of the invention which follows hereinafter.
SUMMARY OF THE INVENTION
[0019] A composition for inhibiting cholesterol absorption from the intestine is described. The composition comprises phytosterols, preferably sitostanol, dispersed in an aqueous base emulsifier, preferably lecithin or SSL. The mole ratio of sterol to emulsifier should be 1:0.1 to 1:10, preferably 1:0.9 to 1:0.5.
[0020] The phytosterol-emulsifier complex is prepared by high shear mixing, for example by vortexing, mixing, sonicating or passing through a small orifice of a phytosterol: emulsifier mixture in water. The dispersed material is then either used as is or dried, for example, by lyophilization or spray-drying. The complex can be used in liquid form prior to any drying, or it can be dried as indicated, and then on contact with liquid it again forms an aqueous vesicular complex which can enter directly into the intestinal micellar phase. No fat is used as a carrier, and surprisingly the system, even when dried, does not change its physical structure from the micelles that contain vesicles, the majority of which contain some plant sterol and some lecithin. In particular, in the present invention, a spray drying adjunct, for example maltodextrin, is added to improve the processing and application performance characteristics of the sterol/lecithin composition.
DETAILED DESCRIPTION OF THE INVENTION
[0021] As previously mentioned, the current invention differs from prior art uses of plant sterols and sitostanol in significant ways.
[0022] First, the dose needed to reduce cholesterol absorption is lower than previously reported, namely 25-300 mg of sitostanol. Second, the preferred formulation does not contain triglycerides or oils. The phytosterol is not dissolved in fat, but rather is combined with phospholipid to form an aqueous vesicular complex which can enter directly into the intestinal micelle phase. Third, the mix can be prepared in solid form by drying an aqueous sitostanol/emulsifier vesicular formulation with retention of solubility in artificial bile. Fourth, the mix is effective when consumed separately from cholesterol-containing foods. Fifth, the mix can be added to non-cholesterol containing and fat-free foods and beverages. Sixth, the mix is prepared in a manner to prevent self association of sitostanol as occurs when it is dried from organic solvents containing sitostanol and solubilizing agents. The mix herein referenced has the advantage of a high degree of bioavailability as assayed with artificial bile in vitro. This is significant and something that cannot be achieved with fat carrier systems.
[0023] The composition is useful for reducing cholesterol absorption in humans at doses between 10 and 1000 mg, and a preferred dose is 100-300 mg. The dose is less than required by current protocols. The composition may be used in capsule or tablet form as a drug or dietary supplement. Alternatively, it may be used in foods as a food additive or substance generally recognized as safe for human consumption.
[0024] In preparation of the composition useful for reducing cholesterol in highly bioavailable form, the first step is to provide an aqueous homogeneous micellar mix of the plant sterol with the preferred emulsifier of choice.
[0025] One preferred method is to use sitostanol because only small amounts are absorbed in the small intestine, but on the other hand, this plant sterol shows high inhibition of cholesterol absorption. Similar compounds are also suitable, including sitosterol, campesterol, stigmasterol. Moreover, lignans, such as sesamin, and saponins are also useful for this purpose, but sitostanol is preferred. Sterol esters may also be used.
[0026] The preferred phospholipid for the present invention is lecithin, with an alternative phospholipid system useful to enhance the bioavailability being a mix of lecithin and lysolecithin. Where the mix was used, it was preferred that the mole ratio of lecithin to lysolecithin be at least 1:0.2, preferably 1:0.5.
[0027] In this first step, the aqueous homogeneous mixture of the plant sterol and the emulsifier are homogeneously mixed to provide a micellar mix. The preferred mixing form is a high shear mixing. By way of example, vortexing, sonicating, passing through a small orifice such as a French press or other mixing means may be employed. The most preferred mixing is sonication. This disperses the material and enhances the formation of a micellar mix that contains vesicles, the majority of which contain some plant sterol and some emulsifier.
[0028] Generally, with respect to sonication, any method that is commonly used for preparation of emulsions can be used to prepare homogeneous mixtures of the plant sterol and the emulsifier, either alone or in combination. For example, Waring blenders, or other high shear mixers can provide acceptable results. Microfluidizers can be used. In this latter procedure, the plant sterol and the emulsifier are forced through ceramic capillaries under high pressure. Where the preferred sonication technique is used, a time within the range of 1.5 minutes to about 4 minutes for sonication is sufficient. On small scale experiments, sonication is typically performed in about 1.5 minutes. Mixers, homogenizers, grinders and spray dryers of various makes and models are well known in the art, as are organic solvents such as hexane.
[0029] The drying process is not critical, so long as it does not destroy the vesicular complex formed between the plant sterol and the emulsifier. Generally, non-drastic drying procedures are preferred such as vacuum drying, freeze drying or low-temperature embient air drying. Where heat is employed, the temperature at atmospheric conditions should not exceed 0.degree. C.
[0030] As earlier explained, the dosage of the dry powder may be within the range of 10 to 1000 mg per day, and a preferred dose being 25 to 300 mg per day. The most preferred doses to achieve significant cholesterol absorption reduction levels are achieved at a dose range of from 100 mg to 300 mg one to four times daily.
[0031] Various permutations of the method and composition of the present invention are presented:
[0032] 1. COMINGLE sterols and lecithin in organic solvent.
[0033] REMOVE solvent to produce solid commingled material.
[0034] GRIND solid to produce powder.
[0035] HYDRATE powder in water (>140F) and addition of suitable spray drying adjunct with vigorous mixing.
[0036] HOMOGENIZE at >3000 psi to produce sterol-lecithin micelle.
[0037] SPRAY DRY to produce free-flowing powder.
[0038] 2. COMINGLE sterols and lecithin in organic solvent.
[0039] REMOVE solvent to produce solid commingled material.
[0040] GRIND solid to produce powder.
[0041] HYDRATE powder in water (>140F) with vigorous mixing.
[0042] HOMOGENIZE at >3000 psi to produce sterol-lecithin micelle.
[0043] ADDITION of suitable spray drying adjunct.
[0044] SPRAY DRY to produce free-flowing powder.
[0045] 3. COMINGLE sterols and lecithin in organic solvent.
[0046] REMOVE solvent to produce granular or powdered commingled material.
[0047] HYDRATE powder in water (>140F) and addition of suitable spray drying adjunct with vigorous mixing.
[0048] HOMOGENIZE at >3000 psi to produce sterol-lecithin micelle.
[0049] SPRAY DRY to produce free-flowing powder.
[0050] 4. COMINGLE sterols and lecithin in organic solvent.
[0051] REMOVE solvent to produce granular or powdered commingled material.
[0052] HYDRATE powder in water (>140F) with vigorous mixing.
[0053] HOMOGENIZE at >3000 psi to produce sterol-lecithin micelle.
[0054] ADDITION of suitable spray drying adjunct.
[0055] SPRAY DRY to produce free-flowing powder.
[0056] Pasteurization may be added between HOMOGENIZE and SPRAY DRY for 1 & 2, and between HOMOGENIZE and ADDITION for 3 & 4.
[0057] The following examples are offered to further illustrate, but not limit the process of the present invention.
EXAMPLES
[0058] 1) Sterols were added to lecithin in hexane. The sterols-lecithin mix were applied to a drum dryer. A solid material of commingled sterols-lecithin was scraped from the drum. The solid was ground to a course powder. The course powder was hydrated in water followed by the addition of maltodextrin (>140F; 1.5 parts course powder, 1.5 parts spray drying adjunct; 7 parts water) under vigorous mixing. The was passed solution through a homogenizer at 8000 psi followed by a High Temperature Short Time pasteurizer set at commonly practiced industry settings. Finally, the solution was spray dried using commonly practiced industry settings to produce a free-flowing powder.
[0059] 2) Sterols were added to lecithin in hexane. The sterols-lecithin mix were applied to a drum dryer. A solid material of commingled sterols-lecithin was scraped from the drum. The solid was ground to a course powder. The course powder was hydrated in water followed (>140F; 1.5 parts course powder, 7 parts water) under vigorous mixing. The solution was passed through a homogenizer at 8000 psi followed by a High Temperature Short Time pasteurizer set a commonly practiced industry settings. Next, 1.5 parts maltodextrin were added under vigorous stirring. The solution was spray dried using commonly practiced industry settings to produce a free-flowing powder. For low pH applications in solution, various gums, such as guar, xanthan, or pectin may be useful as stabilizer.
[0060] 3) Yogurt products of the formulations shown in Appendix A were made using the compositions of the present invention. As will be recognized by those of skill in the art, any appropriate yogurt culture, and any number of substitute ingredients, may be used in such yogurt product formulations.
[0061] It can be seen from the above examples that the composition prepared in accordance with the process of this invention will have improved characteristics for production, processing, handling and applications, and that in general all of the objectives of the invention are achieved.
[0062] It should be understood that certain modifications should be and will be apparent to those of ordinary skill in the art, and that such modifications to the precise procedures in compositions set forth herein are intended to come within the spirit and scope of the invention either literally or by doctrine of equivalents. In this light, the following claims are asserted. All references cited herein are hereby incorporated herein by reference in their entirety. | A process for producing a free-flowing powder comprising water dispersible sterols, the process comprising commingling sterols and lecithin in an organic solvent, removing the solvent to produce a commingled solid material, grinding the commingled solid to produce a powder, hydrating the powder in water, adding a spray drying adjunct before or after homogenization of the powder, and spray drying the homogenized product. | 0 |
[0001] This application is a continuation of U.S. application Ser. No. 14/607,015, filed Jan. 27, 2015, now U.S. Pat. No. 9,555,182, which is a continuation of U.S. application Ser. No. 13/903,241, filed May 28, 2013, now U.S. Pat. No. 8,939,926, which is a continuation of U.S. application Ser. No. 12/925,922, filed Nov. 2, 2010, now U.S. Pat. No. 8,480,606, which is a continuation of U.S. application Ser. 12/322,594, filed Feb. 4, 2009, now U.S. Pat. No. 7,824,356, which is a continuation of U.S. application Ser. No. 10/791,075, filed Mar. 1, 2004, now U.S. Pat. No. 7,488,448.
FIELD OF THE INVENTION
[0002] The field of this invention is cardiac circulatory assist and, more specifically, cardiopulmonary bypass.
BACKGROUND OF THE INVENTION
[0003] During cardiovascular surgical procedures, the heart is often arrested and the patient is placed on cardiopulmonary bypass. In addition, a subset of patients with cardiopulmonary complications and or disease will be placed on partial longer-term cardiopulmonary bypass. These patients include, but are not limited to: neonates with severe pulmonary lung disease, bridge to transplant patients, liver transplant patients and patients with severe myocardial trauma accompanied by pump failure. Such cardiopulmonary bypass is used to support the patient's circulation and/or pulmonary function while the heart is being surgically repaired or the failing organ is allowed to recover. Typical surgical repair procedures include valve replacement, annuloplasty, coronary artery bypass grafting, total heart replacement, cardiac assist placement, repair of tetralogy of Fallot, repair of atrial and ventricular septal defects, heart and/or lung transplantation, liver transplantation and the like. Cardiopulmonary bypass devices use a cannula to remove blood from the patient where it is oxygenated, purged of carbon dioxide, heated or cooled, filtered and pumped back into the systemic circulation of the patient. Blood filters are used in the cardiopulmonary bypass system to trap particulates and gas bubbles that are generated in the extracorporeal loop. Blood filters prevent particulates and gas bubbles from being pumped back into the patient. The most common gas entrained within the blood of an extracorporeal circuit is air. Such particulates and gas bubbles, also known as emboli, can cause blockage in the arterioles and capillary beds and lead to ischemic cell death. Consequences of such ischemic cell death may affect organ function (viz. intestine, pancreas, kidney, brain, etc.) and result in sepsis, renal failure and neurological defects such as loss of memory, cognitive function, and changes in personality.
[0004] Modern blood filters do trap emboli and remove debris before they are pumped back into patients but it has been scientifically validated that small gas bubbles, primarily air, and certain particulate substances missed by these filters are returned to the patients and compromise patient recovery. Patients who undergo cardiopulmonary bypass are often subject to some degree of neurological deficit as a result of the gas bubbles and other embolic materials. This phenomenon is sometimes characterized as “Pump Head”.
[0005] Current blood filters are considered to be adequate for removing larger debris and large gas bubbles from the blood, but patient outcomes would be improved if small gas bubble and particulate removal efficiencies were higher. One of the primary problems with current blood filters is that when the mesh size is increased to screen out smaller particles and bubbles, the pressure drop across the filter becomes unacceptably high at normal blood flow rates. Such unacceptably high pressure gradients can potentially cause tubing or connection failures resulting in blood leaks or air leaks into the system, either of which could be catastrophic. Typical examples of the prior art in blood filters include U.S. Pat. No. 4,919,802 to Katsura, U.S. Pat. No. 4,411,783 to Dickens et al., U.S. Pat. No. 5,279,550 to Habib et al., U.S. Pat. No. 5,5,632,894 to White et al., and U.S. Pat. No. 5,683,355 to Fini et al. These patents disclose filters and bubble traps that are static devices employing filter screens to collect the debris and bubbles.
[0006] Additionally, U.S. Pat. Nos. 4,411,783, 4,919,802, and 5,632,894 disclose use of tangential blood inflow and a gas vent at the top center of the filter to improve bubble removal. The tangential inflow generates centrifugal effects to move the bubbles to the center of the device. However, since these are not active systems, they are unable to generate the rotational velocities necessary to adequately rid the blood of small bubbles that can cause neurological defects. A recent publication by Schoenburg (Ref J Thorac Cardiovasc Surg 2003:126:1455-60) describes an air bubble trap, which incorporates a three channel helix to cause the blood to passively rotate around the axis of the tube causing the centrifugal forces to direct air bubbles to the center of the flow stream where they are evacuated via a special collection tube. None of these devices impart rotational motion using an active drive system, which can rotate the blood at much higher rates and thus generate higher separation forces on the bubbles to remove them from the blood.
[0007] New devices and methods are needed to more efficiently remove gas bubbles from the blood of a patient undergoing circulatory support without traumatizing blood elements and without unacceptably increasing the pressure drop across the filter to dangerous levels.
SUMMARY OF THE INVENTION
[0008] This invention relates to a blood filter, blood-air filter, or trap for removing air or other gas bubbles and particulate matter (both large and small) from the blood of a patient during assisted circulation. The present invention is an active device that accepts blood at its inlet, actively rotates the blood to drive the bubbles toward the center of the device under centripetal force, and allows separation of the blood from the aforementioned bubbles. More dense materials, such as blood cells, move toward the periphery of the filter or are otherwise trapped by filter meshes. The device comprises a chamber or housing with a blood inlet and a blood outlet. In addition, the chamber has a third outlet for removing gas from the blood. The device additionally comprises a stirring rod or impeller to spin the blood circumferentially within the chamber. This stirring rod or impeller is coupled to a rotary motor that generates the rotational energy necessary to separate bubbles from the blood. The present invention actively removes gas bubbles and debris from the blood, including the tiny gas bubbles and particulates which current blood filters are unable to remove. The gas bubbles have less mass than the same volume of blood, i.e. the bubbles are buoyant in blood, so that rotation causes them to move toward the center of the blood filter by centripetal force. The centripetal force accelerates the bubbles until the bubbles reach a radial velocity where the drag force balances the centrifugal force. The blood filter of the present invention is designed to remove the majority of bubbles of size greater than 7 to 10 microns in diameter in the time the blood takes to traverse the volume of the filter. Thus, this is a single-pass bubble filter for a large majority of the bubbles. The design is optimized for bubbles 7 to 10 microns in diameter or larger. Bubbles smaller than 7 to 10 microns are considered less harmful to patients than larger bubbles because they will pass through the capillary beds of the patient.
[0009] In accordance with another aspect of the invention, a method is described to remove bubbles from blood. This method includes the steps of passing the blood into a circular, axially elongate or cylindrical chamber and actively spinning the blood within the chamber at high rotational rates to move the bubbles to the center of the chamber. In a further aspect of the invention, the air is removed from the blood at the center of the chamber and the blood is drawn off along the outer periphery of the chamber where it is ultimately returned to the patient.
[0010] The present invention distinguishes over the cited prior art because it uses an active component to spin the blood to forcibly remove gas bubbles from the blood. The invention is most useful during surgery when cardiopulmonary bypass is instituted to maintain the patient on temporary cardiopulmonary support. It is also useful for removal of gas and bubbles during intravenous infusion of liquids to a patient. Patients with increased risk of pulmonary emboli are especially vulnerable during intravenous infusion and would benefit from such protection.
[0011] For purposes of summarizing the invention, certain aspects, advantages and novel features of the invention are described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A general architecture that implements the various features of the invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention. Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements.
[0013] FIG. 1 illustrates a breakaway view of the blood filter of the current invention showing a cross-sectional view of the internal rotating component and the blood inflow port as well as the motor drive and pole clamp.
[0014] FIG. 2A illustrates a breakaway view of the disposable blood filter of the current invention. An impeller that utilizes vanes is shown in cross-section.
[0015] FIG. 2B illustrates a top view of the vane-type impeller through a cross-sectional view of the disposable blood filter of the present invention.
[0016] FIG. 3A illustrates a front exterior view of the blood filter and motor drive.
[0017] FIG. 3B illustrates a side exterior view of the blood filter and motor drive, showing the blood inlet port and blood outlet port.
[0018] FIG. 4 illustrates a schematic drawing of the cardiopulmonary bypass loop with the blood filter of the current invention in place.
[0019] FIG. 5 illustrates a sectional view of another embodiment of the blood filter using a conical impeller with no vanes.
[0020] FIG. 6 illustrates a sectional view of another embodiment of the blood filter using an axial inlet port and a screen-type cylindrical impeller.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 illustrates a breakaway view of a blood filter assembly 8 of the present invention. The blood filter assembly 8 comprises a disposable blood filter 10 and a motor drive 26 . The disposable blood filter 10 comprises a shell 12 , an impeller 14 , a blood outlet port 16 , a gas outlet or central port 18 , a blood inlet port 20 , an optional baffle 22 , and a bearing shaft 24 . The optional baffle 22 optionally comprises a plurality of vent holes 28 . The impeller 14 comprises a magnetic coupler 30 . The shell 12 optionally comprises a plurality of lock down tabs 46 , a gas trap 57 and a bleed valve 58 .
[0022] The motor drive 26 comprises a motor 32 , a power cable 34 , a power switch 36 , a central shaft 38 , a magnetic driver 40 , a housing 42 , and a plurality of optional lock-down or clamping mechanisms 44 to hold the disposable blood filter shell 12 to the motor drive housing 42 . The motor drive 26 optionally comprises a power-on lamp 48 , an extension arm 54 , and a pole clamp 50 . The optional pole clamp 50 further comprises a setscrew 52 .
[0023] The shell 12 of the disposable blood filter 10 is an axially elongate cylinder or vessel, most preferably disposed with its axis parallel to the direction of gravity. The top of the shell 12 is, preferably, conical. The gas outlet port 18 is preferably disposed along the central axis at either the top or the bottom of the shell 12 . The blood inlet port 20 and the blood outlet port 16 are, preferably located on the periphery of the shell 12 . The blood inlet port 20 may be located lower or higher on the periphery of the shell 12 than the blood outlet port 16 but the gas outlet port 18 , otherwise known as a gas vent, is most preferably located higher than the blood inlet port 20 and the blood outlet port 16 . The gas outlet port 18 is located at the entrance of the gas trap 57 and the bleed valve 58 is located at or near the highest point of the gas trap 57 . The gas outlet port 18 , in another embodiment, is located at the center of the bottom of the blood filter. The gas and blood, which is removed from either gas outlet port 18 is routed back to the venous reservoir of the cardiopulmonary bypass system thus minimizing blood loss during the surgical procedure. The bottom-mounted gas outlet port 18 may be able to take advantage of fluid patterns generated within the shell 12 to enhance separation of gas from the blood.
[0024] The diameter of the blood inlet port 20 and the blood outlet port 16 is generally 1.2 cm and ranges from 0.2 cm to 3.0 cm. The diameter of the gas outlet port 18 is from 0.1 cm to 2.0 cm. The diameter of the shell 12 is generally from 1 cm to 30 cm, more preferably from 3 cm to 15 cm and most preferably 5 to 10 cm. The length of the shell 12 ranges from 2 cm to 30 cm. Smaller lengths and diameters of the shell 12 are preferable because the priming volume of the disposable blood filter 10 is minimized with minimized dimensions and a small priming volume reduces patient blood lost during a bypass procedure.
[0025] The baffle 22 is a cylindrical structure located inside the conical top of the disposable filter 10 under the gas outlet port 18 . The series of vent holes 28 perforate the circumferential periphery of the baffle 22 . The diameter of the baffle 22 is optimized to shunt the blood with gas bubbles away from the blood outlet port 16 . The length of the baffle 22 is generally such that the lowermost portion of the baffle 22 is at or below the height of the blood outlet port 16 . The maximum radius of the baffle 22 is equal to or less than the distance from the innermost extent of the blood outlet port 16 from the center of the shell 12 .
[0026] The gas outlet port 18 directs gas out of the disposable blood filter 10 and into the gas trap 57 where the small gas bubbles coalesce into macroscopic amounts of gas that is then bled off through the bleed valve 58 . The gas trap 57 is, preferably, transparent so that the clinician may monitor the buildup of macroscopic amounts of gas within the gas trap. The bleed valve 58 is either a manual valve, such as a stopcock, or it is an automatic valve that opens when a pre-determined amount of gas builds up within the gas trap 57 . The blood and foam collected in the gas trap 57 are preferably returned to a reservoir for recombination with the rest of the blood in the extracorporeal circulation.
[0027] The bearing shaft 24 holds the impeller 14 at the center of the bottom inside surface of the shell 12 , which is along the central axis of the disposable filter 10 . The impeller 14 rotates freely around the bearing shaft 24 . The impeller 14 may be designed as a simple axially elongate stirring bar with its axis perpendicular to the axis of the shell 12 , like that used by laboratory stirrers. Preferably, the impeller 14 is an axially elongate structure with its axis parallel to that of the shell 12 and a plurality of vanes that engage the blood and force the blood to spin. More preferably, the impeller 14 is a smooth axially elongate cylinder, cone, or other axially elongate shape that rotates and causes the blood to rotate by viscous effects. Such a smooth cylinder is known in the art to move the blood gently, through shear effects, causing minimal damage to blood components such as red cells and leucocytes. In this embodiment, the impeller 14 contains the magnetic coupler 30 . The magnetic coupler 30 is preferably a permanent magnet with a north and a south pole which are disposed at diametrically opposed positions on the impeller 14 and distributed so that the center of mass and the center of force is aligned with the rotational central axis of the impeller 14 . Typical permanent magnet materials include, but are not limited to, samarium cobalt, neodymium iron boron, ceramics, and the like. A coupling magnet on a drive unit will be similarly configured and will attract opposing polarities on the magnetic coupler 30 in the impeller 14 . The magnetic coupler 30 is in one embodiment, embedded and enclosed within the impeller 14 . Typical methods of embedding the magnetic coupler 30 include injection molding, insert molding, machining the cavity and inserting the magnetic coupler 30 followed by gluing or bonding a cap over the magnetic coupler 30 . The impeller 14 with the magnetic coupler 30 is preferably balanced carefully so that the impeller 14 does not vibrate or wobble when it spins.
[0028] The lockdown tabs 46 are located around the bottom outside edge of the cylindrical shell 12 of the disposable filter. Correspondingly, the motor drive 26 has lockdown or clamping mechanisms 44 located around the top outside edge of the cylindrical housing 42 . The lockdown tabs 46 mate with the lockdown mechanisms 44 and when the lockdown mechanisms 44 are in the locked position, the disposable filter 10 is attached to the motor drive 26 . In order to allow for disposability of the blood handling components, the lock-down or clamping mechanisms 44 permit reversible fastening of the blood filter shell 12 to the motor drive 26 . This is important since cross-contamination of patients' blood must be prevented in order to control the spread of infectious diseases. The motor drive 26 may be reusable. In this embodiment, the clamping mechanism 44 is a set of latches that grasp protrusions 46 on shell 12 and hold it to the housing 42 of the motor drive 26 . In other embodiments, the clamping mechanism 44 may also be a bayonet mount, spring-loaded catch, magnetic latch or other fastening mechanism.
[0029] The motor 32 of the motor drive 26 is affixed to the housing 42 . The central shaft 38 is affixed to, and protrudes from, the rotating armature of the motor 32 . The motor drive 26 most preferably uses an electric motor 32 powered by a 6 to 24 volt direct current (DC) power supply. Such DC power supplies comprise batteries or electronics to convert alternating current electricity to direct current. The motor 32 could also be designed to use standard 110 VAC to 220 VAC. A direct current power source is preferable to an alternating current power source because patient and hospital staff protection is maximized with the DC system. The motor 32 is powered through the power cable 34 . The power switch 36 and the power on light 48 are physically affixed to the housing 42 and electrically connected to the power line 34 . The power on light 48 turns on only when the motor 32 is electrically energized by activating the power switch 36 . The electric motor 32 spins at a pre-determined constant speed. The central shaft 38 rotates from 100 to 10,000 RPM and most preferably from 500 to 5,000 RPM. Alternative embodiments of the motor 32 include, but are not limited to, compressed air or hydraulically driven motors.
[0030] In this embodiment, the magnetic driver 40 is affixed to the shaft 38 and rotates with the shaft 38 . The magnetic driver 40 is located near the perimeter of the housing 42 so that when the disposable blood filter 10 is positioned against the motor drive 26 , the magnetic driver 40 is magnetically engaged to the magnetic coupler 30 that is affixed to the impeller 14 of the disposable blood filter 10 . The motor 32 spins the shaft 38 and the magnetic driver 40 . The magnetic driver 40 has a magnetic field that acts through the housing 42 of the motor drive 26 and through the shell 12 of the disposable blood filter 10 . The magnetic field interacts with the magnetic coupler 30 in the impeller 14 and causes the impeller 14 to rotate at the same rate as that of the motor 32 . The magnetic driver 40 is preferably a bar magnet that spins about its central region with north and south poles diametrically opposed and equidistant from the center of rotation.
[0031] The magnetic driver 40 and magnetic coupler 30 may both be permanent magnets. Alternatively, at least one of either the magnetic driver 40 or the magnetic coupler 30 may be permanent magnets with the other being a material that is magnetically attracted to a magnet. In another embodiment, the magnetic coupler 30 or the magnetic driver 40 may be electromagnets energized by batteries or by another type of electrical power supply. Typical permanent magnets are fabricated from materials such as, but not limited to, neodymium iron boron, iron, ceramics, samarium cobalt and the like. Materials that are magnetically attracted to a magnet include, but are not limited to, iron or metallic alloys of iron. The magnetic coupler 30 is desirable because it allows for a sealed disposable blood filter 10 to be attached to the reusable motor drive 26 . In an alternate embodiment, a direct coupling between the central shaft 38 and the impeller 14 may be made using interlocking fingers on the impeller 14 that mate with the shaft 38 through a rotary seal.
[0032] Attachment of the blood filter assembly 8 to a cardiopulmonary bypass system is accomplished using the optional pole clamp 50 . The pole clamp 50 is connected to the housing 42 of the motor drive 26 by the arm 54 and is secured to a pole by the setscrew 52 . By attaching the reusable motor drive 26 of the blood filter assembly 8 to a pole or other part of a pump console in the cardiopulmonary bypass system, interchange of the disposable blood filter 10 is more easily accomplished.
[0033] Typical materials from which the disposable blood filter shell 12 and baffle 22 are fabricated include polycarbonate, polypropylene, polyethylene, polystyrene, polyvinyl chloride, fluorinated ethylene polymer (FEP), poly tetrafluoroethylene (PTFE), polysulfone, and the like. These same materials are used to fabricate the housing 42 of the motor drive 26 , although metals such as aluminum, stainless steel and the like would also work. Optionally, the interior of the shell 12 of the disposable blood filter 10 may be treated with an antithrombogenic material such as heparin and a bonding agent. The impeller 14 is made from materials that include polycarbonate, polypropylene, polyethylene, polystyrene, polyvinyl chloride, fluorinated ethylene polymer (FEP), polysulfone, poly tetrafluoroethylene (PTFE), and the like.
[0034] FIG. 2A shows a breakaway view of the shell 12 of the disposable blood filter 10 , which comprises the blood inlet port 20 and the impeller 14 . The impeller 14 further comprises the bearing shaft 24 , the magnetic coupler 30 and a plurality of vanes 15 .
[0035] Referring to FIG. 2A , the vanes 15 are affixed to, or are integral to, the impeller 14 and appear as fins, rotors or propeller blades. The magnetic coupler 30 is embedded within or affixed to the impeller 14 .
[0036] The vanes 15 are rotated by the impeller 14 , which in turn, is rotated by the magnetic coupler 30 around the bearing shaft 24 . The blood enters the shell 12 through the blood inlet port 20 and is rotated by the vanes 15 on the impeller 14 .
[0037] FIG. 2B shows a top cross-sectional view of the shell 12 of the disposable blood filter 10 . In this embodiment, the impeller 14 has four vanes 15 . Any number of vanes 15 from one to 50 may be employed in the impeller 14 . The length and diameter of the vanes 15 are roughly equal to the overall length and diameter of the impeller 14 .
[0038] FIG. 3A shows an exterior view of the blood filter assembly 8 , comprising the disposable blood filter 10 and the motor drive 26 , viewing along the axis of the blood inlet port 20 and blood outlet port 16 . Also shown in FIG. 3A are the gas outlet port 18 , the gas trap 57 , the bleed valve 58 , the lock-down mechanisms 44 , and the lock-down tabs 46 on the shell 12 . FIG. 3B shows an exterior view of the blood filter assembly 8 , comprising the disposable blood filter 10 and the motor drive 26 , viewing perpendicular to the axis of the blood inlet port 20 and the blood outlet port 16 . Also shown in FIG. 3B are the gas outlet port 18 , the gas trap 57 , the bleed valve 58 , the lock-down mechanisms 44 , and the lock-down tabs 46 on the shell 12 . FIGS. 3A and 3B clearly show the tangential disposition of the blood inlet port 20 and the optional tangential disposition of the blood outlet port 16 . The blood inlet port 20 is disposed so that blood enters the disposable filter 10 in a direction tangential to the shell 12 to assist with generation of a rotational fluid field within the shell 12 .
[0039] FIG. 4 shows a schematic diagram of a typical cardiopulmonary bypass circuit 60 comprising the blood filter assembly 8 of the present invention. The cardiopulmonary bypass circuit 60 further comprises a patient 62 , a venous drainage cannula 64 , a venous reservoir 66 , a circulatory assist pump 68 , a heat exchanger 70 , an oxygenator 72 , an optional gas pump 74 , a gas bleed line 76 , a particulate filter 78 , and an arterial inlet cannula 80 .
[0040] The venous circuit of the patient 62 is connected to a blood inlet of the venous reservoir 66 through the venous drainage cannula 64 . An outlet of the venous reservoir 66 connects to an inlet of the circulatory assist pump 68 and an outlet of the circulatory assist pump 68 connects to an inlet of the heat exchanger 70 . An outlet of the heat exchanger 70 connects to an inlet of the oxygenator 72 and an outlet of the oxygenator 72 connects to the blood inlet port 20 of the blood filter assembly 8 . The gas outlet port 18 of the blood filter assembly 8 connects, by way of the gas trap 57 and bleed valve 58 , to an inlet of the gas pump 74 . An outlet of the gas pump 74 connects to an inlet of the venous reservoir 66 through the gas bleed line 76 . The blood outlet port 16 of the blood filter assembly 8 connects to an inlet of the particulate filter 78 . An outlet of the particulate filter 78 connects to the patient 62 through the arterial inlet cannula 80 .
[0041] In yet another embodiment, the disposable blood filter assembly 10 is integrated into the venous reservoir 66 to minimize the need for additional priming volume. Since the venous reservoir 66 holds between 10 cc and 1000 cc of blood, the disposable blood filter 10 may be affixed thereto or integrated therein so that the internal volume of the disposable blood filter 10 does not add significantly to the priming volume of the cardiopulmonary bypass circuitry. In this embodiment, the drive unit or motor drive 26 for the filter 10 attaches to a component of the venous reservoir 66 to rotate the impeller 14 of the blood filter 10 . Typically, during cardiopulmonary bypass, venous blood is removed from the patient 62 by the venous drainage cannula 64 and is collected, generally by gravity feed, in venous reservoir 66 where it is de-foamed using standard technology such as de-foaming sponges and bonded surfactants. The venous reservoir 66 generally comprises a blood-air interface and blood entering the reservoir entrains air and other gasses into the blood. In addition, a suction line, used to remove blood from the operative field, returns air and blood to the venous reservoir 66 . The de-foaming devices in the venous reservoir 66 are incapable of removing micro-bubbles or small gas bubbles that have become entrained in the blood, thus the need for a blood filter. The blood is pumped from the venous reservoir 66 and through the rest of the cardiopulmonary bypass circuit 60 by the circulatory assist pump 68 . The blood passes through the heat exchanger 70 where it is cooled for the majority of the procedure to reduce the metabolic requirements of the patient 62 . Typical hypothermia temperatures range from 28 to 35 degrees centigrade. Toward the end of the procedure, the heat exchanger 70 is used to warm the blood to normothermia, approximately 37 degrees centigrade. The blood is next pumped through the oxygenator 72 where it is oxygenated and cleared of carbon dioxide. From the oxygenator 72 , the blood is pumped to the blood filter assembly 8 .
[0042] Referring to FIGS. 1, 3A, 3B, and 4 the blood filter assembly 8 of the present invention is designed to move gas bubbles present in the blood toward the center of the shell 12 so that blood may flow from the outside of the shell 12 through the blood outlet port 16 , free of these bubbles. The blood enters the blood filter assembly 8 through the blood inlet port 20 . Preferably, the blood inlet port 20 is positioned tangential to the shell 12 of the disposable filter 10 . The rotating impeller 14 pushes the blood and causes the blood to rotate. Tangential entry of the blood into the disposable filter 10 imparts a rotational velocity to the blood, thus requiring less shear stress on the blood for the motor 32 to turn the impeller 14 and rotationally accelerate the blood to the required velocity.
[0043] The gas bubbles, many as small or smaller than 10 to 25 microns in diameter, need to be moved to the center of the disposable blood filter 10 in the time it takes for the blood to make a single pass through the filter 10 . By way of example, a typical blood flow rate through the cardiopulmonary bypass circuit 60 is approximately 5 liters per minute. A typical diameter for the blood filter 10 is 7.5 centimeters. With a 10-centimeter height, the blood filter will have a priming volume of about 440 cubic centimeters. That means blood will dwell within the blood filter 10 for about 5 seconds. The gas bubbles, therefore, have about 5 seconds to move radially inward to within the diameter of the baffle 22 and, thus, be separated from the blood that flows through the blood outlet port 16 . Rotational rates specified for this blood filter assembly 8 are sufficient to move bubbles as small as 7 to 10 microns to the center of the blood filter 10 within 5 seconds by means of centrifugal force.
[0044] Buoyancy causes the gas bubbles to rise, relative to gravitational attraction, and pass out of the gas outlet port 18 and into the gas trap 57 , although the gas removal may be augmented by an optional external pump 74 , powered by electricity, for example.
[0045] Gas and some blood, removed from the gas outlet port 18 of the disposable blood filter 8 are collected in the gas trap 57 and pumped back into the venous reservoir 66 by optional gas pump 74 through the gas bleed line 76 where the blood component can be reclaimed. The optional gas pump 74 is a continuously operating pump. Optionally, gas pump 74 is a demand pump and pumps only when the volume of gas collects in sufficient quantity to warrant return to the venous reservoir 66 . This may be accomplished using a fluid level sensor mounted in the blood filter assembly 8 or gas bleed line 76 that controllably turns power to the gas pump 74 on and off. The bleed valve 58 is optional and not necessary if the gas pump 74 is used.
[0046] Referring again to FIG. 4 , the blood is pumped from the blood filter assembly 8 through the blood outlet port 16 to the particulate filter 78 . The particulate filter 78 may be integral to the blood outlet port 16 . The particulate filter 78 filters solid debris and particulates, generally larger than 25 microns, using screens or filter meshes. The oxygenated blood is cleared of most particulates greater than 25 microns and most gas bubbles greater than 7 to 10 microns when it is returned to the patient 62 via the arterial inlet cannula 80 .
[0047] FIG. 5 shows another embodiment of the disposable blood filter 10 wherein the impeller 14 is an axially elongate, smooth shape without any vanes or protrusions. This type of impeller 14 uses viscosity to create shear forces that cause the blood to spin. Referring to FIGS. 1 and 5 , the impeller 14 is driven through the magnetic coupler 30 that is adapted to interact with the magnetic driver 40 . The preferred shape of the impeller 14 is conical and helps reduce the priming volume of the system. The blood inlet port 20 , the blood outlet port 16 , and the gas outlet port 18 are disposed in the same configuration as that shown in FIG. 1 .
[0048] FIG. 6 shows yet another embodiment of the disposable blood filter 10 wherein the impeller 14 is an axially elongate perforated structure such as a cylinder or cone. The impeller 14 , in this embodiment, comprises a filter mesh wall 56 . The filter mesh wall 56 is made from a mesh material or screen to provide particulate filtering for the blood that eliminates the need for a secondary particulate filter. The mesh material or screen has a maximum pore size of 25 to 35 microns to limit the size of particulates that can pass through the mesh wall 56 .
[0049] The blood outlet port 16 is disposed tangential to the shell 12 of the disposable blood filter 10 . However, the blood inlet port 20 is disposed along the central axis of the disposable blood filter 10 . The blood inlet port 20 , optionally, rotates with the impeller 14 to pre-rotate the blood as it enters the filter system and to reduce shear forces acting on the blood at the center of the disposable blood filter 10 . The blood enters the filter 10 inside the impeller 14 . The gas outlet port 18 is disposed coaxially around the blood inlet port 20 to allow for gas entrapment and removal. The blood outlet port 16 is disposed outside the filter mesh wall 56 of impeller 14 and blood must pass through the filter mesh walls 56 to reach the blood outlet port 16 .
[0050] In another embodiment, the blood is spun by magnets that directly interact with the ionic potential of the blood.
[0051] This embodiment requires multiple high output electromagnets that are disposed circumferentially around the perimeter of the disposable blood filter 10 . These electromagnets are fired sequentially to form a rotational magnetic field on the blood. A central magnet or a plurality of central magnets is disposed on the core of the disposable blood filter 10 and serves as the alternative pole for the magnets disposed circumferentially around the filter. The blood inlet port 20 and blood outlet port 16 are disposed tangential to the shell 12 of the disposable blood filter 10 . The gas outlet port 18 is disposed as close to the axis of the disposable blood filter 10 as possible, given the central magnet structure, at its highest point.
[0052] In another embodiment of this device, the blood filter assembly 8 also serves as a primary pump in a cardiopulmonary bypass circuit since centrifugal type pumps are regularly used in a large number of clinical cases. Centrifugal pumps are considered less damaging to the blood than their less-expensive roller-pump alternatives.
[0053] In yet another embodiment, the blood filter assembly 8 can be used as a hemoconcentrator. A one-pass hemoconcentrator is useful in separating non-cellular fluids from the cells in the blood at the end of the bypass procedure. The rotational rates of the hemoconcentrator of the current invention will enable such separation of cells. The blood cells are forced to the perimeter of the shell 12 of the disposable blood filter 8 where they are drawn off through the blood outlet port 16 . Non-cellular materials, such as plasma, migrate to the center of the filter where the non-cellular materials are drawn out through the central port 18 . Rotational spin rates of 1 ,000 to 20,000 RPM, and more preferably 5,000 to 10,000 RPM, are required to cause adequate centrifugation effects to separate the cellular components from the non-cellular components in a device of 5 to 15 cm diameter.
[0054] In a further embodiment, a pressure less than the ambient pressure within the cardiopulmonary bypass circuit 60 is applied to the interior of the disposable blood filter shell 12 . The pressure within the cardiopulmonary bypass circuit 60 is, generally, within the range of 0 to 200 mm Hg. By locally reducing the pressure within the blood filter shell 12 , the bubble size will be increased and the efficiency of the bubble separation will be likewise increased. The internal pressure within the disposable blood filter 12 is reduced by adding a pump to forcefully remove blood from the interior of the shell 12 through either the blood Outlet port 16 or the gas outlet port 18 . Additionally, an optional restriction, or narrowing of the channel, is added to the blood inlet port 20 .
[0055] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A system and method for removing gas bubbles from fluid. An active filter apparatus forces the bubbles to the center of the filter, while a pump supplies fluid to the filter. | 0 |
FIELD OF THE INVENTION
Embodiments disclosed herein relate to a power system operated by changing water levels, e.g., tidal, and related methods.
BACKGROUND AND SUMMARY OF THE INVENTION
Although not yet widely used, generating power from changing water levels such as tides has potential for future electricity generation. Tides are more predictable than both wind energy and solar power. What is needed then are effective, lower cost tidal power electrical generating systems and methods.
Advantageously, the present invention pertains to efficient and cost-effective new methods and systems for generating power from tidal energy. In one embodiment, a hydropower generation method utilizes changing water levels. The method comprises collecting water percolating through a permeable substance into a first underground region as a water level is increased. The collected water is released from the first underground region into a second underground region. In this manner a first hydro turbine and generator operatively coupled therebetween can generate power. Water may be released from the second underground region as water level is decreased. This can operate a second hydro turbine and generator operatively coupled therebetween to also generate power.
In another embodiment the present invention pertains to a tidal power system. The system comprises a first underground region for collecting water percolating through a coastal area medium at a higher tide level and a second underground region capable of fluid communication with the first underground region. Water is released from the first underground region to the second underground region through an inflow pipe. The inflow pipe further comprises a first hydro turbine and generator operatively coupled thereto to generate power. The system has an outflow pipe through which water is released from the second underground region. The outflow pipe further comprises a second hydro turbine and generator operatively coupled thereto to generate power. The system is configured to release water at separate times from the first underground region and the second underground regions to operate the hydro turbines and generators and thereby produce electricity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of a tidal power system.
FIG. 2 illustrates filling a seepage region of the tidal power system at or near high tide.
FIG. 3 illustrates a power generating state of the tidal power system at or near high tide.
FIG. 4 illustrates a steady state of the tidal power system.
FIG. 5 illustrates a power generating state of the tidal power system at or near low tide.
DETAILED DESCRIPTION
A power system and method is disclosed. The power system and method may be configured to effectively capture energy from changing water levels such as tides using water percolation through a permeable substance. The specific permeable substance is not particularly important so long as water is capable of being collected through it. Examples of permeable substances include those substances often found on or near coastal waters or beaches. For example, the permeable substance may comprise sand, gravel, rock, and mixtures thereof. In this manner as tides vary between, for example, a low tide and a high tide power may be generated.
In one embodiment a tidal power system may include two parts: at least one seepage region and at least one water storage region. The invention is described herein with respect to one seepage region and one water storage region. However, if desired the system may include two, three, or even four or more seepage regions. Similarly, the system may include two, three, or even four or more water storage regions coupled to the one or more seepage regions. In addition, two or more systems may be coupled together. In this manner, if desired the systems may share a power storage, transmission, and/or distribution system.
The seepage region may be constructed in any convenient manner which manner may differ depending upon, for example, the specific application, available materials, and other components. Generally, the seepage region may comprise an underground region or space which may have one or more structured supports. If desired, the seepage region may employ a filter-like material configured to, for example, block a majority of sand, dirt and other undesirable materials while allowing water to infiltrate the space as it percolates through a permeable substance, e.g., sand, on or near the coastal water. The specific filter-like material to be employed is not particularly critical and, if employed, it may conveniently be selected from a mesh, screen, net, or some combination thereof.
In practice, the water level of the collected water in the seepage region varies by application. In some embodiments the water level generally corresponds with current tide levels. In this manner the collected water may serve as the water source for the tidal power system and hydraulic head during power generation.
The water storage region, like the seepage region, may be constructed in any convenient manner which manner may differ depending upon, for example, the specific application, available materials, and other components. Generally, the water storage region is near the seepage region and located at a similar elevation. The elevation of both regions is generally at or near sea level. The water storage region usually comprises a space or tank that is substantially sealed off or insulated from undesired water infiltration through percolation or otherwise. In practice water may enter the water storage region at a desired time when a water inflow pipe or other connection is opened between the seepage region and the water storage region. For efficiency, the desired time to open the connection to release at least a partial amount up to all of the water may be at or near high tide and/or sometimes during absolute high tide.
As the water storage region fills, water may travel through the water inflow pipe and, if desired, operates a hydro turbine and generator operatively coupled to the water inflow pipe. The type of hydro turbine and generator are not particularly critical and may be selected from any of those known or hereinafter discovered. Generally, the water flow encounters and rotates one more turbines comprising one or more blades, which in turn, rotates a shaft member of a generator for generating electricity.
Once the water storage region is filled to its desired capacity, the water is held in the storage region until it is desired to be released. For efficiency, at least a partial amount up to all of the water may be released at or near low tide and/or sometimes during absolute low tide. When the outflow pipe is opened, water flows out of the water storage region, usually directly into the local body of water adjacent the system. Advantageously, at least some up to all of the water flowing from the water storage region through the outflow pipe may be used to operate a hydro turbine and generator operatively coupled to the water outflow pipe. Generally, the water flow encounters and rotates one or more turbines comprising one or more blades, which in turn rotates a shaft member of a generator for generating electricity.
FIG. 1 illustrates an embodiment of a tidal power system. The tidal power system may be installed in a coastal beach 50 or any other location bordering a body of water 52 experiencing tides or similar water energy. A deeper portion of the beach 50 may be sand 54 that is constantly saturated with water (“saturated sand”), and which generally corresponds with low tide levels. The tidal power system may be positioned at a level in the beach 50 just at or above the saturated sand 54 . The tidal power system includes a seepage region 102 for collecting water percolating through the beach 50 . The seepage region 102 may be an underground space of any suitable size, dimension, or shape within the beach 50 . In one embodiment, the seepage region 102 may be enclosed by wire or plastic mesh or screen, which effectively defines the seepage region 102 . The mesh or screen may completely or partially enclose the seepage region 102 . Any available mesh or screen sizes may be used which are suitable for blocking and preventing a deleterious amount of dirt or sand or other unwanted particles or objects from entering the seepage region while still allowing water to enter the seepage region. The tidal power system further includes a water storage region 106 .
In one embodiment, the water storage region 106 may be a storage tank or any type of enclosure that is sealed off from any unwanted water infiltration. The water storage region 106 may be an suitable size or shape. The water storage region 106 may be positioned directly adjacent the seepage region 102 , or at a suitable distance from the seepage region 102 .
The tidal power system includes an inflow pipe 108 of any suitable size or type that allows fluid communication between the seepage region 102 and the water storage region 106 . The inflow pipe 108 may be disposed as low as possible near a bottom of the seepage region 102 and water storage region 106 . In this manner any use of the hydraulic head when the seepage region is filled may be maximized as will be explained below.
The inflow pipe 108 may include one or more pipe valves 110 of any type configured to control fluid communication between the seepage region 102 and the water storage region 106 . The pipe valves may be manually or automatically operated, including but not limited to, electrically, hydraulically, or pneumatically. The tidal power system further includes an inflow hydro turbine and generator 112 which is operated by flow of water from the seepage region 102 to the water storage region 106 as described below.
The tidal power system further includes an outflow pipe 114 of any suitable size or type that allows fluid communication between the water storage region 106 and a body of water 52 . The outflow pipe 114 may be disposed as low as possible near a bottom of the water storage region 106 . The outflow pipe 114 includes a first pipe valve 116 of any type disposed at a first end or near the water storage tank 106 , and a second pipe valve 118 of any type disposed at a second or distal end of the outflow pipe 114 . The pipe valves may be manually or automatically operated, including but not limited to, electrically, hydraulically, or pneumatically. The outflow pipe 114 further includes a hydro turbine and generator 120 which is operated by flow of water from the water storage region 106 to the body of water 52 as described below.
Methods of using the tidal power system are described as follows in accordance with FIGS. 2-5 . FIG. 2 illustrates a current tide level higher than low tide (e.g., at or near high tide). Pipe valves of the outflow pipe 114 , particularly distal pipe valve 118 , are closed to prevent water from entering the outflow pipe 114 . A pipe valve 110 in the inflow pipe 112 is closed to prevent water from entering the water storage region 106 . Water percolating through the porous material of the beach passes through mesh or screen layer and is collected in the seepage region 102 . Water continues to collect in the seepage region 102 until a water level within the seepage region 102 is substantially equal to the current tide level.
FIG. 3 illustrates a power generating state of the tidal power system, that is, a height differential exists between the tide level and corresponding water level in the seepage region 102 , and water level (or lack thereof) in the water storage region 106 . In a first electrical generation stage, water is released or transferred from the seepage region 102 to the water storage region 106 . At or near high tide, sometimes absolute high tide, the pipe valve 110 in the inflow pipe 108 is opened (outflow pipe valve 116 remains closed), and the water storage region 106 is filled with water from the seepage region 102 through the inflow pipe 108 until water levels between the two regions are substantially equal. Water release from the seepage region to the water storage region operates the hydro turbine and generator 112 operatively coupled to the inflow pipe, which generates electricity. FIG. 3 illustrates a lighthouse 56 being powered by electricity generated by the generator 112 during the first electrical generation stage. However, electricity generated may be stored locally and/or transmitted to any device or location needing electricity, whether for consumption or storage.
FIG. 4 illustrates a steady state of the tidal power system in which no electricity is being generated. That is, there is substantially no water level difference between the seepage region 102 and the water storage tank 106 , and therefore there is little or no potential energy to drive water flow between the two regions. However, the water storage region 106 is filled with water in anticipation of a low tide when electricity may again be generated as described below.
FIG. 5 illustrates a power generating state of the tidal power system, that is, a height differential exists between the water level in the water storage region 106 and the tide level, which is at or near low tide. In a second electrical generation stage, water is released from the water storage region 106 . At or near low tide, or sometimes absolute low tide, outflow pipe valves 116 , 118 are opened, and water is released from the water storage region 106 through the outflow pipe 114 . Generally, water released from the water storage region 106 through the outflow pipe 114 flows directly into the local body of water adjacent to the beach, which is at a lower tide. Water release from the water storage region 106 through the outflow pipe 114 operates the hydro turbine and generator 120 coupled to the outflow pipe, which generates electricity. FIG. 5 again illustrates a lighthouse 56 being powered by electricity generated by the generator 112 during the second electrical generation stage. However, electricity generated may be stored locally and/or transmitted to any device or location needing electricity, whether for consumption or storage. In one embodiment, electricity generated during the first and second electrical generation stages may be transmitted to different locations or devices.
Advantageously, the tidal power system disclosed has little to no interaction with marine life, does not substantially interfere with established and/or navigable waterways, and generally does not come into contact with most floating debris. Moreover, the tidal power system is underground and mostly hidden from sight by land and water. Still further, the tidal power system may have the potential to reduce seepage-induced erosion of coastal beaches. These advantages and more will be apparent to the skilled person upon reading the instant specification.
The claimed subject matter is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description. Such modifications are intended to fall within the scope of the appended claims. | The present invention pertains to a new method and system for producing electricity from tidal energy. In one embodiment the system employs at least one underground region for collecting water percolating at a higher tide level and at least another underground region capable of fluid communication with the first underground region. The system is configured to release water at separate times from the underground regions to operate hydro turbines and generators to produce electricity. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 468,223, filed Feb. 22, 1983, U.S. Pat. No. 4,482,504, which is a continuation-in-part application of application Ser. No. 412,624, filed Aug. 30, 1982 U.S. Pat. No. 4,425,284.
FIELD OF THE INVENTION
This invention is a new process for preparing N-phosphonomethylglycine.
BACKGROUND OF THE INVENTION
N-Phosphonomethylglycine and certain salts are particularly effective as post-emergence herbicides. The commercial herbicide is sold as a formulation containing the isopropylamine salt of N-phosphonomethylglycine.
N-Phosphonomethylglycine can be made by a number of methods. One such method, as described in U.S. Pat. No. 3,160,632 is to react N-phosphinomethylglycine (glycinemethylenephosphonic acid) with mercuric chloride in water at reflux temperature, and subsequently separating the reaction products. Other methods are phosphonomethylation of glycine and the reaction of ethyl glycinate with formaldehyde and diethylphosphite. The latter method is described in U.S. Pat. No. 3,799,758. In addition, there is a series of patents relating to the preparation of N-phosphonomethylglycine, including U.S. Pat. Nos. 3,868,407, 4,197,254 and 4,199,354.
Close prior art is U.S. Pat. No. 3,923,877, which teaches the reaction of 1,3,5-tricyanomethylhexahydro-1,3,5-triazine with excess disubstituted phosphite to form (RO) 2 P(O)CH 2 NHCH 2 CN (R is hydrocarbyl or substituted hydrocarbyl) which is hydrolyzed to yield N-phosphonomethylglycine.
Because of the commercial importance of N-phosphonomethylglycine and certain salts as herbicides, improved methods of preparing these compounds are valuable.
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to a process for preparing N-phosphonomethylglycine which comprises:
(1) reacting 1,3,5-tricarboalkoxymethylhexahydro-1,3,5-triazine with an acyl halide, preferably acyl chloride to form the N-carboalkoxymethyl-N-halomethyl amide of the acyl halide;
(2) reacting the amide with a phosphite to form N-carboalkoxymethyl-N-acyl aminomethyl phosphonate; and
(3) hydrolyzing this phosphonate to yield N-(phosphonomethyl)glycine.
DETAILED DESCRIPTION OF THE INVENTION
The process of this invention may be illustrated by the following reaction scheme: ##STR1## wherein R and R 1 are an aliphatic or aromatic group as defined hereinafter, preferably C 1 -C 4 alkyl, most preferably methyl or ethyl and X is chlorine, bromine, or iodine, preferably chlorine. ##STR2## wherein R, R 1 and X are defined as above and R 2 and R 3 are both aromatic groups or both aliphatic group, preferably R 2 and R 3 are C 1 -C 6 alkyl, more preferably C 1 -C 4 alkyl, and R 4 is an aliphatic group, preferably R 4 is C 1 -C 6 alkyl, more preferably C 1 -C 4 alkyl or R 4 is an alkali metal (M), preferably sodium or potassium. ##STR3## wherein R, R 1 , R 2 and R 3 are as defined above and H + is a strong acid such as hydrochloric, hydrobromic, hydriodic, nitric, sulfuric, phosphonic or chloroacetic acid. Preferably H + is hydrochloric or hydrobromic acid and OH - is a strong base such as sodium hydroxide or potassium hydroxide, preferably in an aqueous, aqueous-alcoholic or alcoholic solution. Preferably, the hydroylsis is run in the presence of a strong acid.
In the above reaction scheme the group R and R 1 are not directly involved in reaction step (a) between 1,3,5-tricarboalkoxymethylhexahydro-1,3,5-triazine and the acyl chloride, Groups R, R 1 , R 2 or R 3 are not directly involved in reaction step (b between the) N-carboalkoxymethyl-N-chloromethyl amide reaction product of step (a) and the phosphite. Groups R, R 1 , R 2 and R 3 are removed in reaction step (c) when the phosphonate reaction product of reaction step (is subjected b) to hydrolysis. Therefore, the nature of groups R, R 1 , R 2 and R 3 is not critical, although groups which would interfere with reaction steps (a) and (b) are to be avoided.
The group "C 1 -C 4 alkyl" encompasses methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, and tert-butyl. The group "C 1 -C 6 alkyl" encompasses the same radicals as C 1 -C 4 alkyl plus the 6 pentyls and the 16 hexyls.
The term "aliphatic group" is used in a broad sense to cover a large class of organic groups characterized by being derived from (1) an acylic (open-chain structure) of the paraffin, olefin and acetylene hydrocarbon series and their derivatives or (2) alicyclic compounds. The aliphatic group can have from 1 to 10 carbon atoms.
The term "aromatic group" is used in a broad sense to distinguish from the aliphatic group and includes a group derived from (1) compounds having 6 to 20 carbon atoms and characterized by the presence of at least one benzene ring, including monocyclic, bicyclic and polycyclic hydrocarbons and their derivatives and (2) heterocyclic compounds having 5 to 19 carbon atoms which are similar in structure and are characterized by having an unsaturated ring structure containing at least one atom other than carbon such as nitrogen, sulfur and oxygen and derivatives of these heterocyclic compounds.
Reaction step (a) preferably is run at a temperature between about 0° to about 150° C., more preferably between about 40° to about 110° C. and most preferably between about 75° to about 85° C. This reaction step can be run at atmospheric, sub-atmospheric or super-atmospheric pressure, preferably at atmospheric pressure. Preferably the reaction is run in a solvent for the acyl halide, such as ethylene dichloride, methylene chloride, tetrahydrofuran or toluene.
Three moles of the acyl halide are needed to react with one mole of the 1,3,5-tricarboalkoxymethylhexahydro-1,3,5-triazine. An excess of acyl halide can be used to insure complete reaction with the triazine. A large excess of the acyl halide can serve as a solvent in this reaction step. The solvent or any excess acyl halide can be removed to isolate the N-carboalkoxymethyl-N-chloromethyl amide of the acyl halide in high yields. However, this amide quickly degrades by hydrolysis and should be kept in an inert atmosphere if isolated. Most preferably no excess acyl halide is used.
In reaction step (b), most preferably about equal mole amounts of N-carboalkoxymethyl-N-halomethyl amide of the acyl halide and the phosphite are reacted. Less preferably, up to 2 mole excess can be used and least preferably up to a 10 mole excess can be used.
The reaction is exothermic and can be run at a temperature between about 0° to about 150° C., more preferably between about 40° to about 100° C.; most preferably between 75° to about 85° C.
No solvent is needed for the reaction, however, any inert solvent can be used, preferably the solvent having a boiling point between about 40° to about 100° C. Examples of such solvents are ethylene chloride, methylene chloride, tetrahydrofuran and toluene. The use of an inert solvent helps dissipate the heat of reaction. Any solvent used in this reaction step will be removed after completion of reaction step (c), so preferably it is one that can be removed by evaporation.
Alkali metal phosphites having the formula ##STR4## wherein R 1 and R 2 are as defined and R 3 is an alkali metal are reacted with N-cyanomethyl-N-halomethyl amide under an inert atmosphere such as nitrogen. The alkali metal phosphite can be prepared by reacting an alkali metal alkoxide, alkali metal hydride or alkali metal with an equal mole amount of a disubstituted phosphite of the formula ##STR5## wherein R 1 and R 2 are as defined. This reaction is run in an inert atmosphere such as nitrogen.
Alkali metal phosphites of the formula ##STR6## where R 1 , R 2 and M are as defined can, becaue of tautomerism, have the following additional structural formula ##STR7## wherein R 1 and R 2 are as defined and M is an alkali metal.
In reaction step (c), a mole of the phosphonate reaction product from reaction step (b) is hydrolyzed with 5 moles of water. The hydrolysis is run in the presence of a strong acid or base as defined above. Preferably the hydrolysis is acid-catalyzed, preferably with an inorganic acid, and most preferably with hydrochloric or hydrobromic acid. The hydrolysis yields the desired N-phosphonomethylglycine. Preferably at least 2 moles of the acid are used. More preferably, a large excess over the 2 mole amount is used. The preferred hydrochloric or hydrobromic acid can be used in concentrated or aqueous form.
This last reaction step is run at a temperature between about 0° to about 200° C., preferably between about 50° to about 125° C. and most preferably between about 100° to about 125° C.
Atmospheric, sub-atmospheric or super-atmospheric pressure can be used. Preferably atmospheric pressure is used during the hydrolysis.
The solid N-phosphonomethylglycine can be recovered by conventional techniques in reaction step (c). Volatile liquid products such as alcohols (methanol) chlorides (methyl chloride), acids (acetic acid), water, and excess acid can be removed by standard stripping techniques. The desired N-phosphonomethylglycine is recovered in high purity by titurating it in isopropyl alcohol and removing it by filtration.
The process of this invention can be better understood by reference to the following specific examples.
EXAMPLE 1
Preparation of N-carboethoxymethyl N-chloromethyl acetamide ##STR8##
1,3,5-Tricarboethoxymethylhexahydro-1,3,5-triazine (5.76 grams, 0.0167 mole) was dissolved in 150 milliliters (ml) of 1,2-dichloroethane in a round-bottom flask. Acetyl chloride (5.4 ml, 0.074 mole) was added dropwise. The reaction mixture was refluxed 15 minutes, then stripped under reduced pressure to yield N-carboethoxymethyl-N-chloromethylacetamide. The structure was confirmed by proton nuclear magnetic resonance.
EXAMPLE 2
Preparation of O,O-dimethyl-N-carboethoxymethyl N-acetylaminomethyl phosphonate ##STR9##
The amide compound prepared in Example 1 was diluted with 10-12 ml of toluene. Trimethylphosphite (6.7 g, 0.0515 mole) was added, and the mixture was refluxed 15 minutes, then stripped under reduced pressure to yield the desired product. The structure was confirmed by proton nuclear magnetic resonance.
EXAMPLE 3
Preparation of N-phosphonomethylglycine ##STR10##
The phosphonate reaction product of Example 2 was combined with 30 ml (0.36 mole) of concentrated hydrochloric acid, refluxed 3 hours, and stripped under reduced pressure. The product was titurated in 50 ml of isopropyl alcohol and filtered to yield 5.6 g of the desired product. The structure was confirmed by proton nuclear magnetic resonance, 13 C nuclear magnetic resonance, infrared, and liquid chromatograph.
EXAMPLE 4
Preparation of O,O-diethyl-N-carboethoxymethyl-N-acetylaminomethyl phosphonate ##STR11##
Three and nine-tenths grams (0.035 ml) of potassium-tbutoxide were slurried in a round bottom flask with 25 ml tetrahydrofuran (dried over molecular sieves) and the slurry was cooled in a water bath. Four and five-tenths ml (0.035 m) of diethyl phosphite were added dropwise over 5 minutes under nitrogen. This mixture was then cooled in an ice bath and 6.77 g (0.035 m) of N-carboethoxymethyl-Nchloromethylacetamide diluted with 25 ml of tetrahydrofuran were added dropwise over 15 minutes. The mixture was allowed to warm to ambient temperature and stirred 3 hours before it was filtered through dicalite and stripped to yield 9.6 g of an amber oil. Structure was confirmed by ir, nmr, ms, and C-13 nmr.
EXAMPLE 5
Preparation of N-phosphonomethylglycine ##STR12##
Six and six-tenths grams (0.022 m) of the compound obtained from Example 4 were combined with 30 ml (0.363 m) of concentrated HCl and refluxed 3 hours then stripped to yield 4.7 g of the desired product, a brown semi-solid. Structure was confirmed by H 1 , nmr, C-13 nmr and lc techniques. | A method of preparing N-phosphonomethylglycine comprising (a) reacting a substituted triazine with an acyl halide to form the N-carboalkoxymethyl-N-halomethyl amide of the acyl halide; reacting the said amide with a phosphite to form a phosphonate compound; and hydrolyzing said phosphonate to yield N-phosphonomethylglycine. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/749,709, filed Jan. 7, 2013, and entitled “Systems and Methods for Firmware Distribution and Update Over Remote Applications”, which is incorporated herein by reference as if set forth herein in its entirety.
TECHNICAL FIELD
[0002] Various embodiments of the invention relate to integration systems for a plurality of distinct products and, more particularly, to systems and methods for updating firmware in embedded systems that do not have access to update servers.
BACKGROUND
[0003] As products are increasing in complexity, many products are being asked to do more as new technology is developed. To extend a product's capabilities the firmware within the embedded system needs to be updated to allow the product to do more. Many of these products, however, do not have a simple way to update the firmware. Many of these products require specialized equipment and or software making the upgrading of the product time consuming and costly. Further, the management and tracking of firmware version and status is becoming increasingly important to the product supplier or manager.
SUMMARY
[0004] Some or all of the above needs may be addressed by certain implementations of the disclosed technology. According to an example implementation, a method is provided. The method includes, receiving, at a carrier device, an application carrying a firmware payload comprising one or more firmware packages associated with one or more of a plurality of target devices, wherein the carrier device is connectable to one or more of the target devices. Further, the method includes determining, with a computer processor, that a first target device in communication with the carrier device is associated with a first firmware package in the firmware payload. The method further includes transferring the firmware package to the first target device after the determination that the first target device is associated with the first firmware package and receiving a status from the first target device regarding installation of the first firmware package on the first target device. According to the example implementation, the method further includes determining, with a computer processor, that a secondary target device in communication with the first target device is associated with a second firmware package in the firmware payload. The method further includes directing the first target device to transfer the second firmware package to the secondary target device and receiving a status from the first target device regarding installation of the second firmware package on the secondary target device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The accompanying drawings illustrate one or more embodiments and/or aspects of the disclosure and, together with the written description, serve to explain the principles of the disclosure. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment, and wherein:
[0006] FIG. 1 illustrates an exemplary process by which a carrier device acquires an application.
[0007] FIG. 2 illustrates an exemplary process by which a carrier device updates the firmware of a target device.
[0008] FIG. 3 illustrates an exemplary process by which a carrier device updates one or more secondary target devices via an intermediary device.
[0009] FIG. 4 illustrates an exemplary process by which a carrier device exchanges information with an update server.
[0010] FIG. 5 illustrates an exemplary process by which an application distribution system notifies a carrier device of an available application update.
DETAILED DESCRIPTION
[0011] Prior to a detailed description of the disclosure, the following definitions are provided as an aid to understanding the subject matter and terminology of aspects of the present systems and methods, are exemplary, and not necessarily limiting of the aspects of the systems and methods, which are expressed in the claims. Whether or not a term is capitalized is not considered definitive or limiting of the meaning of a term. As used in this document, a capitalized term shall have the same meaning as an uncapitalized term, unless the context of the usage specifically indicates that a more restrictive meaning for the capitalized term is intended. However, the capitalization or lack thereof within the remainder of this document is not intended to be necessarily limiting unless the context clearly indicates that such limitation is intended.
Definitions/Glossary
[0012] Application: a software product that is easily obtainable, updatable and removable from a consumer electronics system.
[0013] Application Distribution System: a repository of applications for specific devices and/or operating systems that provide access to a user for installation of new, updating existing and/or maintaining their device. Alternatively referred to as an “application store” or “app store.”
[0014] Carrier Device: a commercially available device, e.g., a cell phone, tablet, or laptop computer, that communicates with a Target Device and, upon a determination that a Target Device requires an update, transports an update to the Target Device.
[0015] Firmware: a portion or complete software that is intended to be operated within an embedded system.
[0016] Target Device: a device or system that is earmarked for an update.
[0017] Update: an update process that replaces an earlier version of all or part of a software system with a newer release.
[0018] Update Server: a device or system that authors and initiates an update.
Overview
[0019] To facilitate an understanding of the principles and features of embodiments of the invention, various illustrative embodiments are explained below. Although exemplary embodiments of the invention are explained in detail, other embodiments are contemplated. Further, in describing the exemplary embodiments, specific terminology will be resorted to for the sake of clarity. It is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways.
[0020] An exemplary embodiment of the firmware update system may update multiple systems within a product through the use of one application carrying firmware payloads to the product (hereafter referred to as a Target Device). The process/methodology would begin by user/technician choosing a commercially available device like a cell phone, tablet or laptop (hereafter referred to as a Carrier Device). They would then select an application from their appropriate application store (hereafter referred to as the App Store). The application would carry with it a software/firmware payload that it could then deliver to an embedded system within the Target Device. The user/technician would then connect the Carrier Device to the Target Device via a wired or wireless connection. The Carrier Device would negotiate with the Target Device to determine if it needs a firmware update. The Target Device may also communicate to other Target Devices that it is connected to (hereafter referred to as Secondary Target Devices) to determine if any of these systems also need a firmware update. Once the Target Devices have determined if the firmware provided as a payload from the Carrier Device's application is needed, it will then receive the firmware update and communicate their status back to the Carrier Device. The Carrier Device will then be disconnected from the Target Device. Once the Carrier Device can communicate with the internet, it will communicate the status of the Target devices back to the Update Server or other Cloud Repository as designated by the Target Device manager or designer. When the Target Device manager or developer wishes to update the Target Device, an updated application with a new payload is uploaded to the App Store. The App Store will then send a push notification to the Carrier Device notifying it to update the payload carrying application on the Carrier Device. From here, the Carrier Device can once again be used to further update the Target Devices.
[0021] For purpose of example and without limitation, various devices may be referred to as Devices A, B, or C. Generally, Device A could be any portable electronic device which has the ability to install, execute, and update applications from available application distribution networks such as, for example, application stores. Device B could be any electronics product that has the ability to connect, either wirelessly or via a wired connection, to a Device A. Device B typically has the ability to negotiate, update, and execute its own applications. Generally, Device C could be any electronics product that has the ability to connect, either wirelessly or via a wired connection, to a Device B, which typically acts as a gateway device, as will be explained in further detail below. Typically, Device C has the ability to negotiate, update, or have its applications updated such that it can then execute its applications.
[0022] Referring now to FIG. 1 , an exemplary process by which a carrier device acquires an application is illustrated. According to one embodiment, Device A (i.e., the carrier device) downloads an application that is published by or on the behalf of the developer of Device B (i.e., target device). Typically, the application is developed specifically with the ability to carry a firmware payload, negotiate with, and update Device B. In one embodiment, Device A registers, downloads, and installs this application from an application distribution system (i.e., app store).
[0023] Referring now to FIG. 2 , an exemplary process is illustrated by which a carrier device updates the firmware of a target device. In one embodiment, a user brings Device A within the proximity of Device B and then connects the two devices either wirelessly (e.g., via WiFi or Bluetooth connection) or via a wired connection (e.g., USB connection). Typically, Device A communicates and negotiates with Device B and establishes whether the firmware of Device B needs to be updated. If there is a newer firmware payload within the Device A application, Device B typically is updated. Generally, Device B is updated without notifying the user or without intervention from the user. Typically, once the firmware is updated, the devices disconnect and Device A application retains the status and update information of Device B, which can be sent to the publisher of the application once internet connectivity is available.
[0024] Referring now to FIG. 3 , an exemplary process by which a carrier device updates one or more secondary target devices is illustrated. According to one embodiment, a user brings Device A within the proximity of Device B such that the devices can establish a connection either wirelessly or via a wired connection. Generally, Device A communicates and negotiates with Device B and establishes whether the firmware of Device C requires an update. Typically, Device B acts as an update gateway for downstream type-C devices that may have limitations for communicating with Device A. In one embodiment, Device A passes the upgrade payload to Device B, which then updates the downstream type-C devices. Generally, Device B then reports to Device A an updated status relating to the type-C, which Device A generally uploads to the publisher of the application once internet connectivity is available.
[0025] Referring now to FIG. 4 , an exemplary process is illustrated by which a carrier device exchanges information with an update server. According to one embodiment, Device A establishes connection with a cloud-based server to upload an update status of target devices B and C. The update server may download new update payloads based on user interaction or without user interaction. Depending on the published application, the user may be able to select types of updates, diagnostics, and personalization of custom features of the target devices.
[0026] Referring now to FIG. 5 , an exemplary process by which an application store notifies users of an update is illustrated. According to one embodiment, Device A establishes a connection with a specific application distribution system (i.e., app store), which may then push an update notification to the device if there is an update to the published application. In one embodiment, this notification could be triggered based on an update for the target devices or used to update the local application for Device A. In one embodiment, the payload for future updates for target devices can either be sent to Device A by direct communication to an Update Server or through an application distribution system.
[0027] In one embodiment, for example, a carrier device acquires an update application, updates a single requisite target device, and then exchanges update information with an update server. Alternatively, in one embodiment, a carrier device may update a plurality of target devices. For example, a carrier device may acquire an update application and then update designated devices B and C. Subsequently, the carrier device exchanges update information relating to devices B and C with an update server.
[0028] In one example, a carrier device may acquire an update application and then update various target devices. After updating the target devices, the carrier devices then exchanges update information with an update server. Subsequently, when there are new updates for the target devices, the carrier device is notified, either via a respective application distribution system or via direct push notification, that updates are available for the target devices. Typically, the carrier device then updates the target devices and exchanges update information with an update server.
[0029] In certain instances, it may be necessary to partially update a target device. According to one embodiment, a carrier device acquires an update application. A user is then presented with update options that allow the user to determine which components the user desires to update (e.g., languages, databases, other personalization, etc.). Alternatively, the update application may be directed with a secure script based on services purchased by the user, which determines what components will be updated. Accordingly, the carrier device updates the target device and then exchanges update information with an update server.
A. Further Exemplary Uses of Certain Embodiments
[0030] For example, the firmware update system may be associated, and in communication with, a car or other vehicle. The user/technician has downloaded an application from his/her App Store on to his Carrier Device. Because the vehicle does not have an internet connection it does not have access to the updated firmware for its different systems. The user/technician brings their chosen Carrier Device with the payload application to the vehicle. The user/technician could attach their device via a USB connection to the head unit in the vehicle (Target Device). The head unit will negotiate a connection with the Carrier Device. The application on the Carrier Device will then communicate the firmware payloads it has available to the head unit. From here it will be determined if any of these payloads are required by the head unit. Should one be determined to be needed by the head unit, the head unit will receive the payload and update its firmware. It will then communicate to the Carrier Device that it has received the firmware upgrade and also communicate any other status messages required to the Carrier Device.
[0031] The head unit would then look at other systems that it is connected to in the vehicle like for example the rear seat entertainment system. The rear seat entertainment system may not have a USB interface but it is connected to the head unit. The head unit will then communicate to the rear seat entertainment system to determine if a firmware upgrade is available for the rear seat entertainment system and if it is, deliver that firmware to the rear seat entertainment system. Once updated, the updated status from the rear seat entertainment system would be communicated back to the head unit and from there onto the Carrier Device.
[0032] Once the head unit has determined that no other Target Devices need any further firmware payloads from the Carrier Devices application, the Target Device and the Carrier Device will be disconnected.
[0033] Once the Carrier Device is able to communicate with the internet, the Target Device(s) status will be communicated to the Update Server or any other repository designated by the Target System's developer or manager.
B. Design Considerations for Certain Embodiments
[0034] Below are some considerations that may be made while developing an embodiment of the integration system. It will be understood that not all considerations may apply to every embodiment of the invention, and considerations not provided below may also be applicable.
[0035] The firmware update designer will need to consider the allowable payload size by the different Carrier Devices they consider for their update system. Some firmware updates such as the map data for a navigation system within a vehicle could be quite large. The designer would need to consider any limitations to the application size as well as how quickly the Carrier Device can deliver that payload to the Target Device.
[0036] The firmware update designer will also need to consider the different methods the Carrier Device can deliver the payload. These include both wired and wireless connections. Different Carrier Devices will have different specifics on how they communicate through these avenues. Care must be taken to develop a strategy that can be leverage across different Carrier Devices with different operating systems and different App Stores to make the update system as accessible as possible.
[0037] The designer must also take care to develop a database management system to be able to track and manage all devices under their care. The timing associated with when Target Devices get updated could be very scattered based on how often and how accessible the Target Devices are to the user/technician's presence.
C. Benefits of Certain Embodiments
[0038] An exemplary embodiment of the present invention addresses some challenges presented by the need to add functionality and or improvements to existing devices as well as track the status of devices that do not have direct access to an update server.
[0039] An exemplary firmware update system of the present invention provides for multiple systems within a product to have their embedded firmware updated through a single commonly available Carrier Device without having to interact with each system with specialized equipment and or software.
[0040] The above example is for a vehicle, but a gateway and methodology may similarly be used in another environment where multiple products are used. For example, a home is another place where one might need to update the firmware on multiple systems. For example a whole home entertainment system with a media server could have several embedded systems that we would want to update the firmware on. These embedded systems within the entertainment system could include an amplifier, control panels, media interfaces and many other products. By connecting to one of the devices within the system (Target Device) with our Carrier Device, this multitude of embedded systems could receive firmware updates.
[0041] While the firmware update system has been disclosed in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions may be made without departing from the spirit and scope of the system, method, and their equivalents, as set forth in claims to be filed in a later non-provisional patent application. | Described herein are firmware update systems and methods for providing a update/upgrade path for a plurality of products. An exemplary firmware update system may comprise Application Store providing applications to commonly available consumer devices like cell phones, tables and/or laptops, whose application provides a method of carrying with it a payload of firmware that can be distributed to a plurality of products. An exemplary integration system may or may not also comprise a central or remote database that tracks and manages the status of the Target Devices. An exemplary integration system may or may not also comprise a Target Device that can in turn communicate with other Target Devices within its realm of communication to provide a firmware update to these Secondary Target Devices. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a manufacturing method and a manufacturing apparatus of an envelope of an image displaying apparatus and so on.
[0003] 2. Related Background Art
[0004] Japanese-Patent Application Laid-Open No. S06-196094 discloses a manufacturing method of a vacuum displaying apparatus with a glass container having display surface glass and substrate glass deposited with low melting glass, the method comprising stages of assembling the glass container having low melting point rod glass placed between display glass and the substrate glass, evacuating internal air of the glass container from a gap provided thereon, and melting and seal-bonding the low melting point rod glass in a state of remaining evacuated as-is.
[0005] Japanese Patent Application Laid-Open No. 2001-28241 discloses a manufacturing method of an image displaying apparatus of seal-bonding via a joining member a first substrate having phosphor excitation means placed thereon and a second substrate having a phosphor glowing by phosphor excitation means placed thereon, the method comprising a heating process of heating the first and second substrates and joining member up to a sealing temperature in a chamber while holding the first and second substrates between first and second heating means with their sealing portions not in contact and evacuating inside of the chamber, and a seal-bonding process of seal-bonding the first and second substrates via the joining member by bringing their sealing portions into contact in a state of having the inside of the chamber evacuated. According to the manufacturing method disclosed by Japanese Patent Application Laid-Open No. 2001-28241, the evacuation and heating process are performed in the state of holding the two substrates at a desired distance not to bring them into contact.
[0006] According to the configuration disclosed by Japanese Patent Application Laid-Open No. 2001-28241, it is necessary, for the sake of holding the first and second substrates without bringing their sealing portions into contact, to fix at least one of the substrates to position adjusting means with a fixture or the like, and move the entire fixed substrate by the position adjusting means in a direction for separating from the other substrate so as to form a gap between the substrates.
[0007] In the case of the configuration for moving the entire substrate fixed on the position adjusting means with a fixture or the like in the direction for separating from the other substrate, however, it generates a wasteful clearance (dead stroke) larger than a sufficient clearance for evacuating a space between the substrates. As for such a configuration generating the dead stroke, a manufacturing apparatus becomes more complicated and larger correspondingly and additional traveling time of the substrate is correspondingly required so that reduction in manufacturing time is interrupted.
SUMMARU OF THE INVENTION
[0008] Thus, an object of the present invention is to provide a manufacturing method and a manufacturing apparatus of an envelope capable of evacuating a space between substrates without generating a dead stroke between the substrates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1A, 1B and 1 C are diagrams showing a process flow and an overview configuration of a manufacturing method of an image displaying apparatus according to an embodiment of the present invention;
[0010] FIGS. 2A, 2B and 2 C are diagrams showing. stepwise a manufacturing process of an envelope according to an embodiment of the present invention;
[0011] FIG. 3 is a diagram showing a process of positioning a rear plate and a face plate;
[0012] FIGS. 4A and 4B are diagrams showing a state in the process shown in FIG. 2B ;
[0013] FIGS. 5A and 5B are diagrams showing a heating mechanism of a plate applied to the manufacturing method and a manufacturing apparatus of the image displaying apparatus according to an embodiment of the present invention; and
[0014] FIGS. 6A and 6B are diagrams showing a positioning spring for positioning and fixing two plates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] A manufacturing method of an envelope of the present invention is the method of forming a hermetically sealed container by seal-bonding edge portions of a pair of substrates via a supporting frame between them in a depressurized atmosphere comprising a process of warping the edge portions of at least one of the pair of substrates and separating it from the other substrate in the depressurized atmosphere before performing the seal-bonding.
[0016] A manufacturing apparatus of the envelope of the present invention is the apparatus for forming a hermetically sealed container by seal-bonding edge portions of a pair of substrates via a supporting frame between them in a depressurized atmosphere comprising separating means for warping the edge portions of at least one of the pair of substrates and separating it from the other substrate.
[0017] According to the manufacturing method of the envelope of the present invention, it is possible, just by warping the edge portions of one of the substrates, to generate a gap between the substrates or extend a clearance between them so as to evacuate a space between the substrates through the gap.
[0018] According to the manufacturing apparatus of the envelope of the present invention, it is possible, just by warping the edge portions of one of the substrates by the separating means, to generate a gap between the substrates or extend a clearance between them so as to evacuate a space between the substrates through the gap.
[0019] As described above, according to the present invention, it is possible to evacuate the space between the substrates without generating a dead stroke between the substrates.
[0020] Next, embodiments of the present invention will be described by referring to the drawings.
[0021] A manufacturing method and a manufacturing apparatus of an envelope of the present invention include the manufacturing methods and manufacturing apparatuses of a glass container having two sheets of glass bonded together And vacuum-sealed, an image displaying apparatus incorporating electron-emitting devices or an image displaying apparatus such as a plasma display. In particular, the manufacturing method and manufacturing apparatus of the image displaying apparatus are desirable forms of application of the present invention in terms of cost reduction.
[0022] The embodiments of the present invention will be described by exemplifying the image displaying apparatus incorporating the electron-emitting device and a phosphor film having electrons emitted by the electron-emitting device irradiated thereon. A concrete description thereof will be given by using FIGS. 1A to 1 C, FIGS. 2A to 2 C and FIG. 3 .
[0023] FIGS. 1A to 1 C are diagrams showing a process flow and an overview configuration of the manufacturing method of the image displaying apparatus according to an embodiment of the present invention. FIG. 1A is a flow chart showing the process flow of the manufacturing method of the image displaying apparatus according to this embodiment. FIG. 1B is a perspective view showing the overview configuration of the image displaying apparatus according to this embodiment. FIG. 1C is a sectional view at a line 1 C to 1 C shown in FIG. 1B .
[0024] First, the configuration of the image displaying apparatus according to this embodiment will be described by referring to FIGS. 1B and 1C . The image displaying apparatus according to this embodiment is configured by an envelope 90 incorporating a rear plate 81 as a substrate configuring an electron source substrate 80 having multiple electron-emitting devices 87 placed on a top surface thereof and having wirings 88 , 89 connected to the electron-emitting devices 87 implemented thereon, a face plate 82 as a substrate having a phosphor film 84 , a metal back 85 and a nonvolatile getter 9 configured on a surface opposed to the rear plate 81 of a glass substrate 83 , and a supporting frame 86 for oppositely placing the rear plate 81 and face plate 82 with mutually predetermined spacing. Each joining portion of the plates 81 , 82 and supporting frame 86 is mutually bonded by using frit glass or In.
[0025] According to this embodiment, supports called spacers 205 are placed between the rear plate 81 and the face plate 82 . It is thereby possible to configure the envelope 90 strong enough against atmospheric pressure even in the case where the image displaying apparatus is a so-called large-area panel. As for the envelope 90 , its size, board thickness of the plates 81 , 82 and placement of the spacers 205 are appropriately designed depending on mechanical conditions such as an atmospheric-pressure-resistant structure for the sake of keeping the inside vacuum.
[0026] It is general to use a substrate made of a low-cost blue plate glass as the rear plate 81 . In that case, however, it is desirable to form a 0.5 μm-thick silicon dioxide film on the substrate as a sodium block layer by a sputter technique. It is also possible to create the rear plate 81 with glass having little sodium component, a quartz substrate or a non-alkali substrate. As for the plasma display, it is possible to use PD-200 (Asahi Glass Co., Ltd.) appropriately as the rear plate 81 , which is electric glass having little alkali component.
[0027] It is general to use the low-cost blue plate glass as the face plate 82 as with the rear plate 81 . However, this embodiment uses PD-200 (Asahi Glass Co., Ltd.) which is the electric glass for the plasma display having little alkali component. This glass material has no glass coloring phenomenon occurring in the case of display use. If the board thickness is 3 mm or so, it has a sufficient shielding effect of suppressing leakage of a soft X-ray generated secondarily even in the case of being driven at an accelerating voltage of 10 kV or more.
[0028] It is also general to use the low-cost blue plate glass as the material of the spacers 205 . It is selected according to the use of the envelope 90 . In the case where position accuracy of the spacers 205 is required, it is desirable to match a thermal expansion coefficient by using the same material as the glass to be bonded together. The spacers 205 should be in a plate-like, column-like, square-column-like or sheet-like form suited to the use, and the number of placements thereof should also be appropriately set up according to the use. In the case of the image displaying apparatus incorporating the electron-emitting devices 87 , the spacers 205 are designed to suit an electron orbit.
[0029] As for joining members 5 and 6 (refer to FIGS. 2A to 2 C for joining the plates 81 , 82 and supporting frame 86 , the frit glass having a comparable thermal expansion coefficient as the plates 81 , 82 or a low melting metal such as In, In—Ag or In—Sn is used. Either different materials or the same material may be used for the joining members 5 and 6 . It is desirable, by way of example, to use In or In—Ag for, both the joining members 5 and 6 .
[0030] It is sufficient to have the joining members 5 and 6 applied to at least one of the plates 81 , 82 and supporting frame 86 . The joining member's 5 and 6 are applied so that total thickness before joining the plates 81 , 82 and supporting frame 86 becomes sufficiently more than that after joining them. According to this embodiment, they are applied so that the thickness of an In film formed by the joining members 5 and 6 after joining becomes 300 μm.
[0031] The face plate 82 has the phosphor film 84 , metal back 85 and nonvolatile getter 9 formed on the surface opposed to the rear plate 81 of the glass substrate 83 so that this portion becomes an image display area. The position for placing the nonvolatile getter 9 on the face plate 82 is on a black conductive body 91 between the metal back 85 and the phosphor film 84 of the face plate 82 . It is desirable to place the nonvolatile getter 9 evenly all over the image display area.
[0032] It is possible to form the nonvolatile getter 9 on the face plate 82 by using a material of which major component is Ti by a vacuum deposition method such as an electron beam or a sputter. According to this embodiment, film thickness of the nonvolatile getter 9 is 800 Å (80 nm). However, the placement position and film thickness of the nonvolatile getter 9 are not limited to the above but may be appropriately designed and set up.
[0033] Next, a manufacturing process of the envelope according to this embodiment will be described by referring to FIG. 1A , FIGS. 2A to 2 C, and FIG. 3 . FIGS. 2A to 2 C are diagrams showing stepwise the manufacturing process of the envelope according to this embodiment, and FIG. 3 is a diagram showing the process of positioning the rear plate and the face plate.
[0034] First, the rear plate (RP) 81 and the face plate (FP) 82 are prepared (step 1 ).
[0035] Next, as shown in FIG. 2A , the rear plate 81 is mounted on a lower support member 4 , a joining member 5 is applied to a predetermined position on the rear plate 81 , and the supporting frame 86 is mounted on the applied joining member 5 , and then a joining member 6 is applied to the top surface of the supporting frame 86 . The joining member is also applied to the portion joined to the top surface of the supporting frame 86 of the face plate 82 . In is used as the joining members according to this embodiment. Furthermore, the spacers 205 are placed at a predetermined position on the rear plate 81 . And the members such as the supporting frame 86 , spacers 205 and joining members 5 , 6 are implemented in a seal bonding chamber (not shown) for manufacturing the envelope 90 so as to finish a preparatory process (step 2 ). In this case, the face plate 82 is held by arms 7 between the rear plate 81 having the supporting frame 86 and spacers 205 provided thereon and an upper support member 8 in the seal bonding chamber. The arms 7 function as separating means for warping the edge portions of the face plate 82 and separating it from the supporting frame 86 .
[0036] Next, according to this embodiment, vacuum baking is performed on baking conditions of 400 degrees C. and 1 hour (step 3 ). These baking conditions are appropriately set up according to the, use of the envelope 90 to be made. In this case, a clearance is provided between the mutually seal-bonded plates 81 and 82 by warping at least one of the two plates 81 and 82 to be convex to the other so as to sufficiently evacuate the space between the plates 81 and 82 . According to this embodiment, as shown in FIG. 2B , corners of the face plate 82 are held by the arms 7 to warp the face plate 82 so that its underside opposed to the rear plate 81 becomes convex. In this case, the space between the plates 81 and 82 is sufficiently evacuated even in the vicinity of the center if there is a clearance of 1 mm or so between the plates 81 and 82 around their circumferences irrespective of whether or not the vicinity of the center of the warped face plate 82 is in contact with the spacers 205 then.
[0037] Thereafter, as shown in FIG. 2C , the arms 7 are lowered to place the face plate 82 on the supporting frame 86 , and the seal bonding is performed at a temperature for melting the joining members 5 and 6 (step 4 ). According to this embodiment, the seal bonding process was performed on condition that the temperature of the plates 81 and 82 was within 160 degrees C. ±5 degrees C.
[0038] Here, in the case where the envelope 90 to be made is a color image displaying apparatus, it is necessary to perform positioning of the plates 81 and 82 when lowering the arms 7 to place the face plate 82 on the supporting frame 86 as shown in FIG. 2C so that phosphors of colors of the phosphor film 84 correspond to the electron-emitting devices 87 on the plate 81 . For that reason, according to this embodiment, mutual positioning of the plates 81 and 82 is sufficiently performed by using a positioning apparatus 200 (refer to FIG. 3 ) for performing the mutual positioning of the plates 81 and 82 . The positioning apparatus 200 moves at least one of the plates 81 and 82 to the other so as to perform positioning in vertical and horizontal directions (XY directions) and a rotation direction (θ direction) in a plane of the plate. In the case of the configuration having no electron-emitting device or phosphor placed on the plates, the accuracy required of the positioning of the plates is not so high and so the positioning apparatus 200 described above is not always necessary.
[0039] On the seal bonding, a required degree of vacuum is 1×10 −6 [Torr] (approx. 1.3×10 −4 [Pa]) or less. Furthermore, there are the cases where a getter process is performed in order to maintain the degree of vacuum in the envelope 90 after the seal bonding. Here, the getter process is a process of, immediately before or after seal-bonding the envelope 90 , heating the getter placed in advance at a predetermined position (not shown) in the envelope 90 by a heating method such as resistance heating or high-frequency heating so as to form an evaporated film (not shown). In this case, the major component of a getter member is ordinarily Ba or the like, and it is possible, by an absorptive action, of the evaporated film formed as described above, to maintain the degree of vacuum in the envelope 910 at 1×10 −5 to 1×10 −7 [Torr] (approx. 1.3×10 −3 to 1.3×10 −5 [Pa]) for instance.
[0040] FIGS. 4A and 4B are diagrams showing a state in the process shown in FIG. 2B , where FIG. 4A is a sectional view thereof and FIG. 4B is a plan view viewing the face plate of FIG. 4A from above. FIG. 4B shows the arms 7 as partially seen through.
[0041] According to this embodiment, the face plate 82 is held by the four arms 7 at the four corners thereof to move the face plate 82 vertically while warping it. It is possible, in such a configuration, to keep warping the face plate 82 with its own weight so as to secure conductance between the two vacuum-sealed plates 81 and 82 . Consequently, it is possible to seal-bond the plates 81 and 82 mutually in the state of having their internal space well evacuated. According to this embodiment, no particular control or apparatus is required other than the arms 7 for moving the face plate 82 vertically and the apparatus for driving them. Therefore, it is possible to reduce the cost of the apparatus for making the envelope 90 .
[0042] The positions for the arms 7 to hold the face plate 82 are set up appropriately depending on the size and board thickness of the face plate 82 . The positions for the arms 7 to hold the face plate 82 are not limited to the four locations at the four corners. It is also possible to have a configuration in which, while holding the face plate 82 with the arms 7 as if lifting it, a member for pushing the center of the face plate 82 downward is further provided separately. According to this configuration, it is possible to further warp the face plate 82 by pushing the center of the face plate 82 downward in the state of holding the four corners of the face plate 82 with the arms 7 .
[0043] FIGS. 5A and 5B are diagrams showing a heating mechanism of the plate according to another embodiment of the manufacturing method and manufacturing apparatus of the image displaying apparatus of the present invention, where FIG. 5A is a plan view and FIG. 5A is a front view.
[0044] In the example shown in FIGS. 5A and 5B , heaters 100 for heating the face plate 82 are placed opposite one another on the plate by being divided vertically and horizontally into three blocks, that is, nine blocks in total. In the case where the face plate 82 consists of the above-mentioned glass substrate, the edge portions warp on heating the face plate 82 and so the gap is generated at the edge portions between the face plate 82 and the rear plate 81 . For that reason, it is possible to evacuate the space between the plates 81 and 82 through the gap in the seal bonding process. Therefore, the heaters 100 function as separating means for warping the edge portions of the face plate 82 and separating it from the supporting frame 86 .
[0045] The heaters 100 may be either set up to uniformly heat the face plate 82 or set up to provide temperature distribution to the face plate 82 . In particular, it is effective, for the sake of warping the edge portions of the face plate 82 , to heat the edge portions of the face plate 82 more strongly than the center thereof. Therefore, it is desirable to render heating by the heaters 100 of blocks 2 , 5 and 8 for heating the edge portions of the face plate 82 stronger than the heating by the heaters for heating the center. According to this embodiment, the heaters 100 get heated to generate a temperature difference of 50 degrees C. at the maximum between the area of the block 5 as the center of the face plate 82 and the other areas in a vacuum baking process. However, the temperature difference becomes ±5 degrees C. or less before the seal bonding process.
[0046] This embodiment uses sheath heaters as the heaters 100 . However, lamp heaters may be used instead of them. The above described the configuration in which the heaters 100 heat the face plate 82 . It is also possible, however, to have the configuration in which the rear plate 81 is heated or both the plates 81 and 82 are heated by the heaters. It is also possible, as described above, to thus heat the plate with the heaters in combination with warping of the plate by holding at least the four corners of the plate with the arms.
Embodiments
[0047] Hereunder, the manufacturing method of the envelope of the present invention will be described in detail by taking up concrete embodiments.
First Embodiment
[0048] In this embodiment, the envelope was made by using a rear plate and a face plate both made of a blue plate glass of 900 mm×580 mm in length and breadth and 2.8 mm in thickness, spacers made of a blue plate glass of 1 mm×1 mm in length and breadth and 0.5 mm in thickness, and a supporting frame of 900 mm×580 mm in length and breadth with a surrounding wall of 4 mm in breadth and 0.2 mm in height (thickness). Raw glass substrates having no electron-emitting device, phosphor film or getter formed thereon were used for the rear plate and face plate respectively. The spacers were placed with 30-mm pitches. In was applied to the joining portions of the plates and the supporting frame.
[0049] The temperature during the vacuum baking process was 200 degrees C. During that time, the positions at 5 mm from the corners of the face plate as the upper plate were supported by the arms, and the face plate was lifted to the height of 3 mm from the top surfaces of the spacers placed on the rear plate to warp it so as to render its underside convex. After thus performing the baking for one hour, the envelope was made by seal-bonding the rear plate and face plate via the supporting frame.
Second Embodiment
[0050] To give a description of this embodiment by referring to FIGS. 1A to 1 C, the envelope as an image displaying apparatus was made by using the rear plate 81 having an SiO 2 film of 3000 Å (300 nm) in thickness formed and electron-emitting devices and wirings further formed on the plate made of PD-200 (Asahi Glass Co., Ltd.) which is electric glass of 900 mm×580 mm in length and breadth and 2.8 mm in thickness, the face plate 82 having the phosphor film 84 and getter 9 formed on the plate made of PD-200 (Asahi Glass Co., Ltd.) which is electric glass of 900 mm×580 mm in length and breadth and 2.8 mm in thickness, the supporting frame 86 made of the blue plate glass of 830 mm×510 mm in length and breadth with a surrounding wall of 4 mm in breadth and 1.3 mm in thickness, and the spacers 205 having an antistatic film (not shown) formed on a surface of PD-200 (Asahi Glass Co., Ltd.) which is the electric glass of 780 mm in length and 200 μm in breadth and 1.6 mm in height. In was used as the joining member of the plates 81 and 82 and the supporting frame 86 . The thickness of the joining member was 300 μm before the seal bonding and 150 μm after the seal bonding.
[0051] The temperature during the vacuum baking process was 400 degrees C. During that time, the positions at 5 mm from the corners of the face plate 82 as the upper plate were supported by the arms, and the face plate 82 was lifted to the height of 3 mm from the top surfaces of the spacers placed on the rear plate 81 to warp it so as to render its underside convex. After thus performing the baking for one hour, the envelope as the image displaying apparatus was made by seal-bonding the rear plate 81 and face plate 82 via the supporting frame 86 .
Third Embodiment
[0052] In this embodiment, the center of the upper face plate 82 was heated by the heaters 100 in the vacuum baking process so that it becomes about 50 degrees C. higher than the other portions. In was applied only to the joining portions of the rear plate 81 and the supporting frame 86 (the frit glass was applied to the joining portions of the face plate 82 and the supporting frame 86 ). Otherwise, the envelope as the image displaying apparatus was made as in the case of the second embodiment.
Fourth Embodiment
[0053] In this embodiment, the centers of both the plates 81 and 82 were heated by the heaters in the vacuum baking process so that they become about 50 degrees C. higher than the other portions. Furthermore, the upper face plate 82 was lifted by the arms 7 to warp it and render its underside convex, and the lower rear plate 81 was warped by using an unshown mechanism to render its upper surface convex. Such a mechanism can be configured, for instance, by providing a pin (not shown) projectable to push the center of the rear plate 81 upward to the lower support member 4 shown in FIGS. 2A to 2 C. In this case, such a pin functions as the separating means for warping the edge portions of the rear plate 81 and separating it from the supporting frame 86 .
[0054] In was applied to the joining portions of the plates 81 , 82 and the supporting frame 86 . Otherwise, the envelope as the image displaying apparatus was made as in the case of the second embodiment.
Fifth Embodiment
[0055] Before putting it in the seal bonding chamber, this embodiment used a positioning spring (refer to FIGS. 6A and 6B ) capable of moving the two plates 81 , 82 only heightwise (in a superposing direction) so as to fix their mutual positions.
[0056] FIGS. 6A and 6B are diagrams showing the positioning spring for positioning and fixing the two plates. As shown in FIGS. 6A and 6B , a positioning spring 180 is in a clip-like form, and is formed to be able to sandwich the plates 81 , 82 joined to the top and under surfaces of the supporting frame 86 .
[0057] The plates 81 , 82 are mutually aligned by the positioning apparatus 200 shown in FIG. 3 , and are mutually positioned thereafter, for instance, by mounting two positioning springs 180 on one side of the plates 81 , 82 as shown in FIG. 6B . To keep that positioning state, a cementing material such as Aron Ceramics of Toagosei Co., Ltd. is applied to the contacting portions of the positioning springs 180 and the plates 81 , 82 , and is hardened and fixed at 120 degrees C. The positioning springs 180 are built into a product in the state of thus being fixed on the plates 81 , 82 , and so they should desirably have the same thermal expansion coefficient as the plates 81 , 82 . For that reason, according to this embodiment, the positioning spring 180 is configured by a nickel alloy having the same thermal expansion coefficient as PD-200 (Asahi Glass Co., Ltd.) which is the material of the plates 81 and 82 .
[0058] Otherwise, the envelope as the image displaying apparatus was made as in the case of the second embodiment.
Sixth Embodiment
[0059] Before putting it in the seal bonding chamber, this embodiment used a positioning spring (refer to FIGS. 6A and 6B ) capable of moving the two plates 81 , 82 only heightwise (in the superposing direction) so as to fix their mutual positions. And in the vacuum baking process, the face plate 82 was warped while holding the face plate 82 above and apart from the rear plate 81 not to be in contact with the spacers 205 on the rear plate 81 . Thereafter, the envelope as the image displaying apparatus was made as in the case of the second embodiment.
Seventh Embodiment
[0060] Before putting it in the seal bonding chamber, this embodiment prepared seven sets of the two plates 81 , 82 having their mutual positions fixed with the positioning spring (refer to FIGS. 6A and 6B ) capable of moving them only heightwise (in the superposing direction). And the seven sets were collectively seal-bonded by a batch processing apparatus capable of simultaneously putting them therein. Otherwise, the envelope as the image displaying apparatus was made as in the case of the fifth embodiment.
[0061] This application claims priority from Japanese Patent Application No. 2004-243622 filed Aug. 24, 2004, which is hereby incorporated by reference herein. | In a manufacturing method of forming a hermetically sealed container by bringing a pair of substrates into intimate contact via a supporting frame between them, one of the substrates is warped in a depressurized atmosphere before getting into intimate contact and is thereby separated from the other substrate so as to evacuate inside of the hermetically sealed container by releasing the depressurized atmosphere therein. Relative positions of the substrates are restored by having the warp undone thereafter. Therefore, it is possible to achieve evacuation inside the hermetically sealed container without causing the relative positions of the substrates to deviate. | 7 |
FIELD OF THE INVENTION
[0001] The invention relates to a beaker type dyeing machine that is especially useful for the controlled dyeing of fabrics and other materials in a laboratory setting.
BACKGROUND OF THE DISCLOSURE
[0002] Many processes for dyeing fabrics on an industrial scale require that dyes and other chemicals be added periodically (e.g., according to a predetermined pattern or sequence). Dye application to textiles depends on dosing a liquid water/dye solution with an activator (e.g., soda ash, sodium sulfate, ammonium sulfate, hydrogen peroxide, or other solid or liquid substances). Activation of dyes is typically most effective if performed when the liquid solution reaches a certain temperature, and just prior to the application of the liquid solution to the fabric.
[0003] Conventional dyeing methods either manually inject the activator into the liquid solution (e.g., using a syringe) at the appropriate time and temperature or include the activator in the original dye mixture prior to the dyeing process. The former process tends to be tedious and requires the activator to be in a fluid form. The latter process tends to lead to suboptimal dyeing of the fabric.
[0004] Thus, there is a need in the art for a beaker type dyeing machine that allows injection of a solid or granular activator.
SUMMARY OF THE INVENTION
[0005] In one embodiment, the present invention is a beaker type dyeing machine. One embodiment of an apparatus for dyeing a material in a beaker includes a cylinder body having a first end and a second end, the first end being configured for coupling to the lid of the beaker, a check valve incorporated into the first end of the cylinder body, and a plug incorporated into the second end of cylinder the body, the plug being operable to control opening and closing of the check valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0007] FIG. 1 is a side view illustrating one embodiment of a beaker type dyeing machine, according to the present invention;
[0008] FIGS. 2-3 are side views illustrating one embodiment of a dispensing cylinder coupled to a beaker; and
[0009] FIG. 4 is a side view illustrating the dispensing cylinder with the removable plug removed.
[0010] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
[0011] In one embodiment, the present invention is a beaker type dyeing machine for dye applications that allows injection of a solid or granular activator. Embodiments of the invention incorporate a dispensing cylinder with a manual plunger into the individual beakers of a beaker type dyeing machine. A measured amount of solid or granular activator is stored in each dispensing cylinder and may be dispensed into the beaker upon depression of the plunger by a human operator. Embodiments of the invention may be incorporated within a beaker type dyeing machine, for example such as that described in U.S. Pat. No. 6,626,015, which is herein incorporated by reference in its entirety.
[0012] FIG. 1 is a side view illustrating one embodiment of a beaker type dyeing machine 100 , according to the present invention. As illustrated, the machine 100 comprises a support 1 , a substantially circular disk 3 coupled to the support 1 , and a plurality of beakers 2 arranged along the periphery of the circular disk 3 . Although the disk 3 is described as being circular in shape, the disk 3 may comprise any shape that is rotatable about an axis of rotation and that can support a plurality of beakers 2 along its periphery. A heater 6 is positioned at a point on the periphery of the circular disk 3 such that the beakers 2 and their contents are heated as the circular disk 3 is rotated and the beakers 2 pass the heater 6 . In one embodiment, the heater 6 is a planar infrared emitter.
[0013] The support 1 comprises a shaft 7 to which the circular disk 3 is directly coupled. Thus, the axis of rotation 16 of the circular disk 3 is disposed through the center of the shaft 7 . The shaft 7 is rotated on bearings 8 and is driven by a motor 9 that continuously rotates the shaft 7 (e.g., in a clockwise or counter-clockwise direction), thereby continuously rotating the circular disk 3 (and the beakers 2 ) about the axis of rotation 16 . In one embodiment, the motor 9 rotates the shaft 7 such that the beakers 2 coupled to the circular disk 3 are rotated at a uniform or non-uniform speed.
[0014] In one embodiment, the motor 9 is a timing belt. In this embodiment, a first timing pulley 10 is coupled to the shaft 7 , and a second timing pulley 11 is coupled to the motor 9 . A timing belt 12 couples the first timing pulley 10 to the second timing pulley 11 .
[0015] As discussed above, the plurality of beakers 2 is arranged around the periphery of the circular disk 3 . In one embodiment, each beaker 2 is positioned such that its longitudinal axis 4 extends in a diagonal or slanted orientation in two planes relative to the axis of rotation 16 of the circular disk 3 .
[0016] The beakers 2 are designed to contain material (e.g., fabric) to be dyed and a liquid solution of dye and water. Each beaker 2 has a lid 5 to which a dispensing cylinder 13 (illustrated in further detail in FIGS. 2-4 ) is coupled, such that the dispensing cylinder 13 extends into the interior volume of the beaker 2 . The dispensing cylinder 13 is filled with a solid or granular activator (not illustrated) that is manually dispensed into the beaker 2 at the appropriate time and temperature.
[0017] FIGS. 2-3 are side views illustrating one embodiment of a dispensing cylinder 13 coupled to a beaker 2 . Specifically, FIG. 2 illustrates the dispensing cylinder 13 with a check valve 14 in the “closed” position, while FIG. 3 illustrates the dispensing cylinder 13 with the check valve 14 in the “open” position.
[0018] The dispensing cylinder 13 comprises a cylinder body 25 and a removable plug 19 . A first end of the cylinder body 25 is disposed through the lid 5 of the beaker 2 and is sealed from the interior volume of the beaker 2 by the check valve 14 . An opposite second end of the cylinder body 25 is sealed by the removable plug 19 .
[0019] The check valve 14 comprises a piston 15 that is coupled to a first rod 18 . A biasing element 17 such as a spring biases the first rod 18 in a direction away from the beaker 2 (i.e., away from the first end of the cylinder body 25 ). A first seal member 26 such as an O-ring seals the check valve 14 from the interior volume of the beaker 2 .
[0020] The removable plug 19 comprises a second rod 21 coupled to a knob 23 . The second rod 21 is coupled to the knob 23 by a second seal member 22 such as an O-ring. A third seal member 20 such as an O-ring seals the removable plug 19 to the cylinder body 25 . When the removable plug 19 is inserted into the cylinder body 25 , the first rod 18 is biased by the biasing element 17 against the second rod 21 , as illustrated in FIG. 2 . This closes the check valve 14 , so that any activator stored within the dispensing cylinder 13 is prevented from escaping into the beaker 2 .
[0021] To open the check valve 14 and dispense the activator, the knob 23 of the removable plug 19 is depressed (e.g., by a human operator). This forces the second rod 21 against the first rod 18 , pushing back on the biasing element 17 and opening the check valve 14 as illustrated in FIG. 3 . In one embodiment, the dispensing cylinder 13 additionally comprises a locking element for reversibly locking the check valve in the open position.
[0022] The dispensing cylinder 13 thus allows activator and/or other additives in solid or granular form to be added to the contents of a beaker 2 while the circular disk 3 of the beaker type dyeing machine 100 rotates. Thus, the activator may be added to the liquid dye solution without interruption the movement of the beakers 2 . Subsequent agitation of the beakers 2 causes the activator to dissolve in the liquid dye solution, rendering the liquid dye solution suitable for application to the materials to be dyed.
[0023] FIG. 4 is a side view illustrating the dispensing cylinder 13 with the removable plug 19 removed. Removing the removable plug 19 allows the dispensing cylinder 13 to be filled with the activator or other additives.
[0024] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | In one embodiment, the present invention is a beaker type dyeing machine. One embodiment of an apparatus for dyeing a material in a beaker includes a cylinder body having a first end and a second end, the first end being configured for coupling to the lid of the beaker, a check valve incorporated into the first end of the cylinder body, and a plug incorporated into the second end of the cylinder body, the plug being operable to control opening and closing of the check valve. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/716,287, filed Sep. 12, 2005, under 35 U.S.C. § 119(e). In addition, this application also claims the benefit of U.S. Provisional Application No. 60/717,726, filed Sep. 15, 2005, under 35 U.S.C. § 119(e). The entire disclosure of each of the above-referenced applications is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The inventions described herein relate to devices and associated methods for the treatment of chronic total occlusions. More particularly, the inventions described herein relate to devices and methods for crossing chronic total occlusions and subsequently performing balloon angioplasty, stenting, atherectomy, or other endovascular methods for opening occluded blood vessels.
BACKGROUND OF THE INVENTION
[0003] Due to age, high cholesterol and other contributing factors, a large percentage of the population has arterial atherosclerosis that totally occludes portions of the patient's vasculature and presents significant risks to patient health. For example, in the case of a total occlusion of a coronary artery, the result may be painful angina, loss of cardiac tissue or patient death. In another example, complete occlusion of the femoral and/or popliteal arteries in the leg may result in limb threatening ischemia and limb amputation.
[0004] Commonly known endovascular devices and techniques are either inefficient (time consuming procedure), have a high risk of perforating a vessel (poor safety) or fail to cross the occlusion (poor efficacy). Physicians currently have difficulty visualizing the native vessel lumen, can not accurately direct endovascular devices toward visualized lumen, or fail to advance devices through the lesion. Bypass surgery is often the preferred treatment for patients with chronic total occlusions, but less invasive techniques would be preferred.
SUMMARY OF THE INVENTION
[0005] To address this and other unmet needs, the present invention provides, in exemplary non-limiting embodiments, devices and methods for the treatment of chronic total occlusions. The disclosed methods and devices are particularly beneficial in crossing coronary total occlusions but may also be useful in other vessels including peripheral arteries and veins. In exemplary embodiments, total occlusions are crossed using methods and devices intended to provide a physician the ability to place a device within the subintimal space, delaminate the connective tissues between layers within the lesion or vessel wall, or remove tissues from the chronic total occlusion or surrounding vessel.
[0006] In an aspect of the disclosure, a subintimal device may be used to guide conventional devices (for example guide wires, stents, lasers, ultrasonic energy, mechanical dissection, or atherectomy) within the vessel lumen. Additionally, a subintimal device may be used to delaminate vessel wall layers and also may be used to remove tissue from the occlusive lesion or surrounding vessel wall. In one example, the positioning of a subintimal device or the establishment of a delamination plane between intima and medial layers is achieved through the use of a mechanical device that has the ability to infuse a fluid (for example saline). Fluid infusion may serve to apply a hydraulic pressure to the tissues and aid in layer delamination and may also serve to protect the vessel wall from the tip of the subintimal device and reduce the chance of vessel perforation. The infusion of fluid may be controlled by pressure or by volume.
[0007] Subintimal device placement may be achieved with a subintimal device directing catheter. The catheter may orient a subintimal device so that it passes along the natural delamination plane between intima and media. The catheter may orient the subintimal device in various geometries with respect to the vessel. For example, the subintimal device may be directed substantially parallel with respect to the vessel lumen or in a helical pattern such that the subintimal device encircles the vessel lumen in a coaxial fashion. The subintimal device directing catheter may be an inflatable balloon catheter having proximal and distal ends with two wire lumens. One lumen may accept a conventional guide wire while the second lumen may accept the subintimal device. In an alternative embodiment, the wire directing catheter may be a guide catheter with distal geometry that steers the subintimal device with the appropriate orientation to enter the subintimal space.
[0008] In an additional disclosure, a subintimal device intended to mechanically delaminate tissue layers may use a device that is inserted into the subintimal space in a first collapsed configuration and is released or actuated into a second expanded configuration. The device may then be withdrawn or manipulated to propagate the area of delamination.
[0009] An additional aspect of the disclosure may allow the physician to remove tissues from the lesion or vessel wall. In one embodiment, a subintimal device is circumferentially collapsed around the total occlusion. Tissue removal is performed through simple device withdrawal or through a procedure that first cuts connective tissues (i.e. the intimal layer proximal and distal of the lesion) and then removes the targeted tissue. In another embodiment, a tissue removal device is passed through the lesion within the native vessel lumen. The targeted tissues may be mechanically engaged and removed through device withdrawal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] It is to be understood that both the foregoing summary and the following detailed description are exemplary. Together with the following detailed description, the drawings illustrate exemplary embodiments and serve to explain certain principles. In the drawings,
[0011] FIG. 1 shows an illustration of a heart showing a coronary artery that contains a chronic total occlusion;
[0012] FIG. 2 is a schematic representation of a coronary artery showing the intimal, medial and adventitial layers;
[0013] FIG. 3 is a partial sectional view of a subintimal device directing balloon catheter embodiment with fluid infusion through the subintimal device lumen within the device directing catheter;
[0014] FIG. 4 is a partial sectional view of a subintimal device directing balloon catheter embodiment with fluid infusion through the subintimal device;
[0015] FIG. 5 is a partial sectional view of an additional subintimal device directing guiding catheter embodiment with fluid infusion through the subintimal device;
[0016] FIGS. 6A and B are partial sectional views of a expandable delamination catheter;
[0017] FIGS. 7 A-D are partial sectional views of a circumferential subintimal tissue removal device;
[0018] FIGS. 8 A-C are an example of subintimal device construction; and
[0019] FIGS. 9A and B are partial sectional views of an intraluminal rotational engagement tissue removal device.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0020] The following detailed description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the invention.
[0021] Referring to FIG. 1 , a diseased heart 100 includes a chronic total occlusion 101 of a coronary artery 102 . FIG. 2 shows coronary artery 102 with intimal layer 200 (for sake of clarity, the multi layer intima is shown as a single homogenous layer). Concentrically outward of the intima is the medial layer 201 (which also is comprised of more than one layer but is shown as a single layer). The transition between the external most portion of the intima and the internal most portion of the media is referred to as the subintimal space. The outermost layer of the artery is the adventitia 202 .
[0022] In an aspect of the disclosure, a subintimal device may be used to guide conventional devices (for example guide wires, stents, lasers, ultrasonic energy, mechanical dissection, or atherectomy) within the vessel lumen. Additionally, a subintimal device may be used to delaminate vessel wall layers and also may be used to remove tissue from the occlusive lesion or surrounding vessel wall. In one embodiment, FIG. 3 shows a subintimal device directing catheter is 300 with its distal balloon 301 that has been advanced over a conventional guide wire 302 and inflated proximal to chronic total occlusion 101 . For the sake of clarity, FIG. 3 shows a subintimal device path that is substantially parallel to the vessel lumen, but other orientations (i.e. helical) may also be considered. Subintimal device lumen 303 is positioned adjacent to the intimal layer 200 and subintimal device 304 has been advanced as to perforate the subintimal layer. A fluid source (i.e. syringe) 305 is in fluid communication with subintimal device lumen 303 through infusion lumen 306 . Fluid may flow from the fluid source 305 through the subintimal device lumen 303 under a controlled pressure or a controlled volume. The infused fluid may enter the subintimal space 307 directly from the subintimal device lumen 303 or from the volume 308 defined by the distal end of the balloon 301 and the proximal edge of the lesion 101 . FIG. 4 shows an alternative fluid infusion path where fluid source 305 is in fluid communication with a lumen within the subintimal device 304 . FIG. 5 shows an alternative subintimal device directing guide catheter 500 where the distal end 501 has a predefined shape or the distal end has an actuating element that allows manipulation by the physician intra-operatively.
[0023] Another aspect of the disclosure may place a subintimal device within the subintimal space in a first collapsed configuration and releases or actuates the subintimal device to a second expanded configuration. The device may then be withdrawn or manipulated to propagate the subintimal dissection. In one embodiment, FIG. 6A shows a subintimal device with internal expandable element 600 that contains one or more expanding elements 601 contained in exterior sheath 602 . FIG. 6B shows exterior sheath 602 in a retracted position allowing expanding elements 601 to elastically expand. The subintimal device is intended to be delivered through the aforementioned subintimal device delivery catheters.
[0024] An additional aspect of the disclosure may allow the physician to remove tissues from the lesion or vessel wall. FIG. 7A shows an embodiment where subintimal device directing balloon catheter is inflated within coronary artery 102 just proximal to chronic total occlusion 101 . Subintimal device 304 is partially delivered around chronic total occlusion 102 coaxially outside the intimal layer 200 and coaxially inside medial layer 201 in a helical pattern. FIG. 7B shows a subintimal device capture catheter 702 positioned across the chronic total occlusion 101 over conventional guide wire 703 and within subintimal device 304 . The distal 704 and proximal 705 ends of the subintimal device 304 have been captured and rotated as to reduce the subintimal device outside diameter and contain the lesion 101 and intima 200 within the coils' internal diameter. The device may be withdrawn through the use of a cutting element. For example, FIGS. 7C and D show the advancement of a cutting element 706 in two stages of advancement showing the cutting of intima 200 proximal of the occlusion 707 and intimal distal of the occlusion 708 .
[0025] An additional aspect of the subintimal device is the construction of the device body. The flexibility and torquability of the device body can affect the physician's ability to achieve a subintimal path. The subintimal device body may be constructed in part or in to total of a single layer coil with geometric features along the coil length that allow adjacent coils to engage (for example mechanical engagement similar to the teeth of a gear). FIG. 8A shows coil 801 closely wound such that the multitude of teeth 802 along the coil edges are in contact such that the peaks of one coil falls within the valleys of the adjacent coil. A conventional coil reacts to an applied torsional load by diametrically expanding or contracting, thus forcing the wire surfaces within a turn of the coil to translate with respect to its neighboring turn. The construction of coil 801 resists the translation of wire surfaces within the coil thus resisting the diametric expansion or contraction (coil deformation). An increased resistance to coil deformation increases the torsional resistance of the device body while the coiled construction provides axial flexibility. An exemplary construction may include a metallic tube where the coil pattern 801 and teeth 802 are cut from the tube diameter using a laser beam. FIG. 8B shows subintimal device body 804 that is for example a continuous metallic tube with distal laser cut coil segment 801 and proximal solid tube 803 . Tube materials include but are not limited to stainless steel and nickel titanium. Alternatively, the coil may be wound from a continuous wire. The wire has a cross section that for example has been mechanically deformed (stamped) to form the teeth and allow coil engagement. FIG. 8C shows an example of a laser cut tooth pattern from the circumference of a tube that has been shown in a flat configuration for purposes of illustration.
[0026] In another embodiment, a tissue removal device may be passed through the lesion within the native vessel lumen. FIG. 9A shows corkscrew device 900 with exterior sheath 902 engaging occlusion after delamination of the intimal layer 901 has been performed by the aforementioned methods and devices. FIG. 9B shows removal of the occlusion and a portion of the intimal layer through axial withdrawal of the corkscrew device.
[0027] From the foregoing, it will be apparent to those skilled in the art that the present invention provides, in exemplary non-limiting embodiments, devices and methods for the treatment of chronic total occlusions. Further, those skilled in the art will recognize that the present invention may be manifested in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, departures in form and detail may be made without departing from the scope and spirit of the present invention as described in the appended claims. | Devices and methods for the treatment of chronic total occlusions are provided. One disclosed embodiment comprises a method of facilitating treatment via a vascular wall defining a vascular lumen containing an occlusion therein. The method includes providing an intravascular device having a distal portion, inserting the device into the vascular lumen, positioning the distal portion in the vascular wall to at least partially surround the occlusion, and removing at least a portion of the surrounded occlusion from the lumen. | 0 |
This invention was made in the course of, or under, a contract with the U.S. Department of Energy.
BACKGROUND OF THE INVENTION
The invention relates to the system and method for the decontamination of radiation contaminated equipment.
Stainless steel is widely used throughout the nuclear industry as a structural material and/or in equipment used for processes contacting nuclear materials. During such uses, the material or equipment can become grossly contaminated with radionuclides as is known in the art such that its usefulness is impaired. Primary contaminants might include: plutonium, americium, uranium and mixed fission products including cerium-144, ruthenium-106, cesium-137 and silver-110m. The equipment must then either be decontaminated, i.e., cleaned, stripped or the like of radionuclides, so that it can be returned to service or be disposed of by dismantling into small volumes for long term storage by burial or in a geologic repository. Failed equipment constitutes a large volume of contaminated radioactive waste which takes up a large volume of storage space, and is difficult to handle due to its radionuclide contamination. The ability to remove the contamination from the surfaces of metal equipment would greatly reduce the amount of waste requiring geologic disposal on the like and the costs associated with such disposal and monitoring of radioactive waste.
Recognizing the problem that this poses, a variety of cleaning solutions have been investigated for use in decontaminating equipment used in the nuclear industry. These solutions have included permanganate, oxalic acid, various detergents, inhibited mineral acids, and chelating agents as well as very corrosive materials like sulfuric acid, phosphoric acid, and hydrochloric acid, and combinations of other solutions. While these cleaning solutions worked to various degrees and can be used to decontaminate nuclear industry equipment to a certain extent, various problems still remain. Similarly, work is currently being done on using electrolysis in a phosphoric acid solution as a technique to decontaminate metals. This electrolysis is accomplished by making the metal piece to be decontaminated the anode and using a 40 to 80% phosphoric acid as a conductor or electrolyte. While this electrolytic process does have the advantage that it effectively decontaminates areas which are inaccessible to normal decontamination agents, it does have the drawback of employing solutions that cannot be easily regenerated, and it creates large volumes of high salt content liquid waste solutions with respect to the amount of material processed. Another disadvantage of this process is that the degree of decontamination of the piece of equipment is sensitive to the position of the cathode relative to the surface of the equipment.
SUMMARY OF INVENTION
In view of the above problems and disadvantages of the prior art, it is an object of this invention to provide a method for radioactive decontamination of equipment.
It is a further object of this invention to provide a process for decontaminating stainless steel which has been grossly contaminated with radionuclides.
It is a further object of this invention to provide a process employing a cerium(III)-cerium(IV)-nitric acid solution for the decontamination of radionuclides on stainless steel.
It is a further object of this invention to provide a process for decontaminating equipment which is grossly contaminated with radionuclides employing an inorganic system wherein the decontaminating solution employs an inorganic reduction-oxidation system.
It is a further object of this invention to provide a process for decontaminating equipment contaminated with radionuclides wherein the active member of the solution may be regenerated by electrolysis during the decontamination cycle.
It is a further object of this invention to provide a process for decontaminating and reclaiming readioactively contaminated equipment, using an inorganic reduction-oxidation system, and regenerating the oxidant in the system to maximize the dissolution of radionuclides into the solution.
Various other objects and advantages will appear from the following description of this invention and the most novel features will be particularly pointed out hereinafter in connection with the appended claims. It will be understood that various changes in the details, materials and steps of the process, which are herein described and illustrated in order to explain the nature of the invention, may be effected by those skilled in the art without departing from the scope of this invention.
The invention comprises, in brief, contacting metals contaminated with radionuclides with an inorganic reduction-oxidation system to accomplish decontamination of the metals by said system. Inorganic reduction-oxidation systems that are useful include cerium(IV)-cerium(III) in nitric acid, chromium (VI)-chromium(III) in nitric acid, silver(II)-silver(I) in nitric acid, and cobalt(III)-cobalt(II) in nitric acid. Other reduction-oxidation systems in other acids may be included as long as the system may exist in two different oxidation states in the acid. It is desirable to regenerate the oxidant by electrolysis.
DESCRIPTION OF DRAWING
The drawing illustrates a typical apparatus for the process and system of this invention.
DETAILED DESCRIPTION
Corrosion of stainless steel and other metals such as mild steel, and black iron in nitric acid or other acids such as sulfuric acid or hydrochloric acid can be accelerated by the presence of certain inorganic reduction-oxidation (redox) systems. These are systems which contain elements capable of existing in two different oxidation states in the nitric acid or the acid being used. Examples of reduction-oxidation systems which can exist in nitric acid are cerium(IV)-cerium(III), chromium(VI)-chromium(III), silver(II)-silver(I), and colbalt(III)-cobalt(II).
This invention is specifically directed to the use of such inorganic reduction-oxidation systems for decontaminating radioactively contaminated metals encountered in the nuclear industry, and specifically where the systems are in nitric acid. Regeneration of the oxidant by electrolysis is included in this invention for the decontamination process. Decontamination is accomplished by dissolution of the surface of the metal piece that is being decontaminated when it is in contact with solution. The invention described herein is directed to the chemical decontamination of the metal parts or pieces and not to any electrolytic decontamination of the contaminated components.
The requirement for decontamination exists not only because some equipment may be salvaged, but also because plutonium contaminated substances must be decontaminated, and if equipment that is grossly contaminated can have the contamination reduced to low levels, the equipment can be cut up for repackaging into much smaller volumes for disposal or storage.
As shown in the drawing, the apparatus 10 includes a container 12 forming a chamber 14 having a solution 16 disposed therein. Solution 16 may be a nitric acid solution containing a reduction-oxidation system as described herein. Pipe 18 is suitably suspended or otherwise immersed in solution 16 by hanger 20 or the like. The radioactive contamination of pipe 18 is significantly reduced by chemical reaction of the immersed surfaces of pipe 18 with solution 16, resulting in reduction of the reduction-oxidation system as described herein. A suitable power source, such as a battery 26, may be used to create an electric circuit between anode 28 and cathode 30 through solution 16 thereby effecting oxidation of the reduced member of the reduction-oxidation system as is known in the art.
Various runs were made using this invention with a cerium(IV)-cerium(III) system in nitric acid. Runs were conducted in solutions wherein the nitric acid was at from about 2 to about 8 Molar(M), the cerium ion was about from 0.1 to 0.3 M, the temperature variation was from about 20° C. to about 100° C. and the electric current to regenerate cerium(IV) was at a current of from 0.5 to 1.5 amps.
The maximum dissolution rate for stainless steel (type 300 series) was achieved in 7 M nitric acid -0.25 M cerium(IV) at 90° C. using 0.5 amperes current to regenerate the cerium(IV). The maximum dissolution rate was 1.5 mils per hour or 29 milligrams per square centimeter per hour. It is to be understood that various other changes may be made by the practitioner to these parameters without departing from the scope of this invention and achieving equal or better results. For example, any suitable current which maintains a high cerium(IV)/cerium(III) ratio may be used.
In one run, a 1/2 inch stainless steel (Type 304) tubing which was immersed approximately 2 inches into a 0.2 M cerium(IV)-4 M nitric acid solution at 80° C. for 10 minutes was partially etched removing surface layers. In another run, a 31/2 inch diameter stainless steel pipe cap after having been partially immersed in a 0.1 M cerium(IV)-4 M nitric acid solution at 80° C. for 50 minutes had a heavy dark corrosion layer on it removed after having been used in a test in which it was heated in a furnace at 1100° C. for two hours. From our analysis, it is obvious that the cerium(IV) solution had attacked the oxide layer and metal surface of both pieces of stainless steel. While the cerium(IV)-cerium(III) system in nitric acid has been described and illustrated, it is to be understood that the various other inorganic reduction-oxidation systems which were described herein may be employed. Examples of reduction oxidation systems which can exist in nitric acid include cerium(IV)-cerium(III), chromium(VI)-chromium(III), silver(II)-silver(I) and cobalt(III)-cobalt(II).
The chemical systems described herein have advantages over the prior art. Nitric acid solutions are widely used throughout the nuclear industry and as such their properties are well known and understood. This facilitates cleanup of the decontamination solution (for example by removal of plutonium and/or other contaminants) by standard chemical separation techniques used routinely in the nuclear industry such as ion exchange or solvent extraction, and/or disposal of the solution following its use as a decontamination agent.
The cerium(IV)-cerium(III) system in nitric acid described herein is a good dissolution agent for plutonium oxide and could be used for removal or recovery of plutonium from equipment highly contaminated with plutonium. In addition, other reduction-oxidation systems as described herein may be used for the dissolution of plutonium dioxide.
The systems as noted herin are low salt systems and therefore there is potentially less waste generated by this process than other processes. In addition, the decontamination is not sensitive to relative distance from an electrode as in electrolytic processes. Thus the process is more effective for irregularly shaped equipment than an electrolytic process which is sensitive to the location of the cathode relative to the piece to be decontaminated. While immersion has been described herein, the process does not require immersion for the equipment being decontaminated. This process would be just as effective by a spray or a flowthrough system. | The invention relates to chemical etching process for reclaiming contaminated equipment wherein a reduction-oxidation system is included in a solution of nitric acid to contact the metal to be decontaminated and effect reduction of the reduction-oxidation system, and includes disposing a pair of electrodes in the reduced solution to permit passage of an electrical current between said electrodes and effect oxidation of the reduction-oxidation system to thereby regenerate the solution and provide decontaminated equipment that is essentially radioactive contamination-free. | 6 |
REFERENCES CITED
U.S. Patent Documents:
3,553,339
January, 1971
Dominguez et al
6,956,596
March, 2003
Kuratani et al
3,638,753
August, 1970
Cunningham
7,179,985
February, 2007
Pickens
4,732,070
March, 1988
Yamashita
STATEMENT OF FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
None
REFERENCE TO SEQUENCE LISTING
None
BACKGROUND OF THE INVENTION
This invention relates generally to the field of musical instruments and more specifically to a complete system for an electronic bass drum.
Virtually every drum kit has a bass drum, whether it is an acoustic set or an electronic set. This invention is designed to replace current bass drums in every type of drum set.
In FIG. 1 , a current technology acoustic drum set is presented, including a conventional acoustic bass drum. Note that there is the bass drum itself 21 , a special bass drum microphone 22 and individual drum microphones 22 a for picking up sounds when more volume is required, an amplifier/mixer or P.A. device 23 and speakers 24 to play the sounds to the audience. Also note that the pitch and voice quality of the bass drum always remains the same, and that the whole setup includes several components that are usually spread out and inaccessible to the drummer, most notably the volume control. And that each component usually has its own heavy wooden case that adds to the weight and setup complexity of the system.
FIG. 1 a shows the same drum kit, except for the acoustic bass drum which has been replaced by my invention 25 . Note that all of the peripheral amplification and sound equipment has also been replaced, by my single instrument. And because the invention includes an electronic drum module, the performer is able to control the voice quality of the bass drum at will, and all volume adjustment controls are readily available.
Current technology electronic drum sets FIG. 2 , usually include a pedal 26 , an impact sensitive electronic kick pad 27 , a drum module 28 and an amplification system or P.A. 29 for performing. There are advantages to using an electronic drum set. The tonal quality of the drums is instantly variable; most modern drum modules offer over 500 different sounds, and these sounds are readily changeable depending upon the style of music played. Also, there is usually a volume control that is easily within reach of the drummer. But there are still drawbacks to existing technology. An external amplification or P.A. system 29 still needs to be set up.
In FIG. 2 a , the electronic bass drum 25 replaces the current kick pad, module, and amplification systems with a single, easily transportable instrument.
Cosmetically, the classic bass drum shape is very much desired by all drummers, and current electronic bass drum technology is shunned by most conventional acoustic drummers for this reason. And there is no system for mounting tom-toms or other percussion instruments on the typical electronic bass drum. My invention overcomes all of these limitations.
BRIEF SUMMARY OF THE INVENTION
An object of the invention is to offer acoustic drummers a bass drum with dozens of different sounds, that cosmetically matches their existing sets.
Another object is to provide an amplification and speaker system built into the shell of a conventional bass drum, eliminating the need for separate components.
A further object is to have tom-tom and other mounting brackets incorporated into an electronic bass drum.
Another object is to have a mounting system for electronic pads that more closely resembles an acoustic set, eliminating bulky racks currently in use.
Yet another object is to eliminate the need for a separate drum module and all of the accompanying wires.
Another object is to have sound level and drum tone changes readily available to the performer.
A further object is to have several acoustic drum microphone jacks readily available.
Yet another object is to have multiple input jacks for the internal drum module readily available.
Another object is to allow other band members the capability of sharing the built-in amplification and speaker systems, conceivably performing solely through this one device.
Yet another object is to incorporate a headset system for a completely quiet band practice.
A further object is to allow for the use of an MP3 player device, such as an IPOD™ device, for practice.
Other objectives and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
BRIEF DESCRIPTIONS OF THE DRAWINGS
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
FIG. 1 shows a common acoustic drum configuration using current technology, as viewed from the front.
FIG. 1 a shows the same drum set with components replaced by the invention.
FIG. 2 shows a common electronic drum set using current technology, as viewed from the rear.
FIG. 2 a shows the same electronic drum set with components replaced by the invention.
FIG. 3 is an overhead view from the right rear of the invention showing the primary features.
FIG. 4 is a frontal view showing loudspeaker installation.
FIG. 5 is a cutaway view showing the internal components of the invention.
FIG. 6 shows the electronic controls and external components from the top rear of the invention, viewed from the right side.
FIG. 7 shows the auxiliary inputs panel on the right side of the instrument.
FIG. 8 shows the headphone jack panel viewed from the left side of the invention.
FIG. 9 a shows a left rear view of an embodiment of the invention for acoustic drum sets, without a built-in drum module.
FIG. 9 b shows a left rear view of an embodiment of the invention for electronic drum sets, without a built-in drum module.
FIG. 10 is a close-up view of the input and output panel required when there is no built-in drum module.
FIG. 11 is a frontal view showing a speaker cover.
DETAILED DESCRIPTION OF THE INVENTION
Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
FIG. 3 gives an overview of most of the essential parts of the electronic bass drum in accordance with one embodiment of the invention, wherein the parts identical to those shown in FIGS. 3 through 11 are designated by the same reference numerals. A cylindrical outer shell 30 is used which has dimensions that are very similar to prior art acoustic bass drum shells. In fact, prior art wooden or acrylic bass drum shells would be useable, and the external finish of said outer shell would probably match the other drums in each individual kit. Stabilization legs 31 and tom-tom mounts 32 are widely available for prior art acoustic bass drums and are useable in the invention as well. All other percussion instrument mounting systems designed for conventional acoustic bass drums will work on this electronic bass drum. The invention is designed to cosmetically mimic existing acoustic bass drums to the fullest extent possible. There is an attachment point 33 for mounting a bass drum pedal at the rear of the invention, and an impact-sensitive electronic drum kick pad 34 is installed for striking with said bass drum pedal. The electronic kick pad signal is sent to the integral bass drum module 36 that is part of the control panel 35 . There is an MP3 player receptacle 37 that allows the drummer to practice along with music. There are several dual purpose input jacks 38 . Drummers who use electronic drums need input jacks for their electronic pads. Acoustic drummers will want input jacks for their drum microphones. A unique switch 39 changes the function of the jacks, and routes all signals either to the drum module in the case of electronic pads, or directly to the internal amplifier in the ease of microphones. Optional microphone volume adjustment controls are shown in FIG. 9 a , item 38 a . The auxiliary input panel 40 of FIG. 3 has several input jacks 56 that allow other performers to play their instruments through the internal amplifier of the invention. Each input to the amplifier has an input volume control 57 . There is also an auxiliary headset panel 41 that allows several band members to listen to the combined inputs to the internal amplifier, as well as the built-in drum module 35 and MP3 player as desired. This arrangement is designed so that an entire band can plug into the invention and practice together silently through headsets, or perform together through the integrated amplifier and speaker system.
FIG. 4 shows the front end of the instrument, where one or more loudspeakers or drivers can be mounted in a variety of ways. In this embodiment, there is depicted a woofer 42 , a mid-range speaker 43 and a tweeter 44 all mounted to the forward wall 45 .
FIG. 5 is a cutaway view of the internal parts of the instrument, and shows how several previously separate components can be combined into a single instrument. The internal amplifier 46 is mounted to wall 48 . There is an optional internal cooling fan 47 that circulates air throughout the invention, in order to prevent the overheating of the electronics of the invention. The drum module electronics are installed in a compartment 49 beneath the main control panel in this embodiment. There is more than adequate room for an array of speakers mounted on the forward wall 45 .
FIG. 6 shows a close-up of the main control panel 35 for the internal amplifier and the integral drum module. Note that this is but one possible arrangement, and there are several ways to set up the controls. All critical control functions are easily within reach, starting with the master amplifier volume control knob 50 . The drum set select knob 52 enables the performer to quickly change the tonal quality of the externally mounted kick pad 34 as well as all other electronic percussion instruments plugged into the device using the input jacks 38 . The module output volume control knob 51 is used to vary the output level of the sounds sent from the drum module to the amplifier. If several musicians were plugged into the invention using the input panel 40 and the drum sound level was too high for the group, this control would be used to lessen the sound level of the drums only. Since most drummers use recorded music to practice with, there is included an MP3 player dock 37 which holds in MP3 player, for example a standard IPOD™ device 37 a . The output from the MP3 player can be heard though the drummer's headphone jack 54 along with all other inputs to the internal amplifier. A volume control 53 for the headset jack 54 is included.
The relative volume for all of the inputs can be controlled by the drummer using the volume adjustment switches 55 . Note that all functions can be changed quickly and easily, and in many cases levels will be adjusted during live play.
FIG. 7 shows the right side of the instrument where the input panel 40 could be located. There is depicted a row of input jacks 56 for other band members to plug in their electric instruments, and each input has a volume control 57 and an equalizer control 58 . Two input jacks for microphones 59 are also shown, with their respective volume control knobs 60 . The number of inputs may vary.
FIG. 8 shows the left side of the invention where the headphones panel 41 could be located. There is depicted a row of headset jacks 61 with each jack having its respective volume control 62 . The number ofjacks may vary. The purpose of this panel is to allow several musicians to listen to any or all of the inputs to the internal amplifier, which may include a drum module, the MP3 player and every musician or singer who is plugged into the previously discussed input panel in FIG. 7 . The purpose of this arrangement is to allow an entire band to rehearse together in situations where noise output from instruments or amplifiers is not allowed, wherein every player can hear all other players simultaneously, while also listening to an MP3 player song if desired.
For drummers who already own drum modules and want a less expensive electronic bass drum, two other embodiments of the invention are offered in FIGS. 9 a and 9 b . Note that the control panel 63 in both embodiments does not contain a drum module. The embodiment shown in FIG. 9 a is designed for drummers with acoustic drum sets who already own or wish to use an external electronic drum module. Microphone input jacks 38 used for the rest of the acoustic set are shown with optional individual volume adjustment controls 38 a , and these signals are sent directly to the internal amplifier.
FIG. 9 b shows an electronic bass drum for an electronic set wherein the drummer has an external drum module, and doesn't need an integrated module in the electronic bass drum. Note that input jacks 38 for drum pads or other electronic instruments are not required in this case, since commercial drum modules all have these input jacks built in.
In both the acoustic and electronic drum setups, the output from the integral electronic kick pad 34 needs to be routed to an external drum module, and signals from the external drum module need to be connected back into the internal amplifier and speaker systems in the invention. This is accomplished using the signal jack panel 64 depicted at the left side of the invention.
FIG. 10 shows a close-up of said panel, comprising an output jack 65 that takes the signals from the integral electronic kick pad to an external drum module when said module is connected to this jack. After the kick pad electronic input is received by said drum module, a signal is produced, then routed to the input jack 66 which connects to the internal amplifier of the invention.
Two auxiliary jacks are also depicted in FIG. 10 , and these jacks can be used in any embodiment of the invention. The output jack for connecting an external amplifier 67 could be used in situations where the internal amplifier and speakers of the invention are not powerful enough to be heard by an entire audience, at a stadium concert for example. The signal from this jack is produced by the internal amplifier, based upon inputs received and sound levels commanded by the drummer. This signal could then conceivably be routed to a huge external amplifier, and a massive wall of speakers could fill the stadium with sound.
The input jack for connecting an external amplifier directly to the loudspeaker or speakers 68 is used when speakers alone are needed by an external amplifier, and the signal from this jack bypasses the internal amplifier of the invention and goes directly to the loudspeakers at the front of the electronic bass drum.
In order to protect the loudspeakers at the front of the instrument from dust, debris or physical damage, a cover is depicted in FIG. 11 . This cover could be made out of speaker cloth or other loosely woven material, so as to allow the sound produced by the speakers to fully project to the audience. Note that a band name or other logo 70 could be written on said cover, completing the mimicry of existing acoustic bass drums.
As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within metes and bounds of the claims, or equivalents of such metes and bounds are therefore intended to be embraced by the claims. | An Electronic Bass Drum includes one or more loudspeakers, an internal amplifier system, an optional electronic drum module and control panel, an impact sensitive electronic kick pad, an attachment for a bass drum pedal, mounting hardware for tom toms or other acoustic or electronic instruments, legs for stabilization, one or more headset jacks for silent play, input jacks for other instruments and/or microphones, and an ipod™ cradle for playing along with music. All of which are enclosed in a cylindrical shell which cosmetically matches the dimensions and design characteristics of a conventional acoustic bass drum. | 6 |
[0001] This application claims the priority of Chinese Patent Application No. 2005 1 0029730.5 filed on Sep. 5, 2005, in the China Intellectual Property Office, the disclosure of which we incorporate here in its entirety by reference.
FIELD
[0002] The present relates to a processing apparatus and method capable of enhancing image color. More particularly, the present relates to a processing apparatus and method for enhancing image color in a color space region.
BACKGROUND
[0003] People's requirements realism and purity are more and higher in the case of collecting, displaying and printing of the image/video. Meantime, capturing during the process of display, non-matching and non-linearity characters between sensitization elements of a capturing apparatus for capturing an image of display and luminescence/color elements of a display/print apparatus cause that these capturing data must be reprocessed to recover nature color and avoid the color component not suitable for human eyes as possible under the existing parts of a physical apparatus. Since requirements for interested color of human eyes under different environments demand that factual collecting and capturing apparatus of image/video have functions of enhancing, modifying and adjusting. For example, there's image saturation, color adjustment and specific color enhancing and modifying function in a TV and video camera.
[0004] The existing display apparatus has the function of whole modification of color and hue for image/video, especially to saturation, color/hue and so on. One of the simplest and most universal apparatus and method is as follows. First, color space conversion module converts image/video from RGB or CMYK etc. color space to YUV or YCbCr etc. color space. Second, coordinates conversion module separates a color component into dependent component such as saturation, color/hue. Then in the case of modifying the saturation component, saturation modification module modifies a saturation component to multiply by a component a, when α>1, the whole image/video saturation is enhanced; For modifying image/video color saturation, hue modification module modifies the phase of a UV plane by adding a chroma component θ to change the hue of the whole image/video.
[0005] However, all these adjusting functions can not be used in a specific region of the color space but in the whole color space. Therefore, in such above-presented method, there are a lot of defects as following: 1. Overly adjusting the saturation of the image/video possibly so as to color the gray scale strip and achromatous object, even color some objects out of bound to be another unacceptable color for human eyes, for example, human face is changed in red. 2. Simply adjusting the saturation of color may cause some data extending out of the largest range to shrink the factual color space, therefore, lowering the image/video quality to some extent. 3. In the case where the hue of some colors is to be modified, the hue of other colors is wrongly changed at the same time possibly. Such a case needs us to avoiding.
SUMMARY
[0006] An object is to provide a processing apparatus for enhancing the image color in a specific region of the color space.
[0007] Another object is to provide a processing method for enhancing the image color to overcome disadvantages associated with known image processing apparatus.
[0008] We describe embodiments in detail with reference to the accompanying drawings.
BRIEF DRAWINGS DESCRIPTION
[0009] FIG. 1 is a block diagram of an embodiment of a processing apparatus for enhancing the image color.
[0010] FIG. 2 is a flowchart of an embodiment of a method for enhancing the image color.
[0011] FIG. 3 is a chart for calculating the enhancement amplitude.
[0012] FIG. 4 is a processed image.
[0013] FIG. 5 is a non-processed image.
[0014] FIG. 6 is a block diagram of an embodiment of a processing apparatus for enhancing the image color.
[0015] FIG. 7 is a flowchart of an embodiment of a method for enhancing the image color.
DETAILED DESCRIPTION
[0016] A device first converts the individual and collective pixel (image point) into a corresponding color representation space (e.g., RGB, CMY, YUV, CIE, or any other color space) and attendant coordinates space (e.g., Cartesian coordinate system, polar coordinate system, and any other coordinate system). In accordance with color region to be enhanced defined by the parameters, to calculate whether the color of the pixel is needed to be enhanced or adjusted, and calculate the direction and magnitude of the enhanced color, then to perform the processing of color enhancement of the pixel and convert the pixel into other color space.
[0017] As shown in FIG. 1 , it is illustrated a structure diagrammatic sketch of an embodiment of a processing apparatus for enhancing the image color. The apparatus includes n color space regional decision and enhance attenuation calculation modules 2 - 1 ˜ 2 -n, the color space conversion module 1 , the color space regional parameter storage module 3 and the color space component enhance module 4 respectively coupled to all of these above-mentioned color space regional decision and enhance attenuation calculation modules 2 - 1 ˜ 2 -n, further including the color space inverse conversion module 5 coupled to the color space component enhance module 4 .
[0018] The coordinate (X 1 , X 2 , . . . X n ,) of a pixel in an original color space is converted to the coordinate (Y 1 , Y 2 , . . . Y n ) in a color space with color enhancement by the color space conversion module 1 . The original color space can use CMY, HIS, YIQ or self-defined color space etc. If only the color space can represent the collective of colors, which can be used as an effective color space. For different color spaces, the color space conversion module 1 can differently perform converting. For example, the matrix uses for converting RGB space to YUV(YCbCr) space simply. Corresponding iterated closeness algorithm is introduced into the approach of converting coordinate of YUV space to polar coordinate (Y, r, θ).
[0019] The color space regional decision and enhance attenuation calculation modules 2 - 1 ˜ 2 -n calculate the enhancement region in color space of the pixel, the enhancement amplitude (Δ 1 , Δ 2 , . . . Δ n ) and the flat transition around the edge of enhancement region in accordance with the collective of region parameters of (Y 1 , Y 2 , . . . Y n ) space and attenuation definition deployed by the color space regional parameter storage module 3 .
[0020] The color space component enhance module 4 implements adjusting amplitude (Δ 2 , Δ 2 , . . . Δ n ) of components in all direction based on enhancement components of each component resulted from calculation of enhancement amplitude. The process of adjustment comprises compensation of luminance, limitation of data edge and so on.
[0021] Each component enhanced is converted to (Z 1 , Z 2 , . . . Z n ) require by other color space during followed process by the color space inverse conversion module 5 .
[0022] FIG. 2 is a flowchart of a method for enhancing the image color. In this exemplary embodiment, the blue, green, red, yellow and skin color are enhanced and adjusted.
[0023] Step A) the color space conversion module converts the image element (pixel, individual or collective image point) to be processed to the color space which is used for enhancement/adjustment.
[0024] If the image element is located in the color space same as the enhancement space, it will not be converted. In this embodiment, the coordinate of the pixel of image and video to be processed is (Y, U, V) in the YUV space. If the pixel is located in the other color space, firstly to convert the pixel to the corresponding color space, YUV color space. Simultaneously since modification is required for saturation and hue (tint), the coordinate of YUV space need to be converted to (Y, r, θ).
[0025] Step B) The color space regional decision and enhance attenuation calculation module calculates the enhanced amplitude of color of the pixel and sends to the color space component enhance module in accordance with the color enhancement parameters of each color space region deployed by the color space regional parameter storage module.
[0026] According to the collective p of parameters of each color space region deployed by the color space regional parameter storage module, to partition the region Ω of color space (Y, r, θ) which is to be enhanced color, for example, defining a three-dimensional region
Ω i □{Yε(Y s,i , Y t,i ), rε(r s,i , r t,i ), θε(θ s,i , θ t,i )} i=1, . . . , n ,
n represents the number of regions, region be one or several;
[0027] Simultaneously, the distributing of YUV color space, the physical character of display apparatus and vision characteristic of human eye are considered. Each color enhancement region is corresponding to each region Ω, in this embodiment, five regions are partitioned, i.e., five Ω spaces.
Δ=f(Y,r,θ,p) (Y,r,θ)εΩ (1)
[0028] Calculating the enhancement amplitude of color, meantime considering two approaches for processing position partition of region Ω i are available to the pixel (Y,r,θ), the first approach is to discriminate the coordinate (Y, r, θ), then to calculate the direction to be enhanced based on its located region(reference to FIG.3 ), For example,
Δ=f(Y,r, θ, p) (Y,r,θ)εΩ i (1)
[0029] Where, (Y, r, θ)εΩ i represents the discrimination result of region to decrease computational complexity of enhancement/adjustment amplitude, p represents reduction coefficient. Here, the setting of Δ is determined by the edge parameters (Y s,i , Y t,i ), (r s,i , r t,i ) (θ s,i , θ t,i ) of region Ω i and the reduction coefficient p of region. Generally speaking, the coordinate (Y, r, θ) of the pixel closer to the boundary of region Ω i ,the weaker the intensity of enhancement is, vice verse, the further, the stronger it is. p determines the speed of the reduction, but the general intensity of enhancement will not go beyond the defined peak value.
[0030] Another approach is to use Serial or parallel pattern to respectively calculate the enhancement/adjustment range of the pixel (Y, r, θ) in each Ω i region, for example,
Δ i =f(Y, r, θ, p) (Y, r,θ)εΩ i (2)
[0031] The function f(.) can use different expressions, for example, Δ i =min(p*Dist((Y, r, θ), Ω i boundary), H i ), wherein Dist((Y, r, θ), Ω i boundary) represents the minimum distance from the enhanced pixel to the boundary of its corresponding located region (Y s,i , Y t,i ), (r s,i , r t,i ), (θ s,i , θ t,i ) p represents corresponding reduction coefficient. And then each Δ i is implemented combined adjustment (such as interpolation) to obtain the intensity Δ for enhancement and adjustment. The combined adjustment means that the settings are adjusted in the direction of each component (such as Y, r, θ) at one time. In the serial pattern, the partition of the region Ω i may be overlapped. However, the partition of the region Ω i can be guaranteed non-overlapping of each region by controlling the set parameters of region Ω i . Generally speaking, the transition of adjusting amplitude of pixels which are around the boundary of the enhancement region ridden on the close parameter p is gently so as to avoid the crisis of the jump. The closer to the boundary of the region Ω i the pixel is, the stronger the enhancement amplitude of the pixel is. Therefore the change of the enhancement amplitude of the pixel around the boundary of the region is not jumped but gently.
[0032] In this embodiment, verifying the blue, green, red, yellow and skin color, the enhancement amplitude is Δ i =min(0.8* Dist((Y, r, θ),Ω i boundary), H i ) here, i equals to the blue, green, skin color, the value of Ω i and H1 seeing the table 1.(Ω i bounded by the (Y s,i , Y t,i ),(r s,i , r t,i ), (θ s,i , θ t,i )
TABLE 1 the color range Region color Y s, i Y t, i r s, i r t, i Θ s, i Θ t, i H 1, i blue 0 150 10 120 270° 10° 100 green 0 160 10 120 180° 270° 100 red 0 120 60 120 80° 170° 80 yellow 160 255 80 128 140° 225° 60 Skin Color 80 200 20 60 70° 160° 20
[0033] According to the object of the color adjusting, except adjustment intensity the information of adjustment direction is needed. Such direction info may describe the info about changing in the same region, also may about changing in the direction of some pixel or some line.
[0034] Step C) the color space component enhance module calculates each enhanced color component in the color space which is located by the pixel in accordance with enhanced amplitude of color, and then outputs the sum of the enhanced color components added with the original color components of pixel.
[0035] In accordance with the adjusting information of color inside region calculated in step B), (including adjusting intensity Δ and adjusting direction), to compute the adjusting mete (Δ y , Δ r , Δ θ ) of three color components (Y, r, θ), such these adjusting mete of three color components is determined from function g(.):
{ Δ Y = g 1 ( Δ , α Y ) Δ r = g 2 ( Δ , α r ) Δ θ = g 3 ( Δ , α θ ) ( 3 )
[0036] The function g (.) can be the linear or non-linear transformation function of adjusting intensity Δ and parameter α.(α R , α G , α B ) respectively represents adjustment weight along three direction of RGB. The expression of g(.) can use many patterns, for example the simplest is Δ y =g l (Δ,α y )=α y ·Δ;
[0037] In the adjustment of the skin color of this embodiment, adjustment in direction 0 uses the non-linear transformation expression, the expression is defined as
Δ θ = g 3 ( Δ , α θ ) = { θ opt - θ , α θ · Δ > θ opt - θ - α θ · Δ , otherwise , θ > θ opt α θ · Δ , otherwise
[0038] The expression in direction Y and r is
{ Δ blue , Y = α blue , Y · Δ blue α blue , Y enhancement gain in direction Y , adjustable Δ blue , r = α blue , r · Δ blue , r α blue , r enhancement gain in direction r , adjustable
[0039] For the adjustment of the red, the expression in direction Y, r and θ is
{ Δ red , Y = α red , Y · Δ red α red , Y enhancement gain in direction Y , adjustable Δ red , r = α red , r · Δ red α red , r enhancement gain in direction γ , adjustable Δ red , θ = α red , θ · Δ red α red , θ enhancement gain in direction θ , adjustable
[0040] For the adjustment of the blue, green and yellow, the expression for adjusting in direction Y, r and θ uses the same as above-presented expression for the red adjustment. Alternatively, the expression in direction θ also can use the similar expression as the skin color. So that, the components after adjusting are
{ Y ′ = Y + Δ Y r ′ = r + Δ r θ ′ = θ + Δ θ ( 4 )
[0041] The (Y,r,θ) before adjusting and the (Y′,r′,θ′) after adjusting should keep continuously and monotony changing to avoid discontinuity and nonconforming.
[0042] Refer to FIG. 4 and FIG. 5 , they are illustrated effect comparing the image with image processing with the image without image processing;
[0043] Step D) if needed, to change the YUV color space located by the coordinate (Y′, r′, θ′) to the color space to perform other processing or output, such as (Y′,U′, V′). In addition, adjust the components' color saturation and hue globally, before inverse converting of the coordinate.
[0044] FIG. 6 is a block diagram of an embodiment of a processing apparatus for enhancing the image color. The apparatus includes n color space regional decision and enhance attenuation calculation module 2 - 1 ˜ 2 -n and color space component enhance module 4 comprising RGB component adaptive regional enhancement module 41 connected with regional adjustment module 42 each other, in which, RGB component adaptive regional enhancement module 41 is coupled to all color space regional decision and enhance attenuation calculation module 2 - 1 ˜ 2 -n.
[0045] In this embodiment, the adjusting is considering in the RGB color space, simultaneously, also considering the part adjusting after making whole adjusting to reduce risk. The process steps are basically same as steps mentioned in the above embodiment. In the RGB color space, it's possible not only to adjust, the Red, Green, Blue, these three color components, but also to correspondingly enhance their complementary color, the Cyan, Magnet and yellow. FIG. 7 is a flowchart of method of this embodiment.
[0046] Step (E) The color space regional decision and enhance attenuation calculation module calculates the enhanced amplitude of color of the pixel and sends to RGB component adaptive regional enhancement module in accordance with the color enhancement parameters of each region of color space deployed by color space regional parameter storage module;
[0047] Step (F) regional adjustment module performs part adjustment such as limiting the data boundary in accordance with original pixel information input, and then sends adjustment information to RGB component adaptive regional enhancement module;
[0048] Step (G) according to enhanced amplitude of color of the pixel, RGB component adaptive regional enhancement module computes each enhancement component of color of the color space which the pixel is located to and then output the sum of these enhanced color components accumulated with the original color components of the pixel.
[0049] The calculation step of these three color components Δ R , Δ G and Δ B is similar to the step presented in the above embodiment, like
{ Δ R = g 1 ( Δ , α R ) Δ G = g 2 ( Δ , α G ) Δ B = g 3 ( Δ , α B ) ,
where, the expression of function g(.) is similar to the mentioned in above embodiment. It has many fashions, and corresponding (α R , α G , α B ) respectively represents adjustment weight in three direction of RGB. The color enhancement is denoted (R′, G′, B′)=f(R, G, B, p, α);
[0050] Parameters p, α determine the intensity and direction of enhancement. For example, when (p i , α i )=Red, the component R of the pixel of region partitioned by the parameters p i , α i will be obviously higher than components GB. When adjusted, Δ R increased, Δ G , Δ B decreased as possible, so as to make the Red be pure and compensate the change of brightness. Simultaneously, as the first exemplary embodiment, the continuity and monotony of the direction of the enhanced intensity of enhancement region also can be pretty guaranteed by the function of f(.), g(.) and parameter (Δ R , Δ G , Δ B ).
[0051] Finally output the color components after adjusting
{ R ′ = R + Δ R G ′ = G + Δ G B ′ = B + Δ B .
[0052] The adjustment of the RGB region maybe influence the change of the whole image brightness, for those application needed keeping brightness, it is needed to compensate the influence of adjustment mete to brightness. For example, Δ Luma,601 =0.299Δ R +0.587Δ G +0.114Δ B ,so the final RGB adjusting mete is written as
Δ′ R =Δ r −κ·Δ Luma,601
Δ′ G =Δ G −κ·Δ Luma,601
Where, κ is the corresponding reduction
Δ′ B =Δ B −κ·Δ Luma,601
coefficient of adjustment, during the range of 0-1. This process is not necessary, because in some applications the requirement for change of brightness is not rigidly requested,
[0053] The present computes the intensity and component direction to be enhanced/adjusted in accordance with the position of pixel in color space (Collective) and parameters of image/video so as to achieve the enhancement of the color components. For the enhancement/adjiustment algorithm is based on the part region of color space, it is possible to accurately compute enhanicement/adjustment inside region and effectively avoid and control risk and side-effect.
[0054] It should be understood that the above embodiments are used only to explain, but not to limit the present. Despite the detailed description of some embodiments, it should be understood that various modifications, changes or equivalent replacements can be made by those skilled in the art without departing from the spirit and scope covered in the following claims. | We describe a processing apparatus and associated method for enhancing image color that includes a color space regional parameter storage module to store parameters of a color space region. A plurality of color space regional decision and enhancement attenuation calculation modules each calculate a color enhancement amplitude of a pixel responsive to the parameters. And a color space component enhancement module calculates a component of the color enhancement amplitude of the pixel in its color space. The processing apparatus and associated method achieve improved color enhancement in a specific region of the color space. | 7 |
RELATED APPLICATION
[0001] This application claims priority to European Patent application No. 14382475.3 filed Nov. 27, 2014, the entirety of which application is incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention refers to a frame of a fuselage of an aircraft and to a section of a fuselage including the frame. The frame is related both to the fuselage structure and to the lifting surfaces located at both sides of the fuselage. The term “lifting surface” includes wings of the aircraft, and associated stabilizing and/or supporting surfaces, such as horizontal stabilisers or pylons for supporting the engines of the aircraft.
BACKGROUND OF THE INVENTION
[0003] Known aircraft structures comprise a fuselage and lifting surfaces located at both sides of the fuselage such as wings or pylons for supporting the engines of the aircraft or other supporting structures.
[0004] Known fuselages comprise a plurality of frames, stringers and beams, which act as reinforcing members of the aircraft skin. In order to integrate lifting surfaces with fuselage structures, an opening is usually performed in the fuselage skin, often implying an interruption in the structure of some of the frames of said fuselage.
[0005] Lifting surfaces may be divided into two or three independent parts, a central box located inside the fuselage and two lateral boxes located at both sides of the fuselage or, as an alternative, the lifting surfaces can be divided into two lateral boxes joined at the symmetry axis of the aircraft. Structural boxes comprise at least a front spar and a rear spar extending in the longitudinal direction of the torsion box, upper and lower skins and ribs extending in the transversal direction of the structural box.
[0006] Wings are usually located at upper or lower positions with respect to a fuselage section while pylons are usually located at a central position of a fuselage section.
[0007] Regarding pylons, a first known configuration may include a pylon extending between both engines and located at a centered position of the height of the cylindrical part of the fuselage. The central part of the pylon is introduced into the fuselage, therefore said configuration implies a discontinuity or, at least, a cut-out in the fuselage skin, with the associated impact in the loads distribution. In some cases, it even entails the discontinuity of some other structural elements such as stringers, longitudinal beams or frames.
[0008] The interface between lateral boxes of the lifting surfaces and the fuselage is usually solved by tension bolts and/or shear rivets. The junction joins the two lateral boxes to the rear part of the fuselage and a significant number of tension bolts need to be installed. Furthermore, the fuselage cylindrical skin needs to be adapted to the flat surface of the junction making the manufacturing and assembly process very complex.
SUMMARY OF THE INVENTION
[0009] A novel aircraft fuselage frame has been conceived and is disclosed here which comprises: a central element adapted to be located within the perimeter of the fuselage, and two lateral extensions projecting outside the perimeter of the fuselage from both sides of the central element, that are a portion of a longitudinal structure of a lifting surface. Furthermore the central element and the two lateral extensions are configured as an integrated piece.
[0010] The invention may be used to provide a more integrated structure having light weight and also ensuring the load continuity between the fuselage and the lifting surfaces. It has to be understood for this application that a structure is called integrated when all its structural components are manufactured together.
[0011] A first advantage is that the total weight of the aircraft is reduced as the junction areas disappear which also simplifies the assembly and removal of said joining additional parts. Moreover load transfer is improved due to said continuos integrated structure.
[0012] From an additional point of view, the claimed frame integrates the traditional transversal reinforcing function of a frame with the traditional longitudinal reinforcing function of, for instance, the central box of a lifting surface and both functions are performed by said frame. Said integration leads to a simplified structure and also to a weight reduction of the aircraft.
[0013] Moreover an upper or lower location of the lateral extensions with respect to the central element allows an increase in the available space inside the fuselage for systems, having a positive impact in assembly, operability and maintenance in comparison with the state of the art solutions in which the central part of the pylon is located in an intermediate position.
[0014] A novel fuselage section has been conceived and is disclosed herein that includes: at least two frames according to the preceding technical features, and a skin portion continuously extending over said two frames.
DESCRIPTION OF THE FIGURES
[0015] To complete the description and in order to provide for a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate preferred embodiments of the invention. The drawings comprise the following figures.
[0016] FIG. 1 shows a known configuration of a fuselage section having three frames and a pylon, the pylon comprising a central box and two lateral boxes.
[0017] FIG. 2 shows a schematic view of a cross section of a first embodiment of the frame of the invention wherein the lateral extensions are a portion of an engine supporting structure.
[0018] FIG. 3 shows a perspective view of a section of a fuselage comprising three frames of the embodiment of the invention shown in FIG. 2 .
[0019] FIG. 4 shows schematic view of a cross section of a second embodiment of the frame of the invention wherein the lateral extensions are an engine supporting structure.
[0020] FIGS. 5 a and 5 b show a plan view ( FIG. 5 a ) and a perspective view ( FIG. 5 b ) of a section of a fuselage comprising three frames of the embodiment of the invention shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 discloses a known structure in which the lifting surface refers to a pylon. The shown structure comprises a plurality of frames ( 2 ) and a lifting surface ( 1 ), that is to say, a pylon that is divided into a central box and two lateral boxes.
[0022] It should be appreciated that the concepts described herein relating to an aircraft pylon may also be used for other aircraft lifting surfaces, such as wings, horizontal stabilizers or other structures. Therefore, although the following explanation is also extensive to other lifting surfaces ( 1 ) having structural boxes going through the fuselage, the following embodiments will refer to pylons for supporting the engines ( 7 ) of an aircraft.
[0023] In the embodiments shown in FIGS. 2 to 5 a and 5 b , the lateral extensions ( 4 ) are or a portion of a longitudinal structure or the whole longitudinal structure of a lifting surface ( 1 ) as previously stated.
[0024] In the case of pylons, the claimed frame ( 2 ) offers the possibility of further joining an extension arm ( 6 ) to the outer edge of the lateral extensions ( 4 ) and hence the lateral extensions ( 4 ) comprise means for connecting said extension arms ( 6 ). The extension arms ( 6 ) are connected to the engines ( 7 ). The extension arms ( 6 ) and also the two lateral extensions ( 4 ) may have different lengths depending on the kind of engines ( 7 ) to be used, thus increasing the flexibility of the claimed structure.
[0025] Two different embodiments will be described in detail. In these embodiments the aircraft structure could comprise at least two frames ( 2 ) as described above wherein the central element ( 3 ) and the lateral extensions ( 4 ) are located in the same fuselage cross-section. In case of having two frames ( 2 ), one of the frames ( 2 ) would be located at a front location and the other at a rear location so that the lateral extensions ( 4 ) would be located in a position equivalent to those of a front and rear spar of a torsion box of a supporting structure in the state of the art.
[0026] More specifically the shown embodiment comprises three consecutive frames ( 2 ). The lateral extensions ( 4 ) of the frame ( 2 ) are a portion of the longitudinal structure of a torsion box of a support structure for attaching the engines ( 7 ) of an aircraft.
[0027] More specifically, as shown in FIG. 3 , a first frame ( 2 ) of the fuselage is located at a front location so that its lateral extensions ( 4 ) are located in a position equivalent to that of the front spar of a torsion box of a supporting structure. A second frame ( 2 ) of the fuselage consecutive to the first frame ( 2 ) is located so that its lateral extensions ( 4 ) are located in a position equivalent to that of a spar of a torsion box of a supporting structure. A third frame ( 2 ) of the fuselage consecutive to the second frame ( 2 ) is located at a rear location so that its lateral extensions ( 4 ) are located in a in a position equivalent to that of a rear spar of a torsion box of a supporting structure. A skin ( 5 ) portion continuously extends over the three frames ( 2 ) and hence over the corresponding two lateral extensions ( 4 ).
[0028] In the first embodiment shown in FIGS. 2 and 3 , the lateral extensions ( 4 ) are further connected to the two extension arms ( 6 ). The skin ( 5 ) extends over the three frames ( 2 ), their corresponding lateral extensions ( 4 ) and the extension arms ( 6 ). The skin ( 5 ) could also extend along the longitudinal direction of the fuselage providing a cruciform shape that should be manufactured in a single panel. Full multi-function of the skin ( 5 ) transmitting loads from the fuselage and from the engine support structure allows obtaining a more lightweight structure.
[0029] The extension arms ( 6 ) are separated elements therefore there is a joining mean between said extension arm ( 6 ) and the lateral extension ( 4 ). Said joining means can be tension bolts and/or shear rivets. Although this embodiment also needs a joining means between the lateral extensions ( 4 ) and the extension arms ( 6 ) it should be noted that the junction between the portion of the lateral extensions ( 4 ) and the extensions arms ( 6 ) is made at a surface independent from the interface area between the fuselage and the lifting surface.
[0030] FIGS. 4 and 5 a and 5 b show a second embodiment of the invention wherein the lateral extensions ( 4 ) extend until they reach the engines ( 7 ). In this embodiment the skin ( 5 ) portion of the fuselage is also extended in the lateral directions of the aircraft structure providing a cruciform shape that should be manufactured in a single panel as it also extends in the longitudinal direction of the aircraft. The previously described configuration of the skin ( 5 ) would also be applicable to said embodiment.
[0031] In this embodiment the full longitudinal structure of the lifting surface ( 1 ) is part of the frame ( 2 ), without any disassembly junction between the longitudinal structure ( 1 ) and the fuselage, so that the penalty weight due to these junctions is removed.
[0032] This second embodiment could also be applied to a wing, HTP, VTP in which the whole extension arm ( 4 ) would be equivalent to a spar of a lateral torsion box that is integrated into the claimed frame ( 2 ).
[0033] The additional advantage of this second embodiment is that it allows fully eliminating the current junction reducing critical load path concentration that could lead to a subsequent reduction engine support structure width and height, reducing additionally the weight penalty as a consequence.
[0034] Therefore the aforementioned junction could be avoided in the embodiment in which the lateral extensions ( 4 ) reach the engines ( 7 ) thus reducing both the cost of the skin ( 5 ) elements and the required hours/work for assembling the portion of the lateral extension ( 4 ), or at least, in the embodiment in which two extension arms ( 6 ) are provided, the junction could be isolated from the fuselage curvature simplifying it.
[0035] Additionally, the lower edge ( 12 ) of the upper portion ( 11 ) of the central element ( 3 ) is aligned with the lower edge ( 13 ) of the lateral extensions ( 4 ). The advantage of this configuration is that the upper portion ( 11 ) of the central element ( 3 ) of the frame ( 2 ) is wider than the rest of the frame ( 2 ) providing a more robust frame ( 2 ) that also benefits load transmission and weight savings due to loads carried by the lower edge ( 13 ) of the lateral extensions ( 4 ) are transmitted directly to the lower edge ( 12 ) of the upper portion ( 11 ). In addition, the upper portion ( 11 ) could be provided with a panel covering the lower edge ( 12 ) but also being the lower edge ( 12 ) of said upper portion ( 11 ) aligned with the lower edge ( 13 ) of the lateral extensions ( 4 ). Moreover the upper portion ( 11 ) of the central element ( 3 ) integrates the traditional transversal reinforcing function of the upper part of a frame with the traditional longitudinal reinforcing function of a spar of the central box of a lifting surface and both functions are performed by said frame.
[0036] Although the embodiments show lateral extensions ( 4 ) that are located at an upper position with respect to a section of the fuselage, a lateral extension ( 4 ) located at a lower position is also possible.
[0037] One of the main advantages of the invention is that it allows manufacturing the frame ( 2 ) including its lateral extensions ( 4 ) and the skin ( 5 ) with one shot panels. Spars and frames could also be manufactured as a single part and as a result of this integration the number of elements to be assembled is reduced.
[0038] Both configurations have the advantage that, comparing with the known architecture, the aircraft structure length is reduced allowing associated penalty weight reduction. This is because known architectures are usually divided into three independent parts, a central box located inside the fuselage at a centered position and two lateral boxes located at both sides of the fuselage joined at their root to the central box and afterwards rising to an upper position with respect to the fuselage section therefore the pylon is not straight. In contrast, in the claimed invention the two lateral extensions are located at an upper or a lower position of the frame and hence the pylon can be straight and therefore the total length of the structure is decreased.
[0039] Another advantage is that as the pylon is straight and therefore the diedric angle is reduced, as previously explained, the engine installation is easier as the installation is carried out by elevating the engine from a lower position to an upper vertical position, whereas in the known configuration the engine is installed from a lower position to an upper and diagonal position, implying a roll movement of the engine.
[0040] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. | An aircraft fuselage frame including a central element adapted to be located within the perimeter of the fuselage, and two lateral extensions projecting outside the perimeter of the fuselage from both sides of the central element that are a portion of a longitudinal structure of a lifting surface. The central element and the two lateral extensions are configured as an integrated piece. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of U.S. application Ser. No. 12/207,562, filed Sep. 10, 2008, which claims priority to, and the benefit of, U.S. Provisional Patent Application No. 60/995,023, filed on Sep. 24, 2007, the entire contents of each of which are hereby incorporated by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates generally to a surgical apparatus for use during anastomosis procedures. More particularly, the present disclosure relates to methods and apparatus to deliver an anvil assembly to a surgical site.
[0004] 2. Description of the Related Art
[0005] Surgical anastomosis is the surgical connection of severed or separate of hollow organs. Typically, an anastomosis procedure follows another surgical procedure where a diseased or defective section of hollow tissue is removed and the remaining end sections are joined. The end sections may be joined by circular, end-to-end, or side-to-side organ reconstruction methods.
[0006] In a circular anastomosis procedure, the two ends of the organ sections are joined by means of a stapling instrument that drives a circular array of staples through the end section of each organ section and simultaneously cores any tissue interior of the driven circular array of staples to free the tubular passage. Examples of instruments for performing circular anastomosis of hollow organs are described in U.S. Pat. Nos. 7,168,604; 6,053,390; 5,588,579; 5,119,983; 5,005,749; 4,646,745; 4,576,167; and 4,473,077, each of which is incorporated herein in its entirety by reference. Typically, these instruments include an elongated shaft having a handle portion at a proximal end to actuate the instrument and a staple holding component disposed at a distal end. An anvil assembly including an anvil rod with an attached anvil head is mounted to the distal end of the instrument adjacent the staple holding component. Opposing end portions of tissue of the hollow organ(s) to be stapled are clamped between the anvil head and the staple holding component. The clamped tissue is stapled by driving one or more staples from the staple holding component so that the ends of the staples pass through the tissue and are deformed by the anvil head. An annular knife is concurrently advanced to core tissue within the hollow organ to free a tubular passage within the organ.
[0007] Certain circular anastomosis procedures entail minimally invasive techniques. In these procedures, surgeons often position an anvil assembly in the desired hollow organ by inserting an anvil delivery system through a patient's esophagus. U.S. Pat. No. 7,179,267, for example, describes a method and apparatus for delivering an anvil assembly through a patient's esophagus. Although surgical apparatus that can deliver an anvil assembly into a hollow organ are well-known in the art, there is a need for more versatile anvil delivery systems.
SUMMARY
[0008] The present disclosure relates to an anvil delivery system including an anvil assembly, a flexible tube, and a fitting coupled to the flexible tube. The fitting includes a body having a proximal end portion and a distal end portion, and a tip on the distal end portion. The proximal end portion is adapted to attach the body of the fitting to the flexible tube. The tip is configured for insertion into a body lumen.
[0009] The present disclosure also relates to an anvil delivery system comprising an anvil assembly, a flexible tube having a first end portion and a second end portion, and a fitting. The fitting has a proximal end portion and a distal end portion, wherein the proximal end portion is removably coupled to the second portion of the flexible tube and the distal end portion includes a tip for advancing through tissue.
[0010] In one embodiment, anvil delivery system further includes a bore extending through the distal end portion of the fitting to receive a suture. In one embodiment the anvil delivery system includes a plurality of protrusions disposed on a proximal end portion of the body of the fitting. In one embodiment, the anvil is pivotable with respect to the flexible tube.
[0011] The present disclosure also relates to a kit. The kit includes a flexible tube having a distal end an open proximal end, an adapter configured to be releasably secured to the flexible tube, and a fitting configured to be attached to the flexible tube after the distal end of the flexible tube has been cut. The fitting includes a body having a proximal end portion configured to attach to the flexible tube and a distal end portion.
[0012] In one embodiment, the kit also includes the anvil assembly.
[0013] In one embodiment, the proximal end portion of the body of the fitting is dimensioned to be supported within the flexible tube.
[0014] In one embodiment, the tip is blunt and configured for insertion into a body lumen. In one embodiment, the fitting includes a bore extending through the distal end portion of the body. In one embodiment, the plurality of protrusions is adapted to operatively attach the body of the fitting to the flexible tube.
[0015] The present disclosure also relates to method of performing a surgical procedure comprising:
providing an anvil assembly having an anvil head and a flexible tube having a first end portion extending from the anvil assembly; cutting a second end portion of the flexible tube, the second end portion being disposed on an opposite end of the flexible tube from the first end portion; attaching a fitting to the second end portion of the flexible tube, the fitting having an insertion tip; inserting the second end portion of the flexible tube into a body; positioning the anvil assembly within the body using the flexible tube; and detaching the flexible tube from the anvil assembly while the anvil assembly is positioned within the body.
[0022] The fitting may include a bore to receive a suture and the inserting step may include the step of grasping the suture to pull the insertion tip to advance the fitting, flexible tube and anvil assembly. The step of attaching the fitting may include the step of inserting a portion of the fitting within the second end portion of the flexible tube to frictionally engage the tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Various embodiments of the presently disclosed surgical apparatus are disclosed herein with reference to the drawings, wherein:
[0024] FIG. 1 is a top plan view of an anvil delivery system according to an embodiment of the present disclosure;
[0025] FIG. 1A is a top plan view of an anvil delivery system with a fitting attached thereto according to an embodiment of the present disclosure;
[0026] FIG. 1B is a side plan view of the anvil delivery system with the fitting shown in FIG. 1A ;
[0027] FIG. 2 is a perspective view of a portion of the anvil delivery system shown in FIG. 1 ;
[0028] FIG. 3 is a side cross-sectional view of a portion of the anvil-delivery system shown in FIG. 1 ;
[0029] FIG. 4 is perspective view of a portion of the anvil delivery system shown in FIG. 1 ;
[0030] FIG. 5 is a side plan view of a fitting according to an embodiment of the present disclosure;
[0031] FIG. 6 is a cross-sectional rear view of the fitting shown in FIG. 5 , taken along section line C-C of FIG. 5 ;
[0032] FIG. 7 is a front plan view of the fitting shown in FIG. 5 ;
[0033] FIG. 8 is a cross-sectional side view of the fitting shown in FIG. 5 , taken along section line A-A of FIG. 7 ;
[0034] FIG. 9 is a cross-sectional side view of a portion of the fitting shown in FIG. 5 , taken along section line B-B of FIG. 6 ; and
[0035] FIG. 10A is a top plan view of an anvil delivery system according to another embodiment of the present disclosure;
[0036] FIG. 10B is a side plan view of the anvil delivery system with the fitting shown in FIG. 10A ;
[0037] FIG. 11 is a top plan view of the fitting according to the embodiment of FIG. 10A ;
[0038] FIG. 12 is a side plan view of the fitting shown in FIG. 11 ;
[0039] FIG. 13 is a cross-sectional side view of the fitting shown in FIG. 11 ; and
[0040] FIG. 14 is a rear plan view of the fitting shown in FIG. 11 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0041] Embodiments of the presently disclosed anvil delivery system will now be described in detail with reference to the drawings wherein like reference numerals designate identical or corresponding elements in each of the several views. In the description that follows, the term “proximal,” as is traditional, will refer to the end of anvil delivery system, or a portion thereof, that is closer to the operator, while the term “distal” will refer to the end of the anvil delivery system that is farther from the operator.
[0042] With reference to FIG. 1 , an anvil delivery system is generally shown as 10 . Anvil delivery system 10 includes a flexible tube 12 , an adapter 14 , and an anvil assembly 16 . Anvil assembly 16 may be a 21 mm or a 25 mm anvil assembly, sold under the trademark EEA ORVIL™. Alternatively, other anvil assemblies may be used with the presently disclosed anvil delivery system. Flexible tube 12 has an open end 12 a and a blunt end on the opposite end. Adapter 14 and anvil assembly 16 are supported on open end 12 a of flexible tube 12 , as described in detail below.
[0043] Referring to FIGS. 2 and 3 , anvil assembly 16 includes an anvil head 30 , an anvil center rod 20 , and an anvil 60 . Anvil 60 , which is supported on anvil head 30 , has a plurality of pockets 60 a for receiving and deforming surgical staples. Center rod 20 is operatively connected to anvil head 30 . In the embodiment shown in FIG. 2 , center rod 20 is pivotably coupled to anvil head 30 . Further, center rod 20 includes flexible legs 26 configured to capture at least a portion of adapter 14 therebetween.
[0044] With continued reference to FIGS. 2 and 3 , adapter 14 includes a first end 14 a dimensioned to be received within open end 12 a of flexible tube 12 and a second end 14 b configured to be received in the center rod 20 of anvil assembly 16 . First end 14 a includes a series of annular rings 22 dimensioned to frictionally retain first end 14 a of adapter 14 within open end 12 a of flexible tube 12 . It is envisioned that other retaining structure can be provided to retain first end 14 b of adapter 14 to flexible tube 12 , e.g., clamps, pins, threads, etc. Second end 14 b of adapter 14 includes a longitudinal guide member 24 dimensioned to be received between flexible legs 26 of center rod 20 of anvil assembly 16 . In addition, second end 14 b of adapter 14 is dimensioned to allow center rod 20 of anvil assembly 16 to freely slide on and off second end 14 b of adapter 14 .
[0045] Referring to FIG. 4 , anvil head 30 of anvil assembly 16 includes spaced apart openings 32 that are in communication with each other. Adapter 14 includes a first throughbore 40 formed in a central hub portion 14 c and a second throughbore 42 formed in first end 14 a. As will be discussed below, anvil delivery system 10 includes a suture 50 to secure anvil assembly 16 to adapter 14 .
[0046] Referring to FIGS. 2 and 4 , suture 50 has a first end 50 a and a second end 50 b. To secure adapter 14 to anvil assembly 16 , first end 50 a of suture 50 is inserted into one opening 32 of anvil head 30 and pulled out of the other opening 32 such that the ends 50 a and 50 b of suture 50 are positioned on opposite sides of center rod 20 of anvil assembly 16 . Next, second end 14 b of adapter 14 is positioned within center rod 20 and each end 50 a and 50 b of suture 50 is inserted through an opposite end of throughbore 40 of central hub portion 14 c of adapter 14 to define a first suture loop 54 (see FIG. 2 ). Each end 50 a and 50 b of suture 50 is pulled tight such that adapter 14 is held against center rod 20 . Thereafter, each end 50 a and 50 b is inserted through an opposite end of throughbore 42 of first end 14 a of adapter 14 to define a second suture loop 56 (see FIG. 2 ). Second suture loop 56 extends about first end 14 a of adapter 14 . The frictional contact between rings 22 of first end 14 a of adapter 14 and the inner surface of flexible tube 12 secures adapter 14 to flexible tube 12 and prevents suture 50 from loosening up.
[0047] With reference to FIGS. 1A and 1B , after operatively connecting flexible tube 12 to anvil assembly 16 via adapter 14 , a healthcare professional may decide to shorten flexible tube 12 . In some bariatric surgeries, for instance, short flexible tubes 12 are beneficial. Therefore, the healthcare professional may decide to cut flexible tube 12 , thereby creating another open end 12 b on the new distal end of flexible tube 12 . Because the cut end of flexible tube 12 may be abrasive and/or include jagged or irregular surfaces, a fitting 62 may be attached to open end 12 b of tube 12 to facilitate smooth atraumatic passage of tube 12 through or into a body lumen.
[0048] With reference to FIGS. 5-9 , fitting 62 includes a body 64 having a proximal end portion 66 adapted to be supported in open end 12 b of flexible tube 12 , a distal end portion 68 , and a middle portion 70 . Distal end portion 68 has bore 74 defined therethrough and a blunt tip 72 configured for insertion into a body lumen such as the esophagus. In a preferred embodiment, the tip 72 is bullet-shaped to aid insertion. Bore 74 may be dimensioned to receive a suture (not shown) so it can be pulled through the lumen if desired. Middle portion 70 is between proximal end portion 66 and distal end portion 68 . Proximal end portion 66 includes a plurality of protrusions 76 adapted to frictionally retain proximal end portion 66 of fitting 62 within open end 12 b of flexible tube 12 .
[0049] In operation, a surgeon employs anvil delivery system 10 to position anvil assembly 16 in the body during minimally invasive procedures. During such procedures, the surgeon initially secures adaptor 14 to open end 12 a of flexible tube, 12 and sutures anvil assembly 16 to central hub portion 14 c of adapter 14 . Flexible tube 12 may then be cut at any desired length. The cut creates a distal open end 12 b from the blunt closed end in flexible tube 12 . After cutting flexible tube 12 , the surgeon secures fitting 62 in open end 12 b. Specifically, proximal end portion 66 of fitting 62 is inserted into open end 12 b. The frictional contact between protrusions 76 of distal end portion 66 of fitting 62 and the inner surface of flexible tube 12 secures fitting 62 to flexible tube 12 .
[0050] For transoral applications, once fitting 62 has been secured to flexible tube 12 , the surgeon inserts fitting 62 in the patent's mouth and moves fitting 62 along with flexible tube 12 down through the esophagus to the surgical site, e.g., stomach. It is also contemplated that the anvil delivery system can be used for other applications besides transoral insertion, such as transgastric and transanal approaches for colorectal, bariatric and other applications. This can be achieved due to the bullet shaped tip which can penetrate tissue, e.g. the stomach wall to deliver the anvil assembly. Other penetrating tip configurations could be provided.
[0051] After insertion, the surgeon should then make a small incision at the surgical site to create an inner access to the fitting 62 . After making the incision, the surgeon pulls fitting 62 through the incision, thereby pulling anvil assembly 16 through the esophagus (or other body tissue or organ depending on the procedure) to the surgical site. If a suture is used through bore 74 , the suture can be grasped and pulled to pull the anvil assembly. As flexible tube 12 is pulled through the incision, the distal end of center rod 20 of anvil assembly 16 advances through the incision. When anvil assembly 16 is properly positioned at the surgical site, the surgeon may release adapter 14 from anvil assembly 16 by cutting suture 40 and sliding center rod 20 from end 14 b of adapter 14 . Next, the flexible tube 12 (with fitting 62 ) and adapter 14 may be pulled from the body through the incision. The surgeon can now mount center rod 20 of anvil assembly 16 on a surgical stapling device (not shown) and perform the desired surgical procedure.
[0052] The components of anvil delivery system 10 may be provided in kit form. The kit may include a flexible tube 12 adapted to be secured to the anvil assembly 16 , an adapter 14 configured to secure an anvil assembly 16 to the flexible tube 12 and a fitting 62 configured to be attached to flexible tube 12 . Fitting 62 , in turn, may include a body 64 having a proximal end portion 66 and a distal end portion 68 , a blunt tip 72 disposed on the distal end portion 68 , and a plurality of protrusions 76 disposed on the proximal end portion 66 . Proximal end portion 66 of body 64 may be dimensioned to be supported within flexible tube 12 . The plurality of protrusions 76 may be adapted to operatively attach the body 64 of the fitting 62 to flexible tube 12 . Blunt tip 72 may be configured for insertion into a body lumen. Fitting 62 may include a bore 74 extending through distal end portion 68 of body 64 . The kit may further include an anvil assembly 16 . In one embodiment, the anvil assembly 16 , the flexible tube 12 , and adapter 14 are fastened together with a suture 50 , as discussed above, and the fitting 62 is provided to blunt the end of flexible tube 12 if the flexible tube 12 has to be cut and to provide an insertion tip.
[0053] With reference to FIGS. 10A and 10B , another embodiment of anvil delivery system 10 includes an alternative fitting 82 . Like fitting 62 , fitting 82 is attached to open end 12 b of tube 12 to facilitate smooth atraumatic passage of tube 12 through or into a body lumen. Since the structure and operation of an anvil delivery system 10 with fitting 62 is substantially identical to the structure and operation of an anvil delivery system 10 with fitting 82 , the present disclosure only discusses in detail the structural features of fitting 82 .
[0054] Referring to FIGS. 11-14 , fitting 82 includes a body 84 having a proximal end portion 86 supported in open end 12 b of flexible tube 12 , a distal end portion 88 , and a middle portion 90 . Distal end portion 88 has a bore 94 defined therethrough and a blunt tip 92 configured for insertion into a body lumen such as the esophagus. Body 90 of fitting 82 has a tapered surface 98 leading to blunt tip 92 . Tip 92 is bullet-shaped to aid insertion. Bore 94 is dimensioned to receive a suture (not shown). The suture is attached to tip 92 and pulled to pull tube 12 through a lumen if desired. Proximal end portion 86 includes a plurality of protrusions 96 adapted to frictionally retain proximal end portion 86 of fitting 82 within open end 12 b of flexible tube 12 . Protrusions 96 are disposed around an outer periphery of proximal end portion 86 .
[0055] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the particular configuration of fitting 62 need not be exactly as shown but rather may be configured in any manner capable of facilitating atraumatic passage of tube 12 through a body lumen. Therefore, the above description should not be construed as limiting, but merely as exemplifications of the embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. | A method for performing a surgical procedure is disclosed which uses an anvil delivery system including an anvil assembly, a flexible tube having a first end portion and a second end portion, and a fitting to deliver the anvil assembly to a desired site. The method includes the steps of cutting a second end portion of the flexible tube, attaching a fitting to the second end portion of the flexible tube which has been cut, inserting the insertion tip into tissue, advancing the insertion tip along with the flexible tube and anvil assembly to the desired site within a patient's body, and removing the flexible tube from the anvil assembly and from the desired site leaving the anvil assembly in a patient's body at the desired site. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to hermetically sealed compressor assemblies. More particularly, the present invention relates to hermetically sealed compressor assemblies having a shell which is staked in place in a unique manner to resist excessive axial and circumferential loading.
Hermetically sealed motor compressors of various designs are well known in the art. These designs include both the piston/cylinder types and scroll types. While the present invention applies equally well to all of the various designs of motor compressor units, it will be described for exemplary purposes embodied in a hermetically sealed scroll type fluid machine.
A scroll type fluid machine has a compressor section and an electrical motor section mounted in a hermetic shell with fluid passages being formed through the walls of the hermetic shell. The fluid passages are normally connected through pipes to external equipment such as, for example, an evaporator and condenser when the machine is used in a refrigeration system.
The scroll type compressor section has a compressor which is comprised of a non-orbiting scroll member which is mated with an orbiting scroll member. These scroll members have spiral wraps formed in conformity with a curve usually close to an involute curve so as to protrude upright from end plates. These scroll members are assembled together such that their wraps mesh with each other to form therebetween compression chambers. The volumes of these compression chambers are progressively changed in response to an oebital movement of the orbiting scroll member. A fluid suction port communicates with a portion of the non-orbiting scroll member near the radially outer end of the outermost compression chamber, while a fluid discharge port opens in the portion of the non-orbiting scroll member close to the center thereof. An Oldham's ring mechanism is placed between the orbiting scroll member and the non-orbiting scroll member so as to prevent the orbiting scroll member from rotating about its own axis.
The non-orbiting scroll member is secured to the main bearing housing by means of a plurality of bolts extending therebetween which allow limited relative axial movement between the bearing housing and the non-orbiting scroll member. The attachment for the non-orbiting scroll member is more fully disclosed in assignee's copending application Ser. No. 07/591,444 entitled "Non-Orbiting Scroll Mounting Arrangements for a Scroll Machine" filed Oct. 1, 1990, the disclosure of which is hereby incorporated herein by reference.
The orbiting scroll member is driven by a crankshaft so as to produce an orbiting movement with respect to the stationary scroll member. Consequently, the volumes of the previously mentioned chambers are progressively decreased to compress the fluid confined in these chambers, and the compressed fluid is discharged from the discharge port as the compression chambers are brought into communication with the discharge port. The housing is fixedly attached to the hermetic shell. The attachment methods for connecting the housing to the hermetic shell include bolting, pin or plug welding and/or press or shrink fitting. While each of these methods offer certain advantages, they also come with individual disadvantages.
The press or shrink fit is the least expensive attachment method and it is capable of withstanding most of the forces normally generated by the assembly. The compressor assembly is capable, however, under certain conditions, of generating forces which could exceed the holding capabilities of the press fit design. When these excessive forces are generated, the housing could slip either axially or circumferentially with respect to the hermetic shell, adversely affecting the operation of the compressor assembly.
Welding of the housing resolves the issues of being able to withstand the forces in excess of the normal, but the cost of producing a welded assembly in volume production is relatively high.
Bolting the housing to the shell will also resolve the issue of being able to withstand the forces in excess of normal, but the cost involved in preparing both the shell and the internal components to be able to accommodate a bolt and still maintain the necessary hermetic seal makes the technique unsuitable to volume production. In addition, the problems of properly completing the fastening operation and the costs associated with the fastener make this an undesirable option.
Accordingly, what is needed is a means of fixedly attaching the housing of a motor compressor unit to the hermetic shell which is capable of withstanding both the normal and the abnormal forces generated during the operation of the compressor. The means of fixedly attaching the housing should be both inexpensive and reliable, and suitable for high volume production.
SUMMARY OF THE PRESENT INVENTION
The present invention provides the art with a means for attaching the housing to the hermetic shell of a motor compressor which is inexpensive, reliable and capable of withstanding both the normal and abnormal forces generated during the operation of the motor compressor.
The hermetic shell of the present invention is plastically deformed into a plurality of apertures formed into the housing of the motor compressor unit. The deformation of the shell is such that material is displaced into the aperture without penetrating through the wall of the hermetic shell, thus maintaining the hermetic integrity of the sealed chamber. The shape of the displaced material of the shell and the aperture is such that a generally cylindrical load bearing interface is created which is capable of withstanding both axially and circumferentially directed forces.
Further objects, features and advantages of the present invention will become apparent from the analysis of the following written specification, the appended claims and the accompanying drawings:
FIG. 1 is a side elevation view partially in cross section of a hermetically sealed compressor in accordance with the present invention.
FIG. 2 is an enlarged view of the tool which is used to create the staking forming a part of the present invention.
FIG. 3 is a further enlarged view of the shape of the staked area designated in FIG. 1 by circle 3--3 in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is illustrated for exemplary purposes in conjunction with a hermetically sealed scroll compressor. It is to be understood that the invention is not limited to a scroll compressor and it is possible to utilize the staked configuration on virtually any type of motor compressor or similar machine.
Referring to the drawings, a scroll type fluid machine 10 in accordance with the present invention, which is in this case a compressor of a refrigeration system, is shown. The fluid machine 10 is comprised of a hermetic shell assembly 12, a compressor section 14 and a motor drive section 16. The hermetic shell assembly 12 is comprised of lower shell 13, an upper cap 15, a bottom cover 17 and a separation plate 19. The bottom cover 17, the lower shell 13, the separation plate 19 and the upper cap 15 are fixedly and sealingly attached in the manner shown by welding during assembly of the fluid machine 10 to form sealed suction chamber 21 and a discharge chamber 56. The hermetic shell 12 further has an inlet fitting 23 and an outlet fitting 25.
The compressor section 14 is comprised of a non-orbiting scroll member 18, an orbiting scroll member 20 and a bearing housing 22. The non-orbiting scroll member 18 is comprised of an end plate and body 24 having a chamber 26 in which is disposed a spiral wrap 28. The non-orbiting scroll has a plurality of embossments 30 which are adapted to be attached to the bearing housing 22 by bolts 32.
The orbiting scroll member 20 is comprised of an end plate 34 and a spiral wrap 36 which extends upright from the end plate 34 into chamber 26. The spiral wrap 36 is meshed with the spiral wrap 28 of the non-orbiting scroll member 18 in the usual manner to form in combination with the bearing housing 22, a compressor section 14 of the fluid machine 10. Closed chambers 52 are defined by the meshing wraps 28 and 36 and the arrangement is in communication with the usual discharge port 54 formed in the central position of the non-orbiting scroll 18. The discharge port 54 communicates with discharge chamber 56 formed by separation plate 19 and upper cap 15.
The bearing housing 22 has a plurality of (3 or 4) radially outwardly extending lobes 38 affixed to the hermetic shell assembly 12. The lobes 38 of the bearing housing align with the embossments 30 of the non-orbiting scroll member 18 and have threaded holes 40 for accepting bolts 32 to attach the non-orbiting scroll member 18 as described above. At its outer end, each lobe 38 has a cylindrical recess 42 disposed therein.
The compressor section 14 further includes a crankshaft 46 having an eccentric shaft portion 48 coupled to the orbiting scroll member 20 through a drive bushing and bearing assembly 50. A counter-balance weight 60 is fixed to the crankshaft 46, which is supported at its lower end by lower bearing assembly 64. Lower bearing assembly 64 is fixedly secured to shell assembly 12 and has a center portion 66 having an elongated bore 68 in which is disposed a journal bearing 70 which is designed to receive the lower end of crankshaft 46.
The motor drive section 16 is comprised of a motor stator 80 securely mounted in the lower shell 13, preferably by press fitting, and a motor rotor 82 coupled to the crankshaft 46 of the compressor section 14.
The lobes 38 of the bearing housing 22 are press fit into the inside diameter of the hermetic shell assembly 12. After proper positioning of the bearing housing 22 inside the lower shell 13, a staking tool 90, is forced radially inwardly against the shell to plastically deform the lower shell 13 in each of the areas of the recesses 42 to form a plurality of circular staked portions 92, as best shown in FIG. 3. The lower shell 13 is deformed sufficiently to cause the edge 94 of recess 42 to bite into the shell metal to form a cylinder retention surface 92, but the plastic deformation of the upper shell is not sufficient to affect the hermetic seal of the sealed chamber 21 by overly weakening or piercing through the shell material. During operation of the scroll type fluid machine, the forces generated by the operation of the compressor in both the axial and circumferential directions must be accommodated by the joints between lobes 38 and lower shell 13. The recesses 42 are preferably sufficient in size and number to support the maximum anticipated abnormal forces which may be generated.
The staking tool 90 is shown in FIGS. 2 and 3 and comprises a generally flat annular circular surface 100 having a spherical surface 102 extending therefrom. A radiused section 104 blends the area where spherical surface 102 meets the annular surface 100. The circular diameter 106 where these two surfaces meet is referred to as the base diameter.
It has been found that with a shell material of draw quality hot rolled steel that very satisfactory results have been obtained when the base diameter 106 is equal to 1.30 to 1.35 times the diameter of the recess 42 formed in the bearing housing 22. The distance which spherical surface 102 extends from the flat circular surface 100 is termed the nose height. It has been found that the nose height should be approximately equal to the thickness of the material used to manufacture the lower shell 13 which is the material being staked. Finally, the radius of spherical surface 102 is termed the nose radius and it should be equal to approximately 0.85 times the diameter of the recess 42. By following the above guidelines, a staked area similar to that shown in FIG. 2 will be achieved. The width of the circular retention surface 92 is equal to approximately one-third of the thickness of the material used to manufacture the lower shell 13 which is the material being staked.
Specifically, the scroll type fluid units 10 which were tested and found to be the most reliable had an lower shell 13 thickness of approximately 3.00 millimeters. The bearing housing 22 had four recesses 42 each having a diameter of approximately 12.70 millimeters. The bearing housing 22 was press fit into the lower shell 13 having an interference fit of 0.20/0.46 millimeters by a hydraulic press using approximately 2000 pounds of force. This lower shell 13 was then staked into the four 12.70 millimeter diameter recesses 42 with four staking tools 90 each having a base diameter 106 of approximately 16.764 millimeters, a nose height of approximately 3.045 millimeters and a nose radius of approximately 10.80 millimeters. This produced the staking configuration shown in FIGS. 2 and 3 having a cylindrical retention surface 92 which was 1.0 to 1.3 millimeters in width.
While it will be apparent that the preferred embodiment of the invention disclosed is well calculated to provide the advantages above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims. | A means for attaching the bearing housing to an outer shell is disclosed. The outer shell is plastically deformed into a plurality of apertures formed into the bearing housing. The deformation of the shell is such that material is displaced into the aperture of the bearing housing member without penetrating through the wall of the shell, thus maintaining the integrity of the shell. The shape of the displaced material of the shell is such that a generally cylindrical load bearing surface having a sharp corner is created which is capable of withstanding both axially and circumferentially directed forces of substantial magnitude. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to a method for producing mop trimmings from a twisted yarn which is cut into pieces.
DESCRIPTION OF THE PRIOR ART
[0002] Yarns, in particular such of cotton, have proven their worth as trimmings for mops as long as the yarns do not untwist as a result of the use of the mop. The cleaning effect of such mop trimmings is impaired however with the increased untwisting of the yarns from the cut free end.
SUMMARY OF THE INVENTION
[0003] The invention is thus based on the object of providing a method for producing mop trimmings of the kind mentioned above in such a way that an untwisting of the yarn pieces used in the mop trimmings from their free ends can be excluded without impairing the cleaning effect.
[0004] The object is achieved in accordance with the invention in such a way that the twisted yarn is subjected to needling prior to cutting.
[0005] As a result of needling the twisted yarns, their twisting is effectively held, so that the likelihood of fringe formation by untwisting of the trimming elements as cut from the yarn is advantageously prevented, namely without any loss of cleaning effect, because the properties of the yarn pieces as demanded in connection with mop trimmings are not changed by the needling. Since the employed yarns can be needled continuously prior to cutting, the additional efforts needed can be kept relatively low since the needle-penetration density does not have to fulfill any high requirements.
[0006] Although it is known (U.S. Pat. No. 4,674,271 A, U.S. Pat. No. 5,081,753 A) to subject yarns to a treatment by needling, the yarns concern continuous yarn filaments which are to be broken by the needling in order to adapt such yarns in their properties to the usual yarns made of staple fibers. The known breakage of the continuous yarn filaments with the help of needles penetrating the yarn cannot provide any suggestion in the respect as to how mop trimmings should be treated in order to enable a permanent cleaning effect. The same applies to an other known needling method (U.S. Pat. No. 3,208,125 A) in which two filaments of continuous fibers are subjected to a needling process prior to their twisting in order to avoid any longitudinal displacement of the two filaments during the twisting. This needling prior to twisting does not prevent any untwisting of the twisted filaments.
[0007] In order to perform the needling of yarns which are used for mop trimmings according to the invention, it is possible to assume a conventional apparatus with a drivable needle board reciprocating in the direction of the needle penetration and a stitch base opposite of the needle board. It is merely necessary to ensure that the yarn cannot escape the penetrating needles. For this reason the stitch base is provided with at least one guide groove for the yarn which extends in the direction of yarn passage, with the needles of the needle board being arranged along the guide groove. With the yarn progress in the guide groove a lateral migration of the yarn to be needled is thus prevented in a simple way, so that the needling of the yarn transversally to the longitudinal direction of the yarn is ensured. The needles can be arranged along the longitudinal axis of the guide groove disposed in a line behind one another or mutually offset transversally to said axis in order to adapt the needling conditions to the respective conditions. In order to allow the needling of several yarns simultaneously, the stitching base can be provided with several parallel guide grooves for each yarn. The smooth run into and out of the guide grooves can be enforced in a simple way by means of guide eyes for the yarn.
[0008] It is understood that during the needling of the yarn it must be ensured that the material to be needled is stripped off from the needles which are moved in the drawing direction. This can be performed by stripping means which are disposed between the needle board and the stitching base on the side of the material which faces the needle board. Particularly advantageous guide conditions are obtained when the stitching base is not plane, but is provided in the known manner with an arrangement which is arched in a convex manner, because in this case a force component is obtained during the tensile load of the yarn to be needled which presses the yarn against the stitching base which renders the provision of a stripper superfluous.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The method in accordance with the invention is now explained in closer detail by reference to the enclosed drawings, wherein:
[0010] [0010]FIG. 1 shows an apparatus in accordance with the invention for needling a twisted yarn in a simplified side view;
[0011] [0011]FIG. 2 shows a stitching base of the apparatus according to FIG. 1 in a top view on an enlarged scale;
[0012] [0012]FIG. 3 shows a partial sectional view along line III-III of FIG. 2 on an enlarged scale, and
[0013] [0013]FIG. 4 shows a partial sectional view along line IV-IV of FIG. 1 on an enlarged scale.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The apparatus according to FIG. 1 consists substantially of a stitching base 1 and a needle board 2 which is disposed opposite of the stitching base 1 , which board is inserted in the conventional manner in a needle beam 3 and can be driven in a reciprocating manner in the penetration direction of the needles 5 by means of a push rod 4 . In contrast to conventional stitching bases, the stitching base in accordance with the invention forms parallel guide grooves 6 for the yarns 7 to be needled which are held under tensile stress between a roller draw-in 8 and a roller pull-off 9 . For the purpose of guiding the yarns which are unwound from the supply coils, guide eyes 10 are diposed on the inlet side of the roller draw-in 8 . A similar set of guide eyes 10 is disposed between the stitching base 1 and the roller pull-off 9 . As is shown in FIG. 4, the individual pass-through openings 11 of the guide eyes 10 are arranged in a division according to the guide grooves 6 in the stitching base 1 , thus producing a secure guidance of the yarns 7 in the direction of the yarn passage 12 .
[0015] According to FIG. 1, the stitching base 1 is provided in the direction of the yarn passage 12 with a convexly arched arrangement, which leads to the force components perpendicular to the stitching base 1 in connection with the tensile stresses applied on yarns 7 by way of the roller draw-in 8 and the roller pull-off 9 . The yarns 7 are therefore pulled into the guide grooves 6 by way of said resulting forces and pressed against the stitching base so that the needles 5 of needle board 2 which penetrate the yarns 7 can be pulled out of the yarns 7 again without having to fear any entrainment of the yarns 7 . It is therefore possible to omit separate strippers between the needle board 2 and the stitching base 1 . The stitching base 1 is provided with respective pass-through openings 13 for the needles 5 . The arrangement according to the illustrated embodiment was made in such a way that the pass-through openings 13 are aligned in a straight line in the longitudinal direction of the guide grooves 6 according to the corresponding needle arrangement. Such an alignment of the needles and holes is not mandatory. In order to increase the needling effect it would be possible to provide a slight offset of the needles 5 and the pass-through holes 13 transversally to the longitudinal direction of the guide grooves 6 .
[0016] As a result of the needling of the yarns 7 transversally to the longitudinal direction of the yarns, the twisting of the yarns 7 is fixed, namely over the entire needled yarn length, so that the yarns 7 can subsequently easily be cut into pieces without any likelihood of them becoming frayed from the cut ends when said cut yarn pieces are used as trimmings for a mop. Since the yarn needling can be performed continuously, the needling of the yarns 7 can be performed within the course of a production line for mop trimmings. It is naturally also possible to wind up the needled yarns again in order to store them intermediately prior to further processing. | A method and an apparatus for producing mop trimmings from a twisted yarn ( 7 ) which is cut into pieces is described. In order to prevent any untwisting of the yarn pieces it is proposed that the twisted yarn ( 7 ) is subjected to a needling prior to cutting. | 3 |
RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 07/849,511, of David Gordon, which application was filed Mar. 11, 1992, now abandoned, and is entitled STORAGE UNIT GENERATION OF REDUNDANCY INFORMATION IN A REDUNDANT STORAGE ARRAY SYSTEM.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to computer system data storage, and more particularly to a system for generating redundancy information in each redundancy data storage unit within a redundant array system.
2. Description of Related Art
A typical data processing system generally involves one or more storage units which are connected to a Central Processor Unit (CPU) either directly or through a control unit and a channel. The function of the storage units is to store data and programs which the CPU uses in performing particular data processing tasks.
Various types of storage units are used in current data processing systems. A typical system may include one or more large capacity tape units and/or disk drives (magnetic, optical, or semiconductor) connected to the system through respective control units for storing data.
However, a problem exists if one of the large capacity storage units fails such that information contained in that unit is no longer available to the system. Generally, such a failure will shut down the entire computer system.
The prior art has suggested several ways of solving the problem of providing reliable data storage. In systems where records are relatively small, it is possible to use error correcting codes which generate ECC syndrome bits that are appended to each data record within a storage unit. With such codes, it is possible to correct a small amount of data that may be read erroneously. However, such codes are generally not suitable for correcting or recreating long records which are in error, and provide no remedy at all if a complete storage unit fails. Therefore, a need exists for providing data reliability external to individual storage units. Other approaches to such "external" reliability have been described in the art. A research group at the University of California, Berkeley, in a paper entitled "A Case for Redundant Arrays of Inexpensive Disks (RAID)", Patterson, et al., Proc. ACM SIGMOD, June 1988, has catalogued a number of different approaches for providing such reliability when using disk drives as failure independent storage units. Arrays of disk drives are characterized in one of five architectures, under the acronym "RAID" (for Redundant Arrays of Inexpensive Disks).
A RAID 1 architecture involves providing a duplicate set of "mirror" storage units and keeping a duplicate copy of all data on each pair of storage units. While such a solution solves the reliability problem, it doubles the cost of storage. A number of implementations of RAID 1 architectures have been made, in particular by Tandem Corporation.
A RAID 2 architecture stores each bit of each word of data, plus Error Detection and Correction (EDC) bits for each word, on separate disk drives. For example, U.S. Pat. No. 4,722,085 to Flora et al. discloses a disk drive memory using a plurality of relatively small, independently operating disk subsystems to function as a large, high capacity disk drive having an unusually high fault tolerance and a very high data transfer bandwidth. A data organizer adds 7 EDC bits (determined using the well-known Hamming code) to each 32-bit data word to provide error detection and error correction capability. The resultant 39-bit word is Written, one bit per disk drive, on to 39 disk drives. If one of the 39 disk drives fails, the remaining 38 bits of each stored 39-bit word can be used to reconstruct each 32-bit data word on a word-by-word basis as each data word is read from the disk drives, thereby obtaining fault tolerance.
An obvious drawback of such a system is the large number of disk drives required for a minimum system (since most large computers use a 32-bit word), and the relatively high ratio of drives required to store the EDC bits (7 drives out of 39). A further limitation of a RAID 2 disk drive memory system is that the individual disk actuators are operated in unison to write each data block, the bits of which are distributed over all of the disk drives. This arrangement has a high data transfer bandwidth, since each individual disk transfers part of a block of data, the net effect being that the entire block is available to the computer system much faster than if a single drive were accessing the block. This is advantageous for large data blocks. However, this arrangement effectively provides only a single read/write head actuator for the entire storage unit. This adversely affects the random access performance of the drive array when data files are small, since only one data file at a time can be accessed by the "single" actuator. Thus, RAID 2 systems are generally not considered to be suitable for computer systems designed for On-Line Transaction Processing (OLTP), such as in banking, financial, and reservation systems, where a large number of random accesses to many small data files comprises the bulk of data storage and transfer operations.
A RAID 3 architecture is based on the concept that each disk drive storage unit has internal means for detecting a fault or data error. Therefore, it is not necessary to store extra information to detect the location of an error; a simpler form of parity-based error correction can thus be used. In this approach, the contents of all storage units subject to failure are "Exclusive OR'd" (XOR'd) to generate parity information. The resulting parity information is stored in a single redundant storage unit. If a storage unit fails, the data on that unit can be reconstructed onto a replacement storage unit by XOR'ing the data from the remaining storage units with the parity information. Such an arrangement has the advantage over the mirrored disk RAID 1 architecture in that only one additional storage unit is required for "N" storage units. A further aspect of the RAID 3 architecture is that the disk drives are operated in a coupled manner, similar to a RAID 2 system, and a single disk drive is designated as the parity unit.
One implementation of a RAID 3 architecture is the Micropolis Corporation Parallel Drive Array, Model 1804 SCSI, that uses four parallel, synchronized disk drives and one redundant parity drive. The failure of one of the four data disk drives can be remedied by the use of the parity bits stored on the parity disk drive. Another example of a RAID 3 system is described in U.S. Pat. No. 4,092,732 to Ouchi.
A RAID 3 disk drive memory system has a much lower ratio of redundancy units to data units than a RAID 2 system. However, a RAID 3 system has the same performance limitation as a RAID 2 system, in that the individual disk actuators are coupled, operating in unison. This adversely affects the random access performance of the drive array when data files are small, since only one data file at a time can be accessed by the "single" actuator. Thus, RAID 3 systems are generally not considered to be suitable for computer systems designed for OLTP purposes.
A RAID 4 architecture uses the same parity error correction concept of the RAID 3 architecture, but improves on the performance of a RAID 3 system with respect to random reading of small files by "uncoupling" the operation of the individual disk drive actuators, and reading and writing a larger minimum amount of data (typically, a disk sector) to each disk (this is also known as block striping). A further aspect of the RAID 4 architecture is that a single storage unit is designated as the parity unit.
A limitation of a RAID 4 system is that Writing a data block on any of the independently operating data storage units also requires writing a new parity block on the parity unit. The parity information stored on the parity unit must be read and XOR'd with the old data (to "remove" the information content of the old data), and the resulting sum must then be XOR'd with the new data (to provide new parity information). Both the data and the parity records then must be rewritten to the disk drives. This process is commonly referred to as a "Read-Modify-Write" (RMW) sequence.
Thus, a Read and a Write on the single parity unit occurs each time a record is changed on any of the data storage units covered by a parity record on the parity unit. The parity unit becomes a bottle-neck to data writing operations since the number of changes to records which can be made per unit of time is a function of the access rate of the parity unit, as opposed to the faster access rate provided by concurrent operation of the multiple data storage units. Because of this limitation, a RAID 4 system is generally not considered to be suitable for computer systems designed for OLTP purposes. Indeed, it appears that a RAID 4 system has not been implemented for any commercial purpose.
A RAID 5 architecture uses the same parity error correction concept of the RAID 4 architecture and independent actuators, but improves on the writing performance of a RAID 4 system by distributing the data and parity information across all of the available disk drives. Typically, "N+1" storage units in a set (also known as a "redundancy group") are divided into a plurality of equally sized address areas referred to as blocks. Each storage unit generally contains the same number of blocks. Blocks from each storage unit in a redundancy group having the same unit address ranges are referred to as "stripes". Each stripe has N blocks of data, plus one parity block on one storage device containing parity for the N data blocks of the stripe. Further stripes each have a parity block, the parity blocks being distributed on different storage units. Parity updating activity associated with every modification of data in a redundancy group is therefore distributed over the different storage units. No single unit is burdened with all of the parity update activity.
For example, in a RAID 5 system comprising 5 disk drives, the parity information for the first stripe of blocks may be Written to the fifth drive; the parity information for the second stripe of blocks may be Written to the fourth drive; the parity information for the third stripe of blocks may be Written to the third drive; etc. The parity block for succeeding stripes typically "precesses" around the disk drives in a helical pattern (although other patterns may be used).
Thus, no single disk drive is used for storing the parity information, and the bottle-neck of the RAID 4 architecture is eliminated. An example of a RAID 5 system is described in U.S. Pat. No. 4,914,656 to Clark et al.
As in a RAID 4 system, a limitation of a RAID 5 system is that a change in a data block requires a Read-Modify-Write sequence comprising two Read and two Write operations: an old parity (OP) block and old data (OD) block must be read and XOR'd, and the resulting sum must then be XOR'd with the new data. Both the data and the parity blocks then must be rewritten to the disk drives. While the two Read operations may be done in parallel, as can the two Write operations, modification of a block of data in a RAID 4 or a RAID 5 system still takes substantially longer then the same operation on a conventional disk. A conventional disk does not require the preliminary Read operation, and thus does not have to wait for the disk drives to rotate back to the previous position in order to perform the Write operation. The rotational latency time alone can amount to about 50% of the time required for a typical data modification operation in a RAID 5 system. Further, two disk storage units are involved for the duration of each data modification operation, limiting the throughput of the system as a whole.
FIG. 1 is block diagram of a generalized RAID 4 system in accordance with the prior art. Shown is a Central Processing Unit (CPU) 1 coupled by a bus 2 to an array controller 3. The array controller 3 is coupled in a RAID 4 configuration to each of the plurality of failure-independent storage units S1-S4 (four being shown by way of example only) and a parity storage unit 4 by an I/O bus 5 (e.g., a SCSI bus).
FIG. 2 shows a high-level flow chart of the steps which must be taken to write a new data (ND) block onto one storage unit of a redundancy array of the type shown in FIG. 1. A typical RMW sequence begins by reading the OD block which will be rewritten by the ND block from one of the four storage units S1-S4 (step 200). The OD block is then transmitted from the storage unit to a controller (step 201). The corresponding old parity (OP) block must then be read from the parity storage unit (step 202) and transmitted to the controller (step 203). Once the OD block and the OP block are present in the controller, they are XOR'd to remove the information content of the OD block from the OP block. The ND block is XOR'd with the XOR sum of the OD block and the OP block to create a new parity (NP) block (step 204). The NP block is then transmitted to (step 205) and Written to (step 206) the parity storage unit. The ND block is then transmitted to (step 207) and Written to (step 208) the storage unit from which the OD block was Read and thereby overwrites the OD block.
The entire RMW sequence requires a total of two Read operations, two Write operations, two XOR operations, and four transmissions between the storage units and the controller.
Due in large part to the amount of time required to initiate and complete a transmission of a block of data between a storage unit and the controller, the RMW sequence takes longer than is desirable. Additionally, even when the two Read operations are done in parallel and the two Write operations are done in parallel, both the storage unit which holds the data and the storage unit which holds the parity information are unavailable for subsequent RMW sequences which could otherwise be started concurrent with a portion of the previous RMW sequence.
For example, in a RAID 5 configuration, assume that one record to be modified is stored in S1 and the associated parity information is stored in S2. A second record which is to be modified is stored in S2 and the associated parity information is stored in S3. Because S2 must be accessed during the modification of the record stored in S1, the present art does not teach how to begin a parallel RMW operation to modify the data stored in S2 until completion of the RMW operation being performed on the data in S1.
The most efficient way to utilize the storage units is to allow each unit to be accessed as soon as it is free to reduce the sum of the time that both storage units involved in a particular RMW operation are unavailable for other RMW operations.
It is therefore desirable to reduce the number of operations, and particularly the number of transmissions between storage units and the controller, which must be performed in the RMW sequence. The present invention provides such a method.
SUMMARY OF THE INVENTION
The present invention is a redundant array storage system in which each parity storage unit generates its own redundancy information. When a new data (ND) block is to be stored on a data storage unit within the redundant array, the ND block is first transmitted from a Central Processor Unit (CPU) to an array controller. In a first embodiment of the invention, an old data (OD) block, which is to be overwritten by the ND block, is Read and transmitted to the array controller. The OD block and the ND block are then transmitted to the corresponding parity storage unit. Within the parity storage unit, the OP block corresponding to the OD block is Read, and the OD block, the OP block, and the ND block are Exclusive OR'd (XOR'd) in the preferred embodiment to create a new parity (NP) block. This NP block is then stored on the parity storage unit without the need for a transfer of either the OP block or the NP block between the controller and the parity storage unit. Meanwhile, the ND block is also transmitted from the array controller to the storage unit onto which it is intended to be stored. This sequence requires only three transfers between the array controller and the various storage units of the redundancy array, thereby increasing the speed at which a RMW sequence can be accomplished.
In a second embodiment of the invention, the ND block and the OD block are XOR'd within the array controller, and the sum is then transmitted to the appropriate parity storage unit. After transmission of this partial sum to the parity storage unit, the partial sum is XOR'd with the OP block to create the NP block.
Thus, this embodiment trades off the time required to compute the XOR sum within the array controller against time required to transmit two blocks rather than one block.
The invention reduces the number of data transfers between the storage units and the array controller by 25%, thereby increasing the speed of RMW sequences. In addition, the invention reduces input/output (I/O) initiation time by 25%, and reduces the computational overhead otherwise incurred by the array controller.
Additional improvements in performance are attained when the storage device is a disk drive unit having two read/write heads. In such a storage unit in which parity information is stored, a first head reads the OP block. The OP block, the OD block, and ND block are XOR'd as the position on the media at which the OP block was stored is rotating from the first head to the second head. By the time the media reaches the second head, the NP block is ready to be written, saving the additional amount of time that it would have taken to return to the first head.
Further aspects of the present invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings. It should be understood, however, that the detailed description and the specific examples, while representing the preferred embodiment of the invention, are given by way of illustration only.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is block diagram of a generalized prior art RAID system.
FIG. 2 is a high level flow chart of a prior art Read-Modify-Write sequence.
FIG. 3 is a block diagram of a generalized RAID system in accordance with the present invention.
FIG. 4 is a high level flow chart of the RMW sequence of the first embodiment of the present invention.
FIG. 5 is a high level flow chart of the RMW sequence of the second embodiment of the present invention.
FIG. 6 is an illustration of a disk drive unit with two read/write heads.
Like reference numbers and designations in the drawings refer to like elements.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this description, the preferred embodiment and examples shown should be considered as exemplars, rather than limitations on the method of the present invention.
FIG. 3 is block diagram of a generalized RAID 4 system in accordance with the present invention. Shown is a Central Processing Unit (CPU) 1 coupled by a bus 2 to an array controller 3. In the embodiment shown, the array controller 3 is coupled in a RAID 3 or RAID 4 configuration to each of a plurality of storage units S1-S4 (four being shown by way of example only) and an error correction storage unit, such as a parity storage unit 4, by an I/O bus 5 (e.g., a SCSI bus). The array controller 3 preferably includes a separately programmable, multi-tasking processor (for example, the MIPS R3000 RISC processor, made by MIPS Corporation of Sunnyvale, Calif.) which can act independently of the CPU 1 to control the storage units S1-S4, and the parity storage unit 4.
The parity storage unit 4 is preferably implemented as a smart storage unit containing a processor 6 (for example, the HP97556 51/4" SCSI disk drive), the program of which can be altered to allow tasks to be performed which lie outside the realm of what is necessary for simply reading and writing data.
In the present invention as shown, a multi-tasking computer program is executed by the array controller 3 in concert with a computer program executed by the independent processor 6 within the parity storage unit 4. However, numerous combinations of software routines performed by the processors within the array controller 3, the CPU 1, the storage units S1-S4 and the parity storage unit 4 are possible to achieve the desired result. In particular, each of the storage units S1-S4 may include a processor 6, such that all of the storage units may be configured as a RAID 5 system. A RAID 3/RAID 4 configuration is shown in FIG. 3 only for the sake of ease of understanding.
When a new data (ND) block is to be written to one of the storage units S1-S4, the ND block is transmitted from the CPU 1 via the bus 2 to the array controller 3. After receipt of an ND block at the array controller 3, the inventive process begins.
FIG. 4 shows a high-level flow chart of a first embodiment of the process that is implemented in the multi-tasking processor of the array controller 3 and the processor 6 of the appropriate parity storage unit 4. In the first step, the OD block to be overwritten by the ND block is Read from the appropriate storage unit S1-S4 (step 400).
Once the OD block is Read it is transmitted to the array controller 3 (step 401). The OD block is then retransmitted along with the ND block in a single transmission from the array controller 3 to the parity storage unit 4 (step 402). Transferring the OD block and the ND block in a single transmission saves the processing overhead which is required to initiate a transmission for each block of data independently. An old error correction code block, which for the purposes of this description is an old parity (OP) block, corresponding to the OD block, is then Read into a buffer within the processor 6 of the parity storage unit 4 (step 403).
Upon receipt of the OD block and the ND block, the internal processor 6 performs an Exclusive OR (XOR) function on the OD block, OP block, and the ND block to generate a new parity (NP) block (step 404). The NP block is then Written to the parity storage unit 4 (step 405), and so replaces the OP block. Concurrently, the ND block is transmitted to the storage unit S1-S4 from which the OD was Read (step 406), and written therein (step 407).
The invention, therefore, requires only three transmissions of data between the array controller 3 and the various storage units S1-S4 and the parity storage unit 4, rather than four transmissions as in the prior art. Because the parity storage unit 4 is involved in only a single data transmission, it becomes rapidly available for the next RMW operation. Furthermore, it is generally possible for a disk-type parity unit 4 to receive the ND and OD blocks, then Read each corresponding OP block and generate the NP block before a complete rotation of the disk media occurs. This allows the NP block to be computed and Written within slightly more than one revolution of the media.
In contrast, in the prior art, after an OP block is Read and transmitted to the array controller 3, the computed NP block from the array controller 3 may not be received in time (due to transmittal overhead in both directions) to be Written over the OP block without being delayed for more revolutions.
Furthermore, a disk-type parity unit may have more than one read/write head 600 per storage media surface (see FIG. 6). Having two read/write heads reduces the rotational latency time (i.e., the time required to rotate to the position at which the data is stored). Each of the two heads are preferably positioned 180° around the storage media and each may read and/or write simultaneously. Magnetic disk drives having such a configuration are available from Conner Peripherals as its "Chinook" 510 megabyte drive.
In such a disk-type parity unit, a first read/write head 600a reads the OP block. The parity unit then generates the NP block before the disk media 602 rotates past a second read/write head 600b. Therefore the NP block is computed and Written in less than a single rotation of the media 602. The placement of the read/write heads 600a, 600b with respect to one another depends upon the speed with which the NP block can be generated from the OP block, the OD block, and the ND block, and the speed at which the media 602 rotates. In an alternative embodiment, any even number of heads 600 may be used.
In addition to decreasing the overall time required to overwrite the OP block with the NP block, the overall time required for the data storage unit which stores the OD block to Read the OD block and Write the ND block can also be reduced by using more than one read/write head 600. In such a configuration, one head 600a Reads the OD block, and a second head 600b Writes the ND block at the same location on the media 602 from which the OD block was Read. Use of at least two read/write heads 600a, 600b increases the speed at which a disk storage unit overwrites the OD block with the ND block since the media rotates less than one rotation between Reading the OD and Writing the ND.
While the above described embodiments of the present invention is illustrated as being used in a RAID 3 or RAID 4 system for ease of understanding, it should be noted that this embodiment may also be used in a RAID 5 system.
A second embodiment of the invention is shown in FIG. 5, which is a high level flow chart. In this embodiment, the OD block is read (step 500) and transmitted to the array controller 3 (step 501), as is the case in the first embodiment. However, upon receiving the OD block, the array controller 3 performs a first XOR operation upon the OD block and the ND block (step 502), creating a SUM block. The SUM block is then transmitted to the parity storage unit 4 (step 503). After the parity storage unit 4 receives the SUM block, the OP block is Read into a parity buffer within the processor 6 of the parity storage unit (step 504). The SUM block is then XOR'd with the OP block by the internal processor 6 to form the NP block (step 505), which is then Written to the parity storage unit 4 (step 506). The ND block is concurrently transmitted to the corresponding storage unit S1-S4 from which the OD block was Read and to which the ND block is to be Written (step 507). The ND block is then Written to the selected storage unit (step 508), and the operation is completed.
By sending the sum of the OD and ND blocks rather than the OD block and the ND block themselves, the total time for the transmission between the array controller 3 and the parity storage unit 4 is reduced. This results in a favorable trade-off between the time required to compute the SUM block within the array control unit and the time required to transmit two blocks rather than one block.
In the embodiment in which the disk-type parity units have at least two read/write heads 600a, 600b, as shown in FIG. 6, the internal processor in the parity unit generates the NP block from the OP block and the SUM block before the storage media 602 rotates from the first head 600a to the second head 600b. This results in an improvement in performance from the simultaneous Read and Write operations of the two read/write heads 600a, 600b, and a consequent reduction in the rotational latency time as noted above.
It will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the present invention can be used with RAID 3, RAID 4, or RAID 5 systems. Furthermore, an error correction method other than XOR-generated parity may be used for the necessary redundancy information. One such method using Reed-Solomon codes is disclosed in U.S. patent application Ser. No. 270,713, filed Nov. 14, 1988, entitled "Array Disk Drive System and Method" and assigned to the assignee of the present invention. Thus, as used herein, "parity" should be understood to also include the broader concept of "redundancy information". The invention can use non-XOR redundancy information in addition to or in lieu of XOR-generated parity. As another example, the invention can be used in an array system configured to attach to a network rather than directly to a CPU. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiment, but only by the scope of the appended claims. | A redundant array based data storage system used in computer systems for reducing the amount of time required to modify data records stored in the redundant array. The storage system reduces the number of transmissions between a storage unit within the redundant array and the array controller by incorporating a parity storage unit which is programmed to perform operations necessary to the calculation of a "parity code" which is used for error detection and correction. By integrating the redundancy information generation into the storage unit used to store the parity information, the number of transmissions between various component parts of the system is reduced, and so the amount of time required to perform a "read-modify-write" operation is reduced. Disk-type parity units having more than one read/write head are used to further increase the performance of the storage system by reducing the disk rotational latency time. | 6 |
CONTINUATION HISTORY
[0001] This application is a continuation of Provisional U.S. Patent Application 60/596,382, filed on Sep. 20, 2005, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an improved design and implementation of portioning utensils, namely spoons, but can be any similar type of utensil.
[0003] In the traditional mode of portioning while cooking or serving, serving and or cooking cannot be done with the same set of utensils as those one might portion food with. This is due largely to the fact that cooking utensils and serving utensils are not graduated or otherwise marked to provide portioning information, such as liquid measure or dry weight.
[0004] Obvious downsides to the current state of the art exist. Persons having restricted diets, limited caloric intake or who wish to better monitor their consumption have no solution for spoons which both serve the purpose of serving and or cooking while simultaneously being able to portion food and/or liquid.
[0005] The consequence of these issues is the necessity to use multiple utensil sets, such as one set of utensils for cooking, one for serving and one or more for measuring while cooking, and yet another for measuring while serving. This becomes very time consuming, not only from the aspect of having to constantly switch utensil sets, but also from having to clean multiple sets of utensils.
[0006] The present invention of a unified transaction is thus a much-improved apparatus for combining the functions of cooking and serving utensils into a single tool. Clearly then, the present invention offers a much more complete and efficient solution that has yet to be addressed.
[0007] All of these aspects of the current mode of portioning food with multiple utensil sets lead to an increased need for a revised tool for measuring and cooking/serving, all of which the present invention addresses.
OBJECTS OF THE INVENTION
[0008] One object of the invention is to provide a revised utensil for portioning.
[0009] Another object of this invention is to provide a revised utensil for cooking.
[0010] Yet another object of this invention is to provide a revised utensil for serving.
[0011] Still another object of this invention is to provide a revised utensil for combining cooking and portioning.
[0012] Still another object of this invention is to provide a revised utensil for combining serving and portioning.
[0013] Other objects and advantages of this invention shall become apparent from the ensuing descriptions of the invention.
SUMMARY OF THE INVENTION
[0014] According to the present invention, a revised utensil is disclosed that is able to simultaneously portion and cook or serve food in desired quantities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings illustrate an embodiment of this invention. However, it is to be understood that this embodiment is intended to be neither exhaustive, nor limiting of the invention. They are but examples of some of the forms in which the invention may be practiced.
[0016] FIG. 1 is a perspective view of the measuring and cooking utensil.
[0017] FIG. 2 is a perspective view of the measuring and serving utensil.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0018] Without any intent to limit the scope of this invention, reference is made to the figures in describing the various embodiments of the invention. FIGS. 1-2 show various aspects of exemplary embodiments of the present invention.
[0019] The present invention relates to a series of utensils, particularly, in the preferred embodiment, spoons 100 , which are specially designed portioning spoons that can be used by a variety of persons to help control their intake and to portion items, and which have elongated handles 102 attached to a bowl 101 which is used to portion and transport food and/or liquid from one location to another.
[0020] These specialized utensils include:
Long-handled cooking spoons 105 (handles ideally around 11 inches, but may be shorter or longer, depending on need) Serving spoons 106 (handles ideally around 7-7½ inches, but may be shorter or longer depending on need) Long-handled pot spoons 105 (handles ideally around 11 inches, but may be shorter or longer, depending on need) Other spoons which may be used in cooking and/or serving
[0025] All of the above-described utensils would also employ a portioning capability, making the utensils dual-purpose. An indicator 103 / 104 such as engraved markings may be inscribed on the handle to show the portions delivered by the spoons. This indicator 103 / 104 may be shown in both English 103 and Metric 104 systems. Alternately or in conjunction, the spoons may have graduations on the bowl of the spoon to show the quantity of food or liquid delivered in the spoon.
[0026] In operation, then, these spoons are designed to help a person desiring to control the intake of food (such as those on a medical diet or watching their weight) by being able to quickly and easily portion the food items without the hassle and complication of measuring cups, scales or other portioning methods.
[0027] The current method of portioning food involves:
cooking food with one set of spoons, transferring the food to another container, obtaining measuring cups; obtaining a scale; filling a container with food with yet another set of utensils; placing such container on a scale or portioning food into same; adjust the portion according to the desired dietary intake; and placing the portion on a plate.
[0036] As can be easily seen, this is drawn out, complicated, and renders several dishes dirty, promotes additional contamination of food, makes the food colder, and is generally cumbersome. However, it is also unnecessary in light of the present invention, since cooking and serving may be done easily with the present invention's portioning food set. The spoons can be in a variety of sizes, such as ¼ cup, ½ cup, ¾ cup, and 1 cup. Dual measurements can be printed on the spoon handle for easy reference, such as cups and ounces, or even metric measurement, both dry and liquid to aid in the versatility of the usage.
[0037] Other benefits include being able to recognize portions easily for times you eat out at restaurants or others' homes, so that approximations can be made on portions. Diabetics can easily serve themselves the correct portions. Suggested daily intake (such as the USRDA) can be portioned easily and without fuss. Another use is to teach children from a young age to portion food easily and without mess so that they may begin learning proper portioning at a young age to prevent problems later in life cause by eating improper quantities, such as diabetes, obesity and malnutrition.
[0038] Though simple in execution, the design is believed novel and innovative, and no prior art is known at this time, since no known art employs the portioning ability with a handle of sufficient length to comfortably reach into pots, bowls and other places where smaller portioning tools cannot be used.
[0039] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. | The present invention is a revised utensil is disclosed that is able to simultaneously portion and cook or serve food in desired quantities. | 6 |
RELATED APPLICATIONS
[0001] This application is a divisional of prior U.S. application Ser. No. 14/807,191, filed Jul. 23, 2015, the entirety of which is herein incorporated by reference. The '191 application claims the benefit of U.S. Provisional Application No. 62/027,964, filed Jul. 23, 2014, the entirety of which is herein incorporated by reference.
BACKGROUND
[0002] The present disclosure relates to portable seating systems, and more particularly to a powered telescopic seating riser having decks capable of being vertically raised.
[0003] Seating risers are designed for use in auditoriums, gymnasiums, and event halls, as examples, to accommodate spectators on portable seats, such as folding chairs, or on seats affixed to the risers. Certain facilities may require seating risers that are capable of being moved between a retracted position for storage and a deployed position for use.
SUMMARY
[0004] A seating system according to an exemplary aspect of the present disclosure includes, among other things, a plurality of seating risers configured to telescope relative to one another. Further, at least one of the plurality of seating risers is a powered seating riser configured to deploy and retract the plurality of seating risers. The powered seating riser includes a belt drive system. Additionally, the plurality of seating risers are adjustable between a lowered position and a raised position.
[0005] Another seating system according to an exemplary aspect of the present disclosure includes, among other things, a plurality of seating risers adjustable between a lowered position and a raised position. The plurality of seating risers are also configured to telescope relative to one another between a deployed position and a retracted position. The system further includes an actuator mounted to a scissor lift, which is configured to adjust a vertical position of at least one of the plurality of seating risers. The actuator slides a roller of the scissor lift in a direction parallel to the deployment and retraction of the plurality of seating risers.
[0006] A method according to an exemplary aspect of the present disclosure includes, among other things, moving a plurality of seating risers to one of a deployed position and a retracted position, and adjusting a height of at least one of the plurality of seating risers between a lowered position and a raised position using a scissor lift. The scissor lift includes a roller configured to slide in a direction parallel to the direction of deployment and retraction of the seating risers.
[0007] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings can be briefly described as follows:
[0009] FIG. 1A is a perspective view of a seating system in a deployed position.
[0010] FIG. 1B is a schematic illustration of the seating system in a retracted position.
[0011] FIG. 2 is a bottom-perspective view of an embodiment of a powered seating riser including a dual-belt drive system.
[0012] FIG. 3A is a perspective view of another example seating system in a retracted position.
[0013] FIG. 3B is a side view of the seating system in the retracted position.
[0014] FIG. 4 is a side view of the seating system of FIG. 3A in a deployed position.
[0015] FIG. 5A is a view of the seating system of FIG. 3A in a raised position.
[0016] FIG. 5B is a side view of the seating system in the raised position.
[0017] FIG. 5C is a view of the seating system, and illustrates gearboxes associated with a scissor lift.
[0018] FIG. 5D is a view of an example right angle gearbox.
[0019] FIG. 6 is a close up view of the encircled area in FIG. 4 .
[0020] FIG. 7 illustrates a sway reduction feature according to the present disclosure.
DETAILED DESCRIPTION
[0021] An exemplary seating system 10 (which is sometimes collectively called a “riser”) has a plurality of telescopic seating risers 12 A- 12 F configured to deploy ( FIG. 1A ) and retract (schematically represented in FIG. 1B ) relative to one another. While six seating risers 12 A- 12 F are shown in FIGS. 1A-1B , it should be understood that this application extends to seating systems with any number of risers. For example, FIG. 3A illustrates an example including three risers.
[0022] Each seating riser 12 A- 12 F (sometimes each “riser” is referred to as a “level” or a “rise”) generally includes a support structure which supports a respective deck. The decks may support spectators thereon, either directly, such as when spectators stand directly on the decks, or indirectly by way of fixed benches or removable seats, such as folding chairs.
[0023] In one example, the lower level seating risers are narrower in width and shorter in height relative to the upper level seating risers (e.g., lowest level seating riser 12 A is narrower in width and shorter in height relative to seating riser 12 B, and so on) to facilitate telescoping of the seating system 10 between the deployed ( FIG. 1A ) and retracted positions ( FIG. 1B ).
[0024] In one example, one of the seating risers is a powered seating riser including a belt drive system 16 . The powered seating riser is operable to drive the deployment (in the “deploy” direction, labeled in the Figures) and retraction (in the “retract” direction, also labeled in the Figures) the seating system 10 , and to further laterally steer the seating risers 12 A- 12 F side-to-side during deployment and retraction. In the disclosed non-limiting embodiment the lowest riser 12 A is the powered seating riser. Although any of the seating risers 12 A- 12 F may be a powered seating riser, the lowest riser 12 A may best facilitate steering of the seating risers 12 A- 12 F in many examples.
[0025] FIG. 2 illustrates an example powered seating riser. In the illustrated example, the powered seating riser includes a dual-belt drive system 16 B. The drive system 16 B includes two variable frequency motors, or drives, 26 A, 26 B, each driving a respective belt, or track, 28 A, 28 B. Conceptually, the dual-belt drive system 16 B provides the seating system 10 with a motive force, as well as steering (e.g., steering in a lateral, side-to-side, direction), in a “tank-like” manner. To this end, the variable frequency drives 26 A, 26 B may be disposed at opposite sides, or flanks, of the powered seating riser 12 A.
[0026] The overall system 10 , along with the dual-belt drive system 16 B, is described in U.S. patent application Ser. No. 13/315,606 (“the '606 application”), filed Dec. 9, 2011, the entirety of which is herein incorporated by reference.
[0027] FIGS. 3A-3B illustrate another seating system 110 according to the present disclosure. The seating system 110 includes three seating risers 112 A- 112 C, although, again, any number of risers could be included. In this example, the lowest riser 112 A is a powered seating riser, substantially similar to the riser 12 A of FIGS. 1A-2 . In particular, the lowest riser 112 A in one example includes the dual-belt drive system of FIG. 2 . The seating system 110 may also include a laser alignment system, such as that described in the '606 application.
[0028] The lowest riser 112 A is configured to be driven forward or rearward, and steered laterally (as needed), to move between a deployed and retracted position. In this example, the lowest riser 112 A moves in response to commands from a controller 130 . The upper risers 112 B, 112 C follow the lowest riser 112 A as it moves between the deployed and retracted positions. FIGS. 3A-3B illustrate the risers 112 A- 112 C in the retracted position. FIG. 4 illustrates the risers 112 A- 112 C in the deployed position.
[0029] Further, the seating system 110 includes a plurality of actuators 114 , 116 , 118 (perhaps best seen in FIGS. 3B and 4 ) configured to vertically move the risers 112 A- 112 C between a lowered position of FIGS. 3A-3B (e.g., see the “lower” direction, labeled in the Figures) and a raised position of FIGS. 5A-5B (e.g., see the “raise” direction, labeled in the Figures). The actuators 114 , 116 , and 118 are electrically coupled to the controller 130 and are responsive to commands from the controller 130 . In one example, the controller 130 commands the actuators such that the several levels (e.g., the risers 112 A- 112 C) change elevation at the same time. In the example, the controller 130 commands the first riser 112 A to start moving vertically (e.g., in the lower direction), and then commands the second riser 112 B to start moving vertically after a delay, which can be a fixed value and vary depending on the particular application. The controller 130 next commands the third riser 112 C to start moving after another delay, and so on (if there are additional risers). Ultimately, the delays reduce the likelihood of a collision between adjacent risers during vertical travel. In this example, if a fourth riser were present, that riser would start moving after the first riser 112 A completes its travel. This “leapfrog effect” would continue until all levels (again, if present) complete their vertical travel.
[0030] It should be understood that the controller 130 is configured to provide the actuators 114 , 116 , 118 , as well as the drive associated with the powered seating riser, with the appropriate instructions. In one example, a user provides instructions to the controller 130 via an interface. In another example, the controller 130 is programmed to automatically deploy and raise the risers, depending on the particular example. The controller 130 may include memory, a processor, hardware, and software necessary to receive, store, and send the appropriate instructions throughout the seating system 110 .
[0031] With reference to FIG. 4 , the lowest seating riser 112 A includes a deck 120 , which is vertically supported by a scissor lift 122 . The scissor lift 122 includes first and second arms 124 , 126 , which are pivotably connected to one another (at point 128 ) and to the deck 120 (at points 131 , 132 ).
[0032] Opposite the connection with the deck 120 , the arm 124 is slidably connected to a roller 134 . The roller 134 is configured to move in a direction parallel to the “deploy” and “retract” directions. This direction of movement allows for increased range (e.g., in the vertical direction) of movement of the scissor lift. The actuator 114 is configured to longitudinally adjust the position of the roller 134 , which in turn raises and lowers the deck 120 . Further, the arm 126 is pivotably connected opposite the pivotable connection 132 , at 136 . In the lowered position, the deck 120 is provided at a height H 1 above a ground surface.
[0033] In this example, the deck 138 of the second riser 112 B is vertically supported by a drivable structure 139 , an intermediate structure 141 , and a vertical support post 142 . The drivable structure 139 is connected to the intermediate structure 141 by way of one or more drivable rollers. The drivable structure 139 and the intermediate structure 141 are each configured to move in directions parallel to the “lower” and “raise” directions. In turn, the intermediate structure 141 is connected to the vertical support post 142 by a plurality of passive rollers. In this example, the actuator 116 drives the rollers of the drivable structure along the intermediate structure 141 , which itself, in turn, travels along the vertical support post 142 . The intermediate structure 141 allows additional vertical travel for the deck 138 , however it is not required in all examples. When in the lowered position, the deck 138 is a height H 2 above a ground surface.
[0034] The third seating riser 112 C includes a deck 140 positioned at a height H 3 in the lowered position. The deck 140 is vertically supported by a drivable structure 145 , which is movable (e.g., by one or more drivable rollers) along a vertical support post 146 in response to the actuator 118 . The drivable structure 145 is moveable in directions parallel to the “lower” and “raise” directions. It should be understood that the actuators 114 , 116 , 118 can be any type of known actuator, such as linear actuators including acme screws, ball screws, or another type of actuator including a nut moveable along a threaded shaft. Further, the linear actuator may be self-locking.
[0035] FIG. 5A is a perspective view illustrating the seating risers 112 A- 112 C in a raised position. In the raised position, the deck 120 is a height H 1 ′ above a ground surface, which in one example is about 40 inches higher than the height H 1 . Further, the deck 138 of the second riser 112 B is a height H 2 ′ above a ground surface, which in one example is about 30 inches higher than the height H 2 . Further, the deck 140 of the third riser 112 C is a height H 3 ′ above a ground surface, which is about 20 inches higher than the height H 3 in one example.
[0036] In this example, the second riser 112 B vertically travels further than the third riser 112 C due to the intermediate structure 141 . Further, the scissor lift 122 associated with the lowest riser 112 A is configured to provide the largest amount of vertical travel. The increased vertical travel associated with the lowest riser 112 A allows the lowest riser 112 A to vertically align with the highest riser of an adjacent seating system (which may be in a vertically lowered position).
[0037] As illustrated in FIG. 5B , when the seating system 110 is in the raised position, the vertical gaps between the decks 120 , 138 , and 140 are sealed (e.g., substantially covered) by vertical flanges 150 , 152 . The flanges 150 , 152 prevent unwanted access to the underside of the decks 120 , 138 and 140 , which increases the safety of the system 110 .
[0038] In FIG. 5B , the actuators 116 , 118 are connected to vertical drives, which may be linear actuators like ball screws or acme screws within respective drivable structures 139 , 145 , by way of a rotatable horizontal arm (such as arm 119 in FIG. 5A ) and a respective right angle gearbox 161 , 163 . The right angle gearboxes 161 , 163 convert an input rotation ninety degrees into an output rotation. Likewise, as illustrated in FIG. 5C , the actuator 114 drives a horizontal arm 115 , which is connected to first and second right angle gearboxes 165 , 167 . The right angle gearboxes 165 , 167 are arranged to drive the roller 134 in the deploy and retract directions. By providing right angle gearboxes between the actuators 114 , 116 , 118 and the respective linear actuators, maintenance is reduced relative to the prior systems (which may include additional parts like chains and sprockets that need lubrication), which in turn increases system reliability.
[0039] One example right angle gearbox G is shown in FIG. 5D . As mentioned, the right angle gearbox G is configured to convert an input rotation I 1 (e.g., from the horizontal arms 115 , 119 ) by ninety degrees to an output rotation I 2 , which in turn drives the linear actuators and adjusts riser position.
[0040] In one example, the scissor lift 122 requires additional vertical space for packaging when the system 110 is in the lowered position. As illustrated in FIG. 6 , in one example, a vertical gap exists between the upper surface of the flange 150 and the lower surface of the second deck 138 . In this example, the arm 124 of the scissor lift 122 includes a projection 154 extending generally in a rearward direction (i.e., a direction parallel to the “retract” direction), which supports a cam 156 . When the seating system 110 is in the lowered position, the cam 156 engages a flap 158 , and rotates the flap 158 such that it contacts the lower surface of the deck 138 . The combination of the vertical flange 150 and the flap 158 effectively seal the underside of the decks 120 , 138 when the system 110 is in the lowered position.
[0041] FIG. 7 illustrates a sway reduction feature according to this disclosure. As illustrated in FIG. 7 , the second deck 138 includes a node 160 projecting downwardly from a lower surface thereof. In this example, the node 160 is a frustoconical projection. The lowest riser 112 A includes an opening 162 adjacent an upper surface of the flange 150 . When in the raised position, the node 160 is received in the opening 162 . Contact between the node 160 and the structure forming the opening 162 restricts lateral movement of the lowest riser 112 A and the second riser 112 B. It should be understood that a similar sway reduction feature can be provided between the second riser 112 B and the upper riser 112 C. Further, each riser can include more than one node/opening pair.
[0042] Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.
[0043] One of ordinary skill in this art would understand that the above-described embodiments are exemplary and non-limiting. That is, modifications of this disclosure would come within the scope of the claims. Accordingly, the following claims should be studied to determine their true scope and content. | A seating system according to an exemplary aspect of the present disclosure includes, among other things, a plurality of seating risers configured to telescope relative to one another. Further, at least one of the plurality of seating risers is a powered seating riser configured to deploy and retract the plurality of seating risers. The powered seating riser includes a belt drive system. Additionally, the plurality of seating risers are adjustable between a lowered position and a raised position. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a technique for changing over optical systems having different magnification powers upon alteration of the size of original in an image forming apparatus in which the original and a film are both disposed in the stationary state so that the original is imaged on a surface of the film and which apparatus is arranged such that a center portion of an original supporting stage is projected substantially onto a center portion of the film.
In the image forming apparatus in which an original is placed on a supporting stage and the image thereof is formed on a light sensitive medium such as film or the like, the original has to be so positioned that the center thereof coincides with that of the image regardless of variation in the size of the original. Otherwise, a portion of the original may be excluded from the image. Further, when originals of different sizes are to be taken on a film of a same size, there are required a plurality of lenses having different magnification powers in accordance with the sizes of the originals. Thus, operator must position an original and select the lens in accordance with the size of the original before photographing it.
However, the operator may neglect the above procedure and select a wrong lens, resulting in wasteful photographing to disadvantage.
In view of the drawback of the prior art described above, it is an object of the present invention to provide a magnification power varying mechanism for automatically changing the taking lens to the one having a requisite magnification power upon positioning of an original.
SUMMARY OF THE INVENTION
For achieving the abovementioned object, the present invention provides a magnification varying mechanism for an image forming apparatus arranged such that a center portion of an original supporting stage is projected substantially to a center portion of an image formed on a light sensitive medium, characterized by a scale for regulating end portions of originals of different sizes, optical systems including lenses having different magnification powers in accordance with the sizes of the originals and a mechanism for changing over the optical systems in interlock with the movement of the abovementioned scale.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing an exemplary embodiment of the present invention,
FIG. 2 is a schematic sectional view of FIG. 1,
FIG. 3 is a view showing an external appearance of an image forming apparatus to which the present invention is applied,
FIG. 4 is an enlarged view of a detecting means shown in FIG. 2,
FIG. 5 is a perspective view showing another exemplary embodiment of the present invention,
FIG. 6 is a schematic view showing a positioning mechanism in the embodiment shown in FIG. 5, and
FIGS. 7 and 8 are sectional and plan views of other embodiment according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, an exemplary embodiment of the present invention will be described. FIG. 3 shows an external appearance of an image forming apparatus which includes a press plate 2 for keeping an original in place, a photographing camera 3, and a manipulation field 4 for manipulating the apparatus. A general arrangement of the image forming apparatus to which the present invention is applied will be described by referring to FIG. 2. The original 2 is disposed on a contact glass plate 5 constituting an original supporting stage and kept immovably in place by the press plate 2. The original 1 is illuminated by a flash lamp 6, wherein light reflected from the original is reflected at a first mirror 7 and a second mirror 8 and transmits through an optical system 9 composed of a taking lens to be focused onto a film 10. The film 10 is contained in the camera 3 shown in FIG. 3, the exposure being effectuated by opening a shutter in synchronism with light emission of the flash lamp.
FIG. 1 is a plan view showing an exemplary embodiment of the present invention, and FIG. 2 shows schematically an internal structure of the image forming apparatus associated with the exemplary embodiment. In the case of the exemplary embodiment of the present invention, two originals, i.e. an original of A4 size according to the ISO (210×297 mm) and an original of 5"×7" (127×178 mm) in size are demonstrated as the originals of different sizes, by way of example. A reference point 5' is provided in the vicinity of the center of the original supporting stage constituted by the contact glass plat 5 so that an image of the original corresponding to this reference point is projected to the center of the film.
The image forming apparatus is so arranged that the optical axis of the taking optical system constantly coincides with the reference point of the original supporting stage and that the flash lamp constituting the illuminating light source illuminates the original around the center of the original supporting stage. Since both of the stage and the flash lamp are disposed fixedly, it is required to align the center of the original with the reference point of the original supporting stage.
More specifically, the image forming apparatus must be able to copy high quality color images of different sizes on a surface of film by varying the magnification. In this conjunction, distribution of quantity of light illuminating the original is critical and it is difficult to ensure the distribution satisfactorily unless the optical axis remains constant.
Describing the exemplary embodiment of the present invention by referring to FIG. 1, a stationary scale 14 is fixedly provided at one edge of the contact glass 5 located at a bottom position as viewed in the figure. The original of A4 size can be positioned by abutting one end thereof against an end of the stationary scale 14. For positioning the original of 5"×7" in size, a movable scale 11 is provided. The movable scale can be rotated around a shaft 17 thereof from a set position (the position for setting in place the original of 5"×7" in size) shown in a solid line to a retracted position extending in parallel with a side of the contact glass 5 indicated by a dotted line for allowing the original of A4 size to be used.
The taking optical system 9 includes a lens 21 for the size of 5"×7" and a lens 22 for the A4 size both of which are disposed on a turret 15 so that a same size of image can be obtained by changing over the magnifications of these lens. When the movable scale 11 is set to the position for accommodating an original of 5"×7" in size, the lens for the size of 5"×7" is employed. When the movable scale 11 is moved to the retracted position for allowing an original of A4 size to be used, the lens for the size of A4 is employed. To this end, a mechanism of automatically changing over the lenses is incorporated, as is explained below.
Referring to FIGS. 1 and 2, when the movable scale 11 is rotated to the set position (position shown in the solid line) for imaging an original of 5"×7" in size, an actuator element 12 mounted on the shaft of the movable scale 11 presses a microswitch 13, whereby a signal is produced to rotate a motor 16 in one direction, as the result of which the turret 15 is rotated by way of a gear wheel 16' mounted on the motor shaft and a gear 15' formed in the turret 15 to thereby bring the lens 21 for the size of 5"×7" to the position of the axis of the taking optics. FIG. 4 shows in an enlarged view an associated detecting structure. When the abovementioned lens has attained the predetermined position, this is detected by a microswitch not shown, whereupon the motor 16 is stopped. The turret 15 is provided with a click stop not shown to fix the turret at the position where the axes of the optical systems are aligned. In this state, an original of 5"×7" in size can be abutted against the movable scale and photographed.
When an original of A4 size is to be photographed, the movable scale 11 is rotated to the retracted position shown in the dotted line in FIG. 1, whereupon the microswitch 13 is restored, producing a signal for rotating the motor 16 in the direction opposite to that mentioned above, as the result of which the turret 15 is rotated in the reverse direction by way of the gear wheels 16' and 15' until the lens for the A4 size has been set at the taking position. The stopping of the motor as well as operation of the chick stop is realized similarly to the manner mentioned before.
With the arrangement described above, operation of moving the movable scale to operative position or inoperative position by operator is interlocked with the automatic selection of the optical system having a proper magnification power.
FIG. 5 shows another exemplary embodiment of the present invention according to which a change-over mechanism composed of a link mechanism is provided between the movable scale and the optical systems. When the movable scale 11 is rotated to the set position corresponding to one original, a lever 18 mounted on a rotatable shaft 17 for the movable scale 11 is rotated. A pin 18' anchored in the lever 18 at the other end thereof engages in an elongated slot-like groove 26 provided in the turret. Rotation of the lever 18 is transmitted to the turret 15 by way of the pin 18' and the groove 26, whereby the turret 15 is rotated around a shaft 23 thereof. When the lens 21 for the size of 5"×7" is brought to the taking position, an arm pin 19' of an arm 19 biased by a spring 20 rides on a slanted face 15a of the turret, resulting in that the turret 15 is pressed against a stopper 25, whereby the optical axis of the optical system is positioned in alignment (FIG. 6).
When the other original of A4 size is used, the movable scale 11 is rotated to the retracted position. In this case, the lever 18 and the turret 15 are rotated in the direction reverse to that mentioned above, whereby the lens for the A4 size is set to the taking position by the turret, while the arm pin 19' abuts on a slanted face 15b of the turret 15 provided on the opposite side to press the turret against the stopper 24. Positioning of the optical axis is thus accomplished. According to the instant embodiment, the motor and the microswitch can be spared, being attendant with reduction in cost. Besides, due to the mechanical structure, reliability is also enhanced.
FIGS. 7 and 8 shows an exemplary embodiment applicable to the movable scale 11 and the stationary scale 14 described above. As the means for positioning an original of slightly different size, the scale is constituted by a scale provided with an offset. A numeral 36 designates a scale for positioning an original having a letter size according to the U.S.A Standards (216×279 mm), and 35 designates a scale for positioning an original of A4 size according to the ISO (210×297 mm), wherein both scales are fixedly mounted on the original supporting stage in a superposed state. The original of the letter size is abutted against a front end of the scale 36 for the positioning thereof, while the original of A4 size is abutted against a front end of the scale 35. A numeral 31 denotes a cover, 32 denotes a side plate having the scale for letter size mounted at one end, 33 denotes a set screw, and 34 denotes a spacer. In FIG. 8, 1a indicates the set state of an original of the A4 size and 1b indicates the state of an original of the letter size.
The scales 35 and 36 may be implemented in one scale formed with the offset. Further, a plurality of offsets may be provided for coping with various sizes of originals. The illustrated embodiment is very effective in handling originals of sizes differing only slightly within a range in which the magnification powers of the lenses need not be changed over. By applying this embodiment to the stationary scale 14 and the movable scale 11, the apparatus can deal with originals of numerous types.
According to the present invention, the scales are provided in correspondence with the sizes of originals, wherein the optical system having a proper magnification power can be selected by abutting an end of an original against the selected scale. Thus, photographing of high quality color image can be carried out in a simplified manner without mishandling. | A copier for providing photographic copies of different sized originals, having an optical system variable for altering the magnification of an original, a scale member movable to locate the end of each respective size of original on the copier, and a link mechanism intercoupling the optical system and the scale to automatically vary the system magnification in accordance with the location of the scale. | 6 |
CROSS RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/353,489, filed on Jun. 10, 2010, the entirety of which application is incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a method of manufacturing pulp and more particularly to a method of manufacturing pulp to be used for making corrugated medium.
[0003] A wide range of methods exist for manufacturing semi-chemical pulp to be used for making a corrugated medium. For example, the high yield hardwood pulps used in manufacturing corrugating medium may be produced using semi-chemical pulping processes including soda/caustic pulping, neutral sulfite semi-chemical (NSSC) pulping, and green liquor pulping. Depending on the manufacturing method used, the pulp yield generally varies from 75 percent (%) to 82% for NSSC pulping and up to 85% to 86% for green liquor and soda/caustic pulping. Typically low yields pulps result from treatment with sulfur containing cooking chemicals, which provide better pulp quality than high yield pulps.
[0004] Standard soda/caustic (SC) pulping is a popular method for puling. SC pulp manufacturing is attractive due to inexpensive cooking chemicals and a relatively easy and simple chemical recovery process. The pulp quality from standard soda/caustic pulping tends to be inferior to the pulp quality generated by NSSC pulping. The pulp quality is a major disadvantage for soda/caustic pulping, especially for paper grades requiring high results for the ring crush test and corrugated medium test (CMT).
BRIEF DESCRIPTION OF THE INVENTION
[0005] A new method and system for soda/caustic pulping has been developed that provides high quality pulp, e.g., higher ring crush and CMT values than typically obtained with the standard soda/caustic pulping. The new method and system may also have the same easy and simple chemical recovery of standard soda/caustic pulping and thereby minimize the environment pollution.
[0006] A method has been conceived to make pulp comprising: cooking chips, e.g., wood chips, in cooking vessel using a soda, caustic or green cooking liquor injected into the cooking vessel; fiberizing the chips discharged from cooking vessel to form a pulp, and removing lignin from the pulp or oxidizing lignin in the pulp by injecting oxygen (O 2 ) into the fiberized chips (pulp). The fiberized chips may be washed to form the pulp adapted to form, for example, a corrugated medium. The method may use cooking liquor that includes one or more of soda (NaOH) and soda ash (Na 2 CO 3 ). The method may also include a mechanical fiberizing process. The pulp may be refined after removing or oxidizing the lignin and used to form corrugated medium. The step of removing or oxidizing the lignin may be performed at a temperature in a range of 120 degrees Fahrenheit (deg. F.) to 300 deg. F. and for a period in a range of 5 minutes to 120 minutes.
[0007] A method has been conceived to make pulp comprising: cooking chips in a cooking vessel using a caustic carbonated pulping cooking liquor injected into the cooking vessel; fiberizing the chips discharged from the cooking vessel to form a fiberized pulp; removing lignin from the pulp or oxidizing lignin in the pulp by injecting oxygen (O 2 ) into the fiberized pulp, and washing the fiberized pulp to form the pulp. The cooking liquor may include at least one of a soda, caustic or green cooking liquor. Further, the cooking liquor may include one or more of soda (NaOH), soda ash (Na 2 CO 3 ) and sodium sulfide (Na 2 S).
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a flow diagram of a method to manufacture pulp.
[0009] FIG. 2 is a table of Pulp Physical Properties resulting from various pulping processes.
DETAILED DESCRIPTION OF THE INVENTION
[0010] FIG. 1 is a flow diagram of a method 10 to manufacture pulp. The new method comprises soda or soda ash (or both) cooking followed by multistage delignification, for manufacturing corrugated medium from wood chips.
[0011] Wood chips 12 (or other comminuted cellulosic fibrous material—collectively referred to as “chips”) may be a mixed-blend of wood from various species of hardwood, deciduous trees including, but not limited to, ash, aspen, beech, basswood, birch, black cherry, black walnut, butternut, buckeye, chestnut, cottonwood, dogwood, elm, eucalyptus, gmelina, hackberry, hickory, holly, locust, magnolia, maple, oak, poplar, red alder, redbud, royal paulownia, sassafras, sweetgum, sycamore, tupelo, willow, yellow-poplar, and combinations thereof. The wood chips may also comprise wood from various varieties within the species of trees. It is contemplated that other species of hardwood, deciduous trees may be used. It is also contemplated that a single species of hardwood, deciduous trees may be used. Bagasse, straw, kenaf, hemp, and combinations thereof may also be used to form the chips. It is contemplated that the chips may include wood from hardwood, deciduous trees in combination with non-wood fibers including those discussed above. The chips may be supplied from a wood yard or a wood room in a pulping mill.
[0012] The chips are fed using a conventional chip feed system 14 to a cooking vessel 16 , such as a batch digester, a continuous digester, and a Pandia type digester. The chip feed system 14 may add steam 18 and liquor 15 , e.g., water, to the chips being transported through the chip feed system to the cooking vessel.
[0013] The chips are treated in cooking vessel 16 with, for example, regular soda ash (Na 2 CO 3 ) which is added in amount approximately 10% of the bone dry weight (bdw) of the chips added to the vessel 16 . The regular soda ash is added from a liquor supply 20 that injects the soda ash, with the cooking liquor, into the vessel of the cooking system 16 or into the chip feed system 14 upstream of the vessel.
[0014] The chips and cooking liquor are heated in the vessel 16 , such as with steam 18 injected to the vessel to a temperature in a range of 330 degrees (deg.) Fahrenheit (F.) to 380 deg. F., or in a range 360 deg. F. to 370 F. The chips are retained in the vessel for a period such as two (2) to fifteen (15) minutes, or 4 to 10 minutes. The chips are mechanically fiberized in a chip fiberizing vessel 17 , such as defiberator or refiner vessel, to a shines content of, for example, 10% to 50%, or 30% to 45%.
[0015] The fiberized chips are discharged from the fiberizing vessel 17 and directed to one or more stages 22 of delignification, such as a continuous or batch chemical reactor(s) 24 . The delignification stages may remove or oxidize the lignin in the fiberized chips using oxidizing agents 26 such as one or more of oxygen, hydrogen peroxide and ozone.
[0016] The fiberized chips from the vessel 17 may be optionally washed 25 using a wash liquid, e.g., water, before entering the delignification stage(s) 22 and washed between each of the individual delignification stages 24 . FIG. 1 shows by the branch “or” in the flow path that the washing or pressing stages 25 are optional, and may precede the delignification stage(s) 22 and be between the individual delignification stages 24 . In particular, FIG. 1 shows alternative flow paths branching at the “or”. The delignification stages 22 may be the same in both braches of the flow path. In particular, each of the delignification stages 22 may add one or more of oxygen (O 2 ) 26 , steam 18 and alkaline solutions 23 to one or more of the individual delignification stages 24 .
[0017] Each of the delignification stages(s) 24 may treat the fiberized chips with oxygen (O 2 ) and maintain the chips at a temperature of, for example, 120 deg. F. to 300 deg. F. or 200 deg. F. to 230 deg. F. These stage(s) 24 may maintain the chips under pressures of 60 pounds per square inch (psig) to 110 psig for a period of 5 to 120 minutes or 20 minutes to 40 minutes at 5% to 45% (or even 10% to 30%) consistency of pulp to liquor.
[0018] The fiberized chips 17 may have a shives content of 35% to 45% after treatment with oxygen (O 2 ) 26 in the delignification stage(s) 22 . The pH level in each of the delignification stages 24 may be alkaline pH. The target pH of the chips being discharged from the delignification stages may be in a range of 7 pH to 12 pH or 8 pH to 10 pH. Downstream of the delignification stages 22 , the oxygen delignified pulp, which may have a shives content of 35% to 45%, is washed 28 and refined 30 before entering a paper machine 32 that forms the pulp into corrugated paper or other corrugated medium.
[0019] Preliminary results have been obtained using the pulping process described above. These results are shown in the table of FIG. 2 . The results indicate a significant improvement in pulp quality using the novel SC pulping process described above. Major physical pulp properties such as Ring Crush, CMT, Mullen, Tensile, and Tear strength were improved by 25% to 40% as compared to standard one stage carbonate pulp for final pulp yields of 75% to 80%. There is a strong correlation between pulp quality improvement and the final yield as well as pulp consistency and degree of pulp washing prior oxygen treatment.
[0020] The oxygen delignification process is described above in the context of a soda, caustic or green (soda/caustic/green) liquor cooking process. This oxygen delignification process is not limited to soda/caustic/green cooking. The oxygen delignification described above may also be applied to all other cooking processes to produce pulp, such as for a corrugated medium.
[0021] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A method to make pulp adapted for forming a corrugated medium, the method includes: cooking chips in a cooking vessel using a caustic carbonated pulping soda/caustic (SC) cooking liquor injected into the cooking vessel; fiberizing the chips discharged from the cooking vessel to form a pulp, and removing lignin from the pulp or oxidizing lignin in the pulp by injecting oxygen (O 2 ) into the fiberized pulp. | 3 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a Divisional Application of currently pending U.S. patent application Ser. No. 11/688,893 filed Mar. 21, 2007, entitled: “ELECTRICAL SIGNATURE ANALYSIS TO QUANTIFY HUMAN AND ANIMAL PERFORMANCE ON FITNESS AND THERAPY EQUIPMENT SUCH AS A TREADMILL.”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
This invention was made with United States Government support under Contract No. DE-AC05-00OR22725 between the United States Department of Energy and U.T. Battelle, LLC. The United States Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
Gait analysis usually involves the measurement and interpretation of sequential events that occur in the gait cycle. The gait cycle includes all of the events occurring from one heel strike to the repeated heel strike of the same foot. Essential gait measurement parameters include space, time, and compressive forces. These measurements must be accurate, reproducible and related in time to be of value. Additional value results from real time data analysis to allow training for gait style modification, or adjustments of gait devices like shoes or braces.
Various types and methods of gait analysis exist today ranging from measured distances and a stopwatch to computerized 3-D video gait analysis systems. The cost, utility and efficacy of each system may limit their application in various settings. The Electrical Signature Analysis (ESA) system described herein provides a highly objective, comprehensive gait performance analysis.
BRIEF SUMMARY OF THE INVENTION
The invention is a human and animal performance data acquisition, analysis, and diagnostic system for fitness and therapy devices having an interface box removably disposed on incoming power wiring to a fitness and therapy device, at least one current transducer removably disposed on said interface box for sensing current signals to said fitness and therapy device, and a means for analyzing, displaying, and reporting said current signals to determine human and animal performance on said device using measurable parameters.
One unique and valuable aspect of the ESA system is its simple and direct ability to measure many of the fundamental characteristics of gait patterns using a standard treadmill. ESA requires no restrictive or sophisticated instrumentation and poses no risk to subjects other than walking on the treadmill at comfortable speeds. The system has an excellent market potential for demonstrating gait aberrations in rehabilitation settings, sports performance for coaches and athletes, and gait enhancements for footwear manufacturers.
ESA can be used to monitor physical condition and performance of human and animals. ESA has long been used as a tool for monitoring the condition and performance of pumps, valves and other electromechanical machinery, but has never been applied as a tool for analyzing human and animal condition and quantifying performance.
To further investigate this concept, electric voltage and current signals were recorded from an AC-powered treadmill as a person walked on the treadmill normally and in several irregular ways that simulated various physical impairments. The variations in walking styles produced many noticeable changes in the treadmill's electrical signatures, and demonstrated this new approach for sensing and measuring variations in human and animal physical condition. These results can serve as a foundation for further development of ESA-based methods and ultimately lead to the creation of new tools for measuring the physical rehabilitation progress of people recovering from injuries and surgeries that alter flexibility, mobility, strength, and balance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the general method of electrical signature analysis.
FIG. 2 is a photograph of the electrical interface box to a treadmill power source.
FIG. 3 is a schematic of a treadmill embodiment having a simplified interface box and a computer means for analyzing, displaying, and reporting the current signals.
FIG. 4 is a schematic of a treadmill embodiment having a simplified interface box and an integrated treadmill means for analyzing, displaying, and reporting the current signals.
FIG. 5 is a schematic of the treadmill test setup.
FIG. 6 is a graphical output of the voltage (top) and current (bottom) signals while a person is walking on a treadmill.
FIGS. 7A-7D are sample computer screens from the treadmill ESA software.
FIG. 8 is a graph showing the raw current waveform (top), full-wave rectified waveform with peaks identified (middle), and stride profile waveform constructed from rectified peaks (bottom).
FIG. 9 is a graph showing the average stride profile for a user walking with a normal gait.
FIG. 10 is a sample output of measurable parameters from the “A” (right) and “B” (left) stride profiles.
FIG. 11 is a graph showing the effect of added weight on an average left stride profile.
FIG. 12 is a graph showing the effect of added weight on an average right stride profile.
FIG. 13 is a graph showing the effect of a taped right ankle on the average stride profiles.
FIG. 14 is a graph showing the effect of an immobilized right leg on the average stride profiles.
DETAILED DESCRIPTION OF THE INVENTION
This invention is a device and method for detecting and monitoring physical condition and performance of humans and animals. It exploits the treadmill's and other electromechanical device's electric motor as a transducer for sensing load variations caused by a person or animal walking on the treadmill, and is a variation of Electrical Signature Analysis (ESA) technologies that were initially developed for assessing the condition of electromechanical machinery.
Treadmill electric voltage and current signals were recorded as a person walked on the treadmill normally and in several irregular ways that simulated various physical impairments. Using current and voltage measurements enables a calculation of power which can be used as an additional analysis parameter. The variations in walking styles produced many noticeable changes in the treadmill's electrical signatures, thus demonstrating the sensitivity needed to perform human and animal gait analysis.
With further development, ESA-based instrumentation can be developed and combined with conventional treadmills and other electrically-powered health equipment to provide new inexpensive tools for monitoring and quantifying the physical rehabilitation progress of people recovering from injuries and surgeries that have affected their gait, flexibility, mobility, strength, and balance. Other than clinical settings, applications of the invention include biomechanics sports conditioning and rehabilitation, direct results measurement for reporting progress and billing support to medical insurance companies, racehorse training and rehabilitation, athletic shoe and orthotic design, and prosthetic research and design.
Gait analysis is essential in physical medicine and is a fundamental tool of the orthopedist, physical therapist, and orthotist/prosthetist. The ability to assess and correct inefficient or dysfunctional gait patterns is fundamental to sound clinical practice. Gait aberrations can result from pain, neurological disorders, and musculoskeletal impairments and can lead to premature joint wear, myotendinous pain and functional disability. Long term, gait disorders may result in permanent disability, loss of balance, loss of independence, and increased fall potential.
ESA gives clinicians a new analysis tool that can be used independently or with other gait analysis techniques to increase accuracy and objectivity of gait analysis. The physical therapist may use this technology to enhance gait efficiency and balance with a large variety of cases in geriatric populations, post-fracture or post-surgical cases, injured athletes, and general sprains or strains. The orthotist may use this technology to study the effects of various braces and orthoses. The prosthetist could study gait efficiency and use this technology to modify prosthesis to enhance the desired gait characteristics.
Beyond the realm of rehabilitation, ESA may prove to be very useful with analysis of athletic performance, particularly with runners. One could establish characteristic ‘signatures’ of elite runners with the ESA process and compare them with other developing runners. The developing athlete can learn to model, and then feel the differences with more efficient running motions using the ESA process. Coaches could use the process to train young runners and to analyze workouts in real time.
Athletic foot wear manufacturers may use the ESA process to study the effect of various shoe modifications with running performance, motion control for stability, and force attenuation. The ESA process could provide objective data for sport specific foot wear related to athletic performance.
The ESA technology was originally invented and developed as a tool for assessing the condition of a wide variety of military, industrial, and consumer electromechanical equipment. ESA can be used to detect equipment defects and degradation, and unwanted changes in process conditions. ESA is truly non-intrusive and does not interfere with the operation of the equipment being monitored.
FIG. 1 illustrates the general ESA method. Load and speed variations in electromechanical systems generally produce correlated variations in current and voltage. ESA analyzes these small perturbations and matches them to their source. The resulting time and frequency signatures reflect loads, stresses, and wear throughout the system and provide the basis for assessing the operational condition of the monitored equipment.
Many machines and electrical appliances have been designed to directly interact with human and animals. The manner in which the human and animal uses the appliance determines how hard the appliance must work, and how much electrical energy is required. For example, if a power saw is not used correctly, additional friction and binding can occur between the saw blade and the material being cut. This results in the saw motor having to work harder; which causes it to draw more current. When used correctly, the motor does not have to work as hard, and the electric current is lower. Thus, by measuring the magnitude of the electric current used by the saw, the manner in which the saw is being used is also measured.
Other examples of machines whose operations are affected by how they are used include treadmills, exercise bikes, elliptical machines, and other fitness equipment used in gyms and physical therapy centers. While these machines have been designed to promote physical fitness, their designs are inherently sensitive to the physical attributes, health, and abilities of the user. Like the saw example, it is believed that by obtaining the electrical signatures of these exercise devices as they are being used, certain signature features will be present that are indicative of the physical condition and abilities of the user. After identifying and correlating these features, they can be used to track improvement or degradation in the user's physical condition over time.
FIG. 3 is a schematic of a treadmill embodiment having a simplified interface box and a computer means for analyzing, displaying, and reporting the current signals. The simplified interface box 39 includes a current transducer for obtaining current signals.
FIG. 4 is a schematic of a treadmill embodiment having a simplified interface box and an integrated treadmill means for analyzing, displaying, and reporting the current signals. The simplified interface box 39 includes a current transducer for obtaining current signals and the data is displayed on the treadmill stand itself. Other anticipated embodiments include a fully integrated treadmill wherein all components of the invention are built into the treadmill.
In the test setup of FIG. 5 , treadmill electrical signals were obtained using an electrical interface box 31 that was plugged into the treadmill 30 and then into a 120 V wall outlet. The interface box 31 contains an external loop 32 for accessing the treadmill electric current using a standard clamp-on current transducer 33 . The interface box 31 also provides access to the full line voltage used by the treadmill 30 . A 20:1 splitter 34 was then used to reduce the voltage levels so that they could be safely recorded on a data recorder 35 . This interface box 31 makes it possible to easily and safely acquire electrical signals from any electrically powered exercise device such as a treadmill, an exercise bicycle, or an elliptical trainer.
FIG. 5 illustrates the general test setup. Electrical signals were obtained with a digital data recorder 35 and subsequently analyzed using a computer 36 and software that was specially developed for this application. Treadmill data were acquired under a variety of conditions. Table 1 summarizes the test conditions and walking styles that were recorded.
TABLE 1
Treadmill
Treadmill
Speed
Incline
Date
(mph)
(%)
Walking Style
Nov. 17, 2005
4
0
Normal walking
Nov. 17, 2005
4
5
Normal walking
Nov. 17, 2005
4
10
Normal walking
Nov. 22, 2005
3
0
Normal walking
Nov. 22, 2005
3
0
Walking, but with extended strides
Nov. 22, 2005
3
0
Walking normal, but using the rails for support
Nov. 22, 2005
3
0
Walking with a scissor gait
Nov. 22, 2005
3
0
Walking with a sore toe
Nov. 22, 2005
3
0
Walking with a stiff knee
Nov. 22, 2005
3
0
Walking normally, but pointing toes out
Nov. 22, 2005
3
0
Walking on toes only
Nov. 22, 2005
4
0
Normal walking
Nov. 22, 2005
5
0
Normal walking
Nov. 22, 2005
5
0
Running
Dec. 2, 2005
3
0
Normal walking with running shoes
Dec. 2, 2005
3
0
Normal walking with no shoes
Dec. 2, 2005
3
0
Normal walking with street shoes
Dec. 2, 2005
3
0
Normal walking with taped ankle
Dec. 2, 2005
3
0
Normal walking with taped ankle and toes
Dec. 2, 2005
3
0
Normal walking with taped ankle and toes, and
immobilized leg
Dec. 2, 2005
3
0
Normal walking with taped ankle and toes, and
restricted (taped) knee
Dec. 2, 2005
3
0
Normal walking with restricted (taped) knee only
Dec. 2, 2005
3
0
Normal walking while carrying 30 lbs of extra weight
Treadmill voltage and current signals were recorded for all tests. To minimize variables, the same treadmill was used for all tests, and the same person served as the test subject for all tests. Several of these tests are further described later.
The recorded voltage and current signals were initially played back and examined using Adobe Audition, a commercially-available software package designed to record, edit, and play audio signals. As shown in FIG. 6 , walking on the treadmill produced very little impact on the magnitude of the voltage signals, but produced dramatic variations in the magnitude of the electric current. For this reason, all additional analysis efforts focused on the current signals.
To analyze the electric current signals in more detail, a data analysis “virtual instrument” was developed using LabVIEW, a graphical data acquisition and analysis platform. The software controls and displays evolved as methods were identified to extract useful details (signatures) from the electric current data. Presently, the software is designed to apply a variety of ESA-based methods on treadmill electric current data that has been saved in the popular Windows sound file (WAV) format.
FIGS. 7A-7D illustrate sample screen information from the software, and shows (in the upper left corner of the screen) various controls that provide the ability to input the treadmill speed (in miles-per-hour) and a range within which the users stride falls. For the example, the data shown is taken from a test when the treadmill was operating at 3.0 miles per hour. The stride range of the user is selected to be between 15 and 45 inches.
The software provides a tool for converting the “raw” electric current data into a revealing stride profile by first full-wave rectifying the current signal, and then using the rectified peaks to build the stride profile waveform. FIG. 8 illustrates this process where the software begins with “raw” data (top graph). After full-wave rectifying, the envelope peaks are automatically identified (middle graph) and used to construct the stride profile (bottom graph). This example shows the normal left-right stride signature of the user. The software then performs a frequency-analysis of the stride waveforms and calculates the overall stride frequency (in steps per second). The individual stride waveforms are then separated into two groups representing the left and right strides.
In order to identify which group is associated with which leg, the user consistently stepped on the treadmill first using his right foot. As this ESA-based system is further developed, a more positive method of identifying right from left is needed. One method of accomplishing this is to have the user wear a sensor on one leg that is preferably more sensitive only to one stride (e.g., their right) and transmit a signal to the data acquisition computer with each right step via a wireless link. The computer can then use this reference signal to positively identify the right stride waveform data from the left. Instruments such as foot switches are available which would positively identify left and right feet.
The load on the treadmill (and hence the current drawn by the treadmills motor) is sensitive to several factors, such as the weight of the user, the surface area of the belt that is in contact with the user, and the frictional losses between the treadmill mechanical surfaces. The software calculates an average stride profile, based on analyzing numerous stride waveforms and after accounting for the slight differences in the stride-to-stride durations in each leg. This averaging process is intended to “average out” the effects of the treadmill itself, since the user contacts a different section of the treadmill belt with each step. The average stride profiles are thus believed to be predominantly influenced by the gait of the user, and thus provide a suitable and sensitive signature for performing gait analysis.
Typical average stride profiles are shown in FIG. 9 for the user walking in a normal gait. As can be seen in the FIG. 9 , differences exist between the right and left stride profile of the user. For example, the average left stride is characterized by a larger overall magnitude (thus indicating a larger load to the treadmill) and is about 5 percent longer in duration than the average right stride. The specific causes for the profile differences are not presently completely understood; however, they are repeatable and thus are believed to reflect user-specific conditions.
To better quantify the differences, the software also measures a variety of parameters that are present in the stride profiles. These parameter measurements are shown in FIG. 10 . Several of these parameters were judged to be very sensitive indicators of gait anomalies such as stride profile, average stride profile, average cycle fraction difference, stride length unbalance, estimated weight unbalance, difference in max location, and difference in slope max location.
Average stride profiles are provided to illustrate the ability of ESA methods to characterize gait variations. The following “abnormal” conditions are presented; normal walking with additional weight, normal walking with taped right ankle, and taped right ankle and toes plus immobilized right leg.
FIGS. 11 and 12 show the effect of the user carrying an additional 30 lbs while walking on the treadmill. When carrying the additional weight, the magnitudes associated with the right stride increased an average of 12.1 percent, and was relatively consistent throughout the entire stride. Similarly, the left side magnitudes increased an average of 11.0 percent. Since both right and left strides were affected approximately the same, the “balance” between the right and left strides was undisturbed.
A test was performed after taping the user's right ankle. This removed the normal flexibility normally associated with the foot. When walking with a taped ankle, the balance between the two strides is significantly disturbed and is dramatically seen in the average stride profiles shown in FIG. 13 . The right profile duration is noticeable shortened, and its magnitudes during the majority of the stride are significantly decreased. In contrast, the duration of the left profile increased, along with an increase in magnitudes throughout most of the stride. Thus, what is seen is a “spreading” of the two profiles as they move in opposite directions. This unbalance between the two strides is indicative of the differences in left and right strides, caused by the restricted movement of the right foot.
A test was performed with several concurrent restrictions: the user's right toes and ankle were taped to prevent motion, and their right leg was immobilized by taping their knee. In this condition, the user walked on the treadmill, thus producing the average stride profiles shown in FIG. 14 . The addition of the taped toes and immobilized leg to the already taped ankle further accentuated the unbalance between the two strides, as shown by the increased spreading between the left and right profiles. In this extreme case, the user spent only 42 percent of the time on their right foot, and 58 percent of the time on their left foot. The differences between the profile magnitudes were substantial. One method of quantifying the profile magnitudes is by measuring the average profile magnitudes and subtracting the minimum magnitude. In this manner, the average increase in treadmill running load associated with each stride is measured.
For the immobile leg case, the average profile magnitude minus the profile minimum for the compensating leg was 6525, which is almost double the magnitude of the right immobilized leg, which was 3344. This measure, along with the change in stride duration, and other measurable parameters are all indicative of the severe unbalance between the two strides, due to the imposed restrictions.
The average stride profiles that have been illustrated are only one way of visualizing and quantifying the treadmills electrical signature changes resulting from a person walking on it. The profiles themselves have many measurable characteristics that should correlate with known gait patterns.
Initial treadmill ESA tests were performed using a test subject who walked in various ways to simulate several foot and leg problems, including a “sore toe” and a “stiff knee.” The ‘sore-toe’ and ‘stiff knee’ gaits represent common clinical gait patterns seen in rehabilitation. The sore-toe or antalgic gait is often seen in cases with pain problems related to the toes, foot or ankle. Examples might include a sprained ankle, bunion, turf toe, osteoarthritis, fracture, or other foot injury. Gait aberrations would be seen throughout the weight-bearing phase of the gait cycle from heel strike, through early, mid and late stance, as well as toe-off. The characteristic pattern is limited compressive loading, apropulsive toe-off, reduced stance time and reduced step and stride length on the affected side.
The ‘stiff knee’ gait would represent an individual who may have had surgery on the knee, wears a knee brace or immobilizer, has osteoarthritis of the hip or knee, or is post fracture and in a cast for immobilization. The characteristic gait abnormalities with the stiff knee are seen from mid-stance to toe-off and through the swing phase. These include reduced step and stride length, reduced swing time, circumduction of the hip to clear the foot, and limited toe-off and propulsion. The immobile extremity would have to be carried forward, which increases loads on the hip and the low back.
Normal gait can be divided into a stance phase, which takes roughly 60% of cycle time, and a swing phase, which takes 40% of the cycle time. Different gait abnormalities affect these phases of the gait pattern differently. The sore toe will want to minimize the time in compressive loading to protect the injured foot, where the stiff knee must be carried forward rather than being propelled forward. The resulting gait aberrations might reflect in the temporal, spatial and compressive measurements of the gait. The ESA process is sensitive to these gait patterns as well as being capable of identifying differences between normal left and right strides.
While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the scope. | The invention is a human and animal performance data acquisition, analysis, and diagnostic system for fitness and therapy devices having an interface box removably disposed on incoming power wiring to a fitness and therapy device, at least one current transducer removably disposed on said interface box for sensing current signals to said fitness and therapy device, and a means for analyzing, displaying, and reporting said current signals to determine human and animal performance on said device using measurable parameters. | 0 |
FIELD OF THE INVENTION
This application relates to asynchronous modems used in data communication systems in general and particularly to designs for such modems which are based upon microprocessor control of the modem's functions.
BACKGROUND PRIOR ART
Modems themselves are, of course, widely known and used to facilitate the transmission of digital signals over analog telephone lines by modulating the digital signals onto an analog signal at the transmitter and demodulating the received signal and decoding the appropriate digital significance at the receiver. The name "modem" is thus an abbreviation for the modulation-demodulation process carried out by a pair of modems communicating over an analog transmission line.
As is also well known, modems operate in pairs and may operate with synchronous or asynchronous DTEs. Synchronous modems generally are reserved for higher speeds and operate with block or periodic error checking protocols for detecting erroneous reception of transmitted characters or digital data. Asynchronous modems, in contrast, are often operated in the "echo back" mode of operation in which the receiving modem's attached data terminal equipment will transmit back over the line a received character to indicate to the transmitter what character has been received and that it has been received. While this mode of operation is inefficient, it is simple and is widely employed or even required as a discipline in various data terminal equipment (DTE) manufacturer's devices.
As modem designs have progressed over the years, wide-spread use has occurred of microprocessor-based logic and filtering mechanisms that employ algorithms instead of physical analog circuits. Such modem designs have appeared in numerous patents. For example, U.S. Pat. No. 4,549,302 shows the typical design of one such modem utilizing a microprocessor, onboard RAM, addressable registers for interfacing to various circuits and functions and a full complement of filtering, tuning and conversion operations for handling the signals coming to or for transmitting signals from the modem to the communication line over the RS232 interface or port to the attached data terminal equipment (DTE).
In fact, the modems have progressed to the point that they may receive and act upon commands directed to them by the DTE. In order to obtain a response from the modem it has been generally required that the modem receive an inband signal in the form of a special header or escape sequence which alerts the modem to the fact that any following characters or commands are intended for it instead of for transmission on the communication line. Indeed, the aforementioned U.S. Pat. No. 4,549,302 is itself directed to a method of correctly recognizing an escape sequence of characters and distinguishing such a sequence from the random occurrence of a sequence of similar appearance that might occur in the data stream. In general, the modem monitors for the occurrence of escape characters in a sequence which includes some periods of time in which no characters are received, i.e. a pause, followed by the receipt of characters which may or may not be followed by another pause. The presence of the pauses distinguishes an intentional occurrence of an escape sequence of characters from an unintentional or randomly occurring one embedded in a stream of data.
However, in an asynchronous modem system, there does exist a significant problem where the sending and receiving DTE's echo received characters for error detection back to their transmitting partner in order to signal reception of a previous character and to indicate what character was understood to be received. This echoing of characters can cause a unique lockup problem to occur in asynchronous modems. Assume that an escape sequence is being transmitted by a first DTE through a modem attached to it in order for the DTE to gain control over the modem's functions. The modem will receive the first character, examine it, determine that it is potentially an escape sequence character and transmit it. It will be received at the remote modem, demodulated, passed over the RS232 interface to the attached DTE and echoed back through the receiving modem to be retransmitted. Of course, the remote modem receiving such a character from its attached DTE will begin to examine the characters that follow to see if an escape sequence is intended. The net result of this form of operation is that, in echo back mode, the remote asynchronous modem will see the same sequence of one or more escape characters and pauses seen by the attached local modem from the DTE which is actually trying to control only the local modem. The echo back feature from the remote DTE to its attached modem will cause the remote modem to enter into the "escaped" mode, awaiting receipt of commands from its DTE. However, the remote DTE does not intend to command or control its modem in this scenario, and the remote modem remains locked to incoming or outgoing data transmission while it patiently awaits commands over its RS232 interface.
OBJECTS OF THE INVENTION
In view of the foregoing known difficulties with asynchronous, echo mode modem systems, it is an object of this invention to provide an improved control method and apparatus that prevent the lockup problem from occurring.
SUMMARY
The foregoing and still other objects not specifically enumerated, are met in the preferred embodiment of the invention. Such an embodiment is described herein by implementing in the transmit logic and buffer section for each modem additional logic or software processes executed by the microprocessor. This additional logic will detect the fact that an escape sequence is being received from an attached DTE and will block the transmission on its outgoing line to the communication system of one or more of the escape sequence characters. This prevents the remote receiving modem and its DTE from entering into an escaped mode waiting for commands. Verification logic is included in each of these improved modems to assure that a true escape sequence has been received. Briefly, each character arriving from a DTE is checked by the modem to determine if it is an escape character. If it is not an escape character it is merely transmitted to the telephone line in the normal manner. However, if an escape character is received, and if the validating conditions such as the preliminary pause of sufficient time which identifies the onset of an escape sequence has been detected and if a sufficient number of the escape characters has been detected and counted, the final such character received will be held in a register and discarded when the escape mode is entered. This character will thus not be transmitted to the remote modem. Thus, detection of the receipt of an escape sequence character is utilized to block transmission of the character to the remote modem in the broadest sense of the invention.
BRIEF DESCRIPTION OF DRAWING
The invention will further be described with reference to a preferred embodiment thereof which is further illustrated and explained with reference to the drawing in which:
FIG. 1 illustrates schematically a typical modem-based data communication link between a local DTE and a remote DTE over a telecommunication line.
FIG. 2 illustrates the typical escape sequence detection apparatus and method employed in the prior art modems which give rise to the asynchronous echo mode lockup problem.
FIG. 3 illustrates a preferred embodiment of the present invention with the additional logic and process functions necessary to alleviate the lockup problem included.
FIG. 4 illustrates in greater detail the process steps to be carried out in the preferred embodiment in order to effectively prevent the lockup problem.
DESCRIPTION OF PREFERRED EMBODIMENT
Turning to FIG. 1, a typical telecommunications link between two DTE's 1 and 2 over a telephone line 5 is facilitated by modems 3 and 4. Each modem includes a transmission buffer 6 or 7 as shown, a microprocessor, random access memory (RAM) and various registers, filters, switches and conversion devices for receiving digital characters from its attached DTE 1 or 2, converting them into an analog modulated form and placing the result on the telecommunications line 5 or, conversely, receiving analog information from the telecommunications line 5, demodulating and decoding the signal and presenting digital signals over the RS232 interface to the attached DTE 1 or 2.
All of the various details of such a modem are well known to those of skill in the art and reference may be had to U.S. Pat. No. 4,549,302 which shows a specific example of such a modem architecture including the modifications referred to earlier for detecting a valid escape sequence by instituting a mechanism and logic for detecting not only the valid escape characters but validation pauses which may be bracketed around the characters in the transmission sequence. None of this will be described in full detail inasmuch as it is a part of the prior art and does not form a specific part of the present invention.
FIG. 2, however, is added to fully explain the difficulty that is encountered in the prior art with typical, asynchronous mode echo back operation utilizing modems of the sort known in the prior art.
In FIG. 2 the DTE 1 presents information to the modem, typically over the international standard EIA232 digital interface. Modem 3 is shown within the dotted box, in FIG. 2, but only those portions which are necessary for detecting and validating the reception of an escape sequence are shown, all other physical and operational functional elements being eliminated for sake of clarity.
In FIG. 2, the processes conducted at the modem 3 which receives an escape sequence of characters arriving from its attached DTE 1 are shown. These processes logically examine the data flow and are conducted in the microprocessor in the preferred embodiment. The logic flow and functions to be performed are described in detail in FIG. 2.
In box 8, the modem awaits arrival of a character from the DTE 1 and checks for whether the elapsed time interval between the receipt of the most recent character and that which preceded it is greater than or equal to a predefined pause time. It is the pause time which validates the fact that an escape sequence is being transmitted by the DTE 1. When a character arrives, its arrival is noted in block 9 and the character is compared on block 11 against stored codes to identify it as an escape character. If the character is not an escape character, it is simply transmitted as shown by block 12 over the telephone line 5 in a continuation of the "data mode" of operation. This normal mode is to be contrasted with the control or "escaped" mode of operation. This is shown by the linkage between the output of block 11 which is connected to blocks 20 and 17.
Another output from block 8 is the elapsed time indication. Whenever an internal timer (shown later) within block 8 detects that the elapsed time between the receipt of a character and the next most recently received character is greater than or equal to a predefined pause time used to validate escape sequences, a signal is generated. A positive indication on the signal output from block 8 is fed to a comparison block 10 which determines whether the content of a counter 17 has been incremented to a value of three in this example, where three is the number of occurrences of an escape character that are required in order to have a valid escape sequence. It will be noted that if the counter value equals 3 in block 10, the yes output goes to block 19 to stop transmission by the modem and enter into the escape mode of operation in which the modem awaits a command. However, the character which was received will have already been transmitted over the telecommunications line as will be seen shortly.
Assuming that an escape character, for example the first escape character to be identified, is found in block 11, a comparison is made in block 13 to determine if the contents of the counter is equal to 0. Presuming this is the first escape character, the contents of the counter 1 in block 17 will be 0. Thus a positive output will be provided to block 14 which checks for whether the elapsed time since the receipt of the previous character is less than the appropriate pause time, i.e. a check is made to determine if this would merely represent the occurrence in a data stream of an escape sequence character since an appropriate pause has not been received. If the "yes" output is provided, the character is transmitted as shown in block 15 and data mode is continued as shown by the connection over line 22 to block 20 and its connection over line 21 back to block 8. However, if the result of the test in block 14 is negative, i.e. the pause time may have been reached, the character is still transmitted as shown by the connection of the " no" output in block 15. However, by block 16, the counter 1 in block 17 is caused to be incremented by one and a pause flag (in another figure) is set to "no" as indicated in block 16 in FIG. 2. The counter is not reset to 0 by block 18 unless the result of the pause time comparison is positive and the contents of the counter are not equal to 3. This eliminates the potential erroneous detection of an escape sequence when the pause between escape sequence characters is greater than or equal to the pause time that is supposed to precede the first escape character and follow the last escape character. Counter 1 is reset thusly if either no escape character is detected or, if even though an escape character is detected, the period of time following the receipt of the escape character and the next escape character is also greater than the pause time, which would constitute an invalid escape sequence.
A valid escape sequence will result in the escape character being detected three times in sequence in block 11 and counter 1 in block 17 being incremented to a count of 3 and supplied to block 10 where, when the pause time following the third or last escape character is found to be met, a true output will be reached from block 10 and transmission will be stopped in block 19. This will not, however, be before the final escape character was transmitted as the result of the checks made in block 14 and block 15. Thus, when a valid escape sequence is received by a modem 3, it will transmit the characters on the communication line 5 and will eventually, in echo back mode, result in the modem 4 at the remote end receiving from its attached DTE2 the echoed back escape sequence. This will trigger modem 4 into going into the escape mode to await control commands which will, of course, not be forthcoming. The lockup condition will thus exist for which the only remedy is to call up a remote terminal operator on another telephone line and direct the resetting of the remote modem 4. This is both cumbersome and, as will be apparent, inconvenient and time-consuming.
Turning to FIG. 3, a preferred embodiment of the present invention is illustrated. Like numerals are utilized for similar boxes and functions to those shown in FIG. 2. It will be noted that block 12 causes the transmission received and of any character that has been held previously. This refers to the new block 26 and the new comparison in block 25 which have been implemented in the preferred embodiment. The flow of operations is nearly the same as that with FIG. 2; however, a significant difference exists.
In FIG. 3, an inquiry is made at the output of block 16 which was not made in FIG. 2. Namely, the content of the counter 1 in block 17 is checked for whether it is equal to 3 or not. If it is, a valid escape sequence has been detected and the final character is held in a register 26 and not sent to block 15 for transmission on the telephone line. This prevents the transmission of the final character in the escape sequence once the escape sequence has been detected as a valid escape sequence and prevents the problem with causing the remote modem 4 to go into lockup or escape mode as noted previously. Block 19 in FIG. 3 is also modified since, when a valid escape sequence is detected, transmission is stopped and escape mode is entered as before but the character held in the register 26 is also discarded. Remaining features and operation of the circuitry and processes shown in FIG. 3 remain logically the same as in FIG. 2.
FIG. 4 illustrates in greater detail some of the elements that are contained in block 8 in FIGS. 2 and 3 together with additional logical processes of the preferred embodiment utilized to implement the control as shown in FIG. 3.
The DTE1 provides its output over the RS232 interface to the input of a modem where a timer value is read in block 27. The timer 28 is driven by an oscillator 29 and is a freerunning counter, for example, of the sort that is usually used in clocking functions and is shown in the noted prior art. The output of the timer value in block 27 is added to a prescribed pause value in block 30 to compute the time that will be required to identify the onset or end of an escape sequence. This value is stored as the "pause time" value in the pause time register 31. The timer value from block 27 is also compared with the content of the pause time register 31 to determine if the present timer value is greater than or equal to the pause time. If the answer is "yes", a flag register 34, typically a 1-bit register or 1-bit in dedicated memory, is set to a "yes" condition as shown in block 34. If the timer value is not yet equal to the pause time, the negative output is applied to block 35 which, if a new character has arrived, causes reinitializing of the timer by the process step in block 38 and the connection from its output over line 43 to the timer 28. The process continues by going to the character arrival block in FIG. 3 as shown by block 39. If no new character has arrived, the output of block 35 returns to the comparison block 32 and data mode continues. If the output of the comparison in block 32 is "yes", a comparison in block 34 is made to determine if the pause flag register 33 is set to a "yes" condition. If it is, and a new character has arrived as shown in block 36, the timer is reinitialized by the output of block 41 over line 43 and operation continues at the "new character arrives" block in FIG. 3 as shown. However, if the pause flag is not set to a "yes" condition, it will be set to the "yes" condition in block 37 and processes continue as shown in block 46 by going back to the pause time comparison in FIG. 3. Also the pause flag register 33 is set to a "yes" condition over line 45 as shown.
It will thus be seen that what is illustrated in FIG. 4 is actually all of the logical processes involved in block 8 as shown in FIGS. 2 and 3, particularly with reference to its cooperation with FIG. 3 for the preferred embodiment.
In the preferred embodiment, all of the process steps may be implemented in microprocessor instruction routines to be handled by the microprocessor within the modem. Normal functions of counting, accumulating, comparing, decision events and energizing of signaling lines are all well known microprocessor functions and may be easily implemented in any given microprocessor when the machine control process instruction set is known. This is easily within the skill of any person in the art having such a device and hence the process steps and functions as shown in the flowcharts of FIGS. 3 and 4 are deemed fully adequate to inform one of ordinary skill in the art how to build an operating example of the preferred embodiment.
As will be obvious to those of skill in the art, the invention may also be easily realized in hardware logic circuits fulfilling the same functions as the flow and logic diagrams in FIGS. 3 and 4, the choice of which form of embodiment is selected being primarily one of convenience and cost. In the current environment, convenience and cost dictate the realization of the preferred embodiment in the form of microcode process routines to be carried out by the microprocessor in the modem.
Having described my invention with reference to the preferred embodiment thereof and having described the best mode contemplated for carrying out the invention, what is desired to be protected by letters patent is set forth in the claims appended hereto by way of example and not by way of limitation. | Lockup in escaped mode for asynchronous paired modems on a communications link utilizing DTE echo back verification protocol is prevented by adding logic to each modem to detect and suppress transmission by the modem to its paired modem of at least one of any escape sequence characters received by a modem from its attached DTE. This prevents the unintentional placement of the paired modem, which would otherwise be transmitting echoed back characters from its DTE, from entering into the escape mode of operation due to what it would recognize as "escape sequence" characters received as "echo back" verification from its DTE. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a method for collecting blood or other fluids from an organ or tissue through a vessel. The method according to the invention is used in the biological, medical and veterinary field for diagnostic and therapeutic purposes and for research purposes to collect blood or other fluids from organs or parts of organs or tissues. In particular, the method according to the invention is used to collect placental blood, that is to say, the blood that is present in the placenta, during childbirth, directly after the birth of the neonate.
In the biological, medical and veterinary fields it is necessary to collect fluids, particularly blood, from organs or tissues or containers in general, both for diagnostic and therapeutic purposes and for research purposes. Two non-limitative examples are: 1. the collection of blood from masses of tumoral tissue, since the blood contained in the tumoral tissue is potentially useful for therapeutic purposes after appropriate treatment; 2. the collection of blood from the placenta during childbirth directly after cutting the umbilical cord. In this second case, the blood is useful since it contains stem cells, which are hematopoietic precursor cells, that is to say, cells which are capable of reconstituting the hematopoietic system and therefore can be used, if the need arises, for transplanting to the same donor or to another compatible recipient.
The procedures currently used to collect placental blood from an umbilical cord are described hereinafter as a typical example of the recovery of fluids from an organ; it is important to note that the reference to this practice is not limitative and is merely an example of situations in which it is necessary to collect blood or another fluid from tissues, organs or other containers in general.
Placental blood from the umbilical cord is collected because it contains hematopoietic stem cells which can be used for transplants. To allow the collected blood and therefore the recovered cells to be truly and successfully usable, the following conditions must be met: 1. the largest possible amount of blood, that is to say, the highest possible number of cells, must be recovered; 2. the collected blood, which is fetal in origin, must not be contaminated by foreign cell populations, such as for example maternal cells; 3. during collection, contact of the blood with the outside (air or other potentially contaminated objects) must be minimized, or the collection procedure must occur in sterile conditions, possibly in a closed environment; 4. the possibility of human error must be minimized.
Steps of Collection
a. Before Expulsion of the Placenta
Blood is currently extracted from the placenta in the medical field, both for diagnostic and therapeutic purposes and for research purposes, as follows: during childbirth, directly after the expulsion of the neonate, the umbilical cord is closed (clamped) in two points and cut in a point which is intermediate between the two closure points. After cutting, the cut end of the umbilical cord which is connected to the placenta protrudes freely from the mother's vagina and is available for collection operations. Typically, blood is collected in the period between the cutting of the umbilical cord and expulsion of the placenta. During this period, the flow of blood is ensured by the pressure generated by uterine contractions, which by compressing the placenta facilitate the outflow of blood through the umbilical cord.
b. After Expulsion of the Placenta
Only a small number of authors reports collection procedures which provide for cord blood collection after expulsion of the placenta by placing the placenta on a frame and collecting the blood by gravity. The limited use of collection after expulsion of the placenta is certainly due to the low yield of collection by gravity and to difficulty in handling the placenta, especially when the sterility of the collected blood must be guaranteed.
Collection Systems
Collection of placental blood from the umbilical cord in the medical field, both for diagnostic and therapeutic purposes and for research purposes, is currently performed with methods which can be traced back to two categories: “open-circuit” systems and “closed-circuit” systems. Both systems are used for collection both before and after expulsion of the placenta.
a. “Open-circuit” Systems
“Open-circuit” systems collect placental blood from the cut umbilical cord in containers which contain anticoagulant. This collection is performed by making the blood flow out directly into the collection container without connecting the end portion of the cord, which is placed loosely at the inlet of the container.
Advantages
The main advantage of this system is the absence of resistances to flow, since there are no bottlenecks or sudden decreases in cross-section of the cord and of its vessels.
A second advantage is that the three vessels which are present in the umbilical cord are simultaneously pervious.
Another advantage of the system is the possibility to express the umbilical cord during collection.
Disadvantages
Various scientific papers have demonstrated that “open-circuit” systems do not ensure sterility and are in fact associated with a particularly high incidence of microbial contaminations. The cut end portion of the umbilical cord in fact has a loose consistency, and since it is simply rested on the inlet of the collecting container it can easily escape from it, consequently contaminating said end portion in addition to losing blood, which contaminates the outside environment.
Furthermore, the system inherently (being an “open” system) collects both the blood that flows out of the vessels of the cord and potentially contaminated liquids which flow along the outer surface of the umbilical cord; in particular, the maternal blood which is abundantly present along the outer surface of the placenta flows along the cord and mixes with the blood of the umbilical cord.
This collection system furthermore exposes the blood to the air of the outside environment, thus facilitating contaminations by microorganisms which are present in the outside environment.
Another drawback is the constant need for an operator assigned to keeping the umbilical cord in the correct position, particularly if repeated maneuvers for expressing and cleaning the cord are performed.
b. “Closed-circuit” Systems
Collection is performed by venipuncture of the cut and clamped end of the umbilical cord, after accurately disinfecting the entry point of the needle. The blood is collected in one or more syringes or in donation pouches.
Advantages
With respect to “open-circuit” systems, “closed-circuit” systems reduce the risks of microbial contamination of the collected blood and do not require continuous cleaning and disinfection of the cord.
Another advantage is reduction of the contamination of the sample with maternal blood or other liquids which flow along the outer surface of the cord.
Disadvantages
“Closed-circuit” systems entail handling needles and therefore expose the operators to the risk of accidental punctures.
Furthermore, the needle inserted in the umbilical vein is not stably fixed to it and can easily come loose, also in view of the highly dynamic nature of childbirth; this problem is particularly felt if collection is continued even after expulsion of the placenta. Accordingly, the continuous presence of an operator is required to ensure the correct placement of the needle during the various steps of collection.
If the needle leaves its seat, blood contaminations and accidental punctures of the operator are possible, and repetition of venipuncture is furthermore required in order to continue collection.
Owing to the limited cross-section of two of the three vessels of the umbilical cord (the arteries), collection is feasible only on one vessel (the vein), consequently reducing the collection potential.
The flow of blood is also hindered by the sudden decrease in cross-section (the needle, no matter how large, can never have the same cross-section as the umbilical vein).
The needle is inserted in an intermediate segment of the umbilical cord, upstream of the closure region; stasis of the blood downstream of the insertion point, with a consequent tendency to clotting, is thus inevitable; moreover, the blood which remains downstream of the insertion point is not recovered.
SUMMARY OF THE INVENTION
The aim of the present invention is to provide an improved method over the prior art cited above, for collecting blood or other fluids from the placenta or other organs or tissues for medical, scientific or other purposes.
An object of the invention is to ensure maximum sterility of the sample by applying a procedure and using a closed-circuit apparatus which minimizes contact of the blood or fluid with potentially contaminated external factors or with the air.
A further object of the present invention is to make the procedure accessible even to personnel who are not specifically trained. The procedure furthermore allows to limit the risks of human error on the part of the operator and, by using the suitable apparatus, to minimize the risk of injury to operators, since no exposed sharp or pointed objects are used.
The above aims and objects, and other aims that will become apparent to those skilled in the art are achieved by a method for collecting blood from the placenta or another organ or tissue through the umbilical cord or a main vessel by means of a closed system which sequentially includes:
1. Cleaning and disinfection of the portion of umbilical cord or vessel which is involved in the collection. The cleaning and disinfection system can be conveniently coupled to the system for connecting the umbilical cord or vessel.
2. Cutting of the cord in a position which is suitable for subsequent coupling to the connection system. The cutting system can be conveniently coupled to the connection system of the umbilical cord.
3. Connection of the umbilical cord or vessel by means of a connection system, optionally of the closed type, which can in turn be connected to a collection container; the connection system optionally includes a system for mixing the blood or other fluid with anticoagulant or other fluid or substance immediately after it has flowed out of the cord or vessel.
4. Optional insertion of the placenta or other organ or tissue in containment means.
5. Application of positive pressure to the placenta. The pressure can be uniform or, as an alternative, uneven, rhythmic, intermittent, centripetal, displacing or of one or more kinds, combined in various manners in order to mobilize the fluids from the more peripheral regions toward the main efferent vessels.
6. Application of continuous or intermittent negative pressure, as required, to the connection or to the collection container in order to facilitate the outflow of blood or other fluids or to free the vessel from clots or other obstacles.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the invention will become apparent from a reading of the detailed description of preferred but not exclusive embodiments of the invention, illustrated only by way of non-limiting examples in the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of the procedure for collecting blood from the umbilical cord;
FIG. 2 is a view of a connection system according to a first aspect of the invention;
FIG. 3 is a view of a connection system according to a second aspect of the invention;
FIGS. 4A, 4 B, 4 C, and 4 D shows the steps of the method using a connection system according to a third aspect of the invention;
FIG. 5 is a view of the container of the placenta connected to the connection system;
FIG. 6 is a schematic view of an apparatus for applying pressure to the placenta and to the proximal portion of the umbilical cord;
FIG. 7 is a view of a first embodiment of an apparatus for applying pressure to the placenta;
FIG. 8 is a schematic view of a second embodiment of an apparatus for applying pressure to the placenta.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the procedure according to the invention, after childbirth 9 , the umbilical cord is closed (clamped) 10 in two points and then cut 11 in a median position between the two closure points. The portion of the umbilical cord that is connected to the placenta protrudes freely from the mother's vagina 12 .
At this point, the end portion must be coupled to the collection container. The end portion of the umbilical cord is disinfected appropriately 13 , optionally with a specifically designed disinfection system, is cut to size, if necessary, in order to adapt to the connection system 14 , and is then coupled to the connection system 15 . Said connection system (FIG. 2) is generally provided with suitable means for locking the cord, which prevents the cord from exiting from the system. The connection system is also provided with hermetic sealing means which isolate the cord portion from the outside environment at the inlet of said connection system, including any liquids which are present or flow on the outside wall of the umbilical cord. The sealing means are shaped appropriately and are constructed so as to not compress or choke the umbilical cord and in any case so as to avoid hindering in any way the collection of the blood or fluid. The connection system is then connected to the collection container, or the collection container can be an integral part of the connection system.
The connection system 39 which comprises means 41 for forming a seal on the umbilical cord which delimit a portion of the umbilical cord toward the placenta 38 a and an open end portion 38 b , means 40 for locking the cord, elements for connection to a collection container 49 so as to delimit a hermetic closed space 50 which comprises an optional access path 48 for applying pressure or for introducing anticoagulant fluid or another fluid or for drawing part of the blood.
The connection system, in one of its possible variations (FIG. 3 ), can also comprise in a single system, in addition to the vessel locking elements and to the sealing elements described above, cleaning and disinfection elements and cutting elements which are such that the operator, holding the end of the free portion of umbilical cord 12 with one hand, can disinfect the involved cord region, cut the cord to size and apply the connection system, which comprises both the locking elements and the sealing systems with a single operation 16 .
The connection system of FIG. 3 comprises means for disinfecting the end portion of the umbilical cord 43 and for cutting it 44 .
An additional variation of the connection system 17 , illustrated in a possible non-limitative embodiment in (FIGS. 4A, 4 B, 4 C, and 4 D), can comprise the various elements required for disinfecting, cutting and locking the cord and hermetic sealing means designed to be applied before separating the neonate from the mother. In this case, the operator can use the same instrument to close, disinfect, cut and lock the cord and place the sealing elements 17 directly after the birth of the neonate.
The connection system of FIG. 4 comprises systems for closing or clamping 45 the umbilical cord upstream 45 a and downstream 45 b of the cutting point of said cord; the clamping elements downstream of the cut or toward the neonate 45 b are temporarily connected to the system and, after cutting the cord, can be disconnected to leave room for the collection container 42 .
Blood collection begins after applying the connection system. Before expulsion of the placenta, placental blood flows out owing to the pressure applied by uterine contractions to the placenta 18 . After a variable period which lasts a few minutes, expulsion of the placenta occurs 19 . During this step, the operator does not have to worry about the connection between the cord and the collection container, since the connection system has suitable locking means which ensure the stable connection between the cord, the connection system and optionally the collection container even during “dynamic” maneuvers such as expulsion of the placenta and transfer thereof to another location.
After expulsion, the placenta is enclosed in a soft container (FIG. 5 ), optionally provided with an absorbent inner surface and an impermeable outer surface, which allows to avoid contaminating the outside environment and the operator 20 and is then subjected to pressure of various kinds by virtue of a suitable apparatus 21 . During this second part of the collection 22 , the flow of blood is ensured by the pressure applied appropriately by the specifically provided apparatus to the placenta. Said apparatus (FIG. 6) can be generally composed of elements which are suitable to apply pressures of various kinds to said placenta in suitable directions.
Another possibility for improving the yield of placental blood collection is the optional application of negative pressure to the point where the blood flows out of the umbilical cord, so as to generate a suction effect 23 . The intensity of the suction is sufficient to facilitate the emptying of the cord and drainage of any obstacles, without however causing collapse of the vessels contained in the cord. The connection system in fact allows (FIG. 2, 3 and 4 ), by virtue of the hermetic sealing and pressure-tight systems, both on the umbilical cord and with the collection container, to create an enclosed space which can be pressurized. The negative pressure can be applied to the connection system both during the collection step before expulsion of the placenta 24 and during the second step after expulsion 25 .
The procedure described so far then entails, after expulsion of the neonate, the cutting, cleaning, disinfection and connection of the cord with a suitable connection system which comprises suitable means for locking and isolating from outside the open end portion of the cord. The connection system can be, or already is, connected to a collection container with suitable sealing means. This is followed by a first collection of blood from the cord prior to expulsion of the placenta. During expulsion of the placenta, the cord remains coupled to the connection system and to the collection container, since the cord is firmly fixed and isolated from outside by virtue of suitable locking and sealing means, respectively. After expulsion, the placenta is inserted in a suitable soft container which has suitable hermetic closure means; said container can be an integral part of the connection system by being for example rolled up and packed on the outer edges of the connection system and activated when required by unrolling along the umbilical cord and then around the placenta to be finally closed at the apex of said placenta. At this point, the placenta contained in the container is subjected to a suitable pressure, such as to facilitate the flow of blood toward the outside through the umbilical cord in the enclosed space. Where necessary, in order to optionally further improve collection or eliminate obstacles or clots of the umbilical cord, it is possible to apply negative pressure to the open end portion of the umbilical cord by virtue of an access path provided in the connection system or in the collection container. By virtue of the sealing elements which are present in the connection system and isolate the enclosed space which accommodates the open end portion of the umbilical cord from the space that contains the placenta, it is also possible to apply the pressure directly in the sealed container of the placenta.
The described procedure allows, by means of a series of simple and safe operations, to maximize yield by virtue of sequential collection before and after expulsion of the placenta. The procedure also provides for the connection of the cord to a system which allows to keep all three vessels of the umbilical cord pervious, allowing them to contribute to the maximum yield of the collection. The operation provides for containment of the placenta and the cord from the initial steps, without using exposed pointed or sharp objects, ensuring the best possible safety of the operator. In the procedure, all the steps of collection are performed in a closed system, in which the blood does not make contact with the outside, thus preventing contamination of the sample. The procedure is easy and practical to use even for personnel who have not been trained specifically.
The procedure is very quick, can be partially automated, is designed to minimize the burden of the operator and can be applied in dynamic working conditions, such as operating rooms, delivery rooms etcetera.
In the system, as soon as the umbilical cord is cut, the placental portion of the umbilical cord from which the blood flows out is connected, after suitable disinfection, to the collection container by means of a closed connection system; said connection system eliminates the possibility of contaminating the blood, since it delimits a sterile closed region in which the blood passes from the umbilical cord to the collection container. The connection system, together with the container in which the placenta is placed, furthermore eliminate contaminations of the outside environment with placental blood, making the maneuver safe for the operator as well.
The system also allows to optimize the collection volume, since it combines collection from the vein and from the two arteries with the safety and practicality characteristics typical of a closed system. The combined use of the apparatus for applying positive pressure furthermore allows, for the first time, to recover volumes of fluid which are up to 100% higher than those obtained with currently used procedures. | A method for collecting blood or fluids in general from a placenta or organ or body tissue through the cut end portion of the umbilical cord or of one or more vascularization vessels or outflow vessels of an organ or tissue, including the steps of connecting the cord, or vessel, to a collection apparatus and then applying pressure to the placenta, or organ or tissue. | 0 |
FIELD OF THE INVENTION
[0001] The present invention pertains to thermal barrier coatings applied to protect components in high temperature environments. In particular, the present invention describes a composition and method for applying a thermal coating system.
BACKGROUND OF THE INVENTION
[0002] Systems located or operated in high temperature environments often include thermal barrier coatings (TBCs) on components to reflect heat and prevent the components from absorbing heat. For example, jet engines and gas turbines include combustors and turbines designed to operate in very demanding high temperature and pressure environments. As a result, many components, such as combustor liners, turbine blades, turbine casings, and rotors routinely operate in high temperature environments that approach or exceed the melting temperature of the constituent elements included in the components. A TBC applied to the surface of these components allows the components to operate at increasingly higher temperatures and/or with increased intervals between maintenance cycles.
[0003] The underlying components are typically designed to operate for extended periods in the structurally demanding high temperature and/or pressure environments. Superalloys such as Rene 80, Rene N4, and other nickel-based superalloys are commonly used in the underlying components. These superalloys may contain, by weight percent, 10 to 80 percent nickel, 5 to 22 percent chromium, up to 10 percent molybdenum, up to 5.5 percent titanium, up to 6.5 percent aluminum, up to 3 percent columbium, up to 9 percent tantalum, up to 15 percent tungsten, up to 2 percent hafnium, up to 1 percent rhenium, up to 1.5 percent vanadium, up to 40 percent cobalt, and up to 6 percent iron.
[0004] Ceramic matrix composites (CMCs) may also be selected for use in the underlying components. Examples of commonly used CMCs include zirconia-based ceramics, alumina-based ceramics, magnesia-based ceramics, and ceramic composites such as alumina-silica (GE Gen 4), or a refractory material with, for example, silicon carbide, silicon nitride, alumina, silica, and/or calcia.
[0005] A suitable TBC applied to the underlying component should include one or more of the following characteristics: low emissivity or high reflectance for heat, particularly infrared heat having a wavelength of 0.5 to 60 micrometers; a smooth finish; and good adhesion to the underlying component. For example, thermal bather coatings known in the art include metal oxides, such as zirconia (ZrO 2 ), partially or fully stabilized by yttria (Y 2 O 3 ), magnesia (MgO), or other noble metal oxides. The selected TBC may be deposited by conventional methods using air plasma spraying (APS), low pressure plasma spraying (LPPS), or a physical vapor deposition (PVD) technique, such as electron beam physical vapor deposition (EBPVD), which yields a strain-tolerant columnar grain structure. The selected TBC may also be applied using a combination of any of the preceding methods to form a tape which is subsequently transferred for application to the underlying substrate, as described, for example, in U.S. Pat. No. 6,165,600, assigned to the same assignee as the present invention.
[0006] The thermal barrier coatings described above have coefficients of thermal expansion that are significantly lower than the coefficients of thermal expansion of the underlying components. As a result, cyclic thermal stresses incident to repetitive heating and cooling of the system components disrupts the adhesion between the TBC and the underlying substrate, leading to T ailing of the coating system.
[0007] A bond coat may be used between the TBC and the underlying substrate to improve the adhesion between the TBC and the underlying substrate. The bond coat may be formed from an oxidation-resistant diffusion coating such as a diffusion aluminide or platinum alumiminide, or an oxidation-resistant alloy such as MCrAlY (where M is iron, cobalt and/or nickel). Aluminide coatings are distinguished from MCrAlY coatings, in that the former are intermetallics, while the latter are metallic solid solutions. U.S. Pat. No. 6,210,791, assigned to the same assignee as the present invention, describes one such bond coat applied between the TBC and the underlying substrate that substantially improves adhesion between the TBC and the underlying substrate. The bond described therein is an alumina and silica mixture in an alcohol solvent.
[0008] The thermal barrier coatings, with our without a bond coat to improve adhesion, typically require some type of post-application drying or heating at 500 to 2000 degrees Fahrenheit to sinter and/or stabilize the coating system. The application and post-application curing produces volatile organic compounds (VOCs) which may exceed current environmental, health, and safety limits for VOC emissions. To reduce VOC emissions during the application and post-application curing, the thickness of the TBC and/or bond coat may be reduced. However, the thinner TBC and/or bond coat results in a corresponding decrease in the thermal reflection of the thermal barrier.
[0009] Therefore, the need exists for an improved thermal coating system to protect system components from excessive heat. Ideally, the thermal coating system will have low emissivity or high reflectance for heat, particularly infrared heat having a wavelength of 0.5 to 60 micrometers. In addition, the thermal coating system should be able to be easily applied so as to produce a smooth finish surface that adheres to the underlying substrate component without producing excessive VOCs during the application or post-application curing.
BRIEF DESCRIPTION OF THE INVENTION
[0010] Aspects and advantages of the invention are set forth below in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[0011] One embodiment of the present invention is a thermal coating system. The thermal coating system includes a substrate, a first coating layer applied to the substrate, and a second coating layer applied to the first coating layer. The substrate is selected from the group consisting of superalloys and ceramic matrix composites. The first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The first group consists of toluene, xylene, cellosolve acetate, EE acetate, and mineral spirits. The second group consists of methyl ethyl ketone, methyl isobutyl ketone, lacquer thinner, and acetone. The second coating layer comprises at least one of zinc titanate or cerium oxide.
[0012] Another embodiment of the present invention is a method for applying a thermal coating system. The method includes applying a first charge to a bond coat mixture, wherein the bond coat mixture comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The first group consists of toluene, xylene, cellosolve acetate, EE acetate, and mineral spirits. The second group consists of methyl ethyl ketone, methyl isobutyl ketone, lacquer thinner, and acetone. The method further includes applying a second charge to a substrate, wherein the second charge has an opposite polarity of the first charge, and spraying the bond coat mixture onto the substrate. The method also includes applying a top coat mixture onto the bond coat mixture, wherein the top coat mixture comprises at least one of zinc titanate or cerium oxide.
[0013] A further embodiment of the present invention is a method for applying a thermal coating system that includes spraying a bond coat mixture onto a substrate using a liquid electrostatic sprayer. The bond coat mixture comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The first group consists of toluene, xylene, cellosolve acetate, EE acetate, and mineral spirits. The second group consists of methyl ethyl ketone, methyl isobutyl ketone, lacquer thinner, and acetone. The method further includes applying a top coat mixture onto the bond coat mixture, wherein the top coat mixture comprises at least one of zinc titanate or cerium oxide.
[0014] Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the specification.
BRIEF DESCRIPTION OF TUE DRAWINGS
[0015] A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
[0016] FIG. 1 provides a cross-sectional view of one embodiment of a coating system within the scope of the present invention;
[0017] FIG. 2 illustrates liquid electrostatic spraying of a coating system within the scope of the present invention; and
[0018] FIG. 3 is a graph of the reflective performance of one embodiment of a thermal barrier coating system within the scope of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention.
[0020] Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0021] FIG. 1 shows a cross-sectional view of a thermal coating system 10 applied to a substrate 12 according to one embodiment of the present invention. In this particular embodiment, the thermal coating system 10 includes first and second coating layers referred to respectively as a bond coat mixture 14 and a top coat mixture 16 .
[0022] The substrate 12 may be any material composition suitable for use in a high temperature environment. For example, superalloys and ceramic matrix composites as previously described are frequently selected for use in high temperature environments because of their suitable strength, ductility, and other physical characteristics.
[0023] The first layer or bond coat mixture 14 is applied to the substrate 12 and provides tight adhesion between the substrate 12 and any additional layers. The bond coat mixture 14 may be a modification of the bond coat described in U.S. Pat. No. 6,210,791, the entirety of which is herein incorporated by reference for all purposes. As described therein, the bond coat mixture 14 may be metallic, non-metallic, or a combination thereof, depending on the underlying substrate, and may include alumina powder, such as aluminum oxide, with a silica binder. An evaporable solvent, typically ethanol or isopropyl alcohol, is added to the bond coat mixture 14 to achieve the desired consistency. A suitable thickness for the bond coat mixture 14 may be approximately 0.5 to 8 mils (0.0005-0.008 inches), depending on the method of application and design needs.
[0024] To reduce the amount of VOCs generated during the application and drying, the bond coat mixture 14 may be applied using liquid electrostatic spraying (LES) techniques. In LES applications, an electrical charge is applied to the material being deposited, and a ground or opposite electrical charge is applied to the substrate. The charged material is then sprayed onto the substrate, and the polar attraction between the charged material and the substrate results in an increased deposit efficiency of the material onto the substrate with significantly less overspray and waste. The increased deposit efficiency produces a more uniform coverage, allowing the application of thinner layers of the material to the substrate to provide the same or better performance. As a result, LES applications provide significant cost savings of materials compared to conventional application techniques. In addition, the thinner application of the materials results in lower VOC emissions during both the application and the subsequent curing.
[0025] The electrical conductivity of the bond coat mixture 14 may need to be adjusted to obtain a desired particle size that allows the use of LES and improves the deposit efficiency. Additives such as toluene, xylene, cellosolve acetate, EE acetate, and mineral spirits may be added to the bond coat mixture 14 to make the mixture less electrically conductive and prevent agglomeration of the bond coat mixture 14 during spraying. Conversely, additives such as methyl ethyl ketone (MIEK), methyl isobutyl ketone (MIBK), lacquer thinner, and acetone may be added to the bond coat mixture 14 to make the mixture more electrically conductive.
[0026] FIG. 2 illustrates an application of the bond coat mixture 14 using LES. A powder spray gun 18 , such as a Nordson Kinetix air spray system sold by Nordson Corporation, Westlake, Ohio, includes a nozzle 20 with an electrode 22 . An opposite charge or ground 24 is applied to a substrate 26 . As the spray gun 18 propels the bond coat mixture 14 through the nozzle 20 , the electrode 22 applies an electrical charge to the bond coat mixture 14 . The charged bond coat mixture 14 flows to the oppositely charged or grounded substrate 26 where the polar attraction between the charged bond coat mixture 14 and substrate 26 deposits the bond coat mixture 14 uniformly on a surface 28 of the substrate 26 . The magnitude of the electrical potential between the charged bond coat mixture 14 and the oppositely charged substrate 26 may be adjusted to increase or decrease the deposition rate on the substrate surface 28 , depending on the desired thickness of the application.
[0027] The use of nano-sized particles as the constituent elements in the bond coat mixture 14 further improves the benefits of LES. For example, LES application of nano-sized particles having an average diameter of less than approximately 500 nanometers may readily achieve uniform thicknesses of the bond coat mixture 14 as low as approximately 0.5 mils (0.0005 inches). A thinner application of the bond coat mixture 14 produces several benefits. For example, a thinner bond coat mixture 14 will have a correspondingly smaller change in temperature across the bond coat mixture 14 , resulting in better adhesion to the substrate 26 . In addition, the nano-sized particles will produce a more tightly packed and dense layer that increases the resistance of the bond coat mixture 14 to erosion.
[0028] Referring back to FIG. 1 , the thinner application of the bond coat mixture 14 using LES may not adequately cover all imperfections 30 in the surface 32 of the substrate 12 . As a result, an additional undercoat layer (not shown) may be included between the bond coat mixture 14 and the substrate 12 . The undercoat layer may comprise the same bond coat as previously described in U.S. Pat. No. 6,210,791. That is, the undercoat layer may comprise an alcohol mixture of alumina powder, such as aluminum oxide, with a silica binder. The undercoat layer may be applied using conventional application techniques known in the art. For example, the undercoat layer may be applied as a slurry spray, using air plasma spraying (APS), low pressure plasma spraying (LPPS), or physical vapor deposition (PVD) techniques such as electron beam physical vapor deposition (EBPVD). If needed, the undercoat layer is applied to a thickness of approximately 1 to 8 mils (0.001-0.008 inches) to fill in any imperfections 30 in the surface 32 of the substrate 12 . For applications in which the substrate surface 32 is sufficiently smooth, the undercoat layer may be reduced in thickness or omitted entirely.
[0029] The top coat mixture 16 is located on top of the bond coat mixture 14 . The combination of the bond coat mixture 14 and top coat mixture 16 provides the desirable smooth, wear, and reflective characteristics of the thermal coating system 10 . Specifically, a smooth outermost surface of the thermal coating system 10 promotes improved aerodynamics across the surface which may be important in various applications. The surface roughness of the top coat mixture 16 is preferably less than approximately 60 micrometers Ra and potentially less than 20 micrometers Ra. In addition, the bond coat mixture 14 tightly adheres the top coat mixture 16 to the substrate 12 to resist wear or spalling even after numerous thermal cycles. Lastly, the top coat mixture 16 possesses the desired reflectance characteristics, particularly for infrared heat having a wavelength between 0.5 and 60 micrometers, to protect the substrate 12 from heat in a high temperature environment.
[0030] The top coat mixture 16 may be comprised of zinc titanate or cerium oxide to provide the desired heat reflectance characteristics of the thermal coating system 10 . Suitable substitutes that may also provide the desired heat reflectance characteristics include barium titanate, yttrium oxide, dysprosium oxide, erbium oxide, europium, lanthanum oxide, lutetium oxide, thorium oxide, tungsten oxide, barium stannate, and barium tungstate, many of which may be supplied by Nano-Tek Technologies, Ltd.
[0031] The top coat mixture 16 may be applied using conventional application techniques known in the art. For example, the top coat mixture 16 may be wetted and layered on top of the bond coat mixture 14 as a slurry spray, using air plasma spraying (APS), low pressure plasma spraying (LPPS), or physical vapor deposition (PVD) techniques such as electron beam physical vapor deposition (EBPVD). The thickness of the top coat mixture 16 depends on the desired heat reflectance and application method and typically ranges from approximately 1 to 10 mils (0.001-0.010 inches).
[0032] In particular embodiments of the present invention, the thermal coating system 10 may be applied to the substrate 12 using a tape process as described in U.S. Pat. No. 6,165,600 and assigned to the same assignee as the present invention. In this process, compositions of the bond coat mixture 14 and/or top coat mixture 16 and/or optional undercoat layer as described above may be cast on a tetrafluoroethylene sheet. After the solvent evaporates from the compositions, the dried compositions are removed from the tetrafluoroethylene sheet and transferred to the substrate 12 to form the thermal coating system 10 . Pressure may then be applied to the thermal coating system 10 to mechanically bond the thermal coating system 10 to the substrate 12 .
[0033] Regardless of the application method, whether directly onto the substrate 12 or using the tape process as previously described, the thermal coating system 10 may be heated or cured after application to the substrate 12 . An autoclave, oven, or similar device may be used to heat the thermal coating system 10 at a temperature of between 500 and 2,000 degrees Fahrenheit. The heat removes the binders and remaining solvent and sinters the thermal coating system layers 14 , 16 . The sintering forms both chemical and mechanical bonds both in the thermal coating system layers 14 , 16 and with the substrate 12 . Alumina in the substrate 12 mixes with the molten bond coat mixture 14 and raises the melting point of the thermal coating system 10 . The melting point of the resulting thermal coating system 10 may thus be increased from approximately 1,500 degrees Fahrenheit to approximately 1,950 degrees Fahrenheit or higher, depending upon the actual composition of the substrate 12 . The increased melting point of the thermal coating system 10 allows the substrate to be exposed to higher temperatures, which, for jet engine and gas turbine applications, typically produces increased thermodynamic efficiency.
[0034] The duration of the heating varies from approximately 30 minutes to several hours, depending on the composition of the substrate 12 , bond coat mixture 14 , and top coat mixture 16 . For example, FIG. 3 provides a graph of the reflective performance of one embodiment of a thermal barrier thermal coating system within the scope of the present invention. In this embodiment, the bond coat mixture 14 was cast on a tetrafluoroethylene sheet and transferred as a tape to the substrate 12 . The top coat mixture 16 was then sprayed onto the bond coat mixture 14 , and the combination was then heated at 1,650 degrees Fahrenheit for approximately 1 hour. The graph provided in FIG. 3 shows the resulting reflectance values for heat applied at various angles to the substrate.
[0035] It should be appreciated by those skilled in the art that modifications and variations can be made to the embodiments of the invention set forth herein without departing from the scope and spirit of the invention as set forth in the appended claims and their equivalents. | A thermal coating includes a substrate, a first coating layer, and a second coating layer. The substrate is selected from the group consisting of superalloys and ceramic matrix composites. The first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The second coating layer comprises at least one of zinc titanate or cerium oxide. A method for applying a thermal coating system includes spraying a bond coat mixture onto a substrate using a liquid electrostatic sprayer. The bond coat mixture comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The method further includes applying a top coat mixture onto the bond coat mixture, wherein the top coat mixture comprises at least one of zinc titanate or cerium oxide. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is continuation-in-part of U.S. patent application Ser. No. 12/200,394, filed Aug. 28, 2008, a continuation-in-part of U.S. patent application Ser. No. 12/469,671, filed May 20, 2009, and a continuation-in-part of U.S. patent application Ser. No. 13/178,447, filed Jul. 7, 2011, the disclosures of which are hereby incorporated by reference.
FIELD
[0002] The invention relates to knee braces.
BACKGROUND
[0003] Orthotic devices and appliances, commonly referred to as “orthotics,” have been utilized for many years by orthotists, physical therapists, and occupational therapists. Orthotics assist in the rehabilitation of a patient's joints and associated skeletal systems. Generally orthotics act to support and protect the joint, while alleviating pain associated with joint movement.
[0004] There are multiple types of osteoarthritis with different effects on the human knee joint.
[0005] Primary osteoarthritis is usually related to aging. With aging the water content of the cartilage increases and the protein makeup of the cartilage degenerates. Repetitive use of the joints over the years can irritate and inflame the cartilage, causing joint pain and swelling. Eventually, cartilage begins to degenerate by flaking or forming tiny crevasses. In advanced cases, there is a total loss of cartilage cushion between the femur and tibia bones at the knee joint. This loss leads to diminished joint space on the affected side of the knee, in turn causing pain and joint mobility limitations. Inflammation of the cartilage can also stimulate new bone outgrowths, or spurs, to form around the joints, in turn causing increased pain and joint inflammation.
[0006] Important components of patient care include minimizing the progression of the damage to the cartilage of the knee joint and preventing the formation of bone spurs from bone-on-bone contact during knee joint bending. In a normal knee the soft cartilage layers between the femur (upper leg bone of the knee) and the tibia (lower leg bone of the knee) are separated by a thin layer of synovial fluid. The synovial fluid provides lubrication and prevents direct contact between the cartilage layers.
[0007] In a patient with osteoarthritis or osteoarthrosis the cartilage has degraded. The result is no longer smooth cartilage surfaces sliding across one-another while lubricated by synovial fluid, but instead rough cartilage surfaces rubbing against one another directly. This rubbing is the source of osteoarthritis/osteoarthrosis pain.
[0008] Bone spurs may form as a result of this joint irritation. These bone spurs sometimes cause bits of bone and cartilage to detach. These detached pieces of bone float within the knee joint, causing further damage.
[0009] Damage to the knee is often isolated to a certain portion of the knee joint. In fact, the most common form of osteoarthritis or osteoarthrosis is unicompartmental, meaning that only one of the three compartments of the knee joint is significantly affected by the loss of cartilage padding.
[0010] The human knee has three compartments. The medial compartment of is on the inside of the centerline of the body, closest to the knee of the other leg. The lateral compartment of the knee is furthest from the centerline of the body. Finally, the patellar compartment is in the center-upper portion of the knee, to the rear of the patella or knee cap.
[0011] The majority of osteoarthritis cases are medial compartment degeneration. Thus, the cartilage or cushioning of the knee joint has significantly deteriorated on the inside portion of the knee. As a result of cartilage degeneration within the medial compartment of the knee the knee becomes imbalanced. The imbalance results in a knee that bows outward. This is often called a “bowleg” condition, referred to as a varus deformity of the knee joint, or genu varum.
[0012] A knee joint with bowleg deformity places significant force on the medial compartment of the knee, resulting in joint pain.
[0013] Alternatively, a patient will have damage to the lateral compartment of the knee. The result is again an unbalanced knee, with the knee bending inwards at the knee joint. The result is a knock-kneed appearance, or valgus deformity of the knee joint.
SUMMARY
[0014] Osteoarthritis knee braces are designed to do two things: First, correct the abnormal bending of the knee joint inwards or outwards (valgus or varus correction). Secondly, many osteoarthritis knee orthotics or braces are designed to prevent the bone-on-bone contact of the femur and tibia bones in the medial or lateral compartment of the knee joint as the patient bears weight during walking. This action of lifting femur, pulling down the tibia, or keeping the femur and tibia bones from coming in contact during the straightening of the knee during heel strike is often called “unloading” the knee joint. By unloading the knee joint, the constant irritation of the degenerated cartilage in the affected compartment of the knee (medial or lateral) can reduced, leading to a significant reduction in pain.
[0015] Prior art braces accomplish this unloading through the use of long struts acting as lever arms, with fulcrums located at the knee joint. Through the use of mechanical means the fulcrum is forced against the knee joint, providing inward force.
[0016] In contrast, the disclosed knee brace does not required the use of long struts and mechanical means to provide a lifting force to the knee. Instead, air bladders present at the knee joint provide inward force. No long lever arm is required, resulting in a shorter and more compact knee brace. This reduces weight, as well as the area of the user's leg that is subjected to pressure from the brace. The shorter and more compact brace migrates less on the leg, and as a result does not slip out of position.
[0017] The use of air bladders also allows for the day-to-day adjustment required by patients. Prior art systems with complicated mechanical means for setting require that adjustment be performed only by an orthotist. But the human body is not static. Muscle mass increases over the period of time the brace is in use, swelling fluctuates, water retention varies. The disclosed knee brace allows the user to adjust the pressure created by the air bladders to match the needs of the day.
[0018] When addressing knee problems, the old methodology was to operate on a patient, fit the patient with a brace, and use the brace to force the patient to correct her gait. This is a process fraught with problems. Knee problems do not appear quickly, but develop over years of gradual degradation. During this time the patient slowly and subtly alters her gait to compensate for the discomfort caused by the damage.
[0019] As a result, by the time the knee pain rises to a level that requires surgery the patient has been walking incorrectly for years. Thus, when the patient begins to walk after surgery her gait is still improper despite the surgical correction of the problem.
[0020] The answer is use of the disclosed knee brace prior to surgery. The disclosed knee brace effectively reduces the pain and discomfort within the joint. When used in conjunction with the swing assist system discussed below, the patient begins to correct her gait before surgery. The result is healthier leg muscle and connective tissue, stronger bones, and a proper gait. The healthier tissue provides the surgeon with better structure for replacement of the knee. And the corrected gait allows the patient to recover more quickly, starting to walk on her new knee with the correct gait.
[0021] An important component of correcting a patient's gait is enabling full extension of the patient's leg, where the knee joint is as open as possible without hyperextension. Many patients have significant trouble extending their legs fully as a result of weak muscles, past pain, and joint inflexibility. When a patient achieves full extension of her leg while walking, the result is a proper heel-to-toe gait. A heel-to-toe gait starts when the heel of the foot contacts the ground first, followed by transitioning weight to the midfoot, with the toes being the final point of contact between the foot and the ground. Incorrect gait is often the result of joint injury/damage.
[0022] A patient with medial compartment osteoarthritis will land on the lateral (outside) portion of the heel/foot during her stride. This is a result of an attempt to shift the load from the affected side of the knee, the medial side, to the unaffected side of the knee, the lateral side.
[0023] The consequences of this imperfect gait are twofold: First, the patient's muscle memory that controls the precise firing sequence for walking becomes altered. Second, the medial quadriceps muscles and Vastus Medialis Obliquus (VMO) muscles are less excited by this altered gait, and thus less exercised. It is this second factor that results in the loss of muscle mass, decreases support of the knee joint, and exacerbates damage to the knee joint.
[0024] The combination of eliminating pain associated with gait, while aiding in the extension of the lower leg, can correct the damaged gait mechanics of a patient.
[0025] With the disclosed knee brace correcting the patient's gait, and the repetitive nature of walking, over time the patient's muscle memory is corrected. This muscle memory correction causes the nerves to activate the proper muscles for a healthy gait. Activation of the proper muscles results in strengthening, and an eventual return to normal muscle structure.
[0026] The patient then experiences the proper heel to toe gait where she lands her the center of her heel at the termination of the swing phase of her gait, transition the weight down the centerline of her foot, and ends the gait by coming off of her toes.
[0027] For some patients, the rehabilitative effect of the disclosed knee brace can allow for removal of the brace and the corrected gait will be maintained.
[0028] The disclosed knee brace uses a swing assist system to help the patient achieve full extension, and thus the proper heel-to-toe gait. The swing assist system includes an energy storage member that extends across the hinge, connecting the upper portion of the support arm to the lower portion of the support arm. The energy storage member gathers energy during flexion of the knee joint and releases it during extension. The result is an improvement in leg extension, even for patients who lack the strength or conditioning to achieve full leg extension in the absence of the disclosed knee brace.
[0029] The swing assist system is installed on one or both of the hinges. There is no requirement that both hinges have a swing assist system, although such an arrangement is likely to produce the most balanced force during extension and flexion of the knee brace.
[0030] The energy storage member of the swing assist system is any device capable of repeatedly storing and releasing rotational energy. Such devices include elastic/rubber bands, elastic/rubber loops, o-rings, o-ring cord stock, torsion springs, coil springs, and all other similar devices.
[0031] The energy storage member attaches to the strut above and below the hinge, or to an extension of the strut above and below the hinge. The energy storage member location relative to the hinge is dependent on the location from which it can best provide energy storage and return. If the energy storage member is an elastic band, it is likely best located on the anterior side of the hinge. If it is a coil spring that is to be extended during flexion, then it is best located on the anterior side of the hinge. If it is a coil spring to be compressed during flexion, it is best located on the posterior side of the hinge.
[0032] Energy storage members that store energy through rotation are likely best located at the rotational center of the hinge.
[0033] The exemplary embodiment included in the below referenced figures uses a looped elastic band as the energy storage member.
[0034] The exemplary knee brace shown in the figures supports and captures the energy storage member in a channel. Rather than using individual setting blocks on the exterior surface of the hinge, the disclosed knee brace uses a channel that is integral to the hinge. Integrating the swing assist mechanism and the hinge was disclosed in the parent patent applications referenced above.
[0035] The integral channel for support of the energy storage member does not allow for the removal/replacement of setting blocks in order to increase/decrease the tension of the elastic member and, therefore, the resulting force. But patient trials showed that patients did not favor a reduction in swing assist force. Instead, it was found that altering the force provided by the swing assist system was counter-productive, requiring the patient to relearn the correct gait. Thus, an integrated swing assist system was created.
[0036] Alternative arrangements exist where support for the energy storage member is not required. The example energy storage member is a looped elastic band, supported across the hinges by the integral channel. Removal of the support allows the looped elastic band to act between the two attachment points.
[0037] The appropriate location for each of the one more air bladders varies depending upon the injury to be treated.
[0038] For the sake of simplicity, the interior of the knee joint will be discussed in terms of medial and lateral compartments. The medial compartment is the interior portion of the knee. For the right knee of a patient, this is the left portion of the knee joint. The lateral compartment is the exterior portion of the knee. For the right knee of a patient, this is the right portion of the knee joint.
[0039] If the damage within the knee is general cartilage deterioration, a bladder is needed at both the medial and lateral locations of the leg. Providing simultaneous external forces against both sides of the knee joint unloads the knee joint, creating space between the cartilage surfaces.
[0040] Compression of both sides of the knee “distracts” the knee joint. The pressure lifts the femur, creating space in the joint. The pressure acts to stretch the top of the tibia away from the base of the femur. A shock-absorption effect is created by the presence of new space. With the new space in the knee joint, cartilage begins to grow. This new cartilage in turn decreases joint pain and improves function. The space also takes up any laxity in the ligaments, increasing knee stability.
[0041] If the knee is carrying its load on the medial side, the knee joint has rolled toward the medial surfaces. This creates space within the lateral side of the knee. Applying force using an air bladder to the lateral side rolls the knee joint toward the lateral side of the knee, creating space in the knee joint.
[0042] Correspondingly, if the knee is carrying its load on the lateral side, the knee joint has rolled toward the lateral surfaces. This creates space within the medial side of the knee. Applying force using an air bladder to the medial side rolls the knee joint toward to medial side of the knee, creating space in the knee joint.
[0043] Air bladders are optionally located nearer to the shin. If such bladders are included, they are always located on the lateral side of the brace. From the lateral position the bladder can help the leg to swing properly, acting to bring the lower portion of the leg toward the midline of the body.
[0044] The determination of which straps are necessary for support of the knee requires knowledge of what damage the knee suffered. If the damage is only to the cartilage of the knee, the forces to be controlled are lateral forces and no straps are needed beyond those opposing the upper and lower cuffs. If instead the damage is to the ACL (Anterior Cruciate Ligament) the upper and lower portions of the knee joint can move relative to one another in the anterior/posterior directions. The brace must then prevent forward translation of the tibia (lower leg bone) relative to the femur (upper leg bone). An ACL tear removes the ligament that prevents the lower leg bone from moving too far forward. The result of such movement is significant pain and further knee injury. The addition of a strap below the knee provides support that the ACL can no longer create.
[0045] The fit of any brace to the patient is important for both patient comfort and brace effectiveness. A brace that is too tight is uncomfortable because it cuts into the patient's tissue. A brace that is too loose is ineffective because it cannot support the load of the knee, and does not maintain the alignment necessary to encourage proper bending location.
[0046] But a proper fit is difficult. Muscle atrophy of one leg may result in legs of differing diameters. During the process of prehabilitation/rehabilition the creation of new muscle mass will cause an increase in leg diameter, further complicating orthotic sizing. If the changes to muscle size exceed the amount that can be adjusted using the straps the patient must purchase an additional orthotic. This is expensive and wasteful.
[0047] The addition of holes to the upper cuff increases the span of sizes over which a single brace can be used. This decreases the number of braces that an orthotist must keep on hand, and allows for nuanced sizing to fit each specific patient. As a result, a patient can be fitted with an off-the-shelf brace that as well as a custom brace.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
[0049] FIG. 1 illustrates a first view of the knee brace.
[0050] FIG. 2 illustrates a second view of the knee brace.
[0051] FIG. 3 illustrates the knee brace in a fully extended position.
[0052] FIG. 4 illustrates the knee brace in a nearly fully flexed position.
DETAILED DESCRIPTION
[0053] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
[0054] Referring to FIGS. 1 and 2 , the knee brace 1 will be disclosed. The knee brace 1 is intended to be worn across the knee joint of a patient's leg. The support structure of the knee brace 1 is comprised of a first upper support arm 2 , second upper support arm 4 , first lower support arm 6 , and a second lower support arm 8 . The support arms 2 / 4 / 6 / 8 are substantially parallel to the leg bones and provide rigid support for the remaining portions of the knee brace 1 .
[0055] The first upper support arm 2 and second upper support arm 4 are connected across a patient's thigh on the anterior side of the knee brace 1 by a flexible upper cuff 10 . An upper cuff pad 12 provides cushion between the patient's leg and the flexible upper cuff 10 . On the posterior side of the knee brace 1 is an upper cuff strap 14 , engaging with the first upper support arm 2 through a first upper clip 16 , in turn engaging a first upper pin 20 (not shown). On the other side of the brace, the upper cuff strap 14 engages with the second upper support arm 4 through a second upper clip 18 , in turn engaging a second upper pin 22 .
[0056] As discussed above, allowing for adjustment of the flexible upper cuff 10 sizing results in a knee brace 1 that is tailored to the leg size and shape of the specific patient, as well as that specific patient's stage of prehabilitation/rehabilitation. This adjustable sizing is accomplished by the inclusion of a first set of upper cuff adjustment holes 24 (not shown) and a second set of upper cuff adjustment holes 26 . The upper pins 20 / 22 are removable, allowing for the position of the flexible upper cuff 10 to be adjusted and then held in place by the upper pins 20 / 22 . The flexible upper cuff 10 is permitted to rotate about the upper pins 20 / 22 , as is the upper cuff strap 14 . This prevents the upper and lower edges of the flexible upper cuff 10 from pressing into the patient's tissue, which in turn causes discomfort.
[0057] The first upper support arm 2 meets the first lower support arm 6 at first hinge 50 . The second upper support arm 4 meets the second lower support arm 8 at second hinge 52 . In the example illustrated the hinges 50 / 52 are polycentric, having many centers or a center that varies depending on the bend angle. Alternatively, the hinges 50 / 52 are unicentric, having only a single center. The motion of a polycentric hinge generally better matches that of a human knee.
[0058] Adjacent to the first hinge 50 , on the inner portion facing the patient's leg, is first knee bladder 30 . Adjacent to the second hinge 52 , also on the inner portion facing the patient's leg, is second knee bladder 32 . As discussed above the number of bladders required is dependent upon the course of treatment. Thus, each bladder 30 / 32 is optional. To prevent discomfort, if either bladder 30 / 32 is removed it is optionally replaced with a pad to prevent contact between the patient's knee and the hinge 50 / 52 .
[0059] The first knee bladder 30 is filled using the first knee bladder hose 38 connected to the first knee bladder nozzle 34 (not shown). The second knee bladder 32 is filled using the second knee bladder hose 40 connected to the second knee bladder nozzle 36 .
[0060] Air bladders are optionally located nearer to the shin. The shin bladder 120 is filled using shin bladder hose 124 connected to shin bladder nozzle 122 (not shown). As with the knee bladders 30 / 32 , the amount of air in the shin bladder 120 is adjustable to accommodate differences in swelling and muscle size.
[0061] The motion of the knee brace hinges 50 / 52 is controlled and limited by a number of individual components. Each hinge 50 / 52 has a flexion limit stop 42 and extension limit stop 44 . The flexion limit stops 42 limit the motion of the knee brace 1 at a certain angle to prevent the brace from flexing to a smaller angle. E.g., allowing flexion to a minimum angle of 120 degrees.
[0062] Each flexion limit stop 42 is adjustable, allowing the orthotist to adjust and set the flexion limit stop 42 to the point appropriate for the patient's stage of recovery.
[0063] The extension limit stops 44 limit the motion of the knee brace 1 at a certain angle to prevent the brace from extending to a larger angle. E.g, allowing extension to a maximum angle of 160 degrees.
[0064] As discussed above, the swing assist system corrects a patient's gait by absorbing energy during flexion and releasing it during extension, increasing the patient's leg extension. The result is a proper heel-toe stride.
[0065] In the example shown in the figures, the first energy storage member 54 and second energy storage member 56 are elastic bands. There is no requirement that the energy storage members 54 / 56 be elastic bands. As disclosed above, it is anticipated that the energy storage members 54 / 56 be any device capable of storing and returning energy. Nor is it required that two energy storage members 54 / 56 be used. While in some instances the patient's gait is best corrected by use of two energy storage members 54 / 56 , a single energy storage member 54 / 56 likely provides sufficient benefit to justify use.
[0066] Energy storage members 54 / 56 that do not interface directly with the hinges 50 / 52 require attachment points. The exemplary elastic bands shown in the figures attach to the support arms at defined points. The first energy storage member 54 attaches to the first upper support arm 2 at the first upper attachment point 60 , and to the first lower support arm 6 at the first lower attachment point 64 (not shown). The second energy storage member 56 attaches to the second upper support arm 4 at the second upper attachment point 62 , and to the second lower support arm at the second lower attachment point 66 .
[0067] To ensure consistent action by the energy storage members 54 / 56 it is useful to guide and contain the energy storage members 54 / 56 . In the example shown in the figures first energy storage member 54 lies partially within a first energy storage member groove 70 and the second energy storage member 56 lies partially within a second energy storage member groove 72 . The respective energy storage grooves 70 / 72 retain their respective energy storage members 54 / 56 during flexion and extension, with emphasis on maintaining placement during flexion.
[0068] In the example shown in the figures, the grooves 70 / 72 are integrated with the hinges 50 / 52 . In other examples the grooves 70 / 72 are constructed from multiple individual pieces, such as setting blocks (disclosed in full in the parent applications).
[0069] Grooves 70 / 72 act to keep the energy storage members 54 / 56 to the front of, or anterior to, the hinges 50 / 52 . The distance between the center of the hinges 50 / 52 and the surface of the grooves 70 / 72 affects the behavior of the energy storage members 54 / 56 during bending. Assuming the energy storage members 54 / 56 are of a type that requires stretching (e.g., an elastic band), having no distance between the center of the hinges 50 / 52 and the energy storage members 54 / 56 will render the energy storage members 54 / 56 useless because the length of the energy storage members 54 / 56 will not change during leg flexion.
[0070] Furthermore, again assuming the energy storage members 54 / 56 are of a type that requires stretching (e.g., an elastic band), the energy storage members 54 / 56 must not cross the center of the hinges 50 / 52 . Allowing the energy storage members 54 / 56 to cross the center of the hinges 50 / 52 causes two problems: First, effectiveness is decreased because the energy storage member 54 / 56 cannot provide consistent force because its change in length is not proportional to the flexion of the brace. Second, after the energy storage members 54 / 56 crosses the center of the hinges 50 / 52 it may act to aid flexion, rather than extension, working against the patient rather than helping.
[0071] The benefits of integrating the grooves 70 / 72 and hinges 50 / 52 include a smaller profile hinge and thus knee brace, simplicity in construction, and a reduction in the number of required parts and fasteners.
[0072] As discussed above, optional additional straps are present in front of the patient's shin bone. When the knee injuries include damage to the ACL the use of such a strap helps to stabilize the knee and compensate for the loss.
[0073] In the disclosed knee brace 1 , the first lower anterior strap bracket 80 connects the lower anterior strap 84 to the second lower anterior strap bracket 82 . This strap crosses the anterior portion of the shin bone, preventing the tibia from sliding forward with respect to the femur.
[0074] Additionally, there is optionally a corresponding strap across the posterior of the lower leg (shin). The lower posterior strap 90 is connected to the first lower support arm 6 by the first lower posterior strap bracket 86 and to the second lower support arm 8 by the second lower posterior strap bracket 88 .
[0075] The first lower support arm 6 and second lower support arm 8 are connected across a patient's thigh by flexible lower cuff 100 . A lower cuff pad 102 provides cushion between the patient's leg and the flexible lower cuff 100 . On the posterior side of the brace is an upper cuff strap 104 , engaging with the first lower support arm 6 through a first lower clip 106 , in turn engaging a first lower pin 110 (not shown). On the other side of the brace, the lower cuff strap 104 engages with the second lower support arm 8 through a second lower clip 108 , in turn engaging a second lower pin 112 .
[0076] In other examples the flexible lower cuff 100 is only semi-flexible, or rigid. If so, it is sometimes integrated with one of both of the first lower support arm 6 and second lower support arm 8 .
[0077] Referring to FIGS. 3 and 4 , the bending of the knee brace 1 will be described. FIG. 3 shows the knee brace 1 in its fully extended position.
[0078] The second lower support arm 8 is contacting the extension stop 44 at extension contact point 45 .
[0079] FIG. 4 shows the knee brace 1 in its nearly fully flexed position. The second lower support arm 8 is nearly contacting the flexion stop 42 at flexion contact point 43 .
[0080] A comparison between FIGS. 3 and 4 shows the lengthening of the second energy storage member 56 . The energy storage member(s) 54 / 56 lengthen during flexion, gathering energy that is later released to assist the patient's leg during extension.
[0081] In FIG. 3 the flexible upper cuff 10 and upper cuff strap 14 with associated attachment hardware are shown slightly clockwise rotated. This is exemplary only, providing an example of how the rotation of the patient's thigh may be compensated for by the knee brace 1 .
[0082] Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
[0083] It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | A knee brace including a swing assist system for the storage and return of energy is disclosed. The knee brace optionally includes bladders for the application of pressure to the knee joint and/or shin of a patient. An optional swing assist mechanism is present at the hinge(s) of the brace, aiding in the extension of the patient's leg and, therefore, correcting the patient's gait. | 0 |
PRIORITY
[0001] This application is a continuation of application Ser. No. 10/004,707, filed on Dec. 3, 2001, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to digital communications technology applied to a transmitter/receiver in a base station and a transmitter/receiver in a mobile station having a turbo encoder. In particular, the present invention relates to a device and method for effectively implementing an interleaver for a turbo encoder. In addition, the present invention provides a technique for removing a puncturing-caused delay.
[0004] 2. Description of the Related Art
[0005] The transmitters/receivers in digital communication systems include channel encoders and decoders. The most widely used channel encoders are convolutional encoders and turbo encoders. The turbo encoder has an internal interleaver that changes the order of data output from a memory relative to the original order of the memory data input by generating random read addresses.
[0006] In general, when puncturing a signal and outputting the next valid signal in the course of successive signal outputting, the puncturing causes an output delay, that is, non-successive output of valid signals before and after the puncturing. FIG. 1 is a block diagram of a conventional interleaver 10 . In FIG. 1 , reference numeral 11 denotes an address generator for generating addresses to change the sequence of input data when it is output. The address generator 11 generates (K-S) invalid addresses if the size S of the input data is less than the size K of a two-dimensional matrix. Reference numeral 12 denotes a puncturer for puncturing the invalid addresses.
[0007] FIG. 2 illustrates a puncturing-caused output delay in the conventional interleaver 10 . Reference numeral 21 denotes an example of an output signal of the address generator 11 shown in FIG. 1 . Marked portions 21 A and 21 B indicate the positions of the invalid addresses. The puncturer 12 receives the addresses in the signal 21 and outputs a signal 22 shown in FIG. 2 , puncturing the marked invalid addresses. As seen from the signal 22 , the address signal is non-continuous due to the puncturing and the address after the puncturing is delayed.
[0008] This conventional technology is applied mainly to channel encoders and channel decoders in UMTS (Universal Mobile Telecommunication System) and requires additional complex operations to process a delay.
[0009] FIG. 3 is a block diagram of a turbo encoder 35 for use as a channel encoder in the UMTS system. Transmission data is fed to a first component encoder 31 and an interleaver 32 through an input port 30 in the turbo encoder 35 . The first component encoder 31 encodes the input data and outputs a first parity bit P 1 . The interleaver 32 changes the order of output data from the original order of the input data. A second component encoder 33 encodes the interleaved data and outputs a second parity bit P 2 . In the meantime, the input data is simply output as a systematic bit X. Thus, the turbo encoder 35 outputs the systematic bit X, the first parity bit P 1 , and the second parity bit P 2 for the input transmission data.
[0010] A controller (not shown) in the UMTS system determines the size of the input data ranging from 40 to 5112 bits and notifies the turbo encoder 35 of the number of input bits. Then, the turbo encoder 35 encodes the input data. The input data varies in length. The interleaver 32 includes a memory for sequentially storing the input data as it is received, and an address generator for generating read addresses according to a predetermined interleaving rule in order to output the input data in a different order. For example, a two-dimensional matrix of size K with 15 rows R and 16 columns C is 240 (K=RC), which is needed to store input data of size S of 237 bits. Therefore, the memory sequentially stores the 237-bit input data in the 240 storing areas of the matrix, leaving 3 bits of storage area unused. The address generator generates addresses according to the interleaving rule. If an interleaving index I, generated according to a predetermined interleaving rule, is greater than the input data size S (237), the address is neglected. If the generated index I is less than or equal to the input data size S (237), data stored at the address in the memory is output to the second component encoder 33 . Having to neglect the addresses larger than data size S causes non-continuous data transmission to the second component encoder 33 , and creates a time delay. The delay makes it difficult to estimate an accurate processing time in the interleaver 32 and additional control circuitry is required to reconstruct the non-continuous data into a continuous data stream.
[0011] Therefore, a need exists for effectively implementing an interleaver for a turbo encoder and to provide a technique for removing a puncturing-caused delay.
SUMMARY OF THE INVENTION
[0012] It is, therefore, an object of the present invention to provide an interleaver and a method for outputting interleaved data without a time delay.
[0013] It is another object of the present invention to provide a device and method for outputting signals without a puncturing-caused time output delay when puncturing is performed on successive output signals.
[0014] It is a further object of the present invention to provide an interleaver for providing successive data to a second component encoder in a turbo encoder.
[0015] It is a still further object of the present invention to provide a method for outputting stored data from a memory.
[0016] To achieve the foregoing and other objects, an apparatus and method are disclosed such that data of size S is stored in a memory of size K, with the memory of size K being a two-dimensional matrix with R rows and C columns, R×C, and interleaving indexes I are generated according to a predetermined interleaving rule to randomly output the data from the memory.
[0017] Disclosed is an apparatus for randomly outputting data stored sequentially in a memory, comprising a delay for receiving a first control signal at a first time period, outputting a second control signal at a second time period, and outputting a third control signal at a third time period; an index generator for receiving one of said first control signal and a fourth control signal and outputting an index upon receipt of said first or fourth control signal, said index representing a location in said memory; and a comparator for comparing said index to a reference parameter representative of the size of said data stored in said memory, and outputting upon receipt of said second control signal to said index generator said fourth control signal if said index is greater than said reference parameter. Also disclosed is an interleaver under control of a controller and having an address generator for outputting an address to a memory, said memory sequentially storing input data and outputting data stored at said address upon receipt of said address, said controller determining a data size of said input data, comprising a delay for receiving a primary index enable signal and outputting a comparator enable signal at a first time period, and outputting an address generator enable signal at a second time period; an index generator for receiving one of said primary index enable signal and a secondary index enable signal, and outputting an index upon receipt of said primary index enable signal or said secondary index enable signal; and a comparator for comparing upon receipt of said comparator enable signal said index and said data size and outputting said secondary index enable signal if said index is greater than said data size; wherein an input of said address generator is connected to the output of said index generator, and outputs upon receipt of said address generator enable signal a memory address associated with a most recently generated index.
[0018] Additionally disclosed is a method of outputting stored data from a memory, comprising the steps of sequentially storing input data into said memory; determining the size of the stored input data; receiving a first control signal and generating a first index; comparing said first index to said data size and generating a second index if said first index is greater than said data size; generating a second control signal; outputting a memory address associated with said first index if said second index is not generated; and outputting a memory address associated with said second index if said second index is generated.
[0019] Generally, if a first index I is greater than data size S, a second index is generated and output prior to outputting invalid data stored in the memory at the location of the first index. Here, puncturing is defined as outputting the next interleaving index without outputting an index greater than the data size. This is similar to the concept of pruning as utilized in the 3GPP (Third Generation Partnership Project).
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
[0021] FIG. 1 illustrates a typical interleaver;
[0022] FIG. 2 illustrates output signals having puncturing-caused time output delay as output from the typical interleaver of FIG. 1 ;
[0023] FIG. 3 illustrates a typical turbo encoder;
[0024] FIG. 4 illustrates an interleaver according to an embodiment of the present invention;
[0025] FIG. 5 is an operational timing diagram of the interleaver according to an embodiment of the present invention; and
[0026] FIG. 6 is a flowchart illustrating the operation of the interleaver according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] A preferred embodiment of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
[0028] Referring now to the drawings, in which like reference numerals identify similar or identical elements throughout the figures, an interleaver according to an embodiment of the present invention will be described with reference to FIG. 4 . Interleaver 40 sequentially stores input data in a memory 45 under the control of a turbo encoder controller (not shown). A primary index enable signal IN_EA 1 is periodically generated by the turbo encoder controller at each time T. The primary index enable signal IN_EA 1 is applied to the input of an index generator 43 and a delay 41 , for use in generating address indexes. Delay 41 delays the primary index enable signal IN_EA 1 by a time T 1 shorter than the period for generating the primary index enable signal IN_EA 1 (i.e., T 1 <T). Delay 41 outputs a first delayed signal as a comparator enable signal COMP_EA. That is, the comparator enable signal COMP_EA is generated before a second primary index enable signal IN_EA 1 is generated.
[0029] The index generator 43 stores information relating to the size K of the two-dimensional matrix and initial parameters needed for generating a pseudo random number. Upon receipt of the primary index enable signal IN_EA 1 , the index generator 43 outputs an index I (I=0, . . . K-1) less than or equal to K using the given initial parameters according to a predefined rule, for example, as defined in the UMTS standard. Index I is input into a comparator 42 and an address generator 44 . The comparator 42 compares index I with the input data size S. If index I is greater than the input data size S, the comparator 42 outputs a secondary index enable signal IN_EA 2 .
[0030] The secondary index enable signal IN_EA 2 is input into the index generator 43 and causes the index generator 43 to generate another index I. The index generator 43 generates an index I upon receipt of either the primary or secondary index enable signal.
[0031] Delay 41 also generates an address enable signal ADD_EA by delaying the primary index enable signal IN_EA 1 for a time T 2 . Time T 2 is longer than the time TI of the comparator enable signal COMP_EA, but less than time T, the period of the primary index enable signal IN_EA 1 (i.e., T 1 <T 2 <T). Delay 41 transmits the address enable signal ADD_EA to the address generator 44 . When address generator 44 receives the address enable signal ADD_EA, the address generator 44 converts the index I received from the index generator 43 to a read address for the memory 45 . Memory 45 then outputs the data stored in that address. Index I at the input of the address generator 44 , at the time the address enable signal ADD_EA is received, is either that index generated by the primary index enable signal IN_EA 1 or the next index I generated by the secondary index enable signal IN_EA 2 , if so generated by comparator 42 . If the index I generated at the primary index enable time is less than the input data size S, the index I is converted to a read address by address generator 44 . If the generated index is greater than the two-dimensional matrix size K, the next index, generated in response to the secondary index enable signal IN_EA 2 output from the comparator 42 , is converted to a read address by address generator 44 . Since the comparator enable signal COMP_EA and the address enable signal ADD_EA are generated before the next primary index enable signal IN_EA 1 , read addresses are successively generated without time delay.
[0032] As is known in digital processing, data is preferably processed on a multiple of a byte (8 bits) basis because the processor, or controller, is designed to process data on the multiple of a byte basis. Data is stored in 8 bits or a multiple of 8 bits at the address designated by the read address in the memory. The four LSBs (Least Significant Bits) of the address represent a row in the (15×16) two-dimensional matrix and its four MSBs (Most Significant Bits) represent a column in the matrix. The controller reads 16 bits in the row designated by the 4-bit LSB and outputs a bit corresponding to the column designated by the 4-bit MSB to the second component encoder. Then, a second component encoder receives successive bits from the interleaver and generates second parity bits. The first component encoder outputs first parity bits by encoding sequential input data without interleaving. The delay requires extensive retiming of the data stream to maintain correlation between the data processed by the encoders. However, since the interleaver according to an embodiment of the present invention produces output data without any puncturing-caused delay, there is no need to consider and compensate for puncturing-caused time output delay to match the data output from the first and the second component encoders.
[0033] FIG. 5 is an operational timing diagram of the interleaver shown in FIG. 4 . In FIG. 5 , signal 51 indicates the primary index enable signal IN_EA 1 . The primary index enable signal IN_EA 1 is generated at every time period T. Signal 51 shows eight primary index enable signals IN_EA 1 51 a - 51 h being generated. Signal 52 shows both the primary index enable signal IN_EA 1 and the secondary index enable signal IN_EA 2 . Two secondary index enable signals IN_EA 2 52 a and 52 b are shown. The combination of primary and secondary index enable signals IN_EA 1 and IN_EA 2 shown on signal line 52 are the inputs to index generator 43 . Signal 53 indicates indexes generated from the index generator 43 , and, in this example, consist of ten indexes 53 A- 53 J. As seen from signal 53 , new indexes are output in response to each of the primary and secondary index enable signals IN_EA 1 and IN_EA 2 . Signal 54 indicates the comparator enable signal COMP_EA, and consists of eight generated signals 54 a - 54 h . The comparator enable signal COMP_EA is produced by delaying the primary index enable signal IN_EA 1 by the first time period T 1 , where T 1 is less than T (i.e., T 1 <T). Signal 55 indicates the address enable signal ADD_EA, and also consists of eight signals 55 a - 55 h . The address enable signal ADD_EA is produced by delaying the primary enable signal IN_EA 1 by a second time period T 2 , where T 2 is greater than T 1 but less than T (i.e., T 1 <T 2 <T). Signal 56 indicates an address signal output from the address generator 44 . As shown in FIG. 5 , eight address signals 56 A′, 56 B′, 56 C′, 56 E′, 56 F′, 56 H′, 56 I′, and 56 J′, are produced as outputs of address generator 44 .
[0034] A description of the operation of the interleaver according to an embodiment of the present invention will now be described with respect to FIGS. 4 and 5 . Memory size K and initial interleaver parameters are stored in a memory of the turbo encoder. Input data is received into memory 45 , and the data size S is determined and stored in the turbo encoder memory. A first index 53 A is output by index generator 43 upon receipt of a first primary index enable signal IN_EA 1 51 a . A first comparator enable signal COMP_EA 54 a is generated by delaying the first primary index enable signal IN_EA 1 51 a in delay 41 for a first time period equal to T 1 . Comparator 42 compares the first index 53 A with the input data size S. Since, in this example, index 53 A is less than S, a secondary index enable signal IN_EA 2 is not generated. After the first primary index enable signal IN_EA 1 51 a is delayed by the second time period T 2 , delay 41 outputs a first address enable signal ADD_EA 55 a , that is received by address generator 44 , which in turn outputs an address 56 A′. Address generator 44 supplies address 56 A′ to memory 45 causing memory 45 to output data stored at address location 56 A′. The data output is forwarded to the second component encoder 33 for encoding.
[0035] A second index 53 B is output by index generator 43 upon receipt of a second primary index enable signal IN_EA 1 51 b . A second comparator enable signal COMP_EA 54 b is generated by delaying the second primary index enable signal IN_EA 1 51 b in delay 41 for the first time period T 1 . Comparator 42 compares the second index 53 B with the input data size S. Since again, in this example, index 53 B is less than S, a secondary index enable signal IN_EA 2 is not generated. After the second primary index enable signal IN_EA 1 51 b is delayed by the second time period T 2 , delay 41 outputs a second address enable signal ADD_EA 55 b , that is received by address generator 44 , which in turn outputs an address 56 B′. Address generator 44 supplies address 56 B′ to memory 45 causing memory 45 to output data stored at address location 56 B′. The data output is forwarded to the second component encoder 33 for encoding.
[0036] A third index 53 C is output by index generator 43 upon receipt of a third primary index enable signal IN_EA 1 51 c . A third comparator enable signal COMP_EA 54 c is generated by delaying the third primary index enable signal IN_EA 1 51 c in delay 41 for the first time period T 1 . Comparator 42 compares the third index 53 C with the input data size S. Since again, in this example, index 53 C is less than S, a secondary index enable signal IN_EA 2 is not generated. After the third primary index enable signal IN_EA 1 51 c is delayed by the third time period T 2 , delay 41 outputs a third address enable signal ADD_EA 55 c , that is received by address generator 44 , which in turn outputs an address 56 C′. Address generator 44 supplies address 56 C′ to memory 45 causing memory 45 to output data stored at address location 56 C′. The data output is forwarded to the third component encoder 33 for encoding.
[0037] When a fourth primary index enable signal IN_EA 1 51 d is supplied to interleaver 40 , index generator 43 outputs a fourth index 53 D. A fourth comparator enable signal COMP_EA 54 d is generated after the fourth primary index signal IN_EA 1 51 d is delayed by the first time period T 1 . Comparator 42 compares the fourth index 53 D with data size S. In this example, the index 53 D is greater than data size S, and therefore, comparator 42 generates a secondary index enable signal IN_EA 2 52 a . In response to the secondary index enable signal IN_EA 2 52 a , index generator 43 generates a fifth index 53 E upon receipt of the secondary index enable signal IN_EA 2 52 a . After the fourth primary index enable signal IN_EA 1 51 d is delayed by the second time period T 2 , delay 41 outputs a fourth address enable signal ADD_EA 55 d , and address generator 44 outputs an address 56 E′ in accordance with the fourth address enable signal ADD_EA 55 d . As address generator 44 did not receive an address enable signal ADD_EA when fourth index 53 D was at its input, address generator 44 did not process the fourth index 53 D. It was only when the fourth address enable signal ADD_EA 55 d was received at address generator 44 that address generator 44 outputs a valid address 56 E′ based on the fifth index 53 E being present at the input of address generator 44 when the fourth address enable signal ADD_EA 55 d is received. In this manner, the invalid index of 53 D is ignored as it represents a memory address greater than the data size S, and a next index 53 E is generated by index generator 43 before address generator 44 acts upon the invalid address. Address generator 44 supplies address 56 E′ to memory 45 causing memory 45 to output data stored at address location 56 E′. The data output is forwarded to the third component encoder 33 for encoding.
[0038] A sixth index 53 F is output by index generator 43 upon receipt of a fifth primary index enable signal IN_EA 1 51 e . A fifth comparator enable signal COMP_EA 54 e is generated by delaying the fifth primary index enable signal IN_EA 1 5 l e in delay 41 for the first time period T 1 . Comparator 42 compares the sixth index 53 F with the input data size S. Since again, in this example, index 53 F is less than data size S, a secondary index enable signal IN_EA 2 is not generated. After the fifth primary index enable signal IN_EA 1 51 e is delayed by the fifth time period T 2 , delay 41 outputs a fifth address enable signal ADD_EA 55 e , that is received by address generator 44 , which in turn outputs an address 56 F′. Address generator 44 supplies address 56 F′ to memory 45 causing memory 45 to output data stored at address location 56 F′. The data output is forwarded to the fifth component encoder 33 for encoding.
[0039] When a sixth primary index enable signal IN_EA 1 51 f is supplied to interleaver 40 , index generator 43 outputs a seventh index 53 G. A sixth comparator enable signal COMP_EA 54 f is generated after the sixth primary index signal IN_EA 1 51 f is delayed by the first time period T 1 . Comparator 42 compares the seventh index 53 G with data size S. In this example, the index of 53 G is again greater than data size S, and therefore, comparator 42 generates a secondary index enable signal IN_EA 2 52 b . In response to the secondary index enable signal IN_EA 2 52 b , index generator 43 generates a eighth index 53 H upon receipt of the secondary index enable signal IN_EA 2 52 b . After the sixth primary index enable signal IN_EA 1 51 f is delayed by the second time period T 2 , delay 41 outputs a sixth address enable signal ADD_EA 55 f , and address generator 44 outputs an address 56 H′ in accordance with the sixth address enable signal ADD_EA 55 f . As address generator 44 did not receive an address enable signal ADD_EA when seventh index 53 G was at its input, address generator 44 did not process the seventh index 53 G. It was only when the sixth address enable signal ADD_EA 55 f was received at address generator 44 that address generator 44 outputs a valid address 56 H′ based on the eighth index 53 H being present at the input of address generator 44 when the sixth address enable signal ADD_EA 55 f is received. In this manner, the invalid index of 53 G is ignored as it represents a memory address greater than the data size S, and a next index 53 H is generated by index generator 43 before address generator 44 acts upon the invalid address. Address generator 44 supplies address 56 H′ to memory 45 causing memory 45 to output data stored at address location 56 H′. The data output is forwarded to the third component encoder 33 for encoding.
[0040] The process continues in a manner similar to the processing of index 53 A for processing indexes 53 I and 53 J, resulting in the generation of addresses 56 I′ and 56 J′ by address generator 44 . This completes one cycle of eight primary index enable signals. In the earlier example where data size S equals 237, this process would continue until all of the 237 valid addresses are generated.
[0041] As described above, if a generated index I is greater than data size S, the secondary index enable signal IN_EA 2 is generated immediately after the comparator 42 is enabled, and a next index is generated by index generator 43 . Then, the address enable signal ADD_EA is generated to thereby generate an address without a time delay. According to the interleaving rule of the UMTS system, no values greater than S are successively generated for input data of any size, and therefore, there is no need for comparing an index generated by the secondary enable signal IN_EA 2 with data size S.
[0042] In the above description, an index is used as a medium to generate an address. Alternatively, the index itself can be output as an address. In this case, the index generator 43 functions as an address generator that selectively outputs an address in response to the address enable signal ADD_EA.
[0043] FIG. 6 is a flowchart illustrate operation of the interleaver 40 according to an embodiment of the present invention. Referring to FIG. 6 , stored in the turbo encoder are the two-dimensional matrix values, R, C and K, and an initial parameter for interleaving. In step 61 , the turbo encoder stores input data sequentially into the memory and determines data size S. In step 62 , a first primary index enable signal IN_EA 1 is received by the delay 41 and the index generator 43 . In step 63 , index generator 43 generates a first index. In step 64 , index I is compared with data size S to determine if I is less than or equal to S. If it is determined that index I is less than or equal to data size S, in step 65 data associated with the first index is output. But, if in step 64 it is determined that index I is greater than data size S, the index generator 43 of interleaver 40 , generates a secondary index enable signal in step 66 . Then, in step 67 , index generator 43 generates a second index. The second index is sent to address generator 44 to output, in step 65 , data associated with the second index. Then in step 68 the turbo encoder controller determines if the number of output indexes is equal to data size S. If the number of output indexes is not equal to data size S, the process returns to step 62 to await a second primary index enable signal. But, if the number of output indexes is equal to data size S, the process ends to await the next block of data, if any.
[0044] Therefore, the inventive device and method enables successive data output without puncturing-caused time delay. While the invention has been shown and described with reference to a certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | Disclosed is a device and method such that data of size S is stored in a memory of size K, a two-dimensional matrix with R rows and C columns, and interleaving indexes I are generated according to a predetermined interleaving rule to randomly output the data from the memory. If a first index I is greater than data size S, a second index is generated and output prior to outputting invalid data stored in the memory at the location of the first index. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a photomask blank for manufacturing a lithography mask such as a photomask to be used in a lithographic process in the manufacture of a semiconductor device, and more particularly to a halftone type phase shift mask blank which is particularly suitable for a KrF excimer laser, an ArF excimer laser and an F 2 excimer laser and a method of manufacturing the halftone type phase shift mask blank.
[0003] 2. Description of the Related Art
[0004] In recent years, it has been apparent that an increase in a resolution and the maintenance of a focal depth which are two important characteristics required for a photolithography are contrary to each other and a practical resolution cannot be enhanced by an increase in the NA of the lens of an exposing apparatus and a reduction in a wavelength (Monthly Semiconductor World 1990. 12, Applied Physics Vol. 60, November (1991)).
[0005] Under such circumstances, attention has been paid to a phase shift lithography as a photolithographic technique in a next generation and a part thereof has been used practically. The phase shift lithography is a method of enhancing the resolution of an optical lithography by changing only a mask without a variation in an optical system, and serves to give a phase difference between exposed lights transmitted through a photomask, thereby rapidly enhancing a resolution by utilizing a mutual interference of the transmitted lights.
[0006] The phase shift mask uses light intensity information and phase information together and various types such as a Levenson type, an auxiliary pattern type and a self-alignment type (an edge enhancement type) have been known. These phase shift masks have more complicated structures and require a more advanced technique for manufacture as compared with a conventional photomask having only the light intensity information.
[0007] As one of the phase shift masks, recently, a phase shift mask referred to as a so-called halftone type phase shift mask has been used practically.
[0008] Since the half tone type phase shift mask has both a shielding function of substantially shielding an exposed light by a light semitransmitting section and a phase shift function of shifting (usually inverting) the phase of a light, it has a feature that a shielding film pattern and a phase shift film pattern do not need to be formed separately, and a structure is simplified and manufacture can also be carried out easily.
[0009] In the half tone phase shift mask, a mask pattern is processed at a dry etching step. In a method of implementing the shielding function and the phase shift function by separate layers, it is necessary to carry out advanced control for obtaining an excellent pattern shape for both the layer having the shielding function and the layer having the phase shift function. On the other hand, it is possible to use the single etching step by constituting the single-layered light semitransmitting section having both the shielding function and the phase shift function. Consequently, a process for manufacturing a mask can be simplified and an excellent pattern shape can easily be obtained.
[0010] As shown in FIG. 1, the halftone type phase shift mask constitutes a mask pattern to be formed on a transparent substrate 100 by a light transmitting section (a transparent substrate exposing section) 200 for transmitting a light having such an intensity as to substantially contribute to exposure and a light semitransmitting section (a shielding section and phase shifter section) 300 for transmitting a light having such an intensity as not to substantially contribute to the exposure (FIG. 1( a )), the phase of the light transmitted through the light semitransmitting section 300 is shifted to have such a relationship that the phase of the light transmitted through the light semitransmitting section 300 is substantially inverted from the phase of the light transmitted through the light transmitting section 200 (FIG. 1( b )), and lights transmitted through the vicinity of the boundary part of the light semitransmitting section 300 and the light transmitting section 200 and going around the other mutual regions by a diffraction phenomenon are set to be cancelled from each other and a light intensity in the boundary part is set to be almost zero, thereby enhancing a contrast, that is, a resolution in the boundary part (FIG. 1( c )).
[0011] Moreover, a light semitransmitting section and a light semitransmitting film (a phase shift layer) in the halftone type phase shift mask or blank are to have a sufficient durability to a pretreatment such as washing in a mask manufacturing process and washing in the use of the mask or an acid solution such as sulfuric acid to be used as a washing liquid and a sufficient durability to an alkaline solution such as ammonium.
[0012] Referring to a phase shift mask capable of implementing these desired optimum characteristics by a single-layered light semitransmitting section, a proposal for a molybdenum silicide oxide nitride film (JP-A-6-214792 and Japanese Patents Nos. 2878143 and 2989156) has been made.
[0013] When the wavelength of a laser to be used for exposure is reduced from i rays (365 nm) or a KrF excimer laser (248 nm) to an ArF excimer laser (193 nm), the deviation of a phase angle with respect to an amount of a change in the thickness of a film is increased. Consequently, it is necessary to enhance a durability to the acid solution and the alkaline solution of the phase shift mask according to the reduction in the wavelength of the exposure.
[0014] When the wavelength of the laser to be used for the exposure is reduced, moreover, the energy of a laser beam is increased. Consequently, there is a problem in that the damage of the light semitransmitting section caused by the exposure is increased and a transmittance and a phase difference which are set are deviated for a period of the lifetime of use which is required for the phase shift mask.
[0015] On the other hand, the wavelength of an exposing light source to be used for a lithography has been reduced and the NA of the lens of an exposing apparatus has been increased with the microfabrication of a semiconductor circuit. However, the increase in the NA of the lens of the exposing apparatus and the maintenance of a focal depth are contrary to each other.
[0016] In order to maintain the focal depth, a flatness has been required for a photomask more strictly. In recent years, a flatness of 0.3 to 0.5 μm has been required. The flatness of the photomask depends on the bending strength of a transparent substrate, the flatness of the substrate which is obtained before the formation of a film, and the internal stress of a film for forming a circuit pattern. In particular, the internal stress of the film for forming the circuit pattern has become a serious problem.
[0017] Under such circumstances, in the application (Japanese Patent Application No. 2001-246080) filed by the applicant, the density of a light semitransmitting section is increased in order to enhance an acid resistance, an alkali resistance and an excimer laser irradiation resistance of the phase shift mask. This application has disclosed a method of dropping a pressure in an atmosphere including argon and a reactive gas to be used for forming a film constituting the light semitransmitting section by sputtering in order to increase the density of the light semitransmitting section.
[0018] Furthermore, the application has disclosed a method of relieving the compressive stress of a light semitransmitting film by carrying out a heat treatment after the formation of the light semitransmitting film based on the fact that the internal stress of the film is increased with a reduction in the pressure in the atmosphere for the execution of the sputtering.
[0019] On the other hand, in the application, a heat treatment is to be carried out at a very high temperature (for example, 600 ° C.) in order to obtain a predetermined stress in some cases. Furthermore, there has been required a method capable of efficiently relieving a compressive stress by the heat treatment.
SUMMARY OF THE INVENTION
[0020] In consideration of the problems described above, it is an object of the invention to provide a method capable of effectively reducing the stress of a thin film for forming a pattern.
[0021] The invention has the following structures.
[0022] (Structure 1) A method of manufacturing a photomask blank having at least a film for forming a mask pattern on a transparent substrate, comprising the steps of:
[0023] causing a sputtering atmosphere to contain at least a helium gas to form at least one layer of the film for forming the mask pattern by sputtering; and
[0024] heating the transparent substrate during or after the film forming step.
[0025] (Structure 2) The method of manufacturing a photomask blank according to the structure 1, wherein the film for forming the mask pattern is provided by sputtering using a mixed gas containing argon and helium as a sputtering gas at the film forming step.
[0026] (Structure 3) The method of manufacturing a photomask blank according to the structure 1 or 2, wherein the photomask blank is a halftone type phase shift mask blank, and the film for forming the mask pattern is a light semitransmitting film constituted by at least one layer which has a predetermined transmittance for an exposed light and shifts a phase of the exposed light with respect to the transparent substrate in a predetermined amount.
[0027] (Structure 4) The method of manufacturing a photomask blank according to any of the structures 1 to 3, wherein the light semitransmitting film includes a film formed by a material containing silicon and nitrogen and/or oxygen, or a metal, silicon and nitrogen and/or oxygen.
[0028] (Structure 5) The method of manufacturing a photomask blank according to any of the structures 1 to 4, wherein a heat treating temperature at the step of heating the transparent substrate is 180° C. or more.
[0029] (Structure 6) A photomask manufactured by using the photomask blank according to any of the structures 1 to 5.
[0030] The invention will be described below in detail.
[0031] The invention provides a method of manufacturing a photomask blank having at least a film for forming a mask pattern on a transparent substrate, comprising the steps of:
[0032] causing a sputtering atmosphere to contain at least a helium gas to form at least one layer of the film for forming the mask pattern by sputtering; and
[0033] heating the transparent substrate during or after the film forming step (structure 1).
[0034] Based on the experiment of the inventors, the invention was achieved by partially or wholly replacing argon with helium to more reduce a compressive stress than that in the case in which the argon has conventionally been used as a sputtering gas. Moreover, it was found that a pressure stress can be reduced more effectively by the execution of a heat treatment during or after the formation of a film. The reason is guessed as follows. Helium which is easily volatilized is caused to be previously present in a film and the helium is volatilized by the heat treatment so that the compressive stress in the film tends to be relieved.
[0035] In the invention, a sputtering pressure is preferably 0.20 to 0.40 Pa, more preferably 0.23 to 0.35 Pa and most preferably 0.25 to 0.31 Pa. If a pressure in the sputtering atmosphere is low as in the range described above, the density of a light semitransmitting film can be increased to cause the same film to be minute. By causing the thin film to be minute, a chemical resistance to acid or alkali, a light resistance and an excimer laser irradiation resistance can be enhanced, and furthermore, pattern precision in a fine pattern can also be improved. When the pressure is less than that within the range, there is a possibility that the internal stress of the film might be so increased as not to be improved by the heat treatment and the stability of the formation of the film might be influenced.
[0036] In the invention, in the case in which the film for forming the mask pattern includes a film having the property of a compressive stress of at least one layer, the compressive stress of the film having the property of the compressive stress can be reduced. The property of the compressive stress implies that a stress applied when only Ar is used as a sputter gas is set to be the compressive stress.
[0037] In the case in which a film having the property of the compressive stress for forming the mask pattern on a transparent substrate has a multilayer structure as will be described below, it is preferable that at least one layer should be subjected to sputtering within the range of a sputtering pressure and it is more preferable that all the films should be subjected to the sputtering within the range of the sputtering pressure.
[0038] In the invention, the preferable sputtering gas in the sputtering atmosphere is a mixed gas containing an inert gas such as argon and helium. It is possible to use another inert gas in place of argon and to add another inert gas to the mixed gas containing argon and helium.
[0039] In the case in which a reactive gas such as nitrogen or oxygen is added into the sputtering atmosphere to carry out reactive sputtering, a preferable content of a sputtering gas is 25 to 34% for He. If the content is less than a lower limit, the effect of reducing a stress is lessened. If the content is more than an upper limit, a sputter rate is reduced so that a productivity is deteriorated. The content of Ar is 5 to 15%. If the content is less than a lower limit, an optical characteristic becomes extremely unstable. If the content is more than an upper limit, the sputter rate is reduced so that the productivity is deteriorated.
[0040] In the invention, examples of the film for forming the mask pattern on the transparent substrate include a light semitransmitting film in a halftone type phase shift mask and a shielding film in a photomask.
[0041] The light semitransmitting film in the halftone type phase shift mask includes a light semitransmitting film having a single layer structure and a light semitransmitting film having a multilayer structure designed in such a manner that a layer having a low transmittance and a layer having a high transmittance are provided in at least two layers and a phase angle and a transmittance have desirable values.
[0042] Examples of the light semitransmitting film having a single layer structure include a material containing oxygen and/or nitrogen in a metal and silicon, a material containing carbon and/or fluorine and/or hydrogen therein, chromium oxide and chromium fluoride, and it is preferable that the light semitransmitting film should be substantially formed of a metal, silicon and nitrogen and/or oxygen. The metal is at least one selected from titanium, vanadium, niobium, molybdenum, tantalum and tungsten. The metal to be usually used often is molybdenum. Molybdenum is particularly excellent in the controllability of a transmittance and a target density in the metals. Titanium, vanadium and niobium are excellent in a durability to an alkali solution and have target densities which are slightly less than the target density of molybdenum.
[0043] Tantalum is excellent in the durability to the alkali solution and the target density and has the controllability of a transmittance which is slightly less than that of molybdenum.
[0044] Tungsten has a similar property to molybdenum and has a discharge characteristic in sputtering which is slightly less than that of molybdenum.
[0045] For the light semitransmitting film having a multilayer structure, it is preferable to use a layer having a high transmittance which is substantially formed of silicon and nitrogen and/or oxygen or a layer having a high transmittance which is substantially formed of a metal (which is the same as the metal in the light semitransmitting film having a single layer structure), silicon and nitrogen and/or oxygen, and to use, for a layer having a low transmittance, a metallic film formed of at least one alloy comprising chromium, molybdenum, tantalum, titanium, tungsten, hafnium and zirconium, or oxides, nitrides, acid nitrides and suicides of these metals or alloys.
[0046] Examples of the shielding film in a photomask include a shielding film having a single layer or multilayer structure formed of chromium or a chromium compound containing oxygen, nitrogen or carbon in chromium or another chromium compound.
[0047] In the invention, in the case in which the film for forming the mask pattern on the transparent substrate has the multilayer structure, it is preferable that at least a film having the property of the compressive stress should contain at least a helium gas in the sputtering atmosphere to carry out sputtering film formation. A film formed by a material containing silicon and nitrogen and/or oxygen, or a metal, silicon and/or nitrogen or oxygen usually has the property of the compressive stress.
[0048] In the invention, the temperature of the heat treatment at the step of heating the transparent substrate during or after the film forming step is preferably 180° C. or more and more preferably 200° C. or more, 300° C. or more and 400° C. or more in order to effectively volatilize helium in the film and to advantageously relieve the compressive stress in the film. When the temperature is raised to be high, a long heat arrival time in a heat treating apparatus is taken and the apparatus is managed with more difficulty. Consequently, a temperature of 500° C. or less is practically preferable.
[0049] As an atmosphere for the heat treatment, it is possible to use an atmosphere or an inert gas such as nitrogen or argon.
[0050] In a gas containing oxygen such as an atmosphere, the characteristic of a light semitransmitting film is slightly changed by the heat treatment in some cases. For this reason, it is preferable that the light semitransmitting film should be formed in consideration of the change during the film formation.
[0051] In the case in which the characteristic of the film is to be prevented from being changed by the heat treatment, it is preferable that the heat treatment should be carried out in an inert gas atmosphere. In case of a heat treatment having a high temperature (for example, 380° C. or more), particularly, the amount of a change in the characteristic of a film is also large. For this reason, it is desirable that the heat treatment should be carried out in the inert gas atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] [0052]FIG. 1 is a diagram for explaining the transfer principle of a halftone type phase shift mask,
[0053] [0053]FIG. 2 is a typical diagram showing a DC magnetron sputtering apparatus used in the embodiments, and
[0054] [0054]FIG. 3 is a chart showing the relationship between an amount of introduction of He and an amount of a change in a flatness.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] Embodiments of the invention will be described below in detail.
[0056] (First Embodiment)
[0057] In the embodiment, description will be given to an advantage obtained by using helium as a sputtering gas and the effect of a heat treatment to be carried out after the formation of a film.
[0058] By using a DC magnetron sputtering apparatus shown in FIG. 2, a light semitransmitting film having a single layer which is substantially formed of molybdenum, silicon and nitrogen was formed on a transparent substrate and a halftone type phase shift mask blank was thus fabricated.
[0059] The DC magnetron sputtering apparatus has a vacuum tank 1 and a magnetron cathode 2 and a substrate holder 3 are provided in the vacuum tank 1 . A sputtering target 5 bonded to a backing plate 4 is attached to the magnetron cathode 2 . The backing plate 4 is directly or indirectly cooled by a water cooling mechanism. The magnetron cathode 2 is electrically coupled to the backing plate 4 and the sputtering target 5 . A transparent substrate 6 is attached to the substrate holder 3 .
[0060] A gas is exhausted from the vacuum tank 1 through an exhaust port 7 by means of a vacuum pump. After an atmosphere in the vacuum tank 1 reaches such a degree of vacuum as not to influence the characteristic of a film to be formed, a mixed gas containing nitrogen is introduced from a gas inlet 8 and a negative voltage is applied to the magnetron cathode 2 by using a DC power source 9 , thereby carrying out sputtering. A pressure in the vacuum tank 1 is measured by a pressure gauge 10 .
[0061] By using a molybdenum silicide target (Mo:Si=20:80), a mixed gas containing Ar, N 2 and He to be a sputtering gas was introduced in amounts of Ar: 10 sccm, N 2 : 80 sccm and He: 0.9, 18, 36, 54 and 69 sccm to form a light semitransmitting film (a phase angle of 182 to 184 degrees and a transmittance of 5 to 6%) on a phase shift mask blank. After the formation of the film, the phase shift mask blank was not subjected to a heat treatment and was subjected to the heat treatment at 200° C. and then 400° C. Thus, the internal stress of the light semitransmitting film was evaluated. The internal stress of the light semitransmitting film was evaluated by measuring an amount of a change in the flatness of a transparent substrate before and after the formation of the light semitransmitting film.
[0062] The flatness was measured within a range of 146 mm square excluding an end of 3 mm of a synthetic quartz substrate (152 mm×152 mm×6.35 mm), and was defined by a difference in a height between a maximum point and a minimum point from the average surface of the substrate. The flatness of the transparent substrate was measured by using an interferometer (FlatMaster 200 manufactured by TROPEL Co., Ltd.).
[0063] [0063]FIG. 3 shows the relationship between the amount of introduction of He of the sputtering gas and an amount of a change in a flatness for each of the blanks which were not subjected to the heat treatment after the formation of the film and were subjected to the heat treatment at 200° C. and then 400° C. The amount of a change in a flatness in FIG. 3 indicates a positive amount of a change, that is, a compressive stress.
[0064] As is apparent from FIG. 3, He is introduced into a sputtering gas so that the amount of a change in a flatness tends to be reduced, and the heat treatment is further carried out so that the amount of a change in a flatness can be more reduced. Thus, it is shown that the compressive stress of a light semitransmitting film can be reduced.
[0065] (Second Embodiment)
[0066] In the embodiment, description will be given to an example in which a halftone type phase shift mask blank for a KrF excimer laser (248 nm) having a single-layered light semitransmitting film which is substantially formed of molybdenum, silicon and nitrogen was manufactured.
[0067] By using the same sputtering apparatus as that in the first embodiment, Mo: Si=20:80 was used as a sputtering target and argon, nitrogen and helium were used for a sputtering gas (a gas flow rate: Ar=10 sccm, N 2 =80 sccm and He=40 sccm) to carry out regulation in such a manner that the phase angle of a light semitransmitting film is approximately 180 degrees with a film forming pressure of 0.28 Pa. Thus, the light semitransmitting film was formed. In that case, a flatness was 1.3 μm.
[0068] Then, a heat treatment was carried out for 30 minutes at 250° C. by using a heat treating apparatus.
[0069] The halftone type phase shift mask blank thus obtained had a transmittance for an exposed light of 6%, a phase angle of approximately 180 degrees, and a flatness of 0.6 μm, which satisfied desired values.
[0070] Moreover, all of a chemical resistance (an acid resistance, an alkali resistance and a functional water resistance), and a light resistance (a KrF excimer laser resistance) almost satisfied desired values.
[0071] (Third Embodiment)
[0072] In the embodiment, description will be given to an example in which a halftone type phase shift mask blank for an ArF excimer laser (193 nm) having a single-layered light semitransmitting film which is substantially formed of molybdenum, silicon and nitrogen was manufactured.
[0073] By utilizing the same sputtering apparatus as that in the first embodiment, Mo: Si=10:90 was used as a sputtering target and argon, nitrogen and helium were used for a sputtering gas (a gas flow rate: Ar=10 sccm, N 2 =80 sccm and He=40 sccm) to carry out regulation in such a manner that the phase angle of a light semitransmitting film is approximately 180 degrees with a film forming pressure of 0.25 Pa. Thus, the light semitransmitting film was formed. In that case, a flatness was 1.3 μm.
[0074] Then, a heat treatment was carried out for 30 minutes at 250° C. by using a heat treating apparatus.
[0075] The halftone type phase shift mask blank thus obtained had a transmittance for an exposed light of 6%, a phase angle of approximately 180 degrees, and a flatness of 0.6 μm, which satisfied desired values.
[0076] Moreover, all of a chemical resistance (an acid resistance, an alkali resistance and a functional water resistance), and a light resistance (an ArF excimer laser resistance) almost satisfied desired values.
[0077] (Fourth Embodiment)
[0078] A resist film (a baking temperature: 190° C. for ArF and 180° C. for Krf) was formed on the light semitransmitting film of the phase shift mask blank according to each of the second and third embodiments and a resist pattern was formed by pattern exposure and development. Next, an exposed portion was removed by etching (dry etching using a CF 4 +O 2 gas), and the pattern (a hole or a dot) of the light semitransmitting film, that is, a light semitransmitting section was obtained. After the resist was removed, the light semitransmitting section was immersed in 98% sulfuric acid (H 2 SO 4 ) at 100° C. for 15 minutes and was washed with the sulfuric acid, and was then rinsed with pure water. Thus, a phase shift mask for an ArF excimer laser and a phase shift mask for a KrF excimer laser were obtained.
[0079] While the invention has been described by taking the preferred embodiments as examples, the invention is not restricted to the embodiments.
[0080] For example, the invention can be applied to a halftone type phase shift mask or blank including a light semitransmitting film having a multilayer structure or a photomask or photomask blank having a single-layered or multilayered shielding film in addition to a halftone type phase shift mask or blank having a single-layered light semitransmitting film.
[0081] The invention can also be applied to a halftone type phase shift mask or blank for an F 2 excimer laser (157 nm) including a light semitransmitting section or light semitransmitting film having a single layer. Furthermore, the invention can also be applied when using an oxygen gas as a reactive gas for sputtering to form a light semitransmitting section or light semitransmitting film having a single layer or multilayer structure including a film containing silicon such as MoSiO, MoSiON, NiSiON, PdSiON, SiON or SiO and oxygen, for example.
[0082] [Advantage of the Invention]
[0083] As described above, according to the invention, a sputtering atmosphere is caused to contain at least a helium gas to form a film by sputtering and a transparent substrate (a thin film formed by the sputtering) is heated during or after the film formation. Thus, it is possible to efficiently reduce the stress of the film. | A method of manufacturing a photomask blank having at least a film for forming a mask pattern on a transparent substrate comprises the steps of causing a sputtering atmosphere to contain at least a helium gas to form a film for forming the mask pattern by sputtering, and heating the transparent substrate during or after the film forming step. | 2 |
BACKGROUND
The invention relates to an exhaust gas catalyst composition, in the following “catalyst composition”, and a process for its preparation.
The reduction of nitrogen oxide emissions represents one of the greatest challenges in environmental protection. Several approaches have been followed to reduce NO x emissions for both mobile and stationary applications including combustion modification methods and denitrification of flue gases. The former, although NO x removal efficiency varies with the technology applied, cannot achieve more than 50-60% of removal efficiency. After-treatment of flue gases can achieve substantially larger efficiencies especially when a catalytic method is employed. Several type of catalysts have been tested which are active under different environments and conditions. The use of a large number of catalysts to eliminate NO is associated with different reaction pathways that can be divided as follows (1):
1. The selective catalytic reduction of NO with ammonia (herein after referred to as SCR), for stationary applications like power stations and chemical industrial plants. 2. The catalytic reduction of NO in the presence of CO, typical of automotive pollution control. 3. The catalytic reduction of NO in the presence of hydrocarbons, a method not in use commercially but potentially interesting for automotive and industrial pollution control. 4. The direct elimination of NO through decomposition for which a durable and stable catalysts has not yet been developed. 5. The sorbing of NO or NO x -trap catalysts.
Among these methods the most widely employed technology for stationary applications is SCR (2-4). It was introduced in the late 1970s for the control of NO x emissions in stack gases for thermal power plants and other industrial facilities. SCR plants are currently operating in USA, Japan, Europe and Far East for a total capacity of the order of 180000 MW. The SCR is based on the reduction of NO x with NH 3 into water and nitrogen according to the reaction:
4NO+4NH 3 +O 2 =4N 2 +.6H 2 O
The technology is operated commercially over metal-oxide SCR catalysts made of a homogeneous mixture of TiO 2 (80-90 wt.-%), WO 3 (6-10 wt.-%) and V 2 O 5 (up to 3 wt.-%) which may contain some SiO 2 (0-10 wt.-%) in the formulation. Titania is used as an active support of high surface area to support the active component V 2 O 5 which is responsible for the activity of catalysts for NO x reduction at low and medium operation temperatures. It is also responsible for the oxidation of SO 2 to SO 3 when SO 2 containing gases are delivered to the catalyst. Therefore, for high-sulfur content off-gases, its amount is kept low (below 1 wt.-%). WO 3 (sometime also MoO 3 ) is employed as a chemical/structural promoter to enlarge the temperature window of application. Silica is often used to improve the catalyst strength and stability. Commercial catalysts are employed as honeycomb monoliths due to several advantages over a packed bed arrangement: lower pressure drop, higher attrition resistance, less plugging by fly ash.
GB 1 495 396 describes a catalyst composition containing as active ingredients oxides from titanium, at least one of molybdenum, tungsten, iron, vanadium, nickel, cobalt, copper, chromium and uranium, and as optional component(s) tin and/or at least one of silver, beryllium, magnesium, zinc, boron, aluminium, yttrium, rare earth metal, silicon, niobium, antimony, bismuth, manganese, thorium and zirconium, which oxides are present as an intimate mixture.
EP 1 145 762 A1 describes a process for the preparation of a vanadia SCR-catalyst supported on titania. The process is characterized in that the catalyst is prepared by dispersing titania in an ammonium metavanadate solution, adjusting the pH of the solution to a value of 7.0-7.1, stirring the resulting suspension for a time for complete adsorption of the vanadium compound on titania, filtering the suspension and drying and calcining the resulting catalyst compound.
In spite of the fact that SCR technology is used worldwide there are still opportunities to improve catalytic performance especially in relation to the following issues: (i) to improve catalyst design in order to obtain at the same time a higher activity in NO x removal and a lower activity in SO 2 oxidation; (ii) to limit ammonia slip and to improve the behaviour of the system under dynamic conditions; (iii) to extend the present applicable temperature range of SCR catalysts towards higher temperature up to 600° C. and to avoid deactivation which occurs at present catalysts when operated at high temperatures. It is in fact known that the activity of a V 2 O 5 /TiO 2 /SiO 2 catalyst increases markedly with a rise in calcinations temperature up to 600-650° C. and then rapidly decreases. This is mainly due to phase transformation of TiO 2 (anatase) into TiO 2 (rutile) and consequent loss of BET surface area with changes in the chemical state of surface vanadium species. Solving these issues will pave the road for use of SCR also in mobile applications; the process using urea as reducing agent is in fact investigated intensively for use in diesel or gasoline lean-burn engines (5-6). The challenges for automotive applications are high SCR activity and improved thermal stability of vanadia-tungsta-titania catalysts in the temperature range 423-1 000 K. Such extreme operating temperatures (compared to “classic” SCR applications where temperature range of the order of 573-773 K are often encountered) are certainly of short duration and may occur at very high power output (low rpm and high load).
SUMMARY
The present invention is aimed to solve the problem related to improvement of thermal stability at higher temperatures where state of the art V/Ti/W/Si and V/Ti/W catalysts still suffer strong deactivation.
The catalyst composition according to the invention is represented by the general formula
REVO/S
wherein
RE is at least one of the group of rare earth metals Y, Ce, Pr, Nd, Sm, Gd, Tb, Dy, Er and Yb in an amount of up to 6.0 wt.-%; V is vanadium in an amount of 0.2-2.5 wt.-%; O is oxygen in an amount of up to 3.5 wt.-%; and S is a support containing TiO 2 in an amount of at least 70 wt.-%, with the rest being WO 3 and optionally SiO 2 .
The invention is based on the observation that promotion of V/Ti/W/Si and V/Ti/W catalysts with rare earth (RE) strongly improves activity even after aging at temperatures of 750° C. for several hours, when the activity of state of the art catalysts drops to negligible values. This allows potential application of these catalysts in the removal of NO x from diesel or gasoline lean-burn automotive engines in addition to stationary applications at high temperatures.
In a preferred embodiment RE is at least one of the group of Pr, Sm, Gd, Tb, Dy and Er, and particularly one of the group of Sm, Gd, Tb, Dy and Er, and more preferred at least one of Er and Tb.
Also preferred is that the support S of the catalyst composition contains SiO 2 in an amount of 4-12 wt.-%, particularly in an amount of 5-10 wt.-%.
The invention is also directed to a first process (process I) for the preparation of a catalyst composition, characterized in that a solid support containing TiO 2 in an amount of at least 70 wt.-%, WO 3 in an amount of 5-20 wt.-%, and optionally SiO 2 in an amount of up to 15 wt.-%, is contacted with an aqueous solution containing an vanadium salt and a salt of at least one rare earth metal selected from the group of Y, Ce, Pr, Nd, Sm, Gd, Tb, Dy, Er and Yb to give a slurry which is brought to dryness and calcined. By bringing the solid support in contact with the solution of the rare earth salt, adsorption on the support takes place.
A second process (process II) for the preparation of a catalyst composition is characterized in that a solid support containing TiO 2 in an amount of at least 70 wt.-%, WO 3 in an amount of 5-20 wt.-%, and optionally SiO 2 in an amount of up to 15 wt.-%, is contacted with a vanadium salt and a hydroxide of at least one rare earth metal selected from the group of Y, Ce, Pr, Nd, Sm, Gd, Tb, Dy, Er and Yb to give a slurry which is brought to dryness and calcined. By bringing the solid support in contact with the hydroxide of the rare earth, adsorption on the support takes place.
A third process (process III) for the preparation of a catalyst composition is characterized in that a solid support containing TiO 2 in an amount of at least 70 wt.-%, WO 3 in an amount of 5-20 wt.-%, and optionally SiO 2 in an amount of up to 15 wt.-%, is contacted with a vanadate (REVO4) of at least one rare earth metal selected from the group of Y, Ce, Pr, Nd, Sm, Gd, Tb, Dy, Er and Yb to give a slurry which is brought to dryness and calcined. By bringing the solid support in contact with the rare earth vanadate, adsorption on the support takes place.
In a more preferred embodiment the rare earth metal is at least one of the group of Pr, Sm, Gd, Tb, Dy and Er, and particularly one of the group of Sm, Gd, Tb, Dy and Er, and more preferred at least one of Er and Tb.
The invention is also directed to a catalyst composition which is obtainable according to the inventive processes mentioned above.
The invention is also directed to a catalyst composition which is obtainable according to the inventive processes mentioned above, containing
said rare earth metal in an amount of up to 6.0 wt.-%; vanadium in an amount of up to 2.5 wt.-%; oxygen in an amount of up to 3.5 wt.-%; TiO 2 in an amount of at least 65 wt.-%, WO 3 in an amount of up to 20 wt.-%, and optionally SiO 2 in an amount of up to 15 wt.-%.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the apparatus used in catalyst testing.
FIG. 2 illustrates the overall picture of activity drop/improvement after aging and a dependence of activity on position of the element in the periodic table.
FIGS. 3 and 4 show respectively X-ray diffraction profiles of fresh and aged V 2 O 5 /WT and V 2 O 5 /WTS.
FIG. 5 shows the effect of aging treatment at temperatures in the range 650-850° C. for Tb—V—O/WTS.
DETAILED DESCRIPTION
In the following preferred embodiments of the invention are described in more detail.
The catalysts according to the invention were obtained starting from two support materials of composition 81% TiO 2 -9% WO 3 -10% SiO 2 (Ti/W/Si) and 90% TiO 2 -10% WO 3 (Ti/W). To this support, a combination of V and RE elements were added to provide a NO x reduction catalysts represented by the formula REVO/Ti—W—Si with RE=Y, Ce, Pr, Nd, Sm, Gd, Tb, Dy, Er and Yb. The content of the active phase was in the range up to 5.1 wt.-% RE element, 0.4-2.1 wt.-% vanadium and up to 2.7 wt.-% oxygen, corresponding to a REVO loading in the range of 2.5-8.5 wt.-%
1. Preparation of a Catalyst According to the Invention Containing 5.0 wt.-% Er and 1.5 wt.-% V on a Ti—W—Si Support
1.1. Preparation of the Ti—W—Si Support
Preparation of the support was carried out according to (7): 92.68 g of titanium tetrachloride (TiCl 4 ) was added dropwise to 1 liter of water under ice cooling with stirring. Then 16.06 g of Lithosol 1530 KD (a tradename for a product of Zschimmer & Schwarz Chemische Fabriken, containing 30% of SiO 2 in the sol state) were added. While thoroughly stirring the mixture at about 30° C., ammonia water was gradually added. When the pH of the mixture reached 7, the addition was stopped. The mixture was aged by allowing it to stand for 2 hours. The resulting TiO 2 —SiO 2 gel was filtered, washed with water, dried at 120° C. for 10 hours and further washed with water, then calcined at 500° C. for 3 hours. The resulting TiO 2 —SiO 2 powder contained 86 mole % of titanium and 14 mole % of silicon as SiO 2 . The resulting powder was designated as (Ti/Si).
A solution of 8.16 g of ammonium paratungstate [(NH 4 ) 10 W 12 O 41 .5H 2 O ]in 500 ml of distilled water was added to 73.4 g of (Ti/Si). They were thoroughly mixed with stirring, concentrated, dried and calcined at 500° C. for 6 hours. The resulting support had a weight % ratio TiO 2 :WO 3 :SiO 2 of 81:9:10.
1.2. Preparation of the Catalyst According to the Invention
An aliquot of 69.7 mg of ammonium metavanadate was dissolved in 10 ml of 1N oxalic acid. The solution was heated in order to obtain the blue complex (NH 4 ) 2 [VO(C 2 O 4 ) 2 ] and then 2478.2 mg of erbium acetate solution (4.6% of Er) were added under mixing. Moreover, some drops of HNO 3 were added in order to avoid the precipitation of the erbium oxalate. Then, the support (1831.8 mg of mixed oxide containing 81% TiO 2 -9% WO 3 -1 0% SiO 2 ) was added. This slurry was brought to dryness under continuous stirring at 80-100° C. Finally, the solid was dried at 120° C. overnight and calcined at 650° C. for 2 hours, pressed into pellet, crushed and sieved in the range 355-425 μm. This will be referred as fresh sample.
Aging of samples was carried out in a tubular furnace at a temperature of 750° C. for 10 hours under air.
1.3. Preparation of the Catalyst According to Process II of the Invention
1.3.1. Preparation of the Erbiumhydroxide (Er(OH) 3 )
Erbitunbydroxide was prepared by dissolving 3.82 g of Er 2 O 3 in approx. 35 ml of HNO 3 /water (1:1) mixture under stirring. As soon as the solution of Er-Nitrate was formed, conc. Ammonia solution was added until precipitation of Er-Hydroxide was completed. The precipitate was separated by filtration, washed several times with distilled water and dried at moderate temperatures (approx. 60° C.) to produce a wet cake of Er-Hydroxide having an Er content of 19.6%.
1.3.2. Preparation of the Catalyst
104. 5 mg of monoethanolamine and 3659 mg of distilled water were mixed. The solution was heated up to 90° C. and 104.54 mg of NH 4 VO 3 added under stirring. To the solution there were added 759.9 mg Er(OH) 3 (Er content being 19.6%) followed by adding of 2747.7 mg of the Ti/W/Si support (containing 81% TiO 2 -9% WO 3 -10% SiO 2 ). This slurry was brought to dryness under continuous stirring at 80-100° C. Finally, the solid was dried at 120° C. overnight and calcined at 650° C. for 2 hours, pressed into pellet, crushed and sieved in the range 355-425 μm. This will be referred as fresh sample.
Aging of samples was carried out in a tubular furnace at a temperature of 750° C. for 10 hours under air.
1.4. Preparation of the Catalyst According to Process III of the Invention
1.4.1. Preparation of the Erbiumvanadate (ErVO 4 )
The crystalline ErVO 4 is prepared by the liquid—phase reaction method.
1.032 g of NH 4 VO 3 are dissolved in distilled water at 80° C. in order to obtain a 0.1 mol/l solution; at the same time an Erbium Nitrate Solution (0.2 mol/l) is prepared by diluting 6.695 g of Er(NO 3 ) 3 solution (containing 22.16% of Er) with distilled water at 80° C.
After mixing the two solutions under continuous stirring the pH was adjusted to 7.0 with the help of ammonia (30% solution). This causes the precipitation of a white-pale pink compound (EbVO 4 ) that was filtered, washed several times with distilled water and dried at 100° C. overnight.
1.4.2. Preparation of the Catalyst
Two slurries were formed dissolving 252.3 mg of ErVO 4 and 2747.7 mg of the Ti/W/Si support (WO 3 /TiO 2 -(10%)SiO 2 ) in distilled water. The two slurries were mixed heating up to 90° C. and stirring. The final slurry was brought to dryness under continuous stirring at 80-100° C. Finally, the solid was dried at 120° C. overnight and calcined at 650° C. for 2 hours, pressed into pellet, crushed and sieved in the range 355-425 μm. This will be referred as fresh sample.
Aging of samples was carried out in a tubular furnace at a temperature of 750° C. for 10 hours under air.
2. Preparation of a State of the Art Catalyst 1.7% V/Ti/W (8)
2.1. Preparation of the Ti—W Support
The preparation of the support was carried out according to (9): 87 g of titanium tetrachloride (TiCl 4 ) were poured into 300 ml of ice water and the solution was neutralized with 3N ammonia water. The resulting precipitate was separated by filtration, and thoroughly washed with distilled water. A solution of 4.58 g of ammonium paratungstate [(NH 4 ) 10 W 12 O 41 .5H 2 O] in 325 ml of distilled water was thoroughly mixed with the resulting cake. The resulting slurry was dried, and calcined at 500° C. for 6 hours in a muffle furnace. The resulting support had a weight % ratio TiO 2 :WO 3 of 90:10.
2.2. Preparation of the Catalyst 1.7% V/Ti/W
An aliquot of 77.2 mg of ammonium metavanadate was dissolved in 10 ml of 1N oxalic acid. The solution was heated in order to obtain the blue complex (NH 4 ) 2 [VO(C 2 O 4 ) 2 ]. Then, the support (1940 mg of mixed oxide containing 90% TiO 2 -10% WO 3 ) was added. This slurry was brought to dryness under continuous stirring at 80-100° C. Finally, the solid was dried at 120° C. overnight and calcined at 650° C. for 2 hours, pressed into pellet, crushed and sieved in the range 355-425 μm.
The specific surface areas of oxide powders were measured by the BET method using N 2 adsorption/desorption at 77K with a Sorptomatic 1990 instrument (Carlo Erba).
3. Catalyst Testing
Catalyst testing was carried out in the apparatus described in FIG. 1 . The gas feed consisted of NH 3 /N 2 , NO/N 2 , O 2 , N 2 . Mass flow meters were used to measure and control the single gaseous stream while an injection pump was used to introduce water. The feed stream was preheated and premixed and ammonia was added to the gaseous mixture immediately before entering the reactor to avoid side reactions. A tubular quartz reactor was employed inserted in a furnace. Temperature was controlled by a thermocouple inserted in the catalyst bed. The gas exiting the reactor was scrubbed with an aqueous solution of phosphoric acid to trap unconverted ammonia and then cooled to condense water vapor. Activity of the catalysts were measured under stationary conditions in a temperature range of 250° C. to 450° C. Unless otherwise reported the standard gas composition and reaction conditions given in Table 1 were used. Conditions were selected in order to have a conversion not exceeding ca. 90% with reference catalyst. Gas composition analysis was carried out with an FTIR spectrometer equipped with a gas cell.
Table 2 shows NOx removal efficiency in the temperature range 250-450° C. for catalysts prepared according to process I containing 0.4-2.1 wt. % V and 1.4-5.1 wt. % RE on Ti/W/Si support. For comparison the activity of the state of the art reference catalyst based on 1.7 wt. % V/Ti/W are also reported.
The NO x reduction activity of all the catalysts examined in the present study increased with increasing reaction temperature up to about 320° C. where a maximum NO x reduction activity was observed. At this point the activity began to decrease due to lower ammonia adsorption capacity. A strong effect is also shown with aging (calcination at 750° C. for 10 h). Particularly for the state of the art catalyst calcined at a temperature of 750° C. strong deactivation is observed with conversion dropping at values between 5-20%. A similar strong deactivation is observed also with La-containing catalyst. All the other catalysts can be broadly divided in two groups: group A catalysts (comprising Y, Ce, Pr and Nd) which suffer a slight deactivation after aging and group B catalysts (comprising Sm, Gd, Th, Dy, Er, —Yb is in the middle of the two groups—) in which deactivation has no effect or even causes an improvement of overall efficiency. The best performances are observed with Er and Tb containing catalysts where a substantial increase of conversion is observed after aging in all temperature range examined.
The overall picture detailing activity drop/improvement after aging is shown in FIG. 2 , which also highlights a dependence of activity on position of the element in the periodic table.
Table 2 shows also the NO x removal efficiency against RE and V loading. The loading amount was controlled by varying the amount of ammonium vanadate and rare earth acetate solutions in the impregnation. The preparation of a 0.4 wt. % V and 1.5 wt. % Er on Ti/W/Si is reported below.
The support was prepared as already described. The supported catalysts were prepared according to the following procedure: 19 mg of ammonium metavanadate were dissolved in 10 ml of oxalic acid 1N. The solution was heated in order to obtain the blue complex (NH 4 ) 2 [VO(C 2 O 4 ) 2 ] and then 619.6 mg of erbium acetate solution (4.6% of Er) were added. Moreover, some drops of HNO 3 were added in order to avoid the precipitation of the erbium oxalate. Then, the support (1831.8 mg of Ti/W/Si) was added. This slurry was brought to dryness under continuous stirring at 80-100° C. Finally, the solid was dried at 120° C. overnight and calcined at 650° C. for 2 hours, pressed into pellet, crushed and sieved in the range 355-425 μm].
Table 2a shows NOx removal efficiency in the temperature range 250-450° C. for catalysts prepared according to process II containing 0.4-2.1 wt. % V and 1.4-5.1 wt. % RE on Ti/W/Si support. For comparison the activity of the state of the art reference catalyst based on 1,7 wt. % V/Ti/W are also reported.
Table 2b shows NOx removal efficiency in the temperature range 250-450° C. for catalysts prepared according to process III containing 0.4-2.1 wt. % V and 1.4-5.1 wt. % RE on Ti/W/Si support. For comparison the activity of the state of the art reference catalyst based on 1,7 wt. % V/Ti/W are also reported.
As listed in table 2 (examples 8-10, 12-13) loading does not affect strongly activity after aging. For all the sample investigated an unusual promotion of activity is observed after aging at 750° C. Catalysts in the fresh state are less active at the lowest loading, (especially at the lowest temperatures) consistently with the presence of a lower amount of active phase containing vanadium. Maximum of activity is observed always at 320° C.
Surface area analysis is reported in Table 4 and 5. With all the catalysts examined aging procedure causes a drop in surface area which is proportional to the amount of RE and V deposited. This would suggest that aging induce an interaction between the active phase containing rare earths and the support.
X-ray diffraction analysis of the supports showed that TiO 2 (anatase) is the only phase detected after aging at 750° C. under air for 10 h, indicating that transformation to rutile does not occur. The presence of silica has no effect on X-ray diffraction profile under these conditions. Aging under more severe conditions (850° C., 10 h) induces a modification of diffraction profile of both supports. Segregation of crystalline WO 3 is observed in both samples while for supports not containing silica, TiO 2 in the form of rutile is clearly evidenced. The introduction of SiO 2 strongly stabilizes anatase against its transformation to rutile. The introduction of vanadium modifies this picture by accelerating segregation of WO 3 -containing phases and transformation of anatase to rutile.
FIGS. 3 and 4 show respectively X-ray diffraction profiles of fresh and aged V 2 O 5 /WT and V 2 O 5 /WTS. Peaks characteristic of V 2 O 5 are not seen in both supports indicating that V 2 O 5 is either amorphous when supported on TiO 2 or that the particle size is below the detection limits of X-ray technique. This is in agreement with the fact that crystalline V 2 O 5 on TiO 2 is observed only at higher loading (10). In the presence of V 2 O 5 the anatase to rutile phase transformation is initiated at lower temperature, as a consequence for WT support after calcinations at 750 for 10 h approx 50% of TiO 2 is in the form of rutile. The presence of V 2 O 5 also accelerates segregation of crystalline WO 3 phase, in accordance with previous observations (10-11).
A more accurate analysis of X-ray diffraction profiles indicate that modification of WO 3 by introduction of foreign cations into the oxide lattice could be responsible of small differences in the peak positions. Formation of mixed Ti x W y O 3 or M x W y O 3 (with M being an impurity present in the support) could be a possibility although no evidence can be found from existing XRD patterns. The presence of residual Ca from commercial additives was responsible of formation of CaWO 4 in structured catalysts of similar composition treated at comparable temperatures (11). Reaction of supported vanadia with TiO 2 to yield V x Ti 1-x O 2 in which vanadium is incorporated into the titania support in the form of rutile has been previously observed. In our case, lattice parameters of TiO 2 (rutile) stabilized in the presence and in the absence of vanadia are coincident, indicating that formation of TiVO solid solution does not occur. SiO 2 -containing support shows a similar behavior although the transformation of TiO 2 (anatase) to rutile is slower, in agreement with what observed in the absence of V 2 O 5 .
Table 6 summarizes XRD data on RE containing catalysts prepared according to process I treated at two different aging temperatures. The diffraction profiles after aging at 650° C. reveals the presence of weak signals due to formation of rare earth vanadates. These can be seen from the majority of RE elements investigated. Calcinations at 750° C. clearly evidence formation of crystalline REVO 4 for all elements with the exception of La. Interestingly, the presence of lanthanides seems to positively influence the degree of rutilization of the support and the process of segregation/formation of WO 3 . For silica containing support rutile is seen only at calcinations temperatures above 750° C. and the appearance of crystalline WO 3 is also retarded (this is true except for Tb, Ce and Pr-containing catalysts where the formation of WO 3 is not affected if compared with V 2 O 5 -only samples). In the absence of silica, segregation of WO 3 and transformation to rutile occur already at temperature of 750° C., although the presence of RE slow down their formation. FIG. 5 shows the effect of aging treatment at temperatures in the range 650-850° C. for Tb—V—O/WTS.
TABLE 1
Reaction conditions and gas composition
Catalyst weight
100.0
mg
Particle size
350-425
μm
Total flow
0.3
l/min
Temperature
250-450°
C.
NO conc.
200
ppm
NH 3 conc.
240
ppm
O 2 conc.
20000
ppm
H 2 O conc.
10%
N 2 conc.
balance
TABLE 2
Activity of fresh and aged catalysts containing
RE and V on TiO2:WO3:SiO2 (81:9:10) matrix
NO conversion in %
Example
RE
V
250° C.
250° C.
320° C.
320° C.
450° C.
450° C.
Nr
RE
[%]
[%]
fresh
aged
fresh
aged
fresh
aged
1
Y
3.7
2.1
49
25
70
49
55
29
2
La
4.6
1.7
31
0
51
0
38
3
3
Ce
4.6
1.7
67
20
86
31
46
21
4
Pr
4.6
1.7
51
25
74
37
35
16
5
Nd
4.7
1.7
40
20
62
30
43
11
6
Sm
4.8
1.6
40
55
64
61
43
29
7
Gd
4.9
1.6
50
48
61
68
47
60
8
Tb
1.4
0.5
22
68
53
90
50
65
9
Tb
2.8
0.9
40
63
68
81
51
45
10
Tb
4.9
1.6
32
52
49
80
40
49
11
Dy
4.9
1.5
48
52
64
75
50
48
12
Er
1.5
0.4
24
46
52
71
49
47
13
Er
5
1.5
40
47
65
80
54
53
14
Yb
5.1
1.5
45
47
72
49
48
25
(Reference)
—
—
1.7
85
5
91
17
17
7
TABLE 2a
Activity of fresh and aged catalysts prepared according to process
II containing RE and V on TiO 2 :WO 3 :SiO 2 (81:9:10) matrix
Example
RE
V
250° C.
250° C.
320° C.
320° C.
450° C.
450° C.
Nr
RE
[%]
[%]
fresh
aged
fresh
aged
fresh
aged
15
Tb
4.9
1.6
61
64
87
82
63
11
16
Er
5
1.5
92
57
97
83
48
11
(Reference)
—
—
1.7
85
5
91
17
17
7
Table 2b Activity of fresh and aged catalysts prepared according to
process III containing RE and V on TiO 2 :WO 3 :SiO 2 (81:9:10) matrix
RE
V
250° C.
250° C.
320° C.
320° C.
450° C.
450° C.
Example Nr
RE
[%]
[%]
fresh
aged
fresh
aged
fresh
aged
17
Tb
4.9
1.6
31
50
53
77
36
33
18
Er
5
1.5
33
73
75
91
64
46
(Reference)
—
—
1.7
85
5
91
17
17
7
TABLE 3
Activity of fresh and aged catalysts prepared according to
process I containing RE and V on TiO2:WO3 (90:10) matrix
NO conversion in %
RE
V
250° C.
250° C.
320° C.
320° C.
450° C.
450° C.
Example Nr
RE
[%]
[%]
fresh
aged
fresh
aged
fresh
aged
17
Er
5
1.5
58
17
81
46
46
9
18
Tb
4.9
1.6
62
25
88
48
48
29
19
Pr
4.6
1.6
64
23
80
40
40
17
20
Ce
4.6
1.7
83
3
94
27
27
6
(Reference)
—
—
1.7
85
5
91
13
36
10
TABLE 4
Surface area of fresh and aged catalysts prepared according to
process I containing RE and V on TiO2:WO3:SiO2 (81:9:10) matrix
Surface area
Example Nr.
RE
RE [%]
V [%]
Fresh
Aged
1
Y
3.7
2.1
62
28
2
La
4.6
1.7
68
22
3
Ce
4.6
1.7
62
17
4
Pr
4.6
1.7
60
28
5
Nd
4.7
1.7
66
24
6
Sm
4.8
1.6
64
28
7
Gd
4.9
1.6
64
28
8
Tb
1.4
0.5
80
56
9
Tb
2.8
0.9
76
45
10
Tb
4.9
1.6
67
35
11
Dy
4.9
1.5
68
19
12
Er
1.5
0.4
—
—
13
Er
5.0
1.5
68
33
14
Yb
5.1
1.5
70
11
TABLE 5
Surface area of fresh and aged V containing catalysts
on TiO2:WO3:SiO2 (81:9:10) and TiO2/WO3 (90:10) matrix
Surface area
Sample
Fresh
Aged
V 2 O 5 on Ti/W/Si (81:9:10)
65
8
Ti/W/Si (81:9:10)
88
70
V 2 O 5 on Ti/W/(90:10)
24
6
Ti/W (90:10)
59
29
TABLE 6
Identification of phases with XRD on samples prepared
according to process I (4.6 ÷ 5% RE loading)
calcined at different temperatures
sup-
Aging at 650° C.
Aging at 750° C.
dopant
port
REVO 4
Rutile
WO 3
REVO 4
Rutile
WO 3
Y
WTS
v. weak
none
none
yes
none
none
La
WTS
none
none
none
weak
none
v. weak
Ce
WTS
v. weak
none
none
yes
none
Yes
Pr
WTS
v. weak
none
v. weak
yes
none
Yes
Nd
WTS
v. weak
none
none
yes
none
v. weak
Sm
WTS
none
none
none
yes
none
v. weak
Gd
WTS
v. weak
none
none
yes
none
v. weak
Tb
WTS
none
none
none
yes
v. weak
Yes
Dy
WTS
v. weak
none
none
yes
none
weak
Er
WTS
v. weak
none
none
yes
none
none
Yb
WTS
v. weak
none
none
yes
none
weak
Ce
WT
none
none
none
yes
yes
yes
Pr
WT
none
none
none
yes
yes
yes
Tb
WT
none
none
none
yes
yes
yes
Er
WT
none
none
none
yes
yes
yes
REFERENCES
1. V. I. Parvulescu, P. Grange, B. Delmon, Cat. Today 46 (1998) 233.
2. P. Forzatti, Appl. Catal. A: General 222 (2001) 221
3. S. E. Park, G. M. Kim, Y. J. Lee, J. S. Chang, S. H. Han, U.S. Pat. No. 5,879,645 (1999).
4. P. S. Ji, H. M. Eum, J. B. Lee, D. H. Kim, I. Y. Lee, I. S. Nam, S. W. Ham, S. T. Choo, U.S. Pat. No. 6,380,128 (2002)
5. G. Madia, M. Elsener, M. Koebel, F. Raimondi, A. Woukan, Applied catalysis B: Environmental 39 (2002) 181.
6. M. Koebel, M. Elsener, M. Kleeman, Catal. Today 59 (2000) 335.
7. A. Inoue, T. Suzuki, K. Saito, Y. Aoki, T. Ono, T. Ohara, U.S. Pat. No. 4,221,760 (1980).
8. A. Schafer-Sindlinger, A. Burkardt, H. Van der Tillaart, T. Kreuzer, E. Lox, W. Weisweller, Eu Patent Application EP 1 145762 A1
9. GB. Patent. 1495396 (1974); Mitsubishi Petrochemical Co. Ltd.
10. R. Y. Saleh, I. E. Wachs, S. S. Chan, C. C. Chersich, J. Catalysis 98 1(986) 102.
11. I. Nova, L. dall'Acqua, L. Lietti, E. Giamello, P. Forzatti, Applied Catalysis B: Environmental 35 (2001) 31. | Catalyst composition represented by the general formula REVO/S wherein RE is at least one of the group of rare earth metals Y, Ce, Pr, Nd, Sm, Gd, Tb, Dy, Er and Yb in an amount of up to 6.0 wt.-%; V is vanadium in an amount of 0.2-2.5 wt.-%; O is oxygen in an amount of up to 3.5 wt.-%; and S is a support containing TiO 2 in an amount of at least 70 wt.-%, with the rest being WO 3 and optionally SiO 2 . This catalyst composition shows high removal efficiencies for NO x even after aging at 750° C. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to level control and, more particularly, to a method and apparatus for maintaining a predetermined upper level in a fluidized particle bed.
It is desirable to deposit pyrolytic carbon coatings on certain objects. For example, uranium particles can be coated with a pyrolytic carbon which, in part, forms a pressure-retentive shell allowing the coated particles to be fabricated into fuel rods for use in nuclear reactors. Another important use for such coatings is for heart valve and other biomedical components because a pyrolytic carbon coating does not react with blood.
Pyrolytic carbon is usually deposited on an object by thermally decomposing gaseous hydrocarbons or other carbonaceous substances in vaporous form in the presence of the object. When pyrolytic carbon is deposited in a fluidized bed apparatus, one of the variables upon which the structure of the pyrolytic carbon will be dependent is the amount of available deposition surface area relative to the volume of the furnace enclosure wherein the deposition is occurring. Pyrolytic carbon which has a microstructure that has smaller growth features will be deposited when the relative amount of deposition surface area is fairly high. Thus, when relatively large objects; for example, objects having at least one dimension equal to 5 mm. or more, are being coated, an ancillary bed of small particles (usually of a size measured in microns) is included within the furnace enclosure together with the larger objects. This arrangement provides sufficient available total surface area to assure that pyrolytic carbon having the desired crystalline form will be deposited. In addition, the random motion of large objects in fluidized beds provides for a relatively uniform deposition of carbon on all surfaces.
However, whenever such submillimeter particles are being coated in a fluidized bed, the total surface area of the particles begins to increase significantly as the diameters of the pyrolytic carbon-coated particles grow. This change in the available deposition surface area in the fluidized bed will result in a change in the physical characteristics of the pyrolytic carbon being deposited if the other coating variables are held constant, e.g., coating temperature, gas flow rate and gas composition; and moreover, when the bed reaches some maximum size, it will collapse and thus limit the thickness of the carbon coating that can be deposited on levitated substrates under constant input conditions. Changes in the physical characteristics of the carbon deposited may be undesirable for any of a number of reasons.
It has been found that pyrolytic carbon having good structural strength and uniform physical properties can be deposited as relatively thick coatings upon relatively large objects in the accompaniment of particles if the available fluidized bed surface area is maintained relatively constant by withdrawing particles which have become enlarged in size as a result of coating and feeding smaller size particles into the deposition enclosure. Commonly assigned U.S. Pat. No. 3,977,896, the teachings of which are hereby incorporated by reference, is directed to this type of process for depositing pyrolytic carbon coatings. In that patent the flow of gaseous atmosphere is introduced beneath and generally centrally of the particle bed. Seed particles having relatively greater densities than that of the coating are introduced to the bed causing the coated particles to levitate where they can be removed through a withdrawal tube, the open end of which is positioned near the top of the bed. The rate at which the particles are removed is controlled by regulating the rate of flow of an inert gas up the tube. The seed particle input is at a constant rate, and the output is measured so that by varying the purge gas flow rate to regulate the output, a substantially constant bed total surface is achieved.
While such a coating process works well, the need for measuring the output and varying the purge gas flow rate in response thereto introduces certain complexities which it is desirable to avoid. It has been found that in many coating applications proper coating can be achieved by maintaining the bed at a predetermined level. The fluidized bed coating process requires an operating temperature of between 1200° and 2000° C. Prior art sensors for detecting bed level to control the rate of addition or removal are inoperable or unreliable under these fluidized bed operating conditions.
SUMMARY OF THE INVENTION
One of the objects of the present invention is to provide reliable level control for a fluidized bed operating at elevated temperatures. The level control of the present invention operates to substantially eliminate dust from the particle discharge pipe for the bed apparatus, which dust otherwise could interfere with the collection of withdrawn particles. The level control also functions to reduce the ratio of smaller particles to larger particles being withdrawn to enhance the coating efficiency of the fluidized bed apparatus. As the level control operates passively to achieve maintenance of a predetermined bed level, the complexity of the overall fluidized bed system is reduced because the need to weigh the output and input, and continually change a flow rate in response thereto is eliminated. Another objective of the level control is reliability, long service life, and simplicity of manufacture. Other features and objects of the present invention will be, in part, apparent and, in part, pointed out hereinafter in the following specification and attendant claims and drawings.
Briefly, fluidized bed apparatus of the present invention includes an enclosure holding the bed of the particle and means for causing upward flow of the gaseous atmosphere carrying a material for forming the coating through the bed of particles to fluidize the particles. Means for adding seed particles to the bed is provided, and weir tube means removes coated particles from the bed when the contents of the bed achieves a predetermined level. Finally, the apparatus includes discharge means removing the coated particles from the tube and conveying them to a collection location.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view, partly sectional and partly schematic in nature, of fluidized bed apparatus of the present invention, including a weir tube for use in level control;
FIG. 2 is an enlarged longitudinal sectional view of the weir tube of FIG. 1; and
FIG. 3 is a sectional view, enlarged in size, taken generally along line 3--3 of FIG. 1 depicting the angular orientation of the spillover hole of the weir tube with respect to the central portion of the fluidized bed.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, fluidized bed apparatus for applying a pyrolytic carbon coating to objects, is generally indicated by reference character 20. The apparatus includes a furnace 22 having a cylindrical outer shell 24. The furnace shell 24 supports the coating enclosure which is defined by a tube 26 having an insert 28 affixed thereto at its lower end. The insert 28 provides the internal coating enclosure with a conical bottom surface 30. A central passageway 32 extends vertically upward through the insert 28, coaxial with the tube 26, and the coating and fluidizing atmosphere is supplied upwardly through this passageway.
The upper end of the tube 26 is provided with a removable closure 34 that may be mounted in any suitable manner; the closure 34 includes a central exit passageway 36 through which the fluidizing and coating gases leave the furnace enclosure and which is connected to an exit conduit 38 through which the gases may be routed for subsequent treatment if desired. An injection device 40 is mounted above the closure and is designed to feed minute particles 41 into the coating enclosure at a desired rate by dropping them downward through an opening 42 in the closure where they will fall nearly the length of the tube 26 until they enter and become a part of the fluidized bed. Induction or alternate heating means 44, is provided for heating the active deposition region of the furnace and the particles and objects being coated to the desired deposition temperature.
In the fluidized bed coating apparatus 20, sometimes referred to hereinafter as a "steady-state bed", the bed of minute particles, submillimeter in size, are levitated generally near the bottom of the heating enclosure in approximately the location shown in FIG. 1 by the upward flowing gas stream. The gas stream is usually made up of a mixture of an inert fluidizing gas plus a carbonaceous substance, such as a gaseous hydrocarbon, for example, methane, ethane, propane, butane or acetylene, or some other carbon-containing substance that is gaseous or easily vaporizable. In FIG. 1, a source 46 of hydrocarbon is illustrated which is equipped with a flow-regulating valve arrangement 48. Also illustrated is a source 50 of inert gas, for example, helium, argon or nitrogen, which is likewise equipped with a suitable flow-regulating valve arrangement 52. These two sources flow into a common line 54 which connects to the vertical passageway 32 in the insert 28.
The total flow of the gas upward through the coating enclosure is regulated so that the fluidized bed occupies the region near the bottom of the tube 26 as depicted in FIG. 1. The upward flow of the gaseous atmosphere through the central passageway causes a generally annular flow pattern to be established in the fluidized bed region, with the minute particles traveling upward in the central portion of the enclosure and then downward generally along the outer perimeter thereof. When particles having a density of at least about 3 grams/cm 3 (i.e., greater than the density of the carbon coating) are used, they will gradually become less dense as they grow in size. The smaller uncoated particles tends to remain in the lower portion of the bed while the less dense coated particles are levitated to the upper portion of the bed. A preferred material for the particles is zironium oxide which has a density of about 5.5 grams/cm 3 .
A weir tube 56, formed of a refractory material, such as graphite or mullite, extends through a vertical hole in the enclosure insert 28 and through a portion of the bed of particles and thereabove adjacent a side of the bed. A spillover hole or entrance 58 in the tube 56 defines a predetermined maximum level L for the bed of particles. When this level is reached, the continuous addition of seed particles in concert with the fluidization of the bed caused by the upward flowing gas stream results in withdrawal of particles having substantial coating thicknesses. An exit conduit 60 receives the withdrawn particles form the weir tube 56 and channels them into a collection chamber 62 where they are received in a container 63.
Referring to FIGS. 2 and 3, the weir tube 56 is provided with a hood 64 to close the upper end of the tube against the entrance of airborne particles and dust. Due to the fluidization process, there is some bubbling and splashing of the particles predominately in the central portion of the bed. When the bubbles burst, particles are sprayed generally radially with respect to the vertical axis of the bed. As the gas bubbles tends to pick up particles from adjacent the bottom of the bed, the sprayed particles tend to be the smaller, relatively thin-coated ones, and therefore, it is not desired that such particles be withdrawn. It is important that the spillover hole is positioned facing away from the central portion of the bed where the bubbling is most likely to occur. More specifically, the spillover hole should face at ninety degrees or greater with respect to the radius intersecting the axis of the weir tube. Furthermore, the weir tube is preferably disposed away from the axis of the bed by a distance equal to at least two-thirds of the spacing between the bed axis and the tube 26. Since the particles which become airborne due to bubbling of the bed do not travel circumferentially, the positioning of the spillover hole 58 facing away from the central portion of the bed, substantially eliminates the entrance of airborne particles in the spillover hole.
The collection chamber 62 is preferably pressurized with inert gas from a suitable source 66 with the rate of gas flow controlled by a valve 68. The flow of inert gas through the collection chamber 62 and up the weir tube 56 through the exit conduit 60 acts as a purge to prevent substantial quantities of dust from falling down into the collection chamber thus maintaining clear the glass walls forming the chamber to permit observation by the operator that the apparatus is functioning properly. It will be appreciated that the flow of inert gas does not have to be varied as it would if it were used to regulate the particle withdrawal rate as in U.S. Pat. No. 3,977,896. Here the purge gas flows at a constant, relatively slow rate sufficient to prevent movement of substantial quantities of dust into the collection chamber 62, but insufficient to prevent coated particles from falling down the weir tube 56 into the collection chamber.
Operation of the apparatus of the present invention is as follows: A supply of particles 41, along with the object or objects to be coated, are placed in the coating enclosure and the enclosure is brought up to its operating temperature of 1200 to 2000 degrees Centigrade with the fluidizing gas flowing. After the operating temperature is attained, the coating gas valve is opened so that the coating gas and the fluidizing gas both flow through the input line 54. The bed level starts to rise slowly due to the particles in the bed acquiring a pyrolytic carbon coating because of the thermal decomposition of the gaseous carbonaceous substances. After a while, the injection device 40 is turned on to add seed particles 41 which increases the rate at which the bed rises. There is also bubbling of the fluidized particles in the central region of the bed above the location of the central gas inlet passageway 32. Although such bubbling and splashing causes particle movement above the predetermined level L established by the position of the spillover hole 58 in the weir tube, such airborne particles cannot enter the tube in significant quantity because the spillover hole faces away from the central bed region. Of course, the circulation provided by the fluidization causes the less dense coated particles to levitate with the just added seed particles and only lightly coated particles, which have greater densities, more likely to remain near the bottom of the bed. When the bed level reaches the spillover hole 58, particles enter the hole where they fall down the tube 56, through the exit conduit 60 and are collected in the container 63 disposed in chamber 62. The provision of hood 64 and the slow purge of inert gas up the weir tube 56 insure that the major portion of dust is removed through the exit conduit 38 and does not travel with the particles through the weir tube.
Upon completion of the coating process, the apparatus 20 is disassembled and the coated objects removed. It will be appreciated that the contents of the container 63 includes small and large particles. The contents can be screened and the large particles disposed of and the smaller ones recycled.
While the fluidized bed apparatus of the present invention has been described in terms of applying a pyrolytic carbon coating to objects due to thermal decomposition of gaseous carbonaceous substances in the presence of the particles, it will be appreciated that the present invention is not limited to this particular use, but has utility in other applications where coatings are to be applied to particles by flowing a gas including the coating material through a bed of the particles.
As a method of providing level control for fluidized bed apparatus, the present invention comprises the following steps:
(A) A substantially vertical weir tube is provided extending through a portion of the particle bed and thereabove adjacent a side of the bed.
(B) A spillover hole is provided in the tube disposed to define a predetermined level of the bed.
(C) The hole is angularly positioned so that it faces away from a central portion of the bed.
(D) The upper end of the tube is covered and the tube is purged at a substantially constant flow rate sufficient to prevent a substantial quantity of dust from moving down the tube but insufficient to prevent coated particles from moving down the tube.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made without departing from the scope of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense. | Fluidized bed apparatus for use in applying a coating, having a relatively lesser density, to particles, having relatively greater densities by causing passage of a gaseous atmosphere through a bed of the particles. The apparatus includes an enclosure holding a bed of the particles and means for causing flowing of the gaseous atmosphere carrying a material for forming the coating through the bed of particles to be fluidized. The apparatus further includes means for adding seed particles to the bed and weir tube means removing coated particles from the bed when the contents of the bed achieves a predetermined level. Finally, the apparatus includes discharge means receiving the coated particles from the tube means and conveying them to a collection location remote from the enclosure. | 8 |
CLAIM OF PRIORITY
[0001] This application is a continuation of, and claims priority from, application Ser. No. 12/074,370, filed on Mar. 3, 2008, titled: ILLUMINATING HEADLAMP PROVIDING SUBSTANTIALLY UNIFORM ILLUMINATION, and claims the benefit of the earlier filing date, pursuant to 35 USC §119(e), to that patent application entitled “Illuminating Headlamp and Method of Illumination,” filed in the US Patent and Trademark Office, on Mar. 30, 2007, and afforded Ser. No. 60/921,150 and pursuant to 35 USC §120 to that patent application entitled “Illumination Assembly,” filed on Oct. 18, 2007 and afforded Ser. No. 11/975,194, the contents of each of which are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] Illumination devices are employed in a wide variety of contexts. Various types of fine work require high intensity illumination over a small area at a relatively short distance from the eyes of a user. Examples of such fine work include surgery, dentistry and watch and jewelry repair. Illuminating headsets are suited for these types of work as they allow a light to be projected at an area while leaving the hands free to manipulate tools or surgical equipment.
[0003] Prior art headsets typically have a remote source of illumination connected by a fiber optic cable to the headset. The remote source of illumination is typically a bulb, which may be, for example, a metal halide or a xenon bulb. A suitable lens is provided to couple the bulb output to a fiber optic cable, in the headset. While the fiber optical cable attached to the headset is cumbersome and may be inconvenient to the user, the power requirements and heat output of metal halide and xenon bulbs make it impractical for these illumination sources to be mounted on the headset.
[0004] In the prior art, the use of light-emitting diodes as a light source has been suggested. U.S. Pat. No. 6,955,444, to Gupta, discloses the use of a headlamp with two LEDs. Each LED is mounted relative to a reflector to provide sufficient illumination on a target region. However, reflectors typically provide a diffuse illuminated region. The use of two LEDs also adds weight, cost and complexity to the device.
[0005] US Published Patent Application serial no. 2005/0099824, to Dowling, also discloses the general concept of integrating an LED into a headlamp. However, this patent application provides little detail as to implementation. Another example in the prior art is the Zeon® LED Portable High-Definition Light, available from Orascoptic, 3225 Deming Way, Suite 190, Middleton, Wis. 53562. This device incorporates a LED mounted in front of reflectors. A collimator captures the light from the LED. The use of the collimator captures a maximum percentage of the light emitted by the LED. However, illumination is not uniform over the target area. Rather the intensity of illumination peaks at the center and then gradually decreases with distance from the center of the illuminated area.
[0006] However, this decrease in the illumination from the center of the target area is disconcerting as it limits the illuminated field of view. Hence, there is a need in the industry for an illuminated headset that provides a target area or zone of substantially uniform illumination.
SUMMARY THE INVENTION
[0007] An illuminating headlamp consisting of a headband and at least one optical device providing illumination at a known distance from said optical device attached to said headband. Each optical device consists of a housing having an open first end and an open second end. There is a light emitting device attached to a mounting which is attached to the second end causing said light emitting device to be orientated at a known angle to an axis of said housing. At least one optically transparent lens is incorporated into said first end, and a means for adjusting said optically transparent lens in order to cause a focal point of the lens to be positioned behind said light emitting device, wherein a zone of substantially uniform illumination is projected at said known distance.
BRIEF DESCRIPTIONS OF THE FIGURES
[0008] The advantages, nature, and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments now to of the described in detail in connection with accompanying drawings where like reference numeral to identify like element throughout the drawings:
[0009] FIG. 1 represents a perspective view of an illuminating headset.
[0010] FIG. 2A represents an isometric drawing of an exemplary LED holding device in accordance with the principles of the invention;
[0011] FIG. 2B represents an exploded view of the device shown in FIG. 2A ;
[0012] FIGS. 3A-3C represent simplified exemplary ray diagrams associated with the device shown in FIG. 1 ;
[0013] FIG. 4 represents a top view of a LED shown in an array shape suitable for use in the device shown in FIG. 1 ;
[0014] FIG. 5 represents a process flow diagram of a method of operation of the device shown in FIG. 1 ;
[0015] FIGS. 6A and 6B represent exemplary illuminated areas associated with focus-ed and defocus-ed operation of the device shown in FIG. 1 ;
[0016] FIGS. 7A and 7B represent exemplary orientation of emitter arrays relative to a single optical device and an assembly as shown in FIG. 1 ;
[0017] FIG. 8 illustrates an exemplary emitter mount of use in the assembly shown in FIG. 2 in accordance with the principles of invention;
[0018] FIGS. 9A-9C illustrate views of the relationship of the light-emitting array in the mounting shown in FIG. 8 ; and
[0019] FIGS. 10A-10D illustrate views of an alternate emitter for use in the assembly shown in FIG. 2 in accordance with the principles of the invention.
DETAILED DESCRIPTION
[0020] It is to be understood that the figures and descriptions of the present invention described herein have been simplified to illustrate the elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity many other elements found in illuminating headsets. However, because these elements are well-known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such element is not provided herein. The disclosure herein is directed to also variations and modifications known to those skilled in the art.
[0021] FIG. 1 represents an illuminating headset assembly. Headband assembly 10 includes generally two light-emitting units, or illumination devices, 100 , 200 , within housing 300 . Illumination devices 100 , 200 are supported relative to one another with housing 300 . Illumination devices 100 , 200 are adapted to emit light in relatively narrow beams that intersect and entirely or substantially overlap at a selected distance from the illumination devices. Headband 500 supports housing 300 including illumination devices 100 , 200 .
[0022] Although headband assembly 10 is shown to include two light-emitting devices, it would be appreciated that assembly 10 may also be constructed to include only a single light-emitting device. As the principles of operation of the light-emitting devices 100 , 200 are generally identical; a description of only one of the devices will be described in detail herein.
[0023] FIG. 2A represents a single one of the light-emitting devices 100 , 200 of an illuminated headset in accordance with the principles of the invention. FIG. 2B represents an exploded view of the device 100 (or 200 ) shown in FIG. 2A .
[0024] Referring to FIG. 2A , device 100 is an illuminating device having an opaque housing 105 having a distal end 106 and a proximal end 107 , an opening 110 at the distal end 106 and a tapering portion 112 intermediate the distal end 106 and the proximal end 107 . Referring to FIG. 2B , a light emitting diode 120 is mounted within a mounting 150 that is positioned in housing 105 near the proximal end 107 . The light emitting diode is positioned to emit light toward opening 110 . Lenses 131 , 132 are positioned in housing 105 distally from the light emitting diode 120 to receive and retransmit through opening 110 a portion of the emitted light. Lenses 131 , 132 allow the focusing or defocusing of light emitted from light emitting diode 120 . Lenses 131 , 132 may be adjusted to provide a zone of substantially uniform illumination at a known distance from the distal end of device 100 .
[0025] Referring to FIG. 2B , lenses 131 , 132 may be held in place by sleeve 133 , o-ring 134 and closing-ring 135 . Lenses 131 , 132 may be spherical or aspherical and may be of a glass composition with or without a plastic coating. Epoxy may be employed to fix lenses 131 , 132 to sleeve 133 . Although only two lenses are illustrated, it would be recognized that the number and selection of lenses may be varied without altering the scope of the invention.
[0026] Mounting bracket 140 is attached to housing 105 near the proximal end of assembly 100 . Mounting bracket 140 is an example of a bracket adapted to be attached to a headband 500 ( FIG. 1 ) so that device 100 may be mounted on the head of a user. Mounting bracket 140 is shown having a body with an opening therethrough to receive the proximal end 107 of housing 105 .
[0027] Mounting pin 142 may be inserted into bore 146 and into corresponding bores in housing 110 and a bore 144 in LED mount 150 (see FIG. 8 ) to secure housing 105 , mounting bracket 140 and LED mount 150 relative to one another.
[0028] LED mount 150 may be in physical contact with housing 105 or otherwise configured to provide good heat conduction from mount 150 to housing 105 . LED mount 150 may be selected from a material that is a good heat conductor. For example, mount 150 may be a copper or a tellurium copper alloy. Housing 105 may be made of a similarly good heat conductor, e.g., copper or aluminum. In one aspect, an uneven outer surface of housing 105 may be provided, as illustrated. Such uneven surface may be represented as grooves defined in the outer surface of housing 105 . The uneven surface increases the surface area and, hence, the spread the heat over a greater surface area. In any event, the surface can also be smooth.
[0029] Although device 100 shown in FIGS. 2A and 2B is shown having a conical shape, it would be recognized by those skilled in the art that this illustrates a preferred embodiment of the invention and that other shapes, e.g., cylindrical, are currently contemplated and considered to be within the scope of the invention.
[0030] FIGS. 3A-3C represent simplified exemplary ray diagrams associated with the device shown in FIGS. 2A and 2B . It will be appreciated that lenses associated with lens 130 are merely schematic and may include a plurality of lenses and/or reflectors. Emitter 120 represents a plurality of light emitting diodes arranged in an array 605 . Array 605 may have a pattern as shown in, and described in further detail with regard to a discussion of, FIG. 4 .
[0031] Referring to FIG. 3A , lens 130 is positioned relative to array 605 with its focal point on array 605 so as to project a focused image of array 605 on an incident or target area 330 . Because of the placement of array 605 at the focal point of lens 130 , details of the array may be seen in within the target image. This focused image is undesirable as it fails to provide a substantially uniform illumination within the target area.
[0032] Referring to FIG. 3B , lens 130 is configured so that its focal point, identified as 332 is behind array 605 . In this case, the defocusing of the light generated by array 605 causes a defocused image 331 to be projected on a target area at the same distance as shown in FIG. 3A . The defocused image provides a distinct zone of substantially uniform illumination without displaying the pattern of array 605 . The illuminated area of image 331 is larger than the focused image 330 shown in FIG. 3A and has a higher intensity of illumination. Image 331 has a generally rectangular form, as array 605 is generally rectangular, in this illustrated example. Examples of a focused image of an array and a defocused image of an array projected on a target area are shown in FIGS. 6A and 6B , respectively.
[0033] FIG. 3C illustrates a configuration wherein the focal point 332 of lens 130 is positioned in front of array 605 . This arrangement provides a blurred image of the array with indistinct edges and great variation in intensity. The image provides less uniformity and lower intensity than the defocused image shown in FIG. 3B .
[0034] As shown in FIGS. 3A-3C and FIGS. 6A and 6B , a defocused image has a larger area, a more even illumination and a higher intensity of illumination when compared to a focused image of emitter array 605 . It will be appreciated that superposition of defocused images of multiple arrays results in both higher illumination intensity and better uniformity of illumination across the illuminated area. In an exemplary embodiment shown, an intensity of about 7,000 foot-candles may be obtained across a field. Devices for providing such intensity are manufactured by Cree with headquarters located in Durham, N.C. The device is sold as the Cree P3 LED: P/N XREWHTL1-0000-07-01 which provides intensity of 7,000 fc at 13″ working distance. The intensity is measured with a Gossen Panlux Light Meter. P/N 3B14095 (Gossen is located in Germany).
[0035] FIG. 4 represents an exemplary LED emitter assembly 600 incorporated into the optical device shown in FIG. 2A . Individual LEDs maybe a Cree XLamp High-Power LED, available from Arrow Electronics, Manalapan, N.J. Array 605 is a two-dimensional array having an overall generally rectangular shape. The array 605 may be on a single die or on more than one die. Generally rectangular sub-arrays 610 , 612 , 614 and elongated sub-array 616 , 618 emit light. These sub-arrays may include individual diode elements that are relatively closely spaced together. For example, the diodes may be spaces at 400 dots per inch (dpi) or 1200 dpi. Relatively narrow areas 620 , which may contain controllers and other devices, for example do not emit light.
[0036] As discussed with regard to FIG. 3A , a focused projection of array 605 will result in an image with projections of sub-arrays 610 , 612 , 614 , 616 and 618 being bright with dark lines corresponding to areas 620 . Furthermore, variations in light output intensity within sub-array areas may occur. Such variation may occur as a result of errors in manufacturing of the LED sub-arrays. As a result of the pattern of variations in intensity, when a focused image of array 605 is projected onto an incident or target area, noticeable variations in illumination intensity occur (see FIG. 6A ).
[0037] However, when a defocused image, as discussed with regard to FIG. 3B , is projected onto a target area, variations in illumination intensity are reduced so as to create a zone of substantially uniform illumination as seen in FIG. 6B .
[0038] FIG. 5 illustrates a method for providing a zone of substantially uniform illumination utilizing the optical devices as shown in FIG. 2A when incorporated into the illuminated headset shown in FIG. 1 . In this exemplary process, an incident plane, such as an opaque sheet, is placed at a desired distance from the illuminated headset 10 . The illumination device 100 ( 200 ) is activated and an image projected onto the incident plane is placed into focus. The projected image of the emitting array may appear to include at least one distinct illuminated area and may have relatively sharp edges. (block 705 ) The lens or lenses ( 130 , 132 ) are then adjusted until a defocused image is obtained, as indicated by block 710 . Lens adjustment may include changing the distance between the lens 130 ( FIG. 2A ) and the array 605 , changing the distance between lenses 131 and 132 , substituting different lenses or adding or removing lenses. As shown in FIG. 3B , the adjustment causes the focal point of the lenses to be behind the array 605 (defocused).
[0039] In one aspect, a light meter may be positioned at the desired distance and the lenses may be adjusted until the illumination intensity detected by the light meter is substantially at a maximum. With each lens adjustment, the area of illumination at the selected distance may also be checked to determine when the area is a minimum desired size. It will also be appreciated that different LEDs may be selected.
[0040] FIG. 6A illustrates the projection 900 of a focused image of array 605 onto a target area at a desired distance from optical device 100 . As discussed previously, narrow, non-light emitting regions 910 of array 605 are discernable from the illuminated area 905 . In addition, the edges of the illuminated area are less intense than that of the center region.
[0041] FIG. 6B illustrates the projection 920 of a defocused image of array 605 onto a target area at a desired distance from optical device 100 . As discussed previously, the illumination across the target area is substantially uniform as denoted by the intensity at the center point 922 and edge point 924 .
[0042] FIG. 7A illustrates a front view of the exemplary optical device 100 shown in FIG. 2A . In this exemplary illustration, the orientation of emitter array 605 is preferably selected be to at an angle of substantially 45 degrees to a transverse axis (not shown) of the devices. The angle of 45 degrees is selected to illuminate an area at a selected distance from the assembly to project an image that is substantially square. Otherwise, the projected illumination may have a wider range in one direction (e.g., horizontal) as opposed to another direction (e.g., vertical). If the angle is changed, then other geometric configurations can be accommodated. For example, at an angle of 90 degrees, the configuration would be a square.
[0043] FIG. 7B illustrates a front view of the incorporation of the optical device shown in FIG. 2A in an assembly 300 shown in FIG. 1 . In this embodiment, the optical devices 100 , 200 are oriented along a horizontal axis of assembly 300 . In this illustrated embodiment, the diode arrays 605 , 606 are shown having the same orientation to the horizontal axis of assembly 300 . The preferred orientation of the array 605 with regard to an axis of assembly 300 is selected for the reasons similar to that discussed above. Although, the arrays 605 , 606 are shown in the same orientation, it would be understand that the orientation of the arrays 605 , 606 may be independently selected and that other orientations, as well as other emitter array shapes, within the optical device have been contemplated and considered to be within the scope of the invention.
[0044] FIG. 8 illustrates an exemplary mount 150 in accordance with the principles of the invention. Mount 150 is preferable selected from materials that act as a good heat conductor, e.g., copper or tellurium copper alloy. Mount 150 is generally a cylindrical hollow body, closed at one end by wall 1108 , which provides a platform for emitter array 605 , and open at the other end. Major cylindrical wall 123 has a bore 144 through a central axis and a corresponding opposite bore (not shown) along an axis through the central axis of end cylindrical wall 124 . End cylindrical wall 124 is coaxial with, and of lesser diameter than major cylindrical wall 123 and the two walls are joined by a shoulder. End wall 1108 has upstanding members 1105 , 1106 at opposite sides, positioned to retain a LED array 605 at a selected orientation relative to bore 144 . End wall 1108 lies in a plane substantially parallel to the axis of bore 144 . Bore 125 provides for wiring that allows connection of array 605 (not shown) to a power source.
[0045] Upstanding members 1105 , 1106 on surface 1108 are positioned to provide a selected orientation of a LED array (not shown) having a rectangular base and a generally rectangular shape, so that the sides of the LED array are parallel to the sides of the base and that the sides of the array are at an angle substantially 45 degrees relative to the central axis of bore 144 and the bore opposite thereto through major wall 123 . As a result of the orientation of pins 321 , 322 ( FIG. 9A ) in bore 144 (and corresponding not shown opposite bore hole) of emitter mount 150 , the angle between the axis of bore 144 (and corresponding not shown opposite bore hole) and the sides of array 605 (not shown) when mounted on emitter mount 150 , is fixed at a substantially 45 degree angle relative to a horizontal axis.
[0046] FIGS. 9A-9C illustrate views of the attachment of mount 150 within the optical device 100 shown in FIG. 2A and an exemplary orientation of the array 605 with regard to the vertical axis of optical device 100 . Pins 321 , 322 provide means for attaching mount 150 to device 100 and setting the orientation of array 605 . FIG. 9A illustrates the insertion of mounting 150 in a distal end of the device 100 and is attachment by pins 321 , 322 . FIG. 9B illustrates a front view of the positioning of array 605 on surface 1108 ( FIG. 8 ) at a preferred angle of substantially 45 degrees to the axis of pins 321 , 322 . FIG. 9C illustrates a front view of a blueprint representation of the positioning of array 605 on surface 1108 . FIG. 9C further illustrates a preferred tolerance for the orientation angle of array 605 .
[0047] FIGS. 10A-10D illustrate an alternative emitter mounting 1222 . Emitter mount 1222 , similar to mount 150 ( FIG. 8 ) is a good heat conductor. In this alterative embodiment, emitter mount 1222 is generally in the form of a hollow body, open at one end and closed at the other. Emitter mount 1222 has a major cylindrical wall 1223 at its open end and a bore hole 1244 through outer wall 1223 . Bore 1244 may be adapted to receive pins 321 , 322 ( FIG. 9A ). Emitter mount 1222 has a generally rectangular hollow body 1232 defining the closed end of emitter mount 1222 . Hollow body 1232 is narrower than major cylindrical wall 1223 and the two are joined by a shoulder 1234 . Hollow body 1232 is centered on the axis of major cylindrical wall 1223 . A bore hole 1238 through rectangular hollow body 1232 accommodates wiring to an emitter array (not shown) positioned on surface 1236 . End wall 1236 is so oriented as to accommodate an emitter at a specified orientation relative to bore hole 1244 . In the illustrated example, as may be particularly shown in FIG. 10D , the sides of end wall 1236 are at angle of substantially 45 degrees relative to bore 1244 . Similarly, bore 1238 in rectangular body 1236 is at an angle, which in the illustrated embodiment is oriented substantially 45 degrees from bore 1244 in main cylindrical wall 1223 .
[0048] While there has been shown, described, and pointed out fundamental novel features of the present invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the apparatus described, in the form and details of the devices disclosed, and in their operation, may be made by those skilled in the art without departing from the spirit of the present invention.
[0049] It is expressly intended that all combinations of those elements that perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Substitutions of elements from one described embodiment to another are also fully intended and contemplated. | An illuminating headlamp consisting of a headband and at least one optical device providing illumination at a known distance from said optical device attached to said headband. Each optical device consists of a housing having an open first end and an open second end. There is a light emitting device attached to a mounting which is attached to the second end causing said light emitting device to be orientated at a known angle to an axis of said housing. At least one optically transparent lens is incorporated into said first end, and a means for adjusting said optically transparent lens in order to cause a focal point of the lens to be positioned behind said light emitting device, wherein a zone of substantially uniform illumination is projected at said known distance. | 5 |
FIELD OF THE INVENTION
The present invention relates to automatic capture of data from a database query and the addition of information to allow trend analysis.
BACKGROUND OF THE INVENTION
A common task in many organizations is the creation and preparation of reports based on data generated using metrics or standards of measurement. Such a report, which provides a snapshot of the data in time, is often just a first step. It is often desirable to capture the same data over time, in order to prepare reports that analyze trends in the data or the underlying entities or conditions. Conventionally, in order to prepare trend reports, the data model used must be extended, the data processing applications must be modified in order to capture data over time, and then trend analysis tools must be used to observe trends in the data. This process requires labor-intensive modifications to the data model and the data processing applications, which is time-consuming and expensive. A need arises for a technique by which data can be captured over time so that trend analysis may be performed that does not require modifications to the data model and the data processing applications.
SUMMARY OF THE INVENTION
The present invention is a method, system, computer program product, and database connectivity layer that provides the capability to capture data over time so that trend analysis may be performed that does not require modifications to the data model and the data processing applications.
In one embodiment of the present invention, a method of automatically capturing data for trend analysis comprises the steps of: receiving a query for data from a database application, issuing the received query to a database management system, receiving a response to the query from the database management system, the response indicating a result dataset, creating or updating a database table that is suitable for trend analysis, and populating or updating the database table with data from the result dataset.
In one aspect of the present invention, the creating step comprises the steps of analyzing a format of the result dataset and creating the database table based on the format of the result dataset or updating an existing database table based on the format of the result dataset.
In one aspect of the present invention, the populating or updating step comprises the step of populating or updating the database table with data from the result dataset and with timestamp information.
In one aspect of the present invention, the response indicating the result dataset indicates a result data table and the populating or updating step further comprises the step of, for each row of data in the result data table, populating or updating a row in the database table with the row of data and with timestamp information.
In one aspect of the present invention, the response indicating the result dataset indicates a result data table and the populating or updating step comprises the steps of determining whether the result data table includes all rows of data in the result dataset, retrieving all rows in the result dataset, if the result data table does not include all rows in the result dataset, and, for each row of data in the result data set, populating or updating a row in the database table with the row of data and with timestamp information.
In one aspect of the present invention, the method further comprises the step of determining whether the result dataset is to be captured for trend analysis; and wherein the creating or updating step comprises the step of creating or updating a database table that is suitable for trend analysis, if the result dataset is to be captured for trend analysis. The creating or updating step may comprise the steps of analyzing a format of the result dataset and creating the database table based on the format of the result dataset or updating an existing database table based on the format of the result dataset. The populating or updating step may comprise the step of populating or updating the database table with data from the result dataset and with timestamp information. The response indicating the result dataset indicates a result data table and the populating or updating step may comprise the step of for each row of data in the result data table, populating or updating a row in the database table with the row of data and with timestamp information. The response indicating the result dataset indicates a result data table and the populating or updating step may comprise the steps of determining whether the result data table includes all rows of data in the result dataset, retrieving all rows in the result dataset, if the result data table does not include all rows in the result dataset, and for each row of data in the result data set, populating or updating a row in the database table with the row of data and with timestamp information.
BRIEF DESCRIPTION OF THE DRAWINGS
The details of the present invention, both as to its structure and operation, can best be understood by referring to the accompanying drawings, in which like reference numbers and designations refer to like elements.
FIG. 1 is a block diagram of an exemplary database management system in which the present invention may be implemented.
FIG. 2 is a block diagram of an exemplary implementation of a database management system in which the present invention may be implemented.
FIG. 3 is an exemplary block diagram and data flow diagram of one embodiment of a database management system that includes trend analysis.
FIG. 4 is a flow diagram of a process of operation of the database management system shown in FIG. 3 .
FIG. 5 is an exemplary block diagram and data flow diagram of one embodiment of a database management system that includes trend analysis.
FIG. 6 is a flow diagram of a process of operation of the database management system shown in FIG. 5 .
FIG. 7 is a flow diagram of a process for performing certain steps of the processes shown in FIGS. 4 and 6 .
DETAILED DESCRIPTION OF THE INVENTION
An exemplary database management system 100 , in which the present invention may be implemented, is shown in FIG. 1 . System 100 includes database 102 , database connectivity layer 104 , and database application 106 . Database management system (DBMS) 100 provides the capability to store, organize, modify, and extract information from database 102 . From a technical standpoint, DBMSs can differ widely. The terms relational, network, flat, and hierarchical all refer to the way a DBMS organizes information internally. The internal organization can affect how quickly and flexibly you can extract information.
Database 102 includes a collection of information organized in such a way that computer software can select and retrieve desired pieces of data. Traditional databases are organized by fields, records, and files. A field is a single piece of information; a record is one complete set of fields; and a file is a collection of records. An alternative concept in database design is known as Hypertext. In a Hypertext database, any object, whether it be a piece of text, a picture, or a film, can be linked to any other object. Hypertext databases are particularly useful for organizing large amounts of disparate information, but they are not designed for numerical analysis.
Typically, a database, such as database 102 , includes not only data, but also low-level database management functions, which perform accesses to the database and store or retrieve data from the database. Such functions are often termed queries and are performed by using a database query language, such as structured query language (SQL). SQL is a standardized query language for requesting information from a database. Historically, SQL has been a popular query language for database management systems running on minicomputers and mainframes. Increasingly, however, SQL is being supported by personal computer database systems because it supports distributed databases (databases that are spread out over several computer systems). This enables several users on a local-area network to access the same database simultaneously.
Most full-scale database systems are relational database systems. Small database systems, however, use other designs that provide less flexibility in posing queries. Relational databases are powerful because they require few assumptions about how data is related or how it will be extracted from the database. As a result, the same database can be viewed in many different ways. An important feature of relational systems is that a single database can be spread across several tables. This differs from flat-file databases, in which each database is self-contained in a single table.
Database application 106 is software that implements a particular set of functions that utilize database 102 . Examples of database applications include:
computerized library systems
automated teller machines
flight reservation systems
computerized parts inventory systems
Typically, a database application, such as database application 106 includes data entry functions 108 and data reporting functions 110 . Data entry functions provide the capability to enter data into database 102 . Data entry may be performed manually, by data entry personnel, automatically, by data entry processing software that receives data from connected sources of data, or by a combination of manual and automated data entry techniques. Data reporting functions 110 provide the capability to select and retrieve data from database 102 and to process and format that data for other uses. Typically, retrieved data is used to display information to a user, but retrieved data may also be used for other functions, such as account settlement, automated ordering, numerical machine control, etc.
Typically, database applications are written using standard programming languages, such as C, C++, JAVA, etc. Database connectivity layer 104 provides an interface between the database application 106 , and the low-level database functionality performed by the database 102 . Typically, database connectivity layer 104 is implemented as an application program interface (API), which is a set of routines, protocols, and tools for building software applications. For example, for a database application 106 written using the JAVA programming language, database connectivity layer may include the Java Database Connectivity, which is a Java API that enables Java programs to execute SQL statements. This allows Java programs to interact with any SQL-compliant database. Since nearly all relational database management systems (DBMSs) support SQL, and because Java itself runs on most platforms, JDBC makes it possible to write a single database application that can run on different platforms and interact with different DBMSs.
As another example, database connectivity layer 104 may include Open DataBase Connectivity (ODBC), which is another standard database access method. The goal of ODBC is to make it possible to access any data from any application, regardless of which database management system (DBMS) is handling the data. JDBC and ODBC are similar in function and purpose, but JDBC is designed specifically for Java programs, whereas ODBC is not.
A block diagram of an exemplary implementation of a database management system 200 , in which the present invention may be implemented, is shown in FIG. 2 . System 200 is typically a programmed general-purpose computer system, such as a personal computer, workstation, server system, and minicomputer or mainframe computer. System 200 includes one or more processors (CPUs) 202 A– 202 N, input/output circuitry 204 , network adapter 206 , and memory 208 . CPUs 202 A– 202 N execute program instructions in order to carry out the functions of the present invention. Typically, CPUs 202 A– 202 N are one or more microprocessors, such as an INTEL PENTIUM® processor. FIG. 2 illustrates an embodiment in which System 200 is implemented as a single multi-processor computer system, in which multiple processors 202 A– 202 N share system resources, such as memory 208 , input/output circuitry 204 , and network adapter 206 . However, the present invention also contemplates embodiments in which System 200 is implemented as a plurality of networked computer systems, which may be single-processor computer systems, multi-processor computer systems, or a mix thereof.
Input/output circuitry 204 provides the capability to input data to, or output data from, database/System 200 . For example, input/output circuitry may include input devices, such as keyboards, mice, touchpads, trackballs, scanners, etc., output devices, such as video adapters, monitors, printers, etc., and input/output devices, such as, modems, etc. Network adapter 206 interfaces database/System 200 with Internet/intranet 210 . Internet/intranet 210 may include one or more standard local area network (LAN) or wide area network (WAN), such as Ethernet, Token Ring, the Internet, or a private or proprietary LAN/WAN.
Memory 208 stores program instructions that are executed by, and data that are used and processed by, CPU 202 to perform the functions of system 200 . Memory 208 may include electronic memory devices, such as random-access memory (RAM), read-only memory (ROM), programmable read-only memory (PROM), electrically erasable programmable read-only memory (EEPROM), flash memory, etc., and electro-mechanical memory, such as magnetic disk drives, tape drives, optical disk drives, etc., which may use an integrated drive electronics (IDE) interface, or a variation or enhancement thereof, such as enhanced IDE (EIDE) or ultra direct memory access (UDMA), or a small computer system interface (SCSI) based interface, or a variation or enhancement thereof, such as fast-SCSI, wide-SCSI, fast and wide-SCSI, etc, or a fiber channel-arbitrated loop (FC-AL) interface.
In the example shown in FIG. 2 , memory 208 includes database application 212 , database connectivity layer 214 , database 216 , mirror database 218 , trendable set database 220 and operating system 222 . Database application 212 is software that implements a particular set of functions that utilize database 216 . Typically, a database application, such as database application 212 includes data entry functions and data reporting functions. Database connectivity layer 214 provides an interface between the database application 212 , and the low-level database functionality performed by the database 216 . Database 216 includes a collection of information organized in such a way that computer software can select and retrieve desired pieces of data. In particular, database 216 includes information upon which trend analysis is to be performed by the present invention. Database 216 may also include low-level database management functions, which perform accesses to the database and store or retrieve data from the database. Mirror database 218 includes a copy of information that was retrieved from database 216 upon which trend analysis is to be performed, along with additional information that is generated in order to facilitate the trend analysis, such as timestamp information. Trendable set database 220 includes information identifying those datasets upon which trend analysis is to be performed. Operating system 222 provides overall system functionality.
In the example shown in FIG. 2 , database application 212 , database connectivity layer 214 , database 216 , mirror database 218 , and trendable set database 220 are all shown included in database management system 200 . However, one of skill in the art would recognize that this is merely one possible implementation. In other implementations, database application 212 , database connectivity layer 214 , database 216 , mirror database 218 , and trendable set database 220 may each be implemented in one or more separate, networked computer systems, they may be grouped in various configurations, or they may be even further distributed. This grouping and distribution of functional components is an implementation detail and the present invention contemplates any and all such possible implementations.
In addition, as shown in FIG. 2 , the present invention contemplates implementation on a system or systems that provide multi-processor, multi-tasking, multi-process, and/or multi-thread computing, as well as implementation on systems that provide only single processor, single thread computing. Multi-processor computing involves performing computing using more than one processor. Multi-tasking computing involves performing computing using more than one operating system task. A task is an operating system concept that refers to the combination of a program being executed and bookkeeping information used by the operating system. Whenever a program is executed, the operating system creates a new task for it. The task is like an envelope for the program in that it identifies the program with a task number and attaches other bookkeeping information to it. Many operating systems, including UNIX®, OS/2®, and WINDOWS®, are capable of running many tasks at the same time and are called multitasking operating systems. Multi-tasking is the ability of an operating system to execute more than one executable at the same time. Each executable is running in its own address space, meaning that the executables have no way to share any of their memory. This has advantages, because it is impossible for any program to damage the execution of any of the other programs running on the system. However, the programs have no way to exchange any information except through the operating system (or by reading files stored on the file system). Multi-process computing is similar to multi-tasking computing, as the terms task and process are often used interchangeably, although some operating systems make a distinction between the two.
An exemplary block diagram and data flow diagram of one embodiment of a database management system 300 that includes trend analysis is shown in FIG. 3 . In this embodiment, database application 302 , including data entry functions 304 and data reporting functions 306 , and database 308 require no modification in order to implement the trend analysis functions provided by the present invention. In addition, database connectivity layer 310 need not be directly modified, but rather is enhanced by a cover layer 312 , which becomes the direct interface with database application 302 . Cover layer 312 captures and implements invocations by database application 302 of functions included in database connectivity layer 310 that may involve trend analysis, but passes through to database connectivity layer 310 invocations by database application 302 of functions that do not involve trend analysis. Generally, this approach is advantageous in an object-oriented software environment, in which polymorphism and abstraction allow the programming code that invokes a function to be independent of the underlying implementation of the function. This allows the programming code of database application 302 to be used without modification, even though some function invocations may perform trend analysis and some do not.
System 300 includes trendable set database 314 , which provides registration of those queries for which trend analysis is to be performed. Cover layer 312 , upon capturing a function invocation from database application 302 for which trend analysis may be performed, will access trendable set database 314 to determine if the particular database query involved has been registered as one for which trend analysis is to be performed. System 300 also includes mirror database 316 , which includes trendable table 318 , which is a copy of information that was retrieved from database 308 upon which trend analysis is to be performed, along with additional information that is generated in order to facilitate the trend analysis, such as timestamp information.
A flow diagram of a process of operation 400 of database management system 300 is shown in FIG. 4 . It is best understood with reference to FIG. 3 . Process 400 begins with step 402 , in which a query is issued by database application 302 . As trend analysis is a data reporting function, rather than a data entry function, the query is issued from among the data reporting functions 306 included in database application 302 . The query is issued to cover layer 312 , which passes the query to database connectivity layer 310 . In step 404 , database connectivity layer 310 issues the query to database 308 . In step 406 , database 308 performs the query by accessing and retrieving the stored information specified by the query and returning the retrieved result set, or a pointer or reference to the retrieved result set, to database connectivity layer 310 and cover layer 312 .
In step 408 , cover layer 312 determines if the particular database query involved has been registered as one for which trend analysis is to be performed. In particular, cover layer 312 performs an access 408 A of trendable set 314 and receives an indication 408 B of whether the particular database query for which the retrieved result set was generated is registered as trendable, that is a query for which trend analysis should be performed. If cover layer 312 determines that the database query involved has not been registered as one for which trend analysis is to be performed, then in step 410 , the retrieved result set, or a pointer or reference to the retrieved result set, is returned to database application 302 .
However, if, in step 408 , cover layer 312 determines that the database query involved has been registered as one for which trend analysis is to be performed, then in step 412 , a trendable copy of a database table, trendable table 318 , that is suitable to store the data included in the retrieved result set is created or updated in mirror database 316 . Trendable table 318 is only created if it is not already in existence. For example, the first time a particular database query for which trend analysis is to be performed is executed, trendable table 318 is created. Subsequent executions of that same query will not cause trendable table 318 to be created. In step 414 , the retrieved result set is transmitted to mirror database 316 and the trendable table 318 is populated or updated with the retrieved result set and other data needed to perform trend analysis, such as a time stamp on each row of data entered into the trendable table 318 . In addition, the retrieved result set is returned to database application 302 The first time a particular database query for which trend analysis is to be performed is executed, the newly created trendable table 318 is populated with the retrieved result set and other data. Subsequent executions of that same query will cause trendable table 318 to be updated with the addition of the current retrieved result set and other data. Thus, multiple executions of a particular database query build up trendable table 318 to contain multiple retrieved result sets, along with the other data, such as timestamp information, that allow trend analysis to be performed. The resulting trendable table 318 , or more commonly a pointer or reference to trendable table 318 , is returned to data base application 302 via cover layer 312 . Trend analysis may then be performed upon the trendable table 318 , as desired.
An exemplary block diagram and data flow diagram of one embodiment of a database management system 500 that includes trend analysis is shown in FIG. 5 . System 500 includes database application 502 , including data entry functions 504 and data reporting functions 506 , database 508 , trendable database connectivity layer 510 and mirror database 512 . In this embodiment, the standard database connectivity layer is replaced by a modified database connectivity layer, trendable database connectivity layer 510 . Trendable database connectivity layer 510 includes new database access routines that provide the capability to automatically generate data needed in order to perform trend analysis. This requires that modifications be made to database application 502 in order to implement the trend analysis functions provided by the present invention. However, this embodiment does not require a database that includes information to indicate the database queries for which trend analysis is to be performed. Rather, database application 502 is modified to invoke the new trendable database functionality, when desired. This embodiment is typically more suited for use with procedural implementations of database applications.
A flow diagram of a process of operation 600 of database management system 500 is shown in FIG. 6 . It is best understood with reference to FIG. 5 . Process 600 begins with step 602 , in which a query is issued by database application 502 by invoking a trendable query function. As trend analysis is a data reporting function, rather than a data entry function, the query is issued from among the data reporting functions 506 included in database application 502 . The query is issued to trendable database connectivity layer 510 . In step 604 , trendable database connectivity layer 510 issues the query to database 508 . In step 606 , database 508 performs the query by accessing and retrieving the stored information specified by the query and returning the retrieved result set, or a pointer or reference to the retrieved result set, to trendable database connectivity layer 510 .
In step 608 , the retrieved result set, or a pointer or reference to the retrieved result set, is returned to database application 502 via trendable DBC 510 . In step 610 , a trendable copy of a database table, trendable table 514 , that is suitable to store the data included in the retrieved result set is created or updated in mirror database 610 . Trendable table 514 is only created if it is not already in existence. For example, the first time a particular database query for which trend analysis is to be performed is executed, trendable table 514 is created. Subsequent executions of that same query will not cause trendable table 514 to be created. In step 612 , the retrieved result set is transmitted to mirror database 516 and the trendable table 514 is populated or updated with the retrieved result set and other data needed to perform trend analysis, such as a time stamp on each row of data entered into the trendable table 514 . In addition, the retrieved result set is returned to database application 502 . The first time a particular database query for which trend analysis is to be performed is executed, the newly created trendable table 514 is populated with the retrieved result set and other data. Subsequent executions of that same query will cause trendable table 514 to be updated with the addition of the current retrieved result set and other data. Thus, multiple executions of a particular database query build up trendable table 514 to contain multiple retrieved result sets, along with the other data, such as timestamp information, that allow trend analysis to be performed. Trend analysis may then be performed upon the trendable table 514 , as desired.
An exemplary flow diagram of a process 700 for creating and populating a trendable copy of a data table, such as is performed in steps 412 and 414 of FIG. 4 or steps 610 and 612 of FIG. 6 , is shown in FIG. 7 . Process 700 begins with step 702 , in which the data table including the retrieved result set is analyzed. The analysis may be performed by using, for example, a database Describe functionality, which analyzes the format of the result set. In step 704 , a trendable table, which will become a trendable copy of the result set table, is created, if it does not already exists, or is updated, if it does already exist. The created trendable table is structured based on the format of the result set table, along with storage for timestamp information that is to be generated. The trendable table must be named and the name given to the trendable table may be specified by the programmer or user, or the name given to the trendable table may be automatically generated. For example, an automatically generated name may be the same as the result set table name, similar to the result set table name, or related to or based on the name of the result set table, depending upon the implementation. Likewise, the name given to the trendable table may be automatically generated by, for example, defaulting to a hash value that is uniquely generated based on the query and the connection that produced the result set. This provides the capability to ensure that different users, identified by different connections, will see different results, based on security settings.
In step 706 , it is determined whether the result set table that was presented to the user (returned to the calling database application) includes all rows in the result set that was retrieved. Typically, this is done simply by counting the number of rows included in the result set that was returned and comparing this number to the number of rows included in the complete result set. If it is determined that the result set table that was presented to the user does not include all rows in the result set that was retrieved, then the process continues with step 708 , in which all rows in the result set are obtained so that they may be included in the trendable table. The process then continues with step 710 . If, in step 706 , it is determined that the result set table that was presented to the user does include all rows in the result set that was retrieved, then the process continues with step 710 .
In step 710 , the trendable table is populated by inserting each row in the result set into the trendable table that was created, along with timestamp information for each inserted row.
The embodiment of a process for creating and populating a trendable copy of a data table that is shown in FIG. 7 includes determining whether the result set table that was presented to the user (returned to the calling database application) includes all rows in the result set that was retrieved. This embodiment has the advantage of being efficient, in that rows of data are only obtained by the trendable table populating process if the rows are not already included in the returned result set. However, in a simpler embodiment, the trendable table populating process may always obtain all rows in the result set, whether returned or not.
One implementation issue that arises has to do with the mirror database, such as mirror database 316 , shown in FIG. 3 , or mirror database 512 , shown in FIG. 5 . The result set table that is generated has certain security rules that control who can look at or modify the result set table. However, in some implementations, the trendable table that is created in the mirror database, which includes the information included in the result set table, may have different security rules than the result set table. It is preferable to use implementations in which the security rules of the result set table are applied to the trendable table as well. A preferred embodiment that provides such an implementation would include a central mirror database that is used for most or all trend analysis. This central database would provide a consistent security implementation in which the security rules of the result set table are applied to the trendable table.
It is important to note that while the present invention has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable storage medium of instructions Examples of computer readable storage media include recordable-type media such as floppy disc, a hard disk drive, RAM, and CD-ROM's.
Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims. | A method, system, computer program product, and database connectivity layer provides the capability to capture data over time so that trend analysis may be performed that does not require modifications to the data model and the data processing applications. A method of automatically capturing data for trend analysis comprises the steps of: receiving a query for data from a database application, issuing the received query to a database management system, receiving a response to the query from the database management system, the response indicating a result dataset, creating or updating a database table that is suitable for trend analysis, and populating or updating the database table with data from the result dataset. | 8 |
FIELD OF THE INVENTION
[0001] This invention is related to a method and system for the concept based retrieval and mining of information using a distributed architecture. More specifically, the present invention partitions a heterogeneous collection of data objects with respect to the conceptual domains found therein and indexes the content of each partitioned sub-collection with Latent Semantic Indexing (LSI), thereby enabling one to query over these distributed LSI vector spaces. Vector space representations of these sub-collections of data objects can be used to select appropriate sources of information needed to respond to a user query or mining operation.
BACKGROUND
[0002] Latent Semantic Indexing (LSI) is an advanced information retrieval (IR) technology that is a variant of the vector retrieval method that exploits dependencies or “semantic similarity” between terms. It is assumed that there exists some underlying or “latent” structure in the pattern of word usage across data objects, such as documents, and that this structure can be discovered statistically. One significant benefit of this approach is that, once a suitable reduced vector space is computed for a collection of documents, a query can retrieve documents similar in meaning or concepts even though the query and document have no matching terms.
[0003] An LSI approach to information retrieval is detailed in commonly assigned U.S. Pat. No. 4,839,853 applies a singular-value decomposition (SVD) to a term-document matrix for a collection, where each entry gives the number of times a term appears in a document. A large term-document matrix is typically decomposed to a set of approximately 150 to 300 orthogonal factors from which the original matrix can be approximated by linear combination. In the LSI-generated vector space, terms and documents are represented by continuous values on each of these orthogonal dimensions; hence, are given numerical representation in the same space. Mathematically, assuming a collection of m documents with n unique terms that, together, form an n×m sparse matrix E with terms as its rows and the documents as its columns, each entry in E gives the number of times a term appears in a document. In the usual case, log-entropy weighting (log(tf+1)entropy) is applied to these raw frequency counts before applying SVD. The structure attributed to document-document and term-term dependencies is expressed mathematically in equation (1) as the SVD of E:
E=U ( E )Σ( E ) V ( E ) T (1)
[0004] where U(E) is an n×n matrix such that U(E) T U(E)=I n , Σ(E) is an n×n diagonal matrix of singular values and V(E) is an n×m matrix such that V(E) T V(E)=I m , assuming for simplicity that E has fewer terms than documents.
[0005] Of course the attraction of SVD is that it can be used to decompose E to a lower dimensional vector space k as set forth in the rank-k reconstruction of equation (2).
E k =U k ( E )Σ k ( E ) V k ( E ) T (2)
[0006] Because the number of factors can be much smaller than the number of unique terms used to construct this space, words will not be independent. Words similar in meaning and documents with similar content, based on the words they contain, will be located near one another in the LSI space. These dependencies enable one to query documents with terms, but also terms with documents, terms with terms, and documents with other documents. In fact, the LSI approach merely treats a query as a “pseudo-document,” or a weighted vector sum based on the words it contains. In the LSI space, the cosine or dot product between term or document vectors corresponds to their estimated similarity, and this measure of similarity can be exploited in interesting ways to query and filter documents. This measure of correspondence between query vector q and document vector d is given by equation (3).
sim ( U k ( E ) T q,U k ( E ) T d ) (3)
[0007] In “Using Linear Algebra for Intelligent Information Retrieval” by M. Berry et al., SIAM Review 37(4): pp. 573-595 the authors provide a formal justification for using the matrix of left singular vectors U k (E) as a vector lexicon.
[0008] Widespread use of LSI has resulted in the identification of certain problems exhibited by LSI when attempting to query massive heterogeneous document collections. An SVD is difficult to compute for extremely large term-by-document matrices, and the precision-recall performance tends to degrade as collections become very large. Surprisingly, much of the technical discussion surrounding LSI has focused on linear algebraic methods and algorithms that implement these, particularly problems of applying SVD to massive, sparse term-document matrices. Evaluations of the effect of changing parameters, e.g., different term weightings and the number of factors extracted by SVD, to the performance of LSI have been performed. Most of the approaches to make LSI scale better have been sought from increasing the complexity of LSI's indexing and search algorithms.
[0009] LSI is limited as an information retrieval and text mining strategy when document collections grow because with large collections there exists an increasing probability of drawing documents from different conceptual domains. This has the effect of increasing the semantic heterogeneity modeled in a single LSI vector space, thus of introducing noise and “confusing” the LSI search algorithm. As polysemy becomes more pronounced in a collection, vectors for terms tend to be represented by the centroid of all vectors for each unique meaning of the term, and since documents vectors are computed from the weighted sum of vectors for the terms they contain, the semantics of these are also confounded.
[0010] In general, the number of conceptual domains grows with the size of a document collection. This may result from new concepts being introduced into the information space, or an existing concept becoming extremely large (in number of documents) with further differentiation of its sub-concepts. In both cases, the compression factor in any vector space-based method has to be increased to accommodate this inflation.
[0011] The deleterious effects of training on a large conceptually undifferentiated document collection are numerous. For example, assume that documents drawn from two conceptual domains, technology and food, are combined without sourcing into a single training set and that LSI is applied to this set to create a single vector space. It is easy to imagine how the semantics of these two domains might become confused. Take for instance the location of vectors representing the terms “chip” and “wafer.” In the technology domain, the following associations may be found: silicon chip, silicon wafer, silicon valley, and copper wafer. However, in the food domain the terms chip and wafer take-on different meanings and there may be very different semantic relationships: potato chip, corn chip, corn sugar, sugar wafer. But these semantic distinctions become confounded in the LSI vector space. By training on this conceptually undifferentiated corpus, vectors are computed for the shared terms “chip” and “wafer” that really don't discriminate well the distinct meanings that these terms have in the two conceptual domains. Instead, two semantically “diluted” vectors that only represent the numerical average or “centroid” of each term's separate meaning in the two domains is indexed.
[0012] Therefore, it would be desirable to have a method and system for performing LSI-based information retrieval and text mining operations that can be efficiently scaled to operate on large heterogeneous sets of data.
[0013] Furthermore, it would be desirable to have a method and system for performing LSI-based information retrieval and text mining operations on large data sets quickly and accurately.
[0014] Additionally, it would be desirable to have a method and system for performing LSI-based information retrieval and text-mining operations on large data sets without the deleterious effects of mixing conceptually differentiated data.
[0015] Also, it would be desirable to have a method and system for the processing of large document collections into a structure that enables development of similarity graph networks of sub-collections having related concept domains.
[0016] Additionally, it would be desirable to have a method and system that enables a user to query the document collection in a flexible manner so that the user can specify the degree of similarity necessary in search results.
SUMMARY
[0017] The present invention provides a method and system for taking a massive, heterogeneous set or collection of data objects (also referred to as a set of documents) and partitioning it into more semantically homogeneous concept spaces or sub-collections. This enables LSI to perform better in the respective vector spaces computed for each of these. Mathematically, this approach amounts to an approximate block-diagonalization of the term-document matrix and obtaining SVD's for each of these blocks. The query process is then a mapping onto the network of overlapping blocks, using similarity metrics to indicate how much these blocks actually overlap.
[0018] Preprocessing the heterogeneous document collection before computing a term-by-document matrix into sub collection of documents sorted by conceptual domain permits each domain (sub-collection) to be processed independently with LSI. This reduces both storage and computational overhead and opens the possibility of distributing vector spaces (and searches of them) over a wider network of resources. An added benefit of this approach would be greater semantic resolution for any one vector space gained from fewer dimensions, i.e., LSI models exhibiting greater parsimony.
[0019] A large data collection or plurality of data collections are screened for the existence of grouping or clustering effects. If a data collection is known to be homogenous then the initial screening/clustering step may be skipped for that collection. This information is then used to segregate documents into more semantically homogeneous sub collections before applying SVD to each. To determine whether a user's query was appropriate for a particular LSI vector space, i.e., whether the intended semantics of a query matched those of a particular document collection, the paired similarity between the semantic structures of all LSI vector spaces is computed. This distance measure is based on the similarity of semantic graphs formed from words shared by each pair of vector spaces. The semantics for a query might be inferred from multiple query terms and by presenting a user with the different semantic contexts for query terms represented in all LSI vector spaces, then exploit this information to properly source queries and fuse hit lists. The main idea is to partition a large collection of documents into smaller sub-collections that are conceptually independent (or nearly independent) of each other, and then build LSI vector spaces for each of the sub-collections
[0020] “Conceptual independence” may mean the presence of some terms common to two LSI spaces whose semantic similarity measure (defined later on) is approximately zero. In this case, the common terms represent polysemy (multiple meanings for a term) over the conceptual domains involved. A multi-resolution conceptual classification is performed on each of the resulting LSI vector spaces. In a realistic situation, there may be quite a few common terms present between any two conceptual domains. To address the possible problem of synonymy and polysemy in the query, a network/graph of the conceptual domains based on links via common terms is generated. Then this graph is examined at query time for terms that are nearest neighbors to ensure that each contextually appropriate LSI space is properly addressed for a user's query terms. The use of LSI in developing a query vector enables the user to select a level of similarity to the initial query. If a user prefers to receive additional documents that may be more peripherally related to the initial query, the system will expand the query vector using LSI techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 depicts a flow diagram of the method of processing document collections in accordance with the present invention;
[0022] [0022]FIGS. 2 a and 2 b depict flow diagrams of the method of processing document collections in accordance with the present invention, particularly the generation of data on the similarity of sub-collections;
[0023] [0023]FIG. 3 depicts a flow diagram of the method of querying the collection of documents processed in accordance with the methods of the present invention; and,
[0024] [0024]FIG. 4 depicts a schematic diagram of one embodiment of a distributed LSI system in accordance with the present invention.
DETAILED DESCRIPTION
[0025] Referring to FIG. 1 the inventive method of the document collection processing of the present invention is set forth. At step 110 the method of the present invention generates a frequency count for each term in each document in the collection (or set) of documents. The term “data objects” in this context refers to information such as documents, files, records etc. Data objects may also be referred to herein as documents.
[0026] In an optional preprocessing step 100 the terms in each document are reduced to their canonical forms and a predetermined set of “stop” words are ignored. Stop words are typically those words that are used as concept connectors but provide no actual content such as “a” “are” “do” “for” etc. The list of common stop words is well known in the art. Suffix strippers that reduce a set of similar words to their canonical forms are also well known in the art. Such a stripper or parser will reduce a set of words such as computed, computing and computer to a stem word “comput” thereby combining the frequency counts for such words and reducing the overall size of the set of terms.
[0027] At step 120 the heterogeneous collection of data objects is partitioned by concept domain into sub-collections of like concept. If it is known that one or more separate sub-collections within a larger collection of data are homogenous in nature, the initial partitioning need not be done for those known homogenous data collections. For initial sorting of data objects into more conceptually homogeneous sub collections, the bisecting k-means algorithm in a recursive form with k=2 at each stage to obtain k clusters is preferably used. Clustering techniques have been explored in “A Comparison of Document Clustering Techniques” by M. Steinbach et al. Technical Report 00-034, Department of Computer Science and Engineering, University of Minnesota. Although the bisecting k-means algorithm is preferred, the “standard” k-means algorithm or other types of spatial clustering algorithms may be utilized. Other types of clustering algorithms including hierarchical clustering algorithms may be used.
[0028] Preferentially, the plurality of data object clusters can be further refined by performing a series of iterations of the bisecting k-means algorithm. At step 130 , the Singular Value Decomposition (described below) is then applied to reduce each of these k clusters or sub-collections of documents to generate a reduced vector space having approximately 200 orthogonal dimensions. At 200 dimensions, the size is manageable yet able to capture the semantic resolution of the sub-collection. Different sizes may be used depending on constraints such as available computing power and time.
[0029] At step 140 , using the k-means or other appropriate algorithm, clustering is then performed on each of these reduced vector spaces to discover vector clusters (representing core concepts) and their centroid vectors for each sub-collection. Alternatively, instead of applying the clustering algorithm to the reduced vector space, the vector clusters and centroid vectors could be obtained from the clustering data obtained at step 120 . Once these centroid vectors are obtained, a predetermined number of closest terms to each of these centroid vectors are found at step 150 . In a preferred embodiment of the present invention the number of key words is set to 10 per cluster although different numbers of key words may be appropriate in different situations. These are used as keywords to label this sub-collection thereby identifying the concept cluster therein. Each of the k vector spaces provides a different resolution to the underlying concepts present in the data and the context of each one is represented by its own set of keywords.
[0030] Having computed the LSI vector space for each contextually related sub collection of documents and having extracted the keywords that represent the core concepts in each, the next step 160 is to establish the contextual similarity between these spaces. Step 160 is necessary to select and search contextually appropriate LSI vector spaces in response to a query. Two graph-link measures are developed to establish a similarity graph network. A user query is passed on to the similarity graph network where proper queries are generated for each LSI vector space, and then each works independently to retrieve useful documents.
[0031] This important step 160 is described in detail below. Sub collections C 1 , C 2 , . . . , C k denote the k concept domains obtained as a partition of the document class C using the k-means clustering algorithm. Terms T 1 , T 2 , . . . , T k denote the corresponding term sets for the k concept domains. With t i denoting the cardinality of T i for i=1, 2, . . . , k and V 1 , V 2 , . . . , V k corresponding to the eigen matrices for the k term spaces in the SVD representation, then there are f factors in each of these LSI spaces and equation (4) forms the rank reduced term eigen basis for the i-th concept domain.
V i =[v 1 i v 2 i . . . v f i ] (4)
[0032] Doument sets, D 1 , D 2 , . . . , D k , are the corresponding document sets for the k concept domains. Let d i denote the cardinality of D i for i=1, 2, . . . , k. Further, let U 1 , U 2 , . . . , U k be the corresponding eigen matrices for the k document spaces in the SVD representation. Here, U i =[u 1 i u 2 i . . . u f i ] forms the rank reduced document eigen basis for the i-th concept domain. T ij =T i ∩T j is the set of common terms for the concept domains C i and C j . In addition, t ij is the cardinality of T ij , m i =V i V i ′ is the term similarity matrix for the concept domain C i , m i Q is the restriction of m i to the term set Q—obtained by selecting only those rows/columns of m i corresponding to the terms appearing in Q (for example, m i Q =m i for Q=T i ). The projection of the term vector v into the term space generated by the SVD is given by V i v for the i-th concept domain.
[0033] The method of the present invention exploits two different ways in which the similarity between two concept domains can be measured as set forth in FIGS. 2 a and 2 b . The first similarity measure is is the number of terms common to each concept domain. With common terms, it is necessary to exclude high frequency terms that act as constructs for the grammar rather than conveying any actual meaning. This is largely achieved during document preprocessing in step 100 by filtering them with a stop-word list, but if such preprocessing was not performed the operation could be performed now in order to exclude unnecessary high frequency terms.
[0034] The first measure captures the frequency of occurrence of common terms between any two concept domains. The underlying idea is that if many terms are common to their vector spaces, then they ought to be describing the same thing, i.e., they have similar semantic content and provide similar context. This process is described with reference to FIG. 2 a . Considering the concept domains C i and C j , in the case where the common set T ij is non-empty, the proximity between these two spaces is defined to be of order zero and the frequency measure to be given by equation (5).
s i j 0 = t i j 2 t i t j ( 5 )
[0035] At step 210 of FIG. 2 a this frequency measure is determined for each pair of sub-collections. When T ij is empty, there are no common terms between sub-collections C i and C j . There may be, however, some other space C 1 which has common terms with both C i and C j , i.e., T i1 and T j1 are both non-empty. Then, the concept spaces C i and C j could be linked via an intermediate space C 1 . At step 220 of FIG. 2 b this is determined. In the case where there are several choices for this intermediate space, the “strongest link” is selected at step 230 using equations (6) and (7). Here, the proximity between C i and C j is stated as being of order one and the frequency measure is given by equation (6) with the similarity measure s1 given by equation (7) where p is the proximity between two spaces.
s i j 1 = max p t i p 2 t p j 2 t i t p 2 t j ( 6 )
s 1=( s ij p +p ) −1 (7)
[0036] The similarity measure above takes into account the proximity between the two concept spaces along with the occurrence of common terms. Using the data from steps 210 and 230 a similarity graph network can be mapped showing a relationship between sub-collections, either directly or through a linking sub-collection at step 240 .
[0037] The second measure of similarity is more sensitive to the semantics of the common terms, not just how many are shared by two concept domains. The semantic relationships between the common terms (no matter how many there are) in each of the concept domains are examined to determine whether they are related in the same way.
[0038] At step 250 of FIG. 2 b , the correlation between two matrices X and Y (both of dimensions m×n) is measured, preferably by use of equations (8), (9) (10) and (11).
r ( X , Y ) = 1 m · n ∑ i = 1 m ∑ j = 1 n ( X i j - X _ S X ) ( Y i j - Y _ S Y ) ( 8 )
[0039] where
X _ = 1 m · n ∑ i = 1 m ∑ j = 1 n X i j , Y _ = 1 m · n ∑ i = 1 m ∑ j = 1 n Y i j , ( 9 )
S X = 1 m · n ∑ i = 1 m ∑ j = 1 n X i j 2 ( 10 )
S Y = 1 m · n ∑ i = 1 m ∑ j = 1 n Y i j 2 ( 11 )
[0040] At step 260 one of the matrices (say X) is held fixed while the other one (Y) is permuted (rows/columns). For each such permutation, the Mantel test statistic is computed at step 265 . At step 270 the number of times where the obtained statistic is greater than or equal to (NGE) the test statistic value obtained with the original X and Y is counted. The total number of such permutations is denoted by N runs . Usually, around 1000 permutations are sufficient for 5% level of significance and 5000 permutations for 1% level of significance. The p-value for the test is then determined at step 275 by equation (12) and the results of the Mantel test are considered acceptable is the p-value is within a predetermined range considering the number of permutations used to achieve the level of significance. For 1000 permutations, the p-value should be less than approximately 0.05 to consider the test result acceptable.
p - value = NGE + 1 N runs + 1 ( 12 )
[0041] Corresponding to the first similarity measure, the semantic measure for a proximity of order zero is determined at step 280 by equation (13).
s i j 0 = r ( m i T i j , m j T i j ) ( 13 )
[0042] Similarly, the measure for the first order proximity is determined at step 285 by equation (14).
s i j 1 = max p r ( m i T i p , m p T i p ) r ( m p T p j , m j T p j ) ( 14 )
[0043] Then at step 290 the final semantic similarity measure s2 is given by equation (15) where p again is the proximity between the two spaces.
s2 = ( s i j p + p ) - 1 ( 15 )
[0044] A preferred embodiment of the present invention uses the second similarity measure when comparing the semantics of LSI vector spaces. But it should be noted that its validity is given by the first similarity measure (the proportion of common terms). Suppose the second measure has a very high value (strong semantic relationship) but it turns out that there were only two common terms out of a total of 100 terms in each concept domain. Then the measure is subject to high error. In this situation, the first measure clearly exposes this fact and provides a metric for validating the semantic measure. Both measures are needed to obtain a clear indication of the semantic similarity (or lack thereof) between two concept domains. The most preferred measure of similarity, therefore, is the product of these two.
[0045] Having measured the contextual similarity between vector spaces, the method resulting similarity graph network and “identifying concept” terms are used in information retrieval or data mining operation. In order to perform an information retrieval, the similarity between the query and a concept domain's vector space so that useful documents in it may be retrieved.
[0046] With reference to FIG. 3, the usual user query Q is a set of terms in
Y i = 1 k T i
[0047] as input at step 310 by the user. The user may also specify the degree of similarity desired in search results. If a greater degree of searching freedom is desired, the system will expand the query vector as described below. A representative query vector is then generated at step 320 as the normalized sum of each of the projected term vectors in the LSI space. Note that there might be several possible cases, e.g., (1) all the terms in Q are present in the concept domain term set T i , (2) some terms are present, or (3) none are present.
[0048] At step 330 , the sub-collections in which all the query terms exist in the term set for a concept domain (i.e., sub-collection) are identified. At step 340 , if such multiple domains exist then, a ranking of the domains, along with the “meaning” each conveys, is helpful to decide which one to query. If a user has an idea of what he or she is looking for, then the “identifying concept” terms provided (as described above) become useful. On the other hand, for the explorative user without a fixed goal, the ranking supports serendipitous discovery.
[0049] The “identifying concept” terms are naturally terms associated with the closest (in cosine measure) projected term vectors to the query vector. Semantically, these terms are also closest to the query terms. As a member of this concept domain, this term set is the best candidate to represent the domain in trying to uncover what the user meant by the query. The ranking is just the value of the cosine measure between the “identifying concept” term vector and the query vector. A list can be presented to the user so that he or she is able to decide which domains should be searched for matching documents. Results are returned to the user in separate lists for each concept domain (sub-collection) at step 350 of FIG. 1. Once the user determines which sub-collections to query based on the lists of ranked sub-collections, at step 360 , the information retrieval software uses the standard LSI approach of cosine based vector space similarity to retrieve document matches at step 370 which are then presented to the user at step 380 . Alternatively, the selection of the best sub-collections to query can be performed automatically by selecting those with the highest rank first. This would tend to be used more in a strict information retrieval system rather in the more interactive text-mining environment. In a more complicated case some of the query terms are missing from the term set for the concept domain. Again, two approaches are used. In the first approach the process chooses to ignore those missing terms and just proceed as before with terms that are present. In the alternative approach, the process examines relationships between existing terms in the concept domain with the non-existent ones present in the query.
[0050] If missing terms are simply ignored, as before, an “identifying concept” term and a rank is presented to the user; but additional care must be taken, for in this case all the query terms do not match. A possible solution is to scale down the rank by the proportion of query terms that were actually used to find the concept term. Then the concept term is obtained exactly as before. The other case in which non-existent query terms are used is actually a particular instance of the next one.
[0051] In the worst-case scenario none of the query terms are present in the term set for a concept domain. The question arises whether one would want to query this domain at all. One thing is sure—if there are concept domains that fall into the previous two cases, they should definitely be exploited before any domain falling into this case. One way that this domain can be queried is to examine associations of terms across concept domains to discover synonyms existing in this domain, starting with the query terms. In other words, the entire information space is explored to obtain not just the query terms themselves, but also terms that are strongly related to them semantically. To control the method, a first order association (degree one) is imposed to limit search (where zero order implies the first case described above).
[0052] This version of the method depicted in the flow diagram 3 differs from the above discussion only in that the query vector for a concept domain is computed at step 320 as the weighted sum of its projected term vectors in a concept domain similar to some other concept domain that actually contains the query terms. The selection of this other concept domain is based on the domain similarity measure described above (the product measure performs well for this). Once the concept domain is selected that contains the query vectors and also is closest in meaning to the one to be queried, the expanded query vector is constructed for the query domain. With this expanded query vector, it is easy to generate “identifying concept” terms, as before in steps 330 through 370 .
[0053] There are two main functions performed in the computation and querying of a distributed LSI space. The first function consists of creating a classification scheme for specifying the multiple LSI vector spaces and consists of steps 110 through 160 and, optionally, step 100 of FIG. 1 and, depending on the similarity technique used, the steps of FIG. 2 a or 2 b . The second function consists of actually querying this, distributed network of spaces as described by steps 310 through 370 of FIG. 3. From a functional perspective, however, these two functions are independent of each other and the first function can be performed at various locations in a distributed network as depicted in FIG. 4. In FIG. 4 a network configuration for a distributed LSI network is set forth in which an LSI hub processor 410 is used to control the various data object clustering and information query requests. LSI hub processor 410 has three functions: brokering queries, generating similarity graph networks and indexing (ore re-indexing) newly arrived documents. As one or more servers 421 - 423 are added to the network each having access to a plurality of data objects in an associated database 431 - 433 , the LSI hub processor 410 controls the distributed processing of the data objects in accordance with the method of the present invention in FIG. 1 and FIGS. 2 a and/or 2 b in order to develop a comprehensive network graph of all data objects across all servers and databases. It should be understood that LSI hub processor 410 may perform some or all of the steps set forth in the partitioning and similarity processing method described above or it may only control the processing in one ore more of the servers 421 - 423 . LSI hub processor 410 can then respond to an information retrieval or data mining query from a user terminal 440 . In response to a query from the user terminal 440 , the LSI hub processor executes the method of the present invention as described in FIG. 2 and sends query results back to user terminal 440 by extracting those data objects from one or more databases 431 - 433 . From user terminal 440 the user may request LSI hub processor 410 to use the expanded query as discussed above providing extra flexibility to the user.
[0054] In this manner LSI hub processor 410 oversees the computationally intensive clustering operations, decomposing operations and generation of the centroid vectors. LSI hub processor 410 may also be used to more efficiently physically partition data between databases by redirecting the placement of similar clusters in the same database in order to create concept domains having a greater number of data objects thereby making subsequent retrieval or text mining operations more efficient. LSI hub processor 410 may also be used to index new documents in a relevant partition, either physically or virtually, in order to place documents having similar semantic attributes in the same conceptual domain. In presenting a result to a user, the LSI hub processor can be requested by the user to present either a ranked list of results grouped by concept domain or a ranked list of results across all queried domains, depending on user preference.
[0055] An embodiment of the present invention was used to partition and query the NSF Awards database that contains abstracts of proposals funded by the NSF since 1989. Information on awards made prior to 1989 is only available if the award has since been amended. A total of 22,877 abstracts selected from 378 different NSF programs were used with a total count of 114,569 unique terms.
[0056] The distributed LSI method of the present invention provides a set of concept classes, the number of these dependent on the level of resolution (or similarity), along with a set of keywords to label each class. The actual selection of the final set of concept classes is an iterative process whereby the user tunes the level of resolution to suit his or her purpose. To assist the user, the algorithm provides some metrics for the current cluster. For example, concepts classes (represented by their keywords) for two such levels of resolution are listed below.
[0057] Level of Resolution: low
[0058] Class 1={ccr, automatically, implementations, techniques, project, algorithms, automatic, systems, abstraction. high-level}
[0059] Class 2={university, award, support, students, at, universities, institutional, provides, attend, faculty}
[0060] Class 3={study, constrain, meridional, thermohaline, ocean, climate, hemispheres, greenland, observations, eastward}
[0061] Class 4={species, which, animals, how, genetic, animal, evolutionary, important, understanding, known}
[0062] Level of Resolution: High
[0063] Class 1{=runtime, high-level, run-time, execution, concurrency, application-specific, software, object-based, object-oriented, dsm}
[0064] Class 2={problems, approximation, algorithmic, algorithms, approximating, algorithm, computationally, solving, developed, algebraic}
[0065] Class 3={support, award, university, institutional, attend, universities, students, forum, faculty, committee}
[0066] Class 4={materials, ceramic, fabricate, microstructures, fabrication, ceramics, fabricated, manufacture, composite, composites}
[0067] Class 5={meridional, wind, magnetosphere, magnetospheric, circulation, hemispheres, imf, magnetohydrodynamic, field-aligned, observations}
[0068] Class 6={plate, tectonic, faulting, strike-slip, tectonics, uplift, compressional, extensional, geodetic, geodynamic}
[0069] Class 7={compositions, isotopic, composition, hydrous, carbonaceous, fractionation, carbon, minerals, dissolution, silicates}
[0070] Class 8={cells, protein, proteins, cell, which, regulation, gene, regulated, biochemical, expression}
[0071] Class 9={species, evolutionary, deb, genus, populations, endangered, ecological, phylogeny, diversification, diversity}
[0072] The preliminary clusters and concept labels obtained using the present invention show that the algorithm seems adept at finding new (or hidden) concepts when the level of resolution is increased. Further, the concept labels returned by the algorithm are accurate and get refined as the level of resolution is increased.
[0073] In this case, a simple implementation of the query algorithm for distributed LSI was used. Given a query (set of terms), the algorithm produces a set of query terms for each LSI space in the distributed environment, which is further, refined by a cut-off score. The algorithm uses a set of similarity metrics, as discussed earlier. Results from individual LSI queries are collected, thresholded and presented to the user, categorized by concept. A subset of the NSF Awards database containing 250 documents was selected from each of the following NSF directorate codes:
[0074] 1. ENG Engineering
[0075] 2. GEO Geosciences
[0076] 3. SBE Social, Behavioral and Economic Sciences
[0077] 4. HER Education and Human Resources
[0078] 5. MPS Mathematical and Physical Sciences
[0079] 6. CSE Computer and Information Science and Engineering
[0080] 7. BIO Biological Sciences
[0081] Through these selections, the entire collection of 1750 documents was ensured to be semantically heterogeneous. Next, eight different LSI spaces were computed—one for all documents belonging to each directorate code, and a final one for the entire collection. The distributed query algorithm was run on the seven LSI spaces and the usual query on the comprehensive space. For comparison purposes, the actual document returned provided the final benchmark because the distributed LSI query mechanism was expected to perform better.
[0082] The main query consisted of the terms {brain, simulation}, and this was fed to the query algorithm. Further, a cut-off of 0.5 (similarity) was set system-wide. The extended query sets (using the cut-off) generated by the algorithm are listed below.
[0083] BIO: {brain, simulations (2), extended, assessment}
[0084] CSE: {neural, simulation}
[0085] EHR, ENG, GEO, MPS: {mechanisms, simulation}
[0086] SBE: {brain, simulation}
[0087] The final query results were as follows. The query on the larger LSI space returned no results which had similarity scores greater than 0.5. However, the top ten contained a couple of documents related to brain simulation but with low scores. These two documents were reported in the results from BIO and SBE with similarity scores greater than 0.5. Another document (not found earlier) was reported from the CSE space with a score above 0.5. This document turned out to be an abstract on neural network algorithms that indeed was related to the query. The other spaces returned no documents with similarity scores above 0.5.
[0088] The above description has been presented only to illustrate and describe the invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. The applications described were chosen and described in order to best explain the principles of the invention and its practical application to enable others skilled in the art to best utilize the invention on various applications and with various modifications as are suited to the particular use contemplated. | The use of latent semantic indexing (LSI) for information retrieval and text mining operations is adapted to work on large heterogeneous data sets by first partitioning the data set into a number of smaller partitions having similar concept domains A similarity graph network is generated in order to expose links between concept domains which are then exploited in determing which domains to query as well as in expanding the query vector. LSI is performed on those partitioned data sets most likely to contain information related to the user query or text mining operation. In this manner LSI can be applied to datasets that heretofore presented scalability problems. Additionally, the computation of the singular value decomposition of the term-by-document matrix can be accomplished at various distributed computers increasing the robustness of the retrieval and text mining system while decreasing search times. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to pump devices and in particular to bellow-type pumps for dispensing fluids or other pasty products.
[0003] 2. State of the Art
[0004] Pumps and pump devices are known. In addition, pumps using bellows systems as springs and pistons are known. For example, U.S. Pat. No. 7,793,803, which is incorporated by reference herein in its entirety, discloses a bellow-type pump and pump system which is known.
[0005] Another type of pump is disclosed in PCT Application PCT/US11/066423, which is incorporated herein by reference in its entirety.
[0006] While various bellow-type pump systems are known, the use of bellows for new delivery requirements and improvements in such pumps are desirable.
BRIEF SUMMARY OF THE INVENTION
[0007] According to various embodiments of the invention, a pump system may include a bellow, a stem, a fluid lock, a base, a pump head and a tube retainer attached together to form a pump. In some embodiments, a portion of the base and tube retainer may act together to form a vent to allow a container attached to the pump system to vent.
[0008] In some embodiments of the invention, a tube retainer may include one or more thin walled portions which may seal against a base of the pump system. Upon actuation of a pump and withdrawal of a product from within a container attached to the pump system, a pressure difference between the interior of the container and an exterior thereof may be sufficient to allow a flexing of the one or more thin walled portions such that they may unseat from the base and allow the container to vent.
[0009] According to other embodiments of the invention, a tube retainer may include one or more valve posts which may fit in openings in a base and seal against the base. The one or more valve posts may be moved and unseated from the base upon actuation of a bellow and contact between the bellow and the one or more valve posts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] While the specification concludes with claims particularly pointing out and distinctly claiming particular embodiments of the present invention, various embodiments of the invention can be more readily understood and appreciated by one of ordinary skill in the art from the following descriptions of various embodiments of the invention when read in conjunction with the accompanying drawings in which:
[0011] FIG. 1 illustrates a cross-sectional view of a pump system according to various embodiments of the invention;
[0012] FIG. 2 illustrates a cross-sectional view of a portion of a pump system according to various embodiments of the invention;
[0013] FIG. 3 illustrates a cross-sectional view of a pump system according to various embodiments of the invention;
[0014] FIG. 4 illustrates a cross-sectional view of a pump system according to various embodiments of the invention;
[0015] FIG. 5 illustrates a cross-sectional view of a portion of a pump system according to various embodiments of the invention;
[0016] FIG. 6 illustrates a tube retainer according to various embodiments of the invention;
[0017] FIG. 7 illustrates a cross-sectional view of a pump system according to various embodiments of the invention;
[0018] FIG. 8 illustrates a blown apart, cross-sectional view of a pump system according to various embodiments of the invention;
[0019] FIG. 9 illustrates a blown apart view of a pump system according to various embodiments of the invention;
[0020] FIG. 10 illustrates a cross-sectional view of a pump system according to various embodiments of the invention; and
[0021] FIG. 11 illustrates a cross-sectional, close-up view of a portion of FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0022] According to embodiments of the invention, a pump system may include a bellow, a stem, and a fluid lock acting together to form a pump for moving a product, such as a liquid or pasty material, from a container to a location outside of the container for use. In some embodiments of the invention, a bellow and stem may form a bellow chamber for holding a product and the stem may seal against the bellow until such time that the pump system is actuated when the seal between the bellow and stem may be broken, allowing product contained in the bellow chamber to flow out of the bellow chamber. In certain embodiments of the invention, the fluid lock or seal may be fitted with or attached to the stem such that as the stem moves, the fluid lock is seated or unseated, thereby blocking fluid flow into a bellow chamber or allowing fluid to flow therethrough when a vacuum or suction force is applied to a fluid in a container. In addition, various embodiments of the invention include one or more features to allow venting of a container attached to the pump system.
[0023] According to various embodiments of the invention, a pump system 300 may include a bellow 310 , a stem 320 , a fluid lock 330 , a base 340 , a pump head 350 and a tube retainer 380 as illustrated in FIGS. 1 through 3 .
[0024] According to other embodiments of the invention, a pump system 300 may include a bellow 310 , a stem 320 , a fluid lock 330 , a base 340 , a pump head 350 , and a tube retainer 370 including one or more venting valves 375 as illustrated in FIGS. 4 through 11 .
[0025] According to various embodiments of the invention, a bellow 310 may be made of a silicon material. In other embodiments, a bellow 310 may be made of any desirable material and such material may be selected to be compatible with a product which will be pumped through the bellow 310 during use of the pump system 300 . Some other materials that may be used to construct, mold, or otherwise form a bellow 310 include TPU, TPE, or other elastomeric polymer materials.
[0026] A bellow 310 according to embodiments of the invention may also take on varying shapes and sizes. The size of a bellow 310 may be adjusted to accommodate an amount of product which is desired for dispensing from the pump system 300 . In addition, the bellow 310 may be shaped or constructed to provide certain actuating forces and return forces based on the thickness of the walls, shapes of the walls, and other characteristics of the bellow 310 .
[0027] According to various embodiments of the invention, a bellow 310 may include a suction valve 312 which may move during the actuation stroke of a pump system 300 and during the return stroke following actuation of the pump system 300 . The suction valve 312 may be attached to the body of the bellow 310 by legs, arms, or other configurations which include gaps between the suction valve 312 and the remainder of the bellow 310 such that product may pass into the bellow 310 when the pump system 300 is in use.
[0028] Bellows 310 according to embodiments of the invention may also include an upper lip which contacts a pump head 350 any may be moved by the pump head 350 during actuation of a pump system 300 . In addition, portions of the upper lip of a bellow 310 may interact with portions of the stem 320 to form a valve or seal a compartment or pump chamber between an interior of a bellow 310 and the stem 320 .
[0029] A stem 320 according to various embodiments of the invention may be configured in any desired shape. A stem 320 may also be made of any desirable material. For example, a stem 320 may be made of a moldable plastic or resin such as polypropylene or other material.
[0030] According to embodiments of the invention, a stem 320 may include a top portion configured to interact with an upper portion or upper lip of a bellow 310 , a neck extending from the top portion to an end portion which may be configured to attach to or mate with a fluid lock 330 . The top portion may be configured in any desired shape to provide the characteristics desired for a pump system 300 . A portion of the neck may pass through a hole in a suction valve 312 of a bellow 310 and the end portion may extend outside the bellow 310 . The end portion of the stem 320 may be connected to, mated with, or otherwise attached to a fluid lock 330 as illustrated in the various Figures.
[0031] A fluid lock 330 according to various embodiments of the invention may be configured in any desired shape and made of any desired material. In some embodiments, a fluid lock 330 may be made of a moldable polymer or resin.
[0032] A fluid lock 330 may attach to an end portion of a stem 320 which projects through a suction valve 312 of a bellow 310 . In some embodiments of the invention, a fluid lock 330 is attached to an end portion of a stem 320 which passes through a portion of a base 340 . The attachment of a fluid lock 330 to a stem 320 may serve to hold a bellow 310 on a base 340 for assembly of a pump system 300 . When assembled with a stem 320 , a fluid lock 330 may seal against a portion of the base 340 , forming a seal and closing access to an opening in the base such that liquid, fluid, or other product may not pass by the fluid lock 330 and into an interior space of the bellow 310 .
[0033] While a fluid lock 330 is shown with various embodiments of the invention, a pump system 300 having no fluid lock 330 may also be used. In such embodiments, an alternative means for stopping fluid or product flow into the bellow 310 upon application of a force to a container may be needed. For example, an additional valve could be molded with or integrated with the base 340 .
[0034] A base 340 according to various embodiments of the invention may be configured in any desirable shape or size. For example, the base 340 illustrated in FIG. 1 differs from the base 340 illustrated in FIG. 4 . A base 340 may include an opening in the base 340 through which product—such as a liquid or fluid—may pass during operation of the pump system 300 . According to some embodiments of the invention, a suction valve 312 of a bellow 310 may seat in an opening, forming a seal therewith during actuation of a pump system 300 such that a fluid or product may not pass into an interior space of the bellow 310 during actuation. Following actuation, the suction valve 312 may unseat from the opening in the base 340 and allow fluid or product to enter an interior space of the bellow 310 until a fluid lock 330 engages and seals with the base 340 , preventing additional fluid or product flow.
[0035] According to various embodiments of the invention, a pump system 300 may include one or more venting features. In some embodiments of the invention, a base 340 may be configured as illustrated in FIGS. 1 through 3 . As illustrated, a base 340 may include a fitment into which a tube retainer 380 may be seated or fitted. According to embodiments of the invention, a tube retainer 380 may include one or more thin walled portions 382 or seal portions which may seal against a portion of the base 340 as illustrated in FIG. 1 . The base 340 may also include one or more openings 342 adjacent to the one or more thin walled portions 382 as illustrated in FIGS. 2 and 3 . As shown, the one or more thin walled portions 382 form a valve or gate between an interior portion of a container 900 and an exterior thereof when the pump system 300 is attached to a container 900 . The one or more openings 342 in the base 340 may allow atmospheric pressure to act on the one or more thin walled portions 382 such that when a pressure difference between an interior of a container 900 and an exterior thereof is different, the atmospheric pressure may unseat or unseal the one or more thin walled portions 382 from the base 340 , allowing the container 900 to vent.
[0036] According to various embodiments of the invention, a tube retainer 380 may be made of a flexible material such that the one or more thin walled portions 382 may flex as desired to allow a container to vent.
[0037] According to other embodiments of the invention, a pump system 300 may include a tube retainer 370 having one or more integral valve posts 375 as illustrated in FIGS. 5 through 10 . In such embodiments, a base 340 may include one or more valve openings 345 into which one or more integral valve posts 375 may fit or seat. The one or more valve posts 375 may include one or more grooves to facilitate bending or deformation of the valve post 375 . In addition, a valve post 375 may include a ball-shaped or rounded vent seal 378 which may press against a conical opening 348 in the base 340 , thereby sealing an interior of a container 900 attached to a pump system 300 from an exterior thereof.
[0038] For example, a close-up view of a valve post 375 seated in a valve opening 345 according to various embodiments of the invention is illustrated in FIGS. 10 and 11 . As illustrated in FIG. 11 , a valve post 375 may include a vent seal 378 seated against a conical opening 348 in the base 340 . As bellow 310 is actuated and it is pushed down over an end portion of the valve post 375 , the bellow 310 may cause the valve post 375 to move, which in turn may unseat the vent seal 378 portion of the valve post 375 from the conical opening 348 . The unseating of the vent seal 378 opens a vent path from an interior of a container 900 attached to the pump system 300 to an exterior thereof, allowing the container 900 to vent.
[0039] According to various embodiments of the invention, any of the configurations illustrated in FIGS. 1 through 11 may be used to form a vent path for a pump system 300 according to embodiments of the invention.
[0040] A base 340 according to various embodiments of the invention may also include additional features for securing a pump system 300 to a container. For example, a base 340 may include threads for attaching the base, and pump system 300 , to a container having a threaded closure. A base 340 may also include lugs or bayonet closure mechanisms and features to secure the base 340 , and the pump system 300 , to a container. Other snap-fitment, plug-fitment, threaded closures, welds or other attachment systems may be incorporated with a base 340 to allow a pump system 300 to be attached to a container 900 .
[0041] A pump system 300 according to embodiments of the invention may be configured to attach to any desired container. For example, a pump system 300 according to embodiments of the invention may be attached to a bottle using a conventional screw-type fitment system. In other embodiments, a base 340 may be welded or otherwise attached to an opening in the tube. Various embodiments of the invention may be attached to other conventional containers such as bottles, bags, tubes, or other containers from which a product may be drawn or pumped. In addition, attachment of a pump system 300 to a container may be by any conventional methods.
[0042] According to some embodiments of the invention, one or more locking features may be added to a pump system 300 to allow a user to lock the pump system 300 and prevent or allow actuation of the pump system 300 as desired.
[0043] Having thus described certain particular embodiments of the invention, it is understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations thereof are contemplated. Rather, the invention is limited only be the appended claims, which include within their scope all equivalent devices or methods which operate according to the principles of the invention as described. | A simplified pump system including a bellow ( 310 ) having a suction valve ( 312 ), a stem ( 320 ), a fluid lock ( 330 ), and a tube retainer ( 380 ) having a vent element wherein the product flow into and out of a pump chamber formed by the bellow ( 310 ) and stem ( 320 ) is controlled by the suction valve ( 312 ) and fluid lock ( 330 ). | 1 |
BACKGROUND OF THE INVENTION
This invention relates to certain novel platinum (O) alkyne complexes and to a novel method of preparing them. By platinum (O) alkyne complexes it is meant herein organometallic platinum complexes with acetylene derivatives as ligands, wherein the platinum atom has a formal oxidation state of zero, as measured by cyclic voltammetry.
Platinum (O) alkyne complexes in general are useful as hydrosilylation catalysts, hydrogenation catalysts, and isomerization catalysts for olefins and alkynes.
Platinum (O) alkyne complexes have a number of advantages over the well known platinum catalyst H 2 PtCl 6 .(H 2 O) x , hereinafter referred to as hexachloroplatinic acid. For example platinum (O) alkyne complexes tend to be more compatible with the reactants they are called upon to catalyze. The platinum (O) alkyne complexes are thus more effective, since it is not necessary to provide excess amounts to make up for losses due to precipitation.
Additionally, platinum (O) alkyne complexes are inherently more chemically stable than hexachloroplatinic acid, especially in the presence of moisture.
The synthesis of platinum (O) alkyne complexes is known. For example, F. Gordon A. Stone, Ligand-Free Platinum Compounds, Acc. Chem. Res. 1981, 14, 317-327, describes the synthesis of platinum (O) alkyne complexes using platinum bis(cyclooctadiene) complexes. Unfortunately, the cyclooctadiene complex itself is difficult to make, involving sensitive intermediates which require special handling. These platinum bis(cyclooctadiene) complexes are much more suitable for laboratory preparations than industrial processes.
N. Boag et al., J. C. S. Dalton (1980) pg. 2170 et seq. describe a number of platinum (O) alkyne complexes synthesized via platinum bis(cyclooctadiene) complexes, and platinum tris(ethylene) complexes.
None of the above references describes a method for the synthesis of platinum (O) alkyne complexes that can be practiced without special handling precautions for the intermediates. Moreover, none of the above references disclose the complexes: ##STR1## C 6 H 5 is to be taken throughout this specification and the appended claims as representing the phenyl radical, i.e. ##STR2##
SUMMARY OF THE INVENTION
It is an object of this invention to provide a simple method for making platinum (O) alkyne complexes. It is a further object to provide new hydrosilylation and hydrogenation catalysts.
These objects and others are attained by the method and compositions of the present invention. The method of the present invention comprises contacting an alkyne with a platinum-vinylsiloxane complex to provide a platinum (O) alkyne complex. In other aspects, the present invention relates to certain specific platinum (O) alkyne complexes and their use.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the compound having the formula ##STR3## The present invention further relates to the compound having the formula ##STR4## The present invention further relates to a method for making platinum (O) alkyne complexes, said method comprising contacting an alkyne with a platinum-vinylsiloxane complex.
In the method of the present invention, an alkyne is contacted with a platinum-vinylsiloxane complex. The platinum-vinylsiloxane complex is the reaction product of hexachloroplatinic acid and a vinylsiloxane having the general unit formula
X.sub.a R.sub.n SiO.sub.(4-a-n)/2,
wherein X is a hydrolyzable radical; R is a monovalent hydrocarbon radical; each a has a value of 0 or 1; each n has a value of 1, 2, or 3; the sum of the values of a and n has a maximum value of 3; and there is at least one R unit in said vinylsiloxane having the formula CH 2 ═CH--.
Platinum-vinylsiloxane compounds have been described in U.S. Pat. No. 3,419,593, issued Dec. 31, 1968 to David N. Willing, the specification of which patent is hereby incorporated herein to further teach a method for making suitable platinum-vinylsiloxane complexes. U.S. Pat. No. 3,775,452, issued Nov. 27, 1973 to Karstedt also disclose methods for making suitable platinum-vinylsiloxane complexes.
In general, platinum-vinylsiloxane complexes are made by contacting a vinylsiloxane as described above with a suitable platinum compound such as hexachloroplatinic acid. Hexachloroplatinic acid is well known and widely available commercially.
R in the above general unit formula for the vinylsiloxane is a monovalent hydrocarbon radical. Thus, R can be an alkyl radical, such as methyl, ethyl, propyl or butyl; an aryl radical such as phenyl or naphthyl; a cycloalkyl radical, such as cyclohexyl, cycloheptyl, and the like; an alkenyl radical, such as vinyl or allyl; or a cycloalkenyl radical, such as cyclohexenyl, cycloheptenyl and the like. At least one R of each vinylsiloxane, on average, must be a vinyl radical.
X in the above general formula is a hydrolyzable radical. For example, X can be a halogen atom, such as F, Cl, Br, or l; an alkoxy or aryloxy radical, such as --OCH 3 , --OC 2 H 5 , --OC 3 H 7 , --OC 6 H 5 , and the like; a carboxy radical, such as acetyl, propionyl, benzoyl, cyclohexanoyl, and the like; and other hydrolyzable groups known in organosilicon chemistry.
The vinylsiloxane can be linear, branched, or cyclic in structure. Examples of appropriate vinylsiloxanes include the following. The term Vi in the following examples of vinylsiloxanes represents the CH 2 ═CH-- radical; the term Me represents the CH 3 -- radical. ##STR5## the last two formulae representing cyclosiloxanes; and other structures.
Briefly, platinum-vinylsiloxane complexes can be made by contacting the vinylsiloxane with hexachloroplatinic acid. Heating can accelerate the formation of the platinum-vinylsiloxane complex.
Alkynes suitable for reacting with the platinum-vinylsiloxane complex are well known and readily available. Suitable alkynes are described by the general formula ##STR6## wherein each R' independently represents a monovalent hydrocarbon radical, a hydride radical, with the proviso that only one R' can be a hydride radical, or a monovalent hydrocarbon radical substituted with a hydroxyl radical. More preferably, each R' is selected from the group consisting of H; ##STR7##
Many suitable alkynes are commercially available. Alternatively, suitable alkynes can be made by dehydrohalogenation of appropriately substituted vicinal dialkyl halides; by reaction of sodium acetylide with appropriate alkyl halides; and by other known methods of synthesizing alkynes.
The method of the present invention is carried out by contacting an alkyne, as defined above, with a platinum-vinylsiloxane complex, also defined above.
The contacting referred to is done by simply exposing the two reactants to one another as by simply mixing. Mixing can be accomplished manually, by placing the two reactants in a single vessel and swirling or shaking. More preferably, mixing is accomplished with a mechanical stirrer or mixer.
The contacting can be done with the two reactants neat, or it can be done in a suitable solvent. The solvent can be polar or non-polar. Solvents which are known to complex with platinum, or that are discovered to complex with platinum, should be avoided.
If a solvent is used, it is highly preferred to select a solvent in which the reactants are soluble and in which the product, the platinum (O) alkyne complex, is insoluble. If such a solvent is used, the product will precipitate, thus facilitating isolation of the product.
Preferably, 2 moles of the alkyne are provided for each mole of platinum present. However, it may be beneficial in some circumstances to provide partial complexes, such as platinum-alkyne-vinylsiloxane complexes. The method of providing such complexes by furnishing less than 2 moles of alkyne for each mole of platinum is encompassed by the method of the present invention.
Similarly, mixed complexes may be formed by providing two or more different alkynes conjointly. Thus, for example, reacting one mole of platinum with one mole of ##STR8## and simultaneously with one mole of ##STR9## will result in a distribution of products including ##STR10## and also the mixed complex, ##STR11##
The production of mixed complexes with two or more different alkynes is also encompassed by the method of the present invention.
The platinum (O) alkyne complexes resulting from the method of the present invention are useful as catalysts for hydrosilylation reactions; as catalysts for hydrogenation of unsaturated organic compounds or polymers; as catalysts for the isomerization of olefins; as catalysts for the oligomerization of acetylene and other alkynes; as flame retardancy additives for silicone rubber; and in many other applications which require a compatible form of platinum.
The platinum (O) alkyne complexes resulting from the method of the present invention are especially useful as curing catalysts for curable silicone compositions comprising
(1) a silicone polymer having at least one unit selected from the group consisting of ##STR12## units and ##STR13## units;
(2) a silicone polymer having at least one ##STR14## unit; and
(3) a platinum (O) alkyne complex formed by contacting an alkyne with a platinum-vinylsiloxane complex.
A curable silicone composition as described above is made by simply mixing the appropriate polymers and platinum (O) alkyne complex together. Simple mixing is accomplished by mixers, such as Myers mixers, sigmoid blade mixers, three-roll mills, two-roll mills, Baker Perkins type mixers, and other known mixers.
Generally from 1 to 99 parts by weight of Component (1), from 1 to 99 parts by weight of Component (2), and a catalytically effective amount of the platinum (O) alkyne complex are used. By catalytically effective amount it is meant herein an amount sufficient to allow the curable composition to be cured in a reasonable amount of time, such as an hour or less, at a reasonable elevated temperature, such as 35° C. or higher.
Catalytically effective amounts of the platinum (O) alkyne complex of the present invention vary from 1 part per million by weight to 0.1% by weight.
More preferably, the amounts of Components (1) and (2) are selected so that approximately equimolar amounts of ##STR15## on the one hand and ##STR16## on the other hand are used.
A curable composition as described above is a useful coating material, such as a paper release coating. If a reinforcing filler, such as amorphous silica, is added to the curable composition, a useful elastomer will result upon cure.
The platinum (O) alkyne complexes produced by the method are useful catalysts for both filled and unfilled curable silicone compositions.
The following Examples are here presented to further teach the method of the present invention and the use of the products of the present invention. All parts and percentages in the Examples are by weight unless otherwise specified.
The term Me in the Examples represents the methyl radical. The term Vi in the Examples represents the vinyl radical.
CHARACTERIZATION METHODS
The products of the method of the present invention were characterized by the following methods:
Yield:
Yields were determined by dividing the weight of the product actually obtained by the weight of product which would result from complete reaction and recovery of product, and multiplying the result of this division by 100%.
Elemental Analysis:
Carbon and hydrogen percentages were determined by the combustion method. The complexes being analyzed were quantitatively burned in oxygen, and the resulting weights of CO 2 and H 2 O were determined. These weights were used to calculate the percentages of carbon and hydrogen originally present in the complex.
Infared and Nuclear Magnetic Resonance Spectroscopy:
Infared and nuclear magnetic resonance spectra were obtained for each complex in the Examples to help identify the product. The spectra determined were consistent with the reported structures in all cases. The infared vibrational frequency of the acetylene bond is often used in characterizing metal-alkyne complexes. The vibrational frequency of the acetylene bond is reported for each complex in the Examples.
EXAMPLE 1
A platinum-vinylsiloxane complex was first formed by reacting hexachloroplatinic acid with (ViMe 2 Si) 2 O. The resulting product was neutralized with NaHCO 3 and filtered. The filtrate was 4.02% platinum.
5.4 g of this platinum-vinylsiloxane complex (1.1 mmole of platinum) was added to 14 ml of a toluene solution of ##STR17## The 14 ml of solution constituted 2.3 mmoles of the alkyne.
This mixture was stirred for 5 hours, after which time the toluene was removed by distillation at a temperature of 20° C. and under reduced pressure. The resulting product was a white solid. The product was washed with pentane and dried under vacuum. The product was identified as ##STR18## This product had a melting range of 99° C.-101° C. Other characterization data are found in Table 1.
EXAMPLE 2-4
The procedures of Example 1 were followed for each of the following alkynes: ##STR19##
Characterization data are found in Table 1.
TABLE 1__________________________________________________________________________Elemental Analysis IRPlatinum CCExample(O) alkyne Yield Calculated Found frequency (cm.sup.-1)__________________________________________________________________________ ##STR20## 56.2 % C: % H: 60.09 4.38 59.97 4.58 18892 ##STR21## 64.2 % C: % H: 40.03 5.85 39.89 6.03 18893 Pt(C.sub.6 H.sub.5 CCC.sub.6 H.sub.5).sub.2 56.2 % C: 60.98 60.75 1881 % H: 3.57 3.634 Pt(HCCCMe.sub.2 OH).sub.2 63.4 % C: 22.04 22.42 1620 % H: 4.40 3.90__________________________________________________________________________
EXAMPLE 5
This Example illustrates the use of a product of the method of the present invention in a hydrosilylation reaction.
11.2 g of 1-octene were heated with 0.0009 g of the platinum (O) alkyne complex of Example 1, at 65° C., for 1 minute. A clear solution resulted. This clear solution was cooled to a temperature of 30° C. MeHSiCl 2 was added to the cooled solution in a dropwise manner. A vigorously exothermic reaction resulted. The temperature of the reaction mixture rose to 110° C., and external cooling was applied. After 30 minutes, the stoichiometric amount of MeHSiCl 2 , 11.5 g, had been added, and the reaction appeared to have stopped.
Gas chromatographic analysis of the product indicated that the major species (84%) of the reaction mixture was n-octyl SiMeCl 2 .
EXAMPLE 6
50 grams of a 30% toluene solution of a silicone gum containing 2 mole percent vinyl substituted groups was mixed with 0.18 g of the platinum (O) alkyne complex produced in Example 3, and 0.15 g of methylvinylcyclosiloxanes.
10 g of the above mixture was subsequently mixed with 40 g of heptane, and 0.04 g of a silicone polymer having the average formula
Me.sub.3 SiO(MeHSiO).sub.40 SiMe.sub.3.
The resulting mixture was a curable silicone composition of the present invention. This curable silicone composition was coated in a thin layer on a sheet of paper and was exposed for 40 seconds in a 77° C. air-circulating oven.
The coating on the paper was cured: The cured coating did not rub off when rubbed by a finger; it did not smear when rubbed by a finger; and the subsequent adhesion of a piece of adhesive tape pressed upon the coating and removed was not noticeably diminished. The above results are characteristic of a well-cured paper coating. | A simplified method of manufacture for platinum (O) alkyne complexes is disclosed, as well as novel platinum (O) alkyne complexes per se. The complexes are made by reacting platinum-vinylsiloxane complexes with alkynes. The complexes are used in hydrosilylation, hydrogenation, isomerization and oligomerization reactions. Curable silicones using these platinum (O) alkyne complexes as curing catalysts are also disclosed. | 2 |
BACKGROUND OF THE INVENTION
a. Field of Invention
This invention pertains to an ease to use, economical protector for locks, and more particularly, for a protector for use with a lock having a body and a generally U-shaped shackle. The protector is particularly effective against the elements.
b. Description of the Prior Art
Locks are used universally to protect various types of personal property or to control access to certain physical locations. Often these locks are exposed to the elements and may be adversely affected by them. An extreme example is the use of padlocks on trucks. Truck drivers use routinely several padlocks mounted for example on the rear to protect their cargo from vandalism. As a result, the padlocks are exposed to rain, snow sleet, mud and all the materials found on roads. Frequently, because of this exposure, locks freeze up and the only way they can be removed is by breaking them. Of course, once broken, they cannot be reused, and the driver must buy another padlock or carry spares.
There were several attempts to solve this problem by providing lock protectors. One such protector is disclosed in U.S. Pat. No. 5,003,795. However this protector is disposed about the whole lock and the hasp of a mail box is engaged by the lock. The only way this protector can be used is by mounting it on the hasp before the lock is installed. Thus the protector cannot be used in applications without hasps, or where two or even more elements are connected to by or coupled to a lock. Moreover this protector is difficult and time consuming to use.
Another protector is disclosed by U.S. Pat. No. 4,651,543. This is a two part protector molded to conform to a particular lock and hence cannot be used for a different lock. A further disadvantage of this protector is that it has several openings, which permit foreign material to enter the lock and hence does not provide adequate protection. Moreover the molded protector is difficult and expensive to manufacture.
Other lock accessories are disclosed in U.S. Pat. No. 858,264 and 1,581,953.
OBJECTIVES AND ADVANTAGES OF THE INVENTION.
In view of the above-described disadvantages of the prior art, it is an objective of the present invention to provide a lock protector which is mounted securely and substantially hermetically about a lock for protection.
A further objective is to provide a protector which is easy to use even in the most inclement weather.
Yet another objective is to provide a lock protector which can be made of a cheap, recycled materials. Other objectives and advantages of the invention shall become apparent form the following description of the invention.
Briefly, a lock protector constructed in accordance with this invention comprises a sheet of a flexible material and having two opposed edges, the sheet being folded over itself and the edges joined together to form a pouch and a flap joined to a wall of the pouch along a fold line. Means are provided to secure the fold to an outer wall of the pouch to form a substantially hermetically closed pocket. The sheet is provided with one or more apertures along the fold line. The aperture is arranged to receive the shackle of a lock before and after it has been passed through a hasp or other hoop or link.
A lock protector constructed in accordance with this invention provides the following advantages:
(a) It protects locks from freezing as well as from rain, salt, sand, and prevents the same from interfering with the lock mechanism.
(b) It extends the useful life of the locks.
(c) It can be made from recycled products and does not require any processes which pollute the environment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of a protector constructed in accordance with this invention;
FIG. 2 shows a side view of the protector of FIG. 1;
FIG. 3 shows how the shackle of a lock is inserted into the protector of FIGS. 1 and 2;
FIG. 4 shows the lock of FIG. 3 being nested in the protector with the shackle open; and
FIG. 5 shows the lock of FIG. 4 with the shackle closed.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2, a lock protector 10 constructed in accordance this invention consists of a sheet 12 having a lower portion 16 and an upper portion or flap 14 and two lateral edges 18 , 20 . A tab A extends away from the flap 14 as shown and is made of the same material as the flap 14 . The tab A is secured to the flap 14 preferably by sewing. The lower portion 16 has been folded over itself to form a pouch 22 . For this purpose the edges 18 , 20 extending along the lower portion are joined by gluing, sewing, stapling or other adhesive or mechanical means dependent on the material of the sheet 12 . The pouch 22 thus formed has a back wall 24 joined to the flap 14 by an imaginary fold line 26 .
Pouch 22 also has an outer surface 28 and the flap 14 has an opposing surface 30 . Surfaces 28 , 30 have complementary securing means for securing these surfaces to each other. For example, as shown in FIG. 1, these two surfaces may be provided with a plurality of VELCRO® strips 32 , 34 . Obviously other means of interlocking or engaging the flap to the pocket may be used. These strips 32 , 34 cooperate so that when the flap 14 is folded along line 26 and the strips 32 and 34 are interlocked or otherwise engaged thereby closing the pouch 22 and forming a substantially hermetically closed pocket As shown in FIG. 1, the edges 18 , 20 are generally v-shaped so that sheet tapers slightly inwardly toward the fold line 26 to form a natural pocket which holds the lock when it is inserted into the protector as described below. Importantly, the sheet 10 is formed with two round apertures 36 , 38 disposed on the fold line 26 as shown.
Referring to FIG. 3, the protector is used as follows. A typical lock 40 has a body 42 and a shackle 44 . The shackle 44 is generally Ushaped and has two opposing legs 46 and 48 . Leg 46 is rotatably attached to the body 42 . Body 42 has a well 50 for accepting and mechanically locking leg 48 . The lock 40 may be opened by a key inserted into a hole (not shown for the sake of clarity) or it may be combination lock.
Before the lock 40 is used, leg 48 is first inserted into one of the holes, such as hole 36 , as seen in FIG. 3 while the flap 14 is held by the Tab A. Next, the protector 10 and the lock 40 are maneuvered so that the body 42 is disposed in pouch 22 . Now the flap 14 is positioned over surface 28 and the strips 32 , 34 are engaged thereby closing the pouch 22 to form a pocket. The protector 10 and the lock 40 , with its shackle 42 still opened are shown in FIG. 4 . It has been found by the present inventor that these steps can be performed fairly easily and rapidly even in the darkness, or with heavy mittens or work gloves on.
Lock 40 is now ready to be used. In FIG. 4, the lock 40 is used for example to join two chain links 52 , 54 . These chain links may belong to the same chain or two different chains. For this purpose, the links 52 , 54 are inserted on shackle 44 by passing them over free leg 48 . Next, the shackle 44 is rotated so that the leg 48 is aligned with well 50 . The shackle is now pressed toward body 42 as indicated by arrow A forcing the leg 48 through aperture 38 and into the well 50 until the leg 48 is locked to body 50 . The final configuration of the protector 10 , lock 40 and links 52 , 54 are shown in FIG. 5 . As can be seen in this Figure the lock 40 is resting with this body firmly secured in the pocket. Shackle 44 is exposed, however this is not important since the delicate mechanism of the lock 40 is disposed in the body 42 , not in the shackle 44 .
Preferably holes 36 , 38 are made slightly smaller than the diameter of the shackle 44 so that they form a close interference therewith.
The protector 10 can be easily opened by pulling flap 14 away with Tab A.
The protector can be sized and shaped so that it can fit a large variety of locks, as long as the diameter of the shackle 44 and the distance between the legs 46 , 48 is about the same.
The sheet 12 can be made from a variety of materials. Preferably the sheet is made of a flexible material such as natural or synthetic rubber. For example, the sheet may be made of butyl rubber which is advantageous because this material sticks to itself when folded thereby providing an air tight seal. The sheet may be about 0.078″ thick. The inventor found that the protector can be cut and formed of a used inner tube of a truck tire. In fact a single inner tube can be used to make a large number of lock protectors as described above. Since other means of recycling inner tubes is quite expensive, this usage provides an attractive and environmentally friendly alternative. Automobile inner tubes can also be used for this purpose.
A preferred method of forming the protector is by sewing the sheet using a #46 polypropylene thread.
An important advantage of the inventor is that the pocket may also be used to hold small documents such as notes, messages, shipping labels, etc.
Obviously, numerous modifications may be made to this invention without departing from its scope as defined in the appended claims. For example, the protector need not be made of a single sheet, but instead may be made of a two or more sheets joined together. Similarly, instead of two round apertures for the shackle, a single extended aperture may be used. | A protector for a padlock of the kind having a body and a shackle, said protector having a pouch for holding the body and a flap for forming a closed pocket with said pouch, with the shackle extending out of the pocket. In this manner the shackle is free to rotate so that it can engage a chain link, a hasp, and so on. The protector is preferably made of flexible material such as rubber. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of copending International Application No. PCT/DE99/02983, filed Sep. 17, 1999, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a magnetoresistive random-access memory (MRAM), whose storage effect resides in the magnetically variable electrical resistance of the memory cell.
Magnetoresistive memories have a magnetoresistive layer system between, for example, a word line and a bit line. The layer system comprises, for example, a soft-magnetic layer and a hard-magnetic layer, which are isolated by a thin tunnel oxide. The resistance between the bit line and the word line depends, then, on whether the magnetization directions in the materials are parallel or antiparallel. Parallel magnetization leads to a lower resistance and antiparallel magnetization direction leads to a higher resistance. In many respects, the relatively high currents or current peaks, required in particular for cell writing, in the word and bit lines are disadvantageous because the current densities resulting therefrom lead to electromigration problems, and to a relatively high power loss. Furthermore, the relatively high currents mean that increased requirements are placed on the peripheral circuits. Since the materials for the bit and word lines must, for example, be process-compatible, readily patternable and have a low resistivity, electromigration problems can be avoided only to a very limited extent by a suitable choice of the line materials. The reduction of the required currents by using thinner magnetic layers encounters technological limits and causes greater reliability problems as the layer thickness decreases. Moreover, from today's standpoint, it cannot be assumed that material-specific optimizations will make a significant contribution to the reduction of the required currents in the foreseeable future.
U.S. Pat. No. 4,455,626 discloses an MRAM whose magnetoresistive layer is situated in a gap in a thicker field concentrator layer. In that case, a memory layer and the field concentrator layer constitute a magnetic path to the magnetoresistive layer.
Furthermore, U.S. Pat. No. 6,028,786 (European published patent application EP 0 875 901 A3) discloses a magnetoresistive memory in which a material having a high relative permeability is used in order to effect a reduction in the current density required for writing.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a magnetoresistive random-access memory, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and in which, with the smallest possible chip area, the current density in the bit and word lines is as low as possible.
With the foregoing and other objects in view there is provided, in accordance with the invention, a magnetoresistive memory, comprising:
two layers formed of a material of a high relative permeability;
magnetic memory cells with associated bit lines and word lines formed between the two layers;
a filling of electrically insulating material having a large relative permeability disposed in at least one region selected from the group consisting of a region laterally between the bit lines, a region laterally between the memory cells, and a region laterally between the word lines.
In accordance with an added feature of the invention, the two layers are electrical insulators, and one of the two layers makes contact with the word line and the other of the two layers makes contact with the bit line.
In accordance with an additional feature of the invention, at least one of the two layers and/or the filling in at least one of the regions is formed of a ferrite.
In accordance with another feature of the invention, the regions are all filled with the same material.
With the above and other objects in view there is also provided, in accordance with an alternative feature of the invention, a magnetoresistive memory which comprises:
bit lines and word lines;
magnetic memory cells disposed at cross-over points of the bit lines and the word lines;
two layers of a material having high relative permeability enclosing therebetween the memory cells with the bit lines and word lines; and
a layer of an electrically insulating material having a low relative permeability between the memory cells with the bit lines and word lines and at least one of the two layers.
In accordance with a concomitant feature of the invention, the layer of the electrically insulating material having a low relative permeability fills a space between the two layers and the memory cells together with the bit and word lines in a region of the memory cells.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a magnetoresistive memory with a low current density, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show two mutually orthogonal sections taken through a first exemplary embodiment of a magnetoresistive memory cell; and
FIGS. 2A and 2B show two mutually orthogonal sections taken through a second exemplary embodiment of a magnetoresistive memory cell according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is principally based on the fact that, on account of improved coupling of a magnetic field generated by the bit lines and/or the word lines into the magnetoresistive memory cell, a lower current density is required in these lines. The invention makes this possible in a particularly space-saving and efficient manner.
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1A thereof, there is shown a sectional illustration in the region of two magnetoresistive cells. Such magnetoresistive memory cells comprise, for example, a soft-magnetic layer WML which is isolated from a hard-magnetic layer by a tunnel oxide. The tunnel oxide is represented by the line between the boxes WML and HML. The tunneling probability, and hence the electrical resistance between the two layers, depends on the magnetization direction of the two layers. The magnetoresistive memory cells are respectively indicated by the soft-magnetic layer WML and the hard-magnetic layer HML and are situated at crossover points between bit lines and word lines. Regions C composed of an electrically insulating material having a high relative permeability are situated laterally between the cells with the layers WML and HML. Moreover, a region B made of electrically insulating material having a high relative permeability is likewise situated laterally between at least two lines LTO 1 and LTO 2 , for example bit lines.
The memory cell WML, HML and the tunnel oxide between the two magnetic layers, together with the associated segment of the bit line LTO and the associated segment of the word line LTU is laterally defined within the vertical box LBZ. The cells of the magneto-resistive memory are therefore vertical stacks that are bounded by the materials in the regions B, C, D.
The section of FIG. 1B is orthogonal to the section of FIG. 1 A and shows, moreover, regions D laterally between at least two lines LTU 1 and LTU 2 , for example word lines, made of an electrically insulating material having a high relative permeability. Moreover, in FIGS. 1A and 1B, a continuous layer A made of an electrically insulating material having a high relative permeability is present. The layer A directly adjoins the bit lines LTO 1 and LTO 2 , and a further continuous layer E made of an electrically insulating material having a high relative permeability is present. The layer E adjoins the word lines LTU 1 and LTU 2 . What this brings about, at the same time in a very space-saving manner, is the insulation of the individual memory cells and, at the same time, a field concentration for reducing the required current density.
The regions C, B, and D here are referred to as fillings, because the high-permeability material essentially fills the spaces between the cells WML, HML, between the word lines, and the bit lines.
The layers A and E and the regions B, C and D may be composed of different or, alternatively, identical electrically insulating materials having a high relative permeability. By way of example, ferrites are suitable as material for the layers A and E and for the regions B, C, and D. It will also be understood that, while the term high relative permeability may be a relative term, the same is understood by those of skill in the pertinent art to be accurately defined in the magnetoresistive memory context.
A further alternative is illustrated in two mutually orthogonal sections in FIGS. 2A and 2B, two magnetoresistive memory cells being illustrated between two layers F and H made of an electrically conductive or poorly insulating material having a high permeability. The essential difference from the first alternative is, however, that the layers F and H make contact neither with the bit lines nor with the word lines. Rather, they are isolated therefrom by an electrically insulating material having a relatively low relative permeability. This makes it possible, for example, to use electrically conductive or poorly insulating materials having a high relative permeability, since, as a result of the electrically insulating material, the bit and word lines and also the memory cells themselves are not short-circuited or bridged.
The layers F and H may be composed of different or else identical electrically conductive or, alternatively, electrically non-conductive materials having a high relative permeability. Electrically conductive layers having a high relative permeability are usually alloys of iron, nickel and/or cobalt. The layer G can fill the entire space between the layers F and H and the memory cells together with word and bit lines. The material of the layer G is an electrical insulator having a low relative permeability and is composed, for example, of silicon dioxide or silicon nitride.
In further embodiments, it is also possible for only the regions B and/or C and/or D to be composed of an electrically insulating material having a high relative permeability, e.g. ferrite. | The magnetoresistive memory has a reduced current density in the bit lines and/or word lines. This avoids electromigration problems. The current density is reduced such that a compact field concentration is attained, for example, by the use of ferrite in the area around the magnetic memory cells. | 7 |
TECHNICAL FIELD
[0001] The present disclosure relates to torsional damping and in particular to a constant velocity joint (CVJ) sealing cover assembly including, a torsional damper.
BACKGROUND
[0002] Universal joints, and especially constant velocity joints, operate to transmit torque between two rotational members. The rotational members are typically interconnected by a cage, or yoke, that allows the rotational members to operate with their respective axes at a relative angle. Constant velocity joints and similar rotating couplings typically include a boot cover assembly and grease cover to enclose and protect the coupling during operation. Since the boot cover assembly is partially flexible, the boot cover assembly is able to seal around the joint while permitting articulation and relative axial movement of differing rotating members of the joint. The boot cover assembly and the grease cover seal lubricant in the joint so as to reduce friction and extend the life of the joint. The boot cover assembly and the grease cover also seal out dirt, water and other contaminants to protect the functionality of the joint. However, leaks may reduce the life of the joint, and contaminants in the grease may disturb the chemical composition of the grease, degrading its performance.
[0003] Universal joints are commonly classified by their operating characteristics. One important operating characteristic relates to the relative angular velocities of the two shafts connected thereby. In a constant velocity type of universal joint, the instantaneous angular velocities of the two shafts are always equal, regardless of the relative angular orientation between the two shafts. In a non-constant velocity type of universal joint, the instantaneous angular velocities of the two shafts vary with the angular orientation (although the average angular velocities for a complete rotation are equal as one shaft accelerates and decelerates relative to the rotational speed of the other shaft, creating a rotational speed oscillation). Another important operating characteristic of a joint may be the ability of the joint to allow relative axial movement between the two shafts. A fixed joint does not allow this relative movement, while a plunge joint does.
[0004] FIG. 1 illustrates an exemplary the CVJ 20 . The CVJ 20 includes driven end 22 and a driving end 24 . The CVJ 20 further includes a joint assembly 26 coupled to a shaft 28 with a boot cover assembly 30 connected therebetween. The CVJ 20 further includes a grease cover 32 that seals the driven end 22 . The boot cover assembly 30 includes a metal cover 34 and a flexible boot 40 . A portion of the metal cover 34 is crimped onto the boot 40 for attachment thereto. The boot cover assembly 30 protects the moving parts of the CVJ 20 during operation. The joint assembly 26 includes a first rotational member 42 , a second rotational member 44 , and a plurality of balls 46 retained in a race 48 . The shaft 28 is splined to the second rotational member 44 to allow axial movement therebetween.
[0005] When the instantaneous angular velocities of two portions of a driveline are not equal, the differences in velocities will impart a torsional oscillation into the driveline. That is, for example, since the instantaneous rotational velocity of at least the balls 46 and the race 48 are different than the instantaneous rotational velocity of the first rotational member 42 and the second rotational member 44 when the joint 20 is operating at an angle (the first rotational member 42 and the second rotational member 44 are not coaxial), torque and rotational velocity that is transmitted from the first rotational member 42 to the second rotational member 44 will include an oscillatory magnitude imparted by a fraction of the rotational inertia of the balls 46 and the race 48 . A rotational speed or torque with an oscillatory magnitude may undesirably drive other vibrations within a drive train or a vehicle, or may reduce the useful life of drivetrain components.
[0006] Other contributors of oscillatory magnitude of rotational speed and torque within a drivetrain include the combustion events in an internal combustion engine, gear backlash, and the magnetic field pull and push between the magnet and the armature of an electric motor. While a large portion of the magnitude of these oscillations may be dampened by the torsional deflection of torque transmitting shafts and torsional dampers, such as those found in clutch disks, some oscillatory magnitude will typically transmit through the driveline. Additionally, shorter shafts may result in less ‘absorption’ of rotational speed and torque oscillations, resulting in a greater magnitude of transmitted oscillations.
[0007] What is needed, therefore, is an apparatus and method of reducing or eliminating the oscillatory magnitude of rotational speed and torque within a drivetrain.
SUMMARY
[0008] An embodiment includes a sealing cover assembly for an articulating joint. The articulating joint includes a first rotational member and a second rotational member. The sealing cover assembly includes a first portion having a plurality of fastening portions. The fastening portions are coupled to the second rotational member for rotation therewith. The sealing cover assembly also includes a second portion adapted for connecting to the driveline and a plurality of damping members constructed of at least a first material and interconnecting the first portion to the second portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Referring now to the drawings, preferred illustrative embodiments are shown in detail. Although the drawings represent some embodiments, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description:
[0010] FIG. 1 is a sectional view of a constant velocity joint.
[0011] FIG. 2 is a sectional view of a joint assembly in accordance with an embodiment.
[0012] FIG. 3 is a sectional view taken along line 3 - 3 of FIG. 2 , with some components visible through a cover plate for clarity.
[0013] FIG. 4 is a sectional view taken along line 4 - 4 of FIG. 3 , with some items removed for clarity.
DETAILED DESCRIPTION
[0014] FIG. 3 illustrates a constant velocity joint 120 having a driven end 122 and a driving end 124 . Joint 120 further includes a joint assembly 126 that is coupled to a shaft 128 . A boot cover assembly 130 is connected between the joint assembly 126 and the shaft 128 . A sealing cover assembly 132 seals the driven end 122 of joint 120 . Joint assembly 126 includes a first rotational member 142 , a second rotational member 144 , and a plurality of balls 146 retained in a race 148 . As illustrated, shaft 128 is splined to second rotational member 144 and the second rotational member 144 is positioned coaxial with the first rotational member 142 .
[0015] As illustrated in FIG. 2 , the sealing cover assembly 132 interconnects the joint 120 with a driveshaft 150 . The driveshaft 150 includes a shaft portion 152 and a flange portion 154 having a plurality of second portion coupling apertures 156 . In the embodiment illustrated, the flange portion 154 is generally triangular shaped and centered on the shaft portion 152 .
[0016] The joint assembly 126 can be any type of articulated universal joint, including a plunging tripod, a fixed tripod, a plunging ball joint, and a fixed ball joint. Typical joint assemblies are disclosed in commonly-owned U.S. Pat. Nos. 6,817,950, 6,776,720, 6,533,669 and 6,368,224, and U.S. Pat. No. 5,899,814, the disclosures of which are hereby incorporated by reference in their entireties. The driven end 122 may be welded or otherwise coupled to a driveshaft or other drivetrain component.
[0017] The sealing cover assembly 132 includes a first portion 160 , a second portion 162 , and a plurality of damping members 164 . The first portion 160 includes a generally circular sealing portion 170 , a generally cylindrical outer portion 172 , and a plurality of fastening portions 174 , and a cover plate 176 . The sealing portion 170 includes a sealing surface 180 ( FIG. 4 ), an opposing interior surface 182 , and a joint mating surface 184 with a plurality of joint mating surface apertures 186 formed therein. The sealing portion 170 may include a vent (not shown) as desired.
[0018] The cover plate 176 includes a cover plate interior surface 190 , a cover plate exterior surface 192 , and a plurality of cover plate apertures 194 . Each damping member 164 includes a body 200 having a first portion coupling portion 202 and a second portion coupling portion 204 .
[0019] The second portion 162 includes a plurality of elongated members 210 that extend through the second portion coupling apertures 156 to couple to the flange portion 154 of the drive shaft 150 . Each member 210 includes a damping member coupling portion 212 and a flange coupling portion 214 .
[0020] A fastener 220 ( FIG. 2 ), such as, for example, a bolt, may be interposed through each cover plate aperture 194 , a fastening portion 174 , a first portion coupling portion 202 , a joint mating surface aperture 186 , and into the first rotational member 142 . As at least one of the fasteners 220 is fastened, such as rotating a bolt as threads extending from the bolt engage a threaded surface formed on the interior of the first rotational member 142 , the first portion 160 is coupled to the first rotational member 142 of the joint 120 , the joint mating surface 184 of the sealing portion 170 is coupled to first rotational member 142 , sealing the lubricant within the joint 120 , and the fastening portion 174 of the first portion 160 is coupled to at least one of the damping members 164 .
[0021] In the embodiment illustrated, the fastening portions 174 are tubular metal bushings that extend from the sealing portion 170 and the first rotational member 142 to the cover plate 176 , and the first portion 160 and the second portion 162 are 8-gauge sheet metal, although other suitable thicknesses and materials may be used. Additionally, while the cover plate 176 is illustrated in a triangular shape in FIG. 3 , the cover plate 176 may be generally circular with arcuate slots (not shown) for the second portions 162 to extend therethrough to better seal the interior of the sealing cover assembly 132 and the damping members 164 from the operating environment of the joint 120 .
[0022] Also in the embodiment illustrated, the sealing cover assembly 132 includes three damping members 164 . although any suitable number of damping members may be used. Specifically, a single annular damping member having appropriately spaced apertures for the second portions 162 and the fastening members 174 may be used.
[0023] The damping members 164 selectively dampen torsional oscillations within the drive train as the joint 120 rotates due to the energy absorbing properties of the material of construction of the damping members 164 . In the embodiment illustrated, the damping members 164 are constructed of a first material that is preferably a flexible material with suitable damping qualities, and may be plastic or any polymer or elastomer, such as rubber, silicone, or thermoplastic elastomer (TPE).
[0024] An embodiment of a method of torsionally damping a driveline with the joint 120 is as follows. During operation torque is transferred between the driveshaft 150 and the shaft 128 through the damping members 164 . When the rotational speed of one of the driveshaft 150 and the shaft 128 includes an oscillatory magnitude, the increase and decrease in rotational speed of one of the driveshaft 150 and the shaft 128 will urge the other of the driveshaft 150 and the shaft 128 to rotate with a similar oscillatory magnitude. However, as the increase in rotational speed is transmitted through the damping members 164 the damping members 164 will absorb, or store, energy, and as the decrease in rotational speed transmits through the damping members 164 the damping members 164 will release the stored energy, resulting in a rotational speed with a lower oscillatory magnitude.
[0025] Thus assembled and operated, the plurality of damping, members 164 interconnect the first portion 160 with the second portion 162 as the sealing, cover assembly 132 provides a rotational damper for the driveline containing the joint 120 .
[0026] The damping members 164 may include wires or other second materials within the body 200 to stiffen the body 200 and permit the body 200 to store a greater amount of energy than if the body were constructed of only the first material. The second material is preferably a metal and/or a metal alloy and may be encircled around the damping, member coupling portion 212 and the fastening members 174 to provide additional resistance against the deformation of the body 200 as torque is applied thereto.
[0027] Although the steps of the method of constructing the joint 120 are listed in a preferred order, the steps may be performed in differing orders or combined such that one operation may perform multiple steps. Furthermore, a step or steps may be initiated before another step or steps are completed, or a step or steps may be initiated and completed after initiation and before completion of (during the performance of) other steps.
[0028] The preceding description has been presented only to illustrate and describe exemplary embodiments of the methods and systems of the present invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims. | A sealing cover assembly for an articulating joint. The articulating joint includes a first rotational member and a second rotational member. The sealing cover assembly includes a first portion having a plurality of fastening portions. The fastening portions are coupled to the second rotational member for rotation therewith. The sealing cover assembly also includes a second portion adapted for connecting to the driveline and a plurality of damping members constructed of at least a first material and interconnecting the first portion to the second portion. | 5 |
CROSS-REFERENCE TO RELATED CASE
This application is related to my commonly assigned, copending U.S. application Ser. No. 096,776 filed Nov. 23, 1979, entitled "Multiple Longitudinal Traversing Shed Weaving Apparatus".
BACKGROUND OF THE INVENTION
The present invention generally relates to the weaving art, and more specifically, relates to a new and improved construction of a so-called multiple longitudinal traversing shed weaving apparatus or loom, meaning a loom wherein a plurality of successive sheds are formed and retained to establish waves of sheds which travel longitudinally of the warp threads. Such type looms have also been referred to in the art as warp-wave looms, in order to distinguish the same from the type of loom using "weft waves" traveling transversely of the warp threads.
Generally speaking, the multiple longitudinal traversing shed weaving apparatus or loom of the present development is of the type comprising a weaving rotor which is provided with shed-retaining elements or members which retain the warp threads, throughout a predetermined path, in their upper shed position or lower shed position. Additionally, there is provided control means which, viewed in the direction of travel of the warp threads, is located forwardly of the weaving rotor and serves for the lateral deflection and allocation of each warp thread to a shed-retaining element which determines the upper shed or lower shed.
Multiple longitudinal traversing shed looms or warp-wave looms, as is known, form together with the so-called wave shed weaving machines, that species of multi-phase weaving machines or looms wherein there are continuously inserted a number of mutually stepwise shifted or staggered weft threads in likewise stepwise shifted and traveling sheds. While with the wave shed weaving machines or looms the sheds are simultaneously multiply formed over the width of the fabric and migrate in the weft direction, in the case of the multiple longitudinal traversing shed weaving looms there is formed, in each case, a shed over the entire fabric width and the successively formed sheds simultaneously move in the direction of the warp threads.
A first type of multiple longitudinal traversing shed weaving machine of the previously mentioned type has been proposed in U.S. Pat. No. 3,848,642 wherein the control means for the lateral deflection of the warp threads are constituted by rotatable control rolls which are provided at their outer surface with closed to-and-fro extending guide grooves positioned at an inclination with respect to the lengthwise axis of the control rolls and provided for each respective warp thread. During rotation of the control rolls the warp threads, in accordance with the course of the guide grooves, are laterally deflected, and thus, are allocated to the desired shed-retaining element. This allocation is augmented by separation elements which dip into the warp threads and are arranged, viewed in the direction of travel of the warp threads, directly after the control rolls.
With this multiple longitudinal traversing shed weaving machine a number of warp threads are allocated in each case with a single shed-retaining element. This leads to the result that the warp threads are relatively markedly deflected by the control rolls. The guiding of the warp threads in the guide grooves causes a pronounced loading of the warp threads, especially a pronounced friction between the warp threads and the guide grooves. Additionally, the control rolls are not variable and when changing over to a new fabric weave must be exchanged or at least restructured.
SUMMARY OF THE INVENTION
Hence, with the foregoing in mind it is a primary object of the present invention to provide a new and improved construction of multiple longitudinal traversing shed weaving apparatus which is not afflicted with the aforementioned drawbacks and limitations of the prior art constructions.
Another and more specific object of the present invention aims at providing a loom of the character described wherein the control means thereof only slightly load the warp threads, and additionally, the loom can be easily accommodated to changes in fabric weaves without having to modify or otherwise restructure the loom.
Yet a further significant object of the present invention aims at providing a new and improved construction of loom of the type described which is relatively simple in design, economical to manufacture, extremely reliable in operation, not readily subject to breakdown or malfunction and requires a minimum of maintenance and servicing.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the loom of the present development is manifested by the features that the control means comprise elements whose stroke can be adjusted in the weft direction.
According to a preferred embodiment of the inventive multiple longitudinal traversing shed weaving apparatus the stroke-adjustable elements are formed by rods extending in the weft direction, these rods being provided with guide eyelets for the warp threads.
The inventive embodiment has the advantage that, on the one hand, between the guide eyelets and the warp threads there arise only very slight frictional forces and, on the other hand, by selecting a suitable actuation mechanism for the rods it is possible to produce any desired fabric weave or pattern, without having to modify or restructure or otherwise alter the control means.
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 schematic cross-sectional view through a multiple longitudinal traversing shed weaving apparatus or loom according to the invention;
FIG. 2 is a schematic view looking in the direction of the arrow II of the loom of FIG. 1;
FIG. 3 is a sectional view, on an enlarged scale, showing details of the arrangement of FIG. 2;
FIG. 4 is a cross-sectional view, taken substantially along the line IV--IV of FIG. 2;
FIG. 5 is a schematic perspective view of the weaving rotor of the loom illustrated in FIG. 1, certain of the parts thereof being shown in exploded illustration; and
FIG. 6 is a fragmentary cross-sectional view of the weaving rotor portrayed in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the illustration thereof only enough of the construction of the loom has been shown to enable those versed in the art to readily understand the underlying principles and concepts of the invention. Turning attention now to FIGS. 1 and 2 the multiple longitudinal traversing shed weaving loom disclosed therein will be seen to essentially comprise a warp beam 1, a back rest or beam 2, a control device or means 3 for the lateral deflection of the warp threads 4, in order to allocate such, in accordance with a predetermined fabric or cloth pattern, to an upper shed position or lower shed position. Additionally, there is provided a weaving rotor 5, a breast beam 6, a take-off device or mechanism 7 for the woven fabric or cloth 8 and a cloth beam 9.
The weaving rotor 5, rotating during operation in the direction indicated by the arrow P, is of substantially roll or cylindrical configuration and is provided at its circumference, viewed in the direction of rotation P, alternately with lamellae or leaf reeds or combs 10 and 11 extending in the lengthwise direction of the weaving rotor 5, and thus, in the weft laying or insertion direction. The lamellae reeds or combs 10 consist of beat-up lamellae or leaf members 12 serving for beating the inserted weft threads. The lamellae reeds or combs 11 consist of guide lamellae or leaf members 13 between which there are alternately arranged the shed-retaining elements 14 and 15 which determine the upper shed position or lower shed position, respectively, of the warp threads 4. By means of the shed-retaining or holding elements 14 and 15 the warp threads 4 are retained, over the entire wrap angle α of approximately 120°, in their upper shed position or lower shed position. The thus formed sheds successively travel towards the fell of the fabric or cloth, and in the time where the sheds are open there is inserted in a step-wise mutually offset fashion to one another into each shed a weft thread.
Adjacent one of the end faces of the weaving rotor 5 there is arranged a unit or device 16 for preparing and inserting the weft threads. This device 16 does not constitute subject matter of the invention and therefore need not here be further considered. It is however mentioned that any suitable weft insertion system can be used in conjunction with the weaving rotor 5, whether such be a weft insertion system working with shuttles, gripper shuttles, projectiles, to-and-fro moving rods or tapes or with a fluid medium. Such type conventional weft insertion systems, used in conjunction with multiple longitudinal traversing shed weaving looms have been disclosed in German Pat. No. 1,089,695 and in each of U.S. Pat. Nos. 2,742,058, 3,848,642, 4,122,871, 4,122,872 and 4,129,153, to which reference may be readily had and the disclosure of which is incorporated herein by reference.
Continuing, by reverting to FIG. 2 it will be apparent that along the outer shell or surface of the weaving rotor 5, on the one hand, the beat-up lamellae or elements 12 of the lamellae reeds 10 are in alignment with one another and, on the other hand, the guide lamellae or elements 13 of the lamellae reeds 11 are in alignment with one another, and that the lines of alignment of the individual guide lamellae or elements 13 extend in the center of the intermediate space, the so-called tube, of the related beat-up lamellae or elements 12, and the lines of alignment of the beat-up lamellae or elements 12 extend in the center of the tube of the related guide lamellae or elements 13. Also it will be additionally seen that the shed-retaining elements 14 are in alignment with one another and equally the shed-retaining elements 15 are in alignment with one another.
The control device or control means 3 comprises a number of, for instance, as shown four rods or bars 17, arranged parallel to the weft insertion direction. The rods 17 are connected with an actuation device 18 and can be moved to-and-fro thereby in the direction of the double-headed arrow A. The rods 17 are equipped with conventional guide eyelets, merely schematically indicated by reference character 90 in FIG. 2, for the warp threads 4, so that the latter, during movement of the rods 17 in their lengthwise direction, are laterally deflected. The number of rods 17 depends upon the nature of the fabric pattern which is to be woven, and in the case of linen weaves it is sufficient to use two such rods 17, while with more complicated patterns or fabric weaves there must be employed a corresponding greater number of such rods or bars 17. The actuation device 18 is in the nature of a conventional control mechanism for dobby looms, such as typified by U.S. Pat. No. 3,171,445, granted Mar. 2, 1965 and U.S. Pat. No. 4,154,268, granted May 15, 1979, to which reference may be had and the disclosure of which is incorporated herein by reference, which, in accordance with a predetermined program, moves each of the rods 17, corresponding to a conventional harness or harness frame, into one of both end positions prior to each dipping of one of both lamellae reeds 10 or 11 into the warp threads 4. In such terminal or end position the related warp thread 4 is located within its tube at the left or at the right of the lamellae or elements 12 or 13, as the case may be, which bounds such tube, and therefore, owing to the displacement through one-half of the tube pitch between the successive lamellae reeds 10 and 11, will be positively leased or drawn into the correct tube of the next lamellae reed.
The difference between the control device 3 and a conventional shed forming mechanism by means of a dobby loom and harnesses or harness frame resides essentially in three points worthy of enumeration:
(1) The mass of a rod 17 is appreciably less than that of each conventionally known harness or harness frame, so that for the displacement thereof quite considerably less energy is required in relation to a harness frame.
(2) The dimensions of a rod 17 are appreciably smaller than that of each known harness frame, so that within the same space there can be accommodated quite a larger number of rods 17.
(3) The displacement path, in other words the stroke of the rod 17 only amounts to a fraction of a normal harness stroke, since such displacement path is not dependent upon the shed opening, rather only must cause pivoting or deflection of a warp thread from the one to the other bounding lamella or element of a tube. Therefore, the displacement of the rod 17 can be accomplished in a considerably shorter amount of time than the displacement of a conventional harness frame and the frequency of the displacements of the rod 17, in comparison to the frequency of the stroke movements of conventional harness frames which, already at the present time, limit the output of single-phase high production looms, can be increased by a multiple.
Now based upon the showing of FIG. 3 there will be explained in greater detail the leasing or drawing-in of the warp threads 4 in the weaving rotor 5. In such FIG. 3 there have been schematically illustrated two lamellae reeds 11 1 and 11 2 having the guide lamellae or elements 13 as well as the lamellae reed 10 extending therebetween and equipped with the beat-up lamellae or elements 12. The warp threads 4, shown by a double line, located in each case in the upper shed position in the lamellae reed 11 1 which has dipped already for some time into the warp threads, are guided by the rods 17 1 . On the other hand, the warp threads 4, shown with a single line, are located in the lamellae reed 11 1 in each case in the lower shed position and are guided by the rods 17 2 . As already stated, for reasons of clarity in illustration both of the other rods 17, shown in FIG. 1, have been omitted, so that in the lamellae reed 10 each second tube does not have any warp thread 4 and in the lamella reed 11 each tube only has one warp thread 4.
It is assumed that the lamellae reed 10 as well as the lamellae reed 11 1 have completely dipped into the warp threads 4 and that the lamellae reed 11 2 will shortly dip into the warp threads 4, and the warp threads 4 guided by the rods 17 1 should reach the lower shed position and the warp threads 4 guided by the rods 17 2 should reach the upper shed position.
To achieve this result the rods 17 1 and 17 2 must be moved by the actuation device 18 (FIG. 2) in such a manner that the warp threads 4, guided by such rods, must assume the position illustrated in full lines. The warp threads 4 guided by the rod 17 1 are thus moved towards the left and the warp threads 4 guided by the rod 17 2 are moved towards the right, until they bear at the beat-up lamellae 12 which bound thereto at the left and right, respectively. In this way the guide lamellae or elements 13 can enter in each case between two spread apart warp threads 4 into the sheet of warp threads. Furthermore, the one of these two spread apart warp threads 4 always arrives into a tube of the lamellae reed 11 2 equipped with a shed-retaining element 14 for the upper shed position and the other warp thread arrives in a tube of the lamellae reed 11 2 having a shed-retaining element 15 for the lower shed position.
If the warp threads 4 in the lamellae reed 11 2 , guided by the rod 17 1 , should arrive at the upper shed position and the warp threads 4, guided by the rod 17 2 , should arrive at the lower shed position, then the rod 17 1 must be moved in the direction of the arrow B and the rod 17 2 in the direction of the arrow C, so that the warp threads 4 assume the broken line and chain-dot line positions, respectively.
The displacement path of the rods 17 1 and 17 2 between both of the warp thread positions, appears in FIG. 3, owing to the scale and the exaggerated large shown thickness of the lamellae or elements 12 and 13 and equally because of the exaggeratedly large shown tube width in the lamellae reeds 10 and 11, appreciably larger than in reality. In fact, this displacement path amounts to only a few millimeters and, as a general rule, is clearly below 10 millimeters.
Now in FIGS. 4 to 6 the weaving rotor 5 has been illustrated in detail. Such weaving rotor 5 will be seen to comprise, in the embodiment under discussion, a substantially tubular-shaped roll 20 which is connected with a drive shaft 21. The roll 20 is provided at its outer surface or shell with a multiplicity of grooves 22 and 23 extending essentially parallel to the lengthwise axis of the rotor 5, and therefore, essentially parallel to the weft insertion direction. These grooves or slots 22 and 23 serve for receiving the lamellae reeds 10 and 11, respectively. The grooves 22 and 23 have a substantially L-shaped cross-sectional configuration. In each case two grooves 22 and 23 form a related pair, wherein the transverse legs of the L-shaped configured or profiled grooves 22 and 23 are directed away from one another, as best seen by referring to FIG. 5. The outer surface or shell of the roll 20 is provided with, for instance, a total of fourteen such pairs of grooves 22 and 23.
Due to this construction of the weaving rotor 5 composed of the roll or cylinder 20 with the peripheral grooves 22 and 23, it is possible to dispense with the use of the shed-holding elements 15 (FIG. 3) for the lower shed position, since support of the warp threads 4, in such lower shed position, as best seen by referring to FIG. 4, can be accomplished by the outer surface of the roll or roller 20. The individual lamellae reeds 10 and 11, instead of being provided with shed-retaining or holding elements 15, (FIG. 3) for the lower shed position, here are equipped with spacer elements 24, as best seen by referring to FIGS. 5 and 6, which at most slightly protrude past the outer surface of the roll 20.
From the showing of FIGS. 4 and 6 it will be apparent that both the guide lamellae or leaves 13 as well as also the shed-retaining elements 14 for the upper shed position of the warp threads 4 are provided with a recess 19. These recesses 19 form for each lamella reed 11 a channel for the weft insertion. Additionally, it will be apparent that each two respective guide lamellae or elements 13 alternately bound a shed-retaining element 14 for the upper shed position of the warp threads 4 and a spacer element 24, respectively, and that each two beat-up lamellae 12 likewise bound a space element 24.
Continuing, as best seen by referring to FIG. 4 the beat-up lamellae or elements 12 of the neighboring lamellae reed in each case are in alignment with the center of the tube of the lamellae reed formed by the guide lamellae or elements 13. As clearly shown in the illustration there is located in each tube of each of both lamellae reeds 10 and 11 two warp threads 4, in the tube between two guide lamellae or elements 13 there are conjointly located both of the warp threads 4 either in the upper shed position or in the lower shed position, and in the tube between two beat-up lamellae 12 there is located in each case a warp thread 4 in the upper shed position and the other warp thread is located in the lower shed position. This illustration corresponds to the use, indicated in FIG. 1, of four rods 17. On the other hand, in FIGS. 2 and 3 there have been shown for sake of clarity in illustration only two rods 17. Hence, each second tube is empty between the beat-up lamellae 12. It is here further still mentioned that the arrangement of the warp threads 4, illustrated in FIG. 4, corresponding to a double stitch linen weave, is random and that with the illustrated weaving rotor 5 together with the control device 3 it is possible to realize all conceivable cloth pattern variations between both of the extreme values, namely: all of the warp threads in the upper shed position or all of the warp threads in the lower shed position.
Each lamella reed 11 is formed of shed-retaining elements 14 for the upper shed position, guide lamellae or elements 13 and spacer elements 24. The lamellae reeds 10 are constructed from spacer elements 24 and beat-up lamellae or elements 12. As best seen by referring to FIG. 5, the shed-retaining elements 14 and the spacer elements 24 are appreciably thicker or wider than the beat-up and guide lamellae 10 and 13, respectively. Preferably, the thickness of the shed-retaining elements 14 arranged between the lamellae or leaves or equivalent structure of the one lamellae reed 11 or 10 and/or the spacer elements 24 amount to three times the thickness of the lamellae of the other lamellae reed 11 and 10, as the case may be.
The individual elements of each lamella reed 10 and 11 are for instance connected by a suitable adhesive so as to form reed portions of, for instance, 100 mm length and these reed portions are inserted into the corresponding grooves 22 or 23 and fixed therein. Upon changing the lamellae density it is possible to simply exchange the individual lamellae reeds 10 or 11, without having to dismantle the entire weaving rotor 5.
The individual elements forming the lamellae reeds 10 and 11 each have a base portion, whose cross-section is accommodated to that of the grooves 22 and 23. The spacer or distance elements 24 are dimensioned such that they do not or only slightly protrude, by means of their upper end, past the outer surface of the roll or cylinder 20. The shed-retaining elements 14 for the upper shed position, the beat-up lamellae or elements 12 and the guide lamellae or elements 13 possess, following their base portion, a respective upper portion 25, 26 or 27 protruding past the outer surface of the roll 20.
The upper portion 25 of the shed-retaining elements 14 for the upper shed position has the shape of a finger which is curved opposite to the direction of rotation P of the weaving rotor 5, whose outer curved surface forms the support for the warp threads 4 in their upper shed position and whose inner curved surface, viewed from the front, bounds the guide channel 19 for the weft insertion from the top and from the front in the direction of rotation P. At its lower region the guide channel 19 is bounded by the outer surface or shell of the roller cylinder 20, towards the rear by the beat-up elements 12 of the neighboring lamellae reed 10.
The upper portion 27 of the guide lamellae 13 has the configuration of a parallelogram-shaped vane, which is provided at its edge confronting the roll or cylinder 20 with a contour or shape corresponding to the inner curvature surface of the finger-shaped upper portion 25 of the shed-retaining elements 14 for the upper shed position, this contour equally bounding the channel 19, from the top and from the front.
The upper portion 26 of the beat-up lamellae 12 has a sickle-like configuration. The tip of the sickle is directed rearwardly opposite to the direction of rotation P of the weaving rotor 5. The outer edge of this upper portion 26 serves for beating the inserted weft threads, and therefore, protrudes from all of the aforementioned upper portions furthest in radial direction away from the outer surface of the roll 20. The outer edge of the upper portion or part 27 of the guide lamellae 13 is located somewhat closer to the roll 20 and the outer curvature surface of the finger-shaped upper portion or part 25 is located somewhat below one-half of the distance between the outer surface of the roll 20 and the outer edge of the upper portion 26 of the beat-up lamellae 12 which beats the laid weft threads.
As best seen by referring to FIG. 6, the configuration and dimensions of the lamellae or elements 12 and 13 and the mutual spacing of the grooves 22 and 23, and therefore, that of the lamellae reeds 10 and 11, is chosen such that between the individual lamellae reeds there is only a small spacing amounting to about 1 mm or less.
Of course, the weaving rotor 5, instead of being structured in the described manner, also could be formed in the manner of a conventional rotational or rotary reed, as is known from the wave shed loom art, of individual lamellae in the form of circular plates provided with projections. This type of weaving rotor must, however, practically be completely dismantled, knocked-down, re-assembled and again installed, whenever there is a change in the article which is being fabricated at the loom.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practised within the scope of the following claims. Accordingly, | A multiple longitudinal traversing shed weaving apparatus comprises a weaving rotor having beat-up or beating elements for the inserted weft threads and shed-retaining elements which retain the warp threads, throughout a predetermined path, in their upper shed position or lower shed position. Each intermediate space between neighboring beat-up elements has operatively associated therewith a respective shed-retaining element which determines the upper shed position or lower shed position. Control means are arranged forwardly of the weaving rotor, viewed in the direction of travel of the warp threads, and serve for the lateral deflection and selective allocation of the warp threads at a shed-retaining element which determines the upper shed position or lower shed position. The control means possesses stroke adjusting elements in the weft direction which are constituted by rods or bars extending in the weft direction. These rods are connected with an actuation device of the type used in a conventional dobby loom. | 3 |
BACKGROUND
(1) Field of the Invention
The invention relates to the digitization of media objects such as X-ray films. More specifically, the invention relates to an autofeeder for media objects in a digitizing system.
(2) Background
In recent years there has been a trend for digitizing media objects such as, for example, X-ray films to render the images thereon easily transmissible from remote locations for reading, and also in an effort to reduce storage requirements. Various systems are available for performing this digitization, including the CobraScan® X-ray scanner available from Radiographic Digital Imaging, Inc. of Compton, Calif. That system includes a clip which accepts a single X-ray film and transports it in front of a imaging window through which an image sensing array captures an image of the X-ray film, thereby digitizing the X-ray image. Where large numbers of X-rays are to be digitized, each one must be manually inserted into the clip before initiating the scanning procedure. This labor-intensive system deters the digitization of large existing libraries of X-ray films, and reduces the convenience of, for example, exchanging a patient's medical history between remote sites, where numerous X-rays are involved.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
FIG. 1 is a perspective view of an autofeeder of one embodiment of the invention.
FIG. 2 is a rear perspective view of the autofeeder of FIG. 1 .
FIG. 3 is a side-sectional view of the autofeeder of FIG. 1 .
FIG. 4 is an enlarged section view of the clip of the autofeeder of FIG. 1 .
FIG. 5 is a partial view of a portion of the clip of one embodiment of the invention.
FIG. 6 is a side-sectional view of the scanner autofeeder assembly of one embodiment of the invention.
FIG. 7 is a side-sectional view of the autofeeder scanner assembly with the autofeeder in a second orientation.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of an autofeeder of one embodiment of the invention. The shown embodiment may be used with the CobraScan® scanner available from Radiographic Digital Imaging, Inc. of Compton, Calif. Such embodiment may be substituted for the light box standard on the CobraScan® unit.
A receptacle 100 is constructed to receive media objects such as X-ray films, or other media types, to be scanned. Exemplary media object 106 is shown in phantom lines. The back surface of the receptacle 100 is partially defined by a suction plate 104 having a plurality of perforations 108 therethrough. As is described below, the suction plate 104 when the suction pump is active sucks adjacent media object 106 against the plate and raises it to be engaged by clip 102 . The suction pump (not shown) is powered when a magnetic switch 112 is activated by magnet 110 when the clip 102 is in the rest position. Insertion of media object 106 into clip 102 causes a rod 116 to rotate, thereby disengaging magnet 110 from the magnetic switch 112 , causing the suction pump 200 to shut off. It is also within the scope and contemplation of this invention to use other switching mechanisms including, without limitation, an optical interruptor, a pressure switch, a toggle switch, etc.
When the suction pump 200 shuts off solenoid valve 210 causes the pressure to be quickly released from the suction chamber and the vacuum cylinder (discussed below). The suction plate 104 then disengages from the media object 106 . The clip 102 then grasping the media object transports it past the scan window (not shown) so that it can be digitized by a digitizer. Discussion of the general operation of the clip as a transport mechanism can be found in copending application Ser. No. 08/089,311, now U.S. Pat. No. 6,208,437 entitled A VIEWING LIGHT BOX SCANNER FOR SCANNING AND VIEWING TRANSMISSIVE AND REFLECTIVE MEDIA IMAGES. On completion of the scan, a release lever 114 is automatically actuated to release the media object into a bin (not shown). The clip 102 then returns to the rest position to receive a next media object from the receptacle 100 .
FIG. 2 is a rear perspective view of the autofeeder of FIG. 1 . A suction pump 200 is coupled to a manifold 201 that distributes the suction between a suction chamber 204 and a vacuum cylinder 202 . In one embodiment the connections between the pump, manifold, chamber and cylinder is via tubes 211 having quick release connection at each end to facilitate easy setup. The facing side of suction chamber 204 , adjacent to the receptacle 100 , is suction plate 104 . Thus, when the pump 200 is activated by the magnetic switch described above, suction is applied through the perforations to the contents of the receptacle 100 . Once the suction engages a media object, the media object prevents further flow of air through the perforations and the suction chamber 204 is evacuated by the suction pump 200 . Once this vacuum is created, the vacuum cylinder 202 is also evacuated.
A magnet 205 is magnetically coupled to the suction chamber to restrain the chamber from rising until enough pressure builds up. This helps to insure that the media object 106 is held firmly against the suction plate 104 before movement begins. Once sufficient pressure builds up in the cylinder 202 the magnetic coupling of magnet 205 is broken and piston arm 208 rises up the cylinder 202 . The suction chamber 204 resides within tracks 206 and is coupled to the piston arm 208 . Accordingly, the suction chamber 204 with media object in tow rises up the tracks 206 until the media object engages the clip, turning the rod 116 and disconnecting the power to the pump. The solenoid valve 210 then promptly releases the pressure within the suction chamber and vacuum cylinder 202 , thereby releasing the film and allowing the piston arm 208 and suction chamber 204 to return to the rest position.
FIG. 3 is a side-sectional view of the autofeeder of FIG. 1 . Suction chamber 204 is almost to the peak of its “up” position, such that media object 106 has been moved from receptacle 100 to just begin to engage jaws 300 , 302 or the clip 102 .
FIG. 4 is an enlarged sectional view of clip 102 . A roller 400 resides in a cavity between jaw 300 and 302 , such that while the roller 400 is in place, jaws 300 and 302 do not close completely. A bias spring 402 is provided to bias jaw 300 into engagement with jaw 302 . Upon insertion of a media object 106 , the roller 400 is rolled into larger cavity 404 and reside in position 450 , such that the jaws 300 , 302 hold the media object between them. Lateral pressure on release lever 114 causes jaw 300 to compress bias spring 402 , releasing media object 106 . At such point, roller 400 will fall under the influence of gravity back between jaw 300 and 302 . In this manner, minimal force is required to insert a media object into the clip. Roller 400 may be spherical (or a series of spheres) such as ball bearings. Alternatively, one or more small cylinders may be used. If cylinders are used the cavity 404 must be of appropriate dimension to ensure that the cylinders retain their longitudinal orientation within the cavity 404 . FIG. 5 is a partial-sectional view of the clip of one embodiment of the invention. A permanent magnet 110 is attached to rod 116 and biased to be in a particular position by spring 502 . When the media object is inserted into the clip, it engages rod 116 , turning permanent magnet 110 so as to disengage a magnetic switch (not shown). Once the media object is released from the clip, the bias spring 502 returns the magnet to an engagement position.
FIG. 6 is a side sectional view of the scanner autofeeder assembly of one embodiment of the invention. A housing 550 has a clip 502 coupled thereto. Housing 500 also defines the scanning window and contains a digitizer such as a linear CCD or other similar image sensing array. Further description of the digitizer may be found in copending patent application Ser. No. 08/089,311 now U.S. Pat. No. 6,208,437, entitled A VIEWING LIGHT BOX SCANNER FOR SCANNING AND VIEWING TRANSMISSIVE AND REFLECTIVE MEDIA IMAGES, and Ser. No. 09/450,031 now U.S. Pat. No. 6,188,501 entitled AN APPARATUS AND METHOD OF CAPTURING IMAGES FROM ALTERNATIVE MEDIA TYPES AN APPARATUS AND METHOD OF CAPTURING IMAGES FROM ALTERNATIVE MEDIA TYPES. Similarly, clip 502 relies on the same sort of transport mechanism as described in those copending applications. The layout of suction plate 504 , suction cavity 604 and vacuum cylinder 602 is substantially as described in connection with FIG. 2 above. A light box is coupled to the housing to form one side of receptacle 600 . A translucent plate 528 forms a portion of the external-most surface of the autofeeder assembly. A plurality of light sources are disposed between the translucent plate and the front wall of the receptacle. In one embodiment these light sources are cold cathode lamps, which are available commercially in diameters of three millimeters. Other light sources are within the scope and contemplation of the invention. The light box assembly, as shown in FIG. 6 , is oriented to align such that a media object inserted into clip 502 is backlighted by the light box for reading. When positioned thus, the autofeeder is disabled.
FIG. 7 shows a side sectional view of the autofeeder scanner assembly with the autofeeder in a second orientation. In this orientation, media objects may be inserted into the receptacle 600 through the top opening. The light box pivots out slightly about piano hinge 520 once the autofeeder light box assembly is first slid along slot 622 to align the suction plate 504 with clip 502 . In this configuration, the operation of the autofeeder is substantially as described above.
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | An autofeeder and media object digitization system. A receptacle for media objects is coupled to align a first wall with a clip to hold the media object. A suction device forming part of the first wall sucks a media object against a suction plate. The suction plate then moves the media object into engagement with the clip. The clip is driven to move the media object past a scanning window. A release lever or the clip is triggered to release the media object after it has passed the scanning window. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method of inkjet printing of inks containing nanoparticles, and to printing apparatus for carrying out the method.
[0002] The method and apparatus are particularly, but not exclusively, suitable for printing of functional inks for electronic applications, where a high density of interconnecting particles and small feature size of the printed pattern are required.
[0003] Printing of functional inks has a long tradition in the electronic field. For example, pigment based inks are used to screen print interconnections and resistors on printed circuit boards. In these applications the thick film inks used consist of a vehicle, and pigments of silver and carbon respectively, where the pigment particles can have a dimension in the nanometer range. More recent developments are aimed at printing not only the passive components of a circuit, but also active components. One example is the disclosure of printed nanoparticulate silicon in International patent application WO 2004/068536 of the present applicant, providing semiconducting layers in devices like solar cells and transistors.
[0004] Traditionally most functional materials have been printed by conventional printing techniques, such as screen printing and flexography, both of which require the fabrication of a master pattern (e.g. a screen or printing plate) for each design to be printed. It is generally held desirable that digital printing methods, such as inkjet printing, should be applied, because of their flexibility in use and higher spatial accuracy. However, to prevent clogging of the ink jet nozzles, ink jet printing requires relatively dispersed solutions of particles and a low viscosity ink. This makes this method unsuitable for certain applications in the electronic field, in which a high density of particles has to be brought to a specific position on a substrate to achieve the required functionality of the printed pattern.
[0005] With regard to the deposition of small feature size patterns, inkjet printing of solutions containing nanoparticles, which provide functional properties to a printed structure, is known. The most common applications are ink jet printing of conductive traces for circuits, using conductive nanoparticles, e.g. silver nanoparticles, dispersed in the ink. In such applications a low resistance is obtained by heat treatment, with the effect of removing the dispersant, and subsequent sintering of the nanoparticles. A more recent development in functional layer deposition is inkjet printing of nanoparticulate transparent conducting oxide, where the patterned structure and the particle packing is controlled by a treatment with electromagnetic radiation in the drying process.
[0006] Another method to enhance the precision of patterning in ink jet printed structures composed of functional inks, including inks containing nanoparticles, is electrohydrodynamic jet printing, described by Jang-Ung Park et al (Nature, Vol 6 (2007) p. 782). In this case the resolution of the printed pattern is enhanced by an electrostatic field, applied to a microcapillary nozzle of the ink jet equipment, which shapes and controls the motion of the drops ejected from the nozzle. However, electrohydrodynamic jet printing has no effect on the density or arrangement of particles in the printed structure, and post processing is necessary to achieve the desired properties.
[0007] In certain applications the functionality of a deposited layer, containing particles in general, and nanoparticles in particular, is provided by an interconnecting network of these particles. To achieve compaction of such layers a modification of electrophoretic deposition has been disclosed by Tuck in GB2355338 for field emitting displays. This work teaches the forced sedimentation of particles from a dilute solution of the binder material by an applied electric field. The amount of binder in the solution is carefully calculated so that, after evaporation of the solvent, the sediment is held in place at the bottom of a microscopic well. As in other conventional electrophoretic deposition techniques, used for coating from a bath of solution, there is no forming of the pattern or control of the fluid flow during the process.
SUMMARY OF THE INVENTION
[0008] According to the invention there is provided a method of depositing ink on a substrate, the method including:
preparing an ink comprising a liquid vehicle and pigment particles dispersed in the vehicle, at least the pigment particles being electrically charged; applying a first potential to an outlet nozzle for the ink; applying at least a second potential to one or more auxiliary electrodes located adjacent the outlet nozzle; and expelling droplets of ink from the outlet nozzle towards a target zone on a substrate,
the configuration of the outlet nozzle and said one or more auxiliary electrodes, and the values of the first and second potentials, being selected to cause pigment particles to be concentrated in the target zone, thereby to deposit a quantity of the pigment particles in the target zone having a higher concentration than the concentration of the pigment particles in the ink.
[0013] The pigment particles may have a permanent charge, or may have an induced charge. In the latter case, the charge on the particles may be induced by the applied potentials.
[0014] The method is preferably designed to utilise the applied potentials to cause electrophoretic motion of the pigment during the deposition process, to concentrate the pigment particles in the target zone.
[0015] The method is preferably further designed to utilise the applied potentials to generate electrohydrodynamic forces on the liquid vehicle of the ink, to cause the liquid vehicle to be dispersed away from the target zone.
[0016] The one or more auxiliary electrodes located adjacent the outlet nozzle may be disposed coaxially around the electrode formed by the nozzle.
[0017] The substrate may be maintained at a defined potential while droplets of ink are expelled from the nozzle towards the target zone.
[0018] Preferably, the substrate is maintained at ground or earth potential.
[0019] Preferably, the potential difference between the outlet nozzle and the one or more auxiliary electrodes is at least as great as the potential difference between the outlet nozzle and the substrate.
[0020] In a preferred embodiment of the method, the potential difference between the outlet nozzle and the one or more auxiliary electrodes is in the range of 1 to 100V.
[0021] The method may comprise locating at least one auxiliary electrode behind the substrate on a common axis with the electrode formed by the nozzle.
[0022] In one embodiment of the method, an additional base plate which supports the substrate is maintained at a defined potential.
[0023] Preferably, the base plate is maintained at ground or earth potential.
[0024] In one embodiment, the base plate is located behind the substrate, that is, with the substrate located between the nozzle and the base plate.
[0025] In another embodiment, the base plate is located between the substrate and the nozzle.
[0026] Where at least one auxiliary electrode is located behind the substrate, the nozzle and said at least one auxiliary electrode behind the substrate may be movable relative to the substrate, the movement of the nozzle and said at least one auxiliary electrode being synchronized.
[0027] In another embodiment, a plurality of electrodes and corresponding holes in a base plate are kept at fixed absolute positions.
[0028] In a further embodiment, the nozzle and the auxiliary electrodes are kept in a fixed position and the substrate is moved relative thereto.
[0029] Preferably, the potential of the auxiliary electrode is maintained more attractive to the charged nanoparticles than the potential of the nozzle.
[0030] In a preferred embodiment, the ratio of the potentials of the auxiliary electrode and the nozzle is maintained greater than the ratio of the radius of a hole in the base plate adjacent the auxiliary electrode, and the radius of the nozzle.
[0031] Further according to the invention there is provided apparatus for depositing ink on a substrate, the apparatus including:
a nozzle defining an outlet for the ink, at least a portion of the nozzle being electrically conductive; a first voltage source for applying a first potential to the outlet nozzle; one or more auxiliary electrodes located adjacent the outlet nozzle; a second voltage source for applying a second potential to said one or more auxiliary electrodes; and means for expelling ink from the nozzle towards a target zone on a substrate, the ink comprising a liquid vehicle and pigment particles dispersed in the vehicle, at least the pigment particles being electrically charged;
the configuration of the nozzle and said one or more auxiliary electrodes, and the values of the first and second potentials being selected to cause pigment particles to be concentrated in the target zone, thereby to deposit a quantity of the pigment particles in the target zone having a higher concentration than the concentration of the pigment particles in the ink.
[0037] In one embodiment, the one or more auxiliary electrodes located adjacent the outlet nozzle may be disposed coaxially around the electrode formed by the nozzle.
[0038] The voltage sources may be arranged to maintain the potential difference between the outlet nozzle and the one or more auxiliary electrodes to be at least as great as the potential difference between the outlet nozzle and the substrate.
[0039] Preferably, the voltage sources are arranged to maintain the potential difference between the outlet nozzle and the one or more auxiliary electrodes in the range of 1 to 100V.
[0040] In another embodiment, at least one auxiliary electrode may be located beyond the nozzle, that is, with the substrate located between the nozzle and the base plate, on a common axis with the electrode formed by the nozzle, so that the substrate is between the nozzle and said at least one auxiliary electrode in use.
[0041] The apparatus may include a base plate arranged to support the substrate, the base plate being maintained at a defined potential.
[0042] The voltage sources may be arranged to maintain the potential of the auxiliary electrode more attractive to the charged nanoparticles than the potential of the nozzle.
[0043] Preferably, the voltage sources are arranged to maintain the ratio of the potentials of the auxiliary electrode and the nozzle greater than the ratio of the radius of a hole in the base plate adjacent the auxiliary electrode and the radius of the nozzle.
[0044] The invention concerns a method of separation and compaction of the pigment particles during inkjet printing by a combination of electrophoretic and electrohydrodynamic effects, which are achieved by the application of non-linear or non-uniform focusing electric fields. Two goals of such a process are firstly to allow the printing of small areas with a high packing density of particles, and secondly to produce a high definition pattern with a small feature size. Particular applications are for the printing of electronic components and circuits which require dense layers of interconnecting semiconducting nanoparticles. Embodiments of the invention, as herein disclosed, further include the specific aspects of the printing system which are required to form the electric fields required. These are described with reference to two preferred embodiments.
[0045] For the purposes of this application an ink can be considered as being composed of two components, a pigment which consists of small particles, and a vehicle, which is a liquid composed of a binder, a solvent and any other suitable liquid or soluble additives such as surfactants, humectants, or siccatives. Preferably the pigment particles are nanoparticles with a characteristic size between 1 nm and 1 micron, although larger particles may be used. In inkjet printing it is generally acknowledged that the pigment should be uniformly dispersed in the vehicle, without agglomeration, and that the viscosity of the ink should be relatively low, to prevent clogging of the printing nozzles.
[0046] Generally these considerations are incompatible with the properties of printed layers of electronic materials, which must be highly agglomerated to allow transfer of charge between individual particles. Hence, further processing steps, such as sintering or pyrolysis of the binder material, are required to obtain good connection between the particles. If the particles can be brought together in the printing process, and separated from the majority of the vehicle, the subsequent steps may be avoided, and such devices can be printed directly. In the method and apparatus of the present invention this is achieved by a combination of electrophoresis, to impart motion to the pigment, and electrohydrodynamics, to spread the liquid phase of the drop.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a schematic sectional diagram of a first embodiment of an ink jet nozzle according to the invention, comprising coaxial tubes;
[0048] FIG. 2 is a schematic sectional diagram of a second embodiment of an ink jet nozzle according to the invention, comprising a single tube and an associated needle electrode;
[0049] FIG. 3 is a schematic illustration of a transistor test structure formed utilising the principle of the invention;
[0050] FIG. 4 is a graph comparing source-drain characteristics of a transistor produced by the method of the invention, with an otherwise similar transistor produced without the method of the invention;
[0051] FIG. 5 is a simplified schematic diagram of an embodiment of inkjet printing apparatus according to the invention; and
[0052] FIG. 6 is a photograph of ink drops containing silicon nanoparticles deposited on filter paper from a nozzle, with an electric potential applied to the nozzle according to the principle of the invention, and by a prior art method.
DESCRIPTION OF EMBODIMENTS
[0053] Although both electrophoretic deposition and electrohydrodynamic jet printing are known, as discussed above, the combination of both in the same process is counterintuitive, and non-trivial to achieve. The key to the method is that the pigment particles must carry a defined charge, and the vehicle must either carry an opposite charge or remain neutral. These charges may be either permanent or induced by the application of electric potentials during the printing process or during feed to the print head.
[0054] In the situation where both particles and vehicle are charged, an applied electric field will cause an absolute motion of both particles and liquid. In the case where the particles are charged but the vehicle is not, although the liquid vehicle will be unaffected by the electric field, the solid matter will still experience a force. In both cases, however, there will be relative motion of the two components, with a concentration of the pigment in a particular area. Preferably, the concentration of the particles should be at the centre of the drop, directly aligned with the axis of the ink jet nozzle. For this to occur, the electric field should have a radial component in the space between the nozzle and the substrate. Hence, depending on the charge carried by the particles the electric field must be either divergent or convergent as the drop approaches the substrate. How this situation can be achieved is described with reference to the following preferred embodiments.
[0055] In FIG. 1 , a first embodiment of apparatus according to the invention comprising an inkjet nozzle structure is shown schematically. The apparatus includes means (not shown in this figure) for expelling ink from the nozzle which can utilise, for example, thermal or piezo-electric technology as is well known to those skilled in the art of inkjet printing. An ink consisting of a liquid vehicle 10 and a nanoparticulate pigment 12 is to be printed onto a substrate 14 . The pigment nanoparticles should carry a defined electric charge, which for the purposes of this example is negative. The liquid vehicle may be either neutral, or carry the opposite charge, which in this case is positive. The charge may be the result of an intrinsic charge separation in the ink, or may be induced by the application of a potential V 1 , which is applied to a first, inner tube 16 of two coaxial conducting tubes 16 and 18 . The tube 16 serves both as an electrode, and defines a nozzle 20 at its lower end for delivering the ink to the substrate.
[0056] The potential V 1 is opposite to the charge on the nanoparticles, and for the purpose of the example is assumed to be positive. The substrate 14 is assumed to form an equipotential plane, which is preferably at ground potential. This is normally the case if the substrate is itself conducting, or consists of a thin dielectric material mounted on a conducting carrier. For thick insulating substrates a number of established methods can be used to maintain a constant potential.
[0057] The second, outer coaxial tube 18 , which extends below the lower end of the nozzle 20 , is maintained at a potential V 2 and serves as a Wehnelt electrode. The potential V 2 should be such that it is repulsive to the charged nanoparticles, and in this case is negative. In a further modification of this embodiment, a multiplicity of such coaxial electrodes could be further used to define the electric field. Alternatively, one of the said electrodes could take the form of a flat plate, with a hole which is coaxial with the other electrodes and is positioned between the substrate and the nozzle 20 .
[0058] The right half of FIG. 1 shows the potential and electric fields arising in such a situation. Immediately below the nozzle 20 the electric field E 1 arising from the applied potential V 1 is aligned with the axis of the nozzle 20 and is directed towards the substrate, and thus has no effect on the trajectory of either the liquid of the ink exiting the nozzle, or the pigment nanoparticles within it. For material slightly off centre, however, the particles experience an electrophoretic drift towards the axis of the nozzle due to the effect of the transverse component of the radially divergent electric field E 2 arising from the applied potential V 2 . To achieve a highly divergent electric field the potential difference between V 2 and V 1 should be at least as great as the potential difference between V 1 and the substrate, for the same distance. If the liquid vehicle carries the opposite charge, it experiences an electrohydrodynamic drift radially outwards. The net result is a concentration of particles directly below the nozzle, with a much higher particle to vehicle ratio (or particle to binder ratio), than in the original ink mixture.
[0059] Thus, in summary, opposing electric potentials are applied to the coaxial electrodes 16 and 18 to form a non-uniform electric field which directs the pigment particles radially inwardly to the centre of the printed area and concentrates them electrophoretically, while the liquid vehicle is simultaneously directed outwardly, away from the centre of the printed area. As discussed in the examples, to achieve a strong electrophoretic motion of the particles, electric fields of the order of volts per micron are required. Consequently, typical values of V 1 and V 2 will be in the range of 1-100V, and preferably in the range 5-50 V.
[0060] In the second embodiment, shown in FIG. 2 , only a single tube 16 defining a nozzle 20 is used in the inkjet printing apparatus and the focusing action geometry of the electric field is attained by the presence of a needle electrode 24 immediately behind the substrate 14 . The tube 16 has, again, a potential V 1 applied to it, while the needle electrode 24 has a potential V 2 applied to it. The potential V 2 of the needle electrode should be more attractive to the charged nanoparticles than the potential V 1 of the nozzle.
[0061] In this embodiment, it is necessary for the electric field to penetrate through the substrate 14 . Consequently, relatively thin dielectric substrates are preferred. The needle electrode 24 may be a single component, mounted on a gantry, and moved by mechanical means to track the position of the print head containing the nozzle 16 . Alternatively, a multiplicity of such electrodes could be mounted in holes at fixed positions, and their potentials switched electrically. A further variation is to keep the positions of the electrodes and nozzles fixed, and move the substrate. In all such cases, an optional back plane 26 could be used to simultaneously support the substrate and define its position, and to increase the convergence of the electric field at the position to be printed. Alternatively, in the case of a thick substrate, the back plane could optionally be placed between the substrate and the nozzle. As shown, the back plane is formed with a hole having a radius r 2 , with the tip of the needle electrode 24 being located at or adjacent the centre of the hole.
[0062] In the case shown, for negatively charged pigment particles 12 in a positively charged vehicle 10 , the potentials V 1 and V 2 are positive, with V 2 preferably being greater than V 1 , and the back plane 26 is maintained at ground potential. As in the first embodiment the effect of an electric field, so produced, is an inward electrophoretic drift of the particles to the centre of the print area, and an outward electrohydrodynamic force on the liquid phase, caused by the transverse component of the divergent electric field E 3 . As described in the example below, this embodiment will function as envisaged for all potentials V 2 greater than or equal to the potential of the back plane, but the secondary electrode will have a greater effect when the ratio of its magnitude (V 2 ) to that of the first electrode (V 1 ) is greater than the ratio of the radius of the hole (r 2 ) to the radius of the nozzle (r 1 ). Ideally this ratio should be V 2 /V 1 >2 r 2 /r 1 .
[0063] The simplified schematic diagram of FIG. 5 , which is not to scale, shows major components of one embodiment of inkjet printing apparatus according to the invention. In FIG. 5 , a reservoir 40 contains a quantity of ink 42 which comprises a liquid vehicle 10 and a nanoparticulate pigment 12 as described above. In communication with the reservoir 40 is a nozzle 20 defined at the lowermost end of a conducting inner tube 16 surrounded by a coaxial conducting outer tube 18 as described above with reference to FIG. 1 . Within the inner tube 16 is a piezo-electric or thermal actuator 44 , connected to a control circuit 46 via a conductor 48 . In a manner known as such to those skilled in the art, a brief electrical pulse is transmitted to the actuator 44 , causing it to deform momentarily (in the case of a piezo-electric actuator) or to heat and vaporize a small quantity of the liquid vehicle 10 of the ink (in the case of a thermal actuator), thus expelling a drop 50 of ink from the nozzle 20 defined at the open end of the tube 16 .
[0064] As best seen in the enlarged detail of FIG. 5 , the distribution of the pigment nanoparticles 12 within the liquid vehicle 10 is substantially uniform, and thus the distribution of the nanoparticles within the drop 50 as it emerges from the nozzle is substantially uniform. However, due to the effect of the electric fields resulting from the potentials V 1 and V 2 applied to the tubes 16 and 18 respectively from respective voltage sources, the pigment nanoparticles 12 are concentrated electrophoretically towards the centre of the drop as it falls, as shown in the falling drop 52 .
EXAMPLE 1
[0065] In a preliminary example, the effect of including electrophoresis into the inkjet printing process has been modeled using single drops deposited, by hand, onto a transistor test structure as shown in FIG. 3 . The structure was formed on a substrate 30 comprising polymethylmethacrylate and took the form of a field effect transistor (FET) having a source electrode 32 , a drain electrode 34 , and a gate electrode 36 deposited on a thin dielectric layer 38 .
[0066] To produce the transistor structure, a dilute low viscosity ink, without binder, was produced by dispersing silicon nanoparticles in triple distilled water. The silicon nanoparticles were produced by milling according to the process described in South African patent application 2008/02727 entitled “Method of Producing Stable Oxygen Terminated Semiconducting Nanoparticles”. To determine the charge on the particles, a potential difference of three volts was applied between the source and drain electrodes. An electrophoretic drift of the particles, in the direction of the positive electrode, indicated that the charge on the particles was negative.
[0067] Compaction or concentration of the particles was achieved by applying a positive bias of 20V to the gate electrode, in a similar manner to the needle electrode of the second embodiment described above, with the gate insulator 36 taking the place of the thin dielectric substrate 14 . The potentials were maintained until the drop had dried completely. For comparison, a deposition of the same ink on a similar structure, without electric fields, was performed.
[0068] FIG. 4 shows the source-drain characteristics of two transistors (i.e. otherwise identical transistors, produced with and without an applied potential during deposition) for different applied gate potentials. The lower curve is for the transistor produced without application of potentials, and the upper curve is for a transistor produced according to the method of the invention.
[0069] The first important difference is that the drain-source currents in the transistor containing the compacted nanoparticles are over ten thousand times higher than corresponding currents in the layer deposited without an applied electric field. Secondly, a similar increase is seen in the source-drain current, which is switched by the application of the gate bias.
Example 2
[0070] A macroscopic model of the second embodiment described above was constructed to investigate the electrophoretic and electrohydrodynamic effects during droplet deposition. In this model, a 23 gauge (0.6 mm) blunt steel needle, representing the single tube 16 of FIG. 2 , was held a distance of 1.5 mm above a solid aluminium backplate held at ground potential. This configuration is equivalent to fixing the potential V 2 of the auxiliary needle electrode 24 and the base plate 26 at ground potential. The resulting electric field is therefore uniform along the axis of the nozzle and divergent at radial distances larger than the nozzle radius, thus actually more closely resembling the field pattern shown in FIG. 1 rather than that in FIG. 2 .
[0071] A dilute low viscosity ink, without binder, was produced by dispersing silicon nanoparticles in triple distilled water. The silicon nanoparticles were produced by milling p-type silicon wafers according to the process described in South African patent application 2008/02727 entitled “Method of Producing Stable Oxygen Terminated Semiconducting Nanoparticles”. On poorly absorbing substrates, such as normal office paper, drops of the size deposited in this system remain as liquids for several tens of minutes, allowing a redistribution of the component materials in the ink. To investigate the distribution of material as the drop was deposited, rather than electrophoretic movement of the silicon nanopowder in the stationary liquid on the substrate, a highly absorbing filter paper was therefore used as a substrate material.
[0072] Application of a negative potential of 1.5 kV to the needle during deposition induced both electrohydrodynamic effects on the liquid vehicle and electrophoretic motion of the silicon nanoparticles relative to the liquid. Both of these effects are seen in FIG. 6 which is a photograph of the dried ink drops deposited with and without an applied electric field. Without application of an electric field the drop ( 1 ) is large, and the deposited material is uniformly spread. When an electric potential is applied to the needle, the water vehicle, and hence the drop, is attracted towards the substrate, leading to the formation of smaller drops at the needle tip. More importantly, however, the radial component of the electric field results in electrophoretic motion of the particles in the drop—during deposition—and a concentration of solid material at the centre of the drop ( 2 ).
[0073] Because of the large dimensions of the experimental model, a large electric potential needs to be applied to the needle compared to those required in the two embodiments. The nominal electric field strength required for electrophoretic motion of the particles in both examples is of the order of 1 kV/mm. When scaled to the actual dimensions of the two embodiments, potential differences, both between V 2 and V 1 , and ground, in the range 1 to 100 V, and preferably in the range 5 to 50 V, will be required. | Apparatus for depositing ink on a substrate includes a nozzle defining an outlet for the ink, with at least a portion of the nozzle being electrically conductive. A first voltage source applies a first potential to the outlet nozzle. One or more auxiliary electrodes are located adjacent the outlet nozzle, and a second voltage source applies a second potential to the auxiliary electrodes. The apparatus includes a piezo-electric or thermal actuator for expelling ink from the nozzle towards a target zone on a substrate, the ink comprising a liquid vehicle and pigment particles dispersed in the vehicle. At least the pigment particles are electrically charged, typically due to the applied potentials. In one embodiment, an auxiliary electrode is disposed coaxially around the electrode formed by the nozzle. In another embodiment, an auxiliary electrode located beyond the nozzle, on a common axis with the electrode formed by the nozzle. The configuration of the nozzle, the auxiliary electrodes, and the values of the first and second potentials are selected to cause pigment particles to be concentrated in the target zone, so that a quantity of the pigment particles is deposited in the target zone having a higher concentration than the concentration of the pigment particles in the ink. The invention extends to a method of depositing ink on a substrate. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/742,487, filed Dec. 5, 2005, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to the field of music. More specifically, the present invention relates to music performance for live and studio music production.
BACKGROUND OF THE INVENTION
[0003] In the past and present, music creation is produced by musicians performing on traditional and contemporary musical instruments. These performances, particularly pop and rock music is at times supplemented with “loops” or “sequences”; sound tracks that extend the musical content of the performance. In sound track enhanced performance, the musicians synchronize their performance with the active sound track assuming the sound track tempo and key. The combined content of live and pre-recorded music results in the complete musical output of the performance.
[0004] For example, a performer on tour has a financial budget that supports ten musicians. The music to be performed is orchestrated for a larger group. Loops/sound tracks are created to extend and enhance the live performance supplementing the performance of the touring musicians. The collection of sound tracks created are “static” and are not intended for real time modification in tempo or tonality during the live performance. Moreover, the playback of the sound track during live performance in many cases is controlled by a sound technician(s) and not the direct responsibility of the performing musician.
[0005] The format of these sound tracks are often audio files such as .mp3, .wav or other high quality sound file. Audio sound files contain data that represent the music in terms of the properties of the sound reproduction and is not a representation of the underlying composed music. Conversely, the MIDI (Musical Instrument Digital Interface) file format is a binary representation of note sequences, key signatures, time signatures, tempo settings and other metadata that comprise a complete musical composition. While the MIDI file contains information that determines the instrumentation and the duration of note values to be played by various instruments and other, it does not specify the actual sound output in terms of quality. It is simply a representation of the underlying music composition. A MIDI output device (a keyboard or audio player that supports MIDI or other device) is used to interpret the embedded MIDI messages in the file and provide the sound output referencing its sound library in accordance with the MIDI specification.
[0006] This use of sound tracks is intended to enhance and extend the performance of live musicians performing on conventional musical instruments. Since the sound tracks themselves are static or fixed, they are used for specific purposes within the performance and do not change. Sound tracks in the form of loops are not typically used or controlled by the performing musician using conventional performance instruments. Further they are not used for improvisation or spontaneous music invention. Hence, the application of this performance resource is currently limited to a supplemental or background performance role.
[0007] Consequently, there is a need in the art for a sound track player that enables musicians to control, modify and synchronize the playback of sound tracks in real time during performance. The sound track player would support real time improvisation, modification of the source sound track (or sound resource) and enable individual musicians real time interactive control and management of a library of sound resource for references during performance. The result of such a sound track player would enable the role of sound resources to elevate from supplementay background to essential and focal; assuming a dominant role in the performance.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention, in one embodiment, is an interactive, real time file playback system for live and studio music performance. Unlike standard file playback technology consisting of one source sound file and one device for output, this playback system, or player, supports the simultaneous and real time synchronization of multiple MIDI and/or audio sources to one or more output devices. Individual clients communicate with the player host through the host command interface. The command interface receives commands from client entities and sets playback configuration parameters, stores and manages playback resources and performs real time performance operations. The player services these requests, manages and routes output to the appropriate output device(s).
[0009] In a further embodiment of the present invention, the playback system can be configured to assist people with physical or mental disabilities enabling them to participate with musicians of all skill levels.
[0010] While multiple embodiments are disclosed herein, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of one embodiment of the functional components.
[0012] FIG. 2 is an activity diagram illustrating the flow of command processing in the embodiment of the present invention.
[0013] FIG. 3 is an activity diagram illustrating the activation of a playback resource.
[0014] FIG. 4 is an activity diagram illustrating the real time processing of an active playback resource(s).
DETAILED DESCRIPTION
[0015] FIG. 1 shows a diagram outlining the functional components of the playback apparatus 1 of one embodiment of the present invention. As shown in FIG. 1 , the playback apparatus 1 includes a command interface 3 that receives command messages 2 from a client 29 . The client 29 may be a physical device, software object or any entity that can communicate command messages 2 with the command interface 3 . The command interface 3 is responsible for parsing and validating the command message 2 and forwarding valid messages to the command dispatch 4 . The command dispatch 4 examines the received command message 2 and routes the command message 2 to the appropriate command handler: configuration handler 5 , MIDI playback handler 6 , audio playback handler 7 or playback resource repository 8 . All command handlers ( 5 , 6 , 7 , 8 ) are singleton object instances. Meaning, only one instance of each handler exists in the playback apparatus 1 . MIDI playback handler 6 and audio playback handler 7 are responsible for sound output. Wherein MIDI playback handler 6 sends output to MIDI output device(s) 9 and audio playback handler 7 sends output to audio output device 10 . In a further embodiment, multiple instances of playback handlers ( 6 , 7 ) may be implemented referencing a central metronome internal clock.
[0016] FIG. 2 is a flow diagram of command message handling in one embodiment of the present invention. As illustrated in FIG. 2 , the client sends a command 11 to the command interface 3 where the command interface is in a wait state 12 for the receipt of a command message 2 . Upon receipt of the client sent command message, the message is validated 13 . If the command message 2 is not valid, the command interface 3 returns to wait state 12 . If the received command message 2 is valid, the message is forwarded by the command dispatch 14 to a command handler 15 for processing.
[0017] FIG. 3 is an activity diagram illustrating the process to activate a playback resource in playback apparatus 1 in one embodiment of the present invention. As illustrated in FIG. 3 , the playback handler ( 6 or 7 ) remains in a wait state 16 until a command message 2 to play is received. The received play command message 2 contains a reference to a playback resource and playback attributes that provide playback parameters to the playback handler ( 6 or 7 ). The referenced playback resource is validated 17 with the playback resource repository 8 . If the playback reference is invalid or disabled, the process returns to the wait state 16 . If the playback reference is valid 17 , the synchronize playback tempo attribute is examined. If the synchronize playback tempo 18 is set to true, the playback resource tempo is updated 19 to the internal playback metronome. If the synchronize playback tempo 18 is false, the playback resource tempo is not modified. The process then examines the playback channel requirement for the playback resource 20 . If the playback handler ( 6 or 7 ) has adequate channels for playback 20 , the playback resource channels are dynamically assigned and the playback resource channels are updated 21 . The playback resource is activated and added to the playback queue 22 .
[0018] FIG. 4 is an activity diagram illustrating the processing of active playback resources in the playback queue. The playback process 30 waits for timer expiration or thread signal 23 to begin processing active playback resources. Upon signal the playback queue is examined for active playback resources 24 contained in the playback queue. If no resources exist in the playback queue, the process returns to the wait state 23 . If one or more playback resources exist in the playback queue, the process traverses the playback queue 25 and process each playback resource. If a playback operation or output event is in the ready state 26 , the playback resource and operation is modified according to the parameters contained in the playback attributes. These real time modifications to playback output events include playback quantization, key transposition, dynamic, expression and other musical or sound variations. | The present invention is method for the playback of multiple MIDI and audio files. More specifically, it is an interactive music playback method that enables real time synchronization, quantization, music and sound modification and management of playback resources. Further, the present invention provides a method of music performance using various sound files. | 6 |
This application claims the benefit of the Korean Application No. P2003-0034082 filed on May 28, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a structure for dispensing an ice in a refrigerator, and more particularly, to a structure for dispensing an ice in a refrigerator, which includes an automated ice-making device for manufacturing pieces of ice and an ice bank for keeping pieces of ice.
2. Description of the Related Art
In general, a refrigerator is divided into a freezing chamber and a chilling chamber. The chilling chamber is maintained at temperature of 3° C. to 4° C., to keep foods or vegetables in a fresh state. The freezing chamber is maintained at a temperature below 0° C., to keep foods in a frozen state.
Recently, various functions are added to the refrigerator so that a user can use it conveniently. Among them, one function is an automated ice-making device.
FIG. 1 is a perspective view showing an example of an automated ice-making device installed in a freezing chamber of a conventional two-door refrigerator, and FIG. 2 is a sectional view taken along the line I—I of FIG. 1 .
As shown, the automated ice-making device 1 includes an ice-making chamber 11 for making pieces of ice, and a water supply part 12 provided at one side of the ice-making chamber 11 to supply water to the ice-making chamber 11 .
In addition, the automated ice-making device 1 includes a control part 13 accommodating a motor (not shown) at the other side of the ice-making chamber 11 , and an ejector 14 rotatably connected to a shaft of the motor accommodated in the control part 13 to dispense the pieces of ice made in the ice-making chamber 11 to an ice bank 19 .
A structure of the automated ice-making device 1 will be described below in detail. A coupling part 15 for coupling the automated ice-making device 1 to the freezing chamber of the refrigerator is formed at a rear side portion of the automated ice-making device 1 . The ice-making chamber 11 defining an ice-making space is provided at a body of the automated ice-making device 1 .
The ice-making chamber 11 is in a hemicylinder shape. Partitioning protrusions 16 for separating and dispensing the pieces of ice are formed at an inner surface of the hemicylinder-shaped ice-making chamber 11 .
As described above, the motor is installed inside the control part 13 formed at one portion of the ice-making chamber 11 , and the ejector 14 is coupled to the shaft of the motor.
A shaft of the ejector 14 is formed across a center of the ice-making chamber 11 , and a plurality of ejector pins 14 a are formed at a side surface of a shaft of the ejector 14 . The ejector pins 14 a are formed spaced apart from each other and provided as many as the number of sections partitioned by the partitioning protrusions 16 of the ice-making chamber 11 .
The ejector pin 14 a is means for dispensing the pieces of ice to the ice bank 19 .
A slide bar 17 is provided at an upper portion of a front hemicylinder of the ice-making chamber 11 , which is approximately halved on center of the ejector 14 . The pieces of ice slide down the slide bar 17 toward the ice bank 19 . The pieces of ice moved by the ejector pins 14 a are loaded on the slide bar 17 , slide down the slide bar 17 , and then are dropped into the ice bank 19 .
A heater 18 is attached to a lower surface of the ice-making chamber 11 . In order to transfer the pieces of ice, they must be separated from the inner surface of the ice-making chamber 11 . The heater 18 increases a temperature of the inner surface of the ice-making chamber 11 to melt the pieces of ice, which are fixedly attached to a surface of the ice-making chamber, such that the pieces of ice are easily separated from the ice-making chamber 11 . The separated ice is moved by the ejector 14 and the ejector pins 14 a.
As shown in FIGS. 3 and 4 , such a conventional automated ice-making device is installed inside the refrigerator and generally fixed to rear wall or side wall inside the freezing chamber. Most refrigerators with the automated ice-making device 1 include a dispenser 21 for allowing a user to directly obtain the ices kept in the ice bank 19 without opening a door 2 of the refrigerator.
Generally, the dispenser 21 is disposed at the door 2 and the automated ice-making device 1 is disposed inside the freezing chamber. Therefore, there are problems that the automated ice-making chamber 1 occupies a large inner space of the freezing chamber 1 . In other words, the automated ice-making device 1 is provided with the ice bank 19 as well as the ice-making chamber 11 , and an ice transfer unit (not shown) for transferring the pieces of ice to the dispenser 21 and an ice crushing part (not shown) are installed in the ice bank 19 , thus occupying a large space of the freezing chamber.
Since the automated ice-making device 1 and the ice bank 19 occupy about 20% or more of the inner space of the freezing chamber, thus limiting the utilization of the inner space of the freezing chamber.
Meanwhile, in order to solve the problems, there has been proposed a refrigerator having an automated ice-making device and an ice bank, both of which are installed at a door of a conventional freezing chamber.
In the above art, the ice transfer unit of the ice bank has an auger installed in a vertical direction and employs a method of moving pieces of ice downwardly. To this end, if the pieces of ice are not discharged for a long time, the pieces of ice are fixedly attached between the augers, thus causing a problem that the augers do not operate.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a structure for dispensing ice in a refrigerator that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a structure for dispensing an ice in a refrigerator, in which an automated ice-making device and an ice bank are installed at a door of a freezing chamber to thereby enable an effective utilization of the freezing chamber space and prevent a malfunction when transferring pieces of ice.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a structure for dispensing ice in a refrigerator comprises: an ice-making device installed in a door of a freezing chamber; an ice bank storing pieces of ice provided from the ice-making device; an ice transfer unit for transferring the pieces of the ice stored in the ice bank in a width direction; and an ice crushing part for crushing the pieces of the ice transferred by the ice transfer unit.
Preferably, the ice-making device includes a water-overflow preventing part, and the ice bank is provided at the door of the freezing chamber.
The ice transfer unit includes a transfer means and a rotating means for rotating the transfer means. Specifically, the transfer means is a spiral auger, and the rotating means is a motor. Preferably, the auger is installed inside the ice bank in a width direction.
The ice crushing part is formed at one end of the auger and includes a fixed blade and a rotating blade. The rotating blade is coupled to the auger of the ice transfer unit and rotates together with the auger.
Preferably, an ice discharge opening is provided at a bottom surface of the ice bank in order to discharge pieces of ice and includes a damper for opening/closing the ice discharge opening.
The ice discharge opening is formed under the ice crushing part and the ice bank is coupled to a dispenser which is formed at the door of the freezing chamber. Preferably, the dispenser includes a large-sized ice selecting part and a small-sized ice selector part.
Preferably, a control part for controlling the ice transfer unit and the damper is provided.
In case the large-sized ice selecting part of the dispenser is selected, the control part operates the motor of the ice transfer unit to open the damper, and when the small-sized ice selecting part of the dispenser is selected, the control part operates the motor of the ice transfer unit to close the damper for a predetermined selected time and then open the damper to thereby discharge the ice.
According to another embodiment of the present invention, the ice discharge opening is provided with a first ice discharge opening and a second ice discharge opening. In this case, there are provided two dampers, i.e., a first damper and a second damper. The first ice discharge opening is formed under the ice transfer unit, and the second ice discharge opening is formed under the ice crushing part.
A control part for controlling the two dampers and the ice transfer unit is provided. In case the large-sized ice selecting part of the dispenser is selected, the control part operates the first damper to open the first ice discharge opening and operates the second damper to close the second ice discharge opening. Meanwhile, when the small-sized ice selecting part of the dispenser is selected, the control part operates the first damper to close the first ice discharge opening and operates the second ice discharge opening to open the second ice discharge opening.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a perspective view showing an example of an automated ice-making device 1 and an ice bank, which are attached to a freezing chamber of a conventional two-door refrigerator;
FIG. 2 is a sectional view taken along the line I—I;
FIGS. 3 and 4 are a schematic plan view and a perspective view of a refrigerator having an automated ice-making device and an ice bank of FIG. 1 , respectively;
FIG. 5 is a schematic sectional view of an automated ice-making device and an ice bank in a structure for dispensing pieces of ice in a refrigerator according to the present invention;
FIG. 6 is a schematic perspective view of the automated ice-making device and the ice bank according to the present invention;
FIG. 7 is a sectional view of an ice bank according to another embodiment of the present invention; and
FIG. 8 is a perspective view of a refrigerator having the structure for dispensing pieces of ice according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
FIG. 5 is a schematic sectional view of an automated ice-making device 10 and an ice bank 50 in a structure for dispensing pieces of ice in a refrigerator according to the present invention. FIG. 6 is a schematic perspective view of the automated ice-making device and the ice bank 50 according to the present invention. FIG. 7 is a sectional view of an ice bank 500 according to another embodiment of the present invention.
As shown in FIGS. 5 and 6 , the ice bank 50 is installed at a lower portion of the automated ice-making device 10 . Since the automated ice-making device 10 is formed at a door 2 , water-overflow preventing parts 101 and 102 are formed in order to prevent an overflowing of water in an ice-making chamber according to opening/closing of the door 2 .
In other words, the first water-overflow preventing part 101 is formed in a panel shape at a position in which the slide bar of the conventional ice-making chamber (refer to FIG. 1 ) is disposed, and the second water-overflow preventing part 102 is extendedly formed in an arc shape at an opposite side of the first water-overflow preventing part 101 , thereby preventing the overflowing of water according to a movement of the door 2 .
The ice bank 50 has a storage space in which pieces of ice dispensed from the automated ice-making device 10 are stored. An ice transfer unit 51 and an ice crushing part 53 are installed inside the ice bank 50 .
The ice transfer unit 51 is means for transferring pieces of ice, which are stored in the ice bank 50 , to an ice discharge opening by operating a lever 21 a of a dispenser 21 for the purpose of eating the pieces of ice.
The ice transfer unit 51 includes a winding transfer means for directly transferring the pieces of ice, and a rotating means for rotating the transfer means. The transfer means is an auger 513 made of a spiral metal rod or a plastic rod, and the rotating means is a motor 511 .
A shaft of the motor 511 is coupled to one end of the auger 513 . The auger 513 is a metal construction in which a spiral metal rod is rotatably coupled to the shaft of the motor. The auger 513 can be made of synthetic resin such as plastics, except metal.
The pieces of ice dropped into the ice bank 50 are placed among the metal rods of the auger 513 . Since the auger 513 is in the spiral shape, the ice disposed inside the auger 513 moves forward if the auger 513 is rotated by the motor 511 .
The pieces of the ice moving forward are dispensed through the ice discharge opening 56 and dropped into the dispenser 21 coupled to the ice discharge opening 56 .
According to the present invention, the auger 513 of the ice transfer unit 51 is installed in a width direction, and the ice crushing part 53 is installed in the ice bank 50 together with the ice transfer unit 51 .
As described in the related art, the pieces of the ices made in the automated ice-making device 10 are formed in hemispherical shapes, thus occupying a large volume. Here, the piece of the ice having the large volume is referred to as “large-sized ice”. People rarely put the large-sized ice in drinking water or food. Instead, after crushing the large-sized ice into the “small-sized” ice, people put the small-sized ice in drinking water.
The ice crushing part for crushing the large-sized ice into the small-sized ice is installed at the end of the auger 513 and includes a plurality of blades 531 and 532 , such that transferred ice is crushed between the blades 531 and 532 .
The blades 531 and 532 can perform the crushing function if any one of a rotating blade 531 and a fixed blade 532 is provided. However, it is preferable to provide both the rotating blade 531 and the fixed blade 532 at the same time.
Preferably, the rotating blade 531 is formed at one end of the auger 513 and thus rotates simultaneously when the auger 513 rotates. In addition, preferably, the fixed blade 532 is installed spaced apart from the rotating blade 531 by a predetermined interval, or it is installed in a circumference direction. In this case, a crushing effect may be improved.
Ice discharge openings 551 and 552 are formed at a lower portion of the ice bank 50 . One or two ice discharge openings 551 and 552 can be provided. As a first embodiment of the present invention, there are provided two ice discharge openings 551 and 552 .
As shown in FIG. 6 , the first ice discharge opening 551 is formed on a bottom surface of the ice bank 50 under the end portion of the auger 513 transferring the pieces of ice, and the second ice discharge opening 552 is formed on a bottom surface of the ice bank 50 under the ice crushing part 53 .
The first ice discharge opening 551 is a discharge opening which is opened when a user wants to a large-sized ice. In this case, the piece of ice moving along the auger 513 is dropped into the dispenser 21 before it is transferred to the blades 531 and 532 .
The second ice discharge opening 552 is a discharge opening which is opened when a user wants a small-sized ice crushed by the ice crushing part 53 . In this case, the pieces of ice are crushed by the blades 531 and 532 and then dropped into the dispenser 21 .
A first damper 561 is provided at the first ice discharge opening 551 . The first damper 561 is means for opening/closing the first ice discharge opening 501 . A second damper 562 is provided at the second ice discharge opening 552 . The second damper 552 is means for opening/closing the second ice discharge opening 552 .
A large-sized ice selecting part 211 and a small-sized ice selecting part 212 are formed at the dispenser 21 provided at the door 2 . The large-sized ice selecting part 211 is a part which is selected when a user wants a large-sized ice, and the small-sized ice selecting part 212 is a part which is selected when a user wants a small-sized ice.
Although not shown, the refrigerator includes a control part for controlling the first damper 561 and the second damper 562 when selecting the large-sized selecting part 211 and the small-sized selecting part 212 .
Hereinafter, detailed description on functions of the control part will be made.
If a user selects the large-sized selecting part 211 of the dispenser 21 , the control part operates the first damper 561 to open the first ice discharge opening 551 and operates the second damper 561 to close the second ice discharge opening 552 .
The control part operates the motor 511 of the ice transfer unit 51 to rotate the auger 513 . According to the rotation of the auger 513 , pieces of the large-sized ice stored in the ice bank 50 are transferred toward the first ice discharge opening 551 . Since the first ice discharge opening 551 is opened by the first damper 561 , the pieces of the large-sized ice are dispensed through the first ice discharge opening 551 and dropped into the dispenser 21 .
If a user selects the small-sized selecting part 212 of the dispenser 21 in order to obtain the crushed ice, the control part operates the first damper 561 to close the first ice discharge opening 551 and operates the second damper 561 to open the second ice discharge opening 552 .
The control part operates the motor 511 of the ice transfer unit 51 to rotate the auger 513 . According to the rotation of the auger 513 , pieces of the large-sized ice stored in the ice bank 50 are transferred. Since the first ice discharge opening 551 is closed by the first damper 561 , the pieces of the large-sized ice are transferred to the ice crushing part 53 , not being dispensed through the first ice discharge opening 551 .
The pieces of the large-sized ice are crushed by the rotating blade 531 and the fixed rotating blade 532 of the ice crushing part 53 and then dropped into the dispenser 21 through the second ice discharge opening 502 .
Although the embodiment of the present invention shows that the large-sized ice and the small-sized ice are dropped through the different openings by forming two ice discharge openings 551 and 552 , the large-sized ice and the small-sized ice can be discharged using a single ice discharge opening 553 and a single damper 563 .
In other words, as shown in FIG. 7 , the large-sized ice and the small-sized ice can be selectively discharged through a single ice discharge opening 503 .
As shown, an ice bank 50 according to another embodiment of the present invention includes a single ice discharge opening 553 formed on a bottom surface, and a damper 563 for opening/closing the ice discharge opening 553 .
If a user selects the large-sized selecting part 211 of the dispenser 21 in order to obtain the large-sized ice, the damper 563 is operated to open the ice discharge opening 553 . Since the ice discharge opening 553 is opened, the large-sized ice transferred through the auger 513 is dropped through the ice discharge opening 553 and then dispensed through the dispenser 21 before it is crushed by the blades 531 and 532 of the ice crushing part 53 .
If a user selects the small-sized selecting part 212 of the dispenser 21 in order to obtain the small-sized ice, the damper 563 is operated to close the ice discharge opening 553 . Since the ice discharge opening 553 is closed, the large-sized ice transferred through the auger 513 is crushed between the rotating blade 531 and the fixed blade 532 of the ice crushing part 53 .
After carrying out the crushing operation for a predetermined time, the damper 563 is opened, such that the crushed ice is discharged to the dispenser 21 . The crushing time can be appropriately controlled by the control part. Further, it is possible to obtain a larger amount of the small-sized ice by repeating the above procedures.
FIG. 8 is a perspective view of the refrigerator according to the present invention, showing that the automated ice-making device 10 and the ice bank 50 are installed in the door 2 of the refrigerator.
As shown in FIG. 7 , according to the present invention, the automated ice-making device 10 and the ice bank 50 are installed in parallel in a width direction with respect to the freezing chamber door, so that a storage space of the ice bank 50 is expanded. Further, since the auger 513 is installed in the width direction, the auger 513 is lengthened and a space is widened. Therefore, it is possible to prevent a malfunction of the auger, which is caused due to the ice.
In the refrigerator of the present invention, both the automated ice-making device and the ice bank are installed in the width direction with respect to the freezing chamber door, which does not influence a thickness of the freezing chamber door. Further, compared with the case the ice bank is installed in a length direction, the storage space is widened so that a large amount of ice is stored.
Furthermore, since the auger of the ice transfer unit is installed in a width direction and there is an affordable space, it is possible to solve the malfunction of the auger due to the ice. A user can selectively eat pieces of ice having different size.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | Disclosed is a structure for dispensing ice in a refrigerator, in which an automated ice-making device and an ice bank are installed at a door of a freezing chamber to thereby make its space utilization effectively. The structure of the present invention includes: an ice-making device installed in a door of a freezing chamber; an ice bank storing pieces of ice provided from the ice-making device; an ice transfer unit for transferring the pieces of the ice stored in the ice bank in a width direction; and an ice crushing part for crushing the pieces of the ice transferred by the ice transfer unit. | 5 |
FIELD OF THE INVENTION
The present invention relates generally to a calender having a vertical roller arrangement with matching carrier-blocks for improved roller separation, and more particularly to a calender having a suspended spindle and an upright slide for engaging upper, center and lower carder-blocks having corresponding upper, center and lower rollers, wherein the carrier-blocks of at least the lower and center rollers are vertically movable along the upright slide. The suspended spindle has threaded sections that threadably engage height-adjustable support-elements for supporting the carrier-blocks during roller separation. A motorized, adjustable carrier-nut is operatively attached to the upper end of the suspended spindle and supported on a stop, while an elevating-device is operatively attached to the lower roller, thereby facilitating the roller movement and allowing the carder-blocks to be lifted.
BACKGROUND OF THE INVENTION
Conventional calenders such as that described in DE-OS 27 31 119, Kayser et al., issued Jan. 25, 1979, typically comprise a vertical roller arrangement with matching, vertically-movable carrier-blocks. During adjustment, the carrier-block of the upper roller is supported by the piston of a hydraulic cylinder, while the lower roller is moved into and out of an operating position for roller separation by positioning nut-shaped support-elements on a suspended spindle. The roller separation is facilitated by an elevating-device, which has two hydraulic cylinders engaged with the upper and lower carder-blocks.
The suspended spindle is fastened to the carrier-block of the upper roller at the upper end of the roller arrangement and is provided with a carrier-nut that can be rotated by a motor. The carder-nut functions only when the rollers are retracted, thereby either resting on a bearing-surface of the upper carder-block or on an insert attached to the beating surface. However, by using this roller adjustment configuration, the rollers are strained by the weight of the suspended spindle.
Another conventional calender is described in DE-PS 22 24 875, Muiller et al., issued Dec. 13, 1973, wherein the carder-nut rests on a register of the upper carrier-block during adjustment. Through rotation, actuated by a motor, the height of the entire suspended spindle and support-elements can be reset. In addition, by using a brake to secure the carder-nut against rotation, the height of the carder-nut does not reset. However, as with the Kayser adjustment configuration, the rollers in the Muller configuration are also strained by the weight of the suspended spindle.
It would be desirable to use a combination of both roller adjustment configurations, where the rollers are not strained by the weight of the suspended spindle. Therefore, an improvement to the prior art would be to provide a calender having a combination of the above roller adjustment configurations, wherein the weight of the suspended spindle is lifted so that the rollers are not strained and the carder-nut is driven by a relatively small motor.
SUMMARY OF THE INVENTION
The present invention provides a calender having rollers and matching carrier-blocks, vertically-arranged in a stand, wherein the rollers are not strained by the weight of the suspended spindle as the weight is supported in the operating position by a carrier-nut positioned on a stop. The weight of the suspended spindle, which could be as much as 33.72 k-lbs (150 kN), is transferred directly to the stand in the operating position and not to the rollers. An insert is provided between a beating surface on the upper-most carrier-block and a primary support-element, wherein the insert has a thickness which allows the suspended spindle and carder-nut to be lifted during elevation of the upper-most carder-block. By using the insert, rotation of the carrier-nut requires little force, which may be provided by a relatively small motor. However, without the insert, the calender functions in the conventional manner, requiring an enormous force to rotate the carrier-nut. In addition, the calender may utilize an insert in the form of a horizontal slider, which is supported on the upper-most carrier-block and operated by an actuator (e.g., a pneumatic or hydraulic piston).
It is also advantageous that the primary support-element be positioned relatively high on the suspended spindle, above the upper-most carrier-block, which results in a shorter free-length of the suspended spindle, thereby reducing the danger of lateral bending.
In a preferred design, the upper roller can be loaded through an energizer. The upper roller is seated in a sliding carrier-block having a bearing-surface, wherein a support-element can be positioned at a relatively small distance below the carrier-nut.
It is beneficial to have the upper and lower rollers seated in the matching carrier-blocks. Thus, adjusting the rollers also adjusts the matching carrier-blocks.
It is also advantageous to have the center rollers seated in the matching bearing-blocks and flexibly linked to the carder-blocks by levers, wherein the carrier-blocks are provided with stops to engage the levers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the calender in an operating position according to the preferred embodiment of the present invention.
FIG. 2 is a side view of the calender of FIG. 1 having separated rollers according to the preferred embodiment of the present invention.
FIG. 3 is a side view of the calender of FIGS. 1 and 2 having a raised suspended spindle according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a preferred calender has a vertical roller arrangement configured in a stand 16, wherein a lower roller 1, three center rollers 2, 3, 4 and an upper roller 5 engage an upright slide 15 with matching carrier-blocks 6, 11, 12, respectively. Lower roller 1 is seated in carrier-block 6 at the lower end of stand 16. By using an elevating-device 7, lower roller 1 is raised to an operating position (FIG. 1) and lower to a resting position (FIG. 2). Elevating-device 7 is driven by the piston of a hydraulic cylinder 8, which engages carrier-block 6. Center rollers 2, 3, 4 are seated in bearing-blocks 9, which are connected to carrier-blocks 11 and swivel by levers 10. Upper roller 5 is seated in carrier-block 12 at the upper end of stand 16 and is lowered to the operating position (FIG. I) by an energizer 13, which is driven by the piston of a hydraulic cylinder 14. Carrier-blocks 6, 11, 12 move vertically along upright slide 15 of stand 16. Therefore, carrier-block 12 is vertically guided along slide 15 as energizer 13 is activated.
Carrier-blocks 11 have upper stops 17 and lower stops 18, which are engaged by either an upward or downward movement of center rollers 2, 3, 4 with the appropriate lever 10. Hydraulic cylinders 19 operate between levers 10 and carrier-blocks 11, thereby compensating for undesirable forces from the overhanging weight of the rollers and carrier-blocks.
A suspended spindle 20 and a carrier-nut 21 are provided at the upper end of stand 16. Carrier-nut 21 is supported by a stop or register 23 and can be rotated by a motor 22 which enables the height of suspended spindle 20 to be adjusted. A support-element 25 is formed as a threaded nut on suspended spindle 20 and supports carrier-block 12 of upper roller 5. Support-elements 24 engage threaded sections 26 of suspended spindle 20 and support carrier-blocks 11 of center rollers 2, 3, 4. Support-elements 24 are tightly connected with threaded sections 26 of suspended spindle 20 and can be rotated by a motor 27, as is known from DE-PS 24 15 836.
A positioning-device 28 is installed between each support-element 24 and matching carrier-block 11. Positioning-device 28 consists of a lower base 29 and an upper plate 30, which can be pushed upward by the pistons of hydraulic cylinders 31 as is known from DE-PS 24 40 688.
On the upper portion of suspended spindle 20 is a primary support-element 39, which functions as a nut and corresponding counter-nut. Support-element 39 is positioned above a bearing-surface 32, located on carrier-block 12. A horizontal-slider 33 and a fork-shaped insert 35 are placed between support-element 39 and bearing surface 32 and moved by an actuator 34. During adjustment, position-indicators 36, 37, 38 indicate the height of carrier-block 6, lower support-element 24 and base 29, respectively, of suspended spindle 20 with respect to carrier-blocks 11.
In operation (FIG. 1), the upward movement of the piston of hydraulic cylinder 8 drives carder-block 6 of lower roller 1 upward, thereby engaging center rollers 2, 3, 4 and upper roller 5, respectively. During engagement, levers 10 move freely between stops 17, 18. When activated, hydraulic cylinders 19 and positioning-devices 28 compensate for the overhanging weight of the rollers, wherein the distance between support-element 39 and beating-surface 32, carder-block 12 and support-element 25 and the thickness of insert 35 are represented by "a ", "b" and "c", respectively.
Separation of rollers 1-5 (FIG. 2) is achieved when hydraulic cylinders 8, 19 and 31 are deactivated. The piston of hydraulic cylinder 8 drops by a distance "H" and center rollers 2, 3, 4 drop until levers 10 are engaged with stops 18. Thus, positioning-devices 28 assume their minimum height. Carder-block 12 of upper roller 5 drops to engage support-element 25, whereby rollers 1-5 are now at a distance S 1 , S 2 , S 3 and S 4 relative to one another. The distance between support-element 39 and beating-surface 32 assumes the value represented by "d", wherein the formula a+b=d>c applies. In this position, insert 35 is moved by actuator 34 between support-element 39 and bearing-surface 32 (FIG. 3).
As elevating-device 7 is reactivated to place hydraulic cylinder 8 under pressure, roller-spaces S 1 , S 2 , S 3 and S 4 will close and rollers 1-5 will be forced upward. In doing so, levers 10 will be pushed up against upper stops 17 of carder-blocks 11, whereby levers 10 will be raised upward from plates 30 of positioning-devices 28. Carder-block 12 of upper roller 5 is also raised upward from support-element 25. Simultaneously, carrier-nut 21 is lifted from register 23 and can then be easily rotated by motor 22. When the distance between carder-block 12 and support-element 25, carrier-nut 21 and register 23, and the thickness of insert 35 have the values shown at "e", "f" and "c", respectively, then the formula f=c-e will apply.
While the embodiment of the invention shown and described is fully capable of achieving the results desired, it is to be understood that this embodiment has been shown and described for purposes of illustration only and not for purposes of limitation. Other variations in the form and details that occur to those skilled in the art and which are within the spirit and scope of the invention are not specifically addressed. Therefore, the invention is limited only by the appended claims. | A calender arrangement having vertically-arranged upper, center and lower rollers with matching upper, center and lower carrier-blocks and a suspended spindle, comprises a support element above a bearing-surface on the upper carrier-block. The support-element aids in lifting the suspended spindle and a carrier-nut when raising the upper carrier-block. An insert is placed between a bearing-surface on the upper carrier-block and the support-element, which comprises a horizontal slider seated on the upper carrier-block, which enables a relatively small motor to be used to reset the carrier-nut. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally pertains to an air bag assembly and, more particularly, to connectors for removably mounting an air bag assembly.
2. Description of the Related Art
Air bag assemblies have been developed to be modular in design to speed installation of the assembly within a vehicle. Air bag assemblies or modules typically include an inflator, an inflatable air bag or cushion, and a cover member. The cover member is separable to allow the cushion to escape therethrough during inflation. The entire assembly or module is typically immovably bolted in place. Although bolting satisfactorily attaches the air bag assembly to the underlying support structure, it takes a considerable amount of time during assembly, and renders the mounted assembly difficult to un-attach and remove. Therefore, there exists a need in the art for an improved connector to rigidly but removably mount an air bag assembly within a vehicle.
Rigidly or immovably mounting the modular air bag assembly is acceptable in most applications. However, in driver's-side air bag assemblies, the cover member of the module occupies the center portion of the steering wheel, and thereby displaces the horn actuator mechanism from its traditional center position on the steering wheel. Separate, relatively small buttons or pads spaced from the center of the steering wheel are added to provide the horn actuation feature.
Naturally, it is desirable for the driver to sound the horn as quickly as possible. However, since the horn actuator pads are relatively small and displaced from the center of the steering wheel, it takes time for the driver to locate the pads, and renders the horn actuators used on these steering wheels somewhat less desirable and effective than those provided by prior steering wheels. Therefore, some consumers may perceive that cars having steering wheels which incorporate rigidly or immovably mounted air bags are less desirable, at least in this respect, than cars which do not incorporate such air bags into the steering wheel.
In response to the limitations of the fixedly-mounted air bag modules and small horn actuation pads discussed above, it has been proposed to mount the air bag module such that it is movable relative to the steering wheel. Movably mounting the air bag module allows it to incorporate a horn-actuation feature and thereby return the horn actuator to its customary and appropriate location in the center of the steering wheel.
Although this method of mounting the air bag module eliminates the problems associated with horn actuator placement, the mounting connectors currently used to movably mount the module to the steering wheel are of the ball-detente type, and are expensive and difficult to manufacture. As such, the problems associated with the known connectors for movably mounting the modules actually encourage manufacturers to continue to fixedly or immovably mount the air bag modules to the steering wheel.
Hence, there exists a need in the art for a simple and inexpensive mounting connector which removably attaches the air bag module to the steering wheel and allows the module to move relative to the steering wheel.
SUMMARY OF THE INVENTION
The present invention provides an improved air bag assembly mounting connector. A first embodiment of the present invention is directed toward a mounting connector for an air bag module which allows the module to move relatively toward and away from a steering wheel of an automobile. The connector removably attaches the air bag module to the steering wheel and cooperates with a mounting plate provided by the steering wheel to define a horn switch. A second embodiment of the present invention is directed toward a mounting connector which rigidly but removably attaches the air bag module to a mounting plate.
In accordance with the first embodiment of the present invention, a steering wheel including an air bag module assembly is provided. The module assembly includes a cover member, an inflator operable to inflate a cushion, a base plate, means for attaching the cushion to the base plate, and a series of mounting connectors for removably attaching the module to a mounting plate provided by the steering wheel. The cover member, which is separable upon inflation of the inflatable cushion to permit the cushion to escape or project therefrom, overlies the inflatable cushion and the base plate and defines an exterior center portion of the steering wheel. The inflator attaches to the base plate and extends through the base plate and into the inflatable cushion.
In further accordance with the first embodiment of the present invention, the mounting connectors have first and second members and means for biasing the first and second members relatively away from each other. The first member telescopingly receives the second member and includes means for retaining at least some of the second member therewithin. The first member has a distal end which attaches the mounting connector to the base plate. The second member includes a series of resiliently deformable arms which extend away from the first member and removably attach to the mounting plate.
In further accordance with the first embodiment of the present invention, the mounting plate defines a first horn switch contact and the first member defines a second horn switch contact. The biasing means normally maintains the first and second contacts relatively away from each other. The biasing means can be overcome by inward force upon the cover member above a predetermined threshold, causing the first member to engage the mounting plate and thereby actuate the horn.
The mounting connectors according to the first embodiment snap-fit the air bag module to the mounting plate, which eases and speeds assembly of the steering wheel, while allowing the center portion of the steering wheel to provide a horn-actuating function as was customary prior to the development of air bags. The connectors are removably mounted or attached to the mounting plate, and thereby allow the air bag module to be removed or withdrawn from the steering wheel for maintenance and service.
In accordance with a second embodiment of the present invention a mounting connector for rigidly but removably attaching an air bag module assembly to a mounting plate is provided. The mounting connector is designed to attach the module to a steering wheel, dashboard, seat back, head rest, or any other location in a passenger compartment for an automobile, air plane, truck, boat, bus or the like where an air bag-type passive occupant restraint is desired.
In further accordance with the second embodiment of the present invention, the mounting connector includes an enlarged head and a series of resiliently deformable arms. Each of the arms have an enlarged retaining distal portion and a proximal mounting portion. The retaining portion removably attaches the module to a mounting plate while the mounting portion attaches the connector to a base plate provided by the module.
In further accordance with the second embodiment of the present invention, the mounting portion provides upper and lower co-axial cylindrical surfaces adjacent a shoulder surface provided by the enlarged head. The upper cylindrical surface is adjacent the retaining portion of the arm. An interference fit between the lower cylindrical surface and the base plate retains the connector on the module.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
These and further features of the present invention will be apparent with reference to the following description and drawings, wherein:
FIG. 1 is an exploded perspective view of an air bag module incorporating a series of mounting connectors in accordance with a first embodiment of the present invention;
FIG. 2 is an exploded perspective view of a base plate and the mounting connectors in accordance with the first embodiment of the present invention;
FIG. 3 is an elevational view, in cross section, of the mounting connector, base plate, and a mounting plate in a normal or at-rest condition in accordance with the first embodiment of the present invention;
FIG. 4 is an elevational view, in cross section, of the mounting connector, base plate, and mounting plate in an inward or horn actuating position, in accordance with the first embodiment of the present invention;
FIG. 5 is an exploded perspective view of the mounting connector according to the first embodiment of the present invention;
FIG. 6 is an exploded perspective view of the air bag module and steering wheel in accordance with the first embodiment of the present invention;
FIG. 7 is a front elevational view of the mounting connector in accordance with a second embodiment of the present invention, with a mounting plate and base plate shown in phantom;
FIG. 8 is an enlarged elevational view, partly in cross section, of a portion of the mounting connector in accordance with the second embodiment of the present invention; and,
FIG. 9 is a top plan view of the mounting connector illustrated in FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-6, an air bag module 10 incorporating mounting connectors 12 in accordance with a first embodiment of the present invention is shown. The air bag module 10 is designed to removably mount to a mounting plate 14 provided by a steering wheel 16 (FIG. 6) and includes, in addition to the mounting connectors 12, a cover member 18, an inflatable cushion 20, a cushion retainer 22, a base plate 24, and an inflator 26 (FIG. 1).
The inflator 26 includes a housing 28 and an inflator module (not shown). The inflator module is preferably of the sodium azide-type, and produces a large volume of gas to quickly inflate the cushion. As shown best in FIG. 1, the inflator housing 28 includes a pair of oppositely-directed cylindrical portions 30 and a thin outwardly extending skirt 32. The cylindrical portions 30 define a cavity for receipt of the inflator module. Conventional fasteners attach the skirt 32 to the base plate 24 while one of the cylindrical portions 30 extends through a central hole 34 in the base plate 24 and into the cushion 20, as is generally well known in the art.
The base plate 24 provides a generally planar rectangular surface 36 in which is formed the central hole 34. The cushion 20 includes a circular opening or mouth (not shown) which overlies the central hole 34 and is secured to the base plate 24 by the cushion retainer 22. More specifically, the cushion fabric adjacent the circular mouth is trapped or sandwiched between the retainer 22 and the baseplate 24, the retainer 22 and cushion 20 thereafter being riveted or otherwise permanently attached to the base plate 24.
Encircling the central hole 34 in the base plate is an array of relatively smaller sized mounting holes 38, as illustrated in FIGS. 1 and 2. Some of the mounting holes are provided to attach the cushion 20 and cushion retainer 22 to the base plate 24 while others of the mounting holes are provided to attach the inflator housing 28 to the base plate 24. At each corner of the rectangular surface 36 is provided an opening 40 which receives one of the mounting connectors 12.
Downwardly-directed flanges 42 extend from the four edges of the base plate 24 and attach to associated panels 44 provided by the cover member 18. The cover member 18, which defines a top surface of the module 10, is separable along a series of seams 46 to allow the inflatable cushion 20 to escape and project there-through upon inflation. A bottom surface of the air bag module 10 is defined by the inflator housing 28 and the base plate 24.
The mounting connectors 12 project downwardly from the baseplate 24 and include three component parts: an outer or first member 48, an inner or second member 50, and a coil spring 52 which biases or urges the inner member 50 relatively away from or telescopingly out of the outer member 48.
The outer member 48 serves as a main section of the mounting connector and is electrically conductive. The outer member 48 has a generally cylindrical main body portion 54 and an upstanding first end or cylindrical neck 56. The neck 56 extends through the opening 40 in the base plate 24, a terminal portion 58 of the neck 56 projecting above the base plate being radially outwardly deformed or bent over to attach the mounting connector 12 to the base plate 24, as shown best in FIGS. 3 and 4. The outer member 48 can be made of any suitable conductive material, such as cold rolled steel.
The main body portion 54 of the outer member 48 receives the coil spring 52 and a first end 60 of the inner member 50. The inner member 50 telescopingly extends from the outer member 48 under the influence of the coil spring 52, the first end 60 being maintained within the main body portion 54 of the outer member 48 by a radially in-turned second end or annular lip 62 provided by the main body portion.
The inner member 50 serves as a connecting section of the mounting connector and is electrically insulative. The inner member 50 includes, in addition to the first end 60, a second end 64 which telescopingly extends from a circular opening defined by the annular lip 62 of the outer member 48. The first end 60 of the inner member 50 is bowl-shaped, and opens toward the neck 56 of the outer member 48 and cooperates with the main body portion 54 to receive the coil spring 52. Preferably, the inner member 50 is formed of a dimensionally stable, heat and corrosion resistive material, such as 6/6 NYLON.
The second end 64 of the inner member includes a transition portion 66 and a series of spaced-apart, outwardly-extending resilient arms 68. The transition portion 66 merges with a bottom of the bowl-shaped first end 60 and is adapted and sized to extend through the circular opening in the outer member 48 defined by the annular lip 62. The resilient arms 68 project from the transition portion 66 and are inwardly deformable to allow them to be removably inserted into a hole 69 in the mounting plate 14 and thereby releasably attach the connector 12 and, hence the module 10, to the mounting plate 14.
A circumferential or annular groove 70 is provided by the second end 64 of the inner member 50 adjacent the union of the transition portion 66 and the resilient arms 68. The groove 70 is discontinuous, being interrupted by the spaces between the arms 68, and limited or bounded by upper and lower shoulder surfaces 72, 74. The groove 70 receives the mounting plate 14 and the upper and lower shoulder surfaces 72, 74 engage opposite sides of the mounting plate to attach the connectors 12 and, thus, the module 10, to the steering wheel 16. More particularly, the upper shoulder surface 72 limits insertion of the connector 12 into the hole 69, while the lower shoulder surface 74 releasably prevents removal of the connector 16 from the hole 69 in the mounting plate 14.
Assembly of the mounting connectors 12 of the first embodiment of the present invention is a relatively simple process. The coil spring 52 is inserted into the cylindrical main body portion 54 of the outer member 48, then the bowl-shaped first end 60 of the inner member 50 is inserted into the main body portion 54 such that the coil spring 52 is received by and extends into the bowl-shaped first end 60. Thereafter, a machine (not shown) forces the inner member 50 into the main body portion 54 while inwardly deforming a terminal edge of the outer member 48 to form the annular lip 62.
As so deformed, the annular lip 62 retains the inner member 50 within the outer member 48 while allowing the inner member 50 to move in a telescoping fashion relative to the outer member 48. The spring 52 biases the inner member to its outwardmost or at-rest position shown in FIG. 3 wherein the bowl-shaped portion of the inner member 50 abuts the annular lip 62 and the transition portion 66 and resilient arms 68 project from the outer member 48. Once the mounting connector 12 is assembled, it is attached to the base plate 24 by inserting the neck 56 of the outer member through one of the openings 40 in the base plate, and radially outwardly deforming the terminal portion 58 of the neck 56.
With the mounting connectors 12 attached to the base plate 24, the cushion 20 and cushion retainer 22 are attached, by rivets or the like, to the base plate 24, as discussed hereinbefore. Thereafter, the panels 44 of the cover member 18 are attached to the flanges 42 of the base plate 24 to complete assembly of the module.
With the module 10 so assembled, and the mounting connectors 12 projecting downwardly from the base plate 24, the air bag module 10 can be snap-fittingly mounted to the steering wheel 16. The resilient arms 68 of the inner member 50 are aligned with the holes 69 provided by the mounting plate 14, and pushed toward the mounting plate 14. The arms 68 are cammed or deformed radially inwardly as they pass through the holes 69. Once through the holes 69, the arms 68 snap outwardly, receiving the mounting plate 14 within the annular groove 70 (i.e., between the shoulder surfaces 72, 74) and generally preventing further movement of the inner member 50 relative to the mounting plate 14.
With reference to FIGS. 3 and 4, the operation of the mounting connectors 12 of the first embodiment as a portion of the horn actuator mechanism is shown. The mounting connectors 12 space the base plate 24 from the mounting plate 14, and provide a contact for a horn actuation switch. More specifically, the bias of the coil spring 52 maintains the outer member 48 of the mounting connector 12 a distance from the mounting plate 14, while the mounting plate 14 serves as the first contact of the horn actuation switch and the outer member's annular lip 62 serves as the second horn switch contact.
The annular lip 62 is usually maintained a short distance from the mounting plate 14 due to the bias of the coil spring 52 (FIG. 3), as discussed previously. When sufficient force is exerted upon the cover member 18 to overcome the spring bias, the entire module 10, with the exception of the inner member 50 of the mounting connector 12, moves toward the mounting plate 14. The movement of the module 10 is limited by engagement of the annular lip 62 with the mounting plate 14, which closes the horn actuation switch (FIG. 4) and sounds the horn. Placement of the mounting connectors 12 at the four corners of the module 10 securely attaches the module 10 to the mounting plate 14, while assuring that inwardly directed pressure at any location on the cover member 18 will actuate the horn.
The module 10 is disengaged or unattached from the mounting plate by radially inwardly deforming the resilient arms 68 to free the lower shoulder surfaces 74 from engagement with the mounting plate 14. A tool (not shown) can be provided to simultaneously disengage all of the mounting connectors 12 from the mounting plate 14. Thereafter, the module 10 is simply pulled away from the mounting plate 14 to complete removal of the module from the steering wheel 16.
With reference to FIGS. 7-9, a mounting connector 110 in accordance with a second embodiment of the present invention is illustrated. The mounting connector 110, which is preferably formed of reinforced nylon, is adapted to rigidly mount a base plate 24 of an air bag module assembly 10 to a mounting plate 14. The air bag module assembly 10 and mounting plate 14 are generally identical to those illustrated in FIGS. 1-6, with the exception of the present embodiment of the mounting connector 110 and any modifications to the plates 14, 24 necessary to allow the base plate 24 and mounting plate 14 to engage in a face-to-face manner, and will therefore not be further discussed hereinafter.
The mounting connector 110 includes an enlarged head 112 and a series of resiliently deformable arms 114. The head 112, which includes a hollow or bowl-shaped lower end, provides a generally planar shoulder surface 116 from which the arms 114 project. The shoulder surface 116 acts as a stop to limit insertion of the mounting connector 110 into the base plate 24 and engages an inner surface 24a of the base plate. The arms 114, which are spaced-apart by notches or slots 118, include a distal retaining portion 120 and a proximal mounting portion 122.
As illustrated best in FIG. 8, the retaining portion 120 of each arm 114 includes an outer camming surface 124 and an engaging surface 126. The camming surface 124 is adapted to slidably engage the base plate 24 and the mounting plate 14, causing the arms 114 to deform radially inward, and allowing insertion of the mounting connector 110 into the plates 14, 24. The camming surface 124 forms an angle A with respect to vertical and, preferably, the angle A is equal to about 8°. The engaging surface 126 is adapted to engage an outer surface 14a of the mounting plate 14 and releasably prevent removal of the mounting connector 110 therefrom. The engaging surface 126 is curved and ramps upwardly as it moves radially inward, and forms an angle B with respect to the shoulder surface 116. The angle B is preferably equal to about 5°.
The mounting portion 122 of each arm 114 includes upper and lower co-axial cylindrical surfaces 130, 132. The upper cylindrical surface 130 merges with the engaging surface 126 and is slightly smaller in diameter than the lower cylindrical surface 132. The lower cylindrical surface 132 merges with the shoulder surface 116 of the enlarged head 112. The upper and lower cylindrical surfaces 130, 132 are interconnected by an arcuate ramping or camming surface 134 which provides a gradual transition from the smaller diameter upper cylindrical surface 130 to the larger diameter lower cylindrical surface 132. The ramping surface 134 preferably forms an angle C of about 45° with respect to the plane defined by the shoulder surface 116.
The notches 118 separating the arms 114 result in discontinuity in the cylindrical surfaces 130, 132, the ramping surface 134, and the shoulder surface 116. The notches 118 extend into the enlarged head 112 a short distance to help promote elastic bending of the arms 114. Preferably, the notches 118 make an angle D with respect to a vertical axis and, most preferably, the angle D is equal to about 5°.
Installation and use of the mounting connector 110 according to the second embodiment of the present invention will hereafter be described with reference to the foregoing description and drawings.
Prior to assembly of the air bag module 10, the retaining portion 120 of the mounting connector 110 is aligned with a mounting hole 40 provided by the base plate 24. Pushing force on the enlarged head 112 moves the retaining portion 120 of the arms 114 through the hole 40, causing the camming surface 124 to engage the base plate 24 and force the arms 114 to resiliently deform radially inward. Once the retaining portions 120 of the arms 114 pass through the hole 40, the arms 114 snap radially outwardly to their original or at-rest position.
Further pushing force on the enlarged head 112 causes the upper cylindrical surface 130 and the camming surface 134 to pass through the hole 40. Thereafter, the edges of the base plate 24 surrounding the hole 40 engage the lower cylindrical surface 132. The diameter of the lower cylindrical surface 132 is preferably sized to closely match the diameter of the hole 40 in the base plate 24 to provide an interference fit between the lower cylindrical surface 132 and the base plate 24. The edges of the base plate 24 surrounding the holes 40 may be serrated, grooved, threaded, or otherwise shaped to enhance frictional contact between the connector 110 and the base plate 24. The interference or press-fit between the mounting connectors 110 and the base plate 24 is the only means required to attach the connector 110 to the base plate 24. Preferably, once inserted in the hole 40, the mounting connector 110 will be capable of resisting at least 45N of outwardly-directed force (i.e., force tending to move the mounting connector 110 out of the base plate 24). This resistance to outward force is necessary because when the module 10 is attached to the mounting plate 14 there is a force tending to push the connectors 110 out of the holes 40, as will be described more fully hereafter.
Depending upon the tolerances maintained during manufacture of the base plate 24 and the mounting connector 110, a portion of the camming surface 134 adjacent the lower cylindrical surface 132 may be deformed due to contact with the base plate 24, especially if the edges surrounding the holes 40 are not smooth. The camming surface 134 also acts to center the connector 110 within the hole 40, which eases and speeds assembly. Once the connectors 110 are attached to the base plate 24, the remainder of the module 10 is assembled as described in the foregoing first embodiment.
The module 10 is attached to the mounting plate 14 by aligning the connectors 110 with the holes 69 in the mounting plate and pushing the module toward the mounting plate 14. The camming surfaces 124 of the retaining portions 120 slidably engage the mounting plate 14 adjacent the holes 69, resiliently deforming the arms 114 and allowing the retaining portion 120 to pass through the holes 69. Once the retaining portions 120 pass through the holes 69, the arms 114 resiliently snap radially outward to their at-rest or normal position. When the arms 114 are being pushed through the holes 69, a force is created which tends to push the connectors 110 away from the base plate 24. This force is counteracted by the interference fit between the connectors 110 and the base plate 24.
The engaging surface 126 contacts a top surface 14a of the mounting plate 14. Forming the engaging surface 126 at an angle relative to the plane defined by the shoulder surface 116 allows the retaining portion to compensate for manufacturing tolerances in the mounting plate 14 and base plate 24 thicknesses. For example, if the mounting plate 14 is slightly thicker than illustrated, the retaining portion 120 will rotate slightly inwardly, the angle B will be slightly less, and the engaging surface 126 will remain in contact with the top surface 14a of the mounting plate 14.
The angle B of the engaging surface 126 therefore compensates for manufacturing tolerances while rigidly attaching the connector 110 to the mounting plate 14. Tolerance compensation provided hereby ensures that the module 10 will not vibrate due to a loose fit between the connector 110 and the mounting plate 14.
The mounting connectors 110 firmly yet removably attach the module 10 to the mounting plate 14. The retaining portion 120 ensures that the module 10 will not be inadvertently or accidentally unattached from the mounting plate 14. Preferably, the retaining portions 120 of the arms have a high tension strength, each connector 110 being capable of withstanding at least about 7500N pulling force.
The module 10 is disengaged or unattached from the mounting plate 14 by radially inwardly deforming the resilient arms 114 to free the engaging surfaces 126 from engagement with the outer surface 14a of the mounting plate 14. A tool (not shown) can be provided to simultaneously disengage all of the mounting connectors 110 from the mounting plate 14. Thereafter, the module 10 is simply pulled away from the mounting plate 14 to complete removal of the module from the mounting plate 114.
While the preferred embodiments of the present invention are shown and described herein, it is to be understood that the same is not so limited but shall cover and include any and all modifications thereof which fall within the purview of the present invention as defined by the claims appended hereto. For example, the term mounting plate as used herein is intended to refer to any support structure to which the air bag module is attached. Also, although the mounting connectors according to the first embodiment are described as being associated with a steering wheel, it should be clear that these connectors can be employed to attach the air bag module to any structure, such as a dashboard, head rest, or seat back. | A connector for an air bag module or assembly which removably mounts the module to a mounting plate provided by a steering wheel or other support structure. A first embodiment of the connector movably mounts the module to the steering wheel, and provides a horn actuation feature. The module is biased to a normal position wherein a first horn switch contact provided by the steering wheel is spaced from a second horn switch contact provided by the module. The bias is overcome by user-applied force which moves the module inwardly relative to the steering wheel and thereby brings the first and second contacts into engagement and actuates the horn. The connectors of the first embodiment include first and second telescopingly related members and a biasing spring which tends to maintain the second member projecting from the first member. The second member includes a series of spaced-apart resilient arms which cooperate to provide a discontinuous annular or circumferential groove which receives a mounting plate provided by the steering wheel. The arms are radially deformable to disconnect the module from the steering wheel. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to Raney nickel catalysts modified by molybdenum, and, more particularly, to new and improved Raney nickel catalysts activated by a molybdenum compound which is adsorbed on the Raney nickel solids.
2. Description of the Prior Art
Raney nickel is a well known hydrogenation catalyst which was described originally in U.S. Pat. No. 1,638,190, and in J.A.C.S. 54, 4116 (1932). Raney nickel is prepared by alloying nickel and aluminum and leaching out the aluminum with alkali to expose the nickel as a finely divided, porous solid in which form nickel is an effective hydrogenation catalyst.
Subsequently, improved Raney nickel catalysts have been provided in the art by alloying various metallic constituents with the nickel and aluminum prior to treatment with alkali. For example, in U.S. Pat. No. 2,948,687 and in the Bull. Soc. Chim. (1946), p. 208-211, molybdenum is alloyed with nickel and aluminum and treated with alkali to provide a nickel-molybdenum alloy catalyst. However, such nickel-molybdenum alloy catalysts are not as effective as the catalysts of this invention for use as hydrogenation catalysts, e.g. of butynediol, particularly with respect to the quality of the product obtained.
Accordingly, it is the object of this invention to provide an improved Raney nickel catalyst which performs effectively in different catalytic hydrogenation processes.
SUMMARY OF THE INVENTION
This invention provides an improved Raney nickel catalyst characterized by having a molybdenum compound adsorbed on the Raney nickel surface. The novel catalyst contains about 0.5-15 parts by weight of molybdenum adsorbed per 100 parts by weight of the Raney nickel solids in the catalyst. Optionally, one or more additional metals, such as copper, cobalt, tungsten, zirconium, platinum or palladium may be included in the catalyst. The novel catalyst is prepared by mixing a liquid suspension of Raney nickel with a molybdenum compound whereby the molybdenum compound is adsorbed by the solid particles.
The catalyst of the invention is particularly effective in the manufacture of high quality butanediol by hydrogenation of butynediol, for selective hydrogenation of carbonyl groups in the presence of unsaturated groups, e.g. for the conversion of furfural to furfuryl alcohol, and for hydrogenation of formaldehyde to methanol.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the present invention, the catalyst is prepared from Raney nickel solids which are suspended in a liquid medium, preferably in water. Then a suitable amount of a molybdenum compound is added to the suspension and the mixture is stirred so that the molybdenum compound can be adsorbed onto the Raney nickel solids.
Generally, the improved Raney nickel catalyst herein is prepared starting with commercially available Raney nickel, which is usually a suspension of about 50% by weight of nickel in water. The commercial slurry may be diluted, if desired, to provide a stirrable concentration of the Raney nickel for reaction with the molybdenum compound.
The suitable amount of the molybdenum compound is added as a solid, dispersion or a solution thereof to the Raney nickel suspension. Typical molybdenum compounds include various molybdenum salts and oxides, including ammonium and alkali molybdates, molybdic trioxide, and the like. Preferably the molybdenum compound is at least partially soluble in the liquid medium of the nickel suspension.
The mixture is then stirred at room temperature for a period of time which is sufficient to adsorb most of the molybdenum compound onto the Raney nickel solids. Usually about 10 minutes to 24 hours is suitable for this purpose, and about one hour generally is ample to adsorb the desired amount of the molybdenum compound onto the nickel solids. The resulting aqueous suspension may then be used as such as catalyst for a hydrogenation process. Any excess molybdenum compound present in suspension or solution does not interfere with the hydrogenation process, and, therefore, filtering of the catalyst suspension is unnecessary.
In accordance with the invention, suitably about 0.5-15 parts by weight of adsorbed molybdenum per 100 parts by weight of Raney nickel solids present is used as the catalyst composition. Preferably, about 2-8 parts by weight and, optimally, about 4 parts by weight molybdenum are used. In practice, the amount of molybdenum in the catalyst may be determined, after additions of known amounts of the molybdenum compound, by analysis of residual molybdenum still in suspension after stirring for given periods of time. Alternatively, the catalyst itself may be analyzed for nickel and molybdenum content.
As described in detail in copending application Ser. No. 924,212, filed July 12, 1978, (FDN-1113), the catalyst of the invention will produce high quality butanediol by a process involving a two-stage catalytic hydrogenation of a butynediol solution containing formaldehyde. During the first stage of the process, or low pressure, low temperature stage, a butanediol product having a much lower carbonyl number is obtained. The carbonyl number is the conventional measure of the undesired aldehyde and acetal content including residual formaldehyde. In the second or finishing stage, which is carried out at higher pressures and/or temperatures than the first stage, much less 2-methyl-1,4-butanediol byproduct (methylbutanediol) is produced concurrently with butanediol.
The results with the catalyst of the invention are very favorable and effective as compared to the results with untreated Raney nickel or with Raney nickel alloy catalysts containing molybdenum which was present in the Raney alloy before leaching. It is also more effective than Raney nickel with metals other than molybdenum adsorbed thereon.
A particular feature of the catalyst of the invention is its increased activity for reducing carbonyl groups sometimes even preferentially to carbon to carbon unsaturated groups in organic compounds which contain both groups. For example, furfural is reduced substantially to furfuryl alcohol by hydrogenation with the catalyst of this invention. On the other hand, Raney nickel itself, or Raney nickel from a molybdenum-containing alloy produces considerable amounts of tetrahydrofurfuryl alcohol byproduct.
The invention now will be illustrated with reference to the following specific examples, which are to be considered as illustrative, but not limiting of, the invention herein.
EXAMPLE 1
Adsorption of Molybdenum on Raney Nickel
To 10.0 g aliquots of Raney nickel solids in 40 ml of water were added various proportions of molybdenum in the form of ammonium molybdate. The suspensions were stirred at room temperature and, at intervals, filtered and the filtrates analyzed for molybdenum content. The following Table I gives the extent of adsorption of molybdenum as a function of time of stirring.
TABLE I______________________________________Ratio of Wt. of Mo to Wt. of Raney Ni Solids0.03 0.04 0.06 0.08 0.12Time % of Mo Charge Adsorbed on Catalyst______________________________________10 min. 86 83 78 75 73 1 hr. 92 87 82 79 7524 hrs. 96 93 89 88 87______________________________________
EXAMPLE 2
Preparation of Catalyst of Invention
To 20.0 g. of commercial Raney nickel containing about 50% nickel particles as an aqueous slurry was added solid ammonium molybdate, (NH 4 ) 6 Mo 7 O 24 4H 2 O, and the mixture was stirred for an hour. The catalyst thus prepared then was added directly to the butynediol solution for use in the hydrogenation process.
Catalysts were prepared in this manner corresponding to 2, 3, 4, 5, 6 and 8 parts by weight of molybdenum added per 100 parts of Raney nickel solids.
EXAMPLE 3
Hydrogenation of Butynediol to Butanediol Raney Nickel (Control Experiment)
A. Low Pressure, Low Temperature Stage (First Stage)
500 g. of aqueous 35% butynediol solution containing 0.40% formaldehyde and a catalyst comprising 20 g. of commercial 50% Raney nickel slurry was hydrogenated under agitation at 60° C. and 300 psig of hydrogen. After 6 hours, the catalyst was allowed to settle and the supernatant product was withdrawn. Thereafter, another 500 ml. of 35% butynediol solution was added and the hydrogenation procedure was repeated. Four successive hydrogenations were run with the same catalyst; the results are given for the fourth run in the series.
The reaction product has a carbonyl number of 48 and a formaldehyde content of 0.22%.
B. High Pressure, High Temperature Stage (Finishing Stage)
The product of the low pressure stage was subjected to finishing hydrogenation over a 15% nickel--7.8% copper--0.5% manganese catalyst on alumina at 2500 psig, and 150° C. for 7.5 Hours. The reaction product, after removing water, then was totally distilled, and, the organics were collected up to a pot temperature of 180° C. at 1 Torr.
The distilled butanediol product had a carbonyl number of 0.3 and a 2-methyl-1,4-butanediol content of 2.0%.
EXAMPLE 4
Raney Nickel-Mo Alloy
The hydrogenation process of Example 3 was repeated using an alloy catalyst containing 3% by weight molybdenum prepared by alkali leaching of a nickel-molybdenum-aluminum alloy.
The butanediol product of the low pressure stage had a carbonyl number of 22 and a formaldehyde content of 0.16%. After the finishing stage, the carbonyl number was 0.3, and the methylbutanediol content was 1.6%.
EXAMPLE 5
Raney Nickel+Mo Compound Adsorbed
The hydrogenation process of Example 3 was repeated using the catalysts of the invention prepared according to Example 2.
The butandiol product of the first stage, for catalysts having added molybdenum content of 2, 3, 4, 5, 6 and 8 parts by weight of molybdenum gave corresponding carbonyl numbers of 9, 7, 5, 5, 6 and 6. The formaldehyde content of the products were 0.10%, 0.08%, 0.09%, 0.09%, 0.10% and 0.08%, respectively.
After the finishing stage the carbonyl numbers were, respectively, 0.3, 0.15, 0.1, 0.1, 0.15 and 0.2. The methylbutanediol contents were, respectively, 0.9%, 0.7%, 0.6%, 0.6% 0.6% and 0.5%.
EXAMPLE 6
Raney Nickel-Cr Alloy+Mo Compound Adsorbed
The hydrogenation process of Example 3 was repeated using a catalyst prepared according to Example 2 from a commercial Raney nickel-chromium alloy containg 3% by weight chromium in the alloy to give a resultant catalyst having 4 parts of molybdenum adsorbed per 100 parts of Raney nickel solids.
The carbonyl number was 4.5 and the formaldehyde content was 0.10% in the low pressure stage. The carbonyl number was 0.1 and the methylbutanediol content was 0.6 after finishing.
EXAMPLE 7
Raney Nickel-Mo Alloy+Mo Compound Adsorbed
The hydrogenation process of Example 3 was repeated using a commercial Raney nickel-molybdenum alloy containing 3% by weight molybdenum which was treated as in example 2 to adsorb 4 parts of molybdenum per 100 parts of the alloy solids.
The carbonyl number was 17 and the formaldehyde content was 0.12% in the first stage; the carbonyl number was 0.3 and the methylbutanediol content was 1.2% after finishing.
EXAMPLE 8
Raney Nickel+Mo and Cu Compounds Adsorbed
A catalyst comprising 4 parts molybdenum compound adsorbed per 100 parts of Raney nickel solids was prepared as in Example 2, then an additional 4 parts of copper, as copper acetate, was dissolved in the butynediol solution, and the hydrogenation process of Example 3 was repeated.
The carbonyl number was 5 and the formaldehyde content was 0.09% in the low pressure stage. The carbonyl number was 0.2 and the methylbutanediol content was 0.6 after finishing.
EXAMPLE 9
Raney Nickel+Cu Compound Adsorbed
The hydrogenation process of Example 3 was repeated using a Raney nickel catalyst having about 6 parts of copper adsorbed per 100 parts of Raney nickel solids, as in U.S. Pat. No. 2,953,605. The carbonyl number was 37 and the formaldehyde content was 0.16% at the end of the first stage. After finishing the carbonyl number was 0.3 and the methylbutanediol content was 2.0%.
EXAMPLE 10
Hydrogenation of Furfural
Three identical hydrogenations were run using (A) unmodified Raney nickel (B) Raney Nickel containing 3% molybdenum alloyed as in the prior art, and (C) Raney nickel containing about 4 parts by weight molybdenum adsorbed per 100 parts of Raney nickel solids according to this invention.
In each hydrogenation, 175 g of furfural in 325 g. aqueous isopropyl alcohol was catalyzed with 10.0 g of the catalyst. After hydrogenation at 60° C. and 300 psig for 6 hours, the following results were obtained.
TABLE II______________________________________ Catalyst Used (A) (B) (C)Components of Reaction Product % of Component______________________________________Furfuryl Alcohol 31.0 70.0 98.0Tetrahydrofurfuryl Alcohol 51.9 25.8 1.6Tetrahydrofurfural 7.4 0.9 0.0Furfural 8.6 2.2 0.1Others 1.1 1.1 0.3______________________________________
EXAMPLE 11
Hydrogenation of Formaldehyde
Two identical hydrogenations were run using (A) unmodified Raney nickel and (B) Raney nickel containing about 4 parts of molybdenum absorbed per 100 parts of Raney nickel solids.
In each hydrogenation 7.25 g. of formaldehyde in 493 ml. of water was catalyzed with 10.0 g. of the catalyst. After hydrogenation at 60° C. and 3000 psig for 6 hours, the following results were obtained:
TABLE III______________________________________ Carbonyl No. % Formaldehyde______________________________________Initial Feed Solution 27.1 1.45Catalyst of HydrogenationUnmodified Raney nickel (A) 7.0 0.36Molybdenum adsorbed on Raneynickel (B) 0.5 0.01______________________________________ | This invention provides an improved Raney nickel catalyst characterized by having a molybdenum compound adsorbed thereon. The novel catalyst contains about 0.5-15 parts by weight of molybdenum adsorbed per 100 parts by weight of Raney nickel solids. Optionally, one or more additional metals may be included in the catalyst. The catalyst is particularly effective in the manufacture of high quality butanediol by hydrogenation of butynediol, and for selective hydrogenation of carbonyl groups, sometimes even in the presence of carbon-carbon unsaturation, e.g. for the conversion of furfural to furfuryl alcohol. | 8 |
The present application is a continuation of application Ser. No. 10/417,594 filed Apr. 17, 2003 which is incorporated herein by reference in its entirety.
BACKGROUND
The present invention relates to barrier movement operators and particularly to such operators which include a timer-to-close feature.
Barrier movement operators are known which include a motor for moving a barrier between open and closed positions and a controller for selectively energizing the motor to move the barrier. Gate operators and garage door operators are examples of the wide range of such barrier movement operators. The controller of a barrier operator may be responsive to stimulus signals to perform various barrier movements with safety. For example, the barrier operator may include a control switch which, when pressed, reverses the direction of travel of the barrier or starts the barrier moving toward the open or closed position.
Most door movement has, for safety concerns, been under the control of a human operator. That is the barrier was opened or closed only when a human was present to provide a movement initiating stimulus. The human, being aware of the environment was a significant part of safely moving the barrier. Humans, however, are not infallible and occasionally the barrier is left open when it should be closed. Doing so may be energy inefficient by allowing heat or cool to escape from a space which should be a closed interior or it may be unwise because unauthorized persons may enter the area to be protected by the barrier.
In order to combat the problem of a left-open barrier, some systems include a timer-to-close feature. This feature generally includes a timer which is enabled when the barrier is in the open position. When the timer indicates that the barrier has remained open for a predetermined period of time, the barrier operator motor is energized to move the barrier to the closed position. A barrier movement operator with a timer-to-close feature is generally equipped with special safety equipment like an alerting light and/or audible signal which are activated prior to moving the barrier to the closed position.
It may be desirable for a user to pause the timer-to-close feature for reasons such as airing out the interior space of which a human user is in control. Known systems with a timer-to-close feature generally provide no user controlled ability to pause the feature without shutting the feature off, requiring at least a complete recycle of the barrier or even a reprogramming of the parameters of the feature. A need exists for a more convenient arrangement for pausing a timer-to-close feature.
Further, known operators having a timer-to-close feature move the barrier directly from the open to the closed position. Such may not always be desirable either for reasons of safety or for reasons predicted by a human operator. A need also exists for a human controlled capability to move the barrier first to a mid-travel stopping point, then to the closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a barrier movement operator;
FIG. 2 is a block diagram of a controller of the barrier movement operator and apparatus which interacts with the controller;
FIG. 3 represents apparatus for defining particular points of barrier travel;
FIG. 4 is a flow diagram of the inhibiting of a timer-to-close feature;
FIG. 5 is a flow diagram of barrier movement with a mid-travel point defined; and
FIG. 6 is a view of a wall control unit for signaling the controller.
DESCRIPTION
FIG. 1 is a view of a barrier movement operator embodying the present invention. FIG. 1 shows a jack shaft balanced, powered jack shaft moved residential garage door movement operator. It will be understood from the following that the improvements described and claimed herein apply to other types of barrier movement systems such as commercial door operators, rolling gate operators, swinging gate operators, other types of balancing such as tension spring, and other types of movement such as high lift and powered rail and trolley.
In the embodiment of FIG. 1 , a panel door 112 is raised and lowered in a pair of side tracks 114 and 116 . Door 112 is connected by cables 105 and 107 to a pair of drums 104 and 108 disposed on a jack shaft 106 and rotated under the power of a motor 150 contained by a head end 102 . The motor is selectively energized by a controller 208 and associated apparatus ( FIG. 2 ) to move the door 112 between a closed position, as shown in FIG. 1 , and an open position. The controller 208 , which includes a programmed microprocessor, responds to user input signals from a wall control 124 and an rf transmitter 118 to initiate door movement. Obstructions to door movement may be detected by an optical transmitter 138 and receiver 142 which “watch” the door opening to detect when an obstruction is beneath the door. Similarly, an optional door edge sensor (not shown) may be attached to the bottom of the door to detect physical contact with an obstruction.
When the barrier movement system is installed, the controller 208 is taught the open and closed positions of the door by known means so that the motor 150 is energized only long enough to move the door between those limit positions. Such limit positions may be learned in the software and data of controller 208 , they may consist of physical door detectors mounted to the rails, the garage, or the door, or they may be physical switches within head end 102 which sense the movement of representations of the door position. FIG. 3 represents one apparatus internal to the head end for setting limits of door travel.
The limit setting arrangement of FIG. 3 comprises a first limit switch 145 , a second limit switch 146 , and a third limit switch 147 . Each limit switch includes an actuator lever, e.g., 148 , which responds to contact by causing its associated switch to change from an open to a closed electrical state. The state of all switches is reported to controller 208 via a communication path 232 . Also included is a threaded shaft 149 which is connected to the output shaft of motor 150 to rotate therewith. In FIG. 3 , the shaft is connected to motor 150 by means of a pulley 155 and belt 156 . Threaded onto shaft 149 are three switching cogs 152 , 153 , and 154 which are kept from rotating during normal operation by a guide rail (not shown) attached to a mounting plate 151 .
The open and closed limits are set by cogs 152 and 154 . They are set by lowering the door to the closed position, displacing mounting plate 151 so that the cogs are free to rotate, and rotating cog 152 until switch 145 changes state. Similarly, the open limit is set by moving the door to the open position and adjusting cog 154 until switch 146 changes state. After setting open and closed limits, controller 208 can accurately control barrier movement.
After the barrier operator is installed, a user may press the command button 134 of wall control which signals controller 208 via a path 126 . Controller assesses the present state of the barrier based on various inputs discussed and sends a signal on a communication path 220 to control relays 222 which apply power to motor 150 . For example, when the barrier 112 is at the open limit and push button 134 is pressed, controller 208 energizes relays 222 to energize motor 150 to move the barrier toward the closed limit. During such movement the optical sensors 138 and 142 , and other safety equipment, are surveyed to assure safe movement of the door. A user can also initiate barrier movement by rf transmitting an appropriate security code from a transmitter 118 in a manner well known in the art. Such an rf transmission is received by a receiver 207 via an antenna 120 and the resultant received signal is sent on to controller 208 . A non-volatile memory 212 stores previously learned security codes and when a match exists between a previously learned code and a received code, the controller operates the door in the same manner as if button 134 of wall control 124 had been pressed.
The present embodiment includes a timer-to-close feature which is in part implemented with routines to be performed by controller 208 . The timer-to-close feature automatically moves the barrier toward the closed position when the barrier has been in the open position for a predetermined period of time. The predetermined period of time may be preset and stored in controller 208 at the time of manufacture or it may be established by known user controlled methods during installation. The present embodiment adds to the timer-to-close feature by permitting the user to conveniently inhibit operation of this feature. A switch 132 of wall control 134 is used to enable and disable the timer-to-close feature.
FIG. 4 is a flow diagram of an embodiment of the timer-to-close feature. The flow begins at block 161 which is entered whenever the door achieves the open position. In block 161 the timer-to-close timer is started. Flow proceeds to block 163 in which when a determination is made as to whether the timer is active. When the timer is active, flow proceeds to blocks 165 and 167 where switch 132 is checked to see if it has been pressed by a user. If not, flow proceeds to block 169 to determine whether the timer has reached the predetermined time out value. If it has not, flow returns to block 165 . As long as the switch 132 is not pressed, the loop of blocks 165 , 167 , and 169 continues until time out is detected in block 169 , and flow proceeds to block 171 where a timer-to-close flag is set indicating that door closing movement was begun by the timer-to-close time out. The motor 150 is then energized in block 173 to move the door toward the closed position. When the door reaches the closed position, the timer-to-close flag is reset.
Should a user press button 132 while the loop of blocks 165 , 167 , and 169 is being executed, flow proceeds from block 167 to block 175 where the timer is turned off, which in the present embodiment includes resetting the timer. From block 175 flow returns to block 163 and on to blocks 177 and 179 where the state of switch 132 is again checked. When there has been no change, flow returns to block 163 and a loop consisting of blocks 163 , 177 and 179 is repeatedly executed. Whenever block 179 detects a press of button 132 , flow proceeds to block 161 where the timer is again started and flow continues as previously described. Optionally the wall control 124 may include an LED 133 which is energized by controller 208 when the timer-to-close is being inhibited and is not energized when timer-to-close is in the normal mode.
As discussed with regard to FIG. 3 , the barrier movement operator described herein includes a limit switch 147 and corresponding limit cog 153 which may be adjusted to identify to controller 208 a position of the barrier intermediate to the positions identified by switches 145 and 146 . The point at which switch 147 changes state is adjusted in the manner described previously with regard to switches 145 and 146 . With such adjustment, the controller 208 will be informed each time the door passes the intermediate position while moving between open and closed positions. In the present embodiment, the passage of the intermediate position while the door is traveling upwardly toward the open position is ignored by controller. FIG. 5 is a flow diagram representing downward or closing movement of the barrier during which the intermediate position is responded to.
The routine of FIG. 5 is performed each time the motor 150 is energized to move the barrier from the open position toward the closed position. The routine begins with the energization of motor 150 for downward motion in block 181 . A block 183 is performed throughout downward door movement to assure door movement safety. A decision block 185 is next performed to identify if the timer-to-close flag has been set. It will be remembered that the timer-to-close flag is set in block 171 ( FIG. 4 ) when the downward motion is initiated by time out of the timer-to-close timer. When block 185 determines that the timer-to-close flag is set, flow proceeds to block 187 where a loop is performed until the mid-travel position set by switch 147 is detected. When the mid-travel position is reached, flow proceeds to block 189 and the motor is stopped to await a mid-travel time out in block 191 , at which point the motor is re-energized in block 193 and finally closed in block 195 . When block 185 determines that the barrier is moving toward the closed position for reasons other than the timer-to-close (such as in response to a user command), flow proceeds from block 185 to continue its closing the barrier without regard for the mid-travel position.
In the embodiments discussed above, the barrier waits at mid-travel until a timer re-initiates door movement as represented in blocks 191 and 193 . Alternatively, blocks 191 and 193 could be replaced with a single block 197 (shown in dotted line on FIG. 5 ) in which a user command is awaited to re-energize the motor.
Motor 150 can be energized to rotate either clockwise or counter-clockwise by power provided from an up and down motor control relay unit 223 of relays 222 . Whenever the barrier is to be moved, controller 208 transmits to the motor control relay unit 223 an appropriate set of signals to control relays 223 to rotate the motor in either the clockwise or counter-clockwise. The choice of clockwise, counter-clockwise rotation is made by controller 208 operating under pre-programmed parameters which are set using assumptions about the installation of the operator. It is possible that, because of decisions made during installation a control signal which causes the motor to rotate counter-clockwise will move the barrier toward the wrong limit. That is, the controller 208 may send a signal to relays 223 which is intended to raise a barrier and the result is that the barrier is lowered.
Wall control unit 124 includes a two position switch in which one position indicates normal barrier travel and the other position indicates the reverse barrier travel. Whenever the barrier motor is to be energized, the controller 208 consults the switch 130 to determine whether the motor is to be energized normally i.e., in accordance with pre-programmed parameters, or in the reverse. For example, by pre-programming, controller 208 may direct the motor to rotate clockwise to move a barrier from open to closed position, and the installed gearing of the motor results in clockwise, rotation which moves the barrier from closed to open position. Such reversal may also happen due to placement of head end on the left of the doorway rather than on the right as shown in FIG. 1 . When a user determines that the barrier is moving in the opposite direction to that expected the user changes the position of switch 130 . At the next command to energize the motor, controller 208 detects the changed setting of switch 130 and directs relays 223 to energize motor 150 for rotation opposite to the energization before the change of switch position. Additionally, controller 208 reverses the sense of the limit switches e.g., 145 and 146 so that proper door operation will result.
The preceding embodiments operate with a timer-to-close timer, the value of which may be set in any manner. The following discusses two examples for setting the timer-to-close timer to a particular value. A first example begins when a user presses the timer learn button 187 for a momentary contact to which controller 208 responds by entering a button oriented learn mode. The button oriented learn mode operates with an optional wall control 124 ′ which is shown in FIG. 6 . Wall control 124 ′ replaces wall control 124 for the present example.
In the button oriented learn mode, controller 208 responds to each press of an open button 135 by adding five seconds to the timer count, to each press of a close button 136 by adding one minute to the timer count and responds to a press of a stop button by clearing the timer count. Accordingly, when the button oriented learn mode is operational a user presses a combination of buttons 135 and 136 to total the desired timer value. The absence of button presses for a predetermined period of time e.g., 20 seconds, allows the controller to leave the learn mode and revert to the operating mode.
A second method of setting the time out period of the timer-to-close timer is a time based learn mode which is entered by holding the timer learn button 187 closed for more than five seconds. In the time based learn mode the barrier should be at the open position when button 187 is pressed or the first act after entering the time based learn mode should be to move the barrier to the open position. Controller 208 then counts the time that the barrier is in the open position. When the appropriate time has passed e.g., five minutes, the user presses either the close button 136 ( FIG. 6 ) or the timer-to-close button. The time base for the timer-to-close timer then becomes the time that the barrier was in the open position. | Methods and apparatus for controlling a barrier movement operator having a timer-to-close feature are disclosed. The methods and apparatus include arrangements for conveniently inhibiting and re-activating the timer-to-close feature and for providing a mid-stop position during movement toward the closed position. Additionally, the embodiments include methods and apparatus for reversing barrier operation. | 4 |
[0001] This invention relates to the filed of immunology, and in particular relates to an antigenic polypeptide derived from HIV (Human Immunodeficiency Virus) envelope protein, a DNA construct and a recombinant viral vector comprising a polynucleotide that encodes said polypeptide, an antibody against said antigenic polypeptide, and the use thereof for preventing or treating HIV infection.
BACKGROUND OF THE INVENTION
[0002] Human immunodeficiency virus (HIV) is the pathogen that causes the acquired immunodeficiency syndrome (AIDS). According to WHO, globally, there were an estimated 33 million people living with HIV in 2007. The annual number of new HIV infections was 2.5 million last year, or an increase of about 6800 daily. Regionally, sub-Saharan Africa and under-developed Asia countries are still home to most of the people living with HIV.
[0003] HIV is one member of Lentivirus genus of the Retroviridae family. Up to now, the epidemic thereof can only be retarded but not terminated; effective antiretroviral therapy can only slow down the development of the disease, while cannot completely eliminate the virus. Moreover, it remains financially unaffordable for those who reside in the developing countries. It is thus widely believed that an effective vaccine is the only solution to restrain the global HIV-1 epidemic.
[0004] Anti-HIV candidate vaccines currently under investigation include: attenuated viable vaccines, deactivated vaccines, DNA vaccines, viable vector vaccines, subunit vaccines and protein vaccines. With respect to the development history of anti-HIVvaccines, they can be divided into 4 generations. The first generation (1980s) of HIV candidate vaccines was mainly based on protein subunit concept. These candidates are capable of inducing neutralizing antibodies, but not cytotoxic T lymphocytes. The second generation (1990s) vaccine is based on the concept of recombinant vectors, especially using virus vectors followed by boosting with subunit recombinant vaccines. This concept is theoretically very attractive because preliminary data suggest that these vaccines induce both humoral and cell-mediated immunity. However, these vaccines have failed to protect vaccines from HIV infection. The third generation (2000-2005) of HIV candidate vaccines was based on the feature of different vaccine vectors and strategy to proceed carefully to expanded phase II and phase III trials to assess the protective efficacy of these candidate vaccines in humans. The new concept is based on inducing potent immune response by HIV conserved epitopes.
[0005] The HIV-1 envelope glycoprotein is the primary target for neutralization, and great efforts have been made to enhance the immunogenicity of Env in AIDS vaccine design. However, the Env glycoproteins frequently change their sequence in response to selective pressure exerted by the immune system, thus presenting the host with ever new antigens (Parren P W, et al. The neutralizing antibody response to HIV-1: viral evasion and escape from humoral immunity. AIDS 1999.13 (Suppl A):S137-162). Furthermore, the trimeric Env structure shields important domains of the Env core, making them inaccessible to antibody-mediated neutralization. Conformational Env re-orientation upon CD4 receptor binding transiently uncovers neutralization-sensitive regions for coreceptor binding until the viral envelope fuses with the host cell membrane In addition, heavy glycosylation on the outside of gp120 hides much of the protein core from antibody attack (Kwong P D, et al. HIV-1 evades antibody-mediated neutralization through conformational masking of receptor-binding sites. Nature 2002. 420:678-682). In all, the HIV Env protein poses a great challenge for generating broad reactive neutralizing antibodies. To induce a potent and cross-reactive neutralizing antibody, an effective envelope immunogen must be modified for HIV vaccine
[0006] Because of the lack of suitable animal model for HIV in nature, and human cannot be used for challenging test, people then turn to other six animal Lentivirus that belong to the same genus with HIV for relevant researches. Wherein, equine infectious anemia virus (EIAV) belongs to the same genus with HIV, and they both have same genome structures, replication modes, and similar protein categories and functions. It has been found that the V1, V2 regions of HIV-1 have a certain corresponding relations with the V3, V4 regions of EIAV (Hotzel I. Conservation of the human immunodeficiency virus type 1 gp120 V1/V2 stem/loop structure in the equine infectious anemia virus (EIAV) gp90. AIDS Res Hum Retroviruses, 2003, 19:923-924; and Huiguang Li, et al. A Conservative Domain Shared by HIV gp120 and EIAV gp90: Implications for HIV Vaccine Design. AIDS Res Hum Retroviruses, 2005, 21:1057-1059).
[0007] But due to the clear differences in the underlying mechanisms of pathogenesis of the two viruses, and which is different with HIV, the primary investigation process of attenuated EIAV vial vaccine is attenuation rather than the process of increasing immunogenicity. Hence, this alteration approach is all along despised by researchers in HIV vaccine development.
[0008] Based on the sequence analysis of the EIAV virulent strain and vaccine strain, and also based on the characteristic amino acid mutations of attenuated EIAV vial vaccine, the inventor utilized the approach of structurally and functionally corresponding positions to perform alterations for corresponding amino acid positions in HIV-1 envelope protein. Surprisingly, the altered antigenic polypeptide of HIV-1 envelope protein and vaccines constructed based on the polypeptide can induce the production of anti-HIV neutralizing antibodies with high tier, broad spectrum and persistence.
SUMMARY OF THE INVENTION
[0009] In one aspect, the present invention provides an antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein, wherein the polypeptide or fragment comprises an amino acid sequence containing a mutation selected from the group consisting of: substitution of the leucine residue at a position corresponding to position 52 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; deletion of the serine residue at a position corresponding to position 138 in SEQ ID NO:1; substitution of the asparagine residue at a position corresponding to position 139 in SEQ ID NO:1 by a glutamine residue; substitution of the arginine residue at a position corresponding to position 166 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; substitution of the serine residue at a position corresponding to position 184 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; substitution of the glutamic acid residue at a position corresponding to position 185 in SEQ ID NO:1 by a lysine, an arginine or a histidine residue; substitution of the serine residue at a position corresponding to position 188 in SEQ ID NO:1 by a glutamine or an asparagine residue; substitution of the glycine residue at a position corresponding to position 235 in SEQ ID NO:1 by an arginine, a lysine or a histidine residue; substitution of the glycine residue at a position corresponding to position 237 in SEQ ID NO:1 by a glutamine or an asparagine residue; substitution of the histidine residue at a position corresponding to position 240 in SEQ ID NO:1 by a tyrosine residue; and any combination thereof.
[0010] In a preferred embodiment, the amino acid sequence of the polypeptide or fragment according to the present invention contains at least the mutation of substitution of the leucine residue at the position corresponding to position 52 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue. In a more preferred embodiment the amino acid sequence of the polypeptide or fragment according to the present invention contains the above mentioned substitution of the leucine residue at the position corresponding to position 52 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; the deletion of the serine residue at the position corresponding to position 138 in SEQ ID NO:1; and the substitution of the asparagine residue at the position corresponding to position 139 in SEQ ID NO:1 by a glutamine residue. In an even more preferred embodiment, the amino acid sequence of the polypeptide or fragment according to the present invention contains the above mentioned mutations at positions corresponding to all the 10 positions in SEQ ID NO:1.
[0011] HIV-1 envelope proteins that can be used in this invention comprise gp120, gp128, gp140, gp140TM, gp145, gp150, gp160, and an equivalent thereof originated from various HIV-1 strains. For example, the HIV-1 envelope protein can be the gp145 of HIV-1 CN54 having the amino acid sequence of SEQ ID NO:2.
[0012] In a specific embodiment, the invention provides an antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein, wherein the polypeptide or fragment thereof comprises an amino acid sequence derived from SEQ ID NO:2 by introducing a mutation into SEQ ID NO:2, wherein the mutation is selected from the group consisting of: substitution of the leucine residue at position 42 by a glutamic acid residue; deletion of the serine residue at position 128; substitution of the asparagine residue at position 129 by a glutamine residue; substitution of the arginine residue at position 155 by a glutamic acid residue; substitution of the serine residue at position 179 by a glutamic acid residue; substitution of the glutamic acid residue at position 180 by a lysine residue; substitution of the serine residue at position 183 by a glutamine residue; substitution of the glycine residue at position 230 by an arginine residue; substitution of the glycine residue at position 232 by a glutamine residue; substitution of the histidine residue at position 235 by a tyrosine residue; and any combination thereof.
[0013] In a preferred embodiment, the polypeptide or fragment according to the present invention comprises an amino acid sequence derived from SEQ ID NO:2, wherein the amino acid sequence contains at least the mutation of substitution of the leucine residue at position 42 by a glutamic acid residue. In a more preferred embodiment, the amino acid sequence derived from SEQ ID NO:2 contains at least the following mutations: substitution of the leucine residue at position 42 by a glutamic acid residue; deletion of the serine residue at position 128; and substitution of the asparagine residue at position 129 by a glutamine residue. In an even more preferred embodiment, the amino acid sequence derived from SEQ ID NO:2 contains the above mentioned mutations at all the 10 positions.
[0014] An antigenic polypeptide or fragment according to the invention can further comprise substitution, deletion or addition of one or more amino acids, and the polypeptide or fragment thereof is capable of inducing protective immune response. Moreover, the antigenic polypeptide or fragment thereof according to the invention can also contain additional modifications, e.g. deletion or addition of a glycosylation site, deletion or rearrangement of the loop region, deletion of the CFI region, and combinations thereof.
[0015] In another aspect, the invention provides a polypeptide vaccine comprising the above described antigenic polypeptide or fragment thereof according to the present invention together with a pharmaceutical acceptable adjuvant and/or carrier.
[0016] In another aspect, the invention also provides an antibody which is capable of specifically binding to the above described antigenic polypeptide or fragment thereof according to the present invention, and the antibody has a broader and higher neutralization activity to HIV-1 virus when compared to an antibody produced by induction with a wild-type envelope protein of HIV-1. Antibodies of the invention comprise polyclonal antibodies, monoclonal antibodies or antigen binding fragments thereof.
[0017] In another aspect, the invention provides an isolated polynucleotide comprising a nucleotide sequence that encodes the above described antigenic polypeptide or fragment thereof according to the invention.
[0018] The invention also provides a DNA construct comprising a polynucleotide operably linked to a promoter, wherein the polynucleotide comprises a nucleotide sequence that encodes the above described antigenic polypeptide or fragment thereof according to the invention. The present invention also provides a DNA vaccine comprising the above mentioned DNA construct together with a pharmaceutical acceptable adjuvant.
[0019] The invention also provides a recombinant viral vector vanccine, which comprises a recombinant viral vector carrying a polynucleotide together with a pharmaceutical acceptable adjuvant, wherein the polynucleotide comprises a nucleotide sequence that encodes the above described antigenic polypeptide or fragment thereof according to the invention. Preferably, the recombinant viral vector is a replicative viral vector, e.g. a replicative recombinant vaccinia vector such as a recombinant vaccinia Tian Tan strain.
[0020] Additionally, the invention also provides a recombinant bacterial vector vaccine, which comprises a recombinant bacterial vector carrying a polynucleotide together with a pharmaceutical acceptable adjuvant, wherein the polynucleotide comprises a nucleotide sequence that encodes the above described antigenic polypeptide or fragment thereof according to the invention.
[0021] In other aspect, the invention also provides a method for preventing or treating HIV-1 virus infection comprising a step of administering the polypeptide vaccine and/or the DNA vaccine and/or the recombinant viral vector vaccine and/or the recombinant bacterial vector vaccine of the invention to a subject in need thereof, or administering the antibody of the invention to a subject in need thereof.
DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 : The restriction analysis results of 7 DNA vaccines:
[0023] Lane 1 is the restriction analysis result of pDRVISV145M1R; lane 2 is the restriction analysis result of pDRVISV145M2R; lane 3 is the restriction analysis result of pDRVISV145M3; lane 4 is the restriction analysis result of pDRVISV145M4R; lane 5 is the restriction analysis result of pDRVISV145M5R; lane 6 is the restriction analysis result of pDRVISV1452M; lane 7 is the restriction analysis result of pDRVISV1455M. As shown in this figure, the size of each vaccine vector gene is 5 Kb, and the size of the inserted target gene is 2.1 Kb.
[0024] FIG. 2 : Identification of 7 DNA vaccines by PCR:
[0025] Lane 1 is the PCR product of pDRVISV145M1R; lane 2 is the PCR product of pDRVISV145M2; lane 3 is the PCR product of pDRVISV145M3R; lane 4 is the PCR product of pDRVISV145M4R; lane 5 is the PCR product of pDRVISV145M5R; lane 6 is the PCR product of pDRVISV1452M; lane 7 is the PCR product of pDRVISV1455M. As shown in this figure, the size of each inserted target gene is 2.1 Kb.
[0026] FIG. 3 : The immunoblot analysis of each DNA vaccines:
[0027] Lane 1 is the expression result of pDRVISV145M1R; lane 2 is the expression result of pDRVISV145M2R; lane 3 is the expression result of pDRVISV145M3R; lane 4 is the expression result of pDRVISV145M4R; lane 5 is the expression result of pDRVISV145M5; lane 6 is the expression result of pDRVISV1452M; lane 7 is negative control; lane 8 is the expression result of pDRVISV1455M. As shown in this figure, each inserted target gene can be correctly expressed.
[0028] FIG. 4 : Identification of recombinant vaccinia vectors by PCR:
[0029] Lane 1 is the PCR result of rTV145 PCR; lane 2 is the PCR result of rTV1455M PCR. As shown in this figure, each inserted target gene is at the correct size of 2.1 Kb.
[0030] FIG. 5 : The immunoblot analysis of the products expressed by recombinant vaccinia vectors:
[0031] Lane 1 is the cellular expression product of Chicken Embryo Fibroblasts (CEF), serving as a negative control; lane 2 is the expression result of wild-type vaccinia Tian Tan strain in CEF, serving as a negative control; lane 3 is the expression result of rTV145 in CEF; lane 4 is the expression result of rTV1455M in CEF. As shown in this figure, the size for the expression products of target genes are 145 KD, indicating that the inserted target genes can be correctly expressed.
[0032] FIG. 6 : ELISA assay of the titers of specifically binding antibodies:
[0033] The average titer of specifically binding antibodies stimulated by antigen 1455M is much higher than that stimulated by unaltered antigen gp145; the antibody titer thereof is increased for more than 3.5 fold (p=0.0020) (* means the p value is less than 0.05, and there is statistically significant difference; **means the p value is less than 0.005, and there is extremely statistically significant difference). The average titer of specifically binding antibodies stimulated by 1455M can reach 2400, the highest titer can reach 9600, which is significantly higher than that of unaltered gp145 (p=0.0177). The reaction intensity of antibodies induced by 145M1R is also significantly higher than that of gp145 (p=0.0177).
[0034] FIG. 7 : Dectection of the neutralization antibody activity of guinea pig sera (1:10 diluted) sampled at the 14 th week:
[0035] The antibodies induced in gp145 immunization group show limited neutralization activity, about ¼ of the guinea pigs display the ability to neutralize all the 8 clinical isolates; while in 1455M immunization group, at least ¾ of the guinea pigs display neutralization activity to all isolates.
[0036] FIG. 8 : Dectection of the neutralization antibody activity of guinea pig sera (1:10 diluted) sampled at the 16 th week:
[0037] The antibody spectrum induced in gp145 immunization group is narrow, half of the B′ sub-type virus are not neutralized; while ¾ of the serum samples from 1455M immunization group guinea pigs shows neutralization activity to all isolates.
[0038] FIG. 9 : Dectection of the neutralization antibody titer of guinea pig sera sampled at the 14 th week:
[0039] Only few guinea pig sera in gp145 immunization group show neutralization activity at 1:10 dilution; while most of the guinea pigs in 1455M immunization group show neutralization activity with titer higher than 1:10.
[0040] FIG. 10 : Dectection of the neutralization antibody titer of guinea pig sera sampled at the 16 th week:
[0041] Most of the guinea pig sera in 1455M immunization group can completely neutraliz all the virus, with the highest titer up to 1:270; while only a few guinea pig sera in gp145 immunization group have an antibody titer higher than 1:10.
DETAILED DESCRIPTION
[0042] Based on the characteristic amino acid mutations of the attenuated live EIAV vaccine, the inventors modified the amino acids in corresponding structural and functional positions of HIV-1 envelope protein.
[0043] Both EIAV and HIV are members of Lentivirus, they have the same genome structures and replication modes, and proteins of similar categories and functions. Therefore, the study on attenuated live EIAV vaccine may provide instructions for the modifications of HIV-1 envelope antigen. But there also exist clear differences in their underlying mechanisms of pathogenesis. At the same time, the primary purpose for the development of attenuated live EIAV vaccine is the attenuation rather than increasing immunogenicity. Hence, this modification approach has not been considered as promising by researchers in HIV vaccine development.
[0044] Up to now, the attenuated live EIAV vaccine developed in China is the only widely used lentiviral vaccine. Since the initial national application in 1979, more than 60 millions of Equus animals have been immunized, controlling the epidemics of the disease. In respect to safety, the vaccine also has been successfully tested for several decades by in-the-field application. EIAV vaccine is attenuated live vaccine developed by Harbin Veterinary Research Institute of Chinese Academy of Agricultural Sciences in 1970s. The vaccine was developed with traditional methods, the nomenclature in the development and passaging process of the vaccine will be briefly described: the wild-type viral strain was isolated from an infected horse in Liaoning Province, referred to as EIAV LN strain (LN). The LN strain was fisrt passaged in donkey for 100 generations to obtain donkey virulent strain (D510), D510 was then passaged on donkey leucocyte for 121 generations to obtain the attenulated live vaccine strain (referred to as donkey leucocyte virus, DLV), which was finally adaptively passaged on fetal donkey dermal cell for 10 generations to obtain fetal donkey dermal cell vaccine strain (FDDV) (Chinese Patent Nos.: 99105852.6 and 99127532.2, U.S. Pat. No. 6,987,020B1).
[0045] Through sequencing the full length envelope proteins of attenuated live EIAV vaccine strains (DLV (SEQ ID NO:5), FDDV (SEQ ID NO:6)) and virulent stains (LN (SEQ ID NO:3), D510 (SEQ ID NO:4)), the inventors found that there are 10 characteristic amino acid mutations on the envelope protein of the attenuated live EIAV vaccine, as shown in Table 1.
[0000]
TABLE 1
10 characteristic amino acid mutations and their positions
on the envelope protein of attenuated live EIAV vaccine
amino acid position number in
46
97
99
102
188
189
192
235
236
320
EIAV envelope protein
amino acid residues in EIAV
A
G
K (H)
H
K
E
S
D
N
K
virulent stains
amino acid residues in attenuated
E
R
Q
Y
E
K
N
—
K
N (E)
Live EIAV vaccine stains
— denotes deletion of amino acid residue
[0046] Based on primary amino acid sequence, structural arrangement in loop region, the formation of disulfide linkages, structure of conservative amino acids, known functional sites as well as number and arrangement of glycosylation sites etc., the inventors performed modifications on the HIV-1 envelope protein according to the characteristic amino acid mutations of the attenuated Live EIAV vaccine.
[0000]
TABLE 2
Characteristics amino acid mutations of EIAV envelope protien
and the mutations and positions on HIV envelope protien after modification.
positions of mutations on EIAV
envelope protein.
positions of mutations on HIV
attenuated live
envelope protein (3)
virulent stains
vaccine stains
domain
before modification
after modification
domain
43 SHKAEMAE 50
43 SHK EMAE 50 (1)
C1
37 GATTLFCA 45
37 GATTT FCA 45
C1
region
region
235 SDNNTW 240
235 S NTW 240 (2)
V4
125 SSNSNDTY 132
125 SSN DTY 132
V1
region
region
317 TNIKRPDY 324
317 TNI RPDY 324
V5
152 TVVRDRK 158
152 TVV DRK 158
V2
region
region
188 LKENSSN 194
188 L NS N 194
V3
178 YSENSSE 184
178 Y NS E 184
V2
region
region
94 WYEGQKHSHYI 104
94 WYE Q HS YI 104
V1
227 IFNGTGPCHNV 237
227 IFN T PC NV 237
C2
region
region
1 positions with bold underline are mutation positions;
2 - denotes the deletion of the amino acid;
3 The amino acid positions og HIV envelope protien are corresponding to the positions on gp145 amino acid sequence if HIV-1 CN54 (SEQ ID NO: 2).
[0047] Accordingly, in one aspect, the present invention provides an antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein, wherein the polypeptide or fragment comprises an amino acid sequence containing a mutation selected from the group consisting of: substitution of the leucine residue at a position corresponding to position 52 (in C1 region) in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; deletion of the serine residue at a position corresponding to position 138 (in V1 region) in SEQ ID NO:1; substitution of the asparagine residue at a position corresponding to position 139 (in V1 region) in SEQ ID NO:1 by a glutamine residue; substitution of the arginine residue at a position corresponding to position 166 (in V2 region) in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; substitution of the serine residue at a position corresponding to position 184 (in V2 region) in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; substitution of the glutamic acid residue at a position corresponding to position 185 (in V2 region) in SEQ ID NO:1 by a lysine, an arginine or a histidine residue; substitution of the serine residue at a position corresponding to position 188 (in V2 region) in SEQ ID NO:1 by a glutamine or an asparagine residue; substitution of the glycine residue at a position corresponding to position 235 (in C2 region) in SEQ ID NO:1 by an arginine, a lysine or a histidine residue; substitution of the glycine residue at a position corresponding to position 237 (in C2 region) in SEQ ID NO:1 by a glutamine or an asparagine residue; substitution of the histidine residue at a position corresponding to position 240 (in C2 region) in SEQ ID NO:1 by a tyrosine residue; and any combination thereof.
[0048] The term “polypeptide” as used herein also includes protein. The term “fragment of polypeptide” means a fragment of the polypeptide with immunogenicity and/or antigenicity.
[0049] In a preferred embodiment, the amino acid sequence of the polypeptide or fragment according to the present invention contains at least the mutation of substitution of the leucine residue at the position corresponding to position 52 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue. In a more preferred embodiment, the amino acid sequence of the polypeptide or fragment according to the present invention contains the above mentioned substitution of the leucine residue at the position corresponding to position 52 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue; the deletion of the serine residue at the position corresponding to position 138 in SEQ ID NO:1; and the substitution of the asparagine residue at the position corresponding to position 139 in SEQ ID NO:1 by a glutamine residue. In an even more preferred embodiment, the amino acid sequence of the polypeptide or fragment according to the present invention contains the above mentioned mutations at positions corresponding to all the 10 positions in SEQ ID NO:1.
[0050] In another preferred embodiment, the amino acid sequence of the polypeptide or fragment according to the invention contains a mutation selected from the group consisting of: substitution of the leucine residue at a position corresponding to position 52 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue, deletion of the serine residue at a position corresponding to position 138 in SEQ ID NO:1, substitution of the asparagine residue at a position corresponding to position 139 in SEQ ID NO:1 by a glutamine residue, substitution of the arginine residue at a position corresponding to position 166 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue, substitution of the serine residue at a position corresponding to position 184 in SEQ ID NO:1 by a glutamic acid or an aspartic acid residue, substitution of the glutamic acid residue at a position corresponding to position 185 in SEQ ID NO:1 by a lysine, an arginine or a histidine residue, substitution of the serine residue at a position corresponding to position 188 in SEQ ID NO:1 by a glutamine or an asparagine residue, and any combinations thereof; and optionally comprising: substitution of the glycine residue at a position corresponding to position 235 in SEQ ID NO:1 by an arginine, a lysine or a histidine residue; substitution of the glycine residue at a position corresponding to position 237 in SEQ ID NO:1 by a glutamine or an asparagine residue, substitution of the histidine residue at a position corresponding to position 240 in SEQ ID NO:1 by a tyrosine residue, or combinations thereof.
[0051] The above mentioned positions are defined according to the gp160 amino acid sequence (SEQ ID NO:1) of HIV-1 international standard strain HXB2 (GenBank Accession Number K03455). A person skilled in the art can understand that, for envelope proteins from other HIV-1 strains, the corresponding positions to be mutated on these proteins can be determined according to their sequence alignments with SEQ ID NO:1. For example, using the gp160 amino acid sequence of HIV-1 international standard strain HXB2 as a reference sequence, the corresponding positions of above mentioned mutations can then be determined for gp160 envelope proteins from different HIV-1 strains, and thereby the modifications can be performed on these proteins. The envelope proteins that can be used in this invention include the typical gp120, gp128, gp140, gp140™, gp145, gp150, gp160, and an equivalent thereof (Bimal K. et al. Modifications of the Human Immunodeficiency Virus Envelope Glycoprotein Enhance Immunogenicity for Genetic Immunization JOURNAL OF VIROLOGY, June 2002, p. 5357-5368). A person skilled in the art can understand that, for the above mentioned different forms of HIV-1 envelope proteins, one can also use a similar approach to introduce the above described amino acid mutations into these proteins.
[0052] In a specific embodiment, the envelope protein used in this invention is HIV-1 CN54 envelope protein gp145 (Genbank Accession Number AX149771), which has an amino acid sequence as shown in SEQ ID NO:2.
[0053] Accordingly, the invention provides an antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein, wherein the polypeptide or fragment thereof comprises an amino acid sequence derived from SEQ ID NO:2 by introducing a mutation into SEQ ID NO:2, wherein the mutation is selected from the group consisting of: substitution of the leucine residue at position 42 (in C1 region) by a glutamic acid residue; deletion of the serine residue at position 128 (in V1 region); substitution of the asparagine residue at position 129 (in V1 region) by a glutamine residue; substitution of the arginine residue at position 155 (in V2 region) by a glutamic acid residue; substitution of the serine residue at position 179 (in V2 region) by a glutamic acid residue; substitution of the glutamic acid residue at position 180 (in V2 region) by a lysine residue; substitution of the serine residue at position 183 (in V2 region) by a glutamine residue; substitution of the glycine residue at position 230 (in C2 region) by an arginine residue; substitution of the glycine residue at position 232 (in C2 region) by a glutamine residue; substitution of the histidine residue at position 235 (in C2 region) by a tyrosine residue; and any combination thereof.
[0054] In a preferred embodiment, the polypeptide or fragment according to the present invention comprises an amino acid sequence derived from SEQ ID NO:2, wherein the amino acid sequence contains at least the mutation of substitution of the leucine residue at position 42 by a glutamic acid residue. In a more preferred embodiment, the amino acid sequence derived from SEQ ID NO:2 contains at least the following mutations: substitution of the leucine residue at position 42 by a glutamic acid residue; deletion of the serine residue at position 128; and substitution of the asparagine residue at position 129 by a glutamine residue. In an even more preferred embodiment, the amino acid sequence derived from SEQ ID NO:2 contains the above mentioned mutations at all the 10 positions.
[0055] In another preferred embodiment, the polypeptide or fragment of the invention comprises an amino acid sequence derived from SEQ ID NO:2 by introducing a mutation into SEQ ID NO:2, wherein the mutation is selected from the group consisting of: substitution of the leucine residue at position 42 by a glutamic acid residue, deletion of the serine residue at position 128, substitution of the asparagine residue at position 129 by a glutamine residue, substitution of the arginine residue at position 155 by a glutamic acid residue, substitution of the serine residue at position 179 by a glutamic acid residue, substitution of the glutamic acid residue at position 180 by a lysine residue, substitution of the serine residue at position 183 by a glutamine residue, and any combination thereof; and optionally comprising: substitution of the glycine residue at position 230 by an arginine residue, substitution of the glycine residue at position 232 by a glutamine residue, substitution of the histidine residue at position 235 by a tyrosine residue, and combinations thereof.
[0056] Any appropriate methods known in the art can be used to prepare the antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein according to the invention. For example, after determining the mutation positions and amino acid residues to be introduced, gene splicing by overlap extension PCR(SOE PCR) (Li C H, et al. 2004. Construction of middle fragment deletion mutant with improved gene splicing by overlap extension; Heckman K L, et al. 2007. Gene splicing and mutagenesis by PCR-driven overlap extension) can be used to introduce the desired mutations at corresponding positions in the coding sequence of HIV-1 envelope protein (e.g. CN54 gp145). Due to the use of primers with complementary ends in SOE PCR, the PCR products form overlapped strands, which can be then further extended in subsequent amplification reactions, and thus different amplification fragments can be overlapped and then ligated, so as to obtain the antigenic polypeptide or a fragment thereof according to the invention. Similarly, other approaches that can introduce mutations can also be used for the modification of corresponding positions, such approaches include but not limited to gene synthesis, gene recombination, gene rearrangement processes etc.
[0057] Accordingly, the invention also provides isolated polynucleotide, which comprises a nucleotide sequence that encodes the antigenic polypeptide or a fragment thereof according to the invention.
[0058] After obtaining the polynucleotide that encodes the antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein according to the invention, the polynucleotide can be inserted into a suitable expression vector, and then transformed into suitable host cell for expression, and then the resulting antigenic polypeptide or a fragment thereof according to the mention can be recovered. Expression systems that can be used in the invention to prepare the antigenic polypeptide or a fragment thereof include but not limited to: E. coli . expression systems, such as Condon strain, Gold strain; yeast expression systems; insect expression systems; phage expression systems; mammalian cell expression systems, such as CHO cell, Vero cell.
[0059] A person skilled in the art can understand that, the substitution, deletion or addition of one or more amino acids, such as conservative substitutions of amino acids, can be used to further modify the antigenic polypeptide or a fragment thereof according to the invention, with the prerequisite that the modified polypeptide or fragment should have the above mentioned amino acid mutations and is still capable of inducing protective immune response. Furthermore, besides the introduction of individual amino acid mutation, one can also further modify the antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein, including but not limited to, deletion or addition of glycosylation site, deletion or rearrangement of loop region, deletion of CFI region (the cleavage site sequence, the fusion domain, and a part of the spacer between the two heptad repeats) etc.
[0060] In another aspect, the invention provides a polypeptide vaccine comprising the above described antigenic polypeptide or fragment thereof according to the present invention together with a pharmaceutical acceptable adjuvant. Suitable adjuvants include but not limited to incomplete Freund's adjuvant, aluminum adjuvant, Bacillus Calmette-Guérin (BCG), oil-based emulsion (such as MF59 and Montanide ISA 720), immune stimulant (such as monophosphoryl lipid A), CpG oligonucleotide, saponin (such as QS21), and bacterial exotoxin-based mucosal adjuvant etc. The vaccines containing the antigenic polypeptide or a fragment thereof according to the invention can be in the form of, e.g. polypeptide vaccines, lipopeptide vaccines, dimeric or polymeric vaccines etc.
[0061] In another aspect, the invention also provides a DNA construct comprising a polynucleotide operably linked to a promoter, wherein the polynucleotide comprises a nucleotide sequence that encodes the above described antigenic polypeptide or fragment thereof according to the invention.
[0062] In preferred embodiments, the invention provides a DNA construct constructed based on gp145 amino acid sequence (SEQ ID NO:2) of HIV-1 CN54, wherein the construct encodes the antigenic polypeptide or a fragment thereof derived from HIV-1 envelope protein. In specific embodiments, the invention provides the following constructs:
[0063] Plasmid pDRVISV145M1R, carrying a polynucleotide that encodes the amino acid sequence of SEQ ID NO:2 with the leucine residue at position 42 replaced by glutamic acid residue. The antigenic polypeptide encoded by this plasmid is called “145M1R”, Escherichia coli strain that contains this plasmid was deposited in CGMCC (China General Microbiological Culture collection Center, Datun Road, Chaoyang District, Beijing, China) on May 22, 2008, under the deposit number: CGMCC No. 2508;
[0064] Plasmid pDRVISV145M2R, carrying a polynucleotide that encodes the amino acid sequence of SEQ ID NO:2 with the serine residue at position 128 deleted and the asparagine residue at position 129 replaced by glutamine residue. The antigenic polypeptide encoded by this plasmid is called “145M2R”, Escherichia coli strain that contains this plasmid was deposited in CGMCC on May 22, 2008, under the deposit number: CGMCC No. 2509;
[0065] Plasmid pDRVISV145M3R, carrying a polynucleotide that encodes the amino acid sequence of SEQ ID NO:2 with the arginine residue at position 155 replaced by glutamic acid residue. The antigenic polypeptide encoded by this plasmid is called “145M3R”, Escherichia coli strain that contains this plasmid was deposited in CGMCC on May 22, 2008, under the deposit number: CGMCC No. 2510;
[0066] Plasmid pDRVISV145M4R, carrying a polynucleotide that encodes the amino acid sequence of SEQ ID NO:2 with the serine residue at position 179 replaced by glutamic acid residue, the glutamic acid residue at position 180 replaced by lysine residue and the serine residue at position 183 replaced by glutamine residue. The antigenic polypeptide encoded by this plasmid is called “145M4R”, Escherichia coli strain that contains this plasmid was deposited in CGMCC on May 22, 2008, under the deposit number: CGMCC No. 2511;
[0067] Plasmid pDRVISV145M5R, carrying a polynucleotide that encodes the amino acid sequence of SEQ ID NO:2 with the glycine residue at position 230 replaced by arginine residue, the glycine residue at position 232 replaced by glutamine residue and the histidine residue at position 235 replaced by tyrosine residue. The antigenic polypeptide encoded by this plasmid is called “145M5R”, Escherichia coli strain that contains this plasmid was deposited in CGMCC on May 22, 2008, under the deposit number: CGMCC No. 2512;
[0068] Plasmid pDRVISV1452M, carrying a polynucleotide that encodes the amino acid sequence of SEQ ID NO:2 with the leucine residue at position 42 replaced by glutamic acid residue, the serine residue at position 128 deleted and the asparagine residue at position 129 replaced by glutamine residue. The antigenic polypeptide encoded by this plasmid is called “1452M”, Escherichia coli strain that contains this plasmid was deposited in CGMCC on May 22, 2008, under the deposit number: CGMCC No. 2513; and
[0069] Plasmid pDRVISV1455M, carrying a polynucleotide that encodes the amino acid sequence of SEQ ID NO:2 with all the 10 mutations (i.e., the leucine residue at position 42 replaced by glutamic acid residue, the serine residue at position 128 deleted, the asparagine residue at position 129 replaced by glutamine residue, the arginine residue at position 155 replaced by glutamic acid residue, the serine residue at position 179 replaced by glutamic acid residue, the glutamic acid residue at position 180 replaced by lysine residue, the serine residue at position 183 replaced by glutamine residue, the glycine residue at position 230 replaced by arginine residue, the glycine residue at position 232 replaced by glutamine residue, the histidine residue at position 235 replaced by tyrosine residue), the antigenic polypeptide encoded by this plasmid is called “1455M”, Escherichia coli strain that contains this plasmid was deposited in CGMCC on May 22, 2008, under the deposit number: CGMCC No. 2514.
[0070] As shown in the examples hereinafter, DNA constructs that respectively carry 1455M, 1452M, 145M1R, 145M2R, 145M3R, and 145M4R can all induce in BALB/c mice model the production of significantly increased specifically-binding antibodies and broad-spectrum neutralizing antibodies with high titers, and the 1455M antigen that contains all the 10 amino acid mutations can stimulate the neutralizing antibody with the broadest spectrum. It can be seen from the results of the examples hereinafter, the mutation of the leucine at position 42 replace by glutamic acid seems to be a key position among the 10 tested mutants, 145M1R, 1452M, 1455M with this mutation can all induce broad-spectrum neutralizing antibodies with high titers; but when compared to 1455M, neutralizing antibody induced by 145M1R cannot neutralize some of the tested HIV-1 clinical isolates, such as XJDC6371. Other mutation positions M2R, M3R, M4R have same effect on increasing the broad spectrum of neutralizing antibodies.
[0071] Not intending to be limited by theories, the inventors predict that the mutation at position 42 increases the α-helical structure in envelope proteins. It has been reported that, the epitopes of cytotoxic T lymphocytes (CTL) related to the protection from vaccine are highly concentrated in the α-helical regions of various HIV-1 proteins (Yusim, K., et al. 2002. Clustering patterns of cytotoxic T-lymphocyte epitopes in human immunodeficiency virus type 1 (HIV-1) proteins reveal imprints of immune evasion on HIV-1 global variation. Journal of virology 76:8757-8768). The α-helical fragment structure induces protective CTL reaction, an effective neutralizing antibody reaction can also be similarly induced. Furthermore, the deletion of the serine residue at position 128 and the mutation at position 129 only lead to the deletion of glycosylation site but do not cause changes in secondary structure; however they can also induce broad-spectrum neutralizing antibody reaction. Based on existing publications (Koch, M., et al. 2003. Structure-based, targeted deglycosylation of HIV-1 gp120 and effects on neutralization sensitivity and antibody recognition. Virology 313:387-400), the inventors think that the deletion of glycosylation site may cause the envelope protein unable to form the oligo-glicoside chain that covers the epitopes, making some of the neutralizing epitopes on the envelope proteins exposed, so as to induce the broad-spectrum neutralizing antibody reaction.
[0072] A person skilled in the art are able to prepare antigenic polypeptides with various other combinations of the mutations, as well as the corresponding DNA construct and further test the protective effects thereof.
[0073] The present invention also provides a DNA vaccine comprising the above mentioned DNA construct together with a pharmaceutical acceptable adjuvant. After administered in vivo, DNA vaccines of the invention can express the above mentioned antigenic polypeptide or a fragment thereof according to the invention.
[0074] Moreover, the invention also provides a recombinant viral vector vaccine, which comprises a recombinant viral vector carrying a polynucleotide together with a pharmaceutical acceptable adjuvant. After administered in vivo, recombinant viral vector vaccines of the invention can express the above mentioned antigenic polypeptide or a fragment thereof according to the invention.
[0075] Recombinant viral vector vaccines that can be used in the invention include but not limited to vaccinia vector, adenovirus vector, adeno-associated virus vector, sendai virus vector, herpes simplex virus vector, human papillomavirus vector, and retroviral vector. Preferably, the recombinant viral vector is a replicative viral vector.
[0076] In a specific embodiment, the recombinant viral vector vaccine of the invention is a replicative recombinant vaccinia Tian Tan strain, which carries polypeptides encoding antigen 1455M. As shown in the examples hereinafter, using the replicative recombinant vaccinia Tian Tan strain, estimations for the immunogenicity of antigens have been carried out in BALB/c female mice model and Huntley guenea pig model. The results show that: the antigen 1455M can significantly stimulate the specific humoral immunity of BALB/c mice and guinea pigs; in particular, the produced neutralizing antibodies have broader antibody-spectrum and higher antibody titers. Furthermore, the protective antibodies can be maintains in guinea pigs for at least 6 weeks. This is by far one of the best known neutralizing antibody results obtained without adding adjuvant.
[0077] A person skilled in the art can understand that, it is also possible to insert the polynucleotides of the invention into attenuated pathogenic bacteria or symbiotic bacteria, so as to prepare recombinant bacterial vector vaccines. After administered to human, such vaccines can present and express antigens encoded therein. Accordingly, the invention also provides a recombinant bacterial vector vaccine, which comprises a recombinant bacterial vector carrying a polynucleotide together with a pharmaceutical acceptable adjuvant, the polynucleotide comprises a nucleotide sequence that encodes the above described antigenic polypeptide or fragment thereof according to the invention. Attenuated bacterial vectors that can be used in this invention include but not limited to attenuated Salmonella, Mycobacterium bovis (BCG), Listeria monocytogenes, shigella, Yersinia enterocolitica, Bordetella pertussis , and Bacillus anthracis . Symbiotic bacterial vectors that can be used in this invention include but not limited to Lactobacillus, Streptococcus gordoni, Staphylococcus.
[0078] The invention also provides a method for preventing or treating HIV-1 virus infection comprising administering the polypeptide vaccine and/or the DNA vaccine and/or the recombinant viral vector vaccine and/or the recombinant bacterial vector vaccine of the invention to a subject in need thereof.
[0079] The vaccines of the invention can be administered through any suitable immunization routes, such as patching; hypodermic, intramuscular, intravenous and intraperitoneal injection etc. Immunization strategies include mucosal immunity and cross immunity etc. A person skilled in the art can understand that, the polypeptide vaccines or DNA vaccines of the invention can be used together with such materials as lipids and nano materials etc. that can increase the presenting efficiency of antigens.
[0080] In another aspect, the invention provide antibodies, which are capable of specifically binding to a polypeptide or fragment thereof according to this invention, and has a broader and higher neutralization activity to HIV-1 virus when compared to an antibody produced by induction with a wild-type envelope protein of HIV-1.
[0081] After administering the polypeptide (or a fragment thereof) vaccines or DNA vaccines of the invention to animals, a protective immune response can be induced, which has a broad-spectrum and is against clinical isolates of various sub-types of HIV-1 from different regions. This suggests that the induced antibodies are different to most of the previous antibodies induced by natural envelope proteins. Using antibody preparation techniques known in the art like hybridoma, it is possible to utilize the polypeptides or fragments thereof or polynucleotides that encode these polypeptides or fragments of the invention to prepare monoclonal antibodies, wherein the neutralization activity of said antibodies against HIV-1 virus are higher than the antibodies produced by induction with a wild-type envelope protein of HIV-1. For example, it is possible to prepare monoclonal antibodies or antigen binding fragments thereof such as intact immunoglobulin molecules, mice-derived antibodies, humanized antibodies, chimeric antibody, scFv, Fab fragments, Fab′ fragments, F(ab′)2, Fv, and disulfide-linked Fv etc. These antibodies have wide application perspectives in the filed of HIV passive immunity.
[0082] Accordingly, the invention also provides a method for preventing or treating HIV-1 virus infection comprising administering the antibody of the invention to a subject in need thereof.
[0083] The invention will be further described with specific examples.
EXAMPLES
Example 1
Construction of DNA Vaccines that Contain Mutations
[0084] 1. Using PCR to Introduce Mutation Positions
[0085] Recombinant plasmid pDRVISV145 (also called PT-140™/DH5a (CGMCC No. 1439)) was used as template to amplify target fragment through PCR (GeneAmp PCR System 9700 Amplifier (Applied Biosystem, USA)). Primers are as follows:
[0000]
Target fragments
Primer pairs
Primer sequences
145M1R
145M1R position upstream primer
SEQ ID NO: 9
gp145 downstream primer
SEQ ID NO: 8
gp145 upstream primer
SEQ ID NO: 7
145M1R position downstream
SEQ ID NO: 10
primer
145M2R
145M2R position upstream primer
SEQ ID NO: 11
gp145 downstream primer
SEQ ID NO: 8
gp145 upstream primer
SEQ ID NO: 7
145M2R position downstream
SEQ ID NO: 12
primer
145M3R
145M3R position upstream primer
SEQ ID NO: 13
gp145 downstream primer
SEQ ID NO: 8
gp145 upstream primer
SEQ ID NO: 7
145M3R position downstream
SEQ ID NO: 14
primer
145M4R
145M4R position upstream primer
SEQ ID NO: 15
gp145 downstream primer
SEQ ID NO: 8
gp145 upstream primer
SEQ ID NO: 7
145M4R position downstream
SEQ ID NO: 16
primer
145M5R
145M5R position upstream primer
SEQ ID NO: 17
gp145 downstream primer
SEQ ID NO: 8
gp145 upstream primer
SEQ ID NO: 7
145M5R position downstream
SEQ ID NO: 18
primer
[0086] Reaction system: Plasmid template 0.5 μl, Pyrobest Taq (5 U/μl) 0.5 μl (Takara), 10× Pyrobest Taq Buffer (MgCl2 added) 5 μl, dNTP (2.5 mM) 4 μl, upstream primer 1 μl, downstream primer 1 μl, adding ddH 2 O to 50 μl (200 μl PCR tube with protuberant cap, Axygen). Reaction conditions: 94° C. 5 min predenature; 94° C. 50 seconds, annealing temperature 50 seconds, 72° C. 2 min, for 35 cycles; 72° C. extension 10 min. Only gp145 upstream primer/145M3R position downstream primer use 60° C. as annealing temperature; the others primers all use 65° C. as annealing temperature. The resulting target gene is recovered from gel (Omega E.Z.N.A. Gel Extraction Kit E.Z.N.A Cycle-Pure Kit). Using the two gene fragments corresponding to each mutation position as template, gp145 upstream primer and gp145 downstream primer as primers, the target gene was amplified through PCR. Reaction system: plasmid template each 0.5 μl, Ex Taq (5 U/μl) 0.5 μl, 10× Ex Taq Buffer (MgCl2 added) 5 μl, dNTP (2.5 mM) 4 μl, upstream primer 1 μl, downstream primer 1 μl, adding ddH 2 O to 50 μl. Reaction conditions: 94° C. 5 min predenature; 94° C. 50 seconds, 68° C. 50 second, 72° C. 2 min, for 35 cycles; 72° C. extension 10 min. The 5 resulting target gene fragments were recovered from gel: 145M1R, 145M2R, 145M3R, 145M4R and 145M5R. Using 145M1R as template, 145M2R position upstream primer and gp145 downstream primer, gp145 upstream primer and 145M2R position downstream primer as primer pairs, the target fragments were amplified through PCR, using the same conditions as above. Then using the 2 target gene fragments recovered from gel as template, gp145 upstream primer and gp145 downstream primer as primers, target gene with the second mutation position was amplified through PCR, using the same conditions as above. The 1452M fragment (containing 145M1R and 145M2R) was recovered from gel. Using 1452M as template, same method as above, a further PCR was performed to introduce mutations. As such, until the 1455M fragment with all the 10 mutations introduced was obtained.
[0087] 2. Restriction enzymes EcoR V and BamH I (Takara) were used to digest HIV-1 CN54 145M1R, 145M2R, 145M3R, 145M4R, 145M5R, 1452M, 1455M and DNA vaccine vector pDRVISV1.0 (CN1560259 (China Patent Application: 200410028280.3); and Haishan Li, et al. Enhancement of Gag-Specific Immune Responses Induced by DNA Vaccination by Incorporation of a 72-bp element from SV40 Enhancer in the Plasmid Vector. Chinese Medical Journal (English) 2007; 120 (6):496-502). Digestion system: plasmids or target genes 10 μl, EcoR V 2 μl, BamH I 2 μl, 10× BamH I buffer K 5 μl, adding ddH 2 O till a total volume 50 μl, 37° C. incubation for 4 h, agarose (GIBCO) gel electrophoresis was performed for separation. Fragment with corresponding size (the inserted target gene fragment is about 2.1 kb, the vector fragment is about 5 kb) was cut for agarose gel recovery (Omega, E.Z.N.A. Gel Extraction Kit E.Z.N.A Cycle-Pure Kit).
[0088] 3. Ligation reaction system: 2× Rapid Ligation Buffer (NEB) 5 μl, the recovered product of synthetic target gene fragment 3 μl, the recovered product of vector fragment T4 DNA ligase (NEB) 1 μl, were allowed for ligation at 4° C. for 8 hours. The ligation products are transformed to E. coli . DH5α competent cells (Takara), spreaded on plate (Qingdao α Medical Mechine) with kanamycin sulfate (Beijing 2 nd Pharm.), 37° C. incubation for 16 h. Monoclonal colonies were picked and inoculated into 3 ml LB medium (Amersham) with 60 μg/ml kanamycin, and cultured at 37° C. for 16 h, shaken at 200 rpm (HZQ-X100 Culture Shaker from Harbin). Omega E.Z.N.A. Plasmid Miniprep Kit I was used to extract mini-preparations of plasmids. After digestion with enzymes, PCR identification, correctly identified plasmids were sent to Invitrogen for sequencing confirmation. Correctly identified plasmids were named as: pDRVISV145M1R, pDRVISV145M2R, pDRVISV145M3R, pDRVISV145M4R, pDRVISV145M5R, pDRVISV1452M and pDRVISV1455M. For enzyme digestion results see FIG. 1 ; PCR identification results see FIG. 2 ; it can be seen from the Figures that the constructed plasmids all have correctly inserted target genes.
[0089] 4. Immunoblot Assay of the Expression of Inserted Target Genes
[0090] 1) Transfected 293T cells (purchased from ATCC) were collected by 10000 rpm centrifugation (Sigma) to prepare protein samples which were then run on 10% SDS-PAGE electrophoresis; ((29:1) Acrylamide from SIGMA; Hoefer EPS 2A200 and PowerPAC1000 both from Bio-Rad);
[0091] 2) Whatman filter paper (Whatman) was cut into same size as the gel, 3 pieces soaked in positive electrode solution, pieces soaked in negative electrode solution; (10× electro-transfer buffer stock: 0.25M Tris (Sigma), 1.92M Glycine (Sigma), 1% SDS (Sigma), pH8.3; positive electrode solution: 7 volumes of stock, 2 volumes of methanol, 1 volume ddH 2 O; negative electrode solution: 1 volume stock, 9 volumes ddH 2 O);
[0092] 3) After electrophoresis at constant voltage 120 V for 45 min, the gel was soaked in negative electrode solution;
[0093] 4) PVDF membrane (Sigma) was soaked in methanol for 15 seconds, then washed with deionized water for 4 times, and then the PVDF membrane was placed in the positive electrode solution and soak for 10 min;
[0094] 5) From the negative electrode to the positive electrode, negative electrode filter paper, gel, PVDF membrane, positive electrode filter paper were placed in this order onto electo-transfer instrument (Bio-Rad), be careful to remove any bubbles between different layers, 10 mA constant stream for 45 min;
[0095] 6) PVDF membrane was taken out and then placed into deionized water and washed 3 times;
[0096] 7) The membrane was then placed into PBS solution with 5% skim milk and blocked for 12 h at 4° C.;
[0097] 8) The membrane was then placed into PBST and washed 3 times, then placed into blocking solution with 1% HIV-1 positive serum, at room temperature for 2 h, PBST washing 5 times;
[0098] 9) Then the membrane was placed into sheep-anti-human IgG-HRP (Zhongshan Jinqiao, Beijing) which was 1:2000 diluted using PBS solution with 5% skim milk, room temperature for 1 hour, PBST washing 5 times;
[0099] 10) Adding color development solution (18 ml ddH 2 O, 2 ml NiCl 2 , 200 μl 1M pH7.6 Tris-HCl, DAB (Sigma) 6 mg, H 2 O 2 30 μl), developing at room temperature for 10 min, washing with distilled water to terminate the reaction.
[0100] The expression identification results of DNA constructs can be seen in FIG. 3 . The results indicate that: all the 7 antigens can be correctly expressed.
Example 2
Construction of Recombinant Tian Tan Strains Using the Mutants
[0101] 1. The Construction of Shuttle Plasmid pSC65 (Deposited as: CGMCC No. 1097)
[0102] Restriction enzymes Xba I and Pml I (Takara) were used to cut HIV-1 CN54 gp145 and 1455M genes from sequencing-confirmed pDRVISV145 and pDRVISV1455M respectively, after gel purification, high fidelity Taq (Takara) was conducted to extend and make the ends blunt; then linked by blunt end ligation process into Sma I (Takara) mono-digested and dephosphorylated pSC65 vector. High fidelity Taq reaction system: Pyrobest Taq 0.5 μl, dNTP (Takara) 1 μl, 10× Pyrobest Taq Buffer (MgCl 2 added) 1 μl, adding deionized water to 10 μl. Reaction condition was: 72° C., 5 min. CIP (NEB) dephosphorylation system: CIP 1 μl, NEB buffer 3 2 μl, deionized water 7 μl. The ligation product was used to transform E. coli . DH5a competent cells, and then spreaded on plate with kanamycin sulfate, cultured at 37° C. for 16 h. Monoclonal colony was picked and inoculated into 3 ml LB medium (Amersham) with 50 μg/ml penicillin, cultured at 37° C. for 18 h, shaken at 200 rpm. The plasmids were then subjected to enzyme identification and PCR identification, correctly identified plasmids were named as pSC145 and pSC1455M, respectively. Escherichia coli strain that contains plasmid pSC1455M was deposited in CGMCC on May 22, 2008, under the deposit number: CGMCC No. 2515. After identification, the two shuttle plasmids were correctly constructed.
[0103] 2. Construction, Purification and Amplification of Recombinant Vaccinia Tian Tan Strain
[0104] 1) vaccinia Tian Tan strain (Purchased from National Vaccine and serum Institute, Beijing) was used in a dose of 0.1 MOI (multiplicity of infection) to infect 143B cells (purchased from ATCC), incubated at 37° C. for 1 hour;
[0105] 2) Adding 250 μl Eagle's medium without serum or antibiotics (purchased from China Center for Disease Control and Prevention) into each of two Eppendorf tubes (Axygen), adding 8 μg plasmid pSC145 or pSC1455M into one of the tube, mixed; adding 10 μl Lipofectamine 2000 transfection agent (Invitrogen) into another tube, mixed; incubation at room temperature for 5 min;
[0106] 3) Mixing the solutions of the two Eppendorf tubes, place at room temperature for 30 min;
[0107] 4) Using 5 ml Eagle's medium without serum or antibiotics to wash the cells for 2 times, and then adding 3 ml Eagle's medium without serum or antibiotics;
[0108] 5) Adding the mixture of DNA plasmids and Lipofectamin2000 into T25 cell culture flask (Corning Costar), incubate at 37° C. in CO2 incubator (SANYO);
[0109] 6) 4 h later, using 4 ml Eagle's maintaining medium to change the solution, then incubating at 37° C. in CO2 incubator, incubating for another 48 h and then using low melting temperature agarose (Gibco) for plaque selection;
[0110] 7) Preparing the low melting temperature agarose: 2% low melting temperature agarose, adding same volume of 2× Eagle′ s complete medium (purchased from China Center for Disease Control and Prevention), adding X-gal (Promega) to final concentration of 200 μg/ml, adding Neutral Red (purchased from China Center for Disease Control and Prevention) to final concentration of 50 μg/ml, slightly pipetting, avoiding the formation of bubbles;
[0111] 8) Carefully pouring the medium in the flask, slowly adding 40° C. plaque solution, waiting until the solution was solidified and then placing the flask into 37° C. CO2 incubator (SANYO);
[0112] 9) Incubating for 4 h and then observing whether the cell present blue plaques;
[0113] 10) Picking blue plaque, and then adding it to 500 μl Eagle's maintaining solution, repeatedly freezing and thawing for 3 times and then storing for future use;
[0114] 11) Pipetting 200 μl of the above mentioned solution that has been repeatedly frozen and thawed for 3 times, adding it in to 80%-90% smeared 143B cells, incubating at 37° C. in CO2 incubator for 48 h, observing the plaque situation, performing the plaque selection and picking again, repeating in this way until more than 5 generations, the resulting purified recombinant vaccinia virus rTV145 and rTV1455M were obtained;
[0115] 12) Discarding the Eagle's medium with 10% bovine serum (Gibco) for Chicken Embryo cell cultures, and changing to half volume of Eagle's maintaining medium with 2% bovine serum. Using the dose of 5MOI to infect Chicken Embryo cells, after mixing, incubating it at 37° C. in 5% CO2 incubator; 2 h later, supplementing the other half volume of Eagle's maintaining medium with 2% bovine serum, then incubating at 37° C. in 5% CO2 incubator (SANYO);
[0116] 13) 48 h later, discarding the cell culture medium, using sterile PBS to wash once, using 1 ml PBS to collect virus, repeatedly freezing and thawing twice and then storing in aliquotes in −80° C. fridge (SANYO).
[0117] Purified recombinant virus was identified with PCR and immunoblot. Results are shown in FIGS. 5 & 6 . The results show that, the constructed recombinant vaccinia can correctly express the inserted gp145 and 1455M genes.
Example 3
Comparison Assay of the Immunogenicity of the Modified Antigens
[0118] 1. Experimental Animals and Immunizing Protocol
[0119] BALB/c female mice (H-2d), 6-8 weeks old, weight 18-25 gram, were purchased from the Institute of Laboratory Animal Science, Chinese Academy of Medical Sciences, and were grown in The Institute of Laboratory Animal Science, Chinese Academy of Medical Sciences.
[0120] Huntley female guinea pigs, 6-8 weeks old, 180 g-220 g, were purchased from National Institute for the Control of Pharmaceutical and Biological Products, and were grown in The Institute of Laboratory Animal Science, Chinese Academy of Medical Sciences.
[0121] 7 BALB/c female mice per group were immunized with DNA vaccines at the 0, 2, 4, 6 week respectively, at the 9 th week blood samples were taken from eye, the whole blood was incubated at 37° C. for 1 h, and then centrifuged at 3000 rpm to separate serum for examination. 4 Huntley female guinea pigs per group were immunized with DNA vaccines at the 0, 2, 4 week respectively, at the 10 th week vaccinia strengthening immunization was performed, at the 14 th , 16 th week, blood samples were taken from heart, the whole blood was incubated at 37° C. for 1 h, and then centrifuged at 3000 rpm to separate serum for examination.
[0122] Each mouse was intramuscularly injected at tibialis anterior with 100 μg DNA vaccine (1 mg/ml), each hind leg with 50 μg. Huntley female guinea pig was intramuscularly injected 250 μg (1 mg/ml) at each hind leg, the immuinizing dose of vaccinia was 1×10 7 PFU (Plaque forming unit).
[0123] 2. ELISA Assay of Specifically Binding Antibodies
[0124] 1) Using coating solution (Na 2 CO 3 1.59 g (Sigma), NaHCO 3 2.93 g (Sigma), adding deionized water to 1000 ml, mixed and then kept at 4° C.) to dilute HIV-1 CN54 envelope protein gp120 antigen (Expressed, purified and prepared in our group, the purity is higher than 90%; the preparation method can be found in master thesis of Jie Feng “The expression purification and primary application of recombinant HIV-1 envelope glycoprotein gp120 and gp4”) to about 5 μg/ml, adding to 96-well palte (Corning Costar) at 100 μl/well, 4° C. coating for 12 h, 1×PBS washing 3 times, adding 200 μl coating solution (PBST formulated 5% BSA (Sigma)) to each well, 37° C. incubate for 1 h.
[0125] 3) 1×PBST washing 3 times, immunity mice sera were double diluted in two series starting from 1:100 and 1:200 respectively, adding 100 μl of serial dilutedsera to each well, and each plate had 2 empty, 2 positive control and 2 negative control wells, 37° C. incubation for 1 h.
[0126] 4) 1×PBST washing 5 times, adding 100 μl 1:2000 diluted sheep-anti-mice IgG-HRP, 37° C. incubation for h.
[0127] 5) 1×PBST washing 5 times, adding 100 μl OPD color development substrate (Sigma), develop at room temperature for 15 min in dark.
[0128] 6) Adding 50 μl 2M sulfate (purchased from Beijing Chemical Agent Company) to each well to terminate the reactions, using ELISA Reader (Thermo Electron Corporation Multiscan ascent plate reader 354) to detect the absorption (A) value for each well at 492 nm wave length. If the absorption of experiment well/control well was larger than 2:1, then the well was determined as positive well.
[0129] The results are shown in FIG. 6 . The results show that, the average specifically-binding antibody titer stimulated by 1455M DNA vaccine alone is much higher than that stimulated by gp145 DNA vaccine; the antibody titer is increased for more than 3.5 fold (p=0.0020). Additionally, it is confirmed in further experiment that, the increase of binding antibody is caused by mutations contained in 1452M; 1452M vaccine can induce much higher average binding antibody titer than gp14, the average antibody titer thereof can reach up to 2400, the highest average titer can reach 9600. While other vaccines like 145M3R, 145M4R, 145M5R do not increase antibody titer after immunization, on the contrary the binding antibody reaction intensity is somehow decreased. The data of the third experiment show that, 145M1R vaccine can induce similar binding antibody titer like 1452M vaccine; through statistic analysis, it has been shown that two groups of specifically-binding antibody titer are significantly higher than unaltered gp145 (p=0.0177, N=8; p=0.0083, N=8). And the data show that the antibody titer induced by 145M1R is slightly higher than that of 1452M vaccine group, the reaction intensity thereof shows extremely significant difference (p=0.0083, N=8). Two experimental results of primates and one clinical experimental result suggest that specifically-binding antibody relates to immune protection. Our altered antigen 1455M (containing all the 10 amino acid mutation positions), 1452M, 145M1R can all significantly increase the reaction intensity of specifically-binding antibody from BALB/c mice.
[0130] 3. BALB/c Female Mice and Serum Antibody Neutralization Examination
[0131] 1) Each group of BALB/c sera is mixed with equal volume; the mice sera and guinea pig sera to be tested are sterilized at 56° C. for half an hour;
[0132] 2) Take 15 μl serum and adding to 135 μl DMEM medium that contains 1 μM indinavir (Gibco); and then perform 2 times' (mice sera), 3 times' (guinea pig sera) gradient dilution;
[0133] 3) Adding 50 μl 200 TCID50 virus to each well, incubate in CO 2 incubator at 37° C. for 1 h;
[0134] 4) Adding 1×104 TZM-bl cell (purchased from ATCC) to each well, incubate in CO 2 incubator at 37° C. for 48 h;
[0135] 5) Discard the medium in each well, adding 200 μl PBS to wash each well twice; adding 50 μl diluted cell lysis (Promega, E1531) to each well; when the cells are completely lysed under microscope (IX70 fluorescence microscope: OLYMPUS), transfer the lysis into 96-weel data reader plate (PerkinElmer Life Sciences flat-bottomed 96-well plate). Adding formulated 100 μl luciferase substrate (Bright-Glo substrate and buffer) (Promega, E1501) to each well, finish the seld-emmision fluorescence detection (Victor 3 luminometer, PerkinElmer).
[0136] 6) Us the formula [1-(Experiment group RLU-cell control RLU)/(control group RLU-cell control RLU)]×100% to calculate RLU pad value; if the value is larger than 50%, then the neutralization reaction of the serum in such dilution is determined as positive.
[0137] See Table 3 for the results of BALB/c female mice serum antibody neutralization examination
[0000]
TABLE 3
The results of BALB/c female mice serum antibody neutralization assay
Vaccine
Neutralization titer against HIV-1 isolates
groups
XJDC6371
XJDC6431
XJDC0793
CBJB105
CBJB248
020101300
pDRVISV145
<6
<6
<6
<6
<6
12
pDRVISV1455M
12
24
24
24
24
12
pDRVISV1452M
<6
24
24
24
24
24
pDRVISV145M1R
<6
24
24
24
24
24
pDRVISV145M2R
<6
12
12
12
12
12
pDRVISV145M3R
<6
<6
<6
<6
12
12
pDRVISV145M4R
<6
<6
<6
<6
12
12
pDRVISV145M5R
<6
<6
<6
<6
<6
<6
[0138] The modified antigen 1455M can induce a broadest spectrum protection (which can neutralize all the clinical isolates of if and B′/C subtypes from Xinjiang, Beijing and Anhui), and can neutralized all the virus with high titer (neutralizing titers to all isolates are larger than 1:12); unmodified gp145 can only neutralize one B′ subtype virus, and has no neutralizing to other isolates. Antibodies induced by antigens 1452M and 145M1R can effectively neutralize most of the clinical isolates with broad spectrum, but the broad spectrum cannot compete with 1455M group. 145M2R antigen can induce antibodies with broad-spectrum neutralizing activity; the intension of the neutralizing antibody with the position mutated is around 1:12. 145M3R and 145M4R antigens can induce a broader-spectrum for neutralizing antibody.
[0139] The results show that the antigen 1455M containing 10 amino acid mutations can significantly broaden the spectrum, increase reaction intensity of neutralizing antibody. It is found through further researches that the induced protective reactions are mainly caused by 1452M that contains the first two mutation regions, and it is finally found out that the induced protective reactions are mainly caused by the first mutation 145M1R. Other mutations like 145M2R, 145M3R, 145M4R etc. can also induce a broad-spectrum for neutralizing antibody.
[0140] The sera neutralizing results of Huntley guinea pigs at the 14 th , 16 th week are shown in FIGS. 7 , 8 , 9 , 10 .
[0141] FIGS. 7 & 8 show that: 1455M antigen induces most of the guinea pigs in the group to produce broad-spectrum (against all the 8 clinical isolates of HIV) neutralizing antibody, and the reaction can last for at least 6 weeks. This means that the antigen can similarly induce broad-spectrum long-lasting neutralizing antibody protection against various subtypes of HIV in human.
[0142] FIGS. 9 & 10 show that 1455M antigen induces most of the guinea pigs in the group to produce neutralizing antibody with high titer (against all the 8 clinical isolates of HIV), the highest titer can reach 1:270; and the reaction can last for at least 6 weeks. This means that the antigen can similarly induce broad-spectrum long-lasting neutralizing antibody protection against various subtypes of HIV in human.
[0143] The above examples are only for illustrating purpose, with no intention to limit this invention. It is clear that, based on the substantial principle of the invention, a person skilled in the art can make various changes and modifications to this invention, therefore, these changes and modifications are also included in the scope of the invention. | Provided are antigenic polypeptides of HIV envelope glycoproteins which are constructed based on amino acid mutation of attenuated live vaccine of Equine Infectious Anemia Virus, DNA constructions and recombinant virus vectors comprising polynucleotides encoding said polypeptides, antibodies against said polypeptides as well as uses thereof in preventing and treating HIV infection. Said antigenic polypeptides and vaccines can induce high titer neutralization antibodies against HIV in organism. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. provisional patent application Ser. No. 60/585,876 filed Jul. 6, 2004 of common title and inventorship, the entire contents which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains generally to purses, wallets, and protective covers, and more particularly to protective check covers and holders. In the most preferred embodiment, a checkbook cover has a pen receiving slot formed therein to encompass and retain a pen strategically therein.
2. Description of the Related Art
In ancient history, mankind was hindered in trade by difficult conversions between individuals. Directly trading one item for another was traditionally complicated, since one or the other party might not like the goods being gained through exchange, and so might not favorably value them. This could and frequently did lead to a failed trading attempt. With the advent of currency, in early form in jewels, precious metals, and then coins minted from the precious metals, and later paper, mankind has been greatly facilitated in the bartering and retail trades, since the currency forms a simple exchange medium through which all goods and services may be valued or priced.
While monetary currency facilitated trading, certain risks have been involved therewith. Most troublesome has been the loss of such currency, either through mishap or theft. Monetary currency has always been difficult, of not impossible, to recover or trace.
A more safe alternative to semi-precious materials or paper currency has been a check, whether personal, bank, or otherwise. These checks represent an authorization for a particular party, as named on the check, to draw upon funds held in the account, in an amount specified directly on the check. By specifying the recipient and amount, the check is generally worthless to anyone other than the designated recipient. If the check is lost, nothing other than the paper, printing and time to prepare the draft is lost. This is typically only a few pennies or dollars worth of loss, depending upon how the check was lost and what additional security measures may be required as a result of the loss. Nevertheless, such loss is generally minor, and inconsequential to the overall amounts at issue.
While checks do provide an added layer of security over simple cash, they still suffer some drawbacks. Among these is the ease by which one or several checks may be forgotten about. Once forgotten, while the check is in transit, a person may readily draw beyond the funds available in the account. Such problems of over-drafting a checking account are very common. Check registers are provided in various forms which may be used at the time of issuance of a bank draft or check to record the writing of the check, typically including the amount of the check, to whom it was written, and the purpose the check has been put to. But, both the check and register require some type of writing instrument or utensil, such as the common ball point pen. This need is not new. However, and in spite of many attempts, no fully adequate method for providing the writing instrument with the register and checks has been put to widespread use prior to the present disclosure.
A variety of constructions have heretofore have been disclosed to hold a writing instrument in a cover. Several patents are incorporated herein by reference for their teachings, including U.S. Pat. No. 3,267,841 to Metcalf; 781,948 to Hegele; Des. 366,146 to Bertrand; Des. 422,406 to Dweck et al; U.S. Pat. No. 863,036 to Mieden; and U.S. Pat. No. 2,450,558 to Ogren. These patents variously illustrate pockets and loops which have been provided to accommodate the writing instrument. However, those who are familiar with loops will understand that the loop is very limited to the size of pen which will be reliably secured therein. If the pen is too large, the loop will tear or fail to accept the pen. If the loop is too large for the pen, the pen will readily slide from the loop and be lost. There is much frustration losing a valuable or favored writing instrument, simply because the holder did not adequately secure the pen. Worse, when these loops are fabricated from vinyl, even a temporary storage of a larger diameter writing instrument may permanently stretch the loop, rendering it useless for previously satisfactory writing instruments. Finally, a loop also may disadvantageously expose the writing end of the writing instrument to undesirable contact, which may lead to bleeding of ink from a pen or breakage or snagging of pencil lead and other components.
While the various pockets provide a number of advantages, including shielding of the writing utensil from exposure or damage to the writing point, these have heretofore required additional fabrication and expense which is most undesirable from a cost and convenience perspective. The present checkbook cover is manufactured from sheet vinyl, and is laminated as only two layers. The ultimate exterior cover is usually opaque, and colored to the desires of the consumer. The interior layer is often transparent, and has suitable geometry to allow ready retention of both the checks and also the check register. These layers are processed in flat form in very high volume from sheet, and are consequently manufactured for very low cost. Any changes from or which interfere with the sheet production techniques will very adversely impact the ultimate sales of the product, which presently sell for little more than the cost of the materials. As a result, the fabrication of pockets, which typically requires additional lamination or assembly, and which cannot be handled in line with the ordinary sheet processing, has not proved to be adequate for consumers to widely adopt such designs, even where only marginally higher costs are required.
A number of additional patents illustrating various concepts are additionally incorporated herein by reference. An example of attaching a writing instrument's pocket clip to a through-hole on one cover surface is illustrated in U.S. Pat. Nos. 5,011,188 and 5,190,317 to Zoland. Other patents include U.S. Pat. No. 3,267,980 to Bird; U.S. Pat. No. 2,647,071 to Schade; and U.S. Pat. No. 702,107 to Loomis. The prior art has failed to provide a method or apparatus for supporting the writing instrument which accommodates writing instruments of varying size and shape, which protects the writing point, and which is readily accessible without opening the cover, while not adding even marginally to the production costs of the cover.
SUMMARY OF THE INVENTION
In a first manifestation, the invention is a checkbook cover cooperative with at least one of a check register and check stack to form a storage chamber accessible from the exterior. The storage chamber accommodates at least one writing instrument therein, while protecting the writing instrument tip from contact or damage. The checkbook cover is fabricated to include an exterior sheet of pliable material which is operative to provide at least limited protection to papers held within. An interior sheet of pliable material forms at least one pocket with the pliable exterior sheet. The pocket is suitable for receiving an exterior of at least one of a check register and check stack. A slot forms an opening passing through the pliable exterior sheet into the storage chamber. The storage chamber is defined by the exterior of the at least one of a check register and check stack and the pliable exterior sheet.
In a second manifestation, the invention is a method of fabricating and using a checkbook cover, using standard fabrication equipment and standard two-sheet lamination. In accord with the method, a perimeter of an exterior cover is formed. A slot is formed fully through the exterior cover and within the perimeter. An interior cover is formed, and the interior and exterior covers are laminated. An exterior of at least one of a check register and check stack is inserted between the exterior cover and interior cover. A writing utensil is inserted between the exterior cover and the exterior of at least one of the check register and check stack.
In a third manifestation, the invention is, in combination, a checkbook cover and a pen. The checkbook cover has an exterior cover, an interior check and register holder affixed adjacent to the cover, and has a slot formed through the exterior cover. The pen has a pocket clip thereon. The pen passes partially through the exterior cover slot to a region between exterior cover and interior check and register holder. The pocket clip encompasses at least a part of the exterior cover.
OBJECTS OF THE INVENTION
Exemplary embodiments of the present invention solve inadequacies of the prior art by providing a checkbook cover which is formed using standard sheet processing techniques, but which includes the additional step of severing at a selected strategic internal location. As a result thereof, the cover may be fabricated without additional production costs, and will provide a highly desirable added benefit not adequately presented in the prior art.
A first object of the invention is to provide a method and apparatus for supporting a writing instrument, the apparatus which accommodates writing instruments of varying size and shape. A second object of the invention is to protect the writing instrument point, and to preferably avoid bleed therefrom. Another object of the present invention is to enable ready access to the pen without opening the cover. A further object of the invention is to add as little as possible to the production costs of the cover. Yet another object of the present invention is to accomplish each of the foregoing objectives while preserving an easy-to-use and understandable construction.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, advantages, and novel features of the present invention can be understood and appreciated by reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a preferred embodiment right-handed checkbook cover designed in accord with the teachings of the present invention from a top and slightly projected view.
FIG. 2 illustrates the preferred embodiment checkbook cover similar to that of FIG. 1 , but in left-handed configuration, and showing the visible components of a properly placed writing instrument, from the same projected view.
FIG. 3 illustrates the slot and pen combination of FIG. 2 from a magnified view taken along line 3 ′ of FIG. 2 .
FIG. 4 illustrates a writing instrument in combination with the preferred embodiment checkbook cover, checks and check register from a cross-sectional view taken along line 4 ′ of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
In a most preferred embodiment of the invention illustrated in FIG. 1 , a checkbook cover 1 resembling those of the prior art has an exterior top surface 10 and bottom surface 16 which wrap about and protect a check register 20 and check stack 30 . About the perimeter of cover 1 is a heat-stamping 17 , which is simply slightly harder material that tends to be tear-resistant. The improvement found in the present invention includes an additional slot 12 terminated at each end by round holes 13 and 14 . Slot 12 preferably passes through the exterior cover, which in the preferred embodiment is fabricated from vinyl. While it is not critical to the performance of the invention exactly when the slot and holes are fabricated into the cover, many of the processes used to form the checkbook cover may be directly applied with only minor modification to permit simultaneous formation. Consequently, for economic reasons, the present slot and round holes will preferably be formed at the time of fabrication of the exterior face 10 of checkbook cover 1 . The shaping will preferably be done as the exterior perimeter of cover 1 is being defined, and so will be a part of the same stamping or severing operation. The formation of slot 12 and round holes 13 , 14 will also most preferably occur prior to the lamination of exterior faces 10 , 16 with inner liner 11 . As is known, checkbook covers are generally formed from an opaque exterior vinyl cover and a clear interior plastic, which may or may not also be comprised by vinyl, or other suitable material. In the preferred embodiment, slot 12 and holes 13 , 14 will only penetrate through exterior face 10 , and will not penetrate through liner 11 . While not essential to function, this is preferred to improve the appearance and slightly improve the durability and function of liner 11 .
Most typically, vinyl checkbook covers are formed with heat-stamped reinforcement 17 adjacent the edges of the cover, and with heat stamped hinges at the central spine. The heat-stamped reinforcement 17 is known to offer much structural integrity to cover 1 , helping to prevent undesirable tearing and the like, while still permitting the bulk of cover 1 to be relatively soft and pliable. Most preferably, heat-stamped reinforcements similar to heat-stamped reinforcement 17 will be applied similarly in areas adjacent the slot and round hole borders found in the present invention, as illustrated by enlarged view in FIG. 3 as heat-stamped reinforcement 18 , to provide similar strengthening against tears and the like.
The most preferred terminating holes 13 , 14 are provided for similar strengthening. Stretching and subsequent tearing will normally only occur at regions of substantial stress or tension within vinyl. Such forces are typically concentrated adjacent the leading edge of a fault. Slot 12 behaves much like a fault, since the vinyl is separated within the slot, and forces would tend to concentrate at the ends thereof. These forces may be particularly large when a writing instrument 40 is being inserted or removed, or in the event writing instrument 40 is accidentally snagged on another object. However, by forming round holes 13 , 14 terminating slot 12 , there is no opportunity for any stress concentration at the slot ends. Instead, any tearing or pulling forces will be distributed relatively equally about the perimeter of round holes 13 , 14 , which, as aforementioned, will most preferably be reinforced by heat stamping 18 or the like. Consequently, round holes 13 , 14 act as force distributors which prevent the undesirable destruction of exterior face 10 . While the most preferred embodiment incorporates round holes, it will be understood that other geometries may be utilized. Nevertheless, for simplicity and relatively even distribution of forces in the vinyl, round holes are used in the present preferred embodiment.
As illustrated in FIGS. 2–4 , a prior art writing instrument 40 , which might for exemplary purposes include a ball point and a pocket clip 42 of one form or another, may be inserted through slot 12 . Most preferably, slot 12 will be positioned more nearly adjacent one edge of exterior cover 10 , rather than being centered, such that the pen barrel may pass inside the checkbook cover and not extend beyond the perimeter of cover 1 . Those familiar with both writing instruments and checkbook covers will recognize that not all covers are fabricated using the same sets of dimensions, nor are all writing instruments. Consequently, it will not be possible to accommodate every pen with every checkbook cover. Nevertheless, cover 1 will be designed to include a slot 12 placed for the particular writing instruments of preference where the cover is not otherwise of sufficient size to fully accommodate all types and styles.
FIG. 4 illustrates the combination checkbook cover and writing instrument of FIG. 3 by side cross-sectional view, showing the position of the various components. From this figure, it will be apparent that writing instrument 40 will preferably pass behind the commonly card or paperboard outside 22 of check register 20 , in a pocket-like space between checkbook register outside 22 and the pocket forming portion 15 of checkbook exterior cover 10 . As designated in the figures, the portion of cover 10 which encompasses the barrel of writing instrument 40 is designated by the reference numeral 15 , while the pen will lie exterior to the portion of exterior cover 10 designated by reference numeral 19 . The effective pocket so formed protects the end of writing instrument 40 distal to clip 42 . In the case of a ball point pen, this will be the end adjacent the ball point. The end is preferably protected from undesirable contact or interference with other objects that may be nearby or adjacent to checkbook cover 1 . As will be apparent then, in the preferred embodiment, writing instrument 40 is retained within this pocket. While this pocket is not totally sealed, the enclosure effectively encompasses the entire writing instrument body except that portion outside of exterior cover 10 which extends beyond clip 42 . Furthermore, as will be apparent, the size of the pocket will ordinarily be such to readily accommodate a wide variety of writing instruments therein. Furthermore, since writing instrument 40 is almost entirely enclosed therein, the risk of loss of writing instrument 40 is greatly reduced. Finally, the stiffness provided by the immediately adjacent check register 20 and check stack 30 provides added rigidity and strength, which help in combination with writing instrument 40 to preserve the integrity of each of the check register 20 , check stack 30 and writing instrument 40 .
From these figures it will be apparent that holes 13 , 14 may be formed in exterior cover 10 either prior to or subsequent to lamination with inner layer 11 , but once again, for economic and manufacturing reasons it will normally be most sensible to fabricate holes 13 , 14 and slot 12 at the time of fabrication of the outer vinyl. Nevertheless, some manufacturing methods and approaches may dictate otherwise. Consequently, those reasonably skilled in the art of checkbook cover fabrication will make a determination of when the most reasonable time will be to fabricate the holes and slot upon a reading of the present disclosure and upon further consideration of the manufacturing methods already employed or planned for at the intended manufacturing location. Likewise, existing covers may be retrofit, though the heat stamp reinforcement may be more difficult or even impractical in that instance.
From these figures, several additional features and options should become more apparent. First of all, preferred checkbook cover 1 may be manufactured from a variety of materials, including leather, metals, resins and plastics, composites, or even combinations of the above. The specific material used may vary, though the standard vinyl covers are preferred owing to the low cost, ease of fabrication, pliability, relative durability, low weight, lack of potential hazard, and existing manufacturing technique and capacity. By way of the present invention, no other materials are required, which permits unitary or two-layer laminates to be formed relatively simply, reliably, and for very low cost directly from sheet. Essentially, the cost is the same for the preferred embodiment as for the prior art, though it is understood that tooling costs may be slightly higher to include the formation of slot 12 , holes 13 , 14 , and heat-stamped reinforcement 18 .
As those skilled in the plastics areas will immediately recognize, while vinyl is preferred, there are a myriad of other materials which may be used alternatively or in combination that will offer similar characteristics and benefits. Consequently, the present invention is not limited to one or a few plastics, but instead the inventor recognizes that many other materials, including composites, laminae, and other such materials may be used. Where plastic sheets are used, it will be understood that various reinforcing fibers or particles, plasticizers, and other ingredients known to enhance the properties of the composition and resulting product may be used.
A variety of designs have been contemplated for the preferred slot 12 and holes 13 , 14 . As shown in FIGS. 2–4 , slot 12 is located adjacent the left top side of checkbook cover 1 . In this configuration, the cover is arranged to be most convenient for a typical left-handed person. This is because the left-handed person will draw the pen out of cover 1 by grasping the pen in the left hand, and pulling to the left. However, those of ordinary skill will recognize that slot 12 may also be located adjacent the right top side of cover 1 , as illustrated for exemplary purposes in FIG. 1 , such that a typical right-handed person may readily grasp the pen in their right hand, and draw it to the right relative to cover 1 . Further, slot 12 , which in the illustrated preferred embodiment cover 1 is linear, may travel other paths, which may even be rather circuitous. Cover 1 , slot 12 and holes 13 , 14 may additionally be arranged, patterned or imprinted to resemble other animate or inanimate objects without deviating from the present invention. The materials used for a particular design may be chosen not only based upon other factors such as water resistance, flexibility and durability, but may also factor in the visual characteristics of the particular design.
While the foregoing details what is felt to be the preferred embodiment of the invention, no material limitations to the scope of the claimed invention are intended. Further, features and design alternatives that would be obvious to one of ordinary skill in the art are considered to be incorporated herein. The scope of the invention is set forth and particularly described in the claims herein below. | A checkbook cover has an exterior cover, an interior check and register holder affixed adjacent to the cover, and a slot formed through the exterior cover. A writing instrument, preferably with a pocket clip thereon, passes partially through the exterior cover slot to a chamber between exterior cover and interior check and register holder. The pocket clip encompasses at least a part of the exterior cover. The checkbook cover is formed using standard sheet processing techniques, but includes the additional step of severing at a selected strategic internal location to form the slot. Additional force distributors, preferably in the form of circular cut-outs, may be formed at the terminations of the slot. Heat stamped reinforcements are provided in the preferred embodiment about the slot and force distributors, to further strengthen the cover. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to an apparatus for holding and spacing workpieces and, in particular, to an apparatus for holding wooden decking planks in a spaced apart relationship during installation.
Wooden decks have become a popular addition to houses. Typically, a plurality of posts are inserted into the ground adjacent the house and a frame for supporting decking is attached to the posts. The frame usually includes generally horizontally extending joists to which are attached the deck planks. The deck planks typically are 2×4 or 2×6 pieces of wood, often extending ten feet or more. These planks are fastened to the joists in side-by-side relationship and spaced apart a predetermined distance to permit water drainage and expansion caused by weather changes.
Rarely is a wooden deck plank straight enough to maintain the predetermined distance from the adjacent plank along its entire length. Therefore, at least two persons are required to install such deck planks. Two or more sets of spacers are positioned between a loose plank to be installed and the adjacent fixed plank which was previously attached to the joists. One person holds the loose plank against the spacers in a first location while another person holds the loose plank against the spacers in a second location and fastens the loose plank to the joists. Such an installation procedure can require significant strength on the part of both installers who must bend the plank to straighten it.
SUMMARY OF THE INVENTION
The present invention concerns an apparatus for installing wooden deck planks. The apparatus has a frame including an elongated base plate attached at opposite shorter ends to the bottom edges of a pair of upstanding end plates. A handle extends between upper ends of the end plates and an actuator, such as a compressed air cylinder, is mounted on the base plate. A generally V-shaped cover extends between the end plates and is attached to opposed longer edges of the base plate to enclose the actuator. A fixed angle clamp is attached to the bottom of the base plate adjacent one end and extends downwardly to engage an edge of a first deck plank already attached to a deck frame. A sliding angle clamp is attached to a piston rod of the actuator and extends downwardly through the base plate from the opposite end. A spacer plate is slidably mounted on the piston rod of the actuator and extends downwardly through the center of the base plate to engage facing edges of the first deck plank and a second loose deck plank. The thickness of the spacer plate is selected to determine the spacing between the facing edges of the deck planks. The actuator is detachably coupled to a source of compressed air and a control device is for operating the actuator between an open position and a closed position.
The second deck plank is placed on the deck frame adjacent to the first deck plank and the apparatus according to the present invention is positioned on the upper surfaces and transverse to the deck planks with the fixed angle engaging the opposite edge of the first deck plant. The actuator is operated to move the piston rod from the open position to the closed position and draw the sliding angle clamp against the opposite edge of the second deck plank forcing the facing edges of the deck planks against the spacer plate. Thus, the second deck plank is held straight, parallel to and spaced the desired distance from the first deck plank while it is attached to the deck frame thereby permitting one person to install a wooden deck floor.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
FIG. 1 is a front elevation view of an apparatus for installing wooden decking in accordance with the present invention;
FIG. 2 is a left side elevation view of the apparatus shown in the FIG. 1;
FIG. 3 is a block diagram view of the power supply and control system of the apparatus shown in the FIG. 1;
FIG. 4 is an enlarged fragmentary cross-sectional view of the sliding angle clamp shown in the FIG. 1;
FIG. 5 is an enlarged fragmentary cross-sectional view of the spacer plate shown in the FIG. 1;
FIG. 6 fragmentary front elevation view similar to the FIG. 1 showing the apparatus in an open position before actuation;
FIG. 7 fragmentary front elevation view similar to the FIG. 6 showing the apparatus in a closed position after actuation; and
FIG. 8 is an enlarged fragmentary front elevation view of the apparatus showing an alternate embodiment actuator control device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in the FIGS. 1 and 2 an apparatus 11 for installing wooden deck planks. The apparatus 11 includes a frame 12 having a handle 13 attached thereto. The frame 12 can include a generally rectangular and planar, horizontally extending base plate 14 having end plates attached at opposite shorter ends thereof. For example, the base plate 14 has a left end plate 15 which is generally narrower at the top and wider at the bottom as best shown in the FIG. 2. A bottom edge of the left end plate 15 is attached to one end of the base plate 14 and an upper end of the left end plate 15 is attached to one end of the handle 13. A right end plate 16 is similar to the left end plate 15 and has a wider lower end attached to an opposite end of the base plate 14. An upper narrower end of the right end plate 16 is attached to an opposite end of the handle 13. The handle 13 can be of any suitable shape such as a rod of generally circular cross section.
Mounted on an upper surface of the base place 14 adjacent to the left end plate 15 is an actuator 17. Although the actuator 17 can be any suitable device, an air cylinder operated by compressed air is shown in the preferred embodiment. Extending from a right hand end of the air cylinder actuator 17 is an output means in the form of a shaft 18 shown in an extended or open position. The shaft 18 can be partially retracted into the air cylinder actuator 17 to a closed position (not shown) and extended to the open position shown in the FIG. 1 in the direction of a double headed arrow 19. The shaft 18 is retracted under the influence of compressed air which is supplied to a power supply inlet connector 20 at the right hand end of the air cylinder actuator 17.
Coupled to the inlet connector 20 is one end of an actuator supply line 21. An opposite end of the supply end 21 is coupled to an outlet connector 22 of a control device 23 such as a three-way valve. The valve 23 has a vent 24 and a power supply inlet connector 25. The inlet connector 25 is coupled to one end of an inlet supply line 26 having an opposite end connected to a power supply inlet connector 27. The inlet connector 27 is mounted on an exterior surface of the left end plate 15 and extends through the left end plate to the inlet supply line 26.
The actuator 17, the control device 23 and the associated supply lines 21 and 26 are enclosed by a cover 28 extending between the facing interior surfaces of the left end plate 15 and the right end plate 16. The cover 28 is in the form of a generally inverted V-shape and has a pair of lower edges which are attached to opposed longer edges of the base plate 14. The control device 23 is attached to an inside surface of the cover 28 and includes a pair of actuating buttons which extend through the cover 28. The control device 23 has an "open" actuating button 29 and a "closed" actuating button 30 which are positioned close to the handle 13 for easy actuation by a finger of a hand on the handle.
The apparatus 11 includes a clamping mechanism having a fixed portion attached to the base plate 14 and a sliding portion which is attached to the shaft 18 of the actuator 17. As shown in the FIGS. 1 and 4, a free end of the shaft 18 is threaded and retains a pair of locking nuts 31. A generally L-shaped angle bracket 32 has a generally vertically extending shorter leg 33 having an aperture 34 formed therein through which the shaft 18 extends. Thus, the angle bracket 32 can be moved back and forth along the threaded end of the shaft 18 to a desired position and locked into place by tightening the nuts 31 on opposite sides of the shorter leg 33. The angle bracket 32 has a longer leg 35 which extends generally parallel to and is spaced above an inner upper surface of the base plate 14. The base plate 14 has a longitudinally extending slot 36 formed therein. A spacer bar 37 is retained in the slot 36 and abuts a lower surface of the longer leg 35 of the angle bracket 32. The spacer bar 37 also extends below an outer lower surface of the base plate 14 and abuts an upper surface of a generally horizontally extending longer leg 38 of a sliding angle clamp 39 which has a generally vertically downwardly extending shorter leg 40. The angle bracket 32, the spacer 37 and the sliding angle clamp 39 are attached together by any suitable means such as a plurality of threaded fasteners 41 which have countersunk heads retained in countersunk apertures formed in the longer leg 38. Each of the threaded fasteners 41 extends through a corresponding aperture formed in the spacer bar 37 and threadably engages a corresponding threaded aperture formed in the longer leg 35 of the angle bracket 32.
A spacer plate 42 is slidably mounted on the base plate 14 as shown in the FIGS. 1 and 5. The spacer plate 42 has an aperture 43 formed therein through which the shaft 18 extends. The diameter of the aperture 43 is somewhat larger than the diameter of the shaft 18 to prevent binding of the spacer plate 42 on the shaft 18 both when the spacer plate 42 is being positioned and when the shaft 18 is being extended and retracted. A pair of generally horizontally extending slots 44 are formed in the spacer plate 42 and extend inwardly from opposite sides thereof. The slots 44 accommodate the base plate 14 and permit the spacer plate 42 to extend downwardly through the slot 36 formed in the base plate 14 and below a lower surface of the base plate 14. As will be discussed below, a lower portion 45 of the spacer plate 42 has a thickness corresponding to the desired predetermined spacing between adjacent planks of a deck floor. In the alternative, the upper portion of the spacer plate 42 can be terminated below the shaft 18 but above the slots 44 and, if additional stability is required, a slider block (not shown) which is wider than the slot 36 could be attached to the upper end of the spacer plate 42 to slide along the upper surface of the base plate 14.
As shown in the FIG. 1, a fixed angle clamp 46 is generally L-shaped and is similar to the sliding angle clamp 39. The fixed angle clamp 46 has a generally horizontally extending longer leg 47 which is fixedly attached to the outer lower surface of the base plate 14. The fixed angle clamp 46 also has a shorter leg 48 which extends vertically downwardly from the bottom surface of the base plate 14. The fixed angle clamp 46 can be attached by any suitable fasteners and various mounting positions can be provided to accommodate different widths of deck planks. A helical return spring 49 can be mounted on the shaft 18 between a face of the actuator 17 and the spacer plate 42 and/or between the spacer plate 42 and the locking nuts 31. If the spacer plate 42 is terminated below the shaft 18, the spring 49 will extend between the actuator 17 and the locking nuts 31.
There is shown in the FIG. 3, a block diagram of the power supply and control systems for the apparatus 11. The actuator 17 is connected by the actuator supply line 21 to the control device 23. In turn, the control device 23 is connected by the inlet supply line 26 to the power supply inlet connector 27. A power supply 50 can be connected by a supply line 51 to the inlet connector 27. In the embodiment shown in the FIGS. 1 and 2, the power supply 50 could be a source of compressed fluid, such as compressed air, coupled by the supply line 51 to the inlet connector 27. The shaft 18 of the actuator 17 is mechanically coupled to a clamping mechanism 52. In the FIGS. 1 and 2, the clamping mechanism 52 includes the sliding angle clamp 39, the spacer plate 42 and the fixed angle clamp 46.
When the power supply 50 has been connected to the inlet connector 27, the closed button 30 can be actuated and the three-way valve control device 23 will permit compressed air to pass from the power supply 50 to the actuator 17 causing the shaft 18 to retract into the actuator 17. The actuator 17 is an air cylinder of conventional design having a piston (not shown) attached to the end of the shaft 18 internal to the actuator 17. As compressed air is introduced through the actuator supply line 21 into the cylinder, the piston will be moved from the right hand end of the actuator cylinder toward the left hand end of the actuator cylinder to retract the shaft 18. Air in the left hand end of the actuator cylinder will be expelled through a vent 53.
When the shaft 18 has been retracted to the closed position, it can be returned to the open position shown in the FIG. 1 by actuating the "open" button 29. The three-way valve control device 23 responds by blocking compressed air from the inlet supply line 26 and connecting the actuator supply line 21 to the vent 24. Now, compressed air in the right hand end of the cylinder of the actuator 17 is free to escape through the actuator supply line 21 and out the vent 24. The shaft 18 can be moved back to the position shown in FIG. 1 either by grasping the sliding angle clamp 39 and pulling it to the right, or under the influence of the return spring 49.
The operation of the apparatus 11 is illustrated in the FIGS. 6 and 7. There is shown in end view a first deck plank 54 and a second deck plank 55 of a deck floor. Assuming that the first plank 54 is fixedly attached to a frame (not shown) of the deck and the second plank 55 is resting loosely on the frame, the apparatus 11 is lowered onto upper surfaces of the first and second planks in a transverse position. The shorter leg 48 of the fixed angle clamp 46 is positioned abutting an edge of the first plank 54 opposite the edge adjacent the second plank 55 and the longer leg 57 rests on an upper surface of the first plank 54. The spacer plate 42 can be moved such that the lower portion 45 is abutting the edge of the first plank 54 facing the second plank 55. At the same time, the longer leg 38 of the sliding angle clamp 39 rests upon an upper surface of the second plank 55 and the shorter leg 40 abuts an edge of the second plank 55 opposite the edge adjacent the first plank 54. The distance between the lower portion 45 and the shorter leg 40 is greater than the width of the second plank 55 such that a gap exists between the lower portion 45 and the facing edge of the second plank 55.
When the "closed" button 30 is depressed, the actuator 17 retracts the shaft 18 pulling the sliding angle clamp 39 in the direction of an arrow 56 shown in the FIG. 6. As shown in the FIG. 7, the facing edge of the second plank 55 is pulled into abutment with the lower portion 45 and the facing edges of the first plank 54 and the second plank 55 are spaced apart the predetermined distance represented by the thickness of the lower portion 45 of the spacer plate 42. The second plank 55 is held straight and properly spaced and can be attached to the deck frame (not shown). When the second plank 55 has been attached, the "open" button 29 is actuated. As shown in the FIG. 2, the apparatus 11 can be rotated, for example, in the direction of an arrow 57 to release the lower portion 45 of the spacer plate 42 from between the facing edges. As shown by a phantom line 58 representing an upper surface of a plank adjacent to the first plank 54, the apparatus 11 can be rolled on the rounded edges extending between the end plates 15 and 16 to slide the lower portion 45 of the spacer plate 42 from between the first plank 54 and the second plank 55. Thus, the apparatus 11 can be operated by one person utilizing one hand leaving that person free to nail or otherwise fasten the second plank 55 to the deck frame.
There is shown in the FIG. 8, an alternate embodiment of the control device 23. Instead of the push buttons 29 and 30, the control device 23 can have a lever 59 positioned on an outer surface of a cover 28'. The lever 59 can be positioned for convenient engagement by a thumb of a hand grasping the handle 13 shown in the FIG. 1. The lever 59 can be rotated in the direction of a double headed arrow 60 about a pivot point 61 representing a point of attachment to and an axis of rotation of a shaft extending from a suitable control device (not shown) mounted inside the cover 28'.
Although the power supply and control system shown in the FIG. 3 has been described in terms of compressed air, any suitable source of energy could be utilized. For example, the power supply 50 could be a source of electrical power, the control 23 could be electrical switching means and the actuator 17 could be a solenoid.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | An apparatus for installing wooden deck planks on a supporting frame of joists has an actuator mounted on a base plate with an output shaft movable between an open position and a closed position. A control device is mounted on the frame for selectively controlling the actuator to move the output shaft. A fixed angle clamp is mounted on the base plate and has a leg for engaging an edge of a first deck plank, a sliding angle clamp is attached to the output shaft and has a leg for engaging an edge of a second deck plank, and a spacer plate is slidably mounted on the base plate between the clamps and has a predetermined thickness corresponding to a desired spacing between adjacent deck planks. When the actuator moves the output shaft to the open position, the base plate can be rested on the upper surfaces of the first deck frame and the second unattached deck plank with the fixed angle clamp leg engaging the opposite edge of the first deck plank and the spacer plate extending between the facing edges of the deck planks. When the actuator moves the output shaft to the closed position, the sliding angle clamp engages the opposite edge of the second plank and the spacer abuts the facing edges of the first and second planks. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a vehicle designed to transport wheelchair bound passengers between two separate locations and elevations, such as between a terminal and an aircraft parked on a ramp.
Commuter and small jet aircraft and other elevated areas are difficult for disabled, handicapped or incapacitated passengers to access without some means to lift them into the door. One prior art device is an elevator mechanism that is towed into position adjacent the aircraft. This device is also provided with an adjustable staircase for use by able-bodied passengers. It is not, however, intended to be used to transport passengers from one location at a first elevation to a second location at a second elevation, nor does it approach the aircraft door directly.
SUMMARY OF THE INVENTION
The present invention is a mobile passenger access lift for transporting disabled, handicapped or incapacitated passengers from one location to another. It is particularly useful in providing boarding access to commuter and small jet aircraft and other elevated areas, such as trains and the like, to wheelchair bound passengers.
The mobile passenger access lift of the present invention is includes a) a welded tubular steel framework which supports a driver's area, a lifting structure, a passenger compartment, and motive power generating components (engine, drive components, wheels, etc.); b) the driver's area includes a seat rest, steering wheel, and foot and hand controls; c) the lifting structure includes steel channel framework, hydraulic cylinders and hydraulic safety features; d) the passenger compartment includes protective enclosure sides, entrance and exit ramps which also serve as gate closures, self-actuating handrails, skid resistant surfaces, cushioned surfaces and tie-down points for wheelchair restraints; e) the motive power generating system and controls include an internal combustion engine, hydraulic pump and reservoir, functional and control valves and hydraulic wheel motors.
The present invention enables the boarding and deplaning of passengers from elevated areas up to 78" above the ground or operating surface in a safe and dignified manner. It is self contained and self propelled, providing mobility for itself as a lifting device as well as for its occupants. The normal occupancy of the vehicle is either the driver alone, or the driver plus a passenger and an attendant, therefor providing for a maximum of three (3) persons. The vehicle may be provided with an optional canopy for passenger and attendant comfort.
The vehicle is designed to approach the aircraft doors, both front an rear, directly from the left side of the fuselage. The operator's compartment is offset to the left front of the elevating passenger compartment thus permitting excellent visual positioning.
Safety features are provided in the design of the vehicle for passenger, attendant, operator, surrounding personnel, aircraft components and the unit itself. One of those safety features is a set of stabilizers which are set in place before the passenger compartment is raised. Other safety features include interlocks to prevent movement of the vehicle under certain conditions and lighting.
Another safety feature is the manner in which the vehicle approaches an aircraft. Using the present invention, the vehicle moves directly toward the fuselage of an aircraft, parallel to the wing, and thus maintains a clear distance from the propeller area at all times.
It is therefore an object of this invention to provide an improved apparatus for transporting passengers, and particularly disabled passengers seated on a boarding wheelchair from one location to another. The invention provides for the passenger and an attendant to be moved between locations having substantially different elevations.
It is a further object of the invention to provide an improved passenger access lift that is provided with stabilizers that automatically extend when the lift is raised; and to provide stabilizers that do not lift the vehicle off the ground.
It is still another object of this invention to provide a passenger access lift that is moved between locations with an unique hydraulic drive system.
It is a further object of this invention to provide a self powered, steerable vehicle for transporting a wheelchair bound passenger from a first location to a second location at a different elevation, the vehicle comprising lift assembly means mounted on the vehicle for movement from a lowermost position to an operator selectable upper position, an operator's compartment containing steering and lift assembly controls, a passenger compartment carried by the lift assembly means, a first ramp associated with the passenger compartment, the first ramp being movable from a loading position to a traveling position, a second ramp associated with the passenger compartment, the second ramp being movable from a loading position to a traveling position, and means for stabilizing the vehicle when the lift assembly means is in other than its lowermost position.
It is still another object of this invention to provide a method of transporting a wheelchair bound passenger from a first location to an aircraft at second location comprising the steps of loading a passenger into a passenger compartment on a transport vehicle by pulling the passenger's wheelchair onto a first or loading ramp and then into the passenger compartment, raising the loading ramp to provide an end closure for the passenger compartment, moving a passenger unloading ramp directly toward the door of an aircraft and parallel to the wing of the aircraft, extending stabilizers to steady the vehicle then raising the passenger compartment to approximately the same elevation as the aircraft, lowering a second or unloading ramp into the door of the aircraft, and unloading the passenger by pulling the passenger's wheelchair from the passenger compartment and over an unloading ramp into the aircraft.
Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a mobile passenger access lift constructed according to this invention showing the loading ramps in their closed position;
FIG. 2 is a plan view of the passenger access lift of FIG. 1 with the loading ramps in their lowered or extended position;
FIG. 3 is a rear end elevational of the passenger access lift with the loading ramps removed;
FIG. 4 is a plan view showing the passenger access lift of this invention parked adjacent an aircraft;
FIG. 5 is a side elevational view of a passenger access lift, taken along lines 5--5 of FIG. 2, with the lift in the lowermost position, the forward ramp in the traveling position and the rear ramp lowered or in the loading position;
FIG. 6 is a side elevational view of a passenger access lift adjacent an aircraft with the lift in an elevated position and the front loading ramp lowered;
FIG. 7 is a detailed view of a stabilizer;
FIG. 8 is a detailed elevational view of a loading ramp;
FIG. 9 is a detailed plan view of a ramp hinge;
FIG. 10 is a detailed elevational view of the ramp hinge of FIG. 9;
FIG. 11 is a perspective view of a platform lift mechanism;
FIG. 12 is a detailed cross sectional view of a lift support column and a platform support roller;
FIG. 13 is a schematic diagram of the hydraulic system providing motive and lifting power to the passenger access lift;
FIG. 14 is a perspective view of a control panel in the operator's compartment; and
FIGS. 15A and 15B together comprise an electrical schematic diagram of the vehicles electrical system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIGS. 1-3 and 5-6 which illustrate a preferred embodiment of the invention, a mobile passenger access lift, shown generally at 10, is a three wheeled vehicle designed to carry an operator or driver 11, a passenger 12 in a boarding wheelchair 13, and an attendant 14.
The vehicle is built on a welded tubular steel frame 20 that includes several longitudinally extending members 22 and transverse members 24 and a rear axle 26. Supported on the frame 20 is a steerable front wheel 30 and a pair of rear wheels 32 and 34. The front wheel is steered by a steering wheel 36. The rear wheels are driven by hydraulic motors 38.
Also carried on the frame 20 are three stabilizers 40, 42 and 44. As shown in FIG. 7, each stabilizer cylinder 45 is attached to the frame 22 by a bracket 46. A pad 47 on the end of piston 48 engages the ground to stabilize the vehicle. A pair of hydraulic hoses 49 connect the stabilizer to the vehicle's hydraulic system, as will be explained. A limit switch LS-ST on one of the stabilizers indicates when its stabilizer pad 47 is in its uppermost position.
An internal combustion engine 50 is shown on the vehicle's left side. This engine provides power to a hydraulic pump 52. Starting power for the engine is provided by a battery 54 which also provides power for other vehicle components, such as a horn, headlights, parking and brake lights, and passenger compartment courtesy lights. A rotating beacon may also be provided as an option.
An operator's compartment 60 includes a seat rest 62, the steering wheel 36, a brake pedal 64 and an automobile type accelerator pedal 66. Also included in the area 60 is a control panel 68 containing hand controls for other functions of the vehicle, as will be explained.
A lift assembly means, shown generally at 70, is carried by the vehicle for moving a passenger and attendant from a lowermost position to an operator selectable upper position. As shown in FIG. 11, the lift assembly means includes a pair of vertical channel members 72 and 74 that are mounted to the frame 20 and, as shown in FIG. 1, a pair of cross members 76 and 78.
a pair of hydraulic lifting cylinders 80 and 81 are supported on cross member 76. Chains 82 have one end connected to the cross member 76, and extend over pulleys 83 supported for rotation on a shaft 84 passing through a clevis 85 attached to the movable piston in each cylinder. The other ends of the chains 82 are connected to a passenger compartment 90.
To counter any uneven distribution of weight on floor of the passenger compartment and to equalize the forces acting on the cylinders, a shaft 86 surrounds the shaft 84 and is provided with gears 87 fixed at each end thereof. Chains 88 extend from the cross arm 78, around the gears 87 and are attached to an arm 89 supported on the passenger compartment 90.
The passenger compartment 90, as shown in FIGS. 1, 3 and 11, includes a pair of side walls 92 and 94 and a floor 96. The interior surfaces of the walls may be cushioned to protect the passengers, and tie downs 95 are provided to secure the wheelchair during movement of the vehicle. The floor is also provided with a skid resistant surface. End members 98 are placed at each end of the side walls to form a partial end wall. The opening between the end members is wide enough for a boarding wheelchair easily to pass therebetween.
The left hand side wall 92 faces the lift assembly means 70 and has secured thereto a pair of brackets 100. Each bracket includes a pair of spaced apart guide rollers 102 (FIG. 12) that engages "V" shaped guides 104 on the interior surface of the channel members 72 and 74. The ends of the chains 84 are attached to the wall 92 at 106. Thus, the passenger compartment is supported for vertical movement on the lift assembly means.
Associated with the passenger compartment 90 are a first or rearward ramp 110 and a second or forward ramp 112. Each ramp includes a floor 116 and short vertical wall edge 118, as shown in FIGS. 9 and 10. The floors of the ramps are provided with skid resistant surfaces. A bracket or hinge 120 is welded to the floor which engages a hinge pin 122 secured to the end wall 98. As shown in FIG. 9, this arrangement permits limited horizontal or lateral movememt of the ramp, if needed, as shown by the arrow 124 in FIG. 2.
Referring to FIG. 8, each ramp is provided with a pair of hand rails 130 hinged to the end wall 98, one of which is shown. A vertical support 132 extends between the end of the handrail and the ramp and is connected at each end by means of a ball joint 134. A cable 136 is connected between the ramp and the end wall 98 to prevent the ramp from descending below the position shown.
Since each ramp is movable from an upper or traveling position, as shown in FIG. 1, to a lower or loading position, as shown in FIG. 8, means are provided to assist the operator in raising the ramp against the force of gravity. A gas cylinder 140 of the type used in automobiles is attached between the hand rail 130 and the end wall 98 to provide a lifting force upwardly on the hand rail.
Since each ramp is provided with two lifting cylinders, one handed raising of the ramp is easily accomplished. Each ramp may be locked in its upper or traveling position by means of an automatically acting latch pin 144. The ramps thus serve the dual function of facilitating access to and from the platform and as closures or gates.
The hydraulic schematic diagram of FIG. 13 shows a preferred system for providing control over the vehicle thus described. Power to the main pump 52 is provided by the engine 50. Of course, an electric motor or other means could be used to provide a source of hydraulic pressure to the system. Hydraulic fluid from a reservoir 150 is sent through a grade selector 152 to a drive selector 154.
The drive selector 154 is provided with an operator controlled handle in the operator's compartment and is operable from a center or neutral position to either a forward or reverse position, thus sending hydraulic fluid to the wheel motors 38 in the appropriate direction to control the motion of the vehicle.
The speed of the vehicle is controlled by an accelerator pedal 66 connected to a valve 156. This valve either bypasses all flow to the motors 38, when the accelerator is up, or permits full flow when the accelerator pedal is fully down. The grade selector 152 diverts hydraulic flow through a gear intensifier 158 whenever it is necessary to increase torque on the motors 38, such as when climbing a grade. The gear intensifiers are not normally used when operating on level ground.
The vehicle may be braked by operating the brake pedal 64, which in turn controls brake valves 160 in the hydraulic lines to the motors 38.
When the operator wishes to raise the passenger compartment, a momentarily actuated weather resistant toggle switch 194 (FIG. 14) in the operator's compartment is moved to control a solenoid actuated lift selector valve 170. An electrical interlock is provided between the toggle switch and a sensor switch associated with parking brake actuator 171 to prevent the raising of the platform if the parking brake is not set.
When the toggle switch is moved to the UP position, and the parking brake is set, the first action taken will be to cause stabilizers 40, 42 and 44 to place their pads 47 firmly in contract with the ground. A pressure reducer 172 insures that the stabilizers will not raise the vehicle off the ground, but sufficient pressure is provided to prevent the vehicle from rocking as the passenger compartment is raised.
Once the stabilizers have fully extended, sufficient pressure will be available to operate the lift cylinders 80 and 81. When the passenger compartment has reached its desired height, the operator will release the toggle switch 194, allowing it to return to its neutral position. This will cause the lift selector 170 also to return to its neutral position. Counter balance valves 174 and 176 act as safety check valves to maintain the lift cylinders and the stabilizers in their present position.
Moving the lift selector toggle switch 194 to the DOWN position will first cause the lift cylinders to retract, lowering the platform, and then cause the stabilizers to retract. One of the stabilizers is provided with a limit switch LS-ST (FIG. 7) to indicate when it has reached its fully retracted position. This limit switch controls the operation of a drive safety valve 178 which will be fully open whenever the stabilizers are not fully retracted, thus preventing the movement of the vehicle by diverting all hydraulic fluid flow from the drive motors 38.
A hand pump 180 may be used to lower the passenger compartment in the event the main pump 52 is inoperative. Emergency Down valve 182 will be opened to provide the necessary circulation path for the hydraulic fluid when the hand pump is used. Moving the vehicle by hand or by towing without the pump motor operating is possible whenever the stabilizers are retracted and if the drive selector 154 is either in the neutral or center position or in the direction of desired travel.
The operator's control panel 68 is shown in FIG. 14. This panel is located in the operator's compartment 60 and includes motor control switch 190 having an off, run, start and accessory position, similar to a conventional automobile switch. An emergency stop switch 191 removes power to the motor whenever the operator presses on the red mushroom shaped button. A switch 192 controls the vehicle's running lights, such as head and tail lights and instrument panel lights 193.
The passenger compartment section of the panel 68 includes a weather proof toggle switch 194 which controls the solenoid actuated lift selector 170. The passenger compartment interior lights are controlled by switch 195 and the rear ramp courtesy lights are controlled by switch 196. Indicator lamp 197 shows when the parking brake is set.
Drive controls are on the right side of the panel 68 and include the grade selector 152, drive selector 154, and horn button 198. An indicator lamp 199 shows when the stabilizers are in the up or retracted position. The electrical schematic diagrams of FIGS. 15A and 15B show the electrical components of the vehicle.
Referring now to FIGS. 4-6, the mode of operation of the passenger access lift will be described. Usually, the rear ramp will be lowered to the position shown in FIG. 5 where a disabled passenger 12 and an attendant 14 may be moved up the ramp and into the passenger compartment 90 of the vehicle. The disable passenger is typically seated in a boarding wheelchair 13 and is preferably moved in to the passenger compartment facing backwards. The rear ramp 110 will then be raised and locked in its traveling position and the vehicle 10 then moved to the area where elevated boarding will occur.
As shown in FIG. 4, the passenger access lift 10 will move directly toward a door 212 of an aircraft 210, parallel to the wing 216 and propeller 218. Of course, either a front or rear door or the aircraft may be approached in this manner. As the operator guides the vehicle toward the door, the operator's compartment 60 will pass to the left of and adjacent any stairway 220 extending from the aircraft. By locating the operator in the forward part of the vehicle and adjacent the forward ramp, placing the vehicle in proper position for extending the ramp 112 into the door 212 of the aircraft 210 is made easier.
At this time, the operator will set the parking brake 171 (a mechanical brake), which will be indicated by parking brake light 197. When the driver operates the lift selector toggle 194 to the UP position, lift selector valve 170 is be actuated. This action will automatically activate the stabilization system by lowering the stabilizer pads 47 into positive contact with the ground.
After the stabilizers 40, 42 and 44 are in position, the passenger platform will raise to a height judged by the operator to be sufficient. The driver or the attendant will then lower the front ramp 112 into the door 212 of the aircraft, between any handrails 222 associated with the aircraft's stairway 220. The ramp's handrails 130 will automatically extend. If necessary, the ramp 112 may be aligned laterally to position it squarely in the door and between the handrails 222. The attendant then removes the wheelchair constraints 95 and safety chain 99 (FIG. 11) and pulls the passenger across the ramp 112 in the direction of the arrow 224 to the elevated destination, as shown in FIG. 6. There are a few circumstances where the passenger will be moved onto an aircraft facing forward, such as when loading through a rear door and where the space in the aircraft does not permit turning the passenger around.
Moving a passenger from the elevated door of an aircraft to the terminal will be accomplished in a similar manner, but the passenger will normally be pulled by the attendant into the vehicle and will end up facing forward of the vehicle, opposite that shown in FIG. 6. The passenger and attendant will then be lowered, the stabilizers retracted, and the vehicle moved to the terminal where the passenger will be off loaded on ramp 110.
A cover or canopy 230 may be provided for the passenger compartment, if desired, as illustrated in FIG. 6.
While the method herein described, and the form of apparatus for carrying this method into effect, constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to this precise method and form of apparatus, and that changes may be made in either without departing from the scope of the invention, which is defined in the appended claim. | A self propelled steerable vehicle for transporting a wheelchair bound passenger between two separate locations, such as between a terminal and an aircraft parked on a ramp, includes a lift assembly mounted on said vehicle for movement from a lowermost position to an operator selectable upper position. The vehicle is provided with an operator's compartment containing steering, braking, motive and lift assembly controls. An internal combustion engine powers a hydraulic system for both moving the vehicle and powering the lift assembly. A passenger's compartment carried by said lift assembly is provided with a pair of ramps which are movable from a loading position to a traveling position. In the loading position, hand rails are automatically extended. Gas cylinders between the hand rails and the ramp assist the operator is raising the ramps. In the traveling position, the ramps act as gates for the passenger compartment. The operator's position is at the front of the vehicle, near the passenger compartment, which allows ready access to the forward ramp. Stabilizers are used when the lift assembly is in other than its lowermost position and are automatically extended prior to the lifting of the passenger compartment. The stabilizers are fully retracted prior to subsequent movement of the vehicle. | 8 |
FIELD OF THE INVENTION
The present invention pertains generally to rivet type fasteners for attachment in holes of work pieces; and more particularly, to self-locking rivet type fasteners that can be released for removal and re-use.
BACKGROUND OF THE INVENTION
Various types of push-in fasteners have been used for engagement in holes of work pieces, to fasten together adjacent panels, or secure objects on the work piece. In a simple form for such a fastener, the work piece is provided with a hole. The fastener includes a head and a shank. The head is sized larger than the hole, so that the head will not pass into or through the hole. The shank includes outwardly biased but yieldable segments, frequently having an inwardly angled tapered tip. The expanded portion of the shank is nominally larger than the hole. Securing the fastener in the work piece is achieved by forcing the shank into the hole. As the shank enters and slides through the hole, the outwardly biased yet yieldable portions move slightly inwardly to allow full insertion of the fastener, until the head engages a surface of the work piece first entered by the fastener. A segment of the shank extends through the hole in the work piece. Due to the shape of the shank and the structure of the shank segments controlling the degree to which each can yield or deflect, withdrawal of the shank from the aligned apertures can be made difficult or prevented. A disadvantage of this type of fastener is that the insertion pressure required to cause the shank segments to yield may be disadvantageously high if the outward biasing force of the segments is sufficient to inhibit or prevent subsequent withdrawal of the fully inserted fastener.
In another type of fastener, the shank includes a hollow core accessed through an opening in the head. A pin is provided. After the shank has been fully inserted, the pin is driven into the core of the shank, thereby urging the shank outwardly and securing the fastener in the hole of the work piece. Two-part fasteners of this type have disadvantages in that the parts can become separated from each other. Proper insertion of the pin into the shank may be troublesome if the access area is limited, or the individual using the fastener does not have sufficient dexterity to handle significantly small pins.
A fastener with a retained movable pin is shown in U.S. Pat. No. 6,074,144. A disadvantage of this design is that multiple steps are required to pre-assemble the fastener before actual use. The pin must be positioned in a pre-locking position after initial molding of the fastener.
Similar structures can be used as a fastening base or anchor on the surface of a work piece, rather than as a fastener joining two work pieces. The fastener is inserted in a work piece, and carries a superstructure on the surface of the work piece. The superstructure is configured for the attachment thereto of another work piece, covering or the like. It would be advantageous in many such applications if the fastener were easily removable and reusable.
What is needed in the art is a self-locking rivet type fastener that includes a pre-lock configuration in which the shank is readily inserted into a hole, with minimal insertion pressure. What is further needed is a self-locking type rivet fastener that expands automatically as part of the insertion process, and that is locked into place upon full insertion. Further what is needed is a releasable type rivet fastener easily used and securely positioned, yet releasable for removal and re-use.
SUMMARY OF THE INVENTION
The present invention provides a rivet-type fastener for securing within a hole of a work piece. The structure of the fastener causes automatic expansion of the fastener as the fastener is inserted in the hole, and engages locking members to secure the fastener in the hole.
In one aspect thereof, the invention provides a fastener for a work piece with a base and first and second arms attached to the base and extending outwardly therefrom. The first and second arms each include proximal segments and distal segments conjoined at ends thereof. A post extends inwardly between the arms, from the conjoined distal segments toward the base. The arms and the post have cooperating structures for spreading the arms and locking the arms in a spread position, as relative axial movement occurs between the arms and the post.
In another aspect of the invention, a fastener is provided with a base having a surface defining a channel, and opposed arms joined to the base in spaced relation on opposite sides of the channel. The arms include distal segments. A post is joined to the distal segments of the arms and extends between the arms towards the base. The post includes a transverse bar between the arms and aligned with the channel. Lateral protrusions extend outwardly from the post, and have tips. Notches in the arms engage the tips of the lateral protrusions in a locked position.
In still another aspect thereof, the invention provides a rivet-style fastener with a base having a,surface defining a channel. First and second opposed arms are joined to the surface of the base, in spaced relation to each other, and on opposite sides of the channel. The arms include relatively thicker proximal segments and relatively thinner distal segments. A post is joined to the distal segments and extends between the arms towards the base. The post includes a transverse bar between the arms and aligned with the channel. The bar has a length greater than the width of the hole. Lateral protrusions extend outwardly from the post, and have wedge surfaces ending at protrusion tips. Notches are provided in the proximal segments for engaging the tips of the lateral protrusions. Ramp surfaces on the arms direct the tips from the unlocked position to a locked position in which the tips are engaged by the notches, and the arms are deflected outwardly.
An advantage of the present invention is providing a unitary rivet-style fastener, with automatic locking structures activated upon insertion of the fastener in a work piece.
Another advantage of the present invention is providing a fastener for a hole in a work piece that locks during insertion and can be unlocked for removal and re-use.
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a self-locking rivet fastener according to the present invention;
FIG. 2 is a perspective view of the fastener shown in FIG. 1;
FIG. 3 is a perspective view of the fastener shown in FIGS. 1 and 2, but showing the lower side of the fastener from that shown in FIG. 2;
FIG. 4 is a perspective view of the fastener shown in FIG. 3, illustrating partial insertion of the fastener in a work piece;
FIG. 5 is an elevational view similar to FIG. 1, but illustrating full insertion of the fastener in the work piece;
FIG. 6 is an elevational view of a second embodiment of the fastener according to the present invention; and
FIG. 7 is a perspective view of yet another embodiment of the fastener according to the present invention.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and 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 or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more specifically to the drawings, and to FIG. 1 in particular, numeral 10 designated a fastener of the present invention. Fastener 10 is useful in fastening together adjacent panels (not shown) having apertures therethrough. Fastener 10 also may be used as an anchor to which other structures can be secured, in which case fastener 10 can be inserted in a single work piece 12 , as shown in FIGS. 4 and 5.
Fastener 10 includes a base 14 that may be of a variety of shapes and configurations, depending on the application of and use for fastener 10 . FIG. 5 illustrates fastener 10 in a vertical orientation in work piece 12 , with base 14 above work piece 12 ; however, it should be understood that fastener 10 also can be used in applications wherein base 14 is below, along side or oriented angularly with respect to work piece 12 . Terms such as “top”, “bottom”, “up”, “down” and variations thereof are used herein for ease in description only, and are used with respect to the orientation of the various views in the drawings. Thus, the terms are not to be understood as limitations on the orientation of fastener 10 , or how it may be used.
In the embodiments illustrated, base 14 is a substantially flat, rectangular, plate-like structure having a top surface 16 , a bottom surface 18 , side surfaces 20 and 22 and end surfaces 24 and 26 . While base 14 is illustrated to be rectangular in the drawings, base 14 could be of other shapes. Additionally, for fastening purposes, top surface 16 can carry a variety of superstructures and fastening components, as necessary. As illustrated in FIGS. 1 through 5, base 14 includes a pair of slots 28 and 30 extending therethrough, from side surface 20 to side surface 22 , intermediate top and bottom surfaces 16 and 18 . Slots 28 and 30 can be used, for example for receiving tabs from panels or other components hung on or secured to fastener 10 .
Bottom surface 18 defines a rectangular channel 32 having channel sides 34 and 36 and a channel floor 38 . Channel sides 34 and 36 angle outwardly from channel floor 38 , so that the opening to channel 32 is wider than channel floor 38 . Channel 32 extends between side surfaces 20 and 22 and separates bottom surface 18 into bottom surface segments 18 A and 18 B. Depending on the size, shape, application and use of base 14 , channel 32 may be disposed intermediate side surfaces 20 and 22 or end surfaces 24 and 26 , perpendicular thereto or at an angle, and in shapes other than the rectangular shape shown. An aperture 40 is formed in base 14 , having openings in and extending from channel floor 38 to top surface 16 .
First and second arms, designated 50 and 70 respectively, are connected to base 14 and extend outwardly from bottom surface 18 on opposite sides of channel 32 . When viewed from either side of fastener 10 , arms 50 and 70 are mirror images of each, being similarly shaped and oppositely directed so as to face each other. Arms 50 and 70 have relatively thicker proximal segments 52 and 72 nearest base 14 , and relatively thinner distal segments 54 and 74 furthest from base 14 . Proximal segments 52 and 72 angle outwardly, slightly, from base 14 . When viewed in side elevation as shown in FIG. 1, arms 50 and 70 define a slight pear shape, in the unlocked position of fastener 10 , as shown. A wider middle is provided near the junction of proximal segments 52 and 72 with distal segments 54 and 74 , and narrower ends both at base 14 and distal segments 54 and 74 .
Proximal segments 52 and 72 define notches 56 and 76 , respectively, generally aligned with and facing each other near ends 58 and 78 of proximal segments 52 and 72 , joining distal segments 54 and 74 , respectively. Notches 56 and 76 are defined by intersecting walls 60 , 62 and 80 , 82 respectively. Ramps 64 and 84 extend from ends 58 and 78 , respectively, each angling inward and toward base 14 , intersecting with walls 62 and 82 of notches 56 and 76 , and forming lips 66 and 86 , respectively.
Distal segments 54 and 74 extend from proximal segments 52 and 72 , respectively, curving inwardly toward each other and forming loops 68 and 88 , respectively, conjoined at a post 90 . Loops 68 and 88 are pliable, accommodating deformation thereof, to enable relative axial movement between post 90 and proximal segments 52 and 72 . Post 90 extends from conjoined distal segments 54 and 74 toward base 14 , between arms 50 and 70 . A transverse bar 92 is provided at the top of post 90 , bar 94 being aligned with channel 32 , but spaced therefrom in an unlocked, relaxed condition of fastener 10 , as shown in FIGS. 1-3. Bar 92 is.sufficiently long to extend beyond the widths of arms 50 and 70 . The width of bar 92 is less than the opening to channel 32 , so that bar 92 will fit in channel 32 , against channel floor 38 . In the embodiment of fastener 10 shown in FIGS. 1-5, a pin 94 extends from bar 92 through aperture 40 , terminating slightly beyond top surface 16 .
First and second protrusions 96 and 98 project laterally from post 90 , and have outer tips 100 and 102 , shaped to be received in notches 56 and 76 , respectively. Protrusions 96 and 98 have wedge surfaces 104 and 106 , respectively, that extend angularly from tips 100 and 102 , both inwardly toward post 90 and upward toward bar 92 .
In the use of fastener 10 , a hole is provided in work piece 12 sufficiently wide for arms 50 and 70 to be pushed therethrough, but sufficiently narrow that the fit of arms 50 and 70 is snug, with some resistance. The insertion of fastener 10 is commenced with fastener 10 in a relaxed, unlocked position as shown in FIGS. 1-3. The width of the hole in work piece 12 can be slightly smaller than the widest dimension defined by arms 50 and 70 . However, the hole should be greater than the dimension defined between tips 100 and 102 , and the thickness of distal segments 52 and 72 in the region of protrusions 96 and 98 . The space between arms 50 and 70 , and the widths thereof can be such that a round hole can be provided in work piece 12 , or the configuration may be such as to require an oblong hole or other shape. With fastener 10 properly oriented in work piece 12 , the hole in work piece 12 directly beneath bar 92 is narrower than the length of bar 92 .
Loops 68 and 88 are placed in the hole of work piece 12 . As force is applied, and fastener 10 is advanced in the hole, proximal segments 52 and 72 encounter the side of the hole in work piece 12 . With additional insertion force applied to base 12 , arms 50 and 70 deflect slightly inward, until the widest portion thereof passes through the hole. The gently curving shape of the outer surfaces of arms 50 and 70 cause the inward deflection of arms 50 and 70 to occur smoothly and easily. After the widest portions thereof pass through the hole in work piece 12 , arms 50 and 70 spring outwardly.
At about the same position, bar 92 will come to rest against work piece 12 , without advancing through the hole in work piece 12 due to the length of bar 92 . Continued insertion of fastener 10 occurs without further movement of post 90 . As proximal segments 52 and 72 are pushed further into work piece 12 , loops 68 and 88 begin to flatten, and ramps 64 and 84 come into contact with wedge surfaces 104 and 106 respectively. Sliding movement of ramps 64 and 84 against wedge surfaces 104 and 106 causes spreading between proximal segments 52 and 72 near ends 58 and 78 .
Bar 92 enters channel 32 as bottom surface 18 approaches work piece 12 , so that bottom surface 18 can rest flush against work piece 12 . The outward tapers of channel sides 34 and 36 direct bar 92 to the bottom of channel 32 , against channel floor 38 . When fastener 10 is fully inserted and locked, bar 92 is secured in channel 32 , between channel floor 38 and work piece 12 .
As bar 92 comes to rest against channel floor 38 , tips 100 and 102 of protrusion 96 and 98 slide past lips 66 and 86 , lodging in notches 56 and 76 , respectively. Arms 50 and 70 are sufficiently spread to prevent withdrawal of fastener 10 from the hole in work piece 12 . With protrusions 96 and 98 lodged between arms 50 and 70 , inward deflection of arms 50 and 70 is inhibited. Thus, fastener 10 is locked in work piece 12 , and can not be withdrawn easily.
An advantage of the present invention, in some embodiments thereof, is that fastener 10 can be unlocked and withdrawn. From the locked position shown in FIG. 5, axial pressure is applied to pin 94 . Tips 100 and 102 are forced downwardly, past lips 66 and 86 , thereby unlocking the fastener. Only minimal distortion of tips 100 and 102 , and/or of lips 66 and 86 is required to dislodge tips 100 and 102 from notches 56 and 76 , thereby unlocking fastener 10 . The fastener can then be pulled outwardly from work piece 12 .
The self-locking feature of the present invention can be used advantageously without the unlocking feature of the invention. FIG. 6 illustrates a second embodiment 120 of the invention that does not include aperture 40 , or pin 94 extending from bar 92 . Further, the present invention can be made unlockable without pin 94 . FIG. 7 illustrates a third embodiment 130 that includes aperture 40 , as described previously, without pin 94 extending therethrough from bar 92 . To unlock third embodiment 130 , an awl, punch or similar probe-like instrument is inserted through aperture 40 against bar 92 . Continued pressure from the instrument against bar 92 provides the aforedescribed unlocking by dislodging tips 100 and 102 from notches 56 and 76 .
Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.
Various features of the invention are set forth in the following claims. | A rivet-type fastener is disclosed, suitable for panel fasteners and other applications in which retention in a hole is required. The act of inserting the fastener expands fastener arms to secure the fastener in the hole, and positions locking protrusions of a post within notches of the arms, to lock the fastener within the hole. In some embodiments the fastener can be released, for removal and re-use. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of PCT application PCT/JP2007/000695 filed on Jun. 26, 2007.
FIELD
The embodiments discussed herein are related to a design support device for supporting the shape design of flexible parts, members, etc.
BACKGROUND
Recently, three-dimensional data is widely prepared in CAD (computer aided design) technology as a design support device for equipment, and the equipment can be designed, operation-verified, etc. in a three-dimensional virtual space. Thus, the verification previously performed by manufacturing a prototype can be performed in a designing stage of a product using product data arranged in the virtual space, thereby enabling a product to be developed in a short period.
An electronic part in electronic equipment is electrically connected by a harness (wire harness), a cable, etc. In the connection wiring of an electric signal using the harness, the cable, etc., there is the increasing need for preliminary verification from a design stage. Since a harness, a cable, etc. are flexible objects and light in weight, their wiring routes are curve-shaped in many cases.
When a designing operation is performed by arranging a harness, a cable, etc. in a virtual space, their routes are first defined as curves, and then the shapes of the harness and the cable are drawn with the curves centered.
In this case, the curves of the routes are divided by the starting point, the end point, and their pass points, and defined as the curves connecting the points. The starting point, the end point, and each pass point are managed by the “pass point information” including “position coordinates” and a “pass direction”. The pass direction indicates the tangent direction of the curve passing the pass point, and is defined as a vector (passing vector). The coordinate system set in the virtual space is roughly classified into an “absolute coordinate system” and a “relative coordinate system”. One absolute coordinate system is defined in a virtual space, and a relative coordinate system is set for each pass point. The pass points in this case include the starting points and the end points of the routes of a harness and a cable. In the description below, the term “pass point” includes the starting point and the end point.
Described below is a conventional shape generating method for a harness and a cable in a virtual space. In the following description, a harness and a cable are generally represented by the term of a “flexible object” for convenience.
{First Conventional Flexible Object Shape Generating Method}
FIG. 1 illustrates a first conventional method for generating the shape of a flexible object in a virtual space.
In this method, as illustrated in FIG. 1 , the distance between a starting point 11 of a flexible object 10 and an end point 12 is divided into a plurality of sections (five sections in this example), and a flexible object in each section is treated as a model 13 of a predetermined shape such as a cylinder, a rectangle, etc. By arranging the model 13 in each section, the shape of a flexible object is expressed. Since the flexible object is generally curved, its center line is a curve 14 . Therefore, the shape of the curve 14 is first determined, then the curve 14 is appropriately divided into a plurality of sections, and a cylindrical or rectangular model 13 is arranged in each section, thereby generating the shape of the flexible object.
The merit of this method is that a change in position or shape of a flexible object can be processed only by changing the coordinates of each model unless there is a change in wire length between the starting point and the end point. That is, since the model of each section before the change can be used as is, it is not necessary to change the model, and the arrangement or the shape of the flexible object can be processed in a high speed.
The demerits of this method are listed below.
When the wire length between the starting point and the endpoint is changed, the section before the change cannot be used as is. Therefore, it is necessary to regenerate the model. Since the shape of each section is only substituted by a model of a fixed shape such as a cylinder, a rectangle, etc., the shape is different from the actual shape of a flexible object. Although a natural shape approximate to a real object by dividing the distance between the starting point and the end point, the processing time increases by increasing the number of sections. When the shapes into which an original flexible object is divided are variable, the section of a large shape cannot conform to a large curvature.
{Second Conventional Flexible Object Shape Generating Method}
FIG. 2 illustrates a second conventional method for generating the shape of a flexible object in a virtual space.
In this method, as illustrated in FIG. 2 , a point is set in a curved portion 24 of the section between a starting point 21 of a flexible object 20 and an end point 22 , and the points are connected by a straight line (approximately straight line) 25 . In this case, the length of the straight line 25 is set as having a predetermined length or less, and the curved portion 24 is approximated by a plurality of short straight lines 25 . Next, a cross-sectional shape 26 is formed with respect to each point, the shape of each cross-sectional shape 26 is connected to that of the adjacent point, thereby generating a model using the curve connecting the starting point 21 to the end point 22 as one model.
The merit of the second conventional method is that the shape of a real object can be correctly represented because the cross-sectional shape of a portion having a large curvature can be minutely obtained.
On the other hand, the demerits of the method are listed below.
Since it is necessary to regenerate the shape after changing a curve, a long changing time is required. Since a flexible object is managed using one model, it is necessary to change the curve and the shape of the entire flexible object each time the curve is changed.
A part of a general structure is regarded as one rigid object, and after the first shape generation, the entire shape is moved or rotated to represent the shape in a three-dimensional virtual space. On the other hand, since the shape of a flexible object such as a harness, a cable, etc. changes depending on the mode of the arrangement of a part in a device, etc., the passing route of a part changes as the part moves and rotates. Therefore, each time a part moves or rotates, it is necessary to recalculate the curve of the route and regenerate the shape of a string, a belt, etc.
Therefore, there are the following problems with the method.
When the route of a flexible object (a harness, a cable, etc.) is changed, it is necessary to recalculate the curve and the shape of the entire harness with the change in the shape of the harness. Accordingly, the computer requires a large capability to perform calculations to dynamically generate the curve and the shape of a flexible object and display them in real time when the route of the flexible object is changed. Even when there is a change only at one portion of the route of a flexible object, the curve is to be regenerated on the entire route. Therefore, when the route of the harness is changed, the changed portion cannot be easily detected.
Patent Document 1: PCT/JP2007/50187
Patent Document 2: PCT/JP2007/50189
SUMMARY
The design support device according to an aspect of the invention is to design a part in string or belt form.
The first aspect of the design support device according to the invention includes: a part editing unit configured to edit a part by changing the position of a pass point through which the part passes; and a section comparison unit configured to compare a section having a plurality of consecutive pass points before the edition by the part editing unit with the sections after the edition by the part editing unit, and extracting the section in which the relative positions or the relative passing directions are different between two pass points in the sections.
In the first aspect of the design support device according to the invention, when a pass point of apart in string or belt form is changed, the part is edited. On the basis of the edition result, a section having a changed point in relative position or relative passing direction after the change is extracted. Thus, for example, a section in which a shape has been changed can be extracted using the relative coordinate system etc. set in each section.
The second aspect of the design support device according to the invention is based on the first aspect of the design support device according to the present invention. By comparing the sections, a section in which the tangent direction of the part shape and the gravitational force direction are different after the edition in at least one pass point of the section is extracted.
The second aspect of the design support device according to the invention extracts a section in which the tangent direction of a part shape and the gravitational force direction are different after the edition for each section. Thus, a section in which it is necessary to regenerate a shape due to a change of the position in an absolute contents system although the relative position and the relative passing direction are not changed can be extracted. The section for which a difference of the pass direction with respect to the gravitational force direction is considered can be, for example, specified. The specification is performed by, for example, a user.
The third aspect of the design support device according to the invention is based on the first or second aspect of the design support device according to the present invention, and further includes a shape generation unit configured to generate a shape in the section extracted by the section comparison unit and connect the shape to the shape of a section outside the extracted section.
According to the third aspect of the design support device of the invention, the shape of a section in which the shape is changed can be generated.
The fourth aspect of the design support device according to the invention is based on any of the first through third aspects, and further includes a display unit configured to change and display the display attribute of the section extracted by the section comparison unit.
According to the fourth aspect of the design support device of the invention, a section in which in which a shape is changed and a section in which a shape is not changed can be identified and displayed.
The fifth aspect of the design support device according to the invention is based on any of the first through fourth aspects, and further includes a change section display unit configured to display the information about the section extracted by the section comparison unit before a change and after the change.
According to the fifth aspect of the design support device of the invention, how a shape has been changed in a section in which the change has been detected can be grasped.
The design support method according to the present invention is to design a part in string or belt form.
The first aspect of the design support method according to the invention includes: editing a part by changing the position of a pass point through which the part passes; comparing a section having a plurality of consecutive pass points before the editing with the sections after the editing, and extracting the section in which the relative positions or the relative passing directions are different between two pass points in the sections.
In the comparing of the second aspect of the design support method according to the invention, a section in which the tangent direction of the part shape and the gravitational force direction are different after the edition in at least one pass point of the section is extracted.
The third aspect of the design support method according to the invention further includes generating a shape in the section extracted in the comparing, and connecting the shape to the shape of a section outside the extracted section.
The first aspect of the storage medium storing the program according to the invention directs a design support computer for designing a part in string or belt shape to perform the process including: editing a part by changing the position of a pass point through which the part passes; and comparing a section having a plurality of consecutive pass points before the editing with the sections after the editing, and extracting the section in which the relative positions or the relative passing directions are different between two pass points in the sections.
In the comparing of the second aspect of the storage medium according to the invention based on the first aspect of the storage medium according to the present invention, a section in which the tangent direction of the part shape and the gravitational force direction are different after the edition in at least one pass point of the section is extracted.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates the first conventional method for generating the shape of a flexible object in a virtual space;
FIG. 2 illustrates the second conventional method for generating the shape of a flexible object in a virtual space;
FIG. 3 illustrates the configuration of a system to which an embodiment of the design support device according to the present invention is applied;
FIG. 4 is an explanatory view of the definition of the “relative position”, “relative passing direction”, and “gravitational force direction” used in an embodiment of the present invention;
FIG. 5A is an explanatory view of the “difference in relative position” used by the section comparison unit in detecting a change in harness shape of a section;
FIG. 5B illustrates a change in relative position after the change of a section 2 illustrated in FIG. 5A ;
FIG. 6A is an explanatory view of the “difference in relative passing direction” used by the section comparison unit in detecting a change in harness shape of a section;
FIG. 6B illustrates a change in relative passing direction after the change of a section 2 illustrated in FIG. 6A ;
FIG. 7A is an explanatory view of the “difference from gravitational force direction” used by the gravitational force direction comparison unit in detecting a change in harness shape of a section;
FIG. 7B illustrates a change in difference from the gravitational force direction after the change of a section 2 illustrated in FIG. 7A ;
FIG. 8 illustrates an example of the section shape management unit managing a harness for each section;
FIG. 9A is an example of a configuration of the section shape management table;
FIG. 9B illustrates in detail the section 3 stored in the section shape management table in FIG. 9A ;
FIG. 10A is a flowchart of the procedure of the gravitational consideration flag setting process performed by the harness management unit;
FIG. 10B is an example of a configuration of the gravitational consideration flag management table provided for the harness management unit;
FIG. 11A is a flowchart illustrating the entire flow of the harness changing process performed by the design support device according to an embodiment of the present invention;
FIG. 11B is a flowchart illustrating in detail the harness shape generating process in FIG. 11A ;
FIG. 11C is flowchart illustrating in detail the curve/shape generating process in FIG. 11B ;
FIG. 12 is an example of displaying a generated harness (before a change) displayed by the section shape display unit on the screen of a display device;
FIG. 13 is another example of displaying a generated harness displayed by the section shape display unit on the screen of a display device;
FIG. 14A is an example of highlight display (highlight display by display color) of a harness displayed by the section shape display unit on the screen of a display device;
FIG. 14B is another example of highlight display (highlight display by shape) of a harness displayed by the section shape display unit on the screen of a display device;
FIG. 15 is an example of section information display displayed by the section shape display unit; and
FIG. 16 illustrates an example of a configuration of a system of a computer executing the design support program according to an embodiment of the present invention;
DESCRIPTION OF EMBODIMENTS
The embodiments of the present invention are described below with reference to the attached drawings.
[Configuration]
{System Configuration}
FIG. 3 illustrates the configuration of a system to which an embodiment of the design support device according to the present invention is applied.
A design support device 100 in FIG. 3 is provided with a harness editing unit 101 , a three-dimensional model management unit 102 , a pass point management unit 103 , a comparison unit 104 , a generation unit 105 , a section shape management unit 106 , and a display unit 107 .
The harness editing unit 101 edits and manages the information about the route design of each harness on the basis of user input from an input device 120 . In the present embodiment, as described later, a “gravitational consideration flag” of a pass point specified by the user is set according to the pass point specification information from the input device 120 . The gravitational consideration flag is set for the pass point at which a change is detected between the pass direction (pass direction vector) and the gravitational force direction (gravitational force direction vector) in the pass points specified by the user. The harness editing unit 101 also receives from the input device 120 the setting information etc. about the highlight shape of each section of the harness specified by the user through the input device 120 , and manages the information.
The three-dimensional model management unit 102 manages the model data (three-dimensional model data of the part arranged in a virtual space) of a part implemented in a device to be designed. The three-dimensional model management unit 102 is provided with a model data database (model data DB) 102 a and a verification model management unit 102 b . The model data DB 102 a is a database for storage and management of the model data of the above-mentioned part. The verification model management unit 102 b manages the model data DB 102 a , and registers and deletes the model data of each part. The pass point management unit 103 manages the information (about the position, the pass direction, the gravitational force direction, etc.) about the pass point of the route of each harness. Hereinafter, the information about the pass point is referred to as “pass point information”.
When the pass point of a harness is changed, the comparison unit 104 acquires the pass point information about the harness from the pass point management unit 103 , and detects a section in which the shape is to be changed about the harness. When a change of a section is detected, three types of parameters, that is, “relative position”, “relative passing direction”, and “gravitational force direction” are used. The comparison unit 104 is provided with a section comparison unit 104 a and a gravitational force direction comparison unit 104 b , and detects a section in which a shape change is required. The section comparison unit 104 a detects a section in which a shape change is required by checking a change in relative position and relative passing direction of each section of the route of a harness. The gravitational force direction comparison unit 104 b detects a section in which a shape change is required by checking a change in “gravitational force direction” of each section of the route of a harness. The definitions of the relative position, the relative passing direction, and the gravitational force direction, and the method of detecting a section in which a shape change is required are described later in detail. When a harness in which a shape change is required is detected, the comparison unit 104 notifies the generation unit 105 of the harness. In this case, it also notifies the generation unit 105 of the information about the section in which a shape change is required.
Upon receipt of the notification from the comparison unit 104 , the generation unit 105 generates the shape of the route of the notified harness. The generation is performed only in a section in which a shape change is required (hereinafter referred to as a “shape regeneration section”). The generation of a shape in the shape regeneration section is performed in the above-mentioned conventional method. Therefore, first, the curve of the shape regeneration section is generated. Next, on the basis of the curve, the shape of the shape regeneration section is generated. The generation unit 105 is provided with a curve generation unit 105 a and a shape generation unit 105 b . The curve generation unit 105 a generates the curve of the shape regeneration section. The shape generation unit 105 b generates the shape of the shape regeneration section on the basis of the curve generated by the curve generation unit 105 a . The generation unit 105 notifies the section shape management unit 106 of the information about the generated shape of the shape regeneration section (hereinafter referred to as shape regeneration section shape information). The shape regeneration section shape information includes the information about the wire lengths before and after the change of the shape regeneration section, etc. The generation unit 105 transmits the generated shape data of each section of the harness to the section shape management unit 106 .
The section shape management unit 106 manages the information about the shape in each section of the harness on the basis of the management information acquired from the harness editing unit 101 and the shape data of each section of the harness received from the generation unit 105 .
The display unit 107 acquires the shape information about the route of the harness from the section shape management unit 106 , and generates the display data of the shape of the harness (hereinafter referred to as “harness shape display data”). The harness shape display data is displayed with the shape-changed section (hereinafter referred to as a “shape change section”) discriminated from the shape-unchanged section. The display unit 107 also generates the display data of the change information about the shape change section (hereinafter referred to as “section information”. The display unit 107 is provided with a section shape display unit 107 a and a section information display unit 107 b . The section shape display unit 107 a generates the harness shape display data. The section information display unit 107 b generates the display data of the section information. The display unit 107 acquires the model data of a part from the three-dimensional model management unit 102 , and arranges the model data in a virtual space in the arrangement position of the part, thereby generating the three-dimensional model display data of the inside of the device in which the part is arranged. By merging the three-dimensional model display data with the harness shape display data generated by the section shape display unit 107 a , the display data of the three-dimensional model (three-dimensional model display data of the device to be designed) in which the part connected by the harness inside the device is generated.
The input device 120 and a display device 130 are connected to the design support device 100 . The input device 120 inputs a command and data to the design support device 100 , and is provided with a pointing device such as a keyboard, a mouse, etc. The user of the design support device 100 inputs necessary data (model data of a part), data of a harness, etc) for design of a device. When the route of a harness is changed, the change position of the pass point set in the route is specified through the input device 120 .
The display device 130 displays a three-dimensional model of a device designed by the design support device 100 , and is provided with a liquid display, a CRT display, etc. The display unit 107 of the design support device 100 outputs the three-dimensional model display data of the device to be designed, the harness shape display data, the display data of the section information, etc. When the above-mentioned data are input, the display device 130 displays the screen corresponding to the display data. The display device 130 also displays the user interface screen for input of an instruction and data by a user to the design support device 100 .
{Definitions of Relative Position, Relative Passing Direction, and Gravitational Force Direction}
The definitions of the above-mentioned “relative position”, “relative passing direction”, and “gravitational force direction” are described below with reference to FIG. 4 .
In FIG. 4 , the point P 2 and the point P 3 are pass points set on the curve of the harness, and the distance between the adjacent pass points P 2 and P 3 is defined as a section. The pass point P 2 of the starting point in the section is defined as a starting point pass point, and the pass point P 3 of the end point is defined as an end point pass point.
The curve L 2 indicated by the broken line in FIG. 4 refers to the harness of the section (hereinafter referred to as a section 2 ) between the pass points P 2 and P 3 . M 2 and M 3 are models of parts, and are, for example, clamping parts (hereinafter referred to as clamp parts). In this example, the pass points P 2 and P 3 are set in the positions in which they are separate from each other by a predetermined distance in the normal direction from the parts M 2 and M 3 respectively.
For the section 2 , a relative coordinate system having the starting point pass point P 2 is set as an origin. The relative coordinate system is a three-dimensional orthogonal coordinate system 202 enclosed by a rectangular frame 201 in FIG. 4 . In the present embodiment, the positive direction of the X axis of the relative coordinate system 202 is set in the pass direction of the harness L 2 at the starting point pass point P 2 . The pass direction of the starting point pass point P 2 is represented by a three-dimensional vector (hereinafter referred to as a pass direction vector) VP 2 . The direction of the X axis of the relative coordinate system having the starting point pass point of the section as an origin is not limited to the pass direction of the starting point pass point. For example, the pass direction of the starting point pass point can be set on the Y axis of the relative coordinate system.
In the relative coordinate system 202 having the pass point P 2 as an origin (0, 0, 0), the coordinates (x3, y3, z3) of the pass point P 3 are determined. In this case, x3, y3, and z3 are respectively defined as the relative positions of the X direction (X-axis direction), the Y direction (Y-axis direction) and the Z direction (Z-axis direction). The pass direction vector VP 2 of the pass point P 2 is set as a unit vector represented by (1, 0, 0) in the relative coordinate system 202 . In the pass point P 3 , the pass direction vector VP 3 is set as a unit vector parallel to the pass direction of the curve L 2 (harness). In this case, the pass direction vector VP 3 in the relative coordinate system 202 is represented by (xv3, yv3, zv3). Therefore, the relative passing direction of the pass point P 3 with respect to the pass point P 2 is represented by (1-xv3, 0-yv3, 0-zv3).
The gravitational force direction is the direction of the universal gravitation, and the vector VG in the gravitational force direction is set in each of the pass points P 2 and P 3 . In the present embodiment, the gravitational force direction vector VG is represented by the coordinates of he absolute coordinate system.
{Change of Relative Position}
Next, the “change of a relative position” used by the section comparison unit 104 a in detecting a change of a harness shape in a section is described with reference to FIGS. 5A and 5B .
FIG. 5A is an example of connecting a part (model) Ms to a part (model) Me through a harness. In FIG. 5A , the curve of the broken line refers to the route of the harness before the change, and the curve of the solid line refers to the route of the curve after the change. In this example, the starting point Ps of the harness is set on the part Ms, and the endpoint Pe of the harness is set on the part Me. In addition, the pass points P 2 and P 3 are set in order from the starting point of the harness as the pass points between the starting point Ps and the end point Pe of the harness. The section between the starting point PS and the pass point P 2 is defined as a section 1 , the section between the pass points P 2 and P 3 is defined as a section 2 , and the section between the pass point P 3 and the end point Pe is defined as a section 3 .
In this example, the position of the pass point P 3 is changed. In FIG. 5A , the pass point P 3 after the change is expressed by pass point P 3 ′. As a result of the change of the position of the pass point P 3 , the route shapes of the section 2 and the section 3 are changed in the harness connecting the starting point Ps and the end point Pe. That is, the shapes of the curve L 2 of the harness of the section 2 and the curve L 3 of the harness of the section 3 change. In this example, the pass direction VP 3 of the pass point P 3 is the same as the pass direction VP′ of the pass point P 3 ′, and the pass direction does not change in the section 3 . Also in this example, the gravitational force direction VG does no change.
FIG. 5B illustrates the values before and after the changes of the “relative position (X, Y, Z)”, “relative passing direction (Rx, Ry, Rz)”, and “difference from the gravitational force direction” of the route of the harness in the section 2 . As illustrated in FIG. 5B , the relative position of the pass point P 3 changes after the change, but the relative passing direction and the difference from gravitational force direction do not change after the change. In this case, as a result of the change of the position of the pass point P 3 in the positive direction of Y, the relative position of the pass point P 3 is changed from (25, −5, 0) to (25, 20, 0). The section comparison unit 104 a detects the change of the relative position of the pass point P 3 according to the pass point position information received from the pass point management unit 103 . Although FIG. 5 B illustrates only the section 2 , the relative position changes also in the section 3 as in the section 2 , and the change is detected by the section comparison unit 104 a.
{Change of Relative Passing Direction}
Next, the “change of the relative passing direction” used by the section comparison unit 104 a in detecting the change of a harness shape of a section is described with reference to FIGS. 6A and 6B . In FIG. 6A , the same component as that illustrated in FIG. 5A is assigned the same reference numeral.
In the example illustrated in FIG. 6A , the position of the pass point P 3 is not changed, but the pass direction at the pass point P 3 , that is, the pass direction vector VP 3 , is changed. By changing the pass direction vector VP 3 , the shapes of the route L 2 of the harness of the section 2 and the route L 3 of the harness of the section 3 are changed. That is, as illustrated in FIG. 5A , the route of the section 2 is changed from L 2 to L 2 ′, and the route of the section 3 is changed from L 3 to L 3 ′. In this example, the gravitational force direction VG is not changed.
FIG. 6B illustrates the “relative position”, the “relative passing direction”, and the “difference from the gravitational force direction”. As illustrated in FIG. 6B , the parameter that changes after the change in the section 2 is only the “relative passing direction”. In this case, the pass direction (pass direction vector VP 3 ) rotates in the Y direction on the X-Y plane. As a result, the relative passing direction (Rx, Ry, Rz) of the section 2 changes from (0.86, 0.52, 0) to (0.62, 0.86, 0). The section comparison unit 104 a detects the change on the basis of the position information about the pass point received from the pass point management unit 103 . In FIG. 6B , as in FIG. 5B , only the values before and after the changes of the “relative position”, the “relative passing direction”, and the “difference from the gravitational force direction” are illustrated, but the value of the relative passing direction VPe of the end point Pe is changed with the change of the pass direction vector VP 3 in the section 3 .
{Difference from the Gravitational Force Direction}
Although there is no change in the “relative position” and the “relative passing direction” between the starting point pass point and the end point pass point of a section, the shape of the harness in the section is changed by the influence of gravity. Therefore, it is necessary to detect a change in the pass direction of a pass point in the absolute coordinate system. Accordingly, in the present embodiment, the concept (parameter) of the “difference from the gravitational force direction” is introduced, and the shape of a harness of a section is generated (changed) with the difference from the gravitational force direction taken into account. The difference from the gravitational force direction refers to the difference between the pass direction of a pass point (pass direction vector) and the gravitational force direction (gravitational force direction vector) in the absolute coordinate system. In the present embodiment, the section comparison unit 104 a detects the difference from the gravitational force direction with respect to the starting point pass point of each section, and regenerates the shape of a section when the difference is equal to or higher than a predetermined value. The pass point for detection of a difference from the gravitational force direction can be an end point pass point of a section, not a starting point pass point of the section.
The difference from the gravitational force direction is described below in detail with reference to FIGS. 7A and 7B . In FIG. 7A , the same component as that illustrated in FIG. 5A is assigned the same reference numeral.
In the example in FIG. 7A , the part Ms is rotated by centering the pass point (starting point) Ps. In FIG. 7A , to identify the part Ms between before and after a change, the part before the change is represented by Ms and the part after the change is represented by Ms′. With the rotation of the part Ms, the shape of the harness connecting the part Ms and the part Me changes over the section 1 through the section 3 . That is, the route of the harness of the section 1 changes from L 1 to L 1 ′, the route of the harness of the section 2 changes from L 2 to L 2 ′, and the route of the harness of the section 3 changes from L 3 to L 3 ′, thereby changing the shape of each route. The curve LC connecting the starting point Ps and the endpoint Pe illustrated in FIG. 7A is a curve indicating the route of the harness when the influence of gravity is not considered.
In the present embodiment, the relative position and the relative passing direction between the pass points are not changed after a change. However, the difference from the gravitational force direction changes. If the section 2 illustrated in FIG. 7A (section between the pass points P 2 and P 3 ) is checked, the difference of the starting point pass point P 2 in the gravitational force direction in the section 2 changes after the change. That is, as illustrated in FIG. 7B , the difference (Rx, Ry, Rz) in the gravitational force direction at the starting point pass point P 2 changes from (0.5, −0.85, 0) to (0.0, −1.0, 0). Thus, in the present embodiment, the “difference from the gravitational force direction” of each section can be detected by detecting the “difference from the gravitational force direction” of a starting point pass point. The “difference from the gravitational force direction” of a section can be detected by detecting the difference from the gravitational force direction of the endpoint pass point, not the starting point pass point.
{Outline of the Method of Detecting a Changed Portion}
The generation of the shape of a harness according to the present embodiment is based on the method of generating the shape of a harness according to the invention (International Application Number PCT/JP2007/50189) filed for application previously by the inventor of the present application, and the method of setting the “pass point” and the “pass direction” used in the present embodiment is described in detail in the specification and the attached drawings of the invention of PCT/JP1007/50189.
In the embodiments of the present invention, a pass point is set between the start point and the end point of a harness. The starting point and the end point are also pass points. Each pass point is provided with “coordinates” and a “pass direction”. As described above with reference to FIG. 4 , the coordinates of a pass point are those in the relative coordinate system (three-dimensional orthogonal coordinate system) having the previous pass point as an origin. The X axis of the relative coordinate system is set to match the pass direction (pass direction vector) of the pass point as the origin. The Y axis of the relative coordinate system is set as the normal direction (normal vector) of the specified surface of the part corresponding to the pass point of the origin. The unit vector of the Z axis of the relative coordinate system is equal to the outer product of the unit vector of the X axis (pass direction vector) and the unit vector of the Y axis (normal vector).
In the present embodiment, a changed portion of a harness is designated in the following procedure.
1. A change of a pass point (changes of the position and the posture (direction) in the absolute coordinates) is detected. 2. A harness corresponding to the detected pass point is selected. 3. The portion for which a change is required in the selected harness (hereinafter referred to as a changed portion) is designated.
In designating the changed portion, a “starting point”, an “end point”, a “pass direction”, and a “gravitational force direction” are verified in each section of a harness. The verification is performed in the procedure (1) through (3). In this example, the section 2 in FIG. 4 is described to explain the procedure (1) through (3).
(1) The position and the pass direction of the pass point P 3 (pass point at the end point of the section 2 ) are changed from the absolute coordinate system into the coordinates of the relative coordinate system using the pass point P 2 (pass point at the starting point of the section 2 ) as the origin. (2) The above-mentioned coordinates change result are compared with the relative position of the pass point P 3 before the change with the relative passing direction. (3) When a change of the gravitational force direction is to be verified (when there is no change in the relative position and the pass direction of the pass point P 3 in the verification in (2)), the value representing the gravitational force direction (gravitational vector) by the above-mentioned relative coordinate system set at the pass point 2 is compared between the value before a change and the value after the change.
If it is determined that the result of the comparison (difference between the values before and after the change) is equal to or larger than a predetermined value in the procedure (1) through (3), then the process of changing the curve and the shape of the harness is performed.
{Section Shape Management Unit}
In the present embodiment, a harness is divided into a plurality of sections in the direction from the starting point to the end point, and manages the shape of the harness in each section. The management is performed by the section shape management unit 106 .
FIG. 8 is an example of the section shape management unit 106 managing a harness for each section. In the example in FIG. 8 , one harness 211 is managed after divided into eight sections of a section 201 (section 1 ) through a section 208 (section 8 ). The shape in the rectangular blown-off frame corresponding to each section indicates the shape of the harness in the corresponding section.
The section 201 is positioned between the starting point Ps (pass point 1 (not illustrated in the attached drawings)) and the pass point P 2 (not illustrated in the attached drawings), and the pass point P 2 is set at the position corresponding to a clamp part 221 - 1 . The section 202 has the pass point P 2 as a starting point and the pass point P 3 (not illustrated in the attached drawings) as an endpoint. The pass point P 3 is set at the position corresponding to a clamp part 221 - 2 .
Similarly, the pass points P 4 (not illustrated in the attached drawings) through P 8 (not illustrated in the attached drawings) are set corresponding to the clamp parts 221 - 3 through 221 - 7 respectively. Then, the section 202 is set between the pass points P 2 and P 3 , the section 203 is set between the pass points P 3 and P 4 , the section 204 is set between the pass points P 4 and P 5 (not illustrated in the attached drawings), the section 205 is set between the pass points P 5 and P 6 (not illustrated in the attached drawings), the section 206 is set between the section P 6 and P 7 (not illustrated in the attached drawings), the section 207 is set between the sections P 7 and P 8 (not illustrated in the attached drawings), and the section 208 is set between the sections P 2 and the end point Pe (not illustrated in the attached drawings).
The section shape management unit 106 individually manages one harness 211 illustrated in FIG. 8 for each of the sections 201 through 208 . The management is performed using the table (section shape management table) held by the section shape management unit 106 .
FIGS. 9A and 9B are examples of the configuration of the section shape management table held by the section shape management unit 106 .
A section shape management table 106 a illustrated in FIG. 9A manages the section shape of the harness 211 illustrated in FIG. 8 . The harness 211 illustrated in FIG. 8 is configured by the sections 1 through 8 . Therefore, the section shape management table 106 a corresponding to the harness 211 stores the shape management information about the entire sections 1 through 8 of the harness 211 , but FIG. 9A illustrates only a part (only the shape management information about the sections 1 through 3 ) of the section shape management table. FIG. 9B illustrates the details of the shape management information about the section 3 stored in the section shape management table.
The section shape management table 106 a stores the shape management information about the sections 1 through 3 of the harness 211 in the format illustrated in FIG. 9A . As described above, the section shape management table 106 a actually stores the shape management information about the sections 1 through 8 .
As described above, the shape of the harness of each section is generated on the basis of the relative coordinate system having a starting point pass point as an origin. The section shape management table 106 a illustrated in FIG. 9A manages the shape of the harness of the sections 1 through 3 by the three items of “section”, “starting point pass point”, and “shape”. The starting point pass point of the section 1 is the pass point P 1 (starting point Ps), and with regard to the section 1 , the relative coordinate system having the pass point P 1 as an origin is set. The X axis of the relative coordinate system is set in the direction parallel to the pass direction of the harness at the pass point P 1 . Then, the Y and Z axes are set on the plane including the origin. The shape item of the section 1 stores harness shape data 231 of the section 1 as illustrated in FIG. 9A . The starting point pass point of the section 2 is a pass point P 2 , and the starting point pass point of the section 3 is the pass point P 3 . The shape items corresponding to the sections 2 and 3 of the section shape management table 106 a respectively stores harness shape data 232 and 233 .
FIG. 9B illustrates the harness shape data of the section 3 stored in the section shape management table 106 a . As illustrated in FIG. 9B , the relative coordinate system having the pass point P 3 as an origin is set at the pass point P 3 as the starting point pass point of the section 3 , and the harness shape data 233 between the starting point pass point P 3 and the end point pass point P 4 is set.
[Operation]
Described below is the operation of the design support device 100 with the above-mentioned configuration according to the present embodiment. The process of the central portion of the present invention is described below.
{Gravitational Consideration Flag Setting Process}
The harness editing unit 101 receives user input information from the input device 120 when a user changes an existing harness design model through the input device 120 , and performs the “gravitational consideration flag setting process” illustrated in FIG. 10A according to the input information.
FIG. 10A is a flowchart of the procedure of the gravitational consideration flag setting process performed by the harness editing unit 101 . The process of the flowchart is performed on the basis of the instruction of the user input on the GUI (graphical user interface) screen displayed on the screen of the display device 130 .
The harness editing unit 101 first selects one harness for which a gravitational consideration flag is to be set according to the user input information received from the input device 120 (S 1 ). Next, with respect to the selected harness, a section to be changed in the gravitational force direction is selected according to the user input information received from the input device 120 (S 2 ). One section or a plurality of sections can be selected. Finally, with respect to each section selected in step S 2 , the gravitational consideration flag is set or released according to the user input information received from the input device 120 (S 3 ).
By performing the process above, the gravitational consideration flag is set or released for the entire sections of the harness selected by the user on the basis of the operation of setting the gravitational consideration flag specified by the user through the input device 120 on the GUI screen displayed on the screen of the display device 130 .
The harness editing unit 101 manages the gravitational consideration flag set or released as described above using, for example, the gravitational consideration flag management table illustrated in FIG. 10B .
A gravitational consideration flag management table 101 a illustrated in FIG. 10B stores the information about “setting” or “releasing” the gravitational consideration flag for the entire sections 1 through n of one harness. The harness editing unit 101 generates and stores the gravitational consideration flag management table in the format illustrated in FIG. 10B for all harnesses selected by the user. The gravitational consideration flag is referred to in the harness shape generating process described later.
{Entire Process Flow of Changing a Harness}
FIG. 11A is a flowchart of the entire process of changing a harness performed by the design support device 100 according to the present embodiment. The process according to the flowchart is performed by the CPU (central processing unit) in the design support device 100 executing the program (design support program) loaded into the main memory.
Described below is the flowchart in FIG. 11A .
First, the position and the posture (direction) of a pass point in the absolute coordinate system are checked, and the pass point for which one of the two pieces of the information has been changed is detected (S 11 ). Next, the harness of the pass point (changed pass point) detected in step S 1 is selected (S 12 ). Then, in the subsequent steps, it is checked whether or not there is any route change in the entire section of the harness selected in step S 12 (hereinafter referred to as a “selected harness”), and a curve/shape generating process etc. is performed for a route changed section.
After a harness is selected in step S 12 , the first section (section 1 ) of the harness is selected next (S 13 ). Then, the “harness shape generating process” is performed for the selected section (section 1 in this case) (S 14 ). The harness shape generating process is described later in detail, but in this process, a change in the above-mentioned “relative position”, “relative passing direction”, and “difference from the gravitational force direction” is checked, and if any of the three types of parameters above is equal to or exceeds a predetermined value, then the “changed portion flag” is set in the ON position.
When the process in step S 14 is completed, the changed portion flag is checked, and it is determined whether or not there is a change of a harness shape in a target section (section 1 in this case) on the basis of the flag (S 15 ). In the determination, if the changed portion flag is set in the ON position, it is determined that the harness shape in the target section has been changed, and control is passed to step S 16 . On the other hand, if the changed portion flag is set in the OFF position, it is determined that there is no change in the harness shape in the target section, and control is returned to step S 13 .
In step S 16 , it is determined whether or not a change display is set in the target section. A change display for each section is set by user through the input device 120 . If it is determined in step S 16 that a change display is set in a target section (a change display has been set), then control is passed to the next step S 17 . On the other hand, if it is determined that there is no change display in a target section (no change display has been set), control is returned to step S 13 .
In step S 17 , a target section in which the harness shape has been changed is temporarily displayed in a color different from the color of the section in which the harness shape has not been changed. A display example is described later. When the process in step S 17 is completed, control is returned to step S 13 .
In the second step S 13 , the next section after the above-mentioned selected harness is selected. In this case, when there is the section 2 , the section 2 is selected, and the section 2 is a new target section. For the section 2 , the process similar to the process for the above-mentioned section 1 is performed in and after step S 13 .
Thus, the processes in steps S 14 through S 17 are performed on the entire sections on the selected harness until it is determined in step S 13 that there is no more target section in the selected harness. If it is determined in step S 13 that there is no more target section in the selected harness, the process of the present flowchart is terminated.
{Harness Shape Generating Process}
Next, the details of the “harness shape generating process” in step S 14 in FIG. 11A is described with reference to FIG. 11B . FIG. 11B is a flowchart of the detailed process flow of the harness shape generating process. The process is performed by the comparison unit 104 and the generation unit 105 .
First, the “relative position” and the “relative passing direction” before and after a change in the target section are calculated (S 31 ). In step S 31 , when the “relative position” and the “relative passing direction” of the target section before the change are stored in memory etc., only the “relative position” and the “relative passing direction” after the change are calculated.
Next, with respect to the “relative position” and the “relative passing direction” of the target section, the difference between a value after a change and a value before the change is calculated (S 32 ). It is determined whether or not the difference is equal to or larger than a predetermined value (S 33 ). If it is equal to or larger than the predetermined value, control is passed to step S 37 . On the other hand, if it is smaller than the predetermined value, control is passed to step S 34 .
In step S 34 , the gravitational consideration flag of the target section is checked, and it is determined whether or not gravity is to be considered. In the determination, it is determined that gravity is to be considered if the gravitational consideration flag of the target section is set in the ON position, and it is determined that gravity is not to be considered if the gravitational consideration flag of the target section is set in the OFF position. If it is determined in step S 34 that it is necessary to consider gravity, then control is passed to step S 35 . If it is determined that it is not necessary to consider gravity, the process of the present flowchart is terminated.
In step S 35 , the difference between the “differences from the gravitational force direction” before and after the change is calculated. Then it is determined (S 36 ) whether or not the difference is equal to or exceeds a predetermined value. If it is equal to or larger than the predetermined value, control is passed to step S 37 . If it is smaller than the predetermined value, the process in the present flowchart is terminated.
In step S 37 , the “curve/shape generating process” for generating the curve and the shape of the route in a target section is performed, the curve of the route in the target section is generated, and then on the basis of the curve, the shape of the route in the target section is generated. The curve/shape generating process is described later in detail.
As described above, in the present embodiment, the difference of the “relative position”, “relative passing direction”, and “difference from the gravitational force direction” after a change is calculated. If any of the three parameters has a difference equal to or larger than a predetermined value, then the shape of the route of the target section is generated. On the other hand, if differences after the change of all of the three types of parameters are smaller than the predetermined value in the target section, no shape of route is generated for the target section. Thus, the harness shape generating process for the harness whose shape is changed can be limited to a necessary section, thereby shortening the harness shape generating time.
{Curve/Shape Generating Process}
Next, the details of the “curve/shape generating process” in step S 38 in FIG. 11B is described below with reference to FIG. 11C . FIG. 11C is a detailed flowchart of the curve/shape generating process. The process is also performed by the curve generation unit 105 a and the shape generation unit 105 b of the generation unit 105 .
First, a curve is generated in the target section (S 51 ). Then, it is determined whether or not a highlight shape is set for the target section (S 52 ). The highlight shape is set through, for example, the input device 120 by user. The setting information is managed by the harness editing unit 101 using a flag etc. If it is determined in step S 52 that a highlight shape is set in a target section, the highlight shape of the route of the target section is generated (S 53 ). Then, control is passed to step S 54 . On the other hand, if it is determined in step S 52 that a highlight shape is not set in the target section, control is immediately passed to step S 54 .
In step S 54 , a normal shape of the route in a target section is generated (S 54 ), and then the process of the present flowchart is terminated.
Thus, the shape of the route in the target section is generated in the order of curve generating and shape generating. In this case, during generating a shape, a highlight shape (shape displayed with highlight) is generated in a section in which a highlight shape is set so that the section can be identified from a section in which a highlight shape is not set. For the section in which a highlight shape is to be set, both a highlight shape and a normal shape are generated so that the user can switch and select between the highlight shape display and the normal shape display. An example of a highlight display of a section in which a highlight shape is set is described later. In the section in which a highlight shape is not set, only a normal shape is generated.
[Shape Display of Harness]
The design support device 100 provides two modes of “normal display” and “highlight display” as the display modes of a harness. The display modes are described below.
{Display of Harness before Change (Normal Display)}
FIG. 12 is an example of the section shape display unit 107 a displaying a generated harness (harness before a change) displayed on the screen of the display device 130 .
In displaying the harness illustrated in FIG. 12 , one harness 301 for connecting a first connector (not illustrated in the attached drawings) to a second connector 322 is displayed in the same color and shape in all sections. The harness 301 is clamped by clamp parts 311 - 2 through 311 - 8 between the first connector and the second connector 322 .
FIG. 13 is another example of the section shape display unit 107 a displaying a generated harness displayed on the screen of the display device 130 . In FIG. 12 , the same component as in FIG. 13 is assigned the same reference numeral. In displaying the screen illustrated in FIG. 13 , the first connector is hidden by a part and its shape is not displayed, but it is represented as a first connector 321 for convenience.
In displaying the generated harness illustrated in FIG. 13 , a pass point is displayed. A connector for connecting the starting point to the endpoint of a harness is also displayed. For the connector, the part name “connector” is displayed. For the pass point, the name “pass point” is displayed near the corresponding clamp parts 311 - 2 through 311 - 8 . In displaying the “pass point”, the numbers (pass point numbers) “2” through “8” are displayed as the leading items in the order from the first connector 321 as the starting point of the harness 301 to the second connector 322 as the end point. For the first connector 321 , “1” indicating the starting point (pass point 1 ) is displayed. For the second connector 322 , “9” indicating the end point (pass point 9 ) is displayed.
The display of a harness in FIGS. 12 and 13 is also a normal display of the harness.
{Highlight Display}
FIGS. 14A and 14B are examples of highlight display of a harness displayed on the screen of the display device 130 by the section shape display unit 107 a . In the highlight display, the section in which the shape has been changed is highlighted for display so that the section in which the shape has been changed and the section in which the shape has not been changed can be easily identified by a user. In FIGS. 14A and 14B , the same component as in FIG. 12 is assigned the same reference numeral.
In the highlight display illustrated in FIG. 14A , the section in which the shape has been changed and the section in which the shape has not been changed can be identified by display color. Practically, the sections L 4 , L 6 , and L 8 in which the shape has been changed are displayed in yellow, and the sections L 1 , L 2 , L 3 , L 5 , and L 7 in which the share has not been changed are displayed in green (same color as the normal display).
In the highlight display illustrated in FIG. 14B , the section in which the shape has been changed and the section in which the shape has not been changed can be identified also by changing the thickness of the shape in addition to the display color. Practically, the sections L 4 , L 6 , and L 8 in which the shape has been changed are displayed in bold yellow, and the sections L 1 , L 2 , L 3 , L 5 , and L 7 in which the share has not been changed are displayed in green (same color as the normal display) of a normal thickness. Thus, in the highlight display illustrated in FIG. 14B , the section in which the shape has been is highlighted and displayed by a combination of the display color and the shape (size of the diameter of the cross-sectional shape). The highlight display in the design support device according to the present invention is not limited to the examples in 14 A and 14 B, but can be variable in addition to the examples above as a display attribute for highlight display of the section in which the shape has been changed.
{Section Information Display}
The section information display unit 107 b according to the present embodiment displays on the screen of the display device 130 various types of section information (length, cross-sectional shape, size, etc.) about the data before and after the change with the user operation for the input device 120 for the section in which the shape of the harness is changed.
An example of displaying section information is described below with reference to FIG. 15 . In FIG. 15 , the same component as in FIG. 14A is assigned the same reference numeral.
In the example illustrated in FIG. 15 , when the user brings a cursor 401 close to a section L 6 in which the shape has been changed, section information 403 about the section L 6 is displayed. The section information 403 includes a section number (“6” in this example), the diameter of the harness of the section L 6 (4 mm in this example), the wire length of the section L 6 before the change (65 mm in this example), and the wire length of the section L 6 after the change (60 mm in this example). The user can be easily and immediately informed that the wire length of the section L 6 has been shortened from 65 mm to 60 mm by checking the display contents of the section information 403 . The contents of the section information about the changed section displayed by the design support device of the present invention are not limited to the example illustrated in FIG. 15 . For example, they can be various types of information about the cross-sectional shape, size, etc. of the harness in a changed section.
[System Configuration of Computer for Realizing Design Support Device According to the Present Embodiment]
The design support device 100 according to the above-mentioned present embodiment can be realized as a program (design support program) operated by a computer.
FIG. 16 is an example of the configuration of the system of the computer for executing the design support program.
A computer 500 illustrated in FIG. 16 is provided with a body 501 , a display 502 , a keyboard 503 , a mouse 504 , and a communication device 505 . The body 501 includes a CPU, a BIOS chip set, a memory, a USB (universal serial bus) port, a serial port, a parallel port, a storage device such as a hard disk device, etc., a drive for magnetic storage media such as a floppy (registered trademark) disk etc., a drive for optical storage media such as a CD, a DVD, etc., a drive for magneto optical storage media such as a MO etc., a NIC (net interface card), etc. The display 502 inputs display data and a control signal from the display control unit of the body 501 , and displays a GUI (graphical user interface) screen, a design screen, etc. The keyboard 503 is used by a user inputting a command and data to the body 501 . The mouse 504 is used in specifying an optional position of the design model displayed on a screen 502 a of the display 502 , and specifying and moving a part of the design model. The communication device 505 is used to access an external server etc. through a network 600 such as a WAN (wide area network), a LAN (local area network), etc. and download a design support program etc. of the present embodiment from the computer of the server etc., and can be a network communication card, a modem, etc. The design support program according to the present embodiment is stored in a portable storage medium 610 that can be read by the computer 500 including a magnetic disk such as a floppy (registered trademark) disk etc., an optical disk such as CD-ROM, a DVD, etc., an IC card memory, etc. In this case, the design support program can be installed on the storage device of the network 600 by attaching the portable storage medium 610 to the corresponding drive of the body 501 . It is also possible for the CPU of the body 501 to execute the design support program with the portable storage medium 610 attached. The design support program according to the present embodiment can also be executed by the CPU of the body 501 by downloading the program from the computer of the server etc. connected over the network 600 through the communication device 105 as described above.
According to the present embodiment as described above, the portion in which the shape is to be regenerated is limited for each section by the processes of (1) through (3) below when the shape of a harness is changed. Therefore, the process of changing the shape of a harness can be performed in a higher speed. Actually, as a result of applying the design support device according to the present embodiment, the time required to change the shape of a harness can be shortened to ⅕ of the time required by the conventional device.
(1) Relating to the pass point of a harness, the distance between adjacent pass points is defined as a “section”, and a shape is modeled for each section. (2) When the shape of a harness is changed, the shape is regenerated only for the section in which the shape has been changed. (3) When the entire harness is moved, and if there is no change in the relative positions of the starting point pass point and the end point pass point of each section, the above-mentioned movement can be processed by changing only the positions and the pass directions of the starting point pass point and the end point pass point of the section without regenerating the shape of each section.
Although there is no change in the relative position and the relative passing direction between the starting point pass point and the endpoint pass point in a section, the shape of a harness is changed by the influence of gravity when there occurs a change in the pass direction of the pass point in the absolute coordinate system. In the present embodiment, a change of a difference from the previous gravitational force direction is checked on the starting point pass point of each section of a harness, and the shape is regenerated for the section in which the change is equal to or exceeds a predetermined value. Thus, the shape model of a harness can be more correct than ever.
The present invention is not limited to the above-mentioned embodiments, but can be varied within the scope of the gist of the present invention. For example, in electronic equipment, the present invention can be applied for supporting the generation of the shape of a cable. In addition, it can be applied for supporting the design in generating the shape of a flexible part other than a harness or a cable, for example, the shape of the strings for the goal area of football, the shape of the strings of the nets for tennis, volleyball, etc. The present invention can also be applied for supporting the design in generating the shape of the strings for a net-shaped hammock.
The present invention can be applied for supporting the design of the shape of the strings used for the goal area of football, the strings of fiber used in an apparel field, etc. in addition to the generation of the shape of a part for connecting devices in electronic equipment such as a harness, a cable, etc., and can be widely applied for industrial uses.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing demonstration of the superiority and or and inferiority of the invention. Although the embodiment(s) of the present inventions has (have) been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention. | A design support device used to design a part in string or belt form, including: a part editing unit configured to edit a part by changing a position of a pass point through which the part passes; and a section comparison unit configured to compare a section having a plurality of consecutive pass points before the edition by the part editing unit with the sections after the edition by the part editing unit, and extracting the section in which relative positions or relative passing directions are different between two pass points in the sections. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to optical data storage systems, and more particularly to such systems which have removable optical media.
2. Description of the Prior Art
Optical data storage systems such as disk drives use laser beams to record and read data from optical data storage disks. The disks are typically packaged in a cartridge for easy removal from the drive. A problem with these systems is that dust and other particles can collect inside the drive and adhere to the optical elements such as the disk or the objective lens which is used to focus light to the disk. The collection of dust and particles causes a degradation in the signal to noise ratio and can ultimately cause the disk drive to fail.
Various schemes have been proposed to try and solve the contamination problem. The optical disk cartridges have been equipped with shutters to prevent contamination of the disk. See Japanese published applications JP 02-304767, published Dec. 18, 1990, by Horie, et al.; and JP 02-187958, published Jul. 24, 1990, by Kishi, et al. Some drives use filters or particle traps. See Japanese published applications JP 61-239482, published Oct. 24, 1986, by Yabuuchi, et al.; JP 02-276056, published Nov. 9, 1990 by Nakano, et al.; JP 02-58789, published Feb. 27, 1990, by Fujino, et al.; JP 01-185840, published Jul. 25, 1989, by Kimura, et al.; JP 63-124282, published May 27, 1988, by Sasaki, et al.; JP 02-14483, published Jan. 18, 1990, by Osumi, et al.; and IBM Technical Disclosure Bulletin, Vol. 33, No. 10B, March 1991, pp. 484, by Yanker. There are also drives which contain lens cleaners. See Japanese published applications JP 01-287893, published Nov. 20, 1989, by Warisaya, et al.; JP 02-105340, published Apr. 17, 1990, by Sugano, et al.; JP 02-31339, published Feb. 1, 1990, by Miyajima, et al.; JP 62-40641, published Feb. 21, 1987, by Kitazawa, et al.; and JP 02-152028, published Jun. 12, 1990, by Suzuki, et al. PCT application W09006576, published Jun. 14, 1990 by Hake shows the use of a lens cover. U.S. Pat. No. 4,814,906, issued Mar. 21, 1989 to Suzuki, et al.; and Japanese published application JP 63-269392, published Nov. 7, 1988 by Ouguchi, et al. show examples of contamination protection schemes for magnetic disk drives.
What is needed is an optical disk drive system with removable media which inexpensively, compactly, and efficiently solves the particle contamination problem without sacrificing the interior airflow necessary for proper cooling.
SUMMARY OF THE INVENTION
Briefly, in a preferred embodiment, the present invention comprises an optical disk drive for use with removable optical media. The drive has an outer housing which has an entrance aperture for receiving the optical media cartridge. An entrance door is positioned over the entrance aperture. The door rotates along a pivot line proximate the central longitudinal axis of the door. When the cartridge is inserted through the entrance aperture, a first portion of the door rotates outward and a second portion of the door rotates inward. The second portion of the door engages the cartridge when the cartridge is positioned in the optical drive. The door remains open and allows cooling airflow above the cartridge.
The optical cartridge divides the interior of the housing into a first and a second compartment when the cartridge is positioned in the optical drive. A sealing member is located between the housing and the cartridge to minimize airflow between the compartments. The entrance aperture is located in the first compartment and the optical elements of the drive are located in the second compartment.
For a fuller understanding of the nature and advantages of the present invention, reference should be made to the following detailed description taken into conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of the optical disk drive of the present invention;
FIG. 2 shows a cross-sectional side view of the drive of FIG. 1;
FIG. 3 shows an interior side view of the entrance door;
FIG. 4 shows a cross-sectional top view of the drive of FIG. 2;
FIG. 5 shows a bottom view of an optical disk cartridge;
FIG. 6 shows a cross-sectional side view of the drive of FIG. 2 with a removable optical disk cartridge inserted;
FIG. 7 shows a cross-sectional top view of the drive of FIG. 1 with an airfoil;
FIG. 8 shows a perspective view of the airfoil and optical head of FIG. 7;
FIGS. 9A, B, C, D and E show top views of various alternative embodiments of the airfoil;
FIGS. 10A and B show a top and side view respectively, of an alternative embodiment of the airfoil;
FIG. 11 shows a perspective view of an alternative embodiment of the airfoil and the optical head; and
FIG. 12 shows a graph of lens coverage versus time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is related to the copending U.S. patent application entitled "Optical Data Storage System With Airflow Deflecting Member," (Ser. No. 07/817,720 now U.S. Pat. No. 5,200,945), by the same inventors.
FIG. 1 is a schematic diagram of an optical data storage system of the present invention and is designated by the general reference number 10. System 10 has an optical data storage medium 12 which is typically a disk having concentric or spiral data tracks. Disk 12 is contained in an optical disk cartridge (not shown). Disk 12 is mounted to a spindle motor 14. An optical head 20 is positioned below disk 12. Head 20 is moved in a radial direction relative to disk 12 by a coarse track actuator 22. A bias magnet 30 is located above disk 12 and is connected to a magnet control 32.
A laser 40 produces a polarized light beam 42. Laser 40 may be a laser diode. One example of such a laser diode is a gallium-aluminum-arsenide laser diode which generates light at approximately 780 nm in wavelength. Light beam 42 is collimated by a lens 44 and circularized by a circularizer 46. Circularizer 46 is preferably a prism.
Beam 42 passes to a beamsplitter 48. A portion of beam 42 is reflected toward a lens 50. Lens 50 focuses the light to a power monitor optical detector 52. Detector 52 is connected to a laser control 54. Detector 52 provides laser control 54 with a power monitor signal which is used to adjust the power of laser 40 as appropriate.
The remaining portion of beam 42 passes through beamsplitter 48 to a mirror 60. Mirror 60 reflects the light toward an objective lens 62. Lens 62 focuses beam 42 onto the disk 12. Lens 62 is mounted in a lens holder 64. Holder 64 may be moved relative to disk 12 by a focus actuator motor 66. Lens 62 and lens holder 64 are attached to a fine track actuator 70 which moves the lens 62 small distances in a radial direction for purposes of maintaining the light beam 42 on the proper track position on the disk. Mirror 60, lens 62, holder 64, focus actuator 66 and fine track actuator 70 are located on the optical head 20.
A light beam 80 is reflected from the disk 12, passes through lens 62 and is reflected by mirror 60. A portion of the light beam 80 is then reflected by beamsplitter 48 to a beamsplitter 90. Beamsplitter 90 divides the beam 80 into a data beam 94 and a servo beam 96.
Data beam 94 passes through a half waveplate 98 to a polarizing beamsplitter 100. Beamsplitter 100 divides beam 94 into two orthogonal polarization components. A first polarization component beam 104 is focussed by a lens 106 to a data optical detector 108. A second polarization component beam 110 is focussed by a lens 112 to a data optical detector 114. A data circuit 116 is connected to detectors 108 and 114, and generates a data signal responsive to the differences in the amount of light detected at detectors 108 and 114 which is representative of the data recorded on disk 12.
Servo beam 96 is focussed by a lens 120 onto a segmented optical detector 122, such as a spot size measuring detector as is known in the art. A focus servo 128, as is known in the art, is connected to detector 122 and motor 66. Servo 128 controls motor 66 to adjust the position of lens 62 as appropriate in order to maintain proper focus. A track and seek servo 130, as is known in the art, is connected to detector 122 and actuators 22 and 70. Servo 130 causes actuator 22 to adjust the position of head 20 as appropriate to seek desired tracks on disk 12, and causes actuator 70 to move lens 62 as appropriate to maintain proper tracking position once the appropriate track is reached. A spindle motor control 132, as is known in the art, is connected to motor 14. A disk drive controller 140, as is known in the art, provides overall control for servo 128 and 130, as well as spindle motor 14, laser control 54 and magnet control 32.
A fixed optical element (FOE) system 150 comprises laser 40, lens 44, circularizer 46, beamsplitter 48, lens 50, detector 52, beamsplitter 90, waveplate 98, beamsplitter 100, lenses 106, 112, 120 and detectors 108, 114 and 122.
The writing and reading operations of system 10 may now be understood. During the write operation, controller 140 causes laser control 54 to energize laser 40 to provide a high power polarized beam 42. Beam 42 is powerful enough to heat a spot on the disk 12 to a temperature above its Curie temperature. The Curie temperature is the temperature at which the magnetic domain of the heated spot may be magnetically oriented. Controller 140 causes magnet control 32 to energize magnet 30. The magnetic domains of the heated spots are then oriented in the same direction as the magnetic field generated by the bias magnet 30. The laser 40 is pulsed responsive to the data to be recorded on the disk. The result is that data is recorded on the disk as spots having an up or down magnetic orientation.
During a read operation, controller 140 causes laser control 54 to energize laser 40 to generate a low power polarized beam 42 which is not powerful enough to heat the disk 12 above its Curie temperature. The reflected light 80 has its plane of polarization rotated one way or the other depending upon the magnetic domain orientations of the spots on the disk 12. This is known as the Kerr effect. These differences in polarization are detected by detectors 108 and 114, and data circuit 116 outputs a digitized data signal representative of the recorded data.
FIG. 2 shows a cross-sectional side view of the system 10. The system 10 has a housing 200 for enclosing and protecting the components of system 10. The spindle motor 14 and spindle motor control 132 are located on an electronic card 202 attached to the housing 200. The FOE 150 is located in an interior enclosure 204 attached to housing 200. Enclosure 204 contains an aperture 206 which allows beam 42 to pass to the optical head 20. Optical head 20 is located between FOE 150 and spindle motor 14. The electronics of the controller 140, magnet control 32, focus servo 128, track and seek servo 130, data circuit 116 and laser control 54 are distributed among electronic cards 210. Cards 210 and bias magnet 30 are attached to the interior of housing 200. An airfoil 212 is attached to optical head 20 and is described in more detail below.
Housing 200 has an entrance aperture 220 and an entrance door 222. Door 222 completely seals entrance 220 when the door is closed. The door 222 rotates about a pair of pivot axles 224. The housing 200 has flanges 226 located along the entrance aperture 220 for engaging door 222. A plurality of exhaust slots 230 are located within housing 200 on a side opposite to that of entrance aperture 220. A fan 232 is attached to the housing 200 and is located proximate the exhaust slots 230.
FIG. 3 shows an interior side view of door 222 taken along line 3--3 of FIG. 2. The axles 224 are attached to door 222 along a pivot line 250. Line 250 is located between the longitudinal edges of the door 222 and is preferably located proximate the central longitudinal axis of door 222. Housing 200 has a pair of journal bearings 252 which receive the axles 224. A pair of springs 254 are positioned along axles 224 between door 222 and bearings 252. The springs 254 force door 222 against ledges 226 such that the door 222 is completely shut. The pivot line 250 divides door 222 into an upper portion 260 and a lower portion 262. When door 222 is opened, portion 260 swings outward and portion 262 swings inward relative to housing 200.
FIG. 4 shows a cross-sectional top view of system 10 taken along line 4--4 of FIG. 2. The airfoil 212 has been removed in order to give a better view of the optical head 20. The optical head 20 includes a carriage 300. Carriage 300 has a pair of journal bearing members 302 which ride along a pair of rails 304. A plurality of rail wheels 306 are rotatably attached to carriage 300 and engage rail 304. Rails 304 are supported by a pair of rail support members 308 which are attached to the interior floor of housing 200. Support members 308 each have a magnet section 310 which receives a coil winding 312. The coil windings 312 are attached to each end of carriage 300. Magnets 310 and coils 312 comprise the course track actuator 22 which moves carriage 300 and lens 62 in a radial direction relative to spindle motor 14.
Lens holder 64 is pivotally mounted to a central post 330. A plurality of coil windings 332 are located on the sides of holder 64. A pair of magnets 334 are attached to carriage 300 and are located proximate the coils 332. Coils 332 and magnets 334 comprise the fine track actuator 70 which causes holder 64 to pivot slightly about post 330. This slight movement is enough to shift lens 62 in a radial direction for purposes of fine tracking.
A pair of magnet posts 340 are attached to carriage 300 and pass through a pair of apertures 342 in holder 64. The apertures 342 are large enough to allow holder 64 to pivot about post 330 without interference occurring at posts 340. A coil winding 344 (shown in FIG. 8) is attached to holder 64 and is positioned around posts 340. Posts 340 and coil 344 comprise the focus actuator 66 which moves holder 64 slightly up or down along post 330 in order to achieve correct focus.
A cartridge ledge 350 is attached to the interior of housing 200 and extends above card 202. Ledge 350 has four cartridge posts 352 which extend above ledge 350 and engage a lower surface of an optical disk cartridge when the cartridge is loaded into system 10.
A sealing member 360 (shown in dotted line) is attached to housing 200 and cartridge ledge 350 and extends around the area above the spindle motor 14 and optical head 20. Sealing member 360 may be made of rubber or other suitable sealing material and is sized to engage the lower surface of an optical disk cartridge.
FIG. 5 shows a bottom view of an optical disk cartridge which is designated by the general reference number 400. Cartridge 400 has an outer casing 402 which houses the optical disk 12. Disk 12 has a hub 404 shaped to engage the spindle motor 14. Spindle motor 14 has a magnet which engages the metal surface of hub 404. Casing 402 has a slot 410 which allows access to disk 12. A shutter door 412 is slidably mounted in a track 414 which is attached to casing 402. Door 412 slides over slot 410 (as shown by the arrow) to protect disk 12 when it is not in use.
FIG. 6 shows a cross-sectional side view of system 10 similar to FIG. 2, except that the system 10 now contains the optical disk cartridge 400. The disk cartridge 400 is inserted through aperture 220. Door 222 rotates to allow the cartridge 400 to be inserted through the lower portion of aperture 220. An edge 450 of door 222 engages the upper surface of cartridge 400. Springs 254 force door 222 in a clockwise direction against the upper surface of cartridge 400. When the cartridge 400 is fully inserted it drops down and hub 404 engages motor 14. A lower surface of cartridge 400 engages posts 352 and sealing member 360. A loading mechanism (not shown) properly positions cartridge 400 and simultaneously opens shutter 412 of the cartridge 400. The loading mechanism is known in the art.
Note that cartridge 400 and sealing member 360 divide the interior of housing 200 into an upper compartment 460 and a lower compartment 462. Upper compartment 460 contains the electronic cards 210 and bias magnet 30 which need the cooling airflow of fan 232. Door 222 allows the upper portion of aperture 222 to remain open so that a good airflow is achieved through the upper compartment 460. The airflow is represented by the arrows. Lower compartment 462 which contains the optical elements of the optical head 20 and FOE 150 is effectively sealed off from the airflow in the upper compartment 460 and the potential for particle contamination is thereby reduced. When the drive is not in use and cartridge 400 is not present, door 222 remains closed to prevent any airflow in housing 200. The optical elements are thereby protected from particle contamination.
Lower compartment 462 is effectively isolated from the airflow caused by fan 232 when the cartridge 400 is inserted. However, shutter 412 of cartridge 400 is open and the spinning disk 12 is exposed to the lower compartment 462. The spinning disk 12 causes a centrifugal airflow near the optical head 20. In order to protect the head 20, and especially the lens 62, from this airflow, system 10 has an airfoil 212.
FIG. 7 shows a cross-sectional top view similar to FIG. 4, except that the airfoil 212 is now shown. Airfoil 212 comprises a plate member 500 which is attached to the top of posts 340 of optical head 20 by cement or other suitable attachment. Plate 500 is preferably sized to cover the entire top of the optical head 20 such that the optical head 20 is screened from the open slot 410 of cartridge 400. Plate 500 may be made of any suitable material, however, a low mass material such as plastic or aluminum is preferred. It is desirable to keep the mass of the optical head to a minimum in order to insure fast access times. Although the plate 500 covers the entire top of the optical head 20 in the preferred embodiments, this low mass requirement may necessitate a smaller plate 500 in some situations.
Plate 500 has a lens aperture 502 which is positioned directly over lens 62. An airflow screening member 504 (also known as an airflow diverting member) extends a distance above plate 500 and substantially surrounds lens aperture 502. In a preferred embodiment member 504 is a ridge. The top of ridge 504 is positioned a distance above the top surface of lens 62 between the top surface of lens 62 and the disk 12. Ridge 504 is symmetrical about an axis 510 which passes through the center of aperture 502. Ridge 504 has an acute angled leading edge 512 along axis 510. An axis 520 extends radially from the center of spindle motor 14 to edge 512. The axes 510 and 520 are approximately perpendicular with respect to one another. Ridge 504 has a gap 522 located on the leeward side or opposite side of aperture 502 as edge 512. Plate 500 and ridge 504 may preferably be covered with a protective coating such as fluro-carbon. This coating may be useful in protecting the optical disk 12 from impact with the ridge 504 in the event there is a severe external shock to the drive.
In operation, disk 12 spins in a clockwise direction from the perspective shown in FIG. 4. This causes an airflow as shown by the arrows. Ridge 504 diverts the airflow away from the lens aperture 502 such that particles do not hit and adhere to lens 62. The ridge 504 is designed to maintain a laminar airflow around aperture 502. There are no turbulent areas which tend to collect particles. Gap 522 prevents a negative pressure region from developing inside ridge 504. Such a negative pressure region may tend to collect particles.
FIG. 8 shows a detailed perspective view of lens holder 64 and airfoil 212. Note that airfoil 212 is attached to the top surface posts 340. Posts 340 are of sufficient height such that the airfoil 212 does not interfere with vertical movement of holder 64.
FIGS. 9A, B, C, D and E show top views of various alternative embodiments of the airfoil. Numerous other configurations of the airfoil are also possible. The important feature is that the airflow screening member be located toward the windward side of the lens such that the lens is screened from the airflow. Preferably the member extends around the lens and is shaped such that a laminar airflow is achieved.
FIG. 10A and 10B show a top view and side view, respectively, of an additional alternative embodiment of the airfoil of the present invention and is designated by the general reference number 600. Airfoil 600 has a plate 602 with a lens aperture 604. Here the screening member is an airfoil surface 606 which extends above plate 602 and surrounds aperture 604. Surface 606 directs the flow of air above aperture 604 in a laminar manner such that there is no turbulence.
FIG. 11 shows a perspective view of an alternative embodiment of the lens holder 64 and is designated by the general reference number 700. Elements of holder 700 which are similar to holder 64 are designated by a prime number. The upper surface of holder 700 has an integral airflow screening member or ridge 702 which substantially surrounds lens 62'. Ridge 702 has an acute angled leading edge 706 and a rear gap 708 similar to that of airfoil 212.
In all of the embodiments, the screening member is preferably aerodynamic in shape such that the airflow is diverted away from the lens in a laminar manner. Numerous other shapes and configurations for the screening member are therefore possible.
FIG. 12 shows a graph of lens coverage versus time in a contaminated environment. The inventors have determined that when the objective lens of an optical disk drive becomes covered by particles over approximately 20-25% of its surface, the signal to noise ratio of the drive is degraded to the point that the drive will no longer function. The graphs are based on experimental data and illustrate the estimated lifetimes for the drives. A line 800 represents the lens coverage for a prior art optical disk drive.
A line 802 represents the lens coverage of the system 10 having the door 222 and the sealing member 360, but not the airfoil 212. A line 804 represents the lens coverage of system 10 with the airfoil 212, but without the aperture door 222 and sealing member 360. A line 806 represents the system 10 having the door 222, the sealing member 360 and the airfoil 212. As can be seen, the present invention greatly slows the particle build up on the lens and extends the life time of the optical drive by a factor of 4 to 5.
The present invention has been described in connection with a magneto-optic rewriteable optical disk drive. However, the present invention could also be used with any other type of optical disk drive including read only memory (ROM), compact disk (CD), write once read many (WORM), or different types of rewriteable optical drives.
While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art without departing from the scope of the present invention as set forth in the following claims. | An optical disk drive is located in a housing having a centrally pivoted door. An optical disk cartridge is inserted into the drive and is received by a sealing member. The cartridge and sealing member divides the interior of the drive into two compartments. The first compartment contains the electronics which need to be cooled and the second compartment contains the optical elements. The door and sealing member allow airflow in the first compartment but prevent it from reaching the second compartment. An airfoil is positioned over the optical elements in the second compartment to protect them from airflow developed by the spinning disk. | 6 |
BACKGROUND OF THE INVENTION
The invention set forth in this specification pertains to new and improved casters. More specifically it pertains to casters which can be easily and conveniently manufactured at a comparatively nominal cost so as to have a desirable appearance.
The term "caster" as used in this specification is intended to designate a device of a type commonly used in supporting various different objects or structures such as various items of furniture, hand trucks, shopping carts and the like so that the objects or structures upon which the casters are used can be turned in various different directions as they are rolled from one location to another. These casters can be constructed in many different ways depending upon their intended use. Thus, for example, a caster may or not be constructed to have a decorative appearance depending upon whether or not it is to be used where its appearance is important for one reason or another.
It is believed that most casters are constructed so as to include a rigid yoke having a center portion or base and arms which extend generally parallel to one another from this central position, a wheel located so that the arms of the yoke extend along its sides, cooperating wheel support means for holding the wheel so that it can rotate about an axis extending between the arms and a caster support located on the central portion of the yoke for mounting the caster so that it can rotate about an axis which is offset relative to the axis of rotation of the wheel. Commonly the yoke in such a caster is a rigid metal structure in which the arms are used to hold a separate axle for the wheel so that the wheel can rotate about a horizontal axis while the caster support allows the caster to rotate about a vertical axis.
Structures as indicated in the preceding discussion are highly utilitarian and are quite desirable. However, in spite of this it is considered that there is a need for new and improved casters, especially for casters which can be easily and economically manufactured at a comparatively nominal cost so as to have a desired-normally an aesthetically pleasing appearance and which are capable of being used for prolonged periods with little or no maintenance. Further, it is considered that there is a need for casters which can be constructed so as to effectively use common polymer materials so as to obtain the economic and aesthetic advantages possible as a result of the use of such materials.
SUMMARY OF THE INVENTION
The invention is intended to fill the "needs" indicated in the preceding discussion. Thus, it is intended to provide casters which are desirable because they effectively use rigid polymers so as to obtain casters which have a desirable appearance and which can be used without the yokes of such casters having to be painted or otherwise treated so as to be protected against corrosion or so as have a desired appearance. The invention is also intended to provide casters which are relatively inexpensive to produce by virtue of the fact that the yokes in such casters can be inexpensively formed into a desired final configuration by known injection molding techniques and by virtue of the fact that they are constructed in such a way that they may be assembled with minimal difficulty.
Further, the invention is intended to provide casters which can be used for prolonged periods with little or no maintenance. It is believed that other, further advantages of the invention will be apparent to those who are concerned with the construction of casters from a consideration of the remainder of this specification.
These "objectives" of the invention are achieved by providing casters such as a caster constructed as indicated in the preceding discussion having a yoke used to support or hold a wheel and a caster suport so that the yoke is formed of two separate housing members shaped so as to have cooperating interfitting means on each for positioning these housing members together and fastener means securing these housing members against relative movement with respect to one another. Preferably--but not necessarily--the housing members are formed of a rigid polymer or "plastic" material or composition.
BRIEF DESCRIPTION OF THE DRAWING
It is considered that there are many other aspects of a desirable caster in accordance with this invention which will be apparent from a detailed consideration of the remainder of this specification in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevational view of a presently preferred embodiment or form of a caster of the invention;
FIG. 2 is a cross-sectional view taken at line 2--2 of FIG. 1;
FIG. 3 is a partial cross-sectional view at an enlarged scale taken at line 3--3 of FIG. 1; and
FIG. 4 is another partial cross-sectional view at an enlarged scale, this view being taken at line 4--4 of FIG. 1.
The particular caster illustrated and described in the remainder of this specification is constructed so as to utilize the concepts or principles of the invention set forth and defined in the appended claims forming a part of this specification. It is believed that it will be apparent to those who are normally concerned with the design and construction of casters that these concepts or principles can be used in differently constructed and/or appearing casters through the use of routine skill in the noted field.
DETAILED DESCRIPTION
The caster 10 shown in the drawing includes two housing members 12 and 13 which, when viewed from their exteriors appear nearly bilaterally symmetrical which are prepferably formed by conventional injection molding techniques out of a commonly available rigid polymer composition but which can also be formed of metal such as an iron alloy. These two members 12 and 13 are shaped so as to include edges 14 and arms 16. They are adapted to be located against one another so the edges 14 on the two members 12 and 13 are against one another as shown. When they are so positioned these members 12 and 13 create or define what may be considered as a yoke 18 having a central portion 20 which includes parts of these edges 14 and, of course, the arms 16.
The member 12 includes an extension 22 a hollow, vertically extending bore 24 including an internal horizontally extending flange 26. The extension 22 and the bore 24 in the housing member 12 can be regarded as a part of the central portion 20 of the yoke 18. A corresponding extension 23 on the housing member 13 fits closely against the extention 22 as shown. This bore 24 is intended to hold a vertically extending shaft 28 serving as a caster support means in mounting the caster 10 in a conventional manner in a known type of bearing member (not shown) so that the caster 10 is capable of being turned about a vertically extending axis which is the same as the axis of the shaft 28. A conventional tapered groove 30 and a top flange 32 are preferably used on the shaft 28 so as to aid in mounting it in such a bearing member. A groove 34 in the shaft 28 accomodates the flange 26 so as to retain the shaft 28 against removal from the caster 10.
The arms 16 are provided with semicircular ends 36 carrying circular internal flanges 38 located so as to face one another. These arms 16 also are provided with centrally located, aligned, cylindrical bosses 40 which also face one another. Both these flanges 38 and the bosses 40 are important in conjunction with a wheel 42 of the caster 10. These flanges 38 fit within circular grooves 44 located in the sides 46 of the wheel 42 so as to extend concentrically around an axle 48 used as a part of the caster 10. This axle 48 is provided with grooved ends 50 which can be press fitted within the interiors 52 of the bosses 40 so as to be secured against rotation.
The axle 48 extends through a centrally located axle opening or hole 54 within the wheel 42. Preferably this hole 54 is dimensioned so as to fit closely around the axle 48 and yet so that the wheel 42 can be turned easily upon this axle 48. The hole 54 extends between enlarged cylindrical bores 56 which fit closely around the bosses 40 in such a manner as to accommodate rotation. With this type of structure either the bores 56 or the hole 54 or both can be considered as a bearing serving to mount the wheel 42 so that is can be rotated relative to the arms 16 and the yoke 18.
The housing members 12 and 13 are secured to one another so that the shaft 28 and the wheel 42 are held in positions as described through the use of a ferrule 58 which fits around the shaft 28 and the extensions 22 and 23 so as to prevent these extensions 22 and 23 from spreading apart. The ferrule 58 is preferably dimensioned so that it can be forced into position and so that it is held in place by friction. If desired other known methods of holding this ferrule 58 in place can be used. Preferably the ferrule is not the only means used for securing these members 12 as described.
In the caster 10 these members 12 and 13 are also provided with internally located closely interfitting holes 60 and shaft-like projections 62 as best shown in figures 3 and 4 of the drawing. These holes 60 and the projections 62 serve as fasteners which prevent the members 12 and 13 from shifting relative to one another and may be easily assembled as shown by pushing them into place so as to create a press fit. If desired, a small quantity of an adhesive (not shown) may be used in the holes 60 so as to secure the projections 62 in place. Obviously other mechanically equivalent fasteners or fastening means can be used in place of the holes and projections 60 and 62, respectively. The periphery 68 of the wheel 42 is spaced from the central portion 20 of the yoke 18 so as to avoid any interference with the wheel 42 turning.
Normally the axle 48 will be formed of steel or a similar material which is significantly stronger than most common polymers or plastics as are available for use in the housing members at a nominal cost. Such materials may tend to "creep" if subjected to significant stress for a prolonged period. With the caster 10 the housing sections are designed so that such stresses in the housing members 12 and 13 will be distributed in such a manner that these housing members 12 and 13 can be formed of many common, relatively inexpensive polymers or plastics without there being any significant danger of these housing members becoming damaged or distorted either due to the stresses normally placed on a caster or due to such creep. Further, the disclosed structure the exteneion 22 is formed in such a way so as to accomodate the loads transmitted through the shaft 28.
Similarly, the ferrule 58 used with the caster 10 will normally be formed of steel or a similar material so as to minimize the chances of this ferrule 58 breaking or becoming damaged or distorted as the caster 10 is used. The design of the caster is thus characterized by the effective use of comparatively inexpensive polymer or plastic material for the largest parts used so as to achieve the economic advantages of such material as well as the ability to use such material without having to paint or otherwise finish it. This is considered significant. Although it is preferable to use a plastic or polymer material for the housing members 12 the latter can, of course, be manufactured from a solid metal composition such as steel.
It is noted that the flanges 38 fit within the grooves 44 in such a manner as to make it difficult for thread or the like to get generally between the wheel 42 and the yoke 18 and to accumulate in such location to an extent that such accumulations interfere with the rotation of the caster 10 by accumulations between the wheel 42 and the yoke 18, the disclosed construction makes it difficult for this to occur. | Desirable casters can be formed by using two separate, interfitting housing members to create the yoke of a caster. As these housing members are assembled they come together so as to hold the wheel of the caster generally between arms of the yoke (which are formed on the housing members) and so as to hold a shaft used in mounting the caster. Fasteners are provided so as to hold the housing members together in an operative configuration. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending application Ser. No. 755,675 filed Dec. 30, 1976, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to prostaglandin derivatives and to a process for preparing them.
The prostaglandins and analogs are well-known organic compounds derived from prostanoic acid which has the following structure and atom numbering: ##STR2##
As drawn hereinafter the formulas represent a particular optically active isomer having the same absolute configuration as PGE 1 obtained from mammalian tissues.
In the formulas, broken line attachments to the cyclopentane ring or side chain indicate substituents in alpha configuration, i.e. below the plane of the ring or side chain. Heavy solid line attachments indicate substituents in beta configuration, i.e. above the plane.
SUMMARY OF THE INVENTION
It is the purpose of this invention to provide novel products having pharmacological activity. It is a further purpose to provide a process for preparing these products and their intermediates.
Accordingly, there is provided an optically active compound of the formula ##STR3## or a mixture comprising that compound and the enantiomer thereof, including the lower alkanoates.
In formula I and in other formulas hereinafter including formulas in the Charts, the terms D, L, Q, R 1 , and the like are as defined in the TABLE. Reference to that Table will establish what is intended to be represented by each formula.
TABLE______________________________________DEFINITION OF TERMS FOR FORMULAS______________________________________D is(1) (CH.sub.2).sub.dC(R.sub.2).sub.2(2) CH.sub.2OCH.sub.2Y or(3) CH.sub.2 CHCHwherein d is zero to 5, R.sub.2 is hydrogen, methyl, orfluoro, being the same or different with the provisothat one R.sub.2 is not methyl when the other is fluoro,and Y is a valence bond, CH.sub.2, or (CH.sub.2).sub.2.D.sub.1 isthe same as D above but withoutCH.sub.2 CHCH.L.sub.1 is ##STR4##or a mixture of ##STR5##wherein R.sub.34 and R.sub.35 are hydrogen, methyl, or fluoro,being the same or different, with the proviso thatone of R.sub.34 and R.sub.35 is fluoro only when the other ishydrogen or fluoro;L.sub.2 and L.sub.3 arehydrogen, alkyl of one to 4 carbon atoms, inclusive,or COOR.sub.32, wherein R.sub.32 is hydrogen, alkyl of one to12 carbon atoms, inclusive, cycloalkyl of 3 to 10carbon atoms, inclusive, aralkyl of 7 to 12 carbonatoms, inclusive, phenyl, or phenyl substituted one, 2,or 3 chloro or alkyl of one to 3 carbon atoms, inclu-sive; being the same or different, with the provisothat not more than one of L.sub.2 and L.sub.3 is COOR.sub.32.M.sub.1 is ##STR6##wherein R.sub.33 is hydrogen or methyl.Q is ##STR7##wherein R.sub.8 is hydrogen, methyl, or ethyl.Q.sub.1 is ##STR8##wherein R.sub.8 is hydrogen, methyl, or ethyl, andR.sub.21 is tetrahydropyranyl, tetrahydrofuranyl, 1-ethoxy-ethyl, or a group of the formula ##STR9##wherein R.sub.14 is alkyl of one to 18 carbon atoms, inclu-sive, cycloalkyl of 3 to 10 carbon atoms, inclusive,aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, orphenyl substituted with one, 2, or 3 alkyl of one to4 carbon atoms, inclusive, wherein R.sub.15 and R.sub.16 are thesame or different, being hydrogen, alkyl of one to 4carbon atoms, inclusive, phenyl or phenyl substitutedwith one, 2, or 3 alkyl of one to 4 carbon atoms, in-clusive, or, when R.sub.15 and R.sub.16 are taken together,(CH.sub.2).sub.a or (CH.sub.2).sub.bO(CH.sub.2).sub. c wherein a is 3, 4,or 5,b is one, 2, or 3, and c is one, 2, or 3 with theproviso that b plus c is 2, 3, or 4, and wherein R.sub.17is hydrogen or phenyl.Q.sub.2 is ##STR10##Q.sub.3 is ##STR11##wherein R.sub.21 is as defined for Q.sub.1 above.R.sub.1 is(1) COOR.sub.3(2) CH.sub.2 OH(3) CH.sub.2 N(R.sub.9)(R.sub.28) ##STR12## ##STR13##wherein R.sub.3 is (a) hydrogen, (b) alkyl of one to 12carbon atoms, inclusive, (c) cycloalkyl of 3 to 10carbon atoms, inclusive, (d) aralkyl of 7 to 12 car-bon atoms, inclusive, (e) phenyl, (f) phenyl sub-stituted with one, 2, or 3 chloro or alkyl of one to4 carbon atoms, inclusive, ##STR14## ##STR15## ##STR16## ##STR17## ##STR18## ##STR19## ##STR20##wherein R.sub.10 is phenyl, p-bromophenyl, p-biphenylyl,p-nitrophenyl, p-benzamidophenyl, or 2-naphthyl,and wherein R.sub.11 is hydrogen or benzoyl, or(n) a pharmacologically acceptable cation,wherein R.sub.9 is hydrogen, methyl, or ethyl, and R.sub.28 ishydrogen, alkyl of one to 4 carbon atoms, inclusive,aralkyl of 7 to 12 carbon atoms, inclusive, phenyl,on phenyl substituted with alkyl of one to 4 carbonatoms, inclusive.R.sub.2 ishydrogen, methyl, or fluoro, being the same or dif-ferent with the proviso that one R.sub.2 is not methylwhen the other is fluoro.R.sub.3 is(a) hydrogen, (b) alkyl of one to 12 carbon atoms,inclusive, (c) cycloalkyl of 3 to 10 carbon atoms,inclusive, (d) aralkyl of 7 to 12 carbon atoms,inclusive, (e) phenyl, (f) phenyl substituted withone, 2, or 3 chloro or alkyl of one to 4 carbon atoms,inclusive, ##STR21## ##STR22## ##STR23## ##STR24## ##STR25## ##STR26## ##STR27##wherein R.sub.10 is phenyl, p-bromophenyl, p-biphenylyl,p-nitrophenyl, p-benzamidophenyl, or 2-naphthyl,and wherein R.sub.11 is hydrogen or benzoyl, or(n)a pharmacologically acceptable cation.R.sub.4 is ##STR28## ##STR29## ##STR30##wherein C.sub.g H.sub.2g is alkylene of one to 9 carbon atoms,inclusive, with one to 5 carbon atoms, inclusive, inthe chain between CR.sub.5 R.sub.6and terminal methyl, whereinR.sub.5 and R.sub.6 are hydrogen, alkyl of one to 4 carbon atoms,inclusive, or fluoro, being the same or different, withthe proviso that one of R.sub.5 and R.sub.6 is fluoro only whenthe other is hydrogen or fluoro and the further provisothat neither R.sub.5 nor R.sub.6 is fluoro when Z is oxa (O);wherein Z represents an oxa atom (O) or C.sub.j H.sub.2j where-in C.sub.j H.sub.2j is a valence bond or alkylene of one to 9carbon atoms, inclusive, with one to 6 carbon atoms,inclusive, in the chain between CR.sub.5 R.sub.6and the phenylring;wherein T is alkyl of one to 4 carbon atoms, inclusive,fluoro, chloro, trifluoromethyl, or alkoxy of one to4 carbon atoms, inclusive, and s is zero, one, 2 or 3,with the proviso that not more than two T's are otherthan alkyl and when s is 2 or 3 the T's are either thesame or different.R.sub.5 and R.sub.6 arehydrogen, alkyl of one to 4 carbon atoms, inclusive,or fluoro, being the same or different, with theproviso that one of R.sub.5 and R.sub.6 is fluoro only whenthe other is hydrogen or fluoro and the further provisothat neither R.sub.5 nor R.sub.6 is fluoro when Z is oxa (O).○ R.sub.7 is ##STR31## ##STR32## ##STR33##R.sub.8 ishydrogen, methyl, or ethyl.R.sub.9 ishydrogen, methyl, or ethyl.R.sub.10 isphenyl, p-bromophenyl, p-phenylyl, p-nitrophenyl,p-benzamidophenyl, or 2-naphthyl.R.sub.11 ishydrogen or benzoyl.R.sub.14 isalkyl of one to 18 carbon atoms, inclusive, cycloalkylof 3 to 10 carbon atoms, inclusive, aralkyl of 7 to12 carbon atoms, inclusive, phenyl or phenyl substi-tuted with one, 2, or 3 alkyl of one to 4 carbonatoms, inclusive.R.sub.15 and R.sub.16 arethe same or different, being hydrogen, alkyl of oneto 4 carbon atoms, inclusive, phenyl or phenyl sub-stituted with one, 2, or 3 alkyl of one to 4 carbonatoms, inclusive, or, when R.sub.15 and R.sub.15 are takentogether (CH.sub.2).sub.aor (CH.sub.2).sub.bO(CH.sub.2).sub.cwherein ais3, 4, or 5, b is one, 2, or 3, and c is one, 2, or 3with the proviso that b plus c is 2, 3, or 4.R.sub.17 ishydrogen or phenyl. ○ R.sub.18 is ##STR34## ##STR35## ##STR36##R.sub.19 is(1)COOR.sub.20(2)CH.sub.2 OH(3)CH.sub.2 N(R.sub.9)(R.sub.28 ) ##STR37## ##STR38##wherein R.sub.20 is the same as R.sub.3 above except that itdoes not include "(n) a pharmacologically acceptablecation", and R.sub.9 and R.sub.28 are as defined herein.R.sub.20 isthe same as R.sub.3 above except that it does not include"(n) a pharmacologically acceptable cation".R.sub.21 istetrahydropyranyl, tetrahydrofuranyl, 1-ethoxyethyl, ##STR39##wherein R.sub.14 is alkyl of one to 18 carbon atoms, inclu-sive, cycloalkyl of 3 to 10 carbon atoms, inclusive,aralkyl of 7 to 12 carbon atoms, inclusive, phenyl,or phenyl substituted with one, 2, or 3 alkyl of oneto 4 carbon atoms, inclusive, wherein R.sub.15 and R.sub.16 arethe same or different, being hydrogen, alkyl of oneto 4 carbon atoms, inclusive, phenyl or phenyl sub-stituted with one, 2, or 3 alkyl of one to 4 carbonatoms, inclusive, or, when R.sub.15 and R.sub.16 are takentogether, (CH.sub.2).sub.aor (CH.sub.2).sub.bO(CH.sub.2).sub.cwherein ais3, 4, or 5, b is one, 2, or 3, and c is one, 2, or 3with the proviso that b plus c is 2, 3, or 4, andwherein R.sub.17 is hydrogen or phenyl. ○ R.sub.22 is ##STR40## ##STR41##wherein R.sub.21 is as defined above and wherein C-9 is ##STR42##R.sub.23 is(1)COOR.sub.20(2)CH.sub.2 OR.sub.21(3)CH.sub.2 N(R.sub.9)(R.sub.28) ##STR43## ##STR44##wherein R.sub.9, R.sub.20, R.sub.21 and R.sub.28 are as defined herein.R.sub.26 is ##STR45## ##STR46##wherein C.sub.g H.sub.2g is alkylene of one to 9 carbon atoms,inclusive, with one to 5 carbon atoms, inclusive, inthe chain between CR.sub.5 R.sub.6 and terminal methyl, whereinR.sub.5 and R.sub.6 are hydrogen, alkyl of one to 4 carbon atoms,inclusive, or fluoro, being the same or different, withthe proviso that one of R.sub.5 and R.sub.6 is fluoro only whenthe other is hydrogen or fluoro and the further provisothat neither R.sub.5 nor R.sub.6 is fluoro when Z is oxa (O);wherein Z represents an oxa atom (O) or C.sub.j H.sub.2j whereinC.sub.j H.sub.2j is a valence bond or alkylene of one to 9 carbonatoms, inclusive, with one to 6 carbon atoms, inclu-sive between CR.sub.5 R.sub.6 and the phenyl ring; wherein T isalkyl of one to 4 carbon atoms, inclusive, fluoro,chloro, trifluoromethyl, of alkoxy of one to 4 carbonatoms, inclusive, and s is zero, one, 2 or 3, with theproviso that not more than two T's are other than alkyland when s is 2 or 3 the T's are either the same ordifferent.R.sub.28 ishydrogen, alkyl of one to 4 carbon atoms, inclusive,aralkyl of 7 to 12 carbon atoms, inclusive, phenyl,or phenyl substituted with alkyl of one to 4 carbonatoms, inclusive.R.sub.29 isbromo or chloro.R.sub.30 is(1)(CH.sub.2).sub.mCH.sub.3, ##STR47## ##STR48##wherein m is one to 5, inclusive, T is chloro, fluoro,trifluoromethyl, alkyl of one to 4 carbon atoms, inclu-sive, or alkoxy of one to 4 carbon atoms, inclusive,and s is zero, one, 2, or 3, the various T's being thesame or different, with the proviso that not more thantwo T's are other than alkyl, with the further provisothat R.sub.30 is ##STR49##wherein T and s are as defined above, only when R.sub.34and R.sub.35 as defined above for L.sub.1 are hydrogen or methyl,being the same or different.R.sub.31 ishydrogen or hydroxy.R.sub.32 ishydrogen, alkyl of one to 12 carbon atoms, inclusive,cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkylof 7 to 12 carbon atoms, inclusive, phenyl, or phenylsubstituted with one, 2, or 3 chloro or alkyl of oneto 4 carbon atoms, inclusive.R.sub.33 ishydrogen or methyl.R.sub.34 and R.sub.35 arehydrogen, methyl, or fluoro, being the same or dif-ferent, with the proviso that one of R.sub.34 and R.sub.35 isfluoro only when the other is hydrogen or fluoro.○R.sub.36 is ##STR50## ##STR51##wherein R.sub.21 is as defined above and wherein C-9 is ##STR52##R.sub.37 isiodo, bromo, or chloro.T isalkyl of one to 4 carbon atoms, inclusive, fluoro,chloro, trifluoromethyl, or alkoxy of one to 4 carbonatoms, inclusive, with the proviso that not more thantwo T's are other than alkyl and when s is 2 or 3 theT's are either the same or different.V.sub.1 is(1)cis-CHCHCH.sub.2(CH.sub.2).sub.pCH.sub.2,(2)cis-CHCHCH.sub.2(CH.sub.2).sub.pCF.sub.2,(3)cis-CHCHD-wherein D is as defined above and p is one, 2, or 3.X is(1)trans-CHCH(2)cis-CHCH(3)CC or(4)CH.sub.2 CH.sub.2.X.sub.1 is(1)trans-CHCH(2)CC or(3)CH.sub.2 CH.sub.2.Y isa valence bond, CH.sub.2 or (CH.sub.2).sub.2.Z isan oxa atom (O) or C.sub.j H.sub.2j wherein C.sub.j H.sub.2j is avalencebond or alkylene of one to 9 carbon atoms, inclusive,with one to 6 carbon atoms, inclusive in the chainbetween CR.sub.5 R.sub.6 and the phenyl ring.a is3, 4, or 5.b isone, 2, or 3.c isone, 2, or 3.d iszero to 5, inclusive.f iszero to 4.m isone to 5, inclusive.p isone, 2, or 3.s iszero, one, 2, or 3.C.sub.g H.sub.2g isalkylene of one to 9 carbon atoms, inclusive, with oneto 5 carbon atoms, inclusive, in the chain betweenCR.sub.5 R.sub.6 and terminal methyl.C.sub.j H.sub.2j isa valence bond or alkylene of one to 9 carbon atoms,inclusive, with one to 6 carbon atoms, inclusive, inthe chain between CR.sub.5 R.sub.6 and the phenyl ring.______________________________________
In formula I as used herein, attachment to R 18 corresponds to bonds to the cyclopentane ring at the C-8, C-9, and C-12 positions following prostaglandin nomenclature, thus ##STR53## and, similarly, in formulas III and IV ##STR54## Within the scope of the prostaglandin derivatives described herein there are represented
(a) PGE compounds when ##STR55##
(b) 11β-PGE compounds when ##STR56##
(c) 11-Deoxy-PGE compounds when ##STR57##
(d) 11-Deoxy-11-methylene-PGE compounds when ##STR58##
(e) 11-Deoxy-11-hydroxymethyl-PGE compounds when ##STR59##
Further within the scope of the prostaglandin derivatives described herein there are represented
(a) PGE-type acids, esters and salts when R 1 is --COOR 3 ,
(b) 2-Decarboxy-2-hydroxymethyl-PGE type compounds when R 1 is --CH 2 OH,
(c) 2-Decarboxy-2-amino-PGE type compounds when R 1 is --CH 2 N(R 9 )(R 28 ),
(d) PGE-type amides when R 1 is ##STR60##
(e) 2-Decarboxy-2-tetrazol-1-yl-PGE type compounds when R 1 is ##STR61##
For those compounds of formula I wherein Q is ##STR62## i.e. wherein the C-15 hydroxyl group is attached to the side chain in alpha configuration, the configuration at C-15 is identical with that of the naturally occuring prostaglandins such as PGE 1 obtained from mammalian tissues. The 15-epimer compounds are represented by formula I when Q is ##STR63## and are identified variously as "15-epi" or "15β" or "15R" by the appropriate prefix in the name. As is known in the art, "R" and "S" designations depend on the neighboring substituents. See R. S. Cahn, J. Chem. Ed. 41, 116 (1964).
A typical example of the compounds of formula I is represented by the formula ##STR64## and named 6-keto-PGE 1 , methyl ester. The formula-II compound is a species of the formula-I compounds wherein D is --(CH 2 ) 3 --, Q is ##STR65## R 1 is COOCH 3 , R 4 is n-pentyl, ##STR66## and X is trans--CH═CH--.
Regardless of the number of carbon atoms in the chain between the keto group and the terminal R 1 group, these compounds are regarded as "6-keto" compounds, from the designation of C-6 in the basic PGE 1 formula referring back to the prostanoic acid skeleton. Compounds having longer or shorter chains are named following the accepted conventions using "homo" or "nor". For example the side chain ##STR67## is named "2a-homo-6-keto . . . ", whereas ##STR68## is named "2-nor-6-keto . . . ".
The products of this invention within the scope of formula I are extremely potent in causing various biological responses. For that reason, these compounds are useful for pharmacological purposes. A few of those biological responses are: inhibition of blood platelet aggregation, stimulation of smooth muscle, systemic blood pressure lowering, inhibiting gastric secretion and reducing undesirable gastrointestinal effects from systemic administration of prostaglandin synthetase inhibitors, controlling spasm and facilitating breathing in asthmatic conditions, decongesting nasal passages, affecting the reproductive organs of mammals as labor inducers, abortifacients, cervical dilators, regulators of the estrus, and regulators of the menstrual cycle, accelerating growth of epidermal cells and keratin in animals, and alleviating the symptoms of proliferating skin diseases.
Because of these biological responses, these novel compounds are useful to study, prevent, control, or alleviate a wide variety of diseases and undesirable physiological conditions in mammals, including humans, useful domestic animals, pets, and zoological specimens, and in laboratory animals, for example, mice, rats, rabbits, and monkeys.
These compounds are useful whenever it is desired to inhibit platelet aggregation, to reduce the adhesive character of platelets, and to remove or prevent the formation of thrombi in mammals, including man, rabbits, and rats. For example, these compounds are useful in the treatment and prevention of myocardial infarcts, to treat and prevent post-operative thrombosis, to promote patency of vascular grafts following surgery, and to treat conditions such as atherosclerosis, arteriosclerosis, blood clotting defects due to lipemia, and other clinical conditions in which the underlying etiology is associated with lipid imbalance or hyperlipidemia. Other in vivo applications include geriatric patients to prevent cerebral ischemic attacks and long term prophylaxis following myocardial infarcts and strokes. For these purposes, these compounds are administered systemically, e.g., intravenously, subcutaneously, intramuscularly, and in the form of sterile implants for prolonged action. For rapid response, especially in emergency situations, the intravenous route of administration is preferred. Doses in the range about 0.01 to about 10 mg. per kg. of body weight per day are used, the exact dose depending on the age, weight, and condition of the patient or animal, and on the frequency and route of administration.
The addition of these compounds to whole blood provides in vitro applications such as, storage of whole blood to be used in heart-lung machines. Additionally whole blood containing these compounds can be circulated through organs, e.g. heart and kidneys, which have been removed from a donor prior to transplant. They are also useful in preparing platelet rich concentrates for use in treating thrombocytopenia, chemotherapy, and radiation therapy. In vitro applications utilize a dose of 0.001-1.0 μg/ml of whole blood.
These compounds are extremely potent in causing stimulation of smooth muscle, and are also highly active in potentiating other known smooth muscle stimulators, for example, oxytocic agents, e.g., oxytocin, and the various ergot alkaloids including derivatives and analogs thereof. Therefore, they are useful in place of or in combination with less than usual amounts of these known smooth muscle stimulators, for example, to relieve the symptoms of paralytic ileus, or to control or prevent atonic uterine bleeding after abortion or delivery, to aid in expulsion of the placenta, and during the puerperium. For the latter purpose, the compound is administered by intravenous infusion immediately after abortion or delivery at a dose in the range about 0.01 to about 50 μg. per kg. of body weight per minute until the desired effect is obtained. Subsequent doses are given by intravenous, subcutaneous, or intramuscular injection or infusion during puerperium in the range 0.01 to 2 mg. per kg. of body weight per day, the exact dose depending on the age, weight, and condition of the patient or animal.
These compounds are useful as hypotensive agents to reduce blood pressure in mammals, including man. For this purpose, the compounds are administered by intravenous infusion at the rate about 0.01 to about 50 μg. per kg. of body weight per minute or in single or multiple doses of about 25 to 500 μg. per kg. of body weight total per day.
These prostaglandin derivatives are useful in mammals, including man and certain useful animals, e.g., dogs and pigs, to reduce and control excessive gastric secretion, thereby reduce or avoid gastrointestinal ulcer formation, and accelerate the healing of such ulcers already present in the gastrointestinal tract. For this purpose, these compounds are injected or infused intravenously, subcutaneously, or intramuscularly in an infusion dose range about 0.1 μg. to about 20 μg. per kg. of body weight per minute, or in a total daily dose by injection or infusion in the range about 0.01 to about 10 mg. per kg. of body weight per day, the exact dose depending on the age, weight, and condition of the patient or animal, and on the frequency and route of administration.
These compounds are also useful in reducing the undesirable gastrointestinal effects resulting from systemic administration of anti-inflammatory prostaglandin synthetase inhibitors, and are used for that purpose by concomitant administration of the prostaglandin derivative and the anti-inflammatory prostaglandin synthetase inhibitor. See Partridge et al., U.S. Pat. No. 3,781,429, for a disclosure that the ulcerogenic effect induced by certain non-steroidal anti-inflammatory agents in rats is inhibited by concomitant oral administration of certain prostaglandins of the E and A series, including PGE 1 , PGE 2 , PGE 3 , 13,14-dihydro-PGE 1 , and the corresponding 11-deoxy-PGE and PGA compounds. Prostaglandins are useful, for example, in reducing the undesirable gastrointestinal effects resulting from systemic administration of indomethacin, phenylbutazone, and aspirin. These are substances specifically mentioned in Partridge et al. as non-steroidal, anti-inflammatory agents. These are also known to be prostaglandin synthetase inhibitors. The anti-inflammatory synthetase inhibitor, for example, indomethacin, aspirin, or phenylbutazone is administered in any of the ways known in the art to alleviate an inflammatory condition, for example, in any dosage regimen and by any of the known routes of systemic administration.
The prostaglandin derivative is administered along with the anti-inflammatory prostaglandin synthetase inhibitor either by the same route of administration or by a different route. For example, if the anti-inflammatory substance is being administered orally, the prostaglandin derivative is also administered orally, or, alternatively, is administered rectally in the form of a suppository or, in the case of women, vaginally in the form of a suppository or a vaginal device for slow release, for example as described in U.S. Pat. No. 3,545,439. Alternatively, if the anti-inflammatory substance is being administered rectally, the prostaglandin derivative is also administered rectally. Further, the prostaglandin derivative can be conveniently administered orally or, in the case of women, vaginally. It is especially convenient when the administration route is to be the same for both anti-inflammatory substance and prostaglandin derivative, to combine both into a single dosage form.
The dosage regimen for the prostaglandin derivative in accord with this treatment will depend upon a variety of factors, including the type, age, weight, sex and medical condition of the mammal, the nature and dosage regimen of the anti-inflammatory, synthetase inhibitor being administered to the mammal, the sensitivity of the particular prostaglandin derivative to be administered. For example, not every human in need of an anti-inflammatory substance experiences the same adverse gastrointestinal effects when taking the substance. The gastrointestinal effects will frequently vary substantially in kind and degree. But it is within the skill of the attending physician or veterinarian to determine that administration of the anti-inflammatory substance is causing undesirable gastrointestinal effects in the human or animal subject and to prescribe an effective amount of the prostaglandin derivative to reduce and then substantially to eliminate those undesirable effects.
These compounds are also useful in the treatment of asthma. For example, these compound are useful as bronchodilators or as inhibitors of mediators, such as SRS-A, and histamine which are released from cells activated by an antigen-antibody complex. Thus, these compounds control spasm and facilitate breathing in conditions such as bronchial asthma, bronchitis, bronchiectasis, pneumonia and emphysema. For these purposes, these compounds are administered in a variety of dosage forms, e.g., orally in the form of tablets, capsules, or liquids; rectally in the form of suppositories; parenterally, subcutaneously, or intramuscularly, with intravenous administration being preferred in emergency situations; by inhalation in the form of aerosols or solutions for nebulizers; or by insufflation in the form of powder. Doses in the range of about 0.01 to 5 mg. per kg. of body weight are used 1 to 4 times a day, the exact dose depending on the age, weight, and condition of the patient and on the frequency and route of administration. For the above use these prostaglandins can be combined advantageously with other anti-asthmatic agents, such as sympathomimetics (isoproterenol, phenylephrine, ephedrine, etc.); xanthine derivatives (theophylline and aminophylline); and corticosteroids (ACTH and prednisolone).
These compounds are effectively administered to human asthma patients by oral inhalation or by aerosol inhalation.
For administration by the oral inhalation route with conventional nebulizers or by oxygen aerosolization it is convenient to provide the instant active ingredient in dilute solution, preferably at concentrations of about 1 part of medicament to form about 100 to 200 parts by weight of total solution. Entirely conventional additives may be employed to stabilize these solutions or to provide isotonic media, for example, sodium chloride, sodium citrate, citric acid, sodium bissulfite, and the like can be employed.
For administration as a self-propelled dosage unit for administering the active ingredient in aerosol form suitable for inhalation therapy the composition can comprise the active ingredient suspended in an inert propellant (such as a mixture of dichlorodifluoromethane and dichlorotetrafluoroethane) together with a co-solvent, such as ethanol, flavoring materials and stabilizers. Instead of a co-solvent there can also be used a dispensing agent such as oleyl alcohol. Suitable means to employ the aerosol inhalation therapy technique are described fully in U.S. Pat. No. 2,868,691 for example.
These compounds are useful in mammals, including man, as nasal decongestants and are used for this purpose in a dose range of about 10 μg. to about 10 mg. per ml. of a pharmacologically suitable liquid vehicle or as an aerosol spray, both for topical application.
These compounds are also usful in treating peripheral vascular disease in humans. The term peripheral vascular disease as used herein means disease of any of the blood vessels outside of the heart and to disease of the lymph vessels, for example, frostbite, ischemic cerebrovascular disease, artheriovenous fistulas, ischemic leg ulcers, phlebitis, venous insufficiency, gangrene, hepatorenal syndrome, ductus arteriosus, non-obstructive mesenteric ischemia, arteritis lymphangitis and the like. These examples are included to be illustrative and should not be construed as limiting the term peripheral vascular disease. For these conditions the compounds of this invention are administered orally or parenterally via injection or infusion directly into a vein or artery, intra-venous or intra-arterial injections being preferred. The dosages of these compounds are in the range of 0.01-1.0 μg. administered by infusions at an hourly rate or by injection on a daily basis, i.e. 1-4 times a day, the exact dose depending on the age, weight, and condition of the patient and on the frequency and route of administration. Treatment is continued for one to five days, although three days is ordinarily sufficient to assure long-lasting therapeutic action. In the event that systemic or side effects are observed the dosage is lowered below the threshold at which such systemic or side effects are observed.
These compounds are accordingly useful for treating peripheral vascular diseases in the extremities of humans who have circulatory insufficiencies in said extremities, such treatment affording relief of rest pain and induction of healing of ulcers. For complete discussion of the nature of and clinical manifestations of human peripheral vascular disease and the method previously known of its treatment with prostaglandins see South African Pat. No. 74/0149 referenced as Derwent Farmdoc No. 58,400V. See Elliott, et al., Lancet, Jan. 18, 1975, pp. 140-142.
These compounds which are useful in place of oxytocin to induce labor are used in pregnant female animals, including man, cows, sheep, and pigs, at or near term, or in pregnant animals with intrauterine death of the fetus from about 20 weeks to term. For this purpose, the compound is infused intravenously at a dose of 0.01 to 50 μg. per kg. of body weight per minute until or near the termination of the second stage of labor, i.e. expulsion of the fetus. These compounds are especially useful when the female is one or more weeks post-mature and natural labor has not started, or 12 to 60 hours after the membranes have ruptured and natural labor has not yet started. An alternative route of administration is oral.
These compounds are further useful for controlling the reproductive cycle in menstruating female mammals, including humans. By the term menstruating the female mammals is meant animals which are mature enough to menstruate, but not so old that regular menstruation has ceased. For that purpose the prostaglandin derivative is administered systemically at a dose level in the range 0.01 mg. to about 20 mg. per kg. of body weight of the female mammal, advantageously during a span of time starting approximately at the time of ovulation and ending approximately at the time of mensus or just prior to mensus. Intravaginal and intrauterine routes are alternate methods of administration. Additionally, expulsion of an embryo or a fetus is accomplished by similar administration of the compound during the first or second trimester of the normal mammalian gestation period.
These compounds are further useful in causing cervical dilation in pregnant and nonpregnant female mammals for purposes of gynecology and obstetrics. In labor induction and in clinical abortion produced by these compounds, cervical dilation is also observed. In cases of infertility, cervical dilation produced by these compounds is useful in assisting sperm movement to the uterus. Cervical dilation by prostaglandins is also useful in operative gynecology such as D and C (Cervical Dilation and Uterine Curettage) where mechanical dilation may cause perforation of the uterus, cervical tears, or infections. It is also useful in diagnostic procedures where dilation is necessary for tissue examination. For these purposes, the prostaglandin derivative is administered locally or systemically.
The prostaglandin derivative, for example, is administered orally or vaginally at doses of about 5 to 50 mg. per treatment of an adult female human, with from one to five treatments per 24 hour period. Alternatively the compound is administered intramuscularly or subcutaneously at doses of about one to 25 mg. per treatment. The exact dosages for these purposes depend on the age, weight, and condition of the patient or animal.
These compounds are further useful in domestic animals as an abortifacient (especially for feedlot heifers), as an aid to estrus detection, and for regulation or synchronization of estrus. Domestic animals include horses, cattle, sheep, and swine. The regulation or synchronization of estrus allows for more efficient management of both conception and labor by enabling the herdsman to breed all his females in short pre-defined intervals. This synchronization results in a higher percentage of live births then the percentage achieved by natural control. The prostaglandin is injected or applied in a feed at doses of 0.1-100 mg. per animal and may be combined with other agents such as steroids. Dosing schedules will depend on the species treated. For example, mares are given the prostaglandin derivative 5 to 8 days after ovulation and return to estrus. Cattle are treated at regular intervals over a 3 week period to advantageously bring all into estrus at the same time.
These compounds including the salts increase the flow of blood in the mammalian kidney, thereby increasing volume and electrolyte content of the urine. For that reason, these compounds are useful in managing cases of renal dysfunction, especially those involving blockage of the renal vascular bed. Illustratively, these compounds are useful to alleviate and correct cases of edema resulting, for example, from massive surface burns, and in the management of shock. For these purposes, these compounds are preferably first administered by intravenous injection at a dose in the range 10 to 1000 μg. per kg. of body weight or by intravenous infusion at a dose in the range 0.1 to 20 μg. per kg. of body weight per minute until the desired effect is obtained. Subsequent doses are given by intravenous, intramuscular, or subcutaneous injection or infusion in the range 0.05 to 2 mg. per kg. of body weight per day.
The compounds so cited above as promoters and acceleraters of growth of epidermal cells and keratin are useful in animals, including humans, useful domestic animals, pets, zoological specimens, and laboratory animals for this purpose. For this reason, these compounds are useful to promote and accelerate healing of skin which has been damaged, for example, by burns, wounds, and abrasions, and after surgery. These compounds are also useful to promote and accelerate adherence and growth of skin autografts, especially small, deep (Davis) grafts which are intended to cover skinless areas by subsequent outward growth rather than initially, and to retard rejection of homografts.
For the above purposes, these compounds are preferably administered topically at or near the cite where cell growth and keratin formation is desired, advantageously as an aerosol liquid or micronized powder spray, as an isotonic aqueous solution in the case of wet dressings, or as a lotion, cream, or ointment in combination with the usual pharmaceutically acceptable diluents. In some instances, for example, when there is substantial fluid loss as in the case of extensive burns or skin loss due to other causes, systemic administration is advantageous, for example, by intravenous injection or infusion, separately or in combination with the usual infusions of blood, plasma, or substitutes thereof. Alternative routes of administration are subcutaneous or intramuscular near the site, oral, sublingual, buccal, rectal, or vaginal. The exact dose depends on such factors as the route of administration, and the age, weight, and condition of the subject. To illustrate, a wet dressing for topical application to second and/or third degree burns of skin area 5 to 25 square centimeters would advantageously involve use of an isotonic aqueous solution containing 1 to 500 μg. per ml. of the prostaglandin derivative. Especially for topical use, these compounds are useful in combination with antibiotics, for example, gentamycin, neomycin, polymixin, bacitracin, spectinomycin, and oxytetracycline, with other antibacterials, for example, mafenide hydrochloride, sulfadiazine, furazolium chloride, and nitrofurazone, and with corticoid steroids, for example, hydrocortisone, prednisolone, methylprednisolone, and fluprednisolone, each of those being used in the combination at the usual concentration suitable for its use alone.
These prostaglandin derivatives are useful for treating proliferating skin diseases of man and domesticated animals, including psoriasis, atopic dermatitis, non-specific dermatitis, primary irritant contact dermatitis, allergic contact dermatitis, basal and squamous cell carcinomas of the skin, lamellar ichthyosis, epidermolytic hyperkeratosis, premalignant sun-induced keratosis, non-malignant keratosis, acne, and seborrheic dermatitis in humans and atopic dermatitis and mange in domesticated animals. These compounds alleviate the symptoms of these proliferative skin diseases: psoriasis, for example, being alleviated when a scale-free psoriasis lesion is noticeably decreased in thickness or noticeably but incompletely cleared or completely cleared.
These compounds are applied topically as compositions including a suitable pharmaceutical carrier, for example, as an ointment, lotion, paste, jelly, spray, or aerosol, using typical bases such as petrolatum, lanolin, polyethylene glycols, and alcohols. These compounds, as the active ingredients, constitute from about 0.1% to about 15% by weight of the composition, preferably from about 0.5% to about 2%. In addition to topical administration, injection may be employed, as intradermally, intra- or peri-lesionally, or subcutaneously, using appropriate sterile saline compositions.
These compounds are useful as anti-inflammatory agents for inhibiting chronic inflammation in mammals including the swelling and other unpleasant effects thereof using methods of treatment and dosages generally in accord with U.S. Pat. No. 3,885,041, which patent is incorporated herein by reference.
Many of the biological responses known for these 6-keto prostaglandin derivatives are also known for the older prostaglandin compounds. However, these derivatives are surprisingly more specific with regard to potency in causing prostaglandin-like biological responses. Each of these novel derivatives is therefore useful in place of the known prostaglandin-type compounds for at least one of the above pharmacological purposes and, moreover, is surprisingly and unexpectedly more useful for that purpose because it causes smaller and fewer undesired side effects than the known prostaglandins.
Furthermore, these novel compounds are administered effectively orally, sublingually, intravaginally, buccally, or rectally, in addition to usual intravenous, intramuscular, or subcutaneous injection or infusion methods used for the known prostaglandins. These qualities are advantageous because they facilitate maintaining uniform levels of these compounds in the body with fewer, shorter, or smaller doses, and make possible self-administration by the patient.
There are further provided the various processes for preparing the 6-keto compounds of formula-I. Thus, one process comprises the steps of starting with a compound of the formula ##STR69## and
(a) transforming that starting compound to a compound of the formula ##STR70##
(b) subjecting the product of step (a) to oxidation to form a compound of the formula ##STR71## and
(c) transforming the product of step (b) to a compound of the formula ##STR72##
Reference to Chart A herein will make clear the steps of that process.
The starting materials of formula III are not the subject of this invention but will be described at a later point in this application. The 6-keto compounds of formula III are in equilibrium with and therefore accompanied by hemi-ketal compounds of the formula ##STR73##
In step "a" of Chart A the starting material III is transformed to a corresponding formula-IV compound.
When the blocking group R 21 is Q 1 , R 22 and R 23 in tetrahydropyranyl or tetrahydrofuranyl, the appropriate reagent, e.g. 2,3-dihydropyran or 2,3-dihydrofuran, is used in an inert solvent such as dichloromethane in the presence of an acid condensing agent such as p-toluenesulfonic acid or pyridine hydrochloride. The reagent is used in slight excess, preferably 1.0 to 1.2 times theory, and the reaction is carried out at about 20°-50° C.
When R 21 is of the formula ##STR74## as defined herein, including 1-ethoxyethyl, the appropriate reagent is a vinyl ether, e.g. ethyl vinyl ether, isoproenyl methyl ether, isobutyl vinyl ether, or any vinyl ether of the formula R 14 --O--C(R 15 )═CR 16 R 17 wherein R 14 , R 15 , R 16 , and R 17 are as defined above; or an unsaturated cyclic or heterocyclic compound, e.g. 1-cyclohex-1-yl methyl ether ##STR75## or 5,6-dihydro-4-methoxy-2H-pyran ##STR76## See C. B. Reese et al., J. Am. Chem. Soc. 89, 3366 (1967). The reaction conditions for such vinyl ethers and unsaturates are similar to those for dihydropyran above.
The 6-keto formula-IV compound, now with blocking groups at C-11 and C-15, is also accompanied by hemi-ketal compounds derived from formula XX but now blocked at C-11 and C-15. It is possible that the C-6 hydroxyl is also reactive to the blocking agent. Whether or not the C-6 hydroxyl is blocked is immaterial to the success of the following step (b). Any ether groups at C-6 are readily removed in the presence of the reagents used in step (b). Any hemi-ketal therefore equilibrates readily and rapidly to the 6-keto compound IV and is transformed to the formula-V compound in step (b).
In step "b" of Chart A, the hydroxyl on the cyclopentane ring at the C-9 position of the formula-IV compound is oxidized to the oxo group of the formula-V compound.
Oxidation reagents useful for this transformation are known in the art. A useful reagent for this purpose is the Jones reagent, i.e., acidified chromic acid. See J. Chem. Soc. 39 (1946). A slight excess beyond the amount necessary to oxidize the C-9 secondary hydroxy groups of the formula-IV reactant is used. Acetone is a suitable diluent for this purpose. Reaction temperature at least as low as about 0° C. should be used. Preferred reaction temperatures are in the range 0° to -50° C. Another useful reagent for this purpose is the Collins reagent, i.e. chromium trioxide in pyridine. See J. C. Collins et al., Tetrahedron Lett., 3363 (1968). Dichloromethane is a suitable diluent for this purpose. Reaction temperatures of below 30° C. should be used. Preferred reaction temperatures are in the range 0° to +30° C. The oxidation proceeds rapidly and is usually complete in about 5 to 20 minutes.
Examples of other oxidation reagents useful for this transformation are silver carbonate on Celite (Chem. Commun. 1102 (1969)), mixtures of chromium trioxide and pyridine J. Am. Chem. Soc. 75, 422 (1953), and Tetrahedron, 18, 1351 (1962)), t-butylchromate in pyridine (Biochem. J. 84, 195 (1962)), mixtures of sulfur trioxide in pyridine and dimethylsulfoxide (J. Am. Chem. Soc. 89, 5505 (1967)), and mixtures of dicyclohexylcarbodiimide and dimethyl sulfoxide (J. Am. Chem. Soc. 87, 5661 (1965)).
In step "c" of Chart A, the blocking groups R 21 are replaced with hydrogen by acid hydrolysis, thereby forming product VI. General procedures are known in the art. For the tetrahydropyranyl groups, for example, the formula-V compound is contacted with methanol-HCl or with acetic acid-water-tetrahydrofuran at 40°-55° C.
Thereafter, additional compounds within the scope of formula I, such as pharmacologically acceptable salts, are optionally made from formula-VI acids by processes described herein or known in the art.
As used in the formulas of Chart A and elsewhere herein, examples of alkyl of one to 4 carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, and isomeric forms thereof. Examples of alkyl of one to 7 carbon atoms, inclusive, are, in addition, pentyl, hexyl, heptyl, and isomeric forms thereof. Examples of alkyl of one to 12 carbon atoms, inclusive, are, in addition, octyl, nonyl, decyl, undecyl, dodecyl, and isomeric forms thereof. Examples of alkyl of one to 18 carbon atoms are, in addition, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, and isomeric forms thereof.
Examples of cycloalkyl of 3 to 10 carbon atoms, inclusive, which includes alkyl-substituted cycloalkyl, are
cyclopropyl,
2-methylcyclopropyl,
2,2-dimethylcyclopropyl,
2,3-diethylcyclopropyl,
2-butylcyclopropyl
cyclobutyl,
2-methylcyclobutyl,
3-propylcyclobutyl,
2,3,4-triethylcyclobutyl,
cyclopentyl,
2,2-dimethylcyclopentyl,
3-pentylcyclopentyl,
3-tert-butylcyclopentyl,
cyclohexyl,
4-tert-butylcyclohexyl,
3-isopropylcyclohexyl,
2,2-dimethylcyclohexyl,
cycloheptyl,
cyclooctyl,
cyclononyl, and
cyclodecyl.
Examples of phenylalkyl of 7 to 10 carbon atoms, inclusive, are
benzyl,
1-phenylethyl,
2-phenylethyl,
2-phenylpropyl,
4-phenylbutyl, and
3-phenylbutyl.
Examples of aralkyl of 7 to 12 carbon atoms, inclusive, are, in addition
2-(1-naphthylethyl), and
1-(2-naphthylmethyl).
Examples of phenyl substituted by one to 3 chloro or alkyl of one to 4 carbon atoms, inclusive are
p-chlorophenyl,
m-chlorophenyl,
o-chlorophenyl,
2,4-dichlorophenyl,
2,4,6-trichlorophenyl,
p-tolyl,
m-tolyl,
o-tolyl,
p-ethylphenyl,
p-tert-butylphenyl,
2,5-dimethylphenyl,
4-chloro-2-methylphenyl, and
2,4-dichloro-3-methylphenyl.
Examples of alkylene of one to 9 carbon atoms, inclusive, with one to 5 carbon atoms, inclusive, in the chain, within the scope of C g H 2g as defined herein, are methylene, ethylene, trimethylene, tetramethylene, and pentamethylene, and those alkylene with one or more alkyl substituents on one or more carbon atoms thereof, e.g. --CH(CH 3 )--, --C(CH 3 ) 2 --, --CH(CH 2 CH 3 )--, --CH 2 --CH(CH 3 )--, --CH(CH 3 )--CH(CH 3 )--, --CH 2 --C(CH 3 ) 2 --, --CH 2 --CH(CH 3 )--CH 3 --, --CH 2 --CH 2 --CH(CH 2 CH 2 CH 3 )--, --CH(CH 3 )--CH(CH 3 )--CH 2 --CH 2 --, --CH 2 --CH 2 --CH 2 --C(CH 3 ) 2 --CH 2 , and --CH 2 --CH 2 --CH 2 --CH 2 --CH(CH 3 )--. Examples of alkylene of one to 9 carbon atoms, inclusive, substituted with zero, one, or 2 fluoro, with one to 6 carbon atoms in the chain, within the scope of C j H 2j as defined herein, are those given above for C g H 2g and hexamethylene, including hexamethylene with one or more alkyl substituents on one or more carbon atoms thereof, and including those alkylene groups with one or 2 fluoro substituents on one or 2 carbon atoms thereof, e.g. --CHF--CH 2 --, --CHF--CHF--, --CH 2 --CH 2 --CF 2 , --CH 2 --CHF--CH 2 --, --CH 2 --CH 2 --CF(CH 3 )--, --CH 2 --CH 2 --CF 2 --CH 2 --, --CH(CH 3 )--CH 2 --CH 2 --CHF--, --CH 2 --CH 2 --CH 2 --CH 2 --CF 2 --, --CHF--CH 2 --CH 2 --CH 2 --CH 2 --CHF--, --CF 2 --CH 2 --CH 2 --CH 2 --CH 2 --CH 2 --, --CH.sub. 2 --CH 2 --CH 2 --CF 2 --CH 2 --CH 2 --, and --CH 2 --CH 2 --CH 2 --CH 2 --CH 2 --CF 2 .
Examples of ##STR77## as defined herein are phenyl,
(o-, m-, or p-)tolyl,
(o-, m-, or p-)ethylphenyl,
(o-, m-, or p-)propylphenyl,
(o-, m-, or p-)butylphenyl,
(o-, m-, or p-)isobutylphenyl,
(o-, m-, or p-)tert-butylphenyl,
2,3-xylyl,
2,4-xylyl,
2,5-xylyl,
2,6-xylyl,
3,4-xylyl,
2,6-diethylphenyl,
2-ethyl-p-tolyl,
4-ethyl-o-tolyl,
5-ethyl-m-tolyl,
2-propyl-(o-, m-, or p-)tolyl,
4-butyl-m-tolyl,
6-tert-butyl-m-tolyl,
4-isopropyl-2,6-xylyl,
3-propyl-4-ethylphenyl,
(2,3,4-, 2,3,5-, 2,3,6-, or 2,4,5-)trimethylphenyl,
(o-, m-, or p-)fluorophenyl,
2-(fluoro-(o-, m-, or p-)tolyl,
4-fluoro-2,5-xylyl,
(2,4-, 2,5-, 2,6-, 3,4-, or 3,5-)difluorophenyl,
(o-, m-, or p-)chlorophenyl,
2-chloro-p-tolyl,
(3-, 4-, 5-, or 6-)chloro-o-tolyl,
4-chloro-2-propylphenyl,
2-isopropyl-4-chlorophenyl,
4-chloro-3,5-xylyl,
(2,3-, 2,4-, 2,5-, 2,6-, 3,4-, or 3,5-)dichlorophenyl,
4-(chloro-3-fluorophenyl,
(3-, or 4-)chloro-2-fluorophenyl,
α,α,α-trifluoro-(o-, m-, or p-)tolyl,
(o-, m-, or p-)methoxyphenyl,
(o-, m-, or p-)ethoxyphenyl,
4- or 5-)chloro-2-methoxyphenyl, and
2,4-dichloro(5- or 6-)methoxyphenyl.
Included in the compounds of formula I are the pharmacologically acceptable salts when R 3 is a cation. Such pharmacologically acceptable salts useful for the purposes described above are those with pharmacologically acceptable metal cations, ammonium, amine cations, or quaternary ammonium cations.
Especially preferred metal cations are those derived from the alkali metals, e.g., lithium, sodium and potassium, and from the alkaline earth metals, e.g., magnesium and calcium, although cationic forms of other metals, e.g., aluminum, zinc, and iron are within the scope of this invention.
Pharmacologically acceptable amine cations are those derived from primary, secondary, or tertiary amines. Examples of suitable amines are methylamine, dimethylamine, trimethylamine, ethylamine, dibutylamine, triisopropylamine, N-methylhexylamine, decylamine, dodecylamine, allylamine, crotylamine, cyclopentylamine, dicyclohexylamine, benzylamine, dibenzylamine, α-phenylethylamine, β-phenylethylamine, ethylenediamine, diethylenetriamine, and like aliphatic, cycloaliphatic, and araliphatic amines containing up to and including about 18 carbon atoms, as well as heterocyclic amines, e.g., piperidine, morpholine, pyrrolidine, piperazine, and lower-alkyl derivatives thereof, e.g., 1-methylpiperidine, 4-ethylmorpholine, 1-isopropylpyrrolidine, 2-methylpyrrolidine, 1,4-dimethylpiperazine, 2-methylpiperidine, and the like, as well as amines containing water-solubilizing or hydrophilic groups, e.g., mono-, di-, and triethanolamine, ethyldiethanolamine, N-butylethanolamine, 2-amino-1-butanol, 2-amino-2-ethyl-1,3-propanediol, 2-amino-2-methyl-1-propanol, tris(hydroxymethyl)aminomethane, N-phenylethanolamine, N-(p-tertamylphenyl)diethanolamine, galactamine, N-methylglycamine, N-methylglucosamine, ephedrine, phenylephrine, epinephrine, procaine, and the like.
Examples of suitable pharmacologically acceptable quaternary ammonium cations are tetramethylammonium, tetraethylammonium, benzyltrimethylammonium, phenyltriethylammonium, and the like.
Salts containing pharmacologically acceptable cations are prepared from the final formula-VI compounds in free acid form, i.e. wherein R 19 is --COOH, by neutralization with appropriate amounts of the corresponding inorganic or organic base, examples of which correspond to the cations and amines listed above. These transformations are carried out by a variety of procedures known in the art to be generally useful for the preparation of inorganic, i.e., metal or ammonium, salts, amine acid addition salts, and quaternary ammonium salts. The choice of procedure depends in part upon the solubility characteristics of the particular salt to be prepared. In the case of the inorganic salts, it is usually suitable to dissolve the formula-VI acid in water containing the stoichiometric amount of a hydroxide, carbonate, or bicarbonate corresponding to the inorganic salt desired. For example, such use of sodium hydroxide, sodium carbonate, or sodium bicarbonate gives a solution of the sodium salt. Evaporation of the water or addition of a water-miscible solvent of moderate polarity, for example, a lower alkanol or a lower alkanone, gives the solid inorganic salt if that form is desired. Amine and quaternary ammonium salts are prepared by similar methods using appropriate solvents.
As discussed above, the compounds of formula I are administered in various ways for various purposes; e.g., intravenously, intramuscularly, subcutaneously, orally, intravaginally, rectally, buccally, sublingually, topically, and in the form of sterile implants for prolonged action.
For intravenous injection or infusion, sterile aqueous isotonic solutions are preferred. For that purpose, it is advantageous because of increased water solubility that R 3 in the formula I compound be hydrogen or a pharmacologically acceptable cation. For subcutaneous or intramuscular injection, sterile solutions or suspensions of the acid, salt, or ester form in aqueous or non-aqueous media are used. Tablets, capsules, and liquid preparations such as syrups, elixirs, and simple solutions, with the usual pharmaceutical carriers are used for oral sublingual administration. For rectal or vaginal administration suppositories prepared as known in the art are used. For tissue implants, a sterile tablet or silicone rubber capsule or other object containing or impregnated with the substance is used.
Various esters of formula I within the scope of R 3 are optionally prepared from the corresponding acids of formula I, the corresponding acids of formula I, i.e. wherein R 1 is --COOH, by methods known in the art. For example, the alkyl, cycloalkyl, and aralkyl esters are prepared by interaction of said acids with the appropriate diazohydrocarbon. For example, when diazomethane is used, the methyl esters are produced. Similar use of diazoethane, diazobutane, 1-diazo-2-ethylhexane, diazocyclohexane, and phenyldiazomethane, for example, gives the ethyl, butyl, 2-ethylhexyl, cyclohexyl, and benzyl esters, respectively. Of these esters, the methyl or ethyl are preferred.
Esterification with diazohydrocarbons is carried out by mixing a solution of the diazohydrocarbon in a suitable inert solvent, preferably diethyl ether, with the acid reactant, advantageously in the same or a different inert diluent. After the esterification reaction is complete, the solvent is removed by evaporation, and the ester purified if desired by conventional methods, preferably by chromatography. It is preferred that contact of the acid reactants with the diazohydrocarbon be no longer than necessary to effect the desired esterification, preferably about one to about ten minutes, to avoid undesired molecular changes. Diazohydrocarbons are known in the art or can be prepared by methods known in the art. See, for example Organic Reactions, John Wiley & Sons, Inc., New York, N.Y., Vol. 8, pp. 389-394 (1954).
An alternative method for esterification of the carboxyl moiety of the novel compounds of formula I comprises transformations of the free acid to the corresponding silver salt, followed by interaction of that salt with an alkyl iodide. Examples of suitable iodides are methyl iodide, ethyl iodide, butyl iodide, isobutyl iodide, tertbutyl iodide, cyclopropyl iodide, cyclopentyl iodide, benzyl iodide, phenethyl iodide, and the like. The silver salts are prepared by conventional methods, for example, by dissolving the acid in cold dilute aqueous ammonia, evaporating the excess ammonia at reduced pressure, and then adding the stoichiometric amount of silver nitrate.
The phenyl and substituted phenyl esters of the formula I compounds are prepared by silylating the acid to protect the hydroxy groups, for example, replacing each --OH with --O--Si--(CH 3 ) 3 . Doing that may also change --COOH to --COO--Si--(CH 3 ) 3 . A brief treatment of the silylated compound with water will change --COO--Si--(CH 3 ) 3 back to --COOH. Procedures for this silylation are known in the art and are available. Then, treatment of the silylated compound with oxalyl chloride gives the acid chloride which is reacted with phenol or the appropriate substituted phenol to give a silylated phenyl or substituted phenyl ester. Then the silyl groups, e.g., --O--Si--(CH 3 ) 3 are changed back to --OH by treatment with dilute acetic acid. Procedures for these transformations are known in the art.
A preferred method for substituted phenyl esters is that disclosed in U.S. Pat. No. 3,890,372 in which a mixed anhydride is reacted with an appropriate phenol or naphthol. The anhydride is formed from the acid with isobutylchloroformate in the presence of a tertiary amine.
Phenacyl-type esters are prepared from the acid using a phenacyl bromide, for example p-phenylphenacyl bromide, in the presence of a tertiary amine. See for example U.S. Pat. No. 3,984,454, German Offenlag. No. 2,535,693, and Derwent Farmdoc No. 16828X.
Compounds in which R 1 is ##STR78## are conveniently prepared from the formula-VI products which are acids, i.e. R 1 is --COOH. The sequence of reactions is described hereinafter in the section on "2-Decarboxy-2-amino PGF Compounds". For example, the acid compound is converted to a mixed anhydride and thence to an amide. Carboxyl reduction of the amide yields the amine. Alternatively the mixed anhydride is converted to an azide, thence to a urethane from which the substituted amines, primary or secondary, are readily available by methods known in the art.
Also included in the compounds of this invention are the lower alkanoates, wherein "lower alkanoate" refers to an ester of an alkanoic acid of one to 8 carbon atoms, inclusive. Examples of such alkanoic acids are formic, acetic, propanoic, butanoic, pentanoic, hexanoic, heptanoic, and octanoic acids, and isomeric forms thereof.
The formula-VI compounds prepared by the process described above are transformed to lower alkanoates by interaction with a carboxyacylating agent, preferably the anhydride of a lower alkanoic acid, i.e., an alkanoic acid of one to 8 carbon atoms, inclusive. For example, use of acetic anhydride gives the corresponding diacetate. Similar use of propionic anhydride, isobutyric anhydride, and hexanoic acid anhydride gives the corresponding carboxyacylates.
The carboxyacylation is advantageously carried out by mixing the hydroxy compound and the acid anhydride, preferably in the presence of a tertiary amine such as pyridine or triethylamine. A substantial excess of the anhydride is used, preferably about 10 to about 1,000 moles of anhydride per mole of the hydroxy compound. The excess anhydride serves as a reaction diluent and solvent. An inert organic diluent, for example dioxane, can also be added. It is preferred to use enough of the tertiary amine to neutralize the carboxylic acid produced by the reaction, as well as any free carboxyl groups present in the hydroxy compound reactant.
The carboxyacylation reaction is preferably carried out in the range about 0° to about 100° C. The necessary reaction time will depend on such factors as the reaction temperature, and the nature of the anhydride. For acetic anhydride, pyridine, and a 25° C. reaction temperature, a 12-to-24-hour reaction time is used.
The carboxyacylated product is isolated from the reaction mixture by conventional methods. For example, the excess anhydride is decomposed with water, and the resulting mixture acidified and then extracted with a solvent such as diethyl ether. The desired carboxylate is recovered from the diethyl ether extract by evaporation. The carboxylate is then purified by conventional methods, advantageously by chromatography.
Another process for the formula-I 6-keto compounds comprises the steps of starting with a halo ether of the formula ##STR79## and
(a) transforming that starting material to a compound of the formula ##STR80##
(b) subjecting the product of step "a" to dehydrohalogenation and hydrolysis to form a compound of the formula ##STR81##
(c) oxidizing the product of step "b" to a compound of the formula ##STR82## and
(d) hydrolyzing the product of step "c" to form a compound of the formula ##STR83## Thereafter, salts within the scope of formula I are prepared from formula-VI acids.
Chart B, herein, shows the steps of this process. The starting materials of formula VII are not the subject of this invention but will be described below. ##STR84##
In the first step "d" of Chart B, the starting material VII is transformed to a corresponding formula-VIII compound. The blocking group R 21 in Q', R 22 , and R 23 may be the same as or different than the blocking group R 21 in Chart A, but the details as to reagents and procedures have already been described above for Chart A, step "a".
In step "e" of Chart B, the formula-VIII halo compound is subjected to dehydrohalogenation and hydrolysis to form the formula IV 6-keto PGF-type compound. In one method a halo compound VIII is contacted with silver carbonate and perchloric acid in an organic medium such as tetrahydrofuran. The reaction is followed with TLC (thin layer chromatography) to determine completion, normally 15-24 hr. at about 25° C. The reaction is preferably done in absence of light.
In another method the halo compound VIII is treated with a dehydrohalogenation reagent known in the art. See for example Fieser and Fieser "Reagents for Organic Synthesis", p. 1308, John Wiley and Sons, Inc., New York, N.Y. (1967). Useful for this purpose are tertiary amines, preferably.
1,5-diazabicyclo[4.3.0]nonene-5 ("DBN")
1,4-diazabicyclo[2.2.2]octane ("DABCO") and
1,5-diazabicyclo[5.4.0]undecene-5("DBU").
The reaction is carried out in an inert medium such as dimethylformamide and is followed by TLC, to show the disappearance of starting material. The reaction proceeds at 25° C. and can be accelerated at 40°-50° C. An intermediate enol ether is thereby obtained, preferably purified by washing free of amine, and thereafter treated with dilute aqueous acid, preferably acetic acid, until the more polar formula-IV compound is formed as shown by TLC.
The formula-IV 6-keto compounds are in equilibrium with and therefore accompanied by hemi-ketals of the formula ##STR85## Such hemi-ketals equilibrate rapidly to the 6-keto compound IV during the oxidation and are transformed to the formula-V compound in step (f).
Thereafter in steps "f" and "g" the product above is oxidized to the formula-V compound, and finally hydrolyzed to yield the formula-VI product. The reagents and conditions for these steps have already been described above for Chart A, steps "b" and "c".
There is further disclosed a process for preparing 6-keto-13,14-didehydro-PGE-type compounds of the formula ##STR86## which comprises the steps of starting with a compound of the formula ##STR87## and
(a) subjecting that starting material to selective halogenation and selective monodehydrohalogenation to form a 5,6,14-trihalo compound represented by the formula ##STR88##
(b) subjecting the product of step "a" to reduction to form a compound of the formula ##STR89##
(c) subjecting the product of step (b) to selective dehalogenation to form a compound of the formula ##STR90##
(d) halogenating and cyclizing to form a compound of the formula ##STR91##
(e) transforming the product of step "d" to a compound of the formula ##STR92##
(f) transforming the product of step "e" to a compound of the formula ##STR93##
(g) subjecting the product of step (f) to oxidation to form a compound of the formula ##STR94##
(h) hydrolyzing the product of step "g" to replace the blocking groups R 21 with hydrogen and thereby form 6-keto-13,14-didehydro PGE-type compounds of formula X.
Chart C, herein, shows the steps of that process. The starting materials of formula XI are 15-oxo PGF type compounds known in the art or available by methods described herein or known in the art. For example see U.S. Pat. No. 3,728,382. It is immaterial whether 5,6-cis or 5,6-trans compounds are used as either one will ultimately yield the desired formula-X compound. ##STR95##
In the first step "h" of Chart C the formula-XII trihalo compound is prepared, for example by reaction of the formula-XI compound with pyridinium hydrobromide perbromide in pyridine. Other halogenating agents are useful, e.g. N-bromo- or N-chloro-succinimide. Other tertiary amines are useful for the selective monodehydrohalogenation.
In step "i", the formula-XIII compound is obtained as a mixture of alpha and beta hydroxy isomers by reduction of XII. For this reduction, use is made of any of the known ketonic carbonyl reducing agents which do not reduce ester or acid groups or carbon-carbon double bonds when the latter is undesirable. Examples of those are the metal borohydrides, especially sodium, potassium, and zinc borohydrides, lithium (tri-tert-butoxy) aluminum hydride, metal trialkoxy borohydrides, e.g., sodium trimethoxyborohydride, lithium borohydride, or diisobutyl aluminum hydride. For production of the preferred natural-configuration prostaglandin derivatives, the alpha form of the formula-XIII compound is separated from the beta isomer by silica gel chromatography using methods known in the art.
In step "j" the C-5 and C-6 halogen atoms are removed by selective dehalogenation for example by contact with zinc in methanolic ammonium chloride, to yield the formula-XIV monohalo compound. Other monohalo compounds within the scope of XIV are known in the art. See for example U.S. Pat. No. 4,029,681.
In step "k" the formula-XIV compound is halogenated and cyclized to form the formula-XV halo ether. For this purpose there are various methods available. For the iodo compounds there may be used an aqueous system containing iodine, potassium iodide, and an alkali carbonate or bicarbonate, or an organic solvent system such as dichloromethane containing iodine in the presence of an alkali metal carbonate. The reaction is carried out at temperatures below 25° C., preferably about 0°-5° C. for 10-20 hours. Thereafter the reaction is quenched with sodium sulfite and sodium carbonate and the formula-XV compound separated from the reaction mixture.
For the bromo compounds, N-bromosuccinimide or N-bromoacetamide are useful. See Fieser et al., Reagents for Organic Synthesis, Vol. 1, pp. 74 and 78, Vol. IV, p. 51, John Wiley and Sons, Inc., N.Y. For the chloro compound various methods are available, for example exchange of bromo with chloro using the silver salt of chlorodifluoroacetic acid. See I. T. Harrison et al., Compendium of Organic Synthetic Methods, p. 346, 1971, Wiley Interscience, N.Y.
The formula-XV halo compounds are obtained as two isomers, one in minor and the other in major quantity, differing in their chromatographic mobility. These C-5 and C-6 isomers are separable by silica gel chromatography, but are normally not separated, as either one yields the desired formula XVII, XVIII, and X compounds.
In step "1" the formula-XVI compound is formed as known in the art or described herein, replacing hydrogen atoms in free hydroxyls in Q 2 , R 19 , and R 7 with blocking groups R 21 .
In step "m" the formula-XVI compound is treated with a dehydrohalogenation reagent preferably potassium t-butoxide, to form the formula-XVII 6-keto-PGF-type compound.
The remaining steps in the process, "n" and "o", are analogous to those in Chart A. For step "n", the formula-XVII compound is subjected to oxidation as in step "b" of Chart A. In step "o" the formula-XVIII compound is hydrolyzed to remove blocking groups as in step "c" of Chart A.
Referring now to Chart D, there is shown a source of the formula-III 6-keto-PGF 1 α -type starting materials for Chart A and the formula-VII halo ether starting materials for Chart B. ##STR96##
The starting materials of formula XIX are known in the art or are readily available by processes known in the art. For example, as to PGF 2 α see U.S. Pat. No. 3,706,789; as to 15-methyl- and 15-ethyl-PGF 2 α, see U.S. Pat. No. 3,728,382; as to 16,16-dimethyl-PGF 2 α, see U.S. Pat. No. 3,903,131; as to 16,16-difluoro-PGF 2 α compounds, see U.S. Pat. Nos. 3,962,293 and 3,969,380; as to 16-phenoxy-17,18,19,20-tetranor-PGF 2 α, see Derwent Farmdoc No. 73279U; as to 17-phenyl-18,19,20-trinor-PGF 2 α, see Derwent Farmdoc No. 31279T; as to 11-deoxy-PGF 2 α, see Derwent Farmdoc No. 10695V; as to 2a,2b-dihomo-PGF 2 α, see Derwent Farmdoc No. 61412S and U.S. Pat. Nos. 3,852,316 and 3,974,159; as to 3-oxo-PGF 2 α, see U.S. Pat. No. 3,923,861; as to 3-oxa-17-phenyl-18,19,20-trinor-PGF 2 α, see U.S. Pat. No. 3,931,289; as to substituted phenacyl esters, see Derwent Farmdoc No. 16828X; as to substituted phenyl esters, see U.S. Pat. No. 3,890,372; as to C-1 alcohols, i.e. 2-decarboxy-2-hydroxymethyl compounds, see U.S. Pat. No. 3,636,120; as to C-2 tetrazolyl derivatives, see U.S. Pat. No. 3,932,389; as to Δ2-PGF 2 α see Derwent Farmdoc No. 46497W and Ger. Offen. No. 2,460,285; as to 5,6-trans-PGF 2 α, see U.S. Pat. No. 3,759,978; as to 2,2-dimethyl-PGF 2 α analogs, see Derwent Farmdoc No. 59033T and Ger. Offen. No. 2,209,039; as to 11β-PGF 2 α compounds, see U.S. Pat. No. 3,890,371; as to 11-deoxy-PGF 2 α, see Derwent Farmdoc No. 10695V; as to 11-deoxy-11-hydroxymethyl-PGF 2 α, see U.S. Pat. Nos. 3,931,282 and 3,950,363; as to 16-methylene-PGF 2 α, see Derwent Farmdoc No. 19594W and Ger. Offen. No. 2,440,919; as to 17,18 -didehydro-PGF 2 α compounds, see U.S. Pat. No. 3,920,726; as to 3-(or 4-)oxa-17,18-didehydro-PGF 2 α compounds, see U.S. Pat. No. 3,920,723; as to 15-oxo-PGF 2 α, see U.S. Pat. No. 3,728,382; as to 15-deoxy-PGF 2 α, see Derwent Farmdoc No. 9239W; as to 13,14-cis compounds, see U.S. Pat. No. 3,932,479; as to 11-deoxy-15-deoxy-PGF 2 α see Derwent Farmdoc No. 5694U; as to ω-homo-PGF 2 α compounds, see Derwent Farmdoc No. 4728W; and as to 2,2-difluoro-PGF 2 α compounds, see Derwent Farmdoc No. 67438R.
As to 2-decarboxy-2-amino-PGF 2 α compounds, see that section incorporated herein, taken from a prior-filed, commonly-owned U.S. patent application.
In step "p" of Chart D, the starting material XIX is subjected to halogenation and cyclization to yield the formula-VII halo compounds. For this purpose there is used any of the halogenating methods described above for step "k" of Chart C. Here also it is immaterial whether 5,6-cis or 5,6-trans compounds of formula-XIX are used or which isomers of the formula-VII halo compounds are used.
In step "q" of Chart D the halo compound is converted to the mixture of compounds III and XX by dehydrohalogenation and hydrolysis. See for example the methods of Chart B, step "e" above. ##STR97##
Chart E, herein, shows the steps of a method for preparing 2-decarboxy-2-hydroxymethyl compounds of the formula ##STR98##
The formula-XXII starting materials for Chart E are lactone intermediates known in the art or readily available by methods known in the art. For example when R 36 is ##STR99## and when R 4 is n-pentyl, see Corey et al., J. Am. Chem. Soc. 92, 397 (1970). When R 4 is ##STR100## wherein R 5 and R 6 are methyl or ethyl, see U.S. Pat. No. 3,954,833. When R 5 and R 6 are fluoro, see U.S. Pat. No. 3,962,293. When Q 1 is ##STR101## see U.S. Pat. No. 3,864,387 and 3,931,279.
When R 36 is ##STR102## these 11β lactones are obtained by isomerizing a corresponding lactone having the 11α configuration, with suitable blocking at the C-15 position if desired, by methods known in the art, such as by way of the 11-mesylate or 11-tosylate.
When R 36 is ##STR103## and R 4 is alkyl, see U.S. Pat. No. 3,931,279 and Derwent Farmdoc Abstract No. 10695V; when R 4 is phenyl-substituted, also see U.S. Pat. No. 3,931,279.
When R 36 is ##STR104## see Ger. Offen. No. 2,437,622 and Derwent Farmdoc No. 12714W. For example a compound of the formula ##STR105## is reduced at the --COOH position to the corresponding --CH 2 OH compound using diborane, and thereafter reacted with a suitable blocking agent.
In step "r" of Chart E the starting material XXII is condensed with an alkyllithium compound of the formula
Li--C.tbd.C--(CH.sub.2).sub.f --C(R.sub.2).sub.2 --CH.sub.2 --O--Si(CH.sub.3).sub.3. XXVII
See C. H. Lin et al. Synthetic Comm. 6, 503 (1976) and Lin J. Org. Chem. 41, 4045 (1976). The lithium compound is conveniently prepared in situ from the silylated alkyne by reaction with methyl- or butyllithium in an ether such as diethylether or tetrahydrofuran. In working up the product the silyl groups are readily removed to yield XXIII.
In step "s" the formula-XXIII compound is oxidized at the C-9 position, preferably with Jones reagent. In this step some of the C-1 alcohol groups are also oxidized to carboxylic acid groups. These are next methylated with diazomethane to facilitate removal of the by-product by chromatography. Blocking groups R 21 are replaced with hydrogen in the conventional way, as by mild acid hydrolysis for THP, to yield the formula-XXIV compound.
In step "t" compound XXIV is reduced to the XXV compound without reducing C 13 -C 14 or C 17 -C 18 ethylenic bonds that are present. For this purpose catalytic hydrogenation is useful, for example, over palladium on barium sulfate.
Chart F, herein, shows the steps of a method for preparing 6,15-di keto compounds of the formula ##STR106## The starting material is an equilibrium mixture of the formula-XXVIII 6-keto-PGF 1 α -type and formula-XXIX hemiketal compounds. See for example Johnson et al. J. Am. Chem. Soc. 99, 4182 (1977). ##STR107##
In step "u", the blocking groups R 21 are added, using methods described herein or known in the art. With dihydropyran, for example, the main product is the bis(THP ether).
In step "v" the free acid is formed by saponification of the carboxylic ester groups and acidification.
In step "w" the blocked 6-keto-PGF 1 α -type compound of formula XXXII is oxidized, for example with Jones reagent, to the formula-XXXIV 6,15-diketo-PGE 1 -type compound.
Finally, the step "x" the blocking groups are removed in the conventional way to obtain the formula-XXXV product. ##STR108##
Chart G shows the steps in a preferred method for preparing amides of the formula ##STR109## The starting materials of formula XXXVI are 5-halo acids within the scope of formula VII of Chart B herein.
In step "y" the formula-XXXVI halo acid is converted to amide XXXVII, e.g. by way of a mixed anhydride. For this purpose, compound XXXVI is treated with isobutyl chloroformate in the presence of a tertiary amine such as triethylamine and thereafter with an amine of the formula HN(R 9 ) (R 28 ).
In step "z" the halo amide XXXVII is then subjected to dehydrohalogenation and hydrolysis to obtain the formula-XXXVIII compound. Silver carbonate and perchloric acid are useful for this purpose.
In step "aa" the formula-XXXVIII 6-keto-PGF 1 α -type compound, having suitable blocking groups at C-11 and C-15, is oxidized to a PGE 1 -type compound by methods known in the art, for example using Jones reagent at about -15° to -20° C.
Finally, in step "bb" the blocking groups are removed, to produce compound XL.
It should be understood that although the Charts have formulas drawn with a specific configuration for the reactants and products, the procedural steps are intended to apply not only to the other optically active isomers, but also to mixtures, including racemic mixtures or mixtures of enantiomeric forms.
If optically active products are desired, optically active starting materials or intermediates are employed or, if racemic starting materials or intermediates are used, the products are resolved by methods known in the art for prostaglandins.
The products formed from each step of the reaction are often mixtures and, as known to one skilled in the art, may be used as such for a succeeding step or, optionally, separated by conventional methods of fractionation, column chromatography, liquid-liquid extraction, and the like, before proceeding.
Compounds within the scope of formula I are transformed from one to another by methods known in the art. Accordingly, a formula-I compound wherein ##STR110## is transformed to another formula-I compound wherein R 18 is another ring within the scope of R 18 , for example an 11-deoxy compound, by methods known or described herein. A compound wherein ##STR111## is transformed to one wherein ##STR112## by acid dehydration. A compound wherein the C 13 -C 14 group "X" is trans--CH═CH-- is transformed by known methods to another compound wherein the C 13 -C 14 group is cis--CH═CH--, --C.tbd.C--, or --CH 2 CH 2 --. For example, --C.tbd.C-- is obtained by selective bromination and dehydrobromination. A compound wherein the C 2 substituent is --COOR 3 , e.g. a methyl ester, is transformed by known methods to another compound having another C 2 substituent within the scope of R 1 , as defined herein, for example --CH 2 OH or ##STR113##
Compounds of formula V (Chart A), XVIII (Chart C), XXIV (Chart E), XXXIV (Chart F), and XXXIX (Chart G) having blocking groups are useful as intermediates in the various processes for preparing other useful compounds as described herein or known in the art.
To obtain the optimum combination of biological response specificity, potency, and duration of activity, certain compounds within the scope of formula I are preferred. For example it is preferred that Q be ##STR114## wherein it is especially preferred that R 8 be hydrogen, or methyl.
When Q is ##STR115## it is preferred that R 8 is methyl.
Another preference for the compounds of formula I, as to R 1 , is that R 3 in --COOR 3 be either hydrogen or alkyl of one to 12 carbon atoms, inclusive, or a salt of a pharmacologically acceptable cation. Further, when R 3 is alkyl, it is more preferred that it be alkyl of one to 4 carbon atoms, and especially methyl or ethyl.
For purposes of stability on long storage it is preferred for the compounds of formula I that R 3 in --COOR 3 be amido-substituted phenyl or phenacyl as illustrated herein.
For oral administration of compounds I it is preferred that R 1 be ##STR116## It is especially preferred that at least one of R 9 and R 28 be hydrogen.
As to variations in D, it is preferred that "d" be 2, 3, or 4, and especially 2. When both R 2 's are fluoro, it is preferred that R 8 in Q be methyl, or that R 4 be ##STR117##
As to variations in R 18 , it is preferred that R 18 be ##STR118##
When R 4 in the compounds of formula I is ##STR119## it is preferred that C g H 2g be alkylene of 2, 3, or 4 carbon atoms, and especially that it be trimethylene. It is further preferred that R 5 and R 6 be hydrogen, methyl, ethyl, or fluoro, being the same or different. It is further preferred, when R 5 and R 6 are not hydrogen, that both R 5 and R 6 be methyl or fluoro. It is especially preferred that R 4 be n-pentyl, 1,1-dimethylpentyl, or 1,1-difluoropentyl.
When R 4 in the compounds of formula I is ##STR120## it is preferred that "s" be either zero or one. When "s" is not zero, it is preferred that T be methyl, chloro, fluoro, trifluoromethyl, or methoxy with meta or para attachment to the phenyl ring. When Z is oxa (--O--), it is preferred that R 5 and R 6 be hydrogen, methyl, or ethyl, being the same or different. It is further preferred, when R 5 and R 6 are not hydrogen, that both R 5 and R 6 be methyl. When Z is C j H 2j , it is preferred that C j H 2j be a valence bond, methylene, or ethylene. It is especially preferred that R 4 be ##STR121##
With respect to Chart H a method is provided whereby the formula Cl PGF 2 α - or 11-deoxy-PGF 2 α -type free acid is transformed to the various 2-decarboxy-2-aminomethyl or 2-decarboxy-2-(substituted amino)methyl-PGF.sub.α - or 11-deoxy-PGF.sub.α -type compounds of formulas CIV, CVI, CVII, CVIII, CIX, or CX.
By the procedure of Chart H the formula CI compound is transformed to a formula CII mixed acid anhydride. These mixed anhydrides are conveniently prepared from the corresponding alkyl, aralkyl, phenyl, or substituted phenyl chloroformate in the presence of an organic base (e.g., triethylamine). Reaction diluents include water in combination with water miscible organic solvents (e.g., tetrahydrofuran). This mixed anhydride is then transformed to either the formula CIII PG-type, amide or formula CV PG-type, azide.
For preparation of the PGF 2 α -type, amide (formula CIII) the formula CII mixed acid anhydride is reacted with liquid ammonia or ammonium hydroxide.
Alternatively, the formula CIII compound is prepared from the formula CI free acid by methods known in the art for transformation to carboxy acids to corresponding carboxyamides. For example, the free acid is transformed to a corresponding methyl ester (employing methods known in the art; e.g., excess etheral diazomethane), and a methyl ester thus prepared is transformed to the formula CIII amide employing the methods described for the transformation of the formula CII mixed acid anhydride to the formula CIII amide. ##STR122##
Thereafter the formula CIV 2-decarboxy-2-aminomethyl-PGF 2 α - or 11-deoxy-PGF 2 α -type compound is prepared from the formula CIII compound by carbonyl reduction. Methods known in the art art are employed in this transformation. For example, lithium aluminum hydride is conveniently employed.
The formula CII compound is alternatively used to prepare the formula CV azide. This reaction is conveniently carried out employing sodium azide by methods known in the art. See for example, Fieser and Fieser, Reagents for Organic Synthesis vol. 1, pgs. 1041-1043, wherein reagents and reaction conditions for the azide formation are discussed.
Finally, the formula CVI urethane is prepared from the formula CV azide reaction with an alkanol, aralkanol, phenol or substituted phenol. For example, when methanol is employed the formula CVI compound is prepared wherein R 32 is methyl. This formula CVI PG-type product is then employed in the preparation of either the formula CVII or CVIII product.
In the preparation of the formula CVII primary amine from the formula CVI urethane, methods known in the art are employed. Thus, for example, treatment of the formula CVII urethane with strong base at temperatures above 50° C. are employed. For example, sodium potassium or lithium hydroxide is employed.
Alternatively, the formula CVI compound is employed in the preparation of the formula CVIII compound. Thus, when L 1 is alkyl the formula CVIII compound is prepared by reduction of the formula CVI urethane wherein R 32 is alkyl. For this purpose, lithium aluminum hydride is the conveniently employed reducing agent.
Thereafter, the formula CVIII product is used to prepare the corresponding CIX urethane by reaction of the formula CVIII secondary amine (wherein L 2 is alkyl) with an alkyl chloroformate. The reaction thus proceeds by methods known in the art for the preparation of carbamates from corresponding secondard amines. Finally, the formula CX product wherein L 2 and L 3 are both alkyl is prepared by reduction of the formula CIX cabamide. Accordingly, methods hereinabove described for the preparation of the formula CVIII compound from the formula CVI compound are used. Optionally, the various reaction steps herein may be preceded by the employment of blocking groups according to R 21 , thus necessitating their subsequent hydrolysis in preparing each of the various products above. Methods described hereinabove for the introduction and hydrolysis of blocking groups according to R 21 are employed.
Finally, the processes described above for converting the formula CII compound to the formula CV compound and the various compounds thereafter, result in shortening the 8α-side chain of the formula CI compound by one carbon atom. Accordingly, the formula CI starting material should be selected so as to compensate for the methylene group which is consumed in the steps of the above synthesis. Thus, where a 2a-homo-product is desired a corresponding formula Cl 2a,2b-dihomo starting material must be employed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is further illustrated by, but not limited to, the following examples.
All temperatures are in degrees centigrade.
Infrared absorption spectra are recorded on a Perkin-Elmer model 421 infrared spectrophotometer. Except when specified otherwise, undiluted (neat) samples are used.
The NMR spectra are recorded on a Varian A-60, A-60D, T-60 or XL-100 spectrophotometer in deuterochloroform solutions with tetramethylsilane as an internal standard.
Mass spectra are recorded on a Varian Model MAT CH7 Mass Spectrometer, a CEC Model 110B Double Focusing High Resolution Mass Spectrometer, or a LKB Model 9000 Gas Chromatograph-Mass Spectrometer (ionization voltage 22 or 70 ev.), and samples are usually run as TMS (trimethylsilyl) derivatives.
"Brine", herein, refers to an aqueous saturated sodium chloride solution.
"DBN", herein, refers to 1,5-diazabicyclo[4.3.0]nonene-5.
"DABCO", herein, refers to 1,4-diazabicyclo[2.2.2]-octane.
"DBU", herein, refers to 1,5-diazabicyclo[5.4.0]undecene-5.
"DIBAL", herein, refers to diisobutylaluminum hydride.
"E" and "Z", herein, follow Blackwood et al., cited above. "Florisil®", herein, is a chromatographic magnesium silicate produced by the Floridin Co. See Fieser et al. "Reagents for Organic Synthesis" p. 393 John Wiley and Sons, Inc., New York, N.Y. (1967).
"HPLC", herein, refers to high pressure liquid chromatography.
"Skellysolve B", herein, refers to mixed isomeric hexanes.
"THP", herein, refers to tetrahydropyran-2-yl.
"TLC", herein refers to thin layer chromatography.
"Concentrating", as used herein, refers to concentration under reduced pressure, preferably at less than 50 mm. and at temperatures below 35° C.
"Drying", as used herein, refers to contacting a compound, in solution, with an anhydrous agent such as sodium sulfate or magnesium sulfate to remove water and filtering to remove solids.
Silica gel chromatography, as used herein, is understood to include elution, collection of fractions, and combination of those fractions shown by TLC to contain the desired product free of starting material and impurities.
The A-IX solvent system used in thin layer chromatography is made up from ethyl acetate-acetic acid-2,2,4-trimethylpentane-water (90:20:50:100) according to M. Hamberg and B. Samuelsson, J. Biol. Chem. 241, 247 (1966).
Preparation 1
5ξ-Iodo-9-deoxy-6,9-epoxy-PGF 1 α, Methyl Ester (Formula VII D is --(CH 2 ) 3 --, Q is ##STR123## R 4 is n-pentyl, ##STR124## R 19 is --COOCH 3 , and X is trans--CH═CH--.)
Refer to Chart D. A suspension of PGF 2 α, methyl ester as its 11,15-bis(tetrahydropyranyl)ether (2.0 g.) in 23 ml. of water is treated with sodium bicarbonate (0.7 g.) and cooled in an ice bath. To the resulting solution is added potassium iodide (1.93 g.) and iodine (2.82 g.) and stirring continued for 16 hr. at about 0° C. Thereafter a solution of sodium sulfite (1.66 g.) and sodium carbonate (0.76 g.) in 10 ml. of water is added. After a few minutes the mixture is extracted with chloroform. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to yield mainly the bis(tetrahydropyranyl) ether of the title compound, 2.2 g., an oil. Hydrolysis of this ether in acetic acid-water-tetrahydrofuran (20:10:3) yields mainly the title compound, which is further purified by silica gel chromatography. R f 0.20 (TLC on silica gel in acetonedichloromethane (30:70)). The mass spectral peaks for the formula-VII compound (TMS derivative) are at 638, 623, 607, 567, 548, 511, and 477.
Following the procedures of Preparation 1, as illustrated in Chart D, but replacing the formula-XIX starting material with the following formula-XIX compounds or C-11 derivatives within the scope of formula XIX:
15-Methyl-PGF 2 α
(15R)-15-Methyl-PGF 2 α
15-Ethyl-PGF 2 α
16,16-Dimethyl-PGF 2 α
16,16-Difluoro-PGF 2 α
16-Phenoxy-17,18,19,20-tetranor-PGF 2 α
17-Phenyl-18,19,20-trinor-PGF 2 α
11-Deoxy-PGF 2 α
2a,2b-Dihomo-PGF 2 α
3-Oxa-PGF 2 α
3-Oxa-17-phenyl-18,19,20-trinor-PGF 2 α
there are obtained the corresponding formula-VII iodo compounds.
Preparation 2
6-Keto-PGF 1 α, Methyl Ester (Formula III, D, Q, R 4 , R 18 , R 19 , and X as defined in Preparation 1).
Refer to Chart D. A solution of the formula-VII iodo compound, methyl ester (Preparation 1, 0.45 g.) in 20 ml. of tetrahydrofuran is treated with silver carbonate (0.250 g.) and perchloric acid (70%, 0.10 ml.), and stirred at about 25° C. for 24 hr. The mixture is diluted with 25 ml. of ethyl acetate and the organic phase is washed with saturated sodium carbonate solution and brine, dried, and concentrated to an oil, 0.41 g. Separation by silica gel chromatography eluting with ethyl acetate-Skellysolve B (3:1) yields the formula-III title compound as a more polar material than the formula-VII starting material. The product is an oil, 0.32 g., having R f 0.38 (TLC on silica gel in acetonedichloromethane (1:1)); infrared spectral peak at 1740 cm -1 for carbonyl; NMR peaks at 5.5, 3.2-4.8, 3.7, 2.1-2.7δ.
Preparation 3
5ξ-Iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , Mixed Isomers (Formula VII) and 9-Deoxy-6ξ,9α-epoxy-6ξ-hydroxy-PGF 1 (Formula XX) and 6-keto-PGF 1 α (Formula III).
A solution of the formula-VII iodo compound methyl ester (Preparation 1, 1.0 g.) in 30 ml. of methanol is treated with 20 ml. of 3 N aqueous potassium hydroxide at about 0° C. for about 5 min., then at about 25° C. for 2 hr. The mixture is acidified with 45 ml. of 2 N potassium acid sulfate and 50 ml. of water to pH 1.0, saturated with sodium chloride and extracted with ethyl acetate. The organic phase is washed with brine, dried over sodium sulfate and concentrated to an oil, 1.3 g. The oil is subjected to silica gel chromatography, eluting with acetone-dichloromethane (30:70 to 50:50) to yield, first the formula-VII free acid compound and later, the mixed formula-III and -XX compounds as a more polar fraction.
The formula-VII compound is an oil, 0.33 g., having R f 0.33 (TLC on silica gel in acetone-dichloromethane (1:1) plus 2% acetic acid), [α] D =+20° (C═0.992 in chloroform), infrared spectral peaks at 3360, 2920, 2860, 2640, 1730, 1710, 1455, 1410, 1380, 1235, 1185, 1075, 1050, 1015, 970, and 730 cm -1 , and mass spectral peaks (TMS derivative) at 696.2554, 681, 625, 606, 569, 535, 479, and 173.
The mixture of 9-deoxy-6ξ,9α-epoxy-6ξ-hydroxy-PGF 1 and 6-keto-PGF 1 α is a solid 0.113 g., melting at 93°-98° C., containing no iodine, having R f 0.13 (TLC on silica gel in acetone-dichloromethane (1:1) plus 2% acetic acid) and having mass spectral peaks (TMS derivative) at 587, 568, 553, 497, 485, 478, 407, 395,, 388, and 173.
Following the procedures of Preparations 2 and 3, but replacing the formula-VII iodo compound therein with those formula-VII iodo compounds described subsequent to Preparation 1, there are obtained the corresponding formula-III and -XX compounds.
Following the procedures of Preparations 1, 2, and 3, as described above, but employing corresponding starting materials, there are prepared the
formula-VII 9-deoxy-6,9-epoxy-5-halo-PGF 1 α -type compounds, including iodo, bromo, and chloro compounds,
formula-III 6-keto-PGF 1 α -type compounds, and
formula-XX 9-deoxy-6,9-epoxy-6-hydroxy-PGF 1 α -type compounds
having the following structural features:
16-Methyl-;
16,16-Dimethyl-;
16-Fluoro-;
16,16-Difluoro-;
17-Phenyl-18,19,20-trinor-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
17-(m-chlorophenyl)-18,19,20-trinor-;
17-(p-fluorophenyl)-18,19,20-trinor-;
16-Methyl-17-phenyl-18,19,20-trinor-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-;
16-Fluoro-17-phenyl-18,19,20-trinor-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-;
16-Phenoxy-17,18,19,20-tetranor-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
16-Phenoxy-18,19,20-trinor-;
16-Methyl-16-phenoxy-18,19,20-trinor-;
16-Methyl-13,14-didehydro-;
16,16-Dimethyl-13,14-didehydro-;
16-Fluoro-13,14-didehydro-;
16,16-Difluoro-13,14-didehydro-;
17-Phenyl-18,19,20-trinor-13,14-didehydro-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
16-Methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
16-Phenoxy-18,19,20-trinor-13,14-didehydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
13,14-Dihydro-;
16-Methyl-13,14-dihydro-;
16,16-Dimethyl-13,14-dihydro-;
16-Fluoro-13,14-dihydro-;
16,16-Difluoro-13,14-dihydro-;
17-Phenyl-18,19,20-trinor-13,14-dihydro-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
16-Methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-Phenoxy-18,19,20-trinor-13,14-dihydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-;
2,2-Difluoro-16-methyl-;
2,2-Difluoro-16,16-dimethyl-;
2,2-Difluoro-16-fluoro-;
2,2-Difluoro-16,16-difluoro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-fluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16,16-difluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-16-methyl-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-13,14-didehydro-;
2,2-Difluoro-16-fluoro-13,14-didehydro-;
2,2-Difluoro-16,16-difluoro-13,14-didehydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-trifluoromethoxyphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-13,14-dihydro-;
2,2-Difluoro-16-methyl-13,14-dihydro-;
2,2-Difluoro-16,16-dimethyl-13,14-dihydro-;
2,2,16-Trifluoro-13,14-dihydro-;
2,2,16,16-Tetrafluoro-13,14-dihydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,10-trinor-13,14-dihydro-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
16-Methyl-cis-13;
16,16-Dimethyl-cis-13-;
16-Fluoro-cis-13-;
16,16-Difluoro-cis-13-;
17-Phenyl-18,19,20-trinor-cis-13-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-cis-13-;
17-(m-chlorophenyl)-18,19,20-trinor-cis-13-;
17-(p-fluorophenyl)-18,19,20-trinor-cis-13-;
16-Methyl-17-phenyl-18,19,20-trinor-cis-13-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-cis-13-;
16-Fluoro-17-phenyl-18,19,20-trinor-cis-13-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-cis-13-;
16-Phenoxy-17,18,19,20-tetranor-cis-13-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-cis-13-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-cis-13-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-cis-13-;
16-Phenoxy-18,19,20-trinor-cis-13-;
16-Methyl-16-phenoxy-18,19,20-trinor-cis-13-;
2,2-Difluoro-cis-13-;
2,2-Difluoro-16-methyl-cis-13-;
2,2-Difluoro-16,16-dimethyl-cis-13-;
2,2-Difluoro-16-fluoro-cis-13-;
2,2-Difluoro-16,16-difluoro-cis-13-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-cis-13-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-cis-13-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-cis-13-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-cis-13-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-cis-13-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-cis-13-;
2,2-Difluoro-16-fluoro-17-phenyl-18,19,20-trinor-cis-13-;
2,2-Difluoro-16,16-difluoro-17-phenyl-18,19,20-trinor-cis-13-;
2,2-Difluoro-16-fluoro-18-phenyl-19,20-dinor-cis-13-;
2,2-Difluoro-16,16-difluoro-18-phenyl-19,20-dinor-cis-13-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-cis-13-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-cis-13-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-cis-13-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-cis-13-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-cis-13-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-cis-13-;
3-Oxa-;
3-Oxa-16-methyl-;
3-Oxa-16,16-dimethyl-;
3-Oxa-16-fluoro-;
3-Oxa-16,16-difluoro-;
3-Oxa-17-phenyl-18,19,20-trinor-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-;
3-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
3-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
3-Oxa-16-phenoxy-18,19,20-trinor-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-;
3-Oxa-13,14-didehydro-;
3-Oxa-16-methyl-13,14-didehydro-;
3-Oxa-16,16-dimethyl-13,14-didehydro-;
3-Oxa-16-fluoro-13,14-didehydro-;
3-Oxa-16,16-difluoro-13,14-didehydro-;
3-Oxa-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
3-Oxa-13,14-dihydro-;
3-Oxa-16-methyl-13,14-dihydro-;
3-Oxa-16,16-dimethyl-13,14-dihydro-;
3-Oxa-16-fluoro-13,14-dihydro-;
3-Oxa-16,16-difluoro-13,14-dihydro-;
3-Oxa-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
3-Oxa-cis-13-;
3-Oxa-16-methyl-cis-13-;
3-Oxa-16,16-dimethyl-cis-13-;
3-Oxa-16-fluoro-cis-13-;
3-Oxa-16,16-difluoro-cis-13-;
3-Oxa-17-phenyl-18,19,20-trinor-cis-13-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-cis-13-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-cis-13-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-cis-13-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-cis-13-;
3-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-cis-13-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-cis-13-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-cis-13-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-cis-13-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-cis-13-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-cis-13-;
3-Oxa-(p-fluorophenoxy)-17,18,19,20-tetranor-cis-13-;
3-Oxa-16-phenoxy-18,19,20-trinor-cis-13-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-cis-13-;
3-Oxa-13,14-dihydro-trans-14,15,-didehydro-;
3-Oxa-16-methyl-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16,16-dimethyl-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16-fluoro-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16,16-difluoro-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-17-phenyl-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-trans-14,15-dihydro-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-trans-14,15-didehydro-;
3-Oxa-16-phenoxy-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-; and
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-trans-14,15-didehydro-.
Likewise following the procedures of Preparations 1, 2, and 3 as described above, but employing corresponding starting materials, there are prepared the
formula-VII 9-deoxy-6,9-epoxy-5-iodo-PGF 1 α -type compounds,
formula-III 6-keto-PGF 1 α -type compounds, and
formula-XX 9-deoxy-6,9-epoxy-6-hydroxy-PGF 1 α -type compounds
having the following structural features:
2,3-Didehydro-;
2,2-Dimethyl-;
2a,2b-Dihomo-;
4-Oxa-4a-homo-;
7a-Homo-;
11β-;
11-Deoxy-;
11-Deoxy-11-methylene-;
11-Deoxy-11-hydroxymethyl-;
15β-;
15-Keto-;
15-Deoxy-;
15-Methyl-15(S)-;
15-Methyl-15(R)-; and
17,18-Didehydro-.
Preparation 4
5ξ-Iodo-9-deoxy-6,9-epoxy-PGF 1 α, p-Phenylphenacyl Ester (Formula VII).
A mixture of the formula-VII iodo acid compound (Preparation 3, Formula VII, 0.20 g.), p-phenylphenacyl bromide (0.50 g.), 0.4 ml. of diisopropylethylamine, and 10 ml. of acetonitrile is stirred at about 25° C. for 40 min. It is mixed with dilute aqueous citric acid and brine and extracted with ethyl acetate. The organic phase is dried and concentrated. The residue is subjected to silica gel chromatography, eluting with ethyl acetate (25-100%)-Skellysolve B to yield the title 5-iodo compound as a colorless oil, 0.20 g.
Preparation 5
2-Decarboxy-2-azidomethyl-PGF 2 α, or 2-nor-PGF 2 α, azide (Formula CV: Z 1 is --CH═CH--(CH 2 ) 3 -- or --CH═CH--(CH 2 ) 2 --, respectively, R 31 is hydroxy, Y 1 is trans --CH═CH--, R 34 and R 35 of the L 1 moiety and R 33 of the M 1 moiety are all hydrogen, and R 30 is n-butyl).
A. To a cold solution (0° C.) of PGF 2 α (7.1 g.), 125 ml. of acetone, 10 ml. of water, and 2.2 g. of triethylamine is added with stirring 3.01 g. of isobutylchloroformate. The mixture is stirred at 0° C. for about 30 min. at which time a cold solution of 7 g. of sodium azide on 35 ml. of water is added. The mixture is then stirred at 0° C. for one hr. at which time it is diluted with 300 ml. of water and extracted with diethyl ether. The organic layers are then combined; washed with water, dilute carbonate solution, saturated saline; dried; and concentrated under reduced pressure, maintaining bath temperature below 30° C., to yield 2-nor-PGF 2 α, azide.
B. 2-Decarboxy-2-azidomethyl-PGF 2 α is prepared by the following reaction sequence:
(1) A solution of t-butyldimethylsilyl chloride (10 g.), imidazole (9.14 g.), and PGF 2 α (3 g.) in 12 ml. of dimethylformamide are magnetically stirred under nitrogen atmosphere for 24 hr. The resulting mixture is then cooled in an ice bath and the reaction quenched by addition of ice water. The resulting mixture is then diluted with 150 ml. of water and extracted with diethyl ether. The combined ethereal extracts are then washed with water, saturated ammonium chloride, a sodium chloride solution, and thereafter dried over sodium sulfate. Solvent is removed under vacuum yielding PGF 2 α, t-butyldimethylsilyl ester, 9,11,15-tris-(t-butyldimethylsilyl ether). NMR absorptions are observed at 0.20, 0.30, 0.83, 0.87, 0.89, 1.07-2.50, 3.10-4.21, and 5.38 δ. Characteristic infrared absorptions are observed at 970, 1000, 1060, 1250, 1355, 1460, 1720, and 2950 cm -1 .
(2) To a magnetically stirred suspension of lithium aluminum hydride (7.75 g.) in 18 ml. of diethyl ether is added dropwise at room temperature over a period of 12 min. 8.71 g. of the reaction product of part (1) above in 40 ml. of diethyl ether. After stirring at ambient temperature for one hr., the resulting product is cooled in an ice water bath and saturated sodium sulfate is added dropwise until the appearance of a milky suspension. The resulting product is coagulated with sodium sulfate, triturated with diethyl ether, and the solvent is removed by suction filtration. Concentration of the diethyl ether under vacuum yields 7.014 g. of 2-decarboxy-2-hydroxymethyl-PGF 2 α, 9,11,15-tris-(t-butyldimethylsilyl ether), NMR absorptions are observed at 0.03, 0.82, 0.87, 1.10-2.60, 3.30-4.30, and 5.37 δ. Characteristic infrared absorptions are observed at 775, 840, 970, 1065, 1250, 1460, 2895, 2995, and 3350 cm -1 .
(3) p-Toluenesulfonyl chloride (3.514 g.), pyridine (44 ml.), and the reaction product of subpart (2), 7.014 g., are placed in a freezer at -20° C. for 3 days. Thereafter, 7.200 g. of 2-decarboxy-2-p-toluenesulfonyloxymethyl-PGF 2 α, 9,11,15-tris-(t-butyldimethylsilyl ether), is recovered. NMR absorptions are observed at 0.10, 0.94, 0.97, 1.10, 2.50, 4.03, 3.80-4.80, 5.45, 7.35, and 7.80 δ. Infrared absorptions are observed at 775, 970, 1180, 1190, 1250, 1360, 1470, 2900, and 2995 cm -1 .
(4) The reaction product of subpart (3) (2.13 g.) is placed in 42 ml. of acetic acid, tetrahydrofuran, and water (3:1:1) containing 0.25 ml. of 10 percent aqueous hydrochloric acid. The reaction mixture becomes homogeneous after vigorous stirring for 16 hr. at room temperature. The resulting solution is then diluted with 500 ml. of ethyl acetate; washed with saturated sodium chloride and ethyl acetate; dried over sodium sulfate; and evaporated under reduced pressure, yielding 1.301 g. of an oil. Crude product is chromatographed on 150 g. of silica gel packed with ethyl acetate. Eluting with ethyl acetate yields 0.953 g. of 2-decarboxy-2-p-toluenesulfonyloxymethyl-PGF 2 α.
(5) The reaction product of subpart (4), (0.500 g.) in 5.0 ml. of dimethylformamide was added to a stirred suspension of sodium azide (1.5 g.) in 20 ml. of dimethylformamide. Stirring is continued at ambient temperature for 3 hr. The reaction mixture is then diluted with water (75 ml.), extracted with diethyl ether (500 ml.), and the etheral extracts washed successively with water, saturated sodium chloride, and dried over sodium sulfate. Removal of the diethyl ether under reduced pressure yields 0.364 g. of 2-decarboxy-2-azidomethyl-PGF 2 α. A characteristic azido infrared absorption is observed at 2110 cm -1 .
Preparation 6
2-Decarboxy-2-aminomethyl-PGF 2 α (Formula CXXV: Z 1 cis--CH═CH--(CH 2 ) 3 --, R 31 is hydroxy, Y 1 is trans--CH═CH--, R 34 and R 35 of the L 1 moiety and R 33 of the M 1 moiety are all hydrogen, and R 30 is n-butyl).
Crude 2-decarboxy-2-azidomethyl-PGF 2 α (Prep. 5, 0.364 g.) in 12 ml. of diethyl ether is added to a magnetically stirred suspension of lithium aluminum hydride (0.380 g.) in 20 ml. of diethyl ether. Reaction temperature is maintained at about 0° C. and addition of lithium aluminum hydride proceeds dropwise over a 4 min. period. After addition is complete, the resulting mixture is stirred at ambient temperature for 1.5 hr. and thereafter placed in an ice bath (0°-5° C.). Excess reducing agent is then destroyed by addition of saturated sodium sulfate. After cessation of gas evolution, the resulting product is coagulated with sodium sulfate, triturated with diethyl ether, and solid salts removed by filtration. The filtrate is then dried with sodium sulfate, and evaporated under reduced pressure to yield 0.304 g. of a slightly yellow oil. This oil (100 mg.) is then purified by preparative thin layer chromatography, yielding 42 g. of title product. NMR absorptions are observed at 0.90, 1.10-2.80, 3.28, 3.65-4.25, and 5.45 δ. Characteristic infrared absorptions are observed at 970, 1060, 1460, 2995, and 3400 cm -1 . The mass spectrum shows parent peak at 699.4786 and other peaks at 628, 684, 595, 217, and 274.
Preparation 7
5ξ-Iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , Amide, less polar and more polar isomers (Formula VII: D is --(CH 2 ) 3 --, Q is ##STR125## R 4 is n-pentyl, ##STR126## R 19 is ##STR127## R 37 is iodo and X is trans--CH═CH--).
A solution of the formula-VII iodo-ether acid, mixed isomers (Preparation 3, 5.0 g.) in 50 ml. of acetone is cooled to about -10° C. and treated with 3.0 ml. of triethylamine and 3.0 ml. of isobutyl chloroformate. After 5 min. there is added 100 ml. of acetonitrile saturated with ammonia, and the reaction mixture allowed to warm to about 25° C. The mixture is filtered, and the filtrate concentrated. The residue is taken up in ethyl acetate and water. The organic phase is washed with water, dried over magnesium sulfate and concentrated. The residue is subjected to silica gel chromatography, eluting with acetone (25-100%)-methylene chloride. There are obtained the formula-VII iodo-ether, amide, less polar isomer, 0.02 g., having R f 0.40 (TLC on silica gel in acetone); a fraction of mixed less and more polar isomers, 2.2 g.; and the more polar isomer, 1.5 g., having R f 0.37 (TLC on silica gel in acetone), infrared absorption at 3250, 3150, 1660, 1610, 1085, 1065, 1050, and 965 cm -1 , and NMR peaks at 6.4, 5.5, 3.5-4.7 and 0.9 δ.
Preparation 8
5ξ-Iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , Methylamide, mixed isomers (Formula VII: R 19 is ##STR128##
A solution of the formula-VII 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , mixed isomers (Preparation 3, 4.66 g.) in 50 ml. of acetone is treated with 1.42 ml. of triethylamine and cooled to -5° C. Thereupon 1.3 ml. of isobutyl chloroformate is added, with stirring at 0° C. for 5 min., followed by 25 ml. of 3 M methylamine in acetonitrile. The solution is stirred for 20 min. more as it warmed to about 25° C. The mixture is filtered and concentrated. The oily residue is triturated with methylene chloride, and filtered to remove a precipitate. The filtrate is subjected to silica gel chromatography, eluting with acetone (50-90%)-methylene chloride, to yield the 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , methylamide mixed isomers, 3.45 g., having NMR peaks at 6.3, 5.4-5.7, 3.2-4.7, 2.78, and 0.7-2.65 δ.
Preparation 9
5ξ-Iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , n-Butylamide, Mixed Isomers (Formula: VII: R 19 is ##STR129##
A solution of the formula-VII iodo-ether acid, mixed isomers (Preparation 3, 5.0 g.) in 50 ml. of acetone is cooled to about -10° C. and treated with 2.0 ml. of triethylamine and 1.9 ml. of isobutyl chloroformate. After 6 min. there is added a solution of 15 ml. of n-butylamine in 20 ml. of acetone. After about 15 min. the reaction mixture is allowed to warm to about 25° C. and stirred for 3 hr. The mixture is concentrated and the residue is taken up in ethyl acetate. The solution is washed with water and brine, dried over magnesium sulfate, and concentrated. The residue is chromatographed on silica gel, eluting with acetone (5-100%)-methylene chloride to yield the title compounds, 5.3 g. The product is rechromatographed to remove color using silica gel and eluting with acetone-methylene chloride (1:3). From 0.48 g. there is obtained the title compounds as a pale yellow oil, 0.35 g., having R f 0.63 (TLC on silica gel in acetone), and infrared absorption peaks at 3300, 3100, 1735, 1715, 1645, 1555, 1070, 1055, 1020, and 965 cm -1 .
Preparation 10
6-Keto-PGF 1 α, n-Butylamide
I. There is first prepared (5Z)-9-deoxy-6,9α-epoxy-Δ 5 -PFG 1 , n-butylamide. A solution of 5ξ-iodo-6ξ,9α-epoxy-PGF 1 n-butylamide (Preparation 9, 3.5 g.) in 100 ml. of benzene is treated with 8 ml. of DBN at 40°-45° C. for about 16 hr. The mixture is cooled, diluted with ice water, and extracted with chloroform, keeping a few drops of triethylamine in the organic phase. The combined organic phases are washed with ice water, dried and concentrated to an oil, 3.64 g. Of this, 3.1 g. is taken up in warm diethyl ether, and the ether solution when cooled yields 1.5 g., mainly solid. The product is recrystallized from ether, 0.85 g., m.p. 102°-104° C.
II. A solution of the above (5Z)-9-deoxy-6,9α-epoxy-Δ 5 -PGF 2 , n-butylamide (3.0 g.) in 25 ml. of tetrahydrofuran is treated with sufficient 10% aqueous potassium hydrogen sulfate solution to bring the pH to 5.0. The mixture is concentrated to remove tetrahydrofuran and the residue is taken up in water and ethyl acetate. Sodium chloride is added to saturation and the organic phase is separated. The aqueous phase is extracted with acetone-ethyl acetate (1:4) and the organic phases are combined. The organic phases are washed with brine, dried, and concentrated. The residue, 2.10 g., is chromatographed on silica gel, eluting with acetone (33-100%)-methylene chloride to yield a 1:1 mixture of the title compound together with the corresponding 9-deoxy-6,9α-epoxy-6-hydroxy compound, having R f 0.57 (TLC on silica gel in acetone). The mixture is dissolved in 10 ml. of tetrahydrofuran and acidified with aqueous potassium hydrogen sulfate, thereby converting the mixture to substantially all 6-keto-PGF 1 α, n-butylamide, having R f 0.58 (TLC on silica gel in acetone). The product is recovered by concentrating the solution, portioning between ethyl acetate and water, washing the organic phase with brine, and concentrating to an oil, 1.90 g., having a high resolution mass spectral peak (TMS derivative) at 641.4258.
Preparation 11
5ξ-Iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , Benzylamide, mixed isomers (Formula VII: R 19 is ##STR130##
Following the procedures of Preparation 8, there are used 4.66 g. of the formula-VII 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , mixed isomers, and 1.08 g. of benzylamine instead of methylamine. The crude product is chromatographed on silica gel, eluting with acetone (50-70%)-methylene chloride, to yield the 5ξ-iodo-9-deoxy-6ξ-9α-epoxy-PGF 1 , benzylamide mixed isomers, 4.1 g., having NMR peaks at 7.3, 6.6, 5.3-5.7, and 3.5-4.6 δ.
Preparation 12
5ξ-Iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , Anilide, mixed isomers (Formula VII R 19 is ##STR131##
Following the procedures of Preparation 8, there are used 4.66 g. of the formula-VII 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , mixed isomers, and 0.94 g. of aniline. The crude product is chromatographed on silica gel, eluting with acetone (10-50%)-methylene chloride, to yield the 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , anilide mixed isomers, 4.0 g., having NMR peaks at 8.4, 6.9-7.7, 5.3-5.7, and 3.4-4.7 δ.
EXAMPLE 1
6-Keto-PGE 1 , Methyl Ester (Formula VI: D is --(CH 2 ) 3 --, Q is ##STR132## R 4 is n-pentyl, ##STR133## R 19 is --COOCH 3 , and X is trans--CH═CH--).
A. Refer to Chart A. A solution of formula-III 6-Keto-PGF 1 α, methyl ester (0.50 g.) in 25 ml. of methylene chloride is treated with 3 ml. of dihydropyran and 3 ml. of a saturated solution of pyridine hydrochloride in methylene chloride and left standing about 5 hr. at about 25° C. or until TLC shows that the starting material has disappeared. and that the bis(tetrahydropyranyl)ether has been formed, having R f 0.22 (TLC on silica gel in acetone-methylene chloride (1:9)) or R f 0.47 (TLC on silica gel in acetone-methylene chloride (1:3)). The reaction mixture is concentrated, washed with aqueous sodium bicarbonate and brine, dried, and concentrated. The residue is subjected to silica gel chromatography, eluting with acetone (10-25%) in methylene chloride to yield the formula-IV bis(tetrahydropyranyl) ether, methyl ester, having infrared peaks at 3500, 1745, 1730, 1200, 1160, 1130, 1110, 1075, 1035, 1020, 980, 915, 870, 815, and 735 cm -1 ; mass spectral lines (TMS) at 552, 522, 366, 348, 331, 330, 304, and 85; and NMR spectral peaks at 5.5, 4.67, 3.65, 3.2-3.7, and 0.9 δ.
B. The reaction product from part A, containing 6-keto-PGF 1 α, bis(tetrahyropyranyl)ether, methyl ester corresponding to formula IV, is oxidized to compound V. A composite from several lots, weighing 0.93 g., in 20 ml. of acetone is treated at -10° C. with 2.0 ml. of Jones reagent. After stirring for 1.5 hr. the reaction mixture is quenched with isopropanol and extracted with diethyl ether. The extract is washed with brine, dried, and concentrated. The residue is subjected to silica gel chromatography, eluting with ethyl acetate (20-50%)-Skellysolve B to yield the formula-V 6-keto-PGE 1 , bis(tetrahydropyranyl)ether, methyl ester, 0.52 g., having R f 0.52 (TLC on silica gel in ethyl acetate-Skellysolve B (1:1)); and infrared peaks at 1745 and 1725 cm -1 (free of OH at 3000-3500).
C. The product of part B is hydrolyzed in 3 ml. of acetic acid and 1.5 ml. of water at 40° C. for 3 hr., then mixed with brine and extracted with chloroform. The organic phase is washed with brine, dried, and concentrated. The residue is subjected to silica gel chromatography eluting with ethyl acetate (25-100%) -Skellysolve B to yield 0.15 g. of the title compound, having infrared peaks at 3380, 1750, 1710, 1250, 1200, 1180, 1105, 1070, and 975 cm -1 , and mass spectral lines (TMS) at 526.3123, 511, 508, 495, 455, 436, 382, 313.2004, and 199. An analytical sample, recrystallized as needles from diethyl ether-hexane, m. 39°-40° C., has R f 0.33 (TLC on silica gel in ethyl acetate).
EXAMPLE 2
6-Keto-PGE 1 (Formula VI: D is --(CH 2 ) 3 --,
Q is ##STR134## R 4 is n-pentyl, ##STR135## R 19 is --COOH, and X is trans--CH═CH--).
A. Refer to Chart B. There is first prepared the formula-VIII bis(tetrahydropyranyl)ether of 9-deoxy-6,9-epoxy-5-iodo-PGF 1 α, methyl ester. The formula-VII product of Preparation 1 (2.0 g.) in 20 ml. of methylene chloride, together with 4 ml. of dihydropyran and 1 ml. of a saturated solution of pyridine hydrochloride in methylene chloride, is left standing 16 hr. at about 25° C. The mixture is washed with aqueous sodium bicarbonate and brine, dried and concentrated to a colorless oil. The residue is subjected to silica gel chromatography, eluting with acetone (10%)-methylene dichloride, to yield about 3.0 g. having R f 0.73 (TLC on silica gel in ethyl acetate); and infrared peaks at 1765, 1215, 1140, 1085, 1045, 1036, 985, 875, 820, and 740 cm -1 (free of OH at 3000-3500).
B. The formula-IV 6-keto PGF-type compound is prepared in several steps as follows. The product of part A above (about 3.0 g.) is mixed with 100 ml. of benzene and 4 ml. of 1,5-diazabicyclo[4.3.0]nonene-5 (DBN) and held at 40° C. for 4 hr., then at about 25° C. for 64 hr. The mixture is washed with ice-water, dried over magnesium sulfate, and concentrated to the enol ether, 9-deoxy-6,9-epoxy-Δ 5 -PGF 1 α, bis(tetrahydropyranyl)ether, methyl ester, 2.5 g. having NMR peaks at 5.55, 4.5-5.1, 3.2-4.5, and 0.9 δ; and infrared peaks at 1740, 1695, 1200, 1165, 1130, 1075, 1035, 1020, 975, and 870 cm -1 .
The enol ether (2.25 g.) is dissolved in 25 ml. of diethyl ether, mixed with 10 ml. of a dilute aqueous solution of potassium hydrogen sulfate and stirred at about 25° C. The reaction is monitored by TLC (silica gel plates in acetone (10%)-methylene chloride) as a more polar material is slowly formed. After several hours 50 ml. of tetrahydrofuran is added and stirring continued. The mixture is concentrated and the residue is extracted with ethyl acetate. The extract is washed with brine, dried, and concentrated to an oil. The residue is subjected to silica gel chromatography eluting with acetone (10-25%)-methylene chloride to yield the formula-IV 6-keto-PGF 1 α, bis(tetrahydropyranyl)ether, methyl ester, 1.91 g., having R f 0.22 (TLC on silica gel in acetone (10%)-methylene chloride), having the same infrared spectrum as the corresponding formula-IV intermediate of Example 1.
C. The acid form of the product of part B is prepared by saponifying that product. The methyl ester of part B (0.75 g.) in 25 ml. methanol and 7 ml. of 3 N. sodium hydroxide is stirred at about 25° C. for 3 hr. The mixture is chilled, saturated with sodium chloride, acidified with potassium hydrogen sulfate, and extracted with ethyl acetate. The extract is washed with brine, dried, and concentrated to an oil, 0.68 g., having R f 0.61 (TLC on silica gel in A-IX solvent).
D. The formula-V 6-keto PGE-type compound is obtained as follows. The product of part C (0.68 g.) in 50 ml. of acetone is cooled to -15° C. and treated with 2 ml. of Jones reagent added slowly with stirring. Stirring is continued at about the same temperature for one hr., then at -5° C. for 0.5 hr. The reaction is quenched with isopropanol and the mixture concentrated to about half volume. Brine is added and the mixture extracted with diethyl ether. The extract is washed with brine, dried, and concentrated to a yellow oil, 0.61 g., having R f 0.64 (TLC on silica gel in A-IX). After silica gel chromatography a fraction is obtained, 0.31 g.
E. The formula-VI title compound is finally obtained on hydrolysis of the blocking groups. The product of part D (0.31 g.) is treated in 7 ml. of acetic acid and 3 ml. of water at 40° C. for one hr. and a further 16 hr. at about 25° C. Brine is added and the mixture is extracted with chloroform. The extract is washed with water, dried, and concentrated to an oil, 0.25 g. This product is subjected to silica gel chromatography, eluting with ethyl acetate (25-100%)-hexane to obtain the title compound, 0.065 g. having NMR peaks at 5.72, 5.57, 3.8-4.3, 2.1-2.8, and 0.9 δ; and infrared absorption peaks at 3420, 3000, 2800, 1755, 1740, 1710, 1315, 1255, 1190, 1160, 1110, 1065, and 970. An analytical sample is obtained as needles on recyrstallizing from diethyl ether-hexane, m. 67°-69° C.
Following the procedures of Example 2, but replacing the preparation of the formula-IV 6-keto PGF-type compound in part B with a preparation using silver carbonate and perchloric acid, the same end product is obtained. Thus, instead of part B, the product of part A (2.5 g.) is mixed with 80 ml. of tetrahydrofuran, silver carbonate (one gram) and 7 drops of 70% perchloric acid. The mixture is stirred vigorously at about 25° C. for 22 hr. Additional perchloric acid (3 drops) is added and stirring continued for 4 hr. The mixture is filtered, the filtrate treated wth brine and sodium carbonate, and extracted with ethyl acetate. The extract is washed with brine, dried, and concentrated to an oil, 2.6 g. Silica gel chromatography, eluting with acetone (10-40%)-methylene chloride, yields the formula-IV 6-keto-PGF 1 α, bis(tetrahydropyranyl)ether, methyl ester, an oil, 0.52 g. having R f 0.35 (TLC on silica gel in ethyl acetate-cyclohexane (1:1)). Thereafter the 6-keto-PGE 1 product is obtained following parts C, D, and E above.
Following the procedures of Example 1 and 2 and Chart B but replacing the formula-VII starting material with the appropriate formula-VII compounds obtained following Preparations 1, 2, and 3, there are obtained formula-VI compounds as follows:
2,2-Difluoro-6-keto-PGE 1 , Methyl Ester
(15S)-15-Methyl-6-keto-PGE 1
(15R)-15-Methyl-6-keto-PGE 1
16,16-Dimethyl-6-keto-PGE 1
2,2-Difluoro-16,16-dimethyl-6-keto-PGE 1 , methyl ester
2,2-Difluoro-(15S)-15-methyl-6-keto-PGE 1 , methyl ester
16-Phenoxy-17,18,19,20-tetranor-6-keto-PGE 1
16-Phenyl-17,18,19,20-tetranor-6-keto-PGE 1
17-Phenyl-18,19,20-trinor-6-keto-PGE 1
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-6-keto-PGE 1 , methyl ester
13,14-Dihydro-6-keto-PGE 1
2,2-Difluoro-13,14-dihydro-6-keto-PGE 1 , methyl ester
2,2-Difluoro-13,14-didehydro-6-keto-PGE 1 , methyl ester.
EXAMPLE 3
6-Keto-13,14-didehydro-PGF 1 α, 11,15-bis(tetrahydropyranyl)ether (Formula XVIII: D 1 is --(CH 2 ) 3 --, Q 3 is ##STR136## wherein THP is tetrahydropyranyl, R 23 is --COOH, R 26 is n-pentyl, ##STR137## and X is --C.tbd.C--) and 5ξ-Bromo-9-deoxy-6ξ,9-epoxy-14-bromo-15-keto-PGF 1 α, Methyl Ester.
A. Refer to Chart C. The 5ξ,6ξ,14-tribromo-15-keto-PFG 1 α, methyl ester (XII) is first prepared. A solution of 15-oxo-PGF 2 α, methyl ester (U.S. Pat. No. 3,728,382, 3.38 g.) in about 25 ml. of pyridine is treated dropwise with a soluton of pyridinium hydrobromide perbromide (7.08 g.) in 35 ml. of pyridine over 2.25 hr. Thereafter the mixture is stirred for 27 hr., diluted with ether and filtered. The filtrate is washed with water, cold hydrobromic acid (5%) aqueous sodium bicarbonate (5%), then dried and concentrated to yield 3.72 g. product. Similarly an additional 1.06 g. is prepared and combined. The product is subjected to silica gel chromatography eluting with hexane-ethyl acetate (65:35) to yield XII, 2.83 g., having NMR peaks at 0.90, 1.1-2.58, 2.58-3.4, 3.4-3.88, 3.67, 3.88-4.61, 6.96, and 7.03 δ; infrared peaks at 3400, 1730, 1685, 1610, 1245, 1200, 1170, 1085, and 1050 cm -1 ; and mass spectral peaks (TMS) at 746.0562, 636, 634, 632, 630, 555, 553, and 551.
There is also obtained, as a separate fraction from the chromatography of the reaction product, 5ξ-bromo-9-deoxy-6ξ,9-epoxy-14-bromo-15-keto-PGF 1 α, methyl ester, 0.93 g., having NMR peaks at 0.90, 1.10-3.03, 3.03-3.46, 3.65, 3.78-5.0, 6.91 and 7.00 δ; infrared peaks at 3480, 2880, 2810, 1735, 1690, 1615, 1245, 1200, 1175, 1150, and 1080 cm -1 ; and mass spectral peaks (TMS) at 594.099, 515, and 478.
B. 5ξ,6ξ,14-Tribromo-PGF 1 α, methyl ester (XIII). A solution of XII (2.38 g.) in 20 ml. of methanol is added to a solution of sodium borohydride (1.28 g.) in 40 ml. of methanol at -35° C. The temperature is held at -25° C. for 1 hr. The mixture is diluted with diethyl ether and quenched with acetic acid. The solution is washed with saline solution (5%) and aqueous bicarbonate (5%) solutons, dried, and concentrated to a mixture of C-15 epimers (XIII). Separation is achieved by silica gel chromatography eluting with hexane-ethyl acetate (3:2 followed by 1:1) to yield, first, the 15R epimer (XIII-15β), 1.57 g. having NMR peaks at 0.9, 1.1-3.35, 3.35-4.65, 3.66, and 5.75-6.21 δ; infrared peaks at 3380, 1735, 1725, 1250, 1200, 1175, 1075, and 1050 cm -1 ; high resolution mass spectral peak (TMS derivative) at 749.0362, and [α] D -11° in ethanol; and second, the 15S epimer (XIII-15α) 0.605 g. having NMR peaks at 0.9, 1.10-3.35, 3.35-4.6, 3.66, and 5.65-6.15 δ; infrared peaks at 3380, 1740, 1650, 1435, 1250, 1200, 1175, 1120, 1080, and 1045 cm -1 ; high resolution mass spectral peak (TMS derivative) at 749.0384; and [α] D -4° in ethanol.
C. 14-Bromo-PGF 2 α, methyl ester (XIV). A solution of XIII-15α (0.60 g.) in 20 ml. of methanol is treated with ammonium chloride (0.11 g.) and zinc dust (0.28 g.). The mixture is stirred for 1.5 hr., diluted with benzene and filtered. The filtrate is washed with 0.2 M. potassium acid sulfate, dried, and concentrated to yield 0.37 g., having R f 0.26 (TLC on silver nitrate-treated silica gel in ethyl acetate); NMR peaks at 0.88, 1.1-2.71, 2.71-3.55, 3.66, 3.80-4.35, 5.23-5.56 and 5.84 δ; and infrared peaks at 3320, 2900, 2820, 1940, 1650, 1430, 1310, 1240, 1215, 1170, 1115, and 1030 cm -1 .
D. 5ξ-iodo-9-deoxy-6ξ,9-epoxy-14-bromo-PGF 1 α, methyl ester (XV). A solution of XIV (1.9 g.) in 30 ml. of methylene chloride is added to a suspension of iodine (2.85 g.), potassium iodide (1.88 g.) sodium acetate (0.92 g.) and water (6 ml.). The mixture is stirred for 2 hr., treated with 20 ml. of 2 N. sodium thiosulfate, washed with aqueous 5% saline solution, dried and concentrated to yield XV, 2.95 g. An analytical sample obtained by subjecting a portion to silica gel chromatography had NMR peaks at 0.89, 1.1-3.18, 3.66, 3.6-4.8, and 5.88 δ; mass spectral peaks (TMS) at 701.1183, 645, 637, 589, 547, 529, 510, and 173; and infrared spectral peaks at 3380, 1740, 1655, 1230, 1170, 1080, and 1050 cm -1 .
E. 5ξ-iodo-9-deoxy-6ξ,9-epoxy-14-bromo-PGF 1 α, 11,15-bis(tetrahydropyranyl) ether, methyl ester (XVI). A solution of XV (1.0 g.) in 10 ml. of methylene chloride is treated with dihydropyran (3 ml.) and 3 ml. of a saturated solution of pyridine hydrochloride in methylene chloride. After 20 hr. the mixture is diluted with diethyl ether, washed with aqueous sodium bicarbonate (5%) and saline solution (5%), dried, and concentrated. The residue is 1.12 g., having NMR peaks at 0.9, 1.05-2.20, 2.2-3.2, 3.2-4.35, 3.66, 4.35-4.15, and 5.7-6.1 δ; and infrared peaks at 2900, 2820, 1760, 1440, 1350, 1210, 1125, 1090, 1035, 1025, 970, and 910 cm -1 .
F. 6-Keto-13,14-didehydro-PGF 1 α, 11,15-bis(tetrahydropyranyl)ether (XVII). A solution of XVI (1.1 g.) in 15 ml. of dimethyl sulfoxide and 1.5 ml. of methanol is treated with potassium t-butoxide (0.504 g.) for 20 hr. The mixture is diluted with 60 ml. of water, cooled, acidified with 5% phosphoric acid, and extracted wth diethyl ether. The organic phase is washed with brine, dried, and concentrated to an oil, 0.81 g., which is subjected to silica gel chromatography, eluting with hexane-ethyl acetate (7.5:2.5) to yield the title compound, 0.313 g., having NMR peaks at 0.9, 1.1-3.0, 3.05-5.1, and 6.5-7.5 δ; and infrared peaks at 3300, 3900, 2810, 2500-2700, 2225, 1740, 1710, 1430-1460, 1190, 1130, 1120, 1075, 1035, 1015, 975, and 905 cm -1 .
EXAMPLE 4
6-Keto-13,14-didehydro-PGE 1 (Formula VI: D is --(CH 2 ) 3 --, Q is ##STR138## R 4 is n-pentyl, ##STR139## R 19 is --COOH, and X is --C.tbd.C--).
Refer to Chart A. A solution of the formula-IV 6-keto-13,14-didehydro-PGF 1 α, 11,15-bis(tetrahydropyranyl)ether (Example 3, 1.1 g.) in 12 ml. of acetone is treated at -10° C. with 2.67 M. Jones reagent added dropwise in three 1 ml. aliquots at 15 min. intervals. The mixture is quenched with isopropanol added dropwise, diluted with diethyl ether, and partitioned with 5% aqueous sodium chloride, dried, and concentrated. The residue consists of the formula-V bis(tetrahydropyranyl)ether of the title compound, 0.26 g., having R f 0.29 (TLC on silica gel in A-IX-cyclohexane (1:1)).
The product above is hydrolyzed in a mixture of acetic acid (15 ml.), water (7.5 ml.) and tetrahydrofuran (1.0 ml.) for 4.5 hr. at about 40° C., then diluted with 30 ml. of water and lyophilized to a yellow oil, 0.14 g. The oil is subjected to silica gel chromatography, eluting with hexaneethyl acetate (3:2), to yield the title compound, 0.048 g., having NMR peaks at 0.90, 1.1-2.05, 2.05-3.33, 4.03-4.70, and 5.5-6.3 δ; mass spectral peaks (TLC) at 582.3210, 567, 511, 492, 477, 436, 421, 410, 402, 387, 291.1768, 173, and 111; and infrared peaks at 3350, 2870, 2500-2600, 2810, 2240, 1740, 1710, 1450, 1400, 1155, and 1080 cm -1 .
EXAMPLE 5
6-Keto-13,14-didehydro-PGF 1 α (Formula III: D is --(CH 2 ) 3 --, Q is ##STR140## R 4 is n-pentyl, ##STR141## R 19 is --COOH, and X is --C.tbd.C--).
A solution of the 5ξ-iodo-9-deoxy-6ξ,9-epoxy-14-bromo-PGF 1 α, methyl ester (Example 3D, 1.67 g.) in 30 ml. of dimethyl sulfoxide is treated with potassium tertbutoxide (1.63 g.) in 3 ml. of methanol at about 25° C. for 23 hr., then diluted with water (6 ml.) and reacted for a further 3 hr. The mixture is diluted with ether and partitioned with cold 3.5% phosphoric acid. The organic phase is washed with 5% sodium chloride solution, dried, and concentrated. The residue (0.87 g.) is subjected to silica gel chromatography eluting with hexane-ethyl acetate (1:1) to yield the formula-III title compound, 0.59 g., having NMR peaks at 0.90, 1.1-3.5, 3.7-5.2, and 5.28-6.51 δ; mass spectral peak (TMS derivative) at 670.3836; and infrared absorption peaks at 3360, 2670, 2230, 1710, 1320, 1245, 1205, 1145, 1115, 1090, 1055, and 995 cm -1 .
EXAMPLE 6
6-Keto-13,14-didehydro-PGF 1 α and 6-Keto-13,14-didehydro-(15R)-PGF 1 α.
A. There are first prepared the 5ξ-bromo-9-deoxy-6ξ,9-epoxy (15R and 15S)-PGF 1 α methyl ester compounds. A solution of the 5ξ-bromo-9-deoxy-6ξ,9-epoxy-14-bromo-15-keto-PGF 1 α, methyl ester (Example 3A, 0.93 g.) in 15 ml. of methanol is added to a solution of sodium borohydride (0.46 g.) in 50 ml. of methanol at -50° C. The reaction is continued at about -30° C. for 1.5 hr. The mixture is carefully acidified with 5 ml. of acetic acid in 250 ml. of diethyl ether. The solution is washed with 0.2 M. potassium hydrogen sulfate, 5% sodium chloride, and 5% sodium bicarbonate, then dried and concentrated to yield the mixed C-15 epimers. The product is combined with 0.39 g. from another run and subjected to silica gel chromatography, eluting with hexane-ethyl acetate (7:3). The respective fractions containing the 15R and 15S products yield 0.34 g. of the 15R and 0.34 g. of the 15S intermediate. The 15R compound has NMR peaks at 0.90, 1.1-2.75, 2.75-3.30, 3.66, 3.78-4.8, 5.80 and 5.90 δ; and infrared peaks at 3350, 1740, 1650, 1430, 1365, 1240, 1190, 1070, and 1050 cm -1 . The 15S compound has NMR peaks at 0.89, 1.1-3.2, 3.2-4.8, 3.66, 5.78, and 5.83 δ; and infrared peaks at 3350, 1740, 1650, 1430, 1365, 1240, 1190, 1070, and 1050 cm -1 .
B. A solution of the 15-S product from part A above (0.29 g.) in 5 ml. of dimethyl sulfoxide and 0.5 ml. of methanol is treated with potassium tert-butoxide (0.3 g.) for 20 hr. On hydrolysis of the methyl ester with 2 L N. NaOH for 3 hr. followed by dilution with 5% sodium chloride, acidifying with 10% phosphoric acid, extraction with diethyl ether, washing with 5% sodium chloride, drying, and concentrating there is obtained 0.20 g. residue. The residue is subjected to silica gel chromatography, eluting with hexane-ethyl acetate (1:1 to 3:2), to yield the 15S title compound, 0.065 g., having the same properties as the product of Example 5.
Likewise, using the 15R intermediate of part A there is obtained the corresponding 15R title compound having R f 0.20 (TLC on silica gel plates in A-IX solvent).
Following the procedures of Example 6 Part B but substituting sodium methoxide for potassium tert-butoxide there are also obtained the title compounds.
EXAMPLE 7
6-Keto-13,14-didehydro-(15R)-PGE 1 (Formula VI)
A. Refer to Chart C. There is first prepared the formula-XIV 14-bromo-(15R)-PGF 2 α, methyl ester. Following the procedure of Example 3-C above, the formula-XIII-15β compound, (15R)-5ξ,6ξ,14-tribromo-PGF 1 α, methyl ester (1.52 g.) is treated with zinc dust and ammonium chloride in methanol to yield the formula-XIV 15R compound, 1.13 g., having R f 0.40 (TLC on silver nitrate-treated silica gel in ethyl acetate), NMR and infrared spectra very similar to those of the 15S epimer of Example 3-C.
B. 5ξ-iodo-9-deoxy-6ξ,9-epoxy-14-bromo-(15R)-PGF 1 α, methyl ester (XV). Following the procedure of Example 3-D, the formula-XIV 14-bromo-(15R)-PGF 2 α, methyl ester (0.98 g.) is iodinated to the formula-XV iodo compound. The product is chromatographed on silica gel, eluting with ethyl acetate (30%)-hexane to yield the desired compound, 0.88 g., having NMR and infrared spectra very similar to those of the 15S epimer of Example 3-D.
C. 5ξ-iodo-9-deoxy-6ξ,9-epoxy-14-bromo-(15R)-PGF 1 α, 11,15-bis(tetrahydropyran-2-yl ether), methyl ester (XVI). Following the procedure of Example 3-E, the formula-XV 5ξ-iodo-9-deoxy-6ξ,9-epoxy-14-bromo-(15R)-PGF 1 α, methyl ester (2.16 g.) is reacted with dihydropyran to form the formula-XVI bis (THP ether), 3.24 g., having R f 0.57 and 0.62 (TLC on silica gel in ethyl acetate-cyclohexane (1:2) and having NMR and infrared spectra very similar to those of the 15S epimer of Example 3-E.
D. 6-Keto-13,14-didehydro-(15R)-PGF 1 α, 11,15-bis(tetrahydropyran-2-yl ether) (XVII). Following the procedure of Example 3-F, the formula-XVI 5ε-iodo-9-deoxy-6ξ,9-epoxy-14-bromo-(15R)-PGF 1 α, 11,15-bis(tetrahydropyran-2-yl ether), methyl ester (3.27 g.) is reacted with potassium t-butoxide in dimethyl sulfoxide-methanol, removing a less polar by-product by silica gel chromatography, to yield the product, 0.74 g., having R f 0.51 (TLC on silica gel in a solvent prepared by diluting the organic phase from ethyl acetate-acetic acid-cyclohexane-water (9:2:5:10) with half its volume of cyclohexane), and having NMR and infrared spectra very similar to those of the 15S epimer of Example 3-F.
E. 6-Keto-13,14-didehydro-(15R)-PGE 1 , 11,15-bis(tetrahydropyran-2-yl ether) (V). Refer to Chart A. Following the procedure of Example 4, the formula-XVII (or IV) 6-keto-13,14-didehydro-(15R)-PGF 1 α, 11,15-bis(tetrahydropyran-2-yl ether) (0.46 g.) is oxidized with Jones reagent to the formula-V compound, 0.23 g., having R f 0.55 (TLC on silica gel in the solvent of section D above, having NMR peaks at 0.90, 1.1-3.2, 3.2-4.65, 4.65-5.2 and 8.91 δ, and infrared absorption bands at 2600-3200, 2220, 1740, 1710, 1195, 1120, 1070, 1035, 995, 980, 965, and 910 cm -1 .
F. 6-Keto-13,14-didehydro-(15R)-PGE 1 (VI). Following the procedure of Example 4, the above bis(THP ether) (0.23 g.) is hydrolyzed and chromatographed to yield the title compound, 0.10 g., m.p. 72° C. when crystallized from diethyl ether-methylene chloride-hexane, having R f 0.36 (TLC on silica gel in the organic phase from ethyl acetate-acetic acid-cyclohexane-water (9:2:5:10)), having NMR peaks at 0.90, 1.1-2.0, 2.0-3.2, 3.9-4.7, and 6.0-6.7 δ, and mass spectral peaks (TMS derivative) at 567.299, 564, 549, 511, 492, 477, 421, 402, 387, 367, 201, and 111.
EXAMPLE 8
2-Decarboxy-2-hydroxymethyl-6-keto-PGE 1 , (Formula XXV: Q is ##STR142## R 2 is hydrogen, R 4 is n-pentyl, ##STR143## X is trans--CH═CH--, and f is one).
I. Refer to Chart E. There is first prepared the formula-XXIII 4,5-acetylenic PGF 1 α type compound. The formula-XXII bis(THP ether) lactone (Corey et al., J. Am. Chem. Soc. 92, 397 (1970)) (6.5 g.) in 30 ml. of tetrahydrofuran is reacted with 4-trimethylsilyloxy-1-pentynyl-lithium (C.H. Lin, J. Org. Chem. 41, 4045 (1976) (3.6 g.) at -70° to -60° C. for about 0.5 hr. The adduct is isolated and dissolved in 30 ml. of isopropyl alcohol-water (4:1) and treated with about 0.5 ml. of 10% aqueous sodium hydrogen sulfate. The mixture is stirred at about 25° C. for 0.5 hr., treated with about 10 ml. of aqueous sodium bicarbonate, and concentrated to remove isopropyl alcohol. The residue is extracted with diethyl ether and the organic phase is washed with water, aqueous sodium hydrogen sulfate, aqueous sodium bicarbonate, and brine, dried, and concentrated. The residue is chromatographed on silica gel eluting with ethyl acetate-hexane (1:5), to yield the formula-XXIII 2-decarboxy-2-hydroxymethyl-4,4,5,5-tetradehydro-6-keto-PGF 1 α, 11,15-bis(tetrahydropyran-2-yl ether), 5.6 g. having NMR peaks at 5.68-5.36, 4.8-4.5, and 4.5-3.18 δ, infrared absorption peaks at 3440, 2210, 1675 and 975 cm -1 , and mass spectral lines (TMS derivative) at 649.3986, 563, 557, 509, 479, 478, 463, and 85.
II. There is next prepared the formula-XXIV 2-decarboxy-2-hydroxymethyl-4,4,5,5-tetradehydro-6-keto-PGE 1 . The product of I above (2.6 g.) is treated in 50 ml. of acetone with Jones reagent (5.6 ml. of 2.67 M) in 30 ml. acetone added dropwise over 5 min. at -30° C. The reaction is quenched with aqueous sodium bisulfite and the mixture concentrated to remove acetone. The residue is extracted with ethyl acetate and the organic phase is washed with brine, dried, and concentrated. The resulting mixture is then methylated with diazomethane to form the methyl ester of any carboxylic acid present.
The above mixture containing 2-decarboxy-2-hydroxymethyl-4,5-tetradehydro-6-keto-PGE 1 , 11,15-bis(tetrahydropyran-2-yl ether) and methyl ester by-products is hydrolyzed in 20 ml. of acetic acid-tetrahydrofuran-water (3:1:1) at 40°-50° C. for 3 hr. The mixture is concentrated and the residue extracted with ethyl acetate. The organic phase is washed with aqueous sodium bicarbonate and brine, dried, and concentrated. The residue is chromatographed on silica gel (HPLC), eluting with acetone (25-50%)-hexane to obtain the more polar formula-XXIV compound, 0.278 g., having NMR peaks at 5.70-5.42, 4.32-3.80, and 3.23 δ, infrared absorption bands at 3480, 2210, 1755, 1670, and 970 cm -1 , and a high resolution mass spectral peak (TMS derivative) at 566.3299.
III. Finally, the title compound is obtained by catalytic hydrogenation of the above compound. The formula-XXIV compound of II above (0.35 g.), together with 35 mg. of palladium on barium sulfate and 5 ml. of pyridine is stirred under hydrogen at one atmosphere at about 25° C. for 0.5 hr. The solids are removed by filtration and the filtrate is concentrated. The residue is chromatographed on 30-50μ silica gel (HPLC), eluting with acetone-hexane (1:1) to yield the formula-XXV title compound, 0.178 g., having NMR peaks at 5.72-5.42, 4.34-3.78, and 3.60 δ, infrared absorption bands at 3360, 1745, 1710, 1590, 1160, 1070, 1015, and 970 cm -1 , and mass spectral lines (TMS derivative) at 570.3563, 555, 552, 499, 480, 465, 426, 409, 383, 375, 355, and 313.
Following the procedures of Example 8 and Chart E, but replacing the formula-XXII starting material with the appropriate lactone known in the art, there are obtained the following formula-XXV compounds
2-Decarboxy-2-hydroxymethyl-6-keto-16-phenyl-17,18,19,20-tetranor-PGE 1
2-Decarboxy-2-hydroxymethyl-6-keto-(15S)-15-methyl-PGE 1 ,
2-Decarboxy-2-hydroxymethyl-6-keto-13,14-dihydro-PGE 1 ,
2-Decarboxy-2-hydroxymethyl-6-keto-13,14-didehydro-PGE 1 .
Alternatively, the 13,14-dihydro- and 13,14-didehydro compounds are obtained by transformations of the above product of Example 8 or the formula-XXIV intermediate of Example 8 using methods known in the art.
EXAMPLE 9
6,15-Diketo-PGE 1 (Formula XXXV)
I. Refer to Chart F. The formula-XXX 11,15-bis(tetrahydropyran-2-yl ether) of 6-keto-PGF 1 α, methyl ester is first prepared. A solution of 6-keto-PGF 1 α, methyl ester (Johnson et al., J. Am. Chem. Soc. 99, 4182 (1977)) (0.3 g.) in 10 ml. of methylene chloride is treated with 2 ml. of dihydropyran and one ml. of a saturated solution of pyridine hydrochloride in methylene chloride and left standing at about 25° C. for several days. The mixture is washed with aqueous sodium bicarbonate, dried, and concentrated. The residue is chromatographed on silica gel, eluting with acetone (0-20%)-methylene chloride, to yield the bis(THP ether), 0.23 g., having R f 0.20 (TLC on silica gel in acetone (10%)-methylene chloride).
II. There is next prepared the formula-XXXII acid. The product above, combined with another lot of similar material (total 1.30 g.) is stirred with 40 ml. of methanol and 10 ml. of 3 N sodium hydroxide at about 25° C. for 3 hr. The mixture is cooled in an ice bath, saturated with sodium chloride, acidified with potassium hydrogen sulfate and immediately extracted with ethyl acetate. The organic phase is washed with brine, dried, and concentrated. The acid has R f 0.52 (TLC on silica gel in A-IX system).
III. There is next prepared the formula-XXXIV 15-oxo compound. The above product is immediately dissolved in 75 ml. of acetone, cooled to -15° C., and treated with 3 ml. of Jones reagent added slowly within 30 min. Stirring is continued for one hr., allowing the temperature to rise to -3° C.; then 0.5 ml. more Jones reagent is added, again at -10° C. and stirring continued for 45 min. The reaction is quenched with isopropyl alcohol, dried, and concentrated to an oil, about 1.5 g., having R f 0.7 (TLC on silica gel in A-IX system).
IV Finally, the title compound is obtained by hydrolysis. The above formula-XXXIV 6,15-diketo-PGE 1 , 11,15-bis(tetrahydropyran-2-yl ether) is treated with 12 ml. of acetic acid and 5 ml. of water at 40° C. for 3 hrs. Then the mixture is cooled, diluted with brine, and extracted with chloroform. The organic phase is washed with brine, dried, and concentrated. The residue is chromatographed on 100 g. of silica gel, eluting with ethyl acetate (60-100%)-hexane, taking 50 ml. fractions and combining fractions 13-20, to yield the formula-XXXV title compound, 0.31 g., having R f 0.36 (TLC on silica gel in A-IX system), NMR peaks at 7.37, 6.82, 6.18, 4.2, 2.1-2.9, and 0.9 δ, and infrared absorption bands at 3400-3200, 2660, 1745, 1715, 1675, 1630, 1290, 1245, 1160, 1095, 1075, 975, 850, and 735 cm -1 .
EXAMPLE 10
6-Keto-PGE 1 , Amide (Formula I)
A solution of 6-keto-PGE 1 (Example 2, 0.17 g.) in 7 ml. of acetone is treated at -10° C. with 0.2 ml. of triethylamine and 0.2 ml. of isobutylchloroformate. After 10 min. stirring the mixture is treated with 4 ml. of a saturated solution of ammonia in acetonitrile. After 15 min. at -10° C. the cooling bath is removed and stirring continued for 5 min. The mixture is then concentrated to one-half volume and diluted with water and ethyl acetate. The organic phase is separated, washed with brine, dried, and concentrated. The oily residue is chromatographed on silica gel, eluting with acetone (40-100%)-methylene chloride to yield the title compound, 0.075 g. An analytical sample is obtained by crystallizing from ethyl acetate-diethyl ether, a powder, m.p. 84°-6° C., having R f 0.23 (TLC on silica gel in methanol-acetic acid-chloroform (10:10:80)) and infrared absorption bands at 3540, 3420, 3200, 1745, 1710, 1655, 1620, 1295, 1245, 1160, 1110, 1075, 1025, and 975 cm -1 .
Following the procedures of Example 10, but replacing the starting material with (15S)-15-methyl-6-keto-PGE 1 , there is obtained the formula-I compound:
(15S)-15-Methyl-6-keto-PGE 1 , amide.
EXAMPLE 11
6-Keto-PGE 1 , Methylamide (Formula XL).
I. Refer to Chart G. There is first prepared the formula-XXXVII 11,15-bis(tetrahydropyran-2-yl ether). A mixture of the formula-VII 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , methylamide (Preparation 8, 1.2 g.) in 25 ml. methylene chloride, with 2 ml. of dihydropyran and 25 mg. of p-toluenesulfonic acid monohydrate is stirred at about 25° C. for one hr. The mixture is then diluted with 75 ml. of methylene chloride, washed with saturated aqueous sodium bicarbonate and brine, dried, and concentrated. The residue, an oil, is chromatographed on silica gel, eluting with acetone (5-40%)-methylene chloride to yield the bis(THP ether) of the 5-iodo compound, mixed isomers, an oil, 1.6 g., having R f 0.10 and 0.03 (TLC on silica gel in acetone (10%)-methylene chloride).
II. There is next prepared the formula-XXXVIII 6-keto-PGF 1 α, methylamide, 11,15-bis(tetrahydropyran-2-yl ether). A solution of the above formula-XXXVII compound in 60 ml. of tetrahydrofuran is treated with silver carbonate (0.75 g.) and about 0.3 ml of perchloric acid, with stirring at about 25° C. for 20 hr. The mixture is filtered, diluted with ethyl acetate, washed with brine, dried, and concentrated to an oil, 1.4 g. The residue is chromatographed on silica gel, eluting with acetone (10-60%)-methylene chloride, to yield the formula-XXXVIII compound, 0.48 g., having R f 0.26 (TLC on silica gel in acetone-methylene chloride (1:1)).
III. Next is prepared the formula-XXXIX 6-keto-PGE 1 , methylamide, 11,15-bis(tetrahydropyran-2-yl ether). A solution of the above formula-XXXVIII compound (0.48 g.) in 15 ml. of acetone is treated at -15° to -20° C. with one ml. of Jones reagent added dropwise and stirred for 45 min. Thereafter one ml. of isopropyl alcohol is added, with stirring for about 30 min. Brine and ethyl acetate are added and the organic phase is washed with brine, dried, and concentrated to an oil, 0.42 g., consisting of the title compound as its bis(THP ether).
IV. Finally, the above formula-XXXIX bis(THP ether) (0.42 g.) is treated in 9 ml. of acetic acid-water-tetrahydrofuran (20:10:3) at 40° C. for 3.5 hr. The solution is diluted with 15 ml. of water and freeze-dried. The residue is taken up in 10 ml. of methylene chloride and chromatographed over silica gel, eluting with acetone (30-80%)-methylene chloride to yield the title compound, 0.11 g., having R f 0.42 (TLC on silica gel in acetone), mass spectral lines (TMS derivative) at 597.3738, 582, 579, 507, 489, and 417, and infrared absorption bands at 3340, 1745, 1705, 1640, 1545, 1270, 1160, 1110, 1075, 1015, and 975 cm -1 .
EXAMPLE 12
6-Keto-PGE 1 , n-Butylamide (Formula XL).
I. Refer to Chart G. There is first prepared the formula-XXXVIII 6-keto-PGF 1 α, n-butylamide, 11,15-bis-(tetrahydropyran-2-yl ether). A solution of 6-keto-PGF 1 α, n-butylamide (Preparation 10, 1.47 g.) in 50 ml. of chloroform is treated at about 25° C. with 8 ml. of dihydropyran and 5 ml. of methylene chloride saturated with pyridine hydrochloride. Additional amounts of reagents are added until the reaction is shown completed by TLC. The mixture is then washed with cold aqueous saturated sodium bicarbonate and brine, dried, and concentrated. The residue is chromatographed on silica gel, eluting with acetone-methylene chloride (1:2) to yield the formula-XXXVIII compound, 0.7 g., having R f 0.41 (TLC on silica gel in ethyl acetate).
II. Next is prepared the formula-XXXIX 6-keto-PGE 1 , n-butylamide, 11,15-bis(tetrahydropyran-2-yl ether), using 0.7 g. of the above formula-XXXVIII compound and following the procedure of Example II-III, there is obtained 0.39 g. of product, having R f 0.55 (TLC on silica gel in ethyl acetate) and a strong infrared absorption band at 1740 cm -1 .
III. Finally, the title compound is obtained by hydrolyzing the product of II above (0.39 g.) in 2 ml. of glacial acetic acid and one ml. of water at 40° C. for 3 hr. The mixture is azeotroped with toluene, concentrating to a solid. The residue is chromatographed on silica gel, eluting with acetone-ethyl acetate (1:1) to yield the title compound, 0.2 g. An analytical sample is obtained on recrystallization from acetone-Skellysolve B, 0.15 g., having R f 0.20 (TLC on silica gel in ethyl acetate), and m.p. 78°-81° C.
EXAMPLE 13
6-Keto-PGE 1 , Benzylamide (Formula XL).
I. Refer to Chart G. There is first prepared the formula-XXXVII 11,15-bis(tetrahydropyran-2-yl ether). Following the procedure of Example 8-1, the 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , benzylamide (Preparation 11, 2.0 g.) is reacted with dihydropyran. The product, an oil, is chromatographed over silica gel, eluting with acetone (5-25%)-methylene chloride, to yield the bis(THP ether), 2.4 g., having R f 0.73 (TLC on silica gel in acetonemethylene chloride (1:1)).
II. There is next prepared the formula-XXXVIII 6-keto-PGF 1 , benzylamide, 11,15-bis(tetrahydropyran-2-yl ether) using the above formula-XXXVII compound. There is first prepared (5Z)-9-deoxy-6,9α-epoxy-Δ 5 -PGF 1 , benzylamide, 11,15-bis(tetrahydropyran-2-yl)ether, by treating the formula-XXXVII compound (2.4 g.) in 100 ml. of benzene with 4 ml. of DBN at 40°-45° C. for 22 hr. The mixture is cooled, diluted with 25 ml. of benzene, and washed with 25 ml. of ice water. The benzene solution is dried and concentrated. The residue, an oil, is essentially the enol ether, (5Z)-9-deoxy-6,9α-epoxy-Δ 5 -PGF 1 , benzylamide, 11,15-bis(tetrahydropyran-2-yl ether).
The above product is converted to the formula-XXXVIII 6-keto compound by treating with 50 ml. of tetrahydrofuran-5% hydrochloric acid (9:1) at about 25° C. for 15 min. The mixture is diluted with 50 ml. of brine and extracted with ethyl acetate. The organic phase is washed with brine, dried and concentrated to yield the formula-XXXVIII bis-(THP ether), 2.0 g., an oil.
III. Next is prepared the formula-XXXIX 6-keto-PGE 1 , benzylamide, 11,15-bis(tetrahydropyran-2-yl ether). The above formula-XXXVIII PGF 1 compound, (1.0 g.) is oxidized in 25 ml. of acetone with Jones reagent (2 ml.) at -10 to -20° C., adding the reagent dropwise over 2 min. The mixture is stirred for 30 min. and the reaction is quenched with 2 ml. of isopropyl alcohol. The mixture is diluted with brine and extracted with ethyl acetate. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to the formula-XXXIX bis(THP ether), 0.97 g.
IV. Finally, the title compound is obtained by hydrolyzing the product of III above (0.97 g.) in 20 ml. of acetic acid-water-tetrahydrofuran (20:10:3) at 40°-45° C. for 3.5 hr. The solution is diluted with 30 ml. of water and freeze-dried. The residue is chromatographed on Florisil®, eluting with acetone (0-100%)-methylene chloride to yield the formula-XL title compound, 0.22 g. plus another 0.07 g. from rechromatographing a mixture with less polar material. The product has R f 0.24 in acetone-methylene chloride (1:1), and NMR peaks at 7.25, 6.5-6.8, 5.4-5.7, 4.2-4.5, 3.5-4.2, 1.9-3.0, and 0.3-1.9δ.
EXAMPLE 14
6-Keto-PGE 1 , Anilide (Formula XL)
I. Refer to Chart G. There is first prepared the formula-XXXVII 11,15-bis(tetrahydropyran-2-yl ether). Following the procedure of Example 11-I, the 5ξ-iodo-9-deoxy-6ξ,9α-epoxy-PGF 1 , anilide (Preparation 12, 1.8 g.) is reacted with dihydropyran. The product, 3.5 g., is chromatographed on silica gel, eluting with acetone (5-20%)-methylene chloride to yield the bis(THP ether), 2.3 g. having R f 0.29 (TLC on silica gel in acetone (10%)-methylene chloride).
II. There is next prepared the formula-XXXVIII 6-keto-PGF 1 α, anilide, 11,15-bis(tetrahydropyran-2-yl ether) using the above formula-XXXVII compound and following the procedure of Example 11-II. The product, 1.98 g., is chromatographed on silica gel, eluting with acetone (10-70%)-methylene chloride to yield the product, 0.53 g., having R f 0.66 (TLC on silica gel in acetone-methylene chloride (1:1)).
III. Next is prepared the formula-XXXIX 6-keto-PGE 1 , anilide, 11,15-bis(tetrahydropyran-2-yl ether) using the above formula-XXXVIII compound and following the procedure of Example 11-III, to obtain 0.54 g. of oil.
IV. Finally, the title compound is obtained by hydrolyzing the product of III above following the procedure of Example 11-IV. The product is chromatographed on silica gel, eluting with acetone (10-60%)-methylene chloride to obtain the title compound, 0.18 g., having R f 0.33 (TLC on silica gel in acetone-methylene chloride (1:1)), high resolution mass spectral peak (TMS derivative) at 659.3837, and infrared absorption peaks at 3460, 3400, 3300, 1750, 1725, 1705, 1660, 1600, 1500, 1310, 1290, 1260, 1155, 1100, 1065, 1030, 970, 755, and 690 cm -1 .
EXAMPLE 15
6-Keto-PGE 1 , p-Phenylphenacyl Ester (Formula VI).
Refer to Chart B. Following the procedures of Example 11, the formula-VII product of Preparation 4, 5ξ-iodo-9-deoxy-6,9-epoxy-PGF 1 α, p-phenylphenacyl ester, is converted, first to its bis(THP ether), then to the formula-IV 6-keto-PGF 1 α -type compound which is oxidized at the C-9 position to the formula-V compound which is finally hydrolyzed to the formula-VI title compound.
Following the procedures of Example 15 and Chart B but replacing the starting material with the corresponding p-phenylphenacyl ester made by methods described herein or known in the art, there are obtained the following formula-VI compunds:
(15S)-15-Methyl-6-keto-PGE 1 , p-phenylphenacyl ester
16,16-Dimethyl-6-keto-PGE 1 , p-phenylphenacyl ester.
EXAMPLE 16
6-Keto-PGE 1 , p-(p-Actamidobenzamido)phenyl Ester (Formula VI)
Refer to Chart B. A solution of the formula-VII 5ξ-iodo-9-deoxy-6,9-epoxy-PGF 1 α free acid (Preparation 3) is converted to the mixed anhydride with isobutylchloroformate in the presence of triethylamine in acetone solution at about -10° C. Thereafter the substituted phenyl ester is obtained using p-(p-acetamidobenzamido)phenol in pyridine at about 25° C.
Thereafter following the procedures of Example 11, the bis(THP ether) is formed and converted to the formula-IV 6-keto-PGF 1 α -type compound, which is oxidized at the C-9 position and finally deblocked by mild acid hydrolysis to form the title compound of formula VI.
Following the procedures of Example 16 and Chart B, but replacing that starting material of formula VII with the appropriate 5-halo compound and that phenol with the appropriate substituted phenol, there are prepared the following substituted phenyl esters within the scope of formula-VI:
6-keto-PGE 1 , p-benzaldehyde semicarbazone ester
(15S)-15-Methyl-6-keto-PGE 1 , p-(p-acetamidobenzamido)phenyl ester
16,16-Dimethyl-6-keto-PGE 1 , p-(p-acetamidobenzamido)phenyl ester
(15S)-15-Methyl-6-keto-PGE 1 , p-benzaldehyde semicarbazone ester
16,16-Dimethyl-6-keto-PGE 1 , p-benzaldehyde semicarbazone ester. | Prostaglandin E (PGE)-type derivatives and analogs having a 6-keto feature are disclosed, including processes for preparing them and the appropriate intermediates, said derivatives having pharmacological activity.
A typical 6-keto compound is 6-keto-PGE 1 , methyl ester, represented by the formula: ##STR1## | 2 |
TECHNICAL FIELD
The present invention relates to equipment for asphalt paving; more particularly, to paving equipment having rubber tires for compacting a layer of hot asphalt, and to paving equipment having steel rollers for smoothing a layer of hot asphalt; and most particularly, to a combination compacting and smoothing asphalt finishing machine wherein rubber tires and steel rollers may be used alternatively for compaction and smoothing, respectively, of the hot asphalt layer.
BACKGROUND OF THE INVENTION
Paving of roads and parking lots with asphalt is a mature prior art. Typically, asphalt paving medium (referred to herein as “asphalt”) is prepared in a batch plant wherein a crushed stone aggregate is mixed with a hot tar preparation, yielding a highly viscous slurry of aggregate in tar that can be poured or laid in a layer onto a designated paving surface and then worked by specialized equipment to provide a durable surface for vehicular traffic when cool.
Hot asphalt, as it comes from the plant and is laid in a layer, contains significant amounts of entrained air and is in a non-compressed state. Thus paving comprises at least three distinct steps: a) laying the asphalt slurry in a layer of approximately the final thickness and lateral distribution; and finishing the layer by b) compacting the layer to remove air and ensure compaction into any depressions in the underlying substrate surface, and c) final smoothing of the compacted layer.
Once the designated surface is prepared to receive the asphalt, the first step of laying the asphalt is typically carried out by a laying machine that receives sequential batches of hot asphalt from delivery trucks and dispenses a continuous ribbon of the material while moving along the surface to be paved. In irregular areas such as parking lots, the distribution may be augmented manually by workers with shovels and/or screeds.
The second step of compacting the asphalt typically is carried out by a compacting machine that travels on one or more sets of smooth-surface, ganged rubber tires and that propels itself along the freshly-laid layer of hot asphalt. The tires are independently suspended in pairs such that the gangs of tires may follow the contours of the underlying surface to compact the asphalt in surface depressions as well as in the higher surface areas. This is an important step in assuring a long-wearing finished surface; failure to compact the material properly in depressions can result in development of potholes and premature failure of the finished layer.
The third step of smoothing the asphalt typically is carried out by a smoothing machine that travels on one or more smooth-surface steel rollers and that propels itself along the freshly-compacted layer of hot asphalt. The steel rollers work the compacted asphalt both forwardly and laterally to eliminate depressions and thus provide an overall even layer. In addition, the steel rollers intensely compact the upper part of the layer to impart a very fine-grained surface finish to the layer.
After the smoothing operation, the finished asphalt layer is allowed to cool and solidify, preferably before vehicular traffic is allowed onto the surface.
A shortcoming of the prior art is that two separate finishing machines are required for compacting and smoothing, respectively. These prior art machines, while very similar in overall construction and operation, are equipped with rubber tires and steel rollers, respectively. Each machine, even modest versions thereof, may cost in excess of $100,000, making ownership of both such machines prohibitive for many smaller paving companies; instead, one or both machines typically is/are rented for specific paving jobs, which entails rental fees, and coordinating rental and construction schedules, and machine transportation to and from the paving site. Further, as a paving business grows and the purchase of paving machines becomes feasible, each additional increment of production capacity requires the purchase of two finishing machines, one of each type.
What is needed in the art is an improvement whereby only one compacting and smoothing finishing machine is required for a paving operation.
It is a principal object of the present invention to reduce the cost of buying or renting finishing machines for an asphalt paving contractor.
It is a further object of the invention to simplify the logistics and reduce the cost of a paving operation.
SUMMARY OF THE INVENTION
Briefly described, a combination compacting and smoothing finishing machine in accordance with the invention comprises one or more primary finishing elements which may be either compacting tires or smoothing rollers. The primary finishing elements are driven and steered by engine and hydraulic mechanisms as in the prior art. The machine further comprises one or more secondary finishing elements which are complementary to the primary elements, being either smoothing rollers or ganged rubber tires. The secondary finishing elements are pivotably attached to the frame of the machine. In a first position, the secondary elements are not in contact with the asphalt layer or with the primary elements and the weight of the machine is borne only by the primary elements. The secondary elements are hydraulically actuable and may be pivoted into a second position wherein only the secondary elements are in contact with the asphalt layer and are in driving contact with the primary elements which are thus raised from contact with the asphalt layer.
Such a machine may be fabricated as an entirely new assembly or may be a retrofit of a prior art single-function compacting or smoothing machine.
Thus, a combination finishing machine in accordance with the invention may function, interchangeably and with equal facility, as either a compacting machine or a smoothing machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is an elevational side view of a prior art finishing machine, which may be either a compacting machine or a smoothing machine; and
FIG. 2 is an elevational side view of a combination compacting and smoothing finishing machine in accordance with the invention.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The advantages and benefits of a combination asphalt compacting and smoothing finishing machine in accordance with the invention may be better appreciated by first considering a prior art compacting or finishing machine.
Referring to FIG. 1 , a prior art asphalt compacting or finishing machine 10 comprises a chassis 12 supporting a motive engine 14 and a hydraulic system 16 driven by engine 14 . Chassis 12 is borne upon at least one front rollable element (“front element”) 18 and at least one rear rollable element (“rear element”) 20 for rolling along a surface 22 of a layer 24 of hot asphalt composition. Typically, front element 18 is steerable by being supported in a suspension fork 26 pivotably connected to chassis 12 about a turning axis 28 and connected to a steering wheel 30 via a steering mechanism (not shown) which may be hydromechanical. Typically, only rear element 20 is motively driven by engine 14 although in some types of prior art machine 10 both the front and rear elements are driven.
A prior art machine 10 typically includes a hydraulic lifting mechanism 30 mounted on a forward portion of chassis 12 which may comprise a lifting arm 32 that is conveniently formed as a bellcrank, a pivot 34 for lifting arm 32 , and a hydraulic cylinder 36 pivotably mounted at a first end 38 on chassis 12 and pivotably connected to lifting arm 32 at a second end 40 . The outer end 42 of lifting arm 32 is thus radially pivotable about pivot 34 by hydraulic cylinder 36 between a raised position 44 and a lowered position 46 .
When prior art machine 10 is a compacting machine, front element 18 and rear element 20 each comprise a plurality of smooth-surfaced rubber tires that are ganged together across at least the width of machine 10 . Typically, the tires are independently suspended in pairs such that each gang of tires may follow the contours of the underlying surface to compact the aerated asphalt in layer 24 . Typically, the front and rear elements contain differing numbers of tires, for example, five and six tires, and are laterally staggered by half a tire width such that all of surface 22 is covered in a single pass of machine 10 . Typically, machine 10 is also provided with substantial dead weight (not shown) distributed appropriately on chassis 12 to assure proper weighting of the front and rear elements. To enhance the dead weight of the overall machine, it is known to fill the tires with water or saline solution.
When prior art machine 10 is a smoothing machine, front element 18 and rear element 20 each comprise one or more smooth-surfaced steel rollers extending across at least the width of machine 10 . The steel rollers work the previously-compacted asphalt layer 24 both forth and back and laterally to eliminate depressions and thus provide an overall even layer. In addition, the steel rollers intensely compact the upper part of the layer to impart a very fine-grained finish to the surface 22 of layer 24 .
Referring now to FIG. 2 , a combination asphalt compacting and smoothing machine 110 in accordance with the present invention has elements in common with prior art machine 10 which are commonly numbered. In addition, front and rear rollable elements 18 , 20 are to be considered as primary elements. The primary elements and features are shown in solid lines, and secondary elements and features are shown in dashed lines. Thus, machine 110 is shown in FIG. 2 in primary-element mode wherein the primary front and rear elements 18 , 20 are in contact with asphalt surface 22 .
At the front of machine 110 , a secondary front rollable element 118 is mounted on a secondary fork 126 attached via a yoke 150 to an angle arm 152 that is pivotably connected to lever arm 32 (defining thereby a front pivotable arm) via a generally vertical hinge pin 154 . Primary front element 18 may be either of a gang of compacting rubber tires or a smoothing steel roller; and secondary front element 118 is the counterpart thereof, being either of a smoothing steel roller or a gang of compacting rubber tires, respectively.
In first position 44 , the axis 156 of secondary front element 118 is higher than the axis 56 of primary front element 18 such that the front portion of machine 110 is supported on surface 22 by primary front element 18 , and secondary front element 118 is separated from surface 22 by a front gap 158 a.
Similarly, at the rear of machine 110 , a secondary rear rollable element 120 is mounted on a rear pivotable arm 160 at a pivot axis 162 , the rear pivotable arm being pivotably connected to chassis 12 at pivot 164 . A hydraulic cylinder 166 operationally connected to hydraulic pump 16 is pivotably connected to secondary element 120 at pivot axis 162 and is pivotably connected to chassis 12 at pivot axis 168 . Primary rear element 20 may be either of a gang of compacting rubber tires or a smoothing steel roller; and secondary rear element 120 is the counterpart thereof, being either of a smoothing steel roller or a gang of compacting rubber tires, respectively. Preferably, a second set of components comprising a second rear pivotable arm 160 and a second hydraulic cylinder 166 is similarly disposed on the opposite side of machine 110 (not visible in FIG. 2 ) and are connected by yoke 170 extending horizontally therebetween.
In a first position 144 , the axis 162 of secondary rear element 120 is higher than the axis 58 of primary rear element 20 such that the rear portion of machine 110 is supported on surface 22 by primary rear element 20 , and secondary rear element 120 is separated from surface 22 by a rear gap 158 b , which may be the same size as front gap 158 a.
In the configuration as described thus far, machine 110 functions substantially identically with prior art machine 10 , being borne on the primary front and rear rollable elements 18 , 20 , whether the front and rear primary elements 18 , 20 are compacting rubber tires or smoothing steel rollers.
A principal advantage of improved machine 110 over prior art machine 10 is that improved machine 110 may function as either a compacting machine or a smoothing machine by switching alternatively between a primary-element mode and a secondary-element mode.
As is seen in FIG. 1 , extending of hydraulic cylinder 36 drives the outer end 42 of lever arm 32 from the “up” position 44 to the “down” position 46 . Such movement is seen in FIG. 2 to drive secondary element axis 156 along arc 157 to a new position 156 a that is lower than axis 56 of primary front element 26 . In so doing, secondary front element 118 engages primary front element 18 at a nip point 172 below the horizontal equatorial level 174 of axis 56 . In this way, secondary front element 126 raises primary front element 18 from contact with surface 22 and becomes instead the load-bearing element for the front portion of machine 110 and is driven by friction with surface 22 , shown herein as surface 22 a . (Note: it will be recognized that the elevation of surface 22 does not change, but rather the machine is raised by a height 176 ; however, for purposes of illustration herein, the surface is lowered rather that the machine being raised. Note further that in a machine wherein both the front and rear elements are positively driven by the engine, the front primary and secondary elements must counter-rotate, and thus in the secondary-element mode, “forward” and “reverse” of the machine are reversed.)
Considering now the rear portion of machine 110 , contraction of hydraulic cylinder 166 drives secondary rear element axis 162 along arc 178 to a new position 162 a that is lower than axis 58 of primary rear element 20 . In so doing, secondary rear element 120 engages primary rear element 20 at a nip point 180 below the horizontal equatorial level 174 of axis 58 . In this way, secondary rear element 120 raises primary rear element 20 from contact with surface 22 by height 176 and becomes instead the load-bearing element for the rear portion of machine 110 and is driven by frictional contact with primary rear element 20 which remains driven by engine 14 . (Note as with the front elements that the rear primary and secondary elements also must counter-rotate.)
In secondary-element mode, the distance between the secondary front and rear element axes 156 a , 162 a is less than the distance between the primary front and rear element axes 56 , 162 , thus causing machine 110 to be borne solely on the secondary front and rear elements 118 , 120 , through weight-bearing contact with the primary front and rear elements 18 , 20 , respectively. Return to primary-element mode is the reverse.
The invention as described thus far is applied to a paving machine having a gang of compacting rubber tires or a smoothing steel roller means at both the front and the rear portions of the machine. However, it is well known in the prior art that paving machines alternatively may be constructed having either of a gang of compacting rubber tires or a smoothing steel roller disposed only at either a front portion or a rear portion of the machine. It should be understood that the combination of a gang of compacting rubber tires and a smoothing steel roller in alternative employment on a single machine as described herein is fully envisioned by the invention and is applicable to design and construction of single-roller machines.
While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims. | A combination compacting and smoothing asphalt finishing machine comprising primary finishing elements which may be either compacting tires or smoothing rollers. The primary elements are driven and steered by engine and hydraulic mechanisms conventionally. The machine further comprises secondary asphalt finishing elements which complement the primary elements, being either smoothing rollers or ganged rubber tires. The secondary elements are pivotably attached to the frame of the machine. In a first position, the secondary elements are not in contact with the asphalt layer or with the primary elements and the weight of the machine is borne only by the primary elements. The secondary elements are hydraulically actuable and may be pivoted into a second position wherein only the secondary elements are in contact with the asphalt layer and are in driving contact with the primary elements which are thus raised from contact with the asphalt layer. | 4 |
FIELD OF THE INVENTION
One or more embodiments of the present invention relate to a probe card for use in test and verification of circuitry and semiconductor wafers. In particular, one or more embodiments of the invention relate to the test and verification of integrated circuits (ICs) fabricated on a semiconductor wafer prior to singulation into integrated circuit dice, or the verification of packaged integrated circuits. An improved probe card and methods directed to the verification of integrated circuits are provided.
BACKGROUND
In the wafer probe tests of semiconductor wafers, including integrated circuits formed on the semiconductor wafers, probe cards are used. The probe cards provide an electrical coupling between a tester or probe station and the semiconductor wafer being probed. The integrated circuits are provided as a plurality of integrated circuit devices (often referred to as “dice” or “bars”) on a planar semiconductor wafer.
The signals that provide power, ground, and input and output signals are electrically coupled to bond pads that are the electrical terminals for the integrated circuit. Because full operational tests and packaging processes for each integrated circuit are very expensive, probe testing is used to verify functionality of the integrated circuit devices and to identify the bad devices prior to the step of singulation. In singulation, the wafer is sawed or separated by laser cutting, mechanical sawing or other means into a plurality of integrated circuit dice. The probe tests provide a method to ensure that only functional devices are processed further. After the singulation process, the ICs are packaged into dual inline packages (DIPs), ball grid array (BGA) and micro-BGA packages, stacked packages, and the like. Because the packaging materials and process steps are quite expensive, tests at probe stations are used to prevent bad devices from being processed further.
Many types of integrated circuits are formed on semiconductor wafers and are subjected to probe testing. For example, programmable logic devices (PLDs) including field programmable gate arrays (FPGAs) and complex programmable logic devices (CPLDs), memory devices including DRAMs and SRAMs, non-volatile devices such as FLASH and EEPROMs, processors including digital signal processors and microprocessors are all formed as integrated circuits on semiconductor wafers and all of these devices may be subjected to wafer probe testing.
Probe cards are used with probe test stations. The probe card provides a means to engage probes with the lands or bond pads of the integrated circuits while they are still physically together on the semiconductor wafer. The probe pin tips are maintained in a precise alignment pattern with the lands or pads on the wafer. The probes are flexible and may be slightly mechanically compressed, that is, they are designed to have a spring function. This is important so the probes can be aligned with the probe points on the wafer and then brought gently into electrical and physical contact with the corresponding bond pad or ball land. The tester can then apply power and ground to one or more of the integrated circuit dice. By inputting signals into the input pins, providing power and ground signals to the appropriate pins, and capturing signals from the output pins, the wafer probe test may exercise one or more of the integrated circuit dice while it is still part of the wafer, thus verifying that it is a functional device.
Various probe card designs are known in the art. Vertical probe cards provide a generally vertical arrangement of the probe pins on an array of probes. These cards may probe one, two, or many integrated circuit dice in parallel. Many hundreds or even thousands of probes may be used. Probe cards of this type are described, for example, by U.S. Pat. No. 7,535,239, entitled “Probe Card Configured for Interchangeable Heads”, issued May 19, 2009, having common inventorship and co-ownership with the present application, which is hereby incorporated in its entirety herein.
Other probe card arrangements are also used in the semiconductor manufacturing field, including horizontal, cantilever, membrane, spring probes, buckling beam probes, and others known to those skilled in the art.
In order to limit the number of probes and probe pins needed on a probe card to a reasonable number, probe cards are designed with certain techniques. One known technique is to identify repeated pins or bond pads on the IC that are coupled to a power supply, and to probe only a few of these pads. The wafer probe tip may damage the surface of the bond pads that are probed so there is an advantage to not probing every pad. Further, the power pads (Vdd, Vss, Ground) are coupled electrically inside the integrated circuit in parallel, and so it is possible to test the integrated circuit without probing all of these pads. The wafer test probe station need only provide sufficient power and ground connections to operate the integrated circuit for testing.
However, problems with the probe pins of the prior art probe cards sometimes occur. When a power signal or ground signal is probed in this manner, the current flowing through the tip of the probe may spike on certain events. These current spikes, when repeated over many test cycles, may cause the probe tip to “burn”. Probe cards are expensive and so are intended to be repeatedly used to test many wafers. The probe pins should remain uniform in shape and have uniform contact resistance so that consistent test results are obtained for each wafer probed. If this is not the case, then the test results may falsely indicate a device is not functional, or other problems with testing may occur. A burned probe tip has experienced thermal stress due to over current. This burn damage can affect its operation by changing the shape and the contact resistance of the probe tip.
Presently, known probe pins are typically rated for 75-100 milliamperes of current. The probe pins for a prior art probe card are uniform in size; typically, the probe pins are about 3 mils in diameter. However and particularly when a limited number of probe pins are used to probe a power signal, or other high current signal, over time the probe pin may become misshapen and contact resistance may increase. This probe pin damage then requires repair of the probe card, increasing test time and costs. If a repair is not made, the probe card may not perform correctly.
FIG. 1 depicts a prior art probe card 10 arranged as a vertical probe card. In FIG. 1 , a substrate 11 is provided. Substrate 11 is typically a printed circuit board (PCB) and has traces and vias that are formed (not shown) to make electrical connections to the probe pins on the probe card. A multiple layer organic (MLO) or multiple layer ceramic (MLC) portion 13 is provided and supports electrically conductive pads or lands 19 . The pads are a good conductor material, typically gold or gold alloys, although copper, palladium, palladium plated nickel, nickel plated over copper, copper, copper alloys and copper nickel layers, and other known conductive pad materials may also be used. Substrate 11 includes conductors and vias to provide electrical connections between the probe pins 17 and a wafer probe tester (not shown) for use in powering and testing the device being probed. Typically, probe cards 10 are used to probe wafers with integrated circuit devices fabricated on them, but they could also be used to test packaged integrated circuit devices, circuit boards, thin film circuits, printed circuits, membranes with conductors formed on them and other devices as well.
Probe pins 17 are each coupled to a corresponding one of these pads 19 . Probe head 15 is formed to provide mechanical support and to ensure the alignment of the probe pins 17 . Probe head 15 is made of, for example, a ceramic housing with holes provided on top and bottom of the housing, a top guide plate and a bottom guide plate, and a thin Mylar in the middle of the head. The probe head thickness is about 4.0-4.5 millimeters but could be more or less than this thickness. The probe head 15 provides physical support and alignment of the probe pins 17 . The free end of probes 17 , such as end 18 , is then available to be placed into physical and electrical contact with a semiconductor wafer. In the prior art probe card 10 of FIG. 1 , each probe tip 17 is of uniform diameter and therefore uniform current carrying capacity. The probe card 10 is brought into physical and electrical contact with the wafer under test and each probe tip 17 touches down on a corresponding bond pad or ball land of the integrated circuit(s) on the wafer. Some probe cards test one integrated circuit on the wafer in a “step and repeat” fashion, while others may test multiple integrated circuit devices in parallel by having probe pins mapped to multiple integrated circuit devices. A unique probe card 10 may be designed for each type of wafer to be tested. Alternatively, for example, for commodity type devices such as DRAMs, the pad layout for the integrated circuit dies and the wafer may be made common so that a standardized probe card may be used with a variety of wafers having a common pad layout. More typically, a specific probe card is designed for each type of wafer to be produced as the universal probe cards have not been as practical.
A continuing need thus exists for a probe card that provides reliable wafer probe testing over a lengthy period of time without burning the probe pins and without the need for replacing certain pins due to over current situations.
SUMMARY
These and other problems are generally solved or circumvented, and technical advantages are generally achieved, by advantageous embodiments of the present invention which include methods and apparatuses for providing a hybrid probe card with non-uniform sized probe pins. The probe pins used for certain higher current situations are enlarged to add additional current carrying capability for those particular probe pins, while the remaining probe pins may remain at the nominal size.
In an exemplary embodiment, an apparatus is provided having a circuit board; a substrate overlying the circuit board; conductor pads on the circuit board to provide electrical connections; a probe head overlying and spaced apart from the conductor pads; and a plurality of uniform sized probe pins supported by the probe head. In this embodiment, each of the plurality of uniform sized probe pins is provided having one end coupled to a respective one of the conductor pads. In this embodiment, the apparatus further comprises at least one non-uniform sized probe pin supported by the probe head. One end of the at least one non-uniform sized probe pin is coupled to a respective one of the conductor pads. Each of the at least one non-uniform sized probe pin has a diameter that is at least 25% thicker than a diameter of each of the plurality of uniform sized probe pins.
In this embodiment, each of the at least one non-uniform sized probe pin can have a greater current carrying capacity than each of the plurality of uniform sized probe pins. The at least one non-uniform sized probe pin can be coupled to corresponding at least one power pad on a semiconductor wafer to be probed. The at least one non-uniform sized probe pin is coupled to a corresponding at least one ground pad on a semiconductor wafer to be probed. A particular one of the at least one non-uniform sized probe pin can be coupled to a first power pad on a semiconductor wafer, where the first power pad has the same power level as a second power pad on the semiconductor wafer, where the second power pad is coupled to another one of the at least one non-uniform sized probe pin. Each of the plurality of uniform sized probe pins can have a diameter of 2.5-3 mils. Each of the at least one non-uniform sized probe pin can have a diameter of 3.5-5 mils. Each of the at least one non-uniform sized probe pin can carry, without physical damage, for example, at least twice as much current as each of the plurality of uniform sized probe pins.
In yet another exemplary embodiment, a method is provided that includes the following steps: providing a semiconductor wafer having an integrated circuit; providing a plurality of bond pads on the integrated circuit; providing a probe card having a plurality of probe pins for testing the integrated circuit; aligning the probe card with the semiconductor wafer; and contacting the semiconductor wafer by probing the plurality of bond pads with tips of the plurality of probe pins to make contact with the semiconductor wafer. In this embodiment, the integrated circuit is tested by: applying power to a first subset of the plurality of bond pads; grounding a second subset of the plurality of bond pads; inputting signals to a third subset of the plurality of bond pads; and receiving signals, using the plurality of probe pins of the probe card, from a fourth subset of the plurality of bond pads. This embodiment includes providing uniform sized probe pins and at least one non-uniform sized probe pin, and each of the at least one non-uniform sized probe pin has a current carrying capacity at least 25% larger than the current carrying capacity of each of the uniform sized probe pins.
In this embodiment, each of the uniform sized probe pins can have a diameter of 2.5-3 mils. Each of the at least one non-uniform sized probe pin can have a diameter greater than 3.5 mils. Each of the at least one non-uniform sized probe pin can have a diameter between 3.5 mils to 5 mils. Each of the uniform sized probe pins can have a current carrying capacity of 75-100 milliamperes. Each of the at least one non-uniform sized probe pin can have a current carrying capacity of at least 125 milliamperes.
In another exemplary embodiment, a method for fabricating a probe card includes: providing an initial wafer probe card having uniform sized probe pins disposed at predetermined locations corresponding to bond pads for an integrated circuit to be probed while it is on a semiconductor wafer; performing wafer probe tests on the integrated circuit using the wafer probe card; and identifying ones of the uniform sized probe pins that indicate damage due to current flow beyond the current carrying capacity of the uniform sized probe pins. In this embodiment, the method further includes forming another wafer probe card having uniform sized probe pins and non-uniform sized probe pins, where the non-uniform sized probe pins are located at locations corresponding to the locations of the identified ones of the uniform sized probe pins. In this embodiment, each of the non-uniform sized probe pins have a current carrying capacity at least 25% greater than each of the uniform sized probe pins.
In this embodiment, each of the uniform sized probe pins can have a diameter of 2.5-3 mils. Each of the non-uniform sized probe pins can have a diameter of 3.5-5 mils. The step of identifying ones of the uniform sized probe pins can further include: identifying locations of the bond pads for the integrated circuit to be probed by the initial wafer probe card during functional testing of the integrated circuit at a wafer probe station; using a circuit simulation tool, simulating the current that flows at the identified locations of the bond pads during the functional testing; comparing, for each location of the bond pads, the maximum current indicated by the circuit simulation tool to the current carrying capacity of a corresponding one of the uniform sized probe pins; and identifying locations of the bond pads where the maximum current exceeds the current carrying capacity of the uniform sized probe pins.
In this embodiment, each of the uniform sized probe pins can have a current carrying capacity of 75-100 milliamperes. Each of the non-uniform sized probe pins can have a maximum current carrying capacity of about 175 to about 250 milliamperes.
The foregoing has outlined rather broadly the features and technical advantages of certain exemplary embodiments of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures or processes for carrying out the same purposes of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a prior art probe card;
FIG. 2 illustrates an embodiment of the hybrid probe card incorporating features of the invention;
FIG. 3 illustrates a probe pin embodiment of the invention; and
FIG. 4 illustrates a wafer test being performed using an embodiment of the hybrid probe card of the invention.
DETAILED DESCRIPTION
FIG. 2 illustrates a first exemplary embodiment of a hybrid probe card 20 of the present invention.
In FIG. 2 , printed circuit board (“PCB”) 11 , pads 19 , substrate 13 , and supporting pads 19 are arranged generally as shown in FIG. 1 . Probe pins 17 are of the same size and current carrying capacity; that is, probe pins 17 have uniform size and uniform current carrying capacity. In addition, probe head 15 supports new probe pins 21 to form the hybrid probe card 20 . Probe pins 21 are enlarged to carry additional current without damage or burning of the probe tips. Probe pins 21 may be, for example, 3.5-5.0 mils in diameter and in one exemplary embodiment are 3.5-4.0 mils in diameter. Probe pins 21 are made of, for example, a commercially available probe material such as Paliney 7, or similar materials. Conductive metals such as copper, gold, nickel, palladium, platinum, tungsten, tungsten rhenium, beryllium copper and the like and alloys containing any of these or other conductors are alternative materials for the probe pins 21 . Materials that may be used may be tempered, and in certain applications the use of non-corrosive, non- reactive and durable conductors are desirable. The enlarged probe pins 21 may carry, as non-limiting examples, maximum currents such as a range from 175 milliamperes to 250 milliamperes without damage. Thus, the enlarged probe pins may carry maximum current of at least 25%, more than the probe pins of the prior art. In exemplary embodiments, the current carrying capacity for the enlarged probe pins may be approximately 100% more (or doubled) than the current carrying capacity for probe pins of the prior art.
For an exemplary embodiment, one, two or several of the enlarged probe pins may be used for each integrated circuit that the probe card will contact. Typically, the enlarged probe pins are used for the power, ground or other high current signals that are to be probed. Often the higher current occurs because only one or two probe pins are used for the positive power supply or ground during a probe wafer test, even though the integrated circuit may in fact have many power and ground pads for use in a system application. This use of a few of the available power pads causes extra current to flow on the pads that are probed, and thus causes the probe pins to carry the extra current.
In one method embodiment, the embodiment probe pins 21 that are of larger diameter may be placed on pads that are known to the chip designer. In order to reliably use the larger probe, it may be desirable to form a larger bond pad at those particular pad locations. This embodiment approach may place a slight burden on the integrated circuit designer; however, it is relatively easy to form the larger bond pads during design of the IC devices. This step may not be necessary if the normal or typical bond pad size for a design is already sufficient for the larger probe pins 21 .
FIG. 3 depicts one exemplary embodiment of the hybrid probe pins 21 . The shape of the probe pins may vary, but generally the cross-sectional area should be maintained. That is, if the probe pin is formed flatter in a portion to enable bending or to create the spring action needed to permit the mechanical compression used to probe a wafer, the cross-sectional area of the probe pin needs to be maintained to avoid limiting the current carrying capacity of the probe pin in the flatter section. Many shapes are possible and are contemplated as alternative embodiments of the present invention.
FIG. 4 depicts in one non-limiting example the probe card 20 embodiment in use in probing a semiconductor wafer 31 . Wafer 31 is placed in physical proximity to and in alignment with the probe card 20 . The probe card 20 and wafer 31 are then placed in physical contact by advancing one or the other toward the other one, so that the tips of the probe pins 17 and 21 make electrical and physical contact with bond pads 22 on the semiconductor wafer 31 . The probe card 20 may form connections to one, two, or many integrated circuits on the semiconductor wafer and functional wafer probe tests may be performed by applying power and ground signals to the integrated circuit and providing input signals, while the output signals coupled to the probe pins are captured and analyzed. A determination of whether a particular integrated circuit device passes the tests is made. Wafer scale probe cards could be formed so that an entire wafer may be tested in one pass or in several passes. The integrated circuits on wafer 31 may be of any type including programmable logic devices, complex programmable logic devices (CPLDs), field programmable gate arrays (FPGAs), memory devices including dynamic and static type memory devices and non-volatile memory such as FLASH and EPROM, processor, mixed signal, analog, and other semiconductor devices may be formed on wafer 31 .
The probe card 20 may be formed in alternative probe card embodiment configurations such as cantilever, spring, buckling beam, etc. probe cards instead of the vertical probe card as shown. These alternative embodiments are also contemplated as within the scope of the present invention and are covered by the appended claims.
The method of determining which of the probe pin should be the enlarged probe pins 21 is also an aspect in one embodiment of the invention. In one embodiment method, electrical circuit simulations may be performed assuming one, two or more Vcc/Vdd or ground connection probes and current maximum levels may be estimated by the simulation. For example, SPICE or other circuit simulation tools may be used. If the current expected for a particular pin from this simulation exceeds the rated current capacity for the uniform or nominal probe pins, then the enlarged probe pins should be used for that particular pad and probe card signal. By using only a few enlarged probes for these signals, additional probe pin locations may be available for more signal probes without otherwise changing the probe card.
Alternatively, observation of a prior art probe card used to perform probe tests of a wafer may be made. Probe pins that are damaged in normal testing or “burned” may be identified, and replaced with the new larger probe pins to form a hybrid probe card. This exemplary embodiment probe card may then be used without the damage to the probe pins that occurred using the probe cards of the prior art, thus increasing reliability, reducing down time, and reducing costs.
The embodiments described above may also be provided as a complete probe card in any configuration including vertical, cantilever probe, buckling beam probe and spring probe cards. The number of enlarged probe pins may be limited to as few as one that is larger than the remaining, uniform sized pins. Alternatively, there may be a number of enlarged probe pins. Use of the enlarged probe pins with higher current carrying capacity may reduce the need for multiple probe pins probing the same power supply or ground signals on an integrated circuit, thereby providing additional probe pin capacity for other signals.
The term “on” or “thereon” as used in the specification and the claims includes when components (e.g., pads) are in physical contact and also when components are separated by one or more intervening components.
These alternative implementations are contemplated as additional embodiments of the present invention and are within the scope of the appended claims. Those skilled in the art will recognize that many obvious modifications to the exemplary embodiments may be made while still using the disclosed inventions. For example, some of the terms used in the foregoing and the appended claims are chosen with regard to the presently used terms in the relevant art and being used in draft standards presently in work. Changes in these terms and abbreviations over time by use in industry and in standard drafting are contemplated and do not change the scope of the inventions disclosed nor limit the scope of the appended claims. These modifications are contemplated as additional embodiments, are considered as within the scope of the invention and fall within the scope of the appended claims. | A hybrid probe card and methods are provided. A plurality of uniform sized probe pins are provided in a probe card for performing wafer probe testing. The probe card also includes at least one enlarged probe pin having a current carrying capacity that is at least 25% greater than the current carrying capacity of the uniform sized probe pins. The enlarged probe pins are provided, e.g., to prevent damage to the probe pins caused by large current flow. Methods for identifying the probe pin locations where the enlarged probe pins should be deployed are described. | 6 |
GOVERNMENT SPONSORSHIP
This invention was made with Government support under Contract N00039-88-C-0051 awarded by the U.S. Department of the Navy. The Government has certain rights in the invention.
This is a divisional of application Ser. No. 07/829,187, filed on Jan. 31, 1992, U.S. Pat. No. 5,221,513.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for metallurgically treating steel gears by thermomechanical means to produce high strength and accurate contact surfaces through a net shape finishing process.
2. Description of the Prior Art
Highly loaded precision gears are normally manufactured by carburizing the surface of low carbon steel gears and reaustenitizing the entire gear prior to hardening by rapid quenching to below the temperature at which the diffusionless transformation process that creates the hardened martensitic structure proceeds to completion, the so-called M f temperature. For medium to high carbon steel gears only the surface of the gears are reaustenitized prior to quenching to produce the hardened martensitic structure. The hardened gears are then finished to net shape by grinding, skiving or other hard finishing operations. A method has been proposed in U.S. Pat. No. 4,373,973 in which a carburized gear is reaustenitized and quenched to above the start of the martensite transformation temperature, the so-called M s temperature, rolled and then quenched to martensite before any diffusional decomposition can form from he metastable austenite. This invention includes light cold-working or burnishing to complete the transformation of remaining austenite. However, no specific process details are described that produce the required metallurgical state for through-hardened, medium- or high-carbon steel gears. Nor does that disclosure describe a specific apparatus which can accomplish this process.
In reducing the concept of U.S. Pat. No. 4,373,973 to practice, we have discovered that certain critical basic issues must be addressed for a metallurgically sound and dimensionally accurate gear to be produced. To achieve metallurgically sound structures, the surface decarburization and attending oxide network characteristic of gas carburizing must be significantly reduced or eliminated. This is because, unlike conventional gear finishing, the outermost surface layers are not removed during the final finishing operation. Metallurgically sound gears also have retained austenite levels of less than 10 percent. Retained austenite is particularly prevalent with high carbon or high hardenability steel compositions. Highly accurate gear teeth require very precise control of the deformation process to minimize root slivers, lead direction errors, and profile direction errors. The present invention includes apparatus and methods to control both metallurgical quality and dimensional accuracy during thermomechanical gear finishing to produce the quality required of precision gears.
Gear finishing by rolling uses two types of motion: (1) in-feed motion in which the axes of the workpiece and the die are brought together to a fixed position to engage the mesh of each to accomplish the deformation process and (2) through-feed motion in which the axes are translated parallel to each other after meshing or synchronization at a fixed distance of separation. In conventional cold rolling operations either one or other method is used. In-feed motion is used primarily for helical gears in which there is no way to compensate for tooth-to-tooth dimensional variations. Through-feed motion is required for spur gears but conventional gear finishing machines do not compensate for dimensional variations along the lead direction. In order to successfully accomplish thermomechanical finishing by rolling, both processes must be used simultaneously and very accurate coordination between the two motions must be maintained to compensate for tooth-to-tooth and lead variations. As a prerequisite for precise control of the rolling die and workpiece during processing, the initial fixed setting must also be precisely controlled. For instance, axial out-of-plane misalignment between the workpiece and tool can produce lead errors. In-plane misalignment between workpiece and tool can lead to profile errors, a non-uniform profile contour along the lead direction, as well as lead errors.
Therefore, to produce gears by thermomechanical processing which possess desirable metallurgical properties and dimensional accuracy, it is necessary to maintain precise control over the environment, thermal conditions and mechanical actions.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided an apparatus that performs thermomechanical processing of gears in which precise control of the thermal conditions, the environment and mechanical actions during the forming process is maintained.
The essence of this invention are the process control methods and architecture for accomplishing the precision motions, the thermal control, and the environmental control using a unique combination of sensors, mechanisms, and software.
The control architecture for the mechanical movements comprises absolute position control and load control of the through-feed motion and absolute position, high resolution relative position and load control of the in-feed motion. Appropriate transducers and sensors are used to monitor each of these motions and loads and the signals from them are used as feedback signals for generating the error signal used in the servo controlled actuators for in-feed and through-feed motion. An optical pyrometer based on infrared detection is used to monitor the temperature of the gear as it is being heated by an AF induction field. During this heating the workpiece is rotated at 100 RPM to distribute the heat uniformly around the circumference of the gear. IR radiation from the gear passes through a fiber optic link to an IR detector, generating a signal which is processed by a rapid response signal processor so that the instantaneous temperature on each tooth and on each portion of the tooth such as top, flank and root can be monitored. This temperature signal is passed continuously to a high speed digital/analog interface for transmission to a supervising microprocessor. The peak, mean and minimum values of tooth-to-tooth temperatures are then used in the control logic for controlling the process. The thermal history during induction heating is also recorded for off-line analysis.
When the thermal criteria have been met, the microprocessor then transmits the command signals to deenergize the induction coil and to proceed with the next step of the process. The material handling mechanism then rapidly transfers the workpiece to a thermally controlled liquid working medium for quenching to the deformation temperature. After the workpiece has reached the deformation temperature, it is worked to its final dimension by combined in-feed and through-feed motion. Precise control of the operation is accomplished by the use of a pressure sensor in the line supplying hydraulic flow to a rotary hydraulic motor powering the rolling die. Variation in the pressure of the rotary hydraulic motor is detected when tight mesh between the workpiece and the die occurs. A signal generated from this detection is used as a logic value to establish the starting position for control of the deformation process. The in-feed motion is controlled from a signal from a high resolution displacement transducer which can measure displacements as fine as 0.0001 inch. The processing parameters are specified using a command generating software and are eventually downloaded to a supervising computer. A sequence generator allows the operator to program the operation with a series of two character commands but has built in checks to prevent operation that can inflict damage on either the workpiece or any part of the apparatus.
The region above the working medium fluid in which the gear is induction heated and subsequently manipulated prior to quenching is maintained in a nitrogen or argon environment. This feature minimizes unwanted oxidation and decarburization that can occur during this portion of the process.
Other and further features, advantages, and benefits of the invention will become apparent in the course of the following description taken in conjunction with the following drawings. It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory but are not to be restrictive of the invention. The accompanying drawings which are incorporated in and constitute a part of this invention, illustrate one of the embodiments of the invention, and, together with the description, serve to explain the principles of the invention in general terms. Like numerals refer to like parts throughout the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall schematic diagram of the essential control architecture required to achieve successful thermomechanical processing in accordance with the invention;
FIG. 2 is a Time-Temperature-Transformation (T-T-T) Diagram of a typical and preferred alloy, 3Ni-1Cr steel, used for gear fabrication according to the invention;
FIG. 3 is a diagrammatic side elevation view of apparatus for gear processing as embodied by the invention;
FIG. 4 is a diagrammatic end elevation view of the apparatus illustrated in FIG. 2;
FIGS. 4A and 4B are detail diagrammatic views illustrating, respectively, two successive positions of components generally illustrated in FIG. 4;
FIGS. 4C and 4D are detail end elevation views of certain parts illustrated in FIG. 4;
FIG. 4E is a detail side elevation view of parts illustrated in FIG. 4C;
FIG. 4F is a cross section view taken generally along line 4D--4D;
FIGS. 4G, 4H, 4I and 4J are detail diagrammatic side elevation views illustrating successive positions of parts illustrated in FIG. 4D;
FIG. 5 is a detail perspective view of an individual tooth of an indexing gear utilized for purposes of the invention;
FIG. 5A is a detail side elevation view of the gear tooth illustrated in FIG. 5;
FIG. 5B is a detail top plan view of the gear tooth illustrated in FIG. 5;
FIGS. 6 and 7 are detail front elevation and side elevation views, respectively, of an induction coil heater used for purposes of the invention;
FIG. 8 is a side elevation view of an out-of-plane adjustment mechanism used for purposes of the invention;
FIG. 8A is a detail top plan view merely illustrating the outline of two components illustrated in FIG. 8;
FIG. 8B is a detail elevation view taken along lines 8B--8B in FIG. 8;
FIG. 9 is a front elevation view of the mechanism illustrated in FIG. 8;
FIG. 10 is a top plan view of the mechanism illustrated in FIGS. 8 and 9;
FIG. 11 is a detail top plan view of an in-plane adjustment mechanism utilized for purposes of the invention;
FIG. 12 is a cross section view taken generally along line 12--12 in FIG. 11;
FIG. 12A is a detail enlarged view of certain parts illustrated in FIG. 12; and
FIG. 13 is a detail elevation view, in section, of a component illustrated in FIG. 3,
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates diagrammatically and schematically a preferred system 20 for performing thermomechanical processing of gears in accordance with the present invention.
The invention can be considered as having two subsystems: a gear processing subsystem 22 by means of which the thermomechanical processes including heating and deformation are applied to perform the net shape processing of a workpiece 24 and a control subsystem 26 which provides for logic sequence and timing that are critical for the successful operation of the invention. As seen diagrammatically in FIGS. 3 and 4, the thermomechanical subsystem 22 is contained in an enclosed compartment 28 providing an inert gas environment for the heating and final quenching of the workpiece 24. A vessel 30 in a sealed relationship with the compartment 28 contains a liquid working medium 32 which may be a commercially available marquenching oil. The workpiece is rapidly immersed in the liquid medium 32 thereby quenching it to the thermomechanical processing temperature of the metastable austenite in which net shape forming is performed. This stage of the process is referred to, metallurgically, asausforming.
The workpiece 24 is referred to initially as a "near net shaped gear blank" and when all processes of the invention have been completed, it is referred to as a "net shaped gear". As a near net shaped gear blank, it may have been hobbed or otherwise formed using conventional techniques. As such, for purposes of the invention, the workpiece 24 is formed with its gear teeth approximately 0.001 to 0.002 inches oversized in tooth thickness relative to the final or desired size so that the gear can meet the dimensional tolerances of AGMA required for high performance gears without the necessity of grinding. The displacement of the metal during the deforming operations performed in accordance with the invention serves to remove the excess tooth thickness while assuring the proper profile. Grinding is eliminated, and for this reason alone there can be as much as a 70% increase in surface durability at any given contact stress level.
High strength gears are generally fabricated from a low carbon alloy carburizing grade steel in which the surface and sub-surface regions have been enriched with carbon to a specified depth. The higher carbon content serves to increase the hardness and to strengthen the material along the gear contacting teeth surfaces and beneath the surface. The elevation in hardness results from transformation of the steel from the face centered cubic crystal structure known as austenite to the body centered tetragonal crystal structure of very fine grain size known as martensite. Less hard but tougher properties can be obtained by isothermal transformation to bainite or a mixture of bainite and martensite upon quenching.
In a conventional gear processing method, the workpiece is quenched rapidly through the austenitic region by immersion into quenching media below the M s temperature. The workpiece is subsequently tempered at a designated temperature to soften the structure and impart ductility. After the tempering treatment is complete, gear finishing is accomplished by grinding in a well known manner for high performance gears.
As mentioned above, the present invention eliminates the grinding operation to provide a microstructurally improved gear tooth surface as will now be described. An important part of this invention is to select a carburizing grade steel, such as carburized nickel-chromium steel, which has a transformation curve with a metastable austenitic condition just above the martensitic range for a period of time sufficiently long to allow shaping of the gear teeth surfaces. There is in shown FIG. 2, the time-temperature-transformation chart for nickel-chromium steel carburized to about 1.0% surface carbon. The carburized nickel-chromium steel is commonly used for manufacturing high performance gears in the aerospace industry.
The time-temperature-transformation curves show the times required for austenite to start and to complete transformation at each temperature. Temperature is indicated along the ordinate and time on a logarithmic scale is indicated along the abscissa.
After the carburized gear is heated above its critical temperature to an initial temperature 10, or approximately 1350° F., to render it austenitic, it is rapidly isothermally quenched (marquenched) from point 12 to point 14 at a rate exceeding a critical cooling rate in a liquid medium such as a standard marquenching oil which is maintained just above the temperature at which martensite starts to form and metastable austenite is obtained. A critical cooling rate is defined by the slope of line 12-14 that avoids the nose 16 of the transformation curve where austenite and cementite start to form.
To allow the maximum time for mechanically operating on the surfaces of the workpiece 24 while in the metastable austenitic condition, the cooling step must terminate temporarily at a temperature just above the martensitic condition. In FIG. 2, the point 14 beginning a new temperature plateau ending at point 17 is shown positioned at about 450° F.
Shaping of gear teeth further in accordance with this invention employs a process which is performed between points 14 and 17 whereby gear swaging or rolling or other operations are used to shape the gear teeth by deforming the metastable austenitic carburized layer prior to and before its conversion to martensite. This occurs during a pre-transformation time interval at a temperature below that for recrystallization of austenite and just above the M s of the carburized layer. This process, to be described, presents a means of developing ultra high strength in the current carburized case hardened gears processed by the conventional heat treat processing.
Following the shaping operation, the gear is transferred to a quench station, as indicated in FIG. 2 by line 17-18. Final quench, preferably utilizing a pressurized gas stream, although a liquid is within the scope of the invention, is initiated at point 18 and is finalized at point 19 in the martensitic range.
The control subsystem 26 of the invention comprises both hardware and software supervising and controlling the thermomechanical operations. The control subsystem is under the primary supervision of a microprocessor 34. All of the functions necessary for the operation of the mechanical, environmental and thermal functions of the apparatus are controlled from this computer. The software used for these functions are preinstalled prior to operation and the algorithms contained in the software are considered part of the invention. The machine operator has a choice of operating each function of the machine separately or initiating a sequence of operations that will actually perform the thermomechanical forming operation. The software is constructed in such a way that each separate function cannot proceed until a requisite condition exists in the apparatus. The sequence of operations or "program" is generated by the operator using a series of two character commands which are stored for execution. The algorithm checks for sequences of operation that cannot be permitted. The program commands are transferred to a unit 36 for routing to the proper component in system 26. The unit 36 is concurrently a high speed signal conditioner, an I/O interface, and a digital/analog (D/A) converter.
During the operation of the system 20 (see FIG. 1), a control signal initializes all functions and sets up the individual subsystems and mechanisms for the operation to proceed. The process begins with a control signal from the interface 36 to an audio frequency (AF) control 38 which in turn energizes an AF work station 40 to provide an electric field to a toroidal-shaped, water cooled, induction coil heater 42 (see especially FIGS. 4, 6, and 7) into which the workpiece is temporarily positioned. The electrical field generated as the result of the operation of the induction coil may be 10 KHz, by way of example.
With particular reference to FIG. 2, which is a time-temperature-transformation diagram of a typical and preferred alloy used for gear fabrication, namely, 3Ni-1Cr steel, the workpiece 24 is heated to a temperature at which austenite is stable, whether it be a hypereutectic steel or a hypoeutectic steel. As heating proceeds, the temperature of the workpiece is monitored by means of an IR detector 44. An optical pyrometer which is an integral part of the IR detector performs this function, obtaining its information via a fiber optic link 46. Heat radiation from the workpiece is received through a sighting hole 48 in the coil 42 (see especially FIGS. 4, 6, and 7) which is transmitted to a high speed thermal signal processor 50. A commercially available signal processor which has been found suitable for this purpose is Vanzetti Systems Infrared Thermomonitor Model No. 3008 manufactured and sold by Vanzetti Systems of Stoughten, Mass.
The signal processor 50 must have a sufficient response time to enable it to distinguish the variations in temperature from top 24A to flank 24B to root 24C of each tooth (see FIG. 6), typically, of a 4 inch diameter, 8 diametral pitch gear as it is rotated at speeds approximately in the range of 80 to 100 RPM, in a manner to be described, during the induction heating operation. The processed signal is then transmitted to the high speed digital to analog (D/A) converter 36 and in turn to the microprocessor based computer 34 in which the preprogrammed algorithm determines whether the temperature profile of the gear has achieved the requisite condition before proceeding to the next processing step. At that point, a logic signal is returned to the D/A converter 36 which sends the appropriate control signal to the induction coil control system represented by the controller 38 and work station 40 to turn off the energy field. The induction heating is performed within the enclosed compartment 28 in a controlled environment of nitrogen, or argon, or other suitable inert gas to minimize the amount of decarburization and oxidation of the workpiece surface.
The workpiece 24 is then rapidly transferred into the liquid working medium 32 where it is quenched to the metastable austenite condition. The mechanism for transferring the workpiece during the thermomechanical processing operation is best seen in FIG. 4 and its assoicated detail drawings, FIGS. 4A-4J. As with the induction heating operation, quenching of the workpiece 24 takes place in the controlled environment provided within the compartment 28.
A support spindle 52 on which the workpiece is suitably releasably secured is mounted for unitary rotation with an upper spindle bearing block 54 which is allowed to slide on the gear transfer slide plate 56 via dovetail slide ways 58 during the transfer operation. Induction heating takes place with the workpiece 24 in the horizontal or dashed line position (FIG. 4). For this operation, the workpiece 24 is extended on the support spindle 52 until it is positioned within the induction coil heater 42 (see especially FIG. 4A). Extension is accomplished by means of a workpiece transfer actuator 60 and its associated actuator rod 62 mounted on a transfer frame 64. After the workpiece is positioned within the induction coil heater 42, a friction drive wheel 66 engages the support spindle 52 to impart rotation to the workpiece during induction heating. A rotational speed in the range of 80 to 100 RPM has been found desirable for purposes of the invention.
When the induction heating cycle is completed, the workpiece is rapidly retracted from the induction coil. Retraction is accomplished by means of a lost motion mechanism which generally comprises a longitudinally extending bracket 54A, apertured transverse ear 54B, actuator rod 62, and an enlarged end 62A of the actuator rod. At one end, the bracket 54A is fixed to the bearing block 54 and the ear 54B is an integral part of its opposite end. The actuator rod extends slidably through the aperture ear 54B and terminates at the enlarged end 62A. In actual fact, the extreme end of the actuator rod 62 may be threaded and the enlarged end 62A may be a nut threadedly received on the apertured end to provide for adjustment of the lost motion mechanism. As seen in FIG. 4B, operation of the actuator 60 to retract the workpiece 24 from the heating zone of the induction coil heater 42 is effective to move the actuator rod 62 to the left (FIGS. 4A and 4B) until the enlarged end 62A engages the ear 54B, following which the bearing block 54 carrying the workpiece 24 and its spindle 52 is then slid to the left on the gear transfer plate 56.
The transfer frame 64 is then rotated to a vertical, or solid line, orientation (FIG. 4). This rotation is accomplished by a swivel actuator 68 operating through an actuator rod 70 whose extreme end is pivotally attached, as at 72, to the workpiece transfer frame 64 which is free to swing about a stationary axle 74. When the transfer frame 64 reaches the vertical orientation, the gear transfer actuator 60 is then operated to extend the workpiece 24 below the level 76 of the liquid working medium 32 within the vessel 30 where it is quenched to the metastable austenitic temperature. The transfer operation which includes withdrawal of the workpiece from the induction coil heater 42, swinging of the transfer frame 64 to the upright position, and immersion of the workpiece in the working medium 32 is performed in an extremely rapid manner, taking place over an interval of approximately two seconds.
The upper spindle bearing block 54 is then transferred via the transfer dovetail slide ways 58 (FIGS. 4 and 4D) to a gear support plate 78 so that the lower end of the workpiece support spindle 52 is captured within a lower spindle bearing block 80. This movement can best be seen with attention to FIGS. 4G-4J. A through-feed actuator 138, mounted on a top plate 139 (FIG. 3), imparts its motion to an actuator guide plate 86 by way of a through-feed rod connector 140. Selected operation of the actuator 138 serves to move the through-feed rod 140 in its longitudinal directions as indicated by a double arrow head 140A (FIG. 4G). After the workpiece transfer frame 64 has swung to the vertical position as indicated by solid lines in FIG. 4, the through-feed actuator 138 is operated to raise the through-feed rod 140, and with it the workpiece support plate 78 and the lower spindle bearing block 80 which is an integral part of the support plate 78. The actuator guide plate 86 is raised until the upper regions of the support plate 78 are proximate to the lower regions of the workpiece transfer frame 64. Thereupon, the actuator rod 62 operated by the workpiece transfer actuator 60 is advanced until its tip end engages the upper spindle bearing block 54. Continued operation of the actuator 60 is effective to transfer the bearing block 54 from the upper dovetail slideways 58 to lower dovetail slideways 58A provided on the workpiece support plate 78. The actuator 60 continues to extend the actuator rod 62 until the bearing block 54 has reached the position generally as indicated in FIG. 4J. The upper spindle bearing block 54 is then locked onto the gear support plate 78 by means of a dovetail locking mechanism 82 (see especially FIG. 4F) which includes hydraulically actuated gib locks.
As seen in FIG. 4F, the dovetail locking mechanism 82 comprises a hydraulic cylinder 82A which operates a gib 82B which, by its operation, eliminates the clearance between the sliding parts provided by the dovetail slideways 58A.
Through-feed motion, as represented by a double arrowhead 84 in FIG. 4, can then proceed by vertical translation of the actuator guide plate 86 on the in-feed translation plate 88. In-feed motion as represented by a double arrowhead 90 in FIG. 3 can proceed simultaneously by sliding of the in-feed translation plate 88 on in-feed slide guides 92 which are supported by in-feed slide bushings 94, all in a manner to be described below in greater detail.
At this point, the rotary actuator 96 which may be hydraulically operated can be activated to provide rotation, via an actuator shaft 98, to a coordinated rolling die 100 and indexing gear 102. Both the rolling die and the indexing gear are supported for rotation on an extension 98A of the actuator shaft 98 in a rolling die support frame 104. The axis of the workpiece 24 is positioned generally parallel to the plane of the axis of the rolling die 100 and of the indexing gear 102 so that meshing will occur as it passes through the indexing gear to synchronize or coordinate the rotation of the workpiece with that of the rolling die. In effect, the indexing gear 102 is a spur gear having modified teeth 106 (see FIGS. 5, 5A, and 5B). In FIG. 5, the outline of an original tooth is indicated by a combination of solid and dashed lines. As modified, indicated solely by solid lines, each tooth extends from a root 108 to a top land 110 and has been tapered on its lead side in a manner extending from a line 112 of departure from a flank 114 across a crest 116 to an opposite line of departure 118 from an opposite flank 120. This construction results in opposed tapered surfaces 122, 124 on the entry side of the teeth 106 which operate as cams to slightly rotate the workpiece 24 into synchronization with the rolling die 100. While other mechanisms could be used to move the workpiece into alignment with the rolling gear die 100 prior to their placement into a meshing relationship, the construction disclosed is a most economical one and is preferred.
The present invention provides for making appropriate adjustments should they be determined desirable to assure that an optimized gear will result from operation of the system 20. To this end, the mechanism of the gear processing subsystem 22 provides for both in-plane and out-of-plane adjustments which are provided relatively between the workpiece 24 and the rolling gear die 100.
The out-of-plane adjustment, that is, adjustment made outside of the plane defined by the axes of both the rolling gear die 100 and the workpiece 24, is provided by means of an adjustment mechanism 125 depicted in greater detail in FIGS. 8-10. By reason of this construction, the bifurcated rolling die support frame 104, when in the unlocked condition, is allowed to rotate around a pin 126. The pin 126 passes through the center of the die support frame 104 and through a load reaction frame 128 on which it is supported. Suitably mounted to an upper surface of the load reaction frame 128 is a cantilever plate 128A. The cantilever plate 128A has a pair of spaced finger members 128B, 128C which extend over the support frame 104 and define a recess 128D between them. An upper adjustment member 104A is also suitably attached to an upper surface of the support frame 104 and includes an them. An upper adjustment member 104A is also suitably attached to an upper surface of the support frame 104 and includes an integral head member 104B which extends upwardly into the recess 128D. Opposed adjustment screws 104C are threadedly received through the finger members 128B, 128C in opposed fashion to engage opposite sides of the head member 104B. Adjustment plate 128A is positioned above the level 76 (FIG. 4) of the liquid working medium 32. Out-of-plane adjustment as represented by angles 104D and 104E is accomplished by the appropriate operation of the adjustment screws 104C, screwing or unscrewing them in a unitary fashion to the extent desired. In order to secure the support frame 104 on the load reaction frame 128 when the desired out-of-plane adjustment has been achieved, a pair of locking bolts 128E which extend through arcuate grooves 128F and into threaded engagement with the support frame 104 are then tightened. This assures that the support frame 104 is locked against further additional undesired movement.
The in-plane adjustments, that is, adjustments made within the plane defined by the axes of both the rolling gear die 100 and the workpiece 24, are made on the workpiece support plate 78 with a locking mechanism 134 the control portions of which also extend above the level 76 (FIG. 4) of the liquid working medium 32. For purposes of the locking mechanism 134, the actuator guide plate 86 is provided with a hollowed-out region defined, in part, by an arcuate in-plane adjustment surface 136 which is congruent with a similar surface 137 on the workpiece support plate 78 opposite the surface on which the bearing blocks 54 and 80 are received. A terminal end of the through-feed rod 140 extends freely through a clearance hole 86A in the actuator guide plate 86, then through a clearance hole 78A in a projection integral with the support plate 78. Fasteners 78C of the ball joint variety serve to pivotably attach the free end of the connector rod 140 to the projection 78B. Longitudinal movement of the rod connector 140 as defined by double arrowhead 144 causes the gear support plate 78 to rotate normal to the radius of an in-plane adjustment surface 136, generally in the manner indicated by double arrowhead 141A. When the proper orientation of the workpiece support plate 78 relative to the actuator guide plate 86 has been achieved, a plurality of suitable fasteners 78D are then tightened to guard against the desired relative movement.
These mechanisms 130 and 134 permit the final adjustments of in-plane and out-of-plane alignments to be made when the system has reached thermal equilibrium. Once the adjustments have been made, the rolling die support frame 104 and the gear support plate 132 are locked in relative alignment. They remain so locked until it becomes desirable to make correcting adjustments at some future time.
As previously noted, through-feed motion is provided by a through-feed actuator 138, mounted on the top plate 139, which imparts its motion to the actuator guide plate 86 through the through-feed rod 140. To accommodate small incremental movements of the actuator guide plate 86 in the in-feed direction, a through-feed rod coupling 142 is provided to provide the through-feed rod 140 with a small amount of lateral flexibility. As seen particularly well in FIG. 13, the coupling 142 includes an upper ring member 200 which freely receives an end of the upper portion of the through-feed rod 140. A domed cap 202 with a peripheral flange 204 is fittingly received on an upper end of the lower through-feed rod 140 which matingly engages with an intermediate member 206 fittingly received on a lower end of the upper through-feed rod 140 and having a lower concave surface 208 slidably engaged with a concave surface 210 of the domed cap 202. The outer peripheries of the upper ring member 200 and of the domed cap 202 are joined by means of studs 212. The studs 212 pass freely through clearance holes 214 provided in an annular flange 216 of the intermediate member 206. It will be appreciated that as the actuator guide plate 86 moves in the direction of a double arrowhead 90 (see FIG. 3), the surfaces 208, 210 will be caused to slide slightly relative to one another and thereby provide the requisite lateral movement of the through-feed rod 140 without causing damage to the system.
The in-feed motion is produced from an in-feed actuator 150 also mounted on the top plate 139 and is transmitted to a sliding in-feed wedge 152 through an in-feed rod connector 154. The vertical motion of the sliding in-feed wedge 152 transmits force to the vertically fixed in-feed wedge 155 which in turn provides in-feed motion to the in-feed translation plate 88. The taper of the wedge mechanism may be, for example, 40:1. The friction of the sliding in-feed wedge 152 is minimized by the use of linear roller bearings 156 between it and the load reaction frame 128 and the in-feed wedge 155. The in-feed translation plate 88 is guided in the horizontal position by four in-feed slide guides 92. Two return springs 160 on the bottom in-feed slide guides 92 and extending between the load reaction frame 128 and the in-feed translation plate 88 provide a return force when the in-feed actuator 150 is withdrawn. The entire working assembly is mounted on a bed plate 162 which is attached to the top plate 139 by four spaced support columns 164.
The workpiece 24 is advanced axially along its lead direction at a preprogrammed rate of through-feed velocity, programmed as incremental position feedback. During this operation the pressure resisting entry of the workpiece is monitored by a through-feed load cell 166 connected between the through-feed actuator 138 and the workpiece 24 by the through-feed rod connector 140. If the through-feed resistance exceeds a preset limit further advance is prevented. Simultaneously the required in-feed position is provided by the in-feed actuator 150 to the in-feed translation plate 88. The in-feed motion determines the position of the workpiece axis relative to the rolling die axis, which is measured by a high resolution displacement transducer 168 located above the level 76 of the liquid working medium 32. The signal from this transducer is the primary feedback for maintaining the proper degree of engagement between die and workpiece. A high resolution displacement transducer 168 measures distance between the axes of the workpiece 24 and the rolling gear die.
In order to properly control the forming action, the amount of absolute displacement between the surfaces of the die teeth and the workpiece teeth must be controlled. This is accomplished by determining the point of meshing contact between the die and workpiece by detecting the increase in hydraulic pressure from a pressure sensor 170 in the rotary actuator 96. This signal is then returned to the microprocessor 34 via the I/O interface 36 where it is used to initialize the signal from the high resolution displacement transducer 168. The in-feed pressure is also monitored with an in-feed load cell 172 to determine if unexpected high in-feed loads are produced by the forming action. The microprocessor 34 will generate a signal to delay in-feed motion if the loads are beyond the pre-set limit. Alternatively, forming loads can be used as the primary control signal and the high resolution displacement transducer 168 can be used to monitor axial displacement. Both in-feed and through-feed processing signals including load, position and displacement are continually monitored and recorded on the hard drive of the computer for later analysis.
After the thermomechanical deformation is complete, the workpiece 24 is removed from the liquid working medium 32 and quenched with a stream of gas from a gas quench system 174. For this operation, the entire sequence previously described following heating of the workpiece and its subsequent immersion into the liquid working medium is re-traced.
The control system employs servovalve operated actuators in which the feedback signals from the through-feed loop is directed to a through-feed conditioner 176 and after conditioning directed to a through-feed servocontroller 178 where it is compared with the command signal to generate the error signal for the servovalve. Likewise the in-feed actuator 150 receives an error signal through the loop containing an in-feed signal conditioner 180 and an in-feed servocontroller 182. Command signals from the command signal generator 36 are alternately provided to each loop to effect operation simultaneously.
While preferred embodiments of the invention have been disclosed in detail, it should be understood by those skilled in the art that various other modifications may be made to the illustrated embodiments without departing from the scope of the invention as described in the specification and defined in the appended claims. | An apparatus is disclosed for performing thermomechanical processing of gears in which precise control of the thermal, metallurgical and mechanical action during the forming process is maintained. The apparatus comprises an induction heating system which reaustenitizes the surface of the gear with minimum decarburization, a material transfer system which provides timely operations on the work piece, tooling and fixture adjustments which provide accurate initial conditions for forming, and a process control architecture that provides the precise sequence and timing necessary to achieve metallurgically sound and dimensionally accurate gears. Using this invention the induction heating cycle can be controlled from the peak, average or minimum gear surface temperature detected with a high response optical pyrometer. An inert environment is maintained around the workpiece during the induction heating and transfer to quenching above the M s temperature. Both through-feed and in-feed motion are simultaneously controlled by load, position and velocity transducers which provide feedback information to a supervising microprocessor. This apparatus produces metallurgically sound and accurate gears. | 2 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/524,988, filed Sep. 20, 2006, which claims the benefit of U.S. Provisional Application Ser. No. 60/719,153, filed Sep. 20, 2005 and U.S. Provisional Application Ser. No. 60/789,656, filed Apr. 5, 2006. The contents of each of the aforementioned Applications is hereby incorporated by reference in its entirety herein.
BACKGROUND
[0002] Fungal infections, particularly those caused by yeasts, are associated with high morbidity and mortality. An increase in the prevalence of nosocomial fungal infections, especially bloodstream infections (BSI) attributed to Candida species, has contributed to an overall increase in the proportion of BSI caused by yeast (Wisplinghoff CID 2004).
[0003] The susceptibility of the various Candida species to available antifungal compounds is constantly being reexamined and results are widely published. The susceptibility of an isolate to a drug is often described in minimum inhibitory concentration units (MIC) which are often defined in terms of the species as a whole, though susceptibilities can vary widely between isolates of a given species. Measurement of MIC values requires isolation of an organism from a clinical sample followed by exposure of the organism to a drug and subsequent measurement of inhibition (reduction in growth). The US National Committee for Clinical Laboratory Standards (NCCLS) guidelines attempt to standardize these techniques and establish so called “breakpoints” differentiating resistant from non-resistant isolates. In general terms, species are described as resistant to a particular drug when a significant proportion of isolates tested have MIC values greater than the breakpoint, or when the recommended dosage of a drug is found to result in failure of treatment in a significant number of cases. Organisms which demonstrate intermediate susceptibilities are described as “susceptible, dose-de pendant”.
[0004] Though the susceptibility of a given species to a particular drug can be highly variable between isolates, and patient populations, the established susceptibility of a species is perceived as a good therapeutic guide. In fact, current guidelines from the Infectious Disease Society of America recommend selection of antifungal therapy based on species identification. Antifungal drugs are approved for, and directed towards the treatment of particular Candida species, however; identification to a species level is not commonly performed rapidly enough to inform initial therapeutic decisions. Treatment of patients with antifungal drugs is therefore often performed prophylactically, without diagnostic information, or empirically based on preliminary diagnostic information; whereas, selection of optimal therapy must await laboratory identification which may take several days by conventional methods.
[0005] Candida albicans, Candida parapsilosis, Candida tropicalis, Candida glabrata , and Candida krusei account for greater than 95% of yeast isolates from blood (Pfaller JCM, Vol. 39, No. 9. p. 3254-3259) and greater than 97% of nosocomial fungal infections (Wisplinghoff CID 2004). A trend in the relative proportions of these high prevalence Candida species has shifted towards a higher incidence of the “drug resistant” species C. glabrata and C. krusei in some patient populations (Trick et al CID 1998). It has been suggested that this change in species proportion reflects a selection of resistant nosocomial strains through the over use of empiric antibiotics.
[0006] The development of antifungal therapy is focused on broad spectrum drugs to reduce the dependence on laboratory identification; however, broad spectrum antifungal drugs may be expensive or associated with adverse side effects. For the antifungal compound, fluconazole, the five most clinically prevalent Candida species are generally regarded to fall in three categories. C. albicans and C. parapsilosis are fluconazole sensitive, C. tropicalis has dose-dependent sensitivity to fluconazole, and C. glabrata with high prevalence of fluconazole resistance and C. krusei which is considered fluconazole resistant. Thus, it is generally accepted that infections of C. albicans or C. parapsilosis can be treated with a normal regime of fluconazole. Fungal infections caused by C. tropicalis can be treated with either an increased dose of fluconazole, or a stronger antifungal drug. C. glabrata and C. krusei infections are generally treated with caspofungin, voriconazole, amphotericin B, or other strong antifungal compounds.
[0007] It would therefore be advantageous to have laboratory tools where the results could be used to select optimal antifungal therapy without having to identify the yeast at the species level.
SUMMARY OF THE INVENTION
[0008] Described herein are reagents, methods and kits to identify and categorize fungi according to their established susceptibilities to antifungal agents. Embodiments of the invention utilize probes targeted toward fungal species in such a way that optimal therapy can be selected without necessitating identification of the organisms at the species level. By short-cutting the traditional approach where optimal selection of therapy is awaiting species identification, information for selection of therapy is available faster without compromising the quality of the information. In addition, the invention circumvents the need for separating fungi which require the same treatment hereby simplifying both the analysis and the result interpretation.
[0009] The methods and reagents provide information for the direction of therapy for treatment of fungal infections in a rapid and simple manner.
[0010] In one embodiment, the invention provides reagents and methods for selection of therapy against clinically prevalent Candida species.
[0011] In another embodiment the invention provides PNA probes and probe sets targeted toward fungal species such that appropriate therapy can be selected without necessitating identification of the organisms to the species level.
[0012] In one embodiment of the invention, the test can provide therapeutic guidance for at least about 70% of yeast species associated with fungemia.
[0013] In one embodiment of the invention, a single 2-color, multiplex test can provide therapeutic guidance for at least about 70-85% of yeast species associated with fungemia.
[0014] In one embodiment of the invention, a single 3-color, multiplex test provides therapeutic guidance for at least about 95% of yeast species associated with fungemia.
[0015] Alternatively, the reagents may be used in an array format rather than a multicolor format where the position of the signal, rather than the color of the signal, provides therapeutic guidance.
[0016] In some instances, the therapeutic guidance is for selection of a certain antifungal drug whereas in other instances the guidance is for avoiding certain antifungal drugs. Also, the guidance may be related to the dosing of a certain drug.
[0017] It is within the embodiment of this invention to use the probes, methods, and kits provided for guidance in the selection of anti-fungal drugs. Embodiments of the invention can provide information which is particularly useful when choosing between fluconazole and other anti-fungal drugs.
[0018] In some instances, absence of a signal by a particular test method provides useful diagnostic information, given that appropriate controls demonstrated that the method was capable of producing a positive result.
[0019] In one aspect, provided herein are reagents for the classification of fungi, comprising a probe set complementary to nucleic acid sequences of at least one fungal drug susceptibility-type.
[0020] In one embodiment, the reagent further comprises one or more additional probe sets complementary to nucleic acid sequences of other fungi of other drug susceptibility-types.
[0021] In another embodiment, the probe sets comprise one or more of nucleic acid probes, locked nucleic acid probes, peptide nucleic acid probes, or other nucleic acid probe mimics or analogues.
[0022] In one embodiment, a fungal drug-susceptibility type comprises a full spectrum of response to a compound, wherein the full spectrum of response comprises one or more of susceptible; susceptible/intermediate; intermediate; susceptible/susceptible, dose-dependant; susceptible, dose-dependant; susceptible, dose-dependant/resistent; susceptible-dose/delivery dependent; intermediately resistant; or resistant.
[0023] In another embodiment, the fungal drug susceptibility-type comprises resistance to an anti-fungal compound, or combination of compounds.
[0024] In another embodiment, the anti-fungal compound or combination of compounds comprises one or more of fluconazole, caspofungin, voriconazole, and amphotericin B.
[0025] In one embodiment, at least one fungal drug susceptibility type comprises one or more of a fluconazole-sensitive drug susceptibility-type; a fluconazole-sensitive, dose dependant drug susceptibility-type; or a fluconazole-resistant drug susceptibility-type.
[0026] In another embodiment, the fluconazole-sensitive drug susceptibility-type comprises one or more of Candida albicans and/or Candida parapsilosis.
[0027] In one embodiment, the fluconazole-sensitive, dose dependant drug susceptibility-type comprises Candida tropicalis.
[0028] In one embodiment, the fluconazole-resistant drug susceptibility-type comprises one or more of Candida glabrata or Candida krusei.
[0029] In another embodiment, the fungi comprise caspofungin-, voriconazole- or amphotericin B-sensitive.
[0030] In one embodiment, the nucleic acid sequences comprise one or more of ribosomal RNA (including, but not limited to 5.8S, 18S and 26S sequences), ribosomal DNA, (including, but not limited to 5.8S, 18S and 26S sequences) or complements thereof.
[0031] In another embodiment, at least a portion of a probe of the probe set is at least about 86% identical to the nucleobase sequence or complement thereof selected from SEQ. ID NOS 1-24.
[0032] In one embodiment, the probe sequences comprise 8-17 subunits in length.
[0033] In one embodiment, the probe set comprises at least one detectable moiety.
[0034] In another embodiment, the detectable moiety or moieties comprise one or more of a conjugate, a branched detection system, a chromophore, a fluorophore, a spin label, a radioisotope, an enzyme, a hapten, an acridinium ester or a luminescent compound.
[0035] In one embodiment, at least one probe is self-reporting.
[0036] In one embodiment, the self-reporting probe comprises a PNA Linear Beacon.
[0037] In another embodiment, at least one probe of the probe set is unlabeled.
[0038] In one embodiment, at least one probe of the probe set is bound to a support.
[0039] In one embodiment, at least one probe of the probe set further comprises a spacer or a linker.
[0040] In one embodiment, in situ hybridization is used to analyze a sample for the presence of fungi.
[0041] In another embodiment, at least two probes are differently labeled and wherein the probes are adapted to distinguish two or more drug susceptibility-types.
[0042] In one embodiment, coincidental fluorescence is used to detect a fungal susceptibility-type.
[0043] In another embodiment, the probe set comprises a PNA probe for fluconazole-sensitive fungi and a PNA probe for fluconazole-resistant fungi.
[0044] In one embodiment, the fluconazole-sensitive fungi comprise one or more of C. albicans or C. parapsilosis and wherein the fluconazole-resistant fungi comprise one or more of C. krusei or C. glabrata
[0045] In another embodiment, the probe set comprises one or more of a PNA probe for fluconazole-sensitive fungi, a PNA probe for fluconazole-sensitive/dose-dependant fungi or a PNA probe for fluconazole-resistant fungi.
[0046] In one embodiment, the fluconazole-sensitive fungi comprise one or more of C. albicans or C. parapsilosis , the fluconazole-sensitive/dose dependant fungi comprise one or more of C. tropicalis and the fluconazole-resistant fungi comprise one or more of C. krusei or C. glabrata
[0047] In one embodiment, three or more differently labeled probe sets are used to distinguish between antifungal drugs.
[0048] According to one aspect, provided herein are methods for determining the susceptibility-type of fungi, comprising contacting a sample with one or more probe sets, wherein the probe set comprises a complementary sequence to a nucleic acid sequence of at least one fungal drug susceptibility-type, and correlating hybridization of a probe to an established susceptibility-type.
[0049] In one embodiment, the hybridization is indicative of presence, identity and/or amount of microorganisms in the sample.
[0050] In another embodiment, the probe sets comprise an azole sensitivity probe set and an azole resistance probe set.
[0051] According to one aspect, provided herein are methods for selecting antifungal therapy, comprising: a) contacting a sample with a probe set, wherein the probe set comprises a complementary sequence to a nucleic acid sequence of at least one fungal drug susceptibility-type; b) hybridizing the probe set to a nucleic acid sample; and c) detecting hybridization; and d) selecting antifungal therapy based on hybridization, if any.
[0052] According to one aspect, provided herein are methods for classifying fungi by therapy comprising a) contacting a sample with a probe set, wherein the probe set comprises a complementary sequence to a nucleic acid sequence of at least one fungal drug susceptibility-type; b) hybridizing the probe set to a nucleic acid sample; and c) detecting hybridization; and d) classifying the fungi based on hybridization.
[0053] According to one aspect, provided herein are methods to select antifungal therapy, comprising a) contacting a sample with at least two probe sets, wherein the probe sets comprises complementary sequences to a nucleic acid sequences of at least one fungal drug susceptibility-type; b) hybridizing the probe set to a nucleic acid sample; and c) detecting hybridization; and d) selecting antifungal therapy based on hybridization, if any.
[0054] In one embodiment, the probe sets comprise one or more of a PNA probe set targeting C. albicans and C. parapsilosis , a PNA probe set targeting C. tropicalis , and a PNA probe set targeting C. glabrata and C. krusei , wherein the PNA probe sets are independently labeled and wherein detection of hybridization of one or more of the PNA probes targeting C. albicans and C. parapsilosis indicates selection of fluconazole, detection of hybridization of one or more of the PNA probes targeting C. tropicalis indicates selection of increased dose of fluconazole and wherein detection of hybridization of one or more PNA probes targeting C. glabrata and C. krusei indicates selection of caspofungin, voriconazole, or amphotericin B.
[0055] In another embodiment, the analysis is in situ.
[0056] In another embodiment, the analysis comprises fluorescence in situ hybridization.
[0057] In another embodiment, the probes or their complementary sequences have been synthesized or amplified in a reaction.
[0058] In one embodiment, results are generated in less than 8 hours.
[0059] In one embodiment, results are generated in less than 3 hours.
[0060] In another embodiment, nucleic acid synthesis or nucleic acid amplification reactions are selected from the group consisting of: Polymerase Chain Reaction (PCR), Ligase Chain Reaction (LCR), Strand Displacement Amplification (SDA), Transcription-Mediated Amplification (TMA), Rolling Circle Amplification (RCA) and Q beta replicase.
[0061] In one embodiment, the method further comprises adding at least one blocking probe to reduce or eliminate hybridization of the probe to a non-target sequence.
[0062] In another embodiment, the nucleic acid sample is immobilized to a surface.
[0063] In another embodiment, at least one probe of at least one probe set is immobilized to a surface.
[0064] In another embodiment, the at least one probe is a component of an array.
[0065] In another embodiment, the probe set comprises one or more of the PNA probe sets described herein.
[0066] In another embodiment, the sample is a biological sample.
[0067] In another embodiment, the biological sample is blood, urine, secretion, sweat, sputum, stool, mucous, or cultures thereof.
[0068] According to one aspect, provided herein are kits for selecting antifungal therapy, comprising a) probe set comprising a complementary sequence to a nucleic acid sequence of at least one fungal drug susceptibility-type and b) other reagents or compositions necessary to perform the assay.
[0069] In one embodiment, the kit is used in an in situ hybridization assay. In another embodiment, the kit is used for a real-time PCR assay.
[0070] In one embodiment, the kit is used to examine clinical samples or cultures thereof.
[0071] Specific PNA probes, kits and methods are provided.
[0072] Generic PNA probes, kits and methods are provided.
DETAILED DESCRIPTION OF THE INVENTION
[0073] Provided herein are methods for detection of nucleic acid targets which confer azole resistance to fungi. A multitude of molecular diagnostic methods are available for detection and identification of organisms involved in infectious disease. Amplification techniques, particularly those using the polymerase chain reaction (PCR) have been described for species identification for a wide range of bacteria and fungi. Amplification methods, probes and primers for detection of nucleic acid targets indicative of the presence of various fungi are described in several places (U.S. Pat. No. 6,858,387, US2003186259, U.S. Pat. No. 6,235,890). In addition, amplification methods have been described for detection of genes involved in antifungal resistance, see US2004185478.
[0074] A detection method which correlates to therapy has also been described (see US2002098483, incorporated herein by reference), through detection of nucleic acid targets (genes) which confer resistance to particular drug types.
[0075] Peptide nucleic acid probes, PNA, are useful tools for detection and analysis of microorganisms, particularly when they are applied in fluorescence in situ hybridization assays (FISH) (Stender, JMicro Meth 48, 2001). PNA FISH assays are commercially available for rapid detection of organisms to a species level. PNA probes have been described elsewhere for detection of Candida species (see US2003175727 incorporated herein by reference), however, as with all other methods for species identification, the time and complexity required for identification of Candida yeast to species often prevents immediate selection of the most appropriate therapy. Likewise, ChromAgar is a novel, simple method which enables species identification of most clinically relevant species in a single test; however, it can take several days to get a result.
[0076] Besides facilitating faster and better selection of appropriate therapy, the tools described herein could also be used to select safe, narrow spectrum, and high potency antifungal drugs that are often not selected due to the time constraints imposed by current speciation methods and susceptibility testing methods.
1. DEFINITIONS
[0077] a. As used herein, the term “nucleobase” means those naturally occurring and those non-naturally occurring heterocyclic moieties commonly known to those who utilize nucleic acid technology or utilize peptide nucleic acid technology to thereby generate polymers that can sequence specifically bind to nucleic acids.
b. As used herein, the term “nucleobase sequence” means any segment of a polymer that comprises nucleobase-containing subunits. Non-limiting examples of suitable polymers or polymer segments include oligodeoxynucleotides, oligoribonucleotides, peptide nucleic acids, nucleic acid analogs, nucleic acid mimics, and/or chimeras.
c. As used herein, the term “target sequence” means the nucleobase sequence that is to be detected in an assay.
d. As used herein, the term “probe” means a polymer (e.g., a DNA, RNA, PNA, chimera or linked polymer) having a probing nucleobase sequence that is designed to sequence-specifically hybridize to a target sequence of a target molecule of an organism of interest.
e. As used herein, “analyze” means that the individual bacteria are marked for detection, identification and/or quantitation and/or for determination of resistance to antibiotics (antimicrobial susceptibility).
f. As used herein, the term “peptide nucleic acid” or “PNA” means any oligomer, linked polymer or chimeric oligomer, comprising two or more PNA subunits (residues), including any of the polymers referred to or claimed as peptide nucleic acids in U.S. Pat. Nos. 5,539,082, 5,527,675, 5,623,049, 5,714,331, 5,736,336, 5,773,571, 5,786,461, 5,837,459, 5,891,625, 5,972,610, 5,986,053, 6,107,470 and 6,357,163. In the most preferred embodiment, a PNA subunit consists of a naturally occurring or non-naturally occurring nucleobase attached to the aza nitrogen of the N-[2-(aminoethyl)] glycine backbone through a methylene carbonyl linkage.
g. As used herein, the term “locked nucleic acid” or “LNA” means any oligomer, linked polymer or chimeric oligomer, comprising one or more LNA subunits (residues), including any of the polymers referred to or claimed as locked nucleic acids, and nucleic acid analogs in U.S. Pat. Nos. 6,639,059, 6,670,461, United States Patent Application numbers US2003077609, US2003224377, US2003082807 and World Patent Office Document number WO03095467. In the most preferred embodiment, a LNA subunit consists of a naturally occurring or non-naturally occurring ribonucleoside in which the 4′ oxygen is joined to the 2′ carbon through a methylene linkage.
h. As used herein, the terms “label” and “detectable moiety” are interchangeable and shall refer to moieties that can be attached to a probe to thereby render the probe detectable by an instrument or method.
i. As used herein the term “established phenotypes” is used to describe features of an organism which have been observed or measured and published by the scientific or medical community, and are generally understood to be a characteristic of the organism.
j. As used herein the term “susceptibility-type”, or “drug susceptibility-type”, is used to indicate the level of response that an infectious organism of a particular type has demonstrated in the past to exposure to a drug. Such levels of response range from no response to a very strong response, and include, but are not limited to “susceptible”, “susceptible/intermediate”, “intermediate”, “susceptible/susceptible, dose-dependant”, “susceptible, dose-dependant”, “susceptible, dose-dependant/resistant”, “susceptible-dose/delivery dependent”, “intermediately resistant”, and “resistant”. Synonymic descriptions of the listed levels of response are also included.
[0078] Some examples of drugs that may be indicated in this context are fluconazole, caspofungin, voriconazole, amphotericin B, or other anti-fungal drug or drugs. For example, an infectious organism which is resistant to the normal therapeutic dose of fluconazole belongs in the “resistant” susceptibility-type for fluconazole.
[0079] A collaborative effort between The US Food and Drug Administration and the Pharmaceutical Research Manufacturers Association published a Target Product Information document in the year 2000 to provide a template for the drug development process. In this document, guidelines are offered for interpretation of the code of regulations governing the labeling of pharmaceutical products (21 CFR 201). Guidelines for 21 CFR 201.56, section b “Clinical Pharmacology” give the following definitions. We incorporate these published definitions only as examples.
[0080] A report of “susceptible” indicates that the pathogen is likely to be inhibited if the antimicrobial compound in blood reaches the concentrations usually achievable. A report of “intermediate” indicates that the result should be considered equivocal, and, if the microorganism is not fully susceptible to alternative, clinically feasible drugs, the test should be repeated. This category implies possible clinical applicability in body sites where the drug is physiologically concentrated or in situations where high dosage of drug can be used. This category also provides a buffer zone which prevents small uncontrolled technical factors from causing major discrepancies in interpretation. A report of “resistant” indicates that the pathogen is not likely to be inhibited if the antimicrobial compound in the blood reaches the concentrations usually achievable; other therapy should be selected.
[0081] Drug susceptibility-type is assessed based on an expected result, which is derived from historical, empirical or experimental evidence.
[0000] k. As use herein, the term “anti-fungal drug” is used to include any compound or mixture of compounds used in a pharmaceutical way to effect the growth, viability, or propagation of a fungus, or suspected fungus. Examples of such compounds include but are not limited to fluconazole, caspofungin, caspofungin acetate, voriconazole, amphotericin B, amphotericin B liposomal, itraconazole, flucytosine, candins, posaconazole, ravuconazole, polyenes, azoles, allylamines, and derivatives, or combinations thereof.
I. As used herein, the term “coincidental fluorescence” is used to describe the perception of a color which is generated by the simultaneous detection of light emissions of two or more labels located near enough in space so as to be irresolvable. The detection of coincidental fluorescence can be either by eye or a photon-sensitive device.
2. DESCRIPTION
I. General:
PNA Synthesis:
[0082] Methods for the chemical assembly of PNAs are well known (see: U.S. Pat. Nos. 5,539,082, 5,527,675, 5,623,049, 5,714,331, 5,736,336, 5,773,571, 5,786,461, 5,837, 459, 5,891,625, 5,972,610, 5,986,053 and 6,107,470).
PNA Labeling:
[0083] Preferred non-limiting methods for labeling PNAs are described in U.S. Pat. Nos. 6,110,676, 6,361,942, 6, 355,421, the examples section of this specification or are otherwise well known in the art of PNA synthesis and peptide synthesis.
LNA Synthesis:
[0084] Methods for the chemical assembly of LNAs are well known (see: Patent Nos. US2003077609, US2003224377, US2003082807 and World Patent Office Document number WO03095467)
LNA Labeling:
[0085] Preferred non-limiting methods for labeling LNAs are described in U.S. Pat. Nos. 6,639,059, 6,670,461, United States Patent Application numbers US2003077609, US2003224377, US2003082807 and World Patent Office Document number WO03095467 or are otherwise well known in the art of LNA synthesis.
Labels:
[0086] Non-limiting examples of detectable moieties (labels) suitable for labeling PNA probes used in the practice of this invention would include a dextran conjugate, a branched nucleic acid detection system, a chromophore, a fluorophore, a spin label, a radioisotope, an enzyme, a hapten, an acridinium ester and a chemiluminescent compound.
[0087] Other suitable labeling reagents and preferred methods of attachment would be recognized by those of ordinary skill in the art of PNA, LNA, peptide or nucleic acid synthesis.
[0088] Preferred haptens include 5 (6)-carboxyfluorescein, 2,4-dinitrophenyl, digoxigenin, and biotin.
[0089] Preferred fluorochromes (fluorophores) include 5 (6)-carboxyfluorescein (Flu), 6-((7-amino-4-methylcoumarin-3-acetyl) amino) hexanoic acid (Cou), 5 (and 6)-carboxy-X— rhodamine (Rox), Cyanine 2 (Cy2) Dye, Cyanine 3 (Cy3) Dye, Cyanine 3.5 (Cy3.5) Dye, Cyanine 5 (Cy5) Dye, Cyanine 5.5 (Cy5.5) Dye Cyanine 7 (Cy7) Dye, Cyanine 9 (Cy9) Dye (Cyanine dyes 2, 3, 3.5, 5 and 5.5 are available as NHS esters from Amersham, Arlington Heights, Ill.), JOE, Tamara or the Alexa dye series (Molecular Probes, Eugene, Oreg.).
[0090] Preferred enzymes include polymerases (e.g. Taq polymerase, Klenow PNA polymerase, T7 DNA polymerase, Sequenase, DNA polymerase 1 and phi29 polymerase), alkaline phosphatase (AP), horseradish peroxidase (HRP) and most preferably, soy bean peroxidase (SBP).
Unlabeled Probes:
[0091] The probes that are used for the practice of this invention need not be labeled with a detectable moiety to be operable within the methods of this invention, for example when attached to a solid support
Self-Indicating Probes:
[0092] Beacon probes are examples of self-indicating probes which include a donor moiety and a acceptor moiety. The donor and acceptor moieties operate such that the acceptor moieties accept energy transferred from the donor moieties or otherwise quench signal from the donor moiety. Though the previously listed fluorophores (with suitable spectral properties) might also operate as energy transfer acceptors, preferably, the acceptor moiety is a quencher moiety. Preferably, the quencher moiety is a non-fluorescent aromatic or heteroaromatic moiety. The preferred quencher moiety is 4-((−4-(dimethylamino) phenyl) azo) benzoic acid (dabcyl). In a preferred embodiment, the self-indicating Beacon probe is a PNA Linear Beacon as more fully described in U.S. Pat. No. 6,485,901.
[0093] In another embodiment, the self-indicating probes of this invention are of the type described in WIPO patent application WO97/45539. These self-indicating probes differ as compared with Beacon probes primarily in that the reporter must interact with the nucleic acid to produce signal.
Spacer/Linker Moieties:
[0094] Generally, spacers are used to minimize the adverse effects that bulky labeling reagents might have on hybridization properties of probes. Preferred spacer/linker moieties for the nucleobase polymers of this invention consist of one or more aminoalkyl carboxylic acids (e.g. aminocaproic acid), the side chain of an amino acid (e.g. the side chain of lysine or ornithine), natural amino acids (e.g. glycine), aminooxyalkylacids (e.g. 8-amino-3,6-dioxaoctanoic acid), alkyl diacids (e.g. succinic acid), alkyloxy diacids (e.g. diglycolic acid) or alkyldiamines (e.g. 1,8-diamino-3,6-dioxaoctane).
Hybridization Conditions/Stringency:
[0095] Those of ordinary skill in the art of nucleic acid hybridization will recognize that factors commonly used to impose or control stringency of hybridization include formamide concentration (or other chemical denaturant reagent), salt concentration (i.e., ionic strength), hybridization temperature, detergent concentration, pH and the presence or absence of chaotropes. Optimal stringency for a probe/target sequence combination is often found by the well known technique of fixing several of the aforementioned stringency factors and then determining the effect of varying a single stringency factor. The same stringency factors can be modulated to thereby control the stringency of hybridization of a PNA to a nucleic acid, except that the hybridization of a PNA is fairly independent of ionic strength. Optimal stringency for an assay may be experimentally determined by examination of each stringency factor until the desired degree of discrimination is achieved.
Suitable Hybridization Conditions:
[0096] Generally, the more closely related the background causing nucleic acid sequences are to the target sequence, the more carefully stringency must be controlled. Blocking probes may also be used as a means to improve discrimination beyond the limits possible by optimization of stringency factors. Suitable hybridization conditions will thus comprise conditions under which the desired degree of discrimination is achieved such that an assay generates an accurate (within the tolerance desired for the assay) and reproducible result.
[0097] Aided by no more than routine experimentation and the disclosure provided herein, those of skill in the art will easily be able to determine suitable hybridization conditions for performing assays utilizing the methods and compositions described herein. Suitable in-situ hybridization or PCR conditions comprise conditions suitable for performing an in-situ hybridization or PCR procedure. Thus, suitable in-situ hybridization or PCR conditions will become apparent to those of skill in the art using the disclosure provided herein, with or without additional routine experimentation.
Blocking Probes:
[0098] Blocking probes are nucleic acid or non-nucleic acid probes that can be used to suppress the binding of the probing nucleobase sequence of the probing polymer to a non-target sequence. Preferred blocking probes are PNA probes (see: U.S. Pat. No. 6,110,676). It is believed that blocking probes operate by hybridization to the non-target sequence to thereby form a more thermodynamically stable complex than is formed by hybridization between the probing nucleobase sequence and the non-target sequence. Formation of the more stable and preferred complex blocks formation of the less stable non-preferred complex between the probing nucleobase sequence and the non-target sequence. Thus, blocking probes can be used with the methods, kits and compositions of this invention to suppress the binding of the probes to a non-target sequence that might be present and interfere with the performance of the assay. Blocking probes are particularly advantageous for discrimination to the phylogenetically closest related species.
Probe Sets:
[0099] Probe sets of this invention comprise one or more probes. In one embodiment, one or more of the PNA probes of the set can be blocking probes. Probes sets may include any group of one or more of the probes of this invention, whether labeled or non-labeled, and may also include probes not specifically described here, but which include at least one of the probes of this invention. Preferred probe of the invention are listed in Table 1.
[0000]
TABLE 1
Sequence ID
Name
Nucleobase sequence
Seq. Id. No. 1
Probe A
AGA-GAG-CAG-CAT-GCA
Seq. Id. No. 2
Probe B
GCA-AGG-GGC-GCA-AA
Seq. Id. No. 3
Probe C
AGG-CAA-GGG-GCG-CA
Seq. Id. No. 4
Probe D
AGA-GGC-AAG-GGG-CG
Seq. Id. No. 5
Probe E
AGA-GGC-AAG-GGG-C
Seq. Id. No. 6
Probe F
GCA-GCG-GTG-CGC-AA
Seq. Id. No. 7
Probe G
AGA-GGC-AGC-GGT-GCG
Seq. Id. No. 8
Probe H
GAG-TAA-CAT-ACA-AAA-T
Seq. Id. No. 9
Probe I
GAG-AGT-AAC-ATA-CAA
Seq. Id. No. 10
Probe J
GAG-AGA-GTA-ACA-TAC
Seq. Id. No. 11
Probe K
AGA-GAG-TAA-CAT-ACA
Seq. Id. No. 12
Probe L
CGA-GAG-AGT-AAC-ATA
Seq. Id. No. 13
Probe M
GAG-AGA-GTA-ACA-TAC-A
Seq. Id. No. 14
Probe N
AAG-AAG-TAA-CAT-ACA
Seq. Id. No. 15
Probe O
CCC-ACG-AGA-GGC-A
Seq. Id. No. 16
Probe P
ACG-AGA-GGC-AAG-G
Seq. Id. No. 17
Probe Q
ACA-GTC-CCA-AAG-TGG-T
Seq. Id. No. 18
Probe R
AGA-ACT-GAC-ACC-CTC-G
Seq. Id. No. 19
Probe S
CCT-TCC-ACA-CAG-ACT-C
Seq. Id. No. 20
Probe T
TAG-GTC-TGG-GAC-ATC
Seq. Id. No. 21
Probe U
CCA-ACG-CAA-TTC-TCC-T
Seq. Id. No. 22
Probe V
CTA-GGT-TTT-TTC-CGG-C
Seq. Id. No. 23
Probe W
GCA-TCA-ACG-CAG-GCT
Seq. Id. No. 24
Probe X
GAC-TCA-GAC-CAC-GA
[0100] Table 1 displays preferred probes of the invention. With reference to Table 1, the column on the left displays the sequence identification number, the center column displays the probe name, and the column on the right displays the nucleobase sequence of the probe.
[0101] The PNA probes of this invention may comprise only a probing nucleobase sequence (as previously described herein) or may comprise additional moieties. Non-limiting examples of additional moieties include detectable moieties (labels), linkers, spacers, natural or non-natural amino acids, or other subunits of PNA, DNA or RNA. Additional moieties may be functional or non-functional in an assay. Generally however, additional moieties will be selected to be functional within the design of the assay in which the PNA probe is to be used. The preferred PNA probes of this invention are labeled with one or more detectable moieties selected from the group consisting of fluorophores, enzymes and haptens.
[0102] In preferred embodiments, the probes of this invention are used in in situ hybridization (ISH) and fluorescence in situ hybridization (FISH) assays. Excess probe used in an ISH or FISH assay typically must be removed so that the detectable moiety of the specifically bound probe can be detected above the background signal that results from still present but unhybridized probe. Generally, the excess probe is washed away after the sample has been incubated with probe for a period of time. However, the use of self-indicating probes is a preferred embodiment of this invention, since there is no requirement that excess self-indicating probe be completely removed (washed away) from the sample since it generates little or no detectable background. In addition to ISH or FISH assays, self-indicating probes comprising the selected probing nucleobase sequence described herein are particularly useful in all kinds of homogeneous assays such as in real-time PCR or useful with self-indicating devices (e.g. lateral flow assay) or self-indicating arrays.
EXAMPLES
[0103] This invention is now illustrated by the following examples, which are not intended to be limiting in any way.
Example 1
[0104]
[0000]
PNA probe sequence
Fluconazole Sensitive Probe Set
Probe A-Fam
Fam-OO-AGAGAGCAGCATGCA-NH 2
(Seq. Id. No. 1)
Fluconazole Resistant Probe Set
Probe B-Tam
Tam-OO-GCAAGGGGCGCAAA-NH 2
(Seq. Id. No. 2)
Probe F-Tam
Tam-OO-GCAGCGGTGCGCAA-NH 2
(Seq. Id. No. 6)
(Note: Conventional nomenclature used to illus-
trate the termini of the PNA probe; O = 8-amino-
3,6-dioxaoctanoic acid; Fam = 5(6)-carboxyfluores-
cein, Tam = 5(6)-carboxytetramethyrhodamine.)
Strains
[0105] Overnight cultures of reference strains were prepared representing various Candida species including C. albicans, C. glabrata, C. guillermondii, C. kefyr, C. krusei, C. lusitaniae, C. parapsilosis, C. tropicalis , as well as baker's yeast, S. cerevisiae , and Staphylococcus epidermidis , a frequent blood culture contaminant.
Preparation of Smears
[0106] For each strain, smears were prepared on a 8-mm diameter well of a Teflon-coated microscope slide (AdvanDx, Woburn, Mass.) by mixing one drop of culture with one drop of phosphate-buffered saline containing 1% (v/v) Triton X-100. The slide was then placed on a, 55° C. slide warmer for 20 min at which point the smears were dry. Subsequently, the smears were disinfected by immersion into 96% (v/v) ethanol for 5-10 minutes and air-dried.
[0000] Fluorescence in situ hybridization (FISH).
[0107] Smears were covered with a drop of hybridization solution containing 10% (w/v) dextran sulfate, 10 mM NaCl, 30% (v/v) formamide, 0.1% (w/v) sodium pyrophosphate, 0.2% (w/v) polyvinylpyrrolidone, 0.2% (w/v) ficoll, 5 mM Na 2 EDTA, 1% (v/v) Triton X-100, 50 mM Tris/HCl pH 7.5 and 250 nM Probe A-Fam, 25 nM Probe B-Tam and 25 nM Probe F-Tam. Coverslips were placed on the smears to ensure even coverage with hybridization solution, and the slides were subsequently placed on a slide warmer (Slidemoat, Boekel, Germany) and incubated for 90 min at 55° C. Following hybridization, the coverslips were removed by submerging the slides into approximately 20 ml/slide pre-warmed 25 mM Tris, pH 10, 137 mM NaCl, 3 mM KCl in a water bath at 55° C. and washed for 30 min. Each smear was finally mounted using one drop of Mounting medium (AdvanDx, Woburn, Mass.) and covered with a coverslip. Microscopic examination was conducted using a fluorescence microscope equipped with a FITC/Texas Red dual band filter set. Fluconazole sensitive fungi were identified by green fluorescent buds and Fluconazole resistant fungi were identified by red fluorescent buds. Results are recorded in Table 2.
[0000]
TABLE 2
Species Id.
Result
Incidence 1
C. albicans
Positive/Green (Fluconazole Sensitive)
54.5%
C. glabrata
Positive/Red (/Fluconazole Resistant)
12.3%
C. krusei
Positive/Red (/Fluconazole Resistant)
1.5%
C. parapsilosis
Negative
17.8%
C. tropicalis
Negative
9.5%
Other Candida spp. 2
Negative
4.5%
S. cerevisiae
Negative
N/A
S. epidermidis
Negative
N/A
1 Average incidence of Candida species for the United States, Europe, Canada, and Latin America. M. A. Pfaller et al. International Surveillance of Bloodstream Infections Due to Candida Species: Frequency of Occurrence and In Vitro Susceptibilities to Fluconazole, Ravuconazole, and Voriconazole of Isolates Collected from 1997 through 1999 in the SENTRY Antimicrobial Surveillance Program. JCM. Vol. 39, No. 9. p. 3254-3259. September 2001.
2 Candida spp. was represented by C. guillermondii , C. kefyr , and C. lusitaniae which all have low prevalence in the clinical setting.
N/A: Not applicable (Non- Candida species used as controls)
[0108] With reference to Table 2, the table displays species identification in the left column, PNA FISH results in the center column, and clinical incidence of the species in the right column. With reference to Table 2, three of the species tested gave a positive result, the C. albicans sample contained green fluorescent buds, and the C. glabrata and C. krusei samples contained red fluorescent buds. The C. parapsilosis slide had cells which displayed a weak yellow fluorescence which was scored negative. The positive results demonstrate that the probe mixture tested produces green signals, indicating fluconazole sensitivity, with C. albicans and red signals, indicating fluconazole resistance, with either C. glabrata or C. krusei . Though only three species are detected with this assay, the species detected represent nearly 70% of the Candida seen clinically in the United States, Europe, Canada, and Latin America.
[0109] This probe mixture and technique would be useful for selection of therapy since a green signal indicates a species ( C. albicans ) which is generally regarded as fluconazole sensitive, whereas a red signal indicates species ( C. glabrata or C. krusei ) which are often or likely fluconazole resistant.
Example 2
[0110] Example 2 was performed exactly as Example 1, except that a second probe was added to the Fluconazole Sensitive probe set.
[0000]
PNA probe sequence
Fluconazole Sensitive Probe Set
Probe A-Fam
Fam-OO-AGAGAGCAGCATGCA-NH 2
(Seq. Id. No. 1)
Probe I-Fam
Fam-OO-GAGAGTAACATACAA-NH 2
(Seq. Id. No. 9)
Fluconazole Resistant Probe Set
Probe B-Tam
Tam-OO-GCAAGGGGCGCAAA-NH 2
(Seq. Id. No. 2)
Probe F-Tam
Tam-OO-GCAGCGGTGCGCAA-NH 2
(Seq. Id. No. 6)
(Note: Conventional nomenclature used to illus-
trate the termini of the PNA probe; O = 8-amino-
3,6-dioxaoctanoic acid; Fam = 5(6)-carboxyfluores-
cein, Tam = 5(6)-carboxytetramethyrhodamine.)
[0111] Probe-I-Fam was added in the hybridization solution at 500 nM, along with the other probes as described in Example 1. Microscopic examination was conducted using a fluorescence microscope equipped with a FITC/Texas Red dual band filter set. Fluconazole Sensitive fungi were identified by green fluorescent buds and Fluconazole Resistant fungi were identified by red fluorescent buds. Results are recorded in Table 3.
[0000]
TABLE 3
Species Id.
Result
Incidence 1
C. albicans
Positive/Green (Fluconazole Sensitive)
54.5%
C. glabrata
Positive/Red (/Fluconazole Resistant)
12.3%
C. krusei
Positive/Red (/Fluconazole Resistant)
1.5%
C. parapsilosis
Positive/Green (Fluconazole Sensitive)
17.8%
C. tropicalis
Negative
9.5%
Other Candida spp. 2
Negative
4.5%
S. cerevisiae
Negative
N/A
S. epidermidis
Negative
N/A
1 Average incidence of Candida species for the United States, Europe, Canada, and Latin America. M. A. Pfaller et al. International Surveillance of Bloodstream Infections Due to Candida Species: Frequency of Occurrence and In Vitro Susceptibilities to Fluconazole, Ravuconazole, and Voriconazole of Isolates Collected from 1997 through 1999 in the SENTRY Antimicrobial Surveillance Program. JCM. Vol. 39, No. 9. p. 3254-3259. September 2001.
2 Candida spp. was represented by C. guillermondii , C. kefyr , and C. lusitaniae which all have low prevalence in the clinical setting.
[0112] With reference to Table 3, the table displays species identification in the left column, PNA FISH results in the center column, and clinical incidence of the species in the right column. With reference to Table 3, only four of the species tested gave a positive result. The C. albicans and C. parapsilosis samples contained green fluorescent buds, and the C. glabrata and C. krusei samples contained red fluorescent buds. The positive results demonstrate that the probe mixture tested produces signals of green, for Fluconazole Sensitive, with C. albicans and C. parapsilosis , and red, for Fluconazole Resistant, with either C. glabrata or C. krusei . Though only four species are detected with this assay, those species represent over 86% of the blood stream infections caused by Candida species in the United States, Europe, Canada, and Latin America.
[0113] This probe mixture and technique would be useful for selection of therapy since a green signal indicates species ( C. albicans and C. parapsilosis ) which are generally regarded as fluconazole sensitive, whereas a red signal indicates species ( C. glabrata or C. krusei ) which are often or likely fluconazole resistant. Neither of the fluorescent signal types (red or green) in this assay positively identifies organisms to a species level; they indicate fluconazole susceptibility-types. C. tropicalis is an example of the “susceptible/dose-dependant” susceptibility-type for fluconazole. Though not detected in this example, a prospective probe set of a third color specific to the fluconazole susceptible/dose-dependant susceptibility-type can be envisioned, for example, a probe set containing Probe-N. Addition of a prospective third probe set for detection of this susceptibility-type, including C. tropicalis , could account for greater than 96% of the blood stream infections caused by Candida species in the United States, Europe, Canada, and Latin America.
Example 3
[0114] Example 3 was performed exactly as Example 1, but with a different probe set.
[0000]
PNA probe sequence
Fluconazole Intermediate Probe Set
Probe N-Tam
Tam-OO-AAGAAGTAACATACA-NH 2
(Seq. Id. No. 14)
(Note: Conventional nomenclature used to
illustrate the termini of the PNA probe;
O = 8-amino-3,6-dioxaoctanoic acid; Tam =
5(6)-carboxytetramethyrhodamine.)
[0115] Probe N-Tam was added in the hybridization solution at 250 nM. Microscopic examination was conducted using a fluorescence microscope equipped with a FITC/Texas Red dual band filter set. Fluconazole Intermediate fungi were identified by red fluorescent buds. Results are recorded in Table 4.
[0000]
TABLE 4
Species Id.
Result
Incidence 1
C. albicans
Negative
54.5%
C. glabrata
Negative
12.3%
C. krusei
Negative
1.5%
C. parapsilosis
Negative
17.8%
C. tropicalis
Positive/Red (Fluconazole Intermediate)
9.5%
Other Candida spp. 2
Negative
4.5%
S. epidermidis
Negative
N/A
1 Average incidence of Candida species for the United States, Europe, Canada, and Latin America. M. A. Pfaller et al. International Surveillance of Bloodstream Infections Due to Candida Species: Frequency of Occurrence and In Vitro Susceptibilities to Fluconazole, Ravuconazole, and Voriconazole of Isolates Collected from 1997 through 1999 in the SENTRY Antimicrobial Surveillance Program. JCM. Vol. 39, No. 9. p. 3254-3259. September 2001.
2 Candida spp. was represented by C. guilliermondii , C. kefyr , and C. lusitaniae which all have low prevalence in the clinical setting.
N/A: Not applicable (Non- Candida species used as controls)
[0116] With reference to Table 4, the table displays species identification in the left column, PNA FISH results in the center column, and clinical incidence of the species in the right column. With reference to Table 4, only one of the species tested gave a positive result. The C. tropicalis sample contained red fluorescent buds. The positive results demonstrate that the probe mixture tested produces red signal, for Fluconazole Intermediate, only with C. tropicalis cells.
[0117] This probe mixture and technique would be useful for selection of therapy since a red signal indicates a species ( C. tropicalis ) which is fluconazole intermediate. Though C. tropicalis is isolated from patients in only ˜10% of BSI caused by fungi, there is clinical value in the ability to rapidly identify the infection as one which is likely sensitive to high doses of fluconazole.
Example 4
[0118] Example 4 was performed exactly as Example 1, but with a different probe set.
[0000]
PNA probe sequence
Caspofungin Susceptible/Dose Dependant Probe Set
Probe S-Fam
Fam-OO-CCTTCCACACAGACTC-NH 2
(Seq. Id. No. 19)
Probe T-Fam
Fam-OO-TAGGTCTGGGACATC-NH 2
(Seq. Id. No. 20)
(Note: Conventional nomenclature used to illus-
trate the termini of the PNA probe; O = 8-amino-
3,6-dioxaoctanoic acid; Fam = 5(6)-carboxyfluores-
cein).
[0119] Probes S-Flu and T-Flu were added in the hybridization solution at 100 nM each. Microscopic examination was conducted using a fluorescence microscope equipped with a FITC/Texas Red dual band filter set. Caspofungin Susceptible/Dose Dependant (S/DD) fungi were identified by green fluorescent buds. Results are recorded in Table 5.
[0000]
TABLE 5
Species Id.
Result
Incidence 1
C. albicans
Negative
54.5%
C. glabrata
Negative
12.3%
C. krusei
Positive/Green (Caspofungin S/DD 3 )
1.5%
C. parapsilosis
Positive/Green (Caspofungin S/DD 3 )
17.8%
C. tropicalis
Negative
9.5%
Other Candida spp. 2
Negative
4.5%
S. epidermidis
Negative
N/A
1 Average incidence of Candida species for the United States, Europe, Canada, and Latin America. M. A. Pfaller et al. International Surveillance of Bloodstream Infections Due to Candida Species: Frequency of Occurrence and In Vitro Susceptibilities to Fluconazole, Ravuconazole, and Voriconazole of Isolates Collected from 1997 through 1999 in the SENTRY Antimicrobial Surveillance Program. JCM. Vol. 39, No. 9. p. 3254-3259. September 2001.
2 Candida spp. was represented by C. guilliermondii , C. kefyr , and C. lusitaniae which all have low prevalence in the clinical setting.
N/A: Not applicable (Non- Candida species used as controls)
3 In Pfaller, et al. (J Clin Microbiol. 2006 Mar; 44(3): 760-3) species were grouped as “most” susceptible to caspofungin that had MIC 90 values between 0.03 and 0.06 ug/ml, and “significantly less” susceptible to caspofungin that had MIC 90 values ≧0.5 ug/ml. Here we interpret “significantly less” susceptibility as susceptible/dose dependant.
[0120] With reference to Table 5, the table displays species identification in the left column, PNA FISH results in the center column, and clinical incidence of the species in the right column. With reference to Table 5, only two of the species tested gave a positive result. The C. parapsilosis and C. krusei samples contained green fluorescent buds. The positive results demonstrate that the probe mixture tested produces green signal, for caspofungin Susceptible/Dose Dependant, only with C. parapsilosis and C. krusei cells.
[0121] This probe mixture and technique would be useful for selection of therapy since a green signal indicates two species ( C. parapsilosis and C. krusei ) which require increased dosage of caspofungin. Though C. parapsilosis and C. krusei are isolated from patients in only ˜19.3% (17.8%+1.5%) of BSI caused by fungi, there is clinical value in the ability to rapidly identify the infection as one which is likely to require higher doses of caspofungin.
Example 5
[0122] Example 5 is performed exactly as Example 4, but with an expanded probe set.
[0000]
PNA probe sequence
Expanded Caspofungin Susceptible/Dose Dependant
Probe Set
Probe S-Fam
Fam-OO-CCTTCCACACAGAGTC-NH 2
(Seq. Id. No. 19)
Probe T-Fam
Fam-OO-TAGGTCTGGGACATC-NH 2
(Seq. Id. No. 20)
Probe W-Fam
Fam-OO-GCATCAACGCAGGCT-NH 2
(Seq. Id. No. 23)
Probe X-Fam
Fam-OO-GACTCAGACCACGA-NH 2
(Seq. Id. No. 24)
(Note: Conventional nomenclature used to illus-
trate the termini of the PNA probe; O = 8-amino-
3,6-dioxaoctanoic acids; Fam = 5(6)-carboxy-
fluorescein)
[0123] All probes are added in the hybridization solution at 100 nM each. Probe W is designed to specifically detect Candida guilliermondii (anamorph of Pichia guilliermondii), and Probe X is designed to specifically detect Candida lusitaniae (also called Clavispora lusitaniae ). Though both of these species are relatively rare in clinical samples, they also require increased dosage of caspofungin (MIC 90 values 20.5 ug/ml). Use of the Expanded Caspofungin Susceptible/Dose Dependant Probe Set as described here would allow detection of four species which typically require increased caspofungin dosage with a single probe set. This probe mixture and technique would be useful for selection of therapy since a green signal should indicate any of four species ( C. parapsilosis, C. krusei, C. guilliermondii , and C. lusitaniae ) which require increased dosage of caspofungin.
EQUIVALENTS
[0124] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Those skilled in the art will be able to ascertain, using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed in the scope of the claims.
[0125] The disclosures of all references mentioned herein are incorporated by reference in their entirety for all purposes. | Provided herein are methods, kits and compositions to classify fungi. Methods are provided for classification of fungi according to established phenotypes, for example, antimicrobial susceptibility profiles. More specifically, the invention provides methods for the use of PNA probes in diagnostic applications, which will aid in the direction of appropriate therapy against fungi. | 2 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a plasma processing apparatus and method.
[0002] There have been known the ECR CVD for depositing thin films on a substrate. In this deposition method, a substrate may be placed in a vacuum chamber apart from the resonating space and a thin film such as an amorphous film is formed on the substrate by virtue of a divergent magnetic field induced in the vacuum chamber.
[0003] The ECR CVD can be performed in combination with other known deposition methods such as heated filament CVD, chemical transportation method, plasma CVD making use of a high frequency power at 13.56 MHz, microwave-assisted CVD. In accordance with this method, a reactive gas is confined and excited by supplying a microwave under a magnetic field in accordance with the electron cycrotron resonance. The excited reactive gas is drifted to a substrate which is located at a position remote from the resonating space. At the remote position, the excited gas is deposited on the substrate or attacks to the substrate to effected anisotropic etching. The pressure in the chamber during process has been maintained at a relatively low pressure, e.g. of the order of 10 −4 Torr. Because of this, it is very difficult to form a highly crystallized film such as a diamond film and to choose the process condition with a broad flexibility
SUMMARY OF THE INVENTION
[0004] It is therefore an object of the invention to provide a plasma processing apparatus and method in which a highly energized plasma gas is confined about the center position at which a substrate to be processed is disposed.
[0005] It is therefore an object of the invention to provide a Plasma Processing apparatus and method in which highly crystallized films can be deposited under flexible condition.
[0006] According to one aspect of the invention, an auxiliary magnet is provided in addition to a main magnet which produces a magnetic field parallel with the microwave propagating direction allowing the plasma gas to resonating with the microwave. The auxiliary magnet is located along the wall of the reaction chamber for the purpose of enhancing the strength of magnetic field at the periphery of the reaction chamber. Since charged particles are subjected to a drifting force proportional to the minus of the gradient of the absolute strength of the magnetic field, plasma gas is confined in the center by virtue of the additional magnetic field induced by the auxiliary magnet.
[0007] The resonance taking place in the reaction chamber includes the electron cycrotron resonance, the whistler mode resonace, or other type resonance which is caused by supplying a microwave under a magnetic field such as the mixed cyclotron resonance. By virtue of such a resonance, a highly energized plasma gas having its high density is obtained. In case of carbon deposition, a highly energized plasma produces a large amount of excited carbon atoms and the high reproducibility is achieved.
[0008] In accordance with the most broad concept, it is noted that the present invention is also effective in case of thermal CVD, photo-assisted CVD or so forth in which no magnetic field is utilized. The reactive gas is confined in the vicinity where deposition is desired in the other deposition systems.
BRIEF DESCRIPTION OF THE INVENTION
[0009] FIG. 1 is a schematic diagram showing a plasma processing apparatus for in accordance with the present invention.
[0010] FIGS. 2 (A) and 2 (B) are a cross sectional view and a side elevation view showing Ioffe bars for use in accordance with the present invention.
[0011] FIG. 3 is a graphical diagram showing the strength of magnetic field in a reaction chamber in accordance with the present invention.
[0012] FIG. 4 is a graphical diagram showing the strength of magnetic field induced only by helmholtz coils in a reaction chamber.
[0013] FIG. 5 is a schematic diagram showing another plasma processing apparatus for in accordance with the present invention.
[0014] FIGS. 6 (A) and 6 (B) are a cross sectional view and a side elevation view showing Ioffe bars another type for use in accordance with the present invention.
[0015] FIG. 7 is a cross sectional view Ioffe bars a further type for use in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring to FIG. 1 , a microwave assisted plasma-CVD apparatus in accordance with the present invention is illustrated. In the figure, the apparatus comprises a reaction vacuum chamber 1 defining a resonating space therein, a loading chamber 8 connected with the vacuum chamber 1 , a substrate holder 3 capable of carrying a substrate 2 to be treated, helmholts coils 5 around the reaction chamber 1 , an auxiliary electro-magneto 6 located inside of the helmholtz coils around the reaction chamber, a mocrowave generator 4 connected to the reaction chamber 1 through a waveguide 7 , an evacuating system 9 , and gas feeding systems 10 and 11 . The holder 3 is made of a highly thermal conductive material, such as alminium nitride, which less disturb the microwave transmission from a microwave introduction window 12 .
[0017] The auxiliary magnet 6 consists of two electro-magnetos providing Ioffe bars which extend in the direction of the microwave propagation (FIGS. 2 (A) and 2 (B)). In FIG. 2 (A), the end marks of arrow denote the current passing direction of each bar. The object of the provision of the Ioffe bars is to strengthen the strength of magnetic field near the cylindrical wall of the reaction chamber 1 . FIG. 3 is a graphical diagram showing the surfaces on each of which the strength of the magnetic field is constant. The abscissa is the distance (r) from the axis of the cylindrical reaction chamber and the ordinate is the axial distance from the center plane of the helmholtz coils 5 . The figure given to each surface denotes the strength (Gauss) of the magnetic field on that surface. As shown in the diagram, the strength of the magnetic field takes a larger value at a nearer position to the cylindrical wall, so that the drifted force excerted on the plasma is alwalys centrifugal. The magnetic field is weakest on the axis of the cylindrical reaction chamber. FIG. 4 is a graphical diagram showing the surfaces on which the magnetic field is constant when the auxiliary magnet is not used.
[0018] Next, the deposition process with this apparatus will be described. A substrate 1 is mounted on the holder 3 and disposed at an appropriate position in the reaction chamber 1 where the microwave and the magnetic field sutisfy the ECR contition. After evacuating the reaction chamber 1 , the substrate 1 is heated to 500° C. and hydrogen gas is leaked into the chamber 1 at 10 SCCM through the gas feeding system 11 . The introduced hydrogen gas is energized into a plasma gas by virtue of a 2.45 microwave emitted from the generator 4 and a magnetic field induced by both the helmholtz coils 5 and the auxiliary magnet 6 . The strength of the portion of the magnetic field that is induced by the coils 5 is about 2 K Gauss at the resonating space (a partion of the reaction chamber). The pressure in the resonating space is maintained at 0.1 Pascal. The surface of the substrate is cleaned by virtue of the plasma.
[0019] Then, the introduction of hydrogen is halted and a carbon compound gas such as C 2 H 2 or CH 4 is introduced into the reaction chamber 1 and excited in the same way as hydrogen as explained above. By this process, a diamond or i-carbon film is deposited on the substrate which has been heated to about 500° C. According to experimental, diamond films were deposited particularly when the substrate temperatures were not higher than 650° C.
[0020] In accordance with the electron beam defraction analysis, a halo pattern was observed at a relative low temperature together with a spot pattern which is peculier to amorphous structures. Such an image indicates the presence of i-carbon. The halo pattern gradually distincted as the substrate temperature was elevated. When the substrate temperature was elevated higher than 650° C., the deposited film became composed mainly of diamond. The diamond film was confirmed by obtaining its Raman spectrum. The spectrum includes a moderate peak near 1500 cm −1 and a sharp peak near 1333 cm −1 .
[0021] For reference, the same process was repeated without inducing a magnetic field in the reaction chamber. The film thus deposited was made of graphite. Even with the presence of magnetic field, no i-carbon film could not be deposited on a substrate at a temperature lower than 150° C.
[0022] The above process can be applied to a method of depositing polycrystalline silicon carbide films by making use of silicon carbide gaseous compounds as the reactive gas, to a method of depositing alminium nitride films by making use of a reactive gas consisting of an aluminium compound gas and ammonia, and a method of depositing films having a high melting point, e.g. films made of tungsten, titanium and molybdenum or their silicon compounds. In the same way, the present invention can be applied for the deposition of BN, CN, TiN and BP.
[0023] FIG. 5 a schematic veiw showing another type of plasma processing apparatus. This apparatus is largely same as the above explained apparatus besides the relationship between the the helmholtz coils 5 and the connection position of the waveguide 7 to the reacion chamber 1 . In the arrangement, it is very important that a microwave is mixed with a reactive gas only in the left side of the center surface C between the helmholtz coils 5 , so that the reactive gas is subjected to the magnetic field that is monotonically decreases toward the left in the resonating space. The magnetic field functions to drift the plamsa gas to the substrate 2 and prevent the gas from producing deposition on the right side wall.
[0024] The Ioffe magnet may be another type magnet. FIGS. 6 (A) and 6 (B) are drafted in correspondence with FIGS. 2 (A) and 2 (B) to show another type of Ioffe magnet sutable for use in accordance with the invention. As shown in the figure, a plurality of rod-shaped permanent magnets are arranged immediately inside of the helmholtz coils 5 with their magnetic moments directed to the circumferential direction as indicated by arrows. The magnetic moments can be arraged in the axial direction as shown in FIG. 7 .
[0025] While a description has been made for several embodiments, the present invention should be limited only by the appended claims and should not be limited by the particualr examles. What follow are some examples of modifications and variation according to the invention. By adding oxygen, water or the like to the reactive gas, the crystallinity of the deposited film can be enhanced. By irradiating the exciting plasma gas with ultraviolet rays between the resonating space and the substrate to be coated, the exciting plasma gas can hold its energy even substantially distant from the resonating space. For instance, a diamond or i-carbon film can be deposited on a large area. Also, by applying a DC bias voltage to the exciting plasma, a larger amount plasma reaches the substrate enabling a high deposition speed. Also, as easily understood by those skilled in the art, the present invention is effective when used for plasma etching, particularly by making use of ECR. The etchant gas is confined by virtue of the magnetic field in the same way as explained above. | A plasma processing apparatus and method is equipped with a vacuum chamber, helmholtz coils, a microwave generator and gas feeding systems. An auxiliary magnet is further provided in order to strengthen the magnetic field in the vacuum chamber to produce centrifugal drifting force which confine the plasma gas about the center position of the vacuum chamber. | 8 |
RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 12/196,455, filed on Aug. 22, 2008, and titled “Spatially Precise Optical Treatment or Measurement of Targets through Birefringent Layers.”
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] None
APPENDICES
[0003] None
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to optical systems that include control of the polarization of light from an independent light source, and particularly to optical treatment or measurement of a target, where the focus or image of the treatment light must be highly resolved, and where the treatment or measurement light traverses a birefringent material before reaching the target. The optical treatment may be an imaging process, or a process of working the target by means of a laser. The optical measurement may be done with coherent or incoherent light.
[0005] Although many optical treatments and measurements are performed on exposed targets, some are performed on targets buried under one or more intervening layers that are substantially transparent to the treatment beam. In this document, a “target” is any location where optical treatment or measurement is desired, whether it lies on an interface surface or within a bulk material. Bottom-surface ablation, as shown in FIG. 1 , involves ablating target film 101 by sending treatment beam 102 through superstrate 103 (and sometimes other intervening films). Bottom-surface ablation has the advantage that gravity draws ablated material 104 from ablation cut 105 downward, away from the workpiece, so it does not re-deposit on the workpiece and need to be cleaned off. In addition, if the treatment or measurement beam is Gaussian, the depth of focus (DOF) in the intervening layer is n times the DOF in air, where n is the refractive index of the intervening layer. This makes the focusing or imaging of the beam on the target less sensitive to surface contours and thickness variation of the workpiece.
[0006] Other optical treatments that may be performed through intervening layers include, but are not limited to, marking (as described in Herrmann's PCT Application No. WO0061634), annealing and other structural and optochemical changes, pinhole remelting, intentional color-center formation, selective curing, and exposure of wavelength-specific resists, dyes, and other photosensitive material. Measurements may include profilometry, reflectometry, absorption, microscopy, and refractive-index measurements. Reasons for sending the treatment beam through an intervening layer may be that the target is not completely solid and needs to be contained; that the target material needs to be sealed away from ambient atmosphere; or that the treatment must be tamper-proof. Measurements are often done through an intervening layer to determine whether the application of the intervening layer altered the characteristics of the underlying layer.
[0007] Spatial resolution is critical to some of these optical treatments and measurements. These treatments and measurements include forming a spatially precise pattern of light at the target; for instance, a focused spot, an image, or an interference pattern. However, if the intervening layer is birefringent, the treatment or measurement beam may be split into two polarization components propagating at different speeds and angles. These separate components form separate patterns at the target, so that the resolution of the resulting treatment or measurement is degraded.
[0008] FIG. 2 is a simplified illustration of this effect in the general case. Incident beam 202 , having arbitrary polarization, enters layer 203 at incident locus 204 (shown here as a point for simplicity; for different beam 202 characteristics, incident locus 204 could be a line or an area). If layer 203 were isotropic, the entire beam would refract along ordinary path 212 and form a pattern 214 on target 201 . However, if layer 203 is birefringent, its characteristics include an optic axis 210 , shown here with arbitrary orientation. When beam 202 enters layer 203 at incident locus 204 , it splits into two orthogonally polarized component beams: ordinary component 212 polarized in direction 213 and extraordinary component 222 polarized in direction 223 . The component beams are refracted at different angles because the effective refractive index of layer 203 is different for the ordinary and extraordinary polarizations. Thus the beam forms two spatially separated patterns at the target: pattern 214 from ordinary component 212 and pattern 224 from extraordinary component 222 .
[0009] Depending on the thickness, the ordinary refractive index, and the birefringent index difference of layer 203 and the incident angle, convergence angle, wavelength, and polarization characteristics of incident treatment beam 202 , the superposed patterns 214 and 224 may appear on the target as a single blurred pattern or a doubled pattern similar to an image viewed through Iceland spar crystal. Even at normal incidence, where the impact of isotropic refractive-index variations on optical treatment and measurement of buried layers is largely mitigated, a birefringent layer can still split the beams along different paths, forming a double pattern at the target, unless the optic axis happens to be parallel or perpendicular to the layer surface. For example, a beam intended to form a 25-micron spot on a target through 3 mm of glass with a birefringent index difference of 0.005 (which is fairly small) was observed to form two overlapping spots with centers separated by 10 microns at the target. Where spot resolution is important to treatment or measurement quality, this is a significant loss of resolution.
[0010] A wide range of materials in current industrial use may form a birefringent layer. Many crystalline materials, including liquid crystals, are inherently birefringent. Microcrystalline thin films may also exhibit some localized birefringence. Glasses and polymers, although usually inherently isotropic, can become birefringent from fabrication stresses (especially if fabricated in large-sheet form) or post-fabrication treatments. A prime example is tempered glass.
[0011] Tempered glass is preferred for use in glass devices that need to be durable, such as solar panels, outdoor displays, and architectural or vehicle glass. Compared to annealed glass of the same composition, tempered glass is stronger, more thermally resistant, and less hazardous in case of breakage because it breaks into small cuboid fragments rather than irregular shards of varying size. However, the residual strain from the rapid, non-uniform cooling that tempers the glass makes it birefringent. Moreover, the birefringent characteristics are not constant but vary with location on each individual sheet. Transparent polymers are also used for some of the same applications but “optical-grade” polymers that are specially constrained for low birefringence are relatively costly, especially large pieces. With polymers, too, the birefringent characteristics vary within a sheet as well as between individual sheets and from batch to batch.
[0012] “Smart” thin-film structures fabricated on glass and transparent polymer are increasingly popular in a wide variety of applications including solar panels, displays and active climate-managing windows and lighting fixtures for buildings and vehicles. Many of these products would also benefit from the safety and durability of tempered glass or the low cost and convenience of non-optical-grade polymer if precision optical treatment and measurement were possible despite the birefringence. Therefore, a need exists for spatially precise measurement and treatment of a target through an intervening birefringent layer without the pattern-doubling effects that birefringence tends to induce.
BRIEF SUMMARY OF THE INVENTION
[0013] An object of this invention is to optically treat or measure buried targets with high spatial precision, despite birefringence in the intervening layers. Accordingly, the invention includes orienting the incident direction of the beam, the polarization of the beam, or both with respect to the material optic axis to match one of the four configurations where the ordinary and extraordinary components are superposed to form a single pattern having substantially the same resolution that it would have in the absence of birefringence.
[0014] Another object of this invention is to adapt to changes in the characteristics of the birefringent layer from location to location on the same workpiece and from workpiece to workpiece. Accordingly, the invention includes monitoring the orientation of the optic axis of the birefringent layer at each desired incident locus and formulating the adjustments that will superpose the ordinary and extraordinary components.
[0015] Another object of this invention is to make precision optical treatment and measurement through birefringent layers an automatable industrial process. Accordingly, some embodiments of this invention include a control loop that continuously monitors the optic-axis orientation of the birefringent layer and drives alignment devices to superpose the ordinary and extraordinary components based on the monitored data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a conceptual diagram of bottom-surface ablation, an example of one of several optical treatments that is performed through an intervening transparent layer.
[0017] FIG. 2 is a simplified illustration of how an intervening birefringent layer splits an incident treatment beam into ordinary and extraordinary components, which propagate at different angles to form separate patterns at the target.
[0018] FIGS. 3 a - 3 d are conceptual diagrams of four configurations of the treatment or measurement beam with respect to the workpiece, each of which results in the ordinary and extraordinary beams being superposed to form a single pattern at the target.
[0019] FIG. 4 illustrates the effect of treatment threshold or measurement noise level on the results of non-ideal configurations.
[0020] FIG. 5 is a conceptual diagram of monitoring embodiment that monitors the orientation of the optic axis indirectly by monitoring its effect on a focused spot.
[0021] FIG. 6 a is a conceptual diagram of an alternate monitoring embodiment usable when the surfaces of the target and birefringent layer (and any other intervening layers) are substantially specular and some measurable light from the monitoring beam is reflected from the target surface.
[0022] FIG. 6 b is a conceptual diagram of an alternate monitoring embodiment that can be used when the target and birefringent layer (and any other intervening layers) transmit at least some measurable light at a wavelength where an image receiver, such as a CCD, is sensitive.
[0023] FIG. 7 is an example schematic of a tool adapted to make the treatment or measurement beam parallel to the optic axis.
[0024] FIG. 8 is an example schematic of a tool adapted to make the treatment or measurement beam perpendicular to both the workpiece surface and the optic axis in the non-trivial case where the target is not flat and the birefringent layer is not plane-parallel.
[0025] FIG. 9 is an example schematic of a tool adapted to adjust the treatment or measurement beam polarization to be parallel or perpendicular to the plane shared by the incident beam and material optic axis.
DETAILED DESCRIPTION OF THE INVENTION
[0026] This invention leverages four relative configurations of the optic axis of a birefringent material, the incident direction of a light beam, and the polarization of an incident light beam, which cause all the light to be refracted at the same angle while traveling through the birefringent material. If all the light is refracted at the same angle instead of being split into two components refracted at different angles, the beam can form a single pattern at the target, as if the intervening layer were not birefringent. The four configurations are:
1. The beam propagates through the birefringent layer in a direction parallel to the optic axis. Under this condition, an incident beam of arbitrary polarization will not split into components traveling in different directions. 2. The optic axis is parallel to the entrance surface of the birefringent material at the incident locus, and the beam enters at normal incidence. Under this condition, a beam polarized linearly, parallel or perpendicular to the optic axis, will not split into components at all. A beam of arbitrary polarization will split into two beams traveling at different speeds, but they will travel in the same direction and remain fully overlapped. 3. The beam polarization is linear, oriented parallel to a plane (the “I-OA plane”) that contains both the incident beam and the optic axis. 4. The beam polarization is linear, oriented perpendicular to the I-OA plane.
[0031] FIGS. 3 a - 3 d are idealized illustrations of configurations 1 through 4 , respectively. In FIG. 3 a , incident beam 302 a may have any polarization entering birefringent layer 303 a at incident locus 303 c ; if incident beam 302 a is parallel to optic axis 310 a , the refracted beam 312 a will form a single pattern on target 301 a . In FIG. 3 b , incident beam 302 b is normal to the entrance surface of birefringent layer 303 b , and optic axis 310 b is in some orientation parallel to that surface at incident locus 304 c . Regardless of its polarization, refracted beam 312 b will form a single pattern on target 301 b . In FIG. 3 c , incident beam 302 c is linearly polarized in direction 313 c , parallel to the I-OA plane 320 c that contains both optic axis 310 c (which may have any orientation in that plane) and incident beam 302 c . Refracted beam 312 c also forms a single pattern on target 301 c . In FIG. 3 d , incident beam 302 d is linearly polarized in direction 313 d , perpendicular to the I-OA plane 320 c that contains both optic axis 310 d (which may have any orientation in that plane) and incident beam 302 d . Refracted beam 312 d also forms a single pattern on target 301 d . The optimal choice among these configurations depends on the nature of the birefringent layer (for instance, its shape, its thickness, and the range of its expected optic-axis orientations) and on the nature of the beam (for instance, its result tolerances, numerical aperture, and working distance).
[0032] One skilled in the art would probably not expect an actual pattern-forming beam to behave as well as the idealized rays in FIGS. 3 a - 3 d . For example, if a beam is focused on the target through the birefringent layer to form a converging cone of light, the light enters the birefringent layer at a range of incident angles rather than a single angle. The optic axis, by contrast, tends to have a single orientation, at least over a small area of the workpiece. Therefore, the entire range of beam propagation angles cannot be simultaneously adjusted to an ideal angle with the optic axis. Image-forming beams, like focused beams, also propagate at a range of angles rather than a single angle. Beams forming interference patterns, however, are often collimated so that all the parts of the beam propagate at substantially the same angle. Another obstacle foreseeable by those skilled in the art is the difficulty, and hence the equipment cost, of adjusting the polarization and refracted beam to precisely the correct angle.
[0033] Contrary to those logical expectations, however, these configurations have been shown to form very well-resolved patterns with fairly tightly focused beams where the polarization and refraction angles are only substantially near the ideal. This is because of inherent limitations in both treatment and measurement with beams of very low intensity.
[0034] FIG. 4 shows the result of slightly non-ideal configuration. An ideal configuration would produce only main peak 414 ; a non-ideal configuration produces a second peak 424 from the second polarization component, some blurring 415 around main peak 414 from some parts of the beam coming in at non-ideal angles or both. The dotted line 400 represents the low-intensity limit of the process. If the process is an optical treatment, limit 400 may be a threshold, such as an ablation or reaction threshold. If the process is an optical measurement, level 400 could be a noise level of a measurement sensor. Any light reaching the target with intensity below limit 400 will not affect the process. Therefore, even though not all parts of the beam are incident at exactly the ideal angle and the second polarization component 424 is not perfectly extinguished, the treatment or measurement of FIG. 4 will behave as if only the above-the-limit light—that is, main peak 414 —were present.
[0035] Therefore, if the extinction is “good enough,” and if the incident angle range is small (e.g., if the beam is focused or the image is formed at a low numerical aperture) and the birefringent index difference is small or the birefringent layer is fairly thin, experiments show that a pattern of acceptable resolution is formed at the target if the polarization is reasonably linear and properly oriented and the propagation direction is corrected in the center of the beam. Beams that carry most of their intensity in the center, such as the Gaussian beams produced by many lasers, are generally more forgiving of “center-only” propagation-direction correction than beams that have more intensity around the edges.
[0036] The low-intensity limit will depend on the wavelength of the beam, its time-dependent intensity characteristics (e.g. pulse profile), and the nature of the target material and any measurement sensor. However, these limits may be available in product specifications or technical publications, or they be measured with reasonable ease; therefore, they can be derived without undue experimentation.
[0037] Monitoring the orientation of the optic axis can be important for achieving acceptable results, especially if the optic axis orientation varies from workpiece to workpiece or from one incident locus to another on a single workpiece. A number of approaches to this measurement exist. Because the monitoring method can be independent of the chosen configuration, they will be discussed separately here.
[0038] In a preferred embodiment shown in FIG. 5 , the orientation of the optic axis is measured indirectly by measuring its effect on a focused spot. Monitor beam 532 should be a wavelength that behaves analogously to the treatment or measurement beam; it may even be a sub-threshold attenuated fraction of the treatment beam or the actual measurement beam. Monitor beam 532 enters through birefringent layer 503 and focuses, if the configuration is not ideally aligned, to two spots 514 and 524 on target 501 . Camera 551 forms an image 552 of the two spots on an image receiver, which may be a CCD array or appropriate equivalent. This image is an intensity map, from which such quantities as the relative intensities I 1 and I 2 of the two spots, their separation d 12 , and the width w 1 of the brightest spot at a predetermined cut-off point can be determined. This monitored data can be compared with stored data, such as the maximum allowable ratio I 2 /I 1 , or the maximum allowable width w 1 (where, for instance, d 12 is so small that only one blurry spot appears). The relative tilt between the beam and workpiece, the beam polarization or both can be manipulated until the measured values fall below the stored maxima.
[0039] FIG. 6 a is a schematic of an alternate monitoring embodiment that can be used when the surfaces of target 601 and birefringent layer 603 (and any other intervening layers) are substantially specular and some measurable light from the monitoring beam is reflected from the target surface. As in FIG. 5 , monitoring beam 632 focuses, in the general case, to two spots 614 and 624 . However, in this embodiment, imaging lens 653 captures the reflected beams and re-focuses them onto image receiver 651 , which may be a CCD array or appropriate equivalent. Received image 652 is analyzed in the same manner as image 552 in FIG. 5 , and the workpiece tilt, polarization or both can be manipulated until the image parameters are within a pre-determined acceptable range, corresponding to the desired resolution of the treatment or measurement.
[0040] FIG. 6 b is a schematic of an alternate monitoring embodiment where the monitoring is done at a wavelength where all the layers of the workpiece transmit at least a measurable amount of light. Extended light source 633 emits light polarized in direction 634 . Source 633 may be an incoherent light source masked by a linear polarizer or it may be a light source that “naturally” emits polarized light, such as an active-matrix LCD display. The light from source 633 is transmitted through target layer 601 b and birefringent layer 603 , then through linear polarizer 663 . Linear polarizer 663 is oriented in direction 664 to “cross” the polarization of source 633 . Imaging lens 654 images light source 633 onto image receiver 652 . If there were no birefringent material between polarized source 611 and crossed polarizer 663 , little or no light would be transmitted through crossed polarizer 663 , and image receiver 652 would be entirely dark. Birefringence in layer 603 , though, changes the polarization of the light so that more light passes through crossed polarizer 663 and reaches image receiver 652 . The figure illustrates a birefringent layer with spatially varying birefringence; the light pattern on image receiver 652 is non-uniform. If the birefringence were constant across birefringent layer 603 , the illumination would be uniform. Images from the receiver for various can be fed to the measurement or treatment tool as a map of the birefringence characteristics of the workpiece.
[0041] Numerous methods also exist in the prior art to monitor the optic axis orientation directly, such as polarization-sensitive optical coherence tomography. In embodiments where the optic axis orientation is monitored directly, the analysis would include the necessary adjustments to relative tilt between the beam and the workpiece, incident polarization angle or both that would produce one of the four desirable configurations.
[0042] In some embodiments, the monitoring is done either periodically or continuously during treatment or measurement, with the monitored data providing feedback for a closed control loop that adjusts the configuration whenever the monitored data changes to indicate an out-of-tolerance misalignment. Optionally, some embodiments may include shutters or other devices to extinguish or attenuate the treatment beam, or stop the measurement, if the monitored data approaches the tolerance limit, then cease to extinguish or attenuate the treatment beam or resume measurement when the configuration is readjusted to a comfortable margin. In other embodiments, the monitoring system may “map” the areas of workpiece to be treated or measured and store the data before the treatment or measurement begins. Still other embodiments, for workpieces where the orientation of the optic axis is expected to be uniform over the treatment or measurement, would only require collecting monitored data at a single representative incident locus before treatment or measurement.
[0043] Once the alignment parameters to produce a desired configuration are known, the measurement or treatment apparatus can produce the desired configuration in a number of ways.
[0044] FIG. 7 is an example schematic of a tool adapted to make the treatment or measurement beam parallel to the optic axis (Configuration 1 ). Configuration 1 is most advantageous when the optic axis orientation is fairly close to perpendicular to the target surface. Light source 760 produces beam 702 . Beam-shaping assembly 761 forms the beam into the desired pattern aimed at target 701 . Beam steering assembly 764 , which may include optics to fine-adjust the translation and angle of beam 702 , may also be present in the beam train. Birefringent layer 703 has optic axis orientation 710 at the locus of incidence. The workpiece (here comprising target layer 701 and birefringent layer 702 ) is supported by workpiece stage 762 . Many treatment and measurement tools include actuators to change the relative position of stage 762 and beam 702 in X, Y, and Z directions 763 , either by moving the stage or by moving the light source and its optics. Because light refracted parallel to optic axis 710 will form a single spot 714 regardless of its polarization, only the relative tilt of beam 702 with respect to the workpiece needs to be adjusted. Adjusting this relative tilt by changing the angle of beam 702 using beam steering assembly 764 can be highly precise but the range can be limited by the aperture or aberration sensitivity of beam-shaping assembly 761 . By contrast, adjusting this angle by tilting the stage in directions 765 can offer a larger adjustment range but because the stage is generally much more massive than the beam-steering optics; the required actuators will be more expensive and may not be as precise. The choice of either or both of these ways to adjust the tilt will depend on the particulars of the workpiece and process types.
[0045] Configuration 2 , adjusting the refracted beam to be perpendicular to both the entrance surface of the birefringent layer and its optic axis, is useful in the special case where the optic axis of the birefringent layer is substantially parallel to the entrance surface of the birefringent layer. Where the target is flat and all the layers above it are plane-parallel, the birefringence may not even manifest as a problem in common normal-incidence treatments and measurements. However, when the target layer is not flat or the birefringent layer is not plane-parallel, the birefringence may cause loss of resolution if no adjustment is done.
[0046] FIG. 8 is an example schematic of a tool adapted to use Configuration 2 with a workpiece where target 803 is not flat and birefringent layer 803 is not plane-parallel. Light source 860 produces beam 802 . Beam-shaping assembly 861 forms the beam into the desired pattern aimed at target 801 . Beam steering assembly 864 , which may include optics to fine-adjust the translation and angle of beam 802 , may also be present in the beam train. Birefringent layer 803 has optic axis orientation 810 at the locus of incidence. Stage 862 supports the workpiece. Many treatment and measurement tools include actuators to change the relative position of stage 862 and beam 802 in X, Y and Z directions 863 , either by moving the stage or by moving the light source and its optics. Because light refracted parallel to optic axis 810 will form a single spot 814 regardless of its polarization, only the relative tilt of beam 802 with respect to the workpiece needs to be adjusted. Here, it needs to be adjusted whenever the angle of the entrance surface of birefringent layer 803 changes enough to unacceptably degrade the resolution of the treatment or measurement. Adjusting this relative tilt by changing the angle of beam 802 using beam steering assembly 864 can be highly precise, but the range can be limited by the aperture or aberration sensitivity of beam-shaping assembly 861 . By contrast, adjusting this angle by tilting the stage in directions 865 can offer a larger adjustment range, but because the stage is generally much more massive than the beam-steering optics, the required actuators will be more expensive and may not be as precise. The choice of either or both of these ways to adjust the tilt will depend on the particulars of the workpiece and process types.
[0047] Configurations 3 and 4 —adjusting the polarization to be parallel or perpendicular, respectively, to the I-OA plane formed by the central axis of the refracted beam and the optic axis of the birefringent layer, are the most useful when the optic axis is neither substantially parallel nor substantially perpendicular to the entrance or target surfaces. However, they impose an extra requirement: that the polarization characteristic of the beam be substantially linear, and that some adjustment can be made to orient the polarization either parallel or perpendicular to the I-OA plane without unacceptable distortion of the pattern from other sources, such as aberrations in the beam-shaping optics.
[0048] FIG. 9 is an example schematic of a preferred embodiment of a tool adapted to adjust the treatment or measurement beam polarization to Configuration 3 or 4 . Light source 960 produces beam 902 . Some light sources, such as some types of laser, produce a beam that is already substantially linearly polarized and collimated. Beam-shaping assembly 961 forms the beam into the desired pattern aimed at target 901 . Beam steering assembly 964 , which may include optics to fine-adjust the translation and angle of beam 902 , may also be present in the beam train. Stage 962 supports the workpiece. Many treatment and measurement tools include actuators to change the relative position of stage 962 and beam 902 in X, Y and Z directions 963 , either by moving the stage or by moving the light source and its optics. Birefringent layer 903 has optic axis orientation 910 at the locus of incidence. When beam 902 enters birefringent layer 903 , it is refracted. The center of the refracted beam and the local optic axis lie in a plane, the I-OA plane 920 . If the polarization of beam 902 is linear and either parallel (Configuration 3 ) or perpendicular (Configuration 4 ) to I-OA plane 920 , a single effective pattern 914 with optimized resolution will be formed at target 901 . Polarization adjuster 967 manipulates the polarization of beam 902 to achieve this.
[0049] Most polarization adjustment devices work best with collimated light. Some light sources, such as many lasers, produce light that is already substantially collimated and linearly polarized. For this type of light source, polarization adjuster 967 may be a rotatable half-wave plate, or any other device for rotating the orientation of a linear polarization. If the light source is collimated, but circularly or randomly polarized, polarization adjuster 967 may be a rotatable linear polarizer (although this method can significantly attenuate the beam). If the light source is not collimated, a collimator 966 may be inserted in the beam train before polarization adjuster 967 .
[0050] The FIG. 9 embodiment is preferred because it does not require disturbing the nominal angle at which the beam reaches the target' too much change in this angle can cause the treatment or measurement pattern to be distorted in some cases. However, if distortion is not a significant risk, alternate embodiments can use a linearly polarized beam of constant orientation and adjust the relative angle between the beam and the entrance surface of the birefringent layer, as in the tools illustrated in FIGS. 6 and 7 , until the polarization is either parallel or perpendicular to the I-OA plane.
[0051] To summarize, this invention mitigates or eliminates the loss of resolution that can occur when a treatment or measurement beam passes through a birefringent layer before reaching its target. Adjustments to the relative angle of the beam axis and workpiece, or to the beam polarization, or both, produce one of four configurations that minimize the resolution loss from the birefringent layer: (1) beam axis parallel to the optic axis of the birefringent material, (2) beam axis perpendicular to both optic axis and entrance surface of the birefringent layer, (3) polarization parallel to the I-OA plane shared by the beam axis and optic axis, or (4) polarization perpendicular to the I-OA plane shared by the beam axis and optic axis. The adjustments are chosen in response to monitored data about the orientation of the optic axis or about the effects of that orientation on a monitoring beam. Monitored data to determine the optimum adjustment can be collected before or during treatment or measurement. Monitored data can be the input, and adjustment commands the output, of a closed control loop.
[0052] Those skilled in the art will recognize that only the claims, not this description or the accompanying drawings, limit the scope of the invention. | A treatment pattern (such as a focused spot, an image, or an interferogram) projected on a treatment target may lose precision if the treatment beam must pass through a birefringent layer before reaching the target. In the general case, the birefringent layer splits the treatment beam into ordinary and extraordinary components, which propagate in different directions and form two patterns, displaced from each other, at the target layer. The degree of birefringence and the orientation of the optic axis, which influence the amount of displacement, often vary between workpieces or between loci on the same workpiece. This invention measures the orientation of the optic axis and uses the data to adjust the treatment beam incidence direction, the treatment beam polarization, or both to superpose the ordinary and extraordinary components into a single treatment pattern at the target, preventing the birefringent layer from causing the pattern to be blurred or doubled. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/055,083, filed Apr. 29, 1993 now abandoned.
FIELD OF THE INVENTION
The present invention deals with specific products, namely, towels, sponges and gauzes which are produced from selectively hot water soluble polyvinyl alcohol resins, The resins are configured into fibers which are, in turn, used to construct the subject finished product.
BACKGROUND OF THE INVENTION
Hospital patient care generates considerable quantities of infectious medical waste in primary and acute care facilities. There has been a general conversion from reusable, cleanable items, to disposable items over the last three decades. These conversions were made to promote antiseptic techniques in patient care and to decrease the potential for cross-infections between patients, staff and the general public. Recent federal and state government regulations such as the Medical Waste Tracking Act of 1988 and OSHA Medical Facility rules have resulted in a substantial increase in medical waste that must be classified as "infectious."
When a patient is admitted to a hospital, the patient produces approximately 55 pounds of medical waste per day. Approximately 20% of this waste is infectious. The current stated objective of the American Hospital Association and the Centers for Disease Control is to treat medical waste as soon as it is generated. Both organizations recognize that medical waste is primarily an occupational hazard for health care workers and not an environmental problem. The best way to deal with infectious medical waste is to disinfect it at the point of generation and dispose of the treated medical waste with minimum handling and storage on premises.
The need for an effective way to dispose of medical waste has been highlighted by the amendment made to 29 C.F.R. §1910.1030 which provides for the federal regulation under the Occupational Safety And Health Act, 29 U.S.C. 655,657 to control bloodborne pathogens. Specifically, the Act calls for the establishment of an exposure control plan, the containment of specimens of blood or other potentially infectious materials and the general tightening of precautionary measures to minimize the spread of disease. A safe and effective way to dispose of hospital waste would greatly facilitate compliance with the above-referenced Act.
As a result, consumption of medical disposable woven or non-woven products has been growing at a rate of approximately 10% a year. In 1988, sales totaled approximately 1.155 Billion Dollars. It is projected that by 1994, sales of medical disposable woven and non-woven products will reach 2.05 Billion Dollars.
In the United States, there are approximately 30 million surgical procedures performed each year. After each surgical procedure, it is necessary that the operating theater be disinfected and sterilized before a new procedure is performed to minimize any exposure the patients may bring to other patients or staff. This is particularly important in light of today's increasingly stringent regulations regarding occupational exposure to blood and bodily fluids.
Towels, sponges and gauzes have been in use since the first days of surgical procedures. They are used either to manipulate tissue, absorb blood and other oxidants of the wound site, as well as being useful to cleanse hands and assist in cleansing certain utensils used in various surgical procedures. Traditionally, towels, sponges and gauzes have been made from cotton fibers, though in recent years attempts have been made to provide replacements from other fibers including polyesters, rayons and other staple materials. These fibers were chosen because of their relative availability and cleanliness as man-made materials. Cotton is an agricultural material with volatile price and availability fluctuations. It has been noted that cotton replacements have, by and large, been unsatisfactory although many attempts have been made to mimic the appearance of cotton, all of which have been in vain.
Hospitals generally discard gauzes, sponges and towels after surgical use. Disposal takes place in either a landfill or by incineration. However, in either case, the handling of articles after use promotes the exposure of certain blood borne diseases to those employees who are charged with the responsibility for bagging and introducing such materials into the disposal process.
It is thus an object of the present invention to provide suitable towels, sponges and gauze capable of being disposed of after use while avoiding additional burdens being placed upon landfills and other disposal sites.
It is yet a further object of the present invention to provide suitable towels, sponges and gauze which, after use, can be solubilized and substantially sterilized in a single operation.
These and further objects will be more readily appreciated when considering the following disclosure and dependent claims.
SUMMARY OF THE INVENTION
The present invention involves an article comprising a member selected from the group consisting essentially of towels, sponges and gauzes. The article is comprised of fibers of polyvinyl alcohol resin which are selectively soluble in aqueous solutions only above approximately 93° C. The polyvinyl alcohol fibers are characterized as having a degree of hydrolysis of at least 99%, being composed of no more than 1/2% sodium acetate and 1/10% methyl alcohol and an average degree of polymerization between approximately 1300 to 1500. The polyvinyl alcohol fibers are produced by a process of dope extrusion and then treated with heat and stretching, the degree of crystallinity and the degree of orientation for the heated and stretched polyvinyl alcohol fibers are approximately 0.70 and 0.52 respectively.
The degree of crystallinity and the degree of orientation is measured by IR spectroscopy. Degree of crystallinity is the ratio of crystalline area to amorphous area. Degree of orientation is the ratio of non-oriented area to oriented area.
DETAILED DESCRIPTION OF THE INVENTION
As noted, the present invention deals with novel towels, sponges and gauzes and a method of disposal for use primarily in the medical industry in hospitals, outpatient facilities, and home environments. At such facilities, towels, sponges and gauzes, particularly in surgical theaters, generally come into contact with human bodily fluids such that disposal and disinfection has become a matter of major concern in light of the lack of biodegradability of prior products and the potential spread of human-borne diseases such as hepatitis-B and AIDS.
In order to cope with these difficulties, it is proposed that suitable towels, sponges and gauzes be composed of fabric produced from fibers comprising polyvinyl alcohol which is water soluble at temperatures only above approximately 93° C. If such articles were soluble at lower temperatures, inadvertent solubilization would occur in the event that the towels, sponges or gauzes were to contact certain fluids above room temperature such as human bodily fluids generated during ordinary surgical procedures. Working with polyvinyl alcohol which dissolves only at higher temperatures such as above approximately 93° C. would prevent inadvertent solubilization yet remain viable in practicing the present invention. In fact, it is contemplated that disposal in a hot water bath such as a washing machine at or near the boiling point of water dedicated solely to solubilizing such products would be an effective disinfecting media. As such, two objectives could be accomplished, namely, that the polymer would be disinfected and would be solubilized for disposal through the sewer systems. Not only would this lessen the burden now being imposed upon current landfill sites, but liquid sewer disposal would provide a comparatively low cost technique in ridding the user of soiled towels, sponges and gauzes.
In one embodiment, articles produced by practicing the present invention could be formed from a yarn which is a unit made from a multiplicity of fibers. The yarn can be formed as either a staple or as filament fibers made from polyvinyl alcohol. This nontoxic, synthetic polymer is produced by alkali or acidic hydrolysis of polyvinyl acetate. The vinyl acetate monomer is produced by reacting either acetylene and acetic acid or ethylene, acetic acid and oxygen. Polyvinyl alcohol can be manufactured as a water soluble or insoluble resin.
Water soluble resins of polyvinyl alcohol can be hot and cold water soluble or hot water soluble only. The temperature at which polyvinyl alcohol dissolves is controlled by changing its degree of hydrolysis, polymer crystallization and orientation, that is, how the polymers are bound to each other. The polyvinyl alcohol resin used in the present invention is intended to have a general range of hydrolysis of greater than 99%, less than 1/2% sodium acetate, less than 1/10% methyl alcohol with a degree of polymerization between 1300 and 1500 as an average.
Polyvinyl alcohol fibers used herein are formed by dissolving suitable hot water soluble polyvinyl acetate resin into deionized or distilled water to a 5% to 15% by solids mixture, thereby creating a "dope." This dope is then allowed to stand for a considerable period of time, for example two weeks, for gel setting. All attempts should be made to keep the dope free of microbial organisms as polyvinyl alcohol is subject to microbial degradation when in solution. This can be accomplished either through ultrafiltration, heating or other means well known to those intent on preserving resin solutions. Such techniques include the addition of anti-microbials such as ester phenolic derivatives such as salicylic or benzoic esters.
Once the above-described resin has been gel set, it is then filtered and forced through a spinneret and into a saturated solution of sodium sulphate wherein the fibers are coagulated into a range of deniers of from 6 to 10. The fiber is then subjected to a drawing between a 2:1 and 5:1 ratio, with 4:1 ratio preferred and heat annealed at their glass transition point to produce hot water soluble fibers. The degree of crystallinity and the degree of orientation for the heated and stretched polyvinyl alcohol fibers are approximately 0.70 and 0.52 respectively. The fibers so produced are then either chopped into a staple between approximately 1" to 2" in length or formed into tow bundles which can then be stretch broken with a fiber length of 1" and 6". These fibers are then formed into a yarn either by conventional cotton spinning methods, woolen spinning methods or spun directly from the stretch broken tow. A preferred yarn size is between 60 singles and 0.5 singles, with up to four plies of each of these yarns. The yarns can be spun in the Z or S direction with a weaving twist multiple between 3 and 6 with 3.5 to 4.0 twist multiple preferred.
The above-described yarn can ba colored, if desired. If colored, the yarn should be dope dyed in the resin solution. Pigments are useful that are insoluble in water to produce the highest quality light sublimentation and mark-off resistance. Fabric can be formed by weaving or by other well known techniques. For example, yarns can be intermingled in a perpendicular fashion or can be woven, or yarns can be single knit, double knit, interlocked, warped knit, or crocheted, as desired. It is even possible to bypass the yarn formation method and produce a nonwoven fabric directly from the fiber which is commonly referred to as either air laid, dry laid, wet laid, hydroentangled, thermo bonded, or chemical bonded. Uniquely, these products are formed into fabrics, de-sized as necessary and cut, sewn and uniquely washed at up to 160° F. before further processing. These items, while intended to be single use disposable products in hot water, are uniquely exposed to water between 30° and 60° C. to reduce bioburden, remove fugitive color, bleach or wash away stray bits of fiber and yarn which may become contaminants in the wound site. | Towel, sponge and gauze products composed of fibers of polyvinyl alcohol resin. The fibers are selectively soluble in aqueous solutions only above approximately 93° C. Polyvinyl alcohol fibers have a degree of hydrolysis of at least 99%, are composed of no more than 1/2% sodium acetate, 1/10% methyl alcohol and an average degree of polymerization between approximately 1300 to 1500. The polyvinyl alcohol fibers being produced by a process of dope extrusion. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to surface treatment of a semiconductor device and more particularly to a method for forming an ultra thin film on the surface of a semiconductor wafer.
[0003] 2. Description of the Related Art
[0004] It is known that a layer of thin native silicon dioxide (SiO 2 ) tends to form naturally on bare silicon surfaces. Typically, the presence of the native oxide is undesirable, since the quality and consistency of the native oxide layer is unknown and unpredictable. For this reason, the thin layer of native oxide is generally removed from the surface of the silicon substrate before processing.
[0005] In the manufacture of integrated circuits, however, SiO 2 has long been used as a dielectric for integrated circuits because of its excellent thermal stability and relatively good dielectric properties (k˜4.0). Commonly the operational voltage requirement for most integrated circuits is ˜5 volts. Thus, it is frequently desirable to form an SiO 2 insulating layer directly on the surface of the silicon semiconductor substrate or wafer, which will not break or overheat when subjected to the operational voltage.
[0006] Unfortunately, most conventional manufacturing processes used for growing thin films are inefficient and wasteful. Typically, most conventional manufacturing processes are batch type processing methods, which may process from between 100 to 150 wafers per processing cycle. Because of the non-uniform nature of the processes and because of an inability to control growth, batch type processes yield many unusable wafers. These conventional processes also require relatively high cycle times. For example, some process can require from 8 to 10 hours for ramping up (heating) and ramping down (cooling) between processing cycles.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method for forming an ultra thin layer of dielectric material on a silicon surface. Preferably, the ultra thin layer can be made of SiO 2 or similar materials, such as SiN and Ta 2 O 5 . In the present invention, silicon substrates or wafers are loaded onto an appropriate wafer carrier and then introduced into a semiconductor wafer processing system. A wafer transport mechanism can be used to remove a single silicon wafer from the carrier and transport the wafer to a processing chamber. The processing chamber may be, for example, a furnace, an annealer, or other chamber for conducting thermal processing.
[0008] In accordance with the present invention, the silicon wafer is loaded into the processing chamber while the processing chamber is under a vacuum pressure. The semiconductor wafer and chamber are heated. Once the chamber reaches a steady-state processing temperature, a process gas, such as oxygen, is introduced into the chamber under pressure. The chemical reaction which takes place in the processing chamber causes the oxygen to react with the surface of the silicon wafer to form an ultra thin SiO 2 layer thereon. The growth rate of the layer is dependent on the pressure of the reactive gas, which can be controlled to produce the desired thickness of the thin film layer. The thickness of the ultra thin SiO 2 layer may be on the order of between about 10 Å to 50 Å. Advantageously, the thin layer of SiO 2 may be formed within about 10-20 minutes in a process temperature of about 800° C. to about 850° C., whereafter the wafer is removed from the chamber and cooled.
[0009] In some embodiments, the oxygen may react with Ta (Source TaETO) to form an ultra thin layer of Ta 2 O 5 . The Ta 2 O 5 layer may range in thickness from between about 50 Å to 250 Å. Advantageously, the thin layer of Ta 2 O 5 may be formed within about 10-20 minutes in a deposition process temperature of about 300° C. to about 500° C., or in an annealing process of between about 400° C. to about 800° C.
[0010] In one aspect of the invention, a method is provided for forming a thin film on a semiconductor wafer. The method includes loading a semiconductor wafer into a process chamber while the process chamber is under vacuum pressure, or alternatively, while the partial pressure of the reactive gas is substantially zero. The process gas is introduced under pressure into the process chamber. The semiconductor wafer is unloaded from the process chamber while the process chamber is under a vacuum pressure, or alternatively while the partial pressure of the reactive gas is substantially zero.
[0011] Because the method of the present invention provides a controllable thin layer growth rate, a higher percentage yield of wafers can be achieved in a shorter cycle time. In addition, since higher yields are produced from smaller wafer batch sizes, the overall footprint of the processing system for a required productivity level can be reduced, which saves valuable manufacturing space. Beneficially, the increase in throughput saves energy and reduces waste.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a simplified diagram of the processing system of the present invention;
[0013] [0013]FIG. 2 is a flow diagram of the process method in accordance with the present invention;
[0014] [0014]FIG. 3A is a simplified illustration of an embodiment of a furnace in accordance with the present invention; FIG. 3B is a simplified illustration of a heating element for use in the furnace embodiment of FIG. 3A;
[0015] [0015]FIG. 4A is a simplified illustration of an embodiment of a furnace in accordance with the present invention; FIG. 4B is a simplified illustration of a heating element for use in the furnace embodiment of FIG. 4A;
[0016] [0016]FIG. 5A is a simplified diagram of an alternative embodiment of a processing system in accordance with the present invention;
[0017] [0017]FIG. 5B is a simplified illustration of a furnace for use with the processing system of FIG. 5A;
[0018] [0018]FIG. 6 is a schematic illustration of a side view of one embodiment of a semiconductor wafer processing system in accordance with the present invention;
[0019] FIGS. 7 A- 7 C are simplified illustrations of an embodiment of FIG. 6; and
[0020] [0020]FIG. 8 is a graph representation of the pressure/temperature variation within the processing chamber as a function of time in accordance with the present invention.
DETAILED DESCRIPTION
[0021] [0021]FIG. 1 is a simplified diagram of a processing system 10 that establishes a representative environment for the present invention. Processing system 10 may include a loading station 12 , which has multiple platforms 17 for supporting and moving a wafer cassette 14 up and into a loadlock 16 . Wafer cassette 14 may be a removable cassette, which is loaded onto platform 17 , either manually or with automated guided vehicles (AGV). Wafer cassette 14 may also be a fixed cassette, in which case wafers are loaded onto cassette 14 using conventional atmospheric robots or loaders (not shown). Once wafer cassette 14 is inside loadlock 16 , processing system 10 can be pumped down to vacuum. A wafer transport system 18 housed within transfer chamber 20 , described in greater detail below, rotates toward loadlock 16 and picks up at least one wafer 22 from cassette 14 . A processing chamber 24 , also under vacuum, receives wafer 22 from wafer transport system 18 through a gate valve 29 .
[0022] Wafer transport system 18 is capable of lifting wafer 22 from wafer cassette 14 and, through a combination of linear and rotational translations, transporting the wafer through vacuum chamber valves 28 and 29 , and depositing the wafer at the appropriate position within furnace 24 . Similarly, wafer transport system 18 is capable of transporting wafer 22 from one processing chamber 24 to another (not shown) and from a processing chamber back to wafer loading station 12 .
[0023] In one embodiment, wafer transport system 18 includes a robot arm 30 and a controller 32 . Robot arm 30 may be any conventional wafer processing robotic arm, which provides R (translation) and Θ (rotation) movements. A gripper or end effector (not shown) may be attached to the end of robot arm 30 . The end effector may be made of a heat resistant material, such as quartz, for picking-up and placing wafer 22 . An example of a commercially available type of robot arm is the SHR3000 robot (“SHR3000 robot”) from the JEL Corporation of Hiroshima, Japan. The SHR3000 robot can rotate 340°, has 200 mm of vertical motion, and can extend its arms 390 mm in the horizontal plane. Another example of a type of wafer processing robot is disclosed in U.S. patent application Ser. No. 09/451,677, filed Nov. 30, 1999, which is herein incorporated by reference for all purposes.
[0024] Once wafer 22 is positioned in chamber 24 , transport system 18 retracts and gate valve 29 closes to begin processing. After wafer 22 is processed, gate valve 29 opens to allow transport system 18 to pick-up and remove wafer 22 from the processing chamber.
[0025] [0025]FIG. 2 is a flow diagram of an embodiment of the method of the present invention, which can be performed using processing system 10 of FIG. 1. In this embodiment, processing chamber 24 is a furnace. Furnace 24 may be any conventional type wafer processing furnace, such as any lamp-based or resistively heated furnace. In accordance with the present invention, furnace 24 can be pumped down ( 40 ) to a vacuum pressure using a conventional pumping system 32 . Pumping down ( 40 ) furnace 24 ensures that substantially all moisture and oxygen are removed from the furnace to prohibit the formation of a native SiO 2 . Optionally, furnace 24 may be filled with an inert gas ( 42 ), such as Argon or Helium, to ensure that residual oxygen and moisture are substantially removed from furnace 24 . As further described below, furnace 24 may also be filled with N 2 for diluting the reactive gas.
[0026] As understood with reference to the graph of FIG. 8, furnace 24 can be preheated to a steady state temperature T S , which can range from about 200° C. to about 1200° C. At least one silicon wafer 22 is loaded ( 44 ) into furnace 24 using transport system 18 . After the wafer is loaded ( 44 ) into furnace 24 , wafer 22 is heated from the initial temperature T S to a processing temperature T P . The processing temperature T P can range from between about 200° C. to about 1200° C.; preferably a range of between about 400° C. to about 1100° C.
[0027] In one embodiment, as the wafer temperature in furnace 24 approaches processing temperature T S , a process gas, such as oxygen, is introduced ( 48 ) into chamber 24 . The rate of flow of the process gas through processing chamber 24 or the partial pressure of the reactive gas is controlled to control the desired rate of growth. It should be understood that when furnace 24 has been pulled to vacuum, the pressure line in FIG. 8 represents the actual pressure P A of furnace 24 . Wafer 22 is held in furnace 24 exposed to the oxygen for a time long enough to accomplish the growth of the layer of SiO 2 The thickness of the SiO 2 layer can range from about 10 Å to about 50 Å; preferably between about 10 Å to about 30 Å. Generally, the processing time can range from about 1 to 20 minutes, depending on the process temperature and process ambient conditions.
[0028] In an alternative embodiment, the growth rate of the thin film layer can be controlled by controlling the partial pressure P P (FIG. 8) of the reactive gas relative to all gases introduced ( 48 ) into furnace 24 . For example, an inert gas, such as Helium or Argon, may be introduced into furnace 24 , creating a specific chamber pressure. The reactive gas can be introduced such that the partial pressure P P of the reactive gas relative to the chamber pressure is at the desired pressure level for formation of the thin film layer. Optionally, an inert gas, such as N 2 or the like, can be introduced into furnace 24 prior to, with, or after the introduction of the reactive gas to dilute the reactive gas to the desired partial pressure P P . For example, with no intent to limit the invention thereby, under a partial pressure of 1 Torr the growth rate of O 2 can be maintained at 10-20 Å/hr. and at a partial pressure of 1 atm the growth rate of O 2 can be maintained at 1-2 Å/min.
[0029] Referring again to FIG. 2, the growth of SiO 2 on the wafer surface can be stopped at processing temperatures by pulling furnace 24 to vacuum ( 49 ) before removing wafer 22 from the furnace. The wafer is then removed ( 50 ) from chamber 24 , using transport system 18 . The wafer is allowed to cool to between about 50° C. and 90° C. before being returned to cassette 14 . In an alternative embodiment, the growth of the SiO 2 layer can be slowed or almost stopped by removing the wafer from furnace 24 . Removal of the wafer causes the wafer to cool below processing temperatures.
[0030] [0030]FIGS. 3A and 4A, are simplified illustrations of embodiments of furnace 24 . In each embodiment, furnace 24 may include a closed-end process inner chamber 52 , which defines an interior cavity 54 . In one embodiment, inner chamber 52 may be constructed with a substantially rectangular cross-section, having a minimal internal volume surrounding wafer 22 . For example, the volume of inner chamber 52 may be no greater than about 5000 mm 3 , preferably the volume is less than about 3000 mm 3 . One result of the small chamber volume is that uniformity in temperature is more easily maintained. Additionally, the small tube volume allows furnace 24 to be made smaller, and as a result, system 10 may be made smaller, requiring less clean room floor space. Inner chamber 52 may be made of quartz, silicon carbide, Al 2 O 3 , or other suitable material.
[0031] In one embodiment, inner chamber 52 includes a wafer support structure 56 , which supports wafer 22 during processing. Wafer support structure 56 may be formed into the inner wall of inner chamber 52 . An open central portion of wafer support structure 56 allows wafer 22 to be supported on a peripheral edge 58 of wafer 22 .
[0032] [0032]FIGS. 3A, 4A, 3 B and 4 B illustrate embodiments for use with heating elements of reactor 24 . The heating elements are configured to surround inner process chamber 52 . In the embodiment, shown in FIGS. 3A and 3B, the heating elements include heating device 60 . Heating device 60 includes a plurality of tubes 62 , preferably aluminum tubes, disposed in parallel across a top and bottom portion of inner chamber 52 . Each aluminum tube 62 includes a resistive heating element 64 disposed therein.
[0033] Each resistive heating element 64 includes a resistive heating element core and a filament wire. The core is usually made of a ceramic material, but may be made of any high temperature rated, non-conductive material. The filament wire is wrapped around the core to allow for an optimal amount of radiated heat energy to emanate from the element. The filament wire may be any suitable resistively heatable wire, which is made from a high thermal conductivity material for increased thermal response and high temperature stability, such as SiC, SiC coated graphite, graphite, NiCr, AlNi and other alloys. Preferably, the resistive heating filament wire is made of a combination Al—Ni—Fe material, known commonly as Kantal A-1 or AF, available from Omega Corp. of Stamford, Conn.
[0034] Each tube 62 is in relative close proximity to each other element, for example, each tube 62 may be spaced between about 0 mm and 50 mm, preferably between about 1 mm and 20 mm. Accordingly, the close spacing provides for an even heating temperature distribution across wafer 22 when positioned in inner chamber 52 . The plurality of tubes 62 are contained in a quartz container 66 to reduce the possibility of metal contamination.
[0035] [0035]FIGS. 4A and 4B illustrate an alternative embodiment of the heating element of reactor 24 . In this embodiment, heating device 70 includes a ribbon shaped heating element 71 wrapped around a quartz plate 72 . Each heating device 70 can be disposed in parallel across a top and bottom portion of inner chamber 52 . Alternatively, heating element 71 can include a plurality of individual resistive heating elements combined to form the heating element.
[0036] Advantageously, a direct line voltage of between about 100 volts and about 500 volts may be used to power the resistive elements described above. Thus, no complex power transformer is needed in the present invention for controlling the output of the resistive heating elements.
[0037] [0037]FIG. 5A is a simplified diagram of an alternative embodiment of processing system 100 in accordance with the present invention. Processing system 100 includes components consistent with the description of the embodiments above, where like components are numbered similarly. The alternative embodiment of FIG. 5A includes a transport system 102 capable of simultaneously transporting a plurality of wafers 22 from loadlock 16 to process chamber 104 . Further, process chamber 104 is capable of simultaneously receiving and processing the plurality of wafers 22 . In this alternative embodiment, wafer transport system 102 includes a robot arm 106 coupled to a plurality of end-effectors 108 . End-effectors 108 are arranged in a stacked configuration and spaced apart with sufficient space to simultaneously access a plurality of wafers 22 in cassette 14 . Wafer transport system 102 is capable of lifting the multiple wafers 22 from wafer cassette 14 and, through a combination of linear and rotational translations, transporting wafers 22 through vacuum chamber valves 28 and 29 , and depositing the wafer at the appropriate position within processing chamber 104 . Similarly, wafer transport system 102 is capable of transporting wafers 22 from one processing chamber 104 to another (not shown) and from a processing chamber back to wafer loading station 12 .
[0038] In one embodiment, robot arm 106 is moved up and down as indicated by arrow 110 . In this manner, robot arm 106 can move the plurality of end-effectors 108 into position to pick up the wafers. In this embodiment, robot arm 106 controls five end-effectors 108 . Thus, each end effector 108 is capable of servicing approximately 20% of wafer cassette 14 .
[0039] In yet another embodiment, robot arm 106 is fixed for movement in the vertical direction. In this embodiment, wafer loading station 12 includes the capability of moving wafer cassette 14 in the direction indicated by arrow 112 once wafer cassette 14 is in loadlock 16 . Wafer cassette 14 is moved incrementally a distance sufficient to allow each end-effector 108 to access a portion of wafers 22 .
[0040] [0040]FIG. 5B is a simplified illustration of a front view of furnace 104 . As shown in FIG. 5B, furnace 104 is a series of stacked furnaces including a plurality of inner chambers 52 . Each inner chamber 52 is capable of receiving one wafer 22 delivered by robot arm 106 and end effectors 108 (FIG. 5A). Advantageously, in the stacked arrangement, the bottom heating device 114 , for example, can serve as the beating device for a subsequent inner chamber 52 . This arrangement saves energy, materials, and floor space.
[0041] [0041]FIG. 6 is an illustration of yet another alternative embodiment of processing system 80 in accordance with the present invention. Processing system 80 includes components consistent with the description of the embodiments above, where like components are numbered similarly. Processing system 80 includes a process chamber 82 capable of processing a plurality of wafers 22 . In this embodiment, wafer 22 is removed from cassette 14 and transported through process system 80 by wafer transport system 86 into process chamber 82 . Wafer transport system 86 lifts a wafer 22 from wafer cassette 14 and, through a combination of linear and rotational translations, transports the wafer through transport chamber 88 , and deposits the wafer at the appropriate position within furnace 82 . Similarly, wafer transport system 86 is capable of transporting wafer 22 from one processing chamber to another (not shown) and from a processing chamber back to wafer loading station 12 .
[0042] [0042]FIGS. 7A and 7B show an embodiment of process chamber 82 (FIG. 6) which includes a heating assembly 120 includes heating member or plate 121 , at least one heat source 122 , and a coupling mechanism 124 . Heating assembly 120 may be positioned suspended within process chamber 82 , in a cantilevered relationship on a wall of process chamber 82 . Alternatively, heating assembly 120 may rest on mounts emanating up from a floor of process chamber 82 .
[0043] Heating plate 121 may have a large mass relative to wafer 22 , and may be fabricated from a material, such as silicon carbide, quartz, inconel, aluminum, steel, or any other material that will not react at high processing temperatures with any ambient gases or with wafer 22 . Arranged on a top surface of heating plate 121 may be wafer supports 126 . In a preferred embodiment, wafer supports 126 extend outward from the surface of heating plate 121 to support the single wafer 22 . Wafer supports 126 are sized to ensure that wafer 22 is held in close proximity to heating plate 121 . For example, wafer supports 126 may each have a height of between about 50 μm and about 20 mm, preferably about 2 mm to about 8 mm. The present invention includes at least three wafer supports 126 to ensure stability. However, the total contact area between wafer supports 126 and wafer is less than about 350 mm 2 , preferably less than about 300 mm 2 .
[0044] Heating plate 121 may be formed into any geometric shape, preferably a shape which resembles that of the wafer. In a preferred embodiment, heating plate 121 is a circular plate. The dimensions of heating plate 121 may be larger than the dimensions of wafer 22 , such that the surface area of the wafer is completely overlaid by the surface area of heating plate 121 . Preferably, the diameter of heating plate 121 may be no less than the diameter of wafer 22 , preferably, the diameter of heating plate 121 is greater than the diameter of wafer 22 . For example, the radius of heating plate 121 is greater than the radius of wafer 22 by about a length of between about 1 mm and 100 mm, preferably 25 mm.
[0045] In one embodiment, on a periphery of heating plate 121 is coupled at least one heat source 122 . Heat source 122 may be a resistive heating element or other conductive/radiant heat source, which can be made to contact a peripheral portion of heating plate 121 or may be embedded within heating plate 121 . The resistive heating element may be made of any high temperature rated material, such as a suitable resistively heatable wire, which is made from a high mass material for increased thermal response and high temperature stability, such as SiC, SiC coated graphite, graphite, AlCr, AlNi and other alloys. Resistive heating elements of this type are available from Omega Corp. of Stamford, Conn.
[0046] Coupling mechanism 124 includes a mounting bracket 128 and electrical leads 130 to provide an electrical power connection to heat source 122 . Mounting bracket 128 may be coupled to an internal wall of process chamber 82 using conventional mounting techniques. Once mounted, electrical leads 130 can extend outside of process chamber 82 to be connectable to an appropriate power source. The power source may be a direct line voltage of between about 100 volts and about 500 volts.
[0047] [0047]FIG. 7C is an illustration of yet another embodiment of the present invention. As shown in the figure, a plurality of heating plates 121 may be stacked together within process chamber 82 . In a preferred embodiment, mounting holes 132 (FIG. 7B) are provided on a periphery of heating plates 121 and extend therethrough. Any appropriate number of mounting holes may be used to ensure that each heating plate 121 is supported. However, each mounting hole is positioned, such that the loading/unloading of wafer 22 is not hampered. Preferably, as illustrated in FIG. 7B, each mounting hole 132 is positioned on a half of heating plate 121 near coupling mechanism 124 . This arrangement ensures that the loading/unloading of wafer 22 onto heating member 120 is not impeded. In one embodiment, a rod 134 or similar member is threaded through mounting holes 132 and spacers 136 . Spacers 136 keep heating plate 121 an appropriate distance away from one another, which ensures that wafer supports 126 and wafer 22 can be fit in-between the stacked heating plate by, for example, robot arm 106 (FIG. 5A) or wafer transport system 86 (FIG. 6). The distance between the stacked heating plates may be between about 10 mm and 50 mm, for example, about 20 mm. The top most stacked heating plate 138 may be the same in structure and performance as the other heating plates 121 , except that the top most heating plate 138 may not be used to support wafer 22 .
[0048] The description of the invention given above is provided for purposes of illustration and is not intended to be limiting. The invention is set forth in the following claims. | A method for forming a thin film on a semiconductor wafer. The method includes loading a semiconductor wafer into a process chamber while the process chamber is under vacuum pressure, or alternatively, while the partial pressure of the reactive gas is substantially zero. The process gas is introduced under pressure into the process chamber. The semiconductor wafer is unloaded from the process chamber while the process chamber is under a vacuum pressure, or alternatively while the partial pressure of the reactive gas is substantially zero. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an air intake system of an engine and more particularly to an air intake system of an engine having a tumble generating valve for generating tumble stream in a combustion chamber of the engine.
2. Discussion of Related Arts
It is well known that the combustion condition of an internal combustion engine enhances when a tumble stream is generated in a combustion chamber of the engine. When the combustion condition enhances, miscellaneous advantages such as an improvement of startability of an engine, an improvement of exhaust emissions by making a lean mixture condition and the like, are provided.
Japanese Patent Application Laid-open No. Toku-Kai-Hei 5-209582 discloses an air intake system in which an intake port is divided into two parts, a light load port and a heavy load port, by a partition and a tumble generating valve is provided on the heavy load port side. A fuel injector is disposed opposite to the partition such that injected fuel collides against the partition directly and a part of the partition against which fuel collides is shaped in convex and concave so as to enhance atomization of fuel.
The tumble generating valve (hereinafter referred to as TGV) is closed at starting. That is, at starting, in order to enhance startability or to make lean air-fuel mixture, air-fuel mixture is supplied only from the light load port side with the TGV closed so as to generate a tumble stream in the combustion chamber. Further, from the view point of reducing cranking time, it is desirable that the TGV has been closed before the ignition switch is turned on in order to delete time lag necessary for closing the TGV when the ignition switch is turned on. Hence, the TGV is closed when the engine stops and is maintained in a closed condition until the engine is started again.
However, when the TGV is left closed while the engine is in standstill, the engine is cooled down and as a result the TGV is apt to be stained with oil, residues and the like. Further, when temperature is low, the TGV might be frozen by water. As a result, there is a problem that the TGV is stuck due to stains or frozen water.
One solution of this problem is that the TGV is left open when the engine is in standstill. However, since it is necessary to close the TGV once when the engine is started, the starting time is elongated by an operation time (0.5 to 1.0 second) of the TGV from an open to closed condition. This elongation of starting time provides a driver with a bad operational feeling and spoils a customer's satisfaction. Accordingly, the structure of the TGV remaining open can not introduced easily.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an air intake system having a tumble generating valve (TGV) capable of preventing a faulty operation without spoiling startability of an engine.
To attain the object, an air intake system of an internal combustion engine having an intake passage divided into a first passage and a second passage downstream of a throttle valve and a control valve provided in the first passage for controlling a flow of air comprises an electronic control unit provided to open and hold the control valve at a specified opening angle while the engine is inoperative after the engine is stopped. Also, the electronic control unit of the air intake system is adopted to fully close the control valve before opening the control valve at the specified angle.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view showing an air intake system of an engine according to an embodiment of the present invention;
FIG. 2 is a flowchart showing a control strategy of a TGV of the air intake system of FIG. 1 when an engine is stopped; and
FIG. 3 is a flowchart showing a control strategy of a TGV of the air intake system of FIG. 1 when an engine is stopped.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, reference numeral 1 denotes a cylinder block of an engine and reference numeral 2 denotes a cylinder head in which an intake port 3 and an exhaust port 4 are formed. The intake port 3 and exhaust port 4 are provided with an intake valve (not shown) and an exhaust valve (not shown) respectively. The cylinder block 1 includes a cylinder bore 5 in which a piston 6 is slidably disposed. Further, a combustion chamber 7 is formed by an inner wall of the cylinder bore 5 , a top surface of the piston 6 and an undersurface of the cylinder head 2 . Further, the intake port 3 is connected at the upstream side thereof with an air intake system 10 .
The air intake system 10 has an intake manifold 11 communicating with the intake port 3 and a throttle valve 12 on he upstream side thereof. As shown in FIG. 1, a partition 8 is provided at and part close to the intake port 3 of the intake manifold 11 so as to separate an air intake passage 9 into two passages. That is, a main passage (first passage) 13 and a tumble passage (second passage) 14 are formed in the intake manifold 11 .
There is provided a tumble generating valve (TGV) 15 in the main passage 13 . The TGV 15 has a valve 16 and a shaft 17 and is controlled by an electronic control unit (ECU) 18 . When an opening angle of the TGV is controlled at 0 degree, the main passage 13 is in a closed condition.
The shaft 17 is actuated by a DC motor (not shown). The DC motor is controlled by the ECU 18 which outputs control signals based on an ON-OFF signal of the ignition switch, an engine speed and the like. The shaft 17 is shared with TGVs of other cylinders so as to actuate other TGVs simultaneously when the shaft 17 is driven. Further, the shaft 17 is connected with the DC motor through gears and the like so that the reduced number of rotation of the motor is transmitted to the shaft 17 .
On the other hand, the tumble passage 14 is provided with a fuel injector 19 . When the TGV 15 is closed and intake air is delivered to the intake port 3 only through the tumble passage 14 , a tumble stream is generated in the combustion chamber 7 as shown by a broken line of FIG. 1 .
Next, how to control the TGV 15 of thus constituted air intake system 10 will be described by reference to FIG. 2 . First, when the engine is in standstill, the TGV 15 is not completely closed but the valve 16 is held slightly open. That is, when the engine is started, the valve 16 is transferred from a slightly open condition to a fully closed condition.
At a step S 1 , it is checked whether the ignition switch is turned on or off. Then, in case where the ignition switch is turned on, the program goes to a step S 2 where it is checked whether or not the engine is operative. In case where the engine is operative, the program goes to a step S 3 where the TGV 15 is normally controlled. Then, the program goes to a step S 4 where a flag F 1 is set and the program leaves the routine.
On the other hand, in case where it is judged at the step S 2 that the engine is not operative, that is, the engine is in standstill, the program goes to a step S 5 where the flag F 1 is checked. When the engine stalls, since the flag F 1 is set, the program goes from the step S 5 to a step S 6 .
At the step S 6 , the TGV 15 (drive motor) is energized for 1.5 seconds for example to be rendered fully closed once. At this moment, the ECU 18 recognizes this position as 0 degree. Then, the program goes to a step S 7 where the TGV 15 is energized in an opening direction for 0.3 seconds for example to be rendered open by 10 degrees. After the TGV 15 is set in a slightly open condition, the program goes to S 8 where the flag F 1 is cleared. Then, the program goes to a step S 9 where a flag F 2 which will be described hereinafter is checked.
Since this is not a case where the ignition switch is suddenly turned off while the engine is operative, the flag F 1 has not yet set and the program goes from the step S 9 directly to RETURN.
After that, at a next routine, when the ignition switch is left on, the program steps from S 1 to S 2 . Since the engine is already stopped and the flag F 1 is cleared, the program leaves the routine through the step S 5 . On the other hand, the ignition switch is turned OFF, the program goes from the step S 1 to a step S 12 . Since the flag F 1 has been already cleared, the program goes to a step S 11 where the power source of the ECU 18 is shut-off and an execution of the routine is stopped.
In case where the ignition switch is turned off while the engine is operative, there is a very short instant that the engine is in standstill with the ignition switch turned on. Hence, in order to do a series of operation S 1 , S 2 , S 5 , S 6 and S 7 until the TGV is in the slightly open condition, a very fast processing is needed.
However, it is difficult to require such fast processing from the ECU 18 which must do miscellaneous engine controls. Accordingly, in case where the ignition switch is suddenly turned off, the flag F 2 is set after this condition is recognized and the TGV 15 is controlled from a fully closed condition to a slightly open condition while some leeway time is given to the shutting-off of the power source of the ECU 18 .
Since the ignition switch is turned off, the program goes from the step S 1 to the step S 12 where the flag F 1 is checked. In this case, since the engine was operative immediately before, the flag F 1 which has been set at the step S 4 is still remained. On the other hand, in case where the ignition switch has been turned off after the program passed steps S 1 , S 2 , S 5 , S 6 , S 7 and S 8 , the flag F 1 has been cleared. That is, it can be judged by confirming the existence of the flag F 1 at the step S 12 whether or not the ignition switch has been suddenly turned OFF while the engine is operated.
As a result of confirmation at the step S 12 , in case where the flag F 1 is set, it is judged that the ignition switch is turned off and the program goes to a step S 13 where the flag F 2 is set. After the flag F 2 is set, the program goes to S 6 where the TGV 15 is fully closed. Then, the program goes to the step S 7 in which the TGV 15 is slightly open and goes to the step S 8 .
At the step S 8 , the flag F 1 is cleared and the program steps to a step S 9 .
At the step S 9 , the flag F 2 is checked. In this case, since the flag F 2 is set, the program goes to a step S 10 where the flag F 2 is cleared. Further, the program goes to a step S 11 where the power source of the ECU 18 is shut off and then the program leaves the routine. In this case, since the ignition switch is turned off and also the power source of the ECU 18 is shut off, the present routine is finished here.
According to the air intake system 10 of the present invention, the TGV 15 is set to a slightly open condition (opening angle is 10 degrees in this embodiment) and is held in this condition until the engine is started next again. While the engine is in standstill, a small clearance is made between the valve 16 of the TGV 15 and the inner wall of the main passage 13 . This small clearance prevents the valve 16 from being stuck or inappropriately operated due to stains and frozen water adhered to surroundings of the valve 16 . Accordingly, a faulty operation of the TGV 15 due to stains or frozen water can be prevented without particularly using new devices or members.
Next, how to control the TGV 15 at when the engine is started will be described by reference to FIG. 3 . As shown in FIG. 3, when the ignition switch is turned on, at a step S 21 it is checked whether or not the engine is started. Unless the engine is started, the program goes to a step S 22 where the TGV 15 is fully closed and leaves the routine.
That is, the ECU 18 energizes the TGV 15 in a closing direction for 0.5 seconds to fully close the TGV 15 which has been slightly opened by the control when the engine stops previously. At this moment, time needed for fully closing the TGV 15 is very short, about 0.1 to 0.3 seconds. Accordingly, the air intake system 10 using this type TGV can prevents the TGV 15 from being stuck without spoiling startability.
Further, when the TGV 15 is fully closed, the main passage 13 is closed and as a result air is supplied to the intake port 3 only through the tumble passage 14 . As a result, a tumble stream is formed in the combustion chamber 7 and startability can be enhanced. On the other hand, when the engine starting is confirmed at the step 21 , the program goes to s step S 23 where the TGV 15 is controlled in an ordinary manner and leaves the routine.
According to the aforesaid embodiment, the TGV is designed so as to be fully closed once when the engine stops but it is possible to directly place the valve in a slightly open condition.
Further, time energizing the TGV 15 and an valve opening angle in a slightly open condition are not restricted to examples described before. For example, the valve opening angle in a slightly open condition can be established arbitrarily within the scope of not affecting the extension of starting time. However, considering the closing time of the valve, the valve opening angle is preferably less than 15 degrees.
Further, in this embodiment the air intake system incorporating a tumble generating valve (TGV) is described but the present invention may be applied to an air intake system having a swirl control valve (SCV) for generating a swirl stream in the combustion chamber.
While the presently preferred embodiment of the present invention has been shown and described, it is to be understood that this disclosure is for the purpose of illustration and that various changes and modifications may be made without departing from the scope of the invention as set forth in the appended claims. | An intake passage of an internal combustion engine is divided into two intake passages downstream of a throttle valve. A tumble generating valve is disposed in one of these two intake passages. When the engine is stopped, the tumble generating valve is fully closed once and then opens by a specified opening angle. While the engine is inoperative, the tumble generating valve is held at that angle until the engine is started again. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to automotive seat assemblies having arm rests which are pivotally mounted to the seat back and seat backs which can be rotated forward, or dumped, to provide access to the area behind the seat. More particularly, this invention relates to a mechanism for moving the arm rest to a position along side the seat back in response to forward rotation of the seat back.
Seats which dump forward are used in a number of applications. These include front seats in two door automobiles, rear seats in station wagons, and pickup trucks and utility vehicles with storage space behind the seats. Certain vehicles, primarily pick-up trucks and other utility vehicles, are often equipped with large bucket seats frequently referred to as captain's chairs. Such a seat often includes an arm rest attached to the seat back on one or both sides of the seat back. These arm rests are hinged to the seat back to allow the arm rest to be rotated upward along the side of the seat back and out of the way for passengers entering the vehicle.
A problem with arm rests attached to the seat back is that if the arm rests are not moved upward, the arm rest may interfere with other interior vehicle components as the seat back is dumped. This can limit the amount of tilting of the seat back, thus reducing the access to the area behind the seat.
The outboard arm rest typically does not present a problem as the occupant will raise this arm rest to the upper position before leaving the vehicle to dump the seat back. The inboard arm rest, however, is frequently left in the horizontal position thus limiting the tilting of the seat back.
Accordingly, it is an object of this invention to provide a seat assembly for a motor vehicle in which the arm rest is automatically rotated along the side of the seat back when the seat back is dumped forward.
SUMMARY OF THE INVENTION
In one embodiment, the arm rest is automatically moved by a cable which is attached to the seat cushion and arm rest such that when the seat back is rotated forward, the tension in the cable is increased creating a moment about the arm rest pivot to rotate the arm rest upward relative to the seat back.
In a second embodiment, a spring is used to maintain the tension in the cable at or above a predetermined level to prevent slack in the cable.
In a third embodiment, a solid link is attached to the side of the seat cushion, forward of the seat back pivot and to the arm rest, forward of the arm rest pivot. The arm rest, link, seat cushion and seat back thus form a four bar linkage. As the seat back is dumped, the link causes the arm rest to rotate relative to the seat back. The arm rest can be manually raised along the side of the seat back when the seat back is in its upright position. This is accomplished by providing a slot in the link at its lower end such that the link can be pulled upward as the arm rest is manually moved.
Further objects, features and advantages of the invention will become apparent from a consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the seat assembly with the automatic arm rest adjusting mechanism of this invention;
FIG. 2 is a side elevation view of the seat assembly of FIG. 1 partially cut away to show a form of the automatic arm rest adjusting mechanism that utilizes a cable;
FIG. 3 is a side view of the seat assembly of FIG. 1 showing the seat back in a reclined position in broken lines and the manually lifted position of the arm rest also in broken lines;
FIG. 4 is a side view of the seat assembly like FIG. 3 showing the seat back in a forwardly dumped position and the resulting lifted position of the arm rest;
FIG. 5 is a side elevation view of the seat assembly containing an automatic arm rest adjusting mechanism which utilizes a solid link;
FIG. 6 is a side elevation view of the seat assembly of FIG. 5 showing the seat back in the dumped position;
FIG. 7 is a broken away fragmentary side elvation view of the seat assembly of FIG. 2 with a cable adjust mechanism employing a spring to maintain tension in the cable;
FIG. 8 is a side view of the spring tension device of FIG. 7 with the arm rest in the manually raised position along the side of the seat back;
FIG. 9 is a rear elevation view of the seat assembly having the arm rest adjusting mechanism of FIG. 7;
FIG. 10 is an exploded perspective view of the seat assembly of FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, in FIG. 1 one form of a seat assembly 10 is shown embodying the principles of this invention. Seat 10 contains a lower seat cushion 12 having a front end 13 and rear end 11. Mounted to the rear end 11 of cushion 12 is a seat back 14. The lower end of seat back 14 is pivotally mounted to the seat cushion by a back pivot member 15. Extending forward from the seat back along its side between the lower and upper end thereof is an arm rest 16. Arm rest 16 extends forward in a generally horizontal operative position. Arm rest 16 is pivotally mounted to seat back 14 by an arm pivot member 18. To prevent the arm rest 16 from interfering with other vehicle components as the seat back is dumped from an upright position to a forwardly inclined position, the arm rest is pivoted upwardly to a position along the side of the seat back. The arm rest can be pivoted manually upward by the vehicle occupant if so desired. To avoid an interference between the arm rest and other components when dumping the seat back if the vehicle occupant forgets to raise the arm rest, a mechanism to automatically raise the arm rest in response to the forward motion of the seat back is provided and described below.
One mechanism to automatically lift the arm rest is shown in FIG. 2 where a portion of the arm rest and seat upholestery is cut away to show the lift mechanism. One end of a cable 20 is attached to the frame 22 of seat cushion 12 by an anchor member 23. The member 23 is located rearward of back pivot member 15. Cable 20 passes behind and over cam plate 24 around arm pivot member 18 and is attached to arm rest frame 26 by an attaching member 28. Cam plate 24 includes an arcuate surface 25 spaced radially from pivot member 18. Attachment 28 is above and forward of pivot 18. The location of attachment 23 rearward of back pivot member 15 results in cam action of the cable moving over the surface of cam plate 24 as the seat back is tilted forward. When the seat back is tilted forward, the tension in cable 20, acting on arm rest frame 26 through attachment 28, creates a counterclockwise moment about arm pivot member 18 which will rotate the arm rest 16 upward relative to the seat back.
Cable 20 will permit manual rotation of arm rest 16 to the position shown with broken lines in FIG. 3 while the seat back 14 is in the upright position. This motion is shown by arrow 30. Additionally, cable 20 permits seat back 14 to be reclined rearward as shown by arrow 32 to the position shown in broken lines.
When seat back 14 is dumped about pivot member 15, the distance between cable attachment 23 and the point of cable contact with cam 24 increases. This causes arm rest 16 to rotate relative to seat back 14. As the arm rest rotates, the length of cable in contact with the cam decreases to compensate for the increased distance from anchor 23 to cam 24.
Referring now to FIGS. 5 and 6, another embodiment of the automatic arm rest lift mechanism of this invention is shown. In this embodiment, a link 40 is attached to seat cushion 12 by a pin 42 and to arm rest 16 by a pin 44. Pins 42 and 44 extend through apertures at each end of the link 40. The link 40, seat cushion 12, seat back 14 and arm rest 16 cooperate to form a four bar linkage. Pins 42 and 44 are located forward of pivot members 15 and 18 respectively. When the seat back 14 is rotated forward about the back pivot 15, the link 40 exerts an upward force on the arm rest 16 creating a counterclockwise moment about pivot 18 to rotate arm rest 16 upward.
The aperture in link 40 at pin 42 includes a slot 46 which enables the arm rest 16 to be manually raised when seat back 14 is in the upright position as shown by arrow 48 and the broken line 17. In addition, slot 46 allows seat back 14 to be tilted rearward as shown by arrow 50 and broken line 21.
A variation of the cable actuated arm rest embodiment shown in FIGS. 1-4 is shown in FIGS. 7 through 10. In this variation, a spring is used to maintain the tension on the cable. Mounted to arm rest frame 26, is a "C" channel 62 which, when attached to frame 26, defines a hollow spring guide 64. Fixed within the spring guide is a stop 66 having a center opening through which extends a secondary cable 70 attached at one end to the primary cable 72. The opposite end of cable 70 is attached to a hollow sliding block 74 which slides within spring guide 64. Coil spring 76 surrounds cable 70 within spring guide 64 and is compressed by movement of sliding block 74 toward pivot 18.
The secondary cable 70 has a slightly smaller diameter than primary cable 72. This allows for easy movement of the secondary cable within the spring guide. A single cable could be used or, alternatively, a metal rod could be used in place of the secondary cable.
The sliding block 74 at the radially outer end of secondary cable 70 is used primarily to engage one end of spring 76 for compression of the spring. Other fittings may be used at the end of cable 70 for engaging the spring 76.
Cable 72 wraps around a cam plate 78 about pivot member 18 and extends downward to cable anchor 80 mounted to seat cushion frame 82 as shown in FIG. 9. Cable 72 includes a threaded bolt 84 at its end which is used to adjust the cable length during assembly of the seat. Bolt 84 extends through an aperture in the anchor plate 85 attached to seat cushion frame 82 and is held in place by nut 86. A cable guide 88 is attached to the seat back 14 to ensure that the cable 72 is routed properly as the seat back moves forward.
When the seat back is in the upright position and the arm rest in the horizontal position as shown in FIG. 7, the sliding block 74 is in contact with stop 66 and and spring 76 is at maximum compression. As the seat back 14 is moved forward from this position, the tension in cable 72 creates a clockwise moment about pivot 18 as seen in FIG. 7. This moment causes arm rest 16 to rotate relative to the seat back 14 toward a position along side the seat back.
Arm rest 16 can also be manually rotated to a position along side upright seat back 14 as shown by broken lines 19 in FIG. 7. In this position, the sliding block 74 is moved to the end of spring channel 64 away from pivot member 18 by spring 76 as shown in FIG. 8. Spring 76 is used in this manner to maintain the tension in cable 72 at a predetermined level to avoid slack in cable 72.
FIGS. 9 and 10 illustrates the details of the arm rest assembly. Screws 89 are used to attach the "C" channel 62 to the arm rest frame 26 forming the hollow spring guide 64. Bolt 91 attaches the arm rest frame 26 to pivot point 18 through the spacer ring 93 and plate 95. Spacer 99 and plate 95 are mounted to stud 97 by set screw 94 to provide a positioning stop to support the arm rest 16 in a generally horizontal position extending from seat back 14 when the seat back is in the upright position.
As can be seen, either a cable or a link can be used to provide a means whereby the arm rest is moved from its operative position extending forward from the seat back to a position along side the seat back. The arm rest is moved in response to forward motion of the seat back from an upright position to a forwardly inclined position. This is accomplished by the cable or the link creating a moment about the arm rest pivot to rotate the arm rest relative to the seat back. In addition, both the cable and link allow the arm rest to be manually raised along side the upright seat back and allow the seat back to be reclined rearward.
It is to be understood that the invention is not limited to the exact construction or method illustrated and described above, but that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. | An adjusting mechanism is disclosed for automatically raising the arm rest of a vehicle front seat assembly when the seat back is tilted forward to permit ingress to and egress from the back seat of a two door motor vehicle. In one embodiment a solid link is attached to the arm rest and to the seat cushion to exert an upward force on the arm rest as the seat back is moved forward. In two other embodiments, a cable attached to the arm rest and to the seat cushion is provided which exerts an upward force on the arm rest as the tension in the cable increases when the seat back is rotated forward. In one embodiment, a spring is used to maintain the tension in the cable at a predetermined level. | 1 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/526,949 filed Aug. 24, 2011 by the same inventors and bearing the same title as the present application, which is hereby incorporated by reference as if repeated herein in its entirety, including the drawings.
BACKGROUND
[0002] The present invention relates generally to communications systems and more particularly to a communication system for connecting people to emergency services, responders and service providers, friends and family.
[0003] Existing emergency call centers provide insufficient services for many special needs citizens. There exists no simple means to access emergency call centers that uses the full capability of existing technology that provides access to these call centers beyond a “voice-only” communication. A need exists as well for public safety authorities to receive and share information with citizens in a crisis or between and among first responder personnel.
SUMMARY OF THE INVENTION
[0004] The present invention solves these and other problems by providing a method and apparatus for creating a social network for emergency response situations. The present invention combines the power of social networks with the simplicity of a mobile application (App) suitable for execution on a handheld computing device to provide individuals and enterprises with easy, immediate access to the necessary answering points to share information in an emergency or accident.
[0005] The present invention provides an easy to use application on any smart phone or other similar device, including tablets, thereby enabling any individual to connect with the nearest Public Safety Answering Point (PSAP) via voice, text, image or video communication.
[0006] In addition, the present invention allows individuals to create a customized private social emergency response network (e.g., doctor or health care provider or group) and personal emergency response network (e.g., family and friends).
[0007] Moreover, the present invention provides a powerful solution for enterprise needs such as telematics, health care, home or office security firms, as well as any non 9-1-1 (or 112/999/066 etc.) call center or command and control center, and a wide range of other security and response needs. The present invention accomplishes the aforesaid by creating an emergency response social network, customized by the individual or enterprise and the PSAP based on their capability, which establishes a platform for the individuals and enterprises to communicate using a wide range of next generation applications. The present invention can direct calls or transfer of text, images, or video to any call center.
[0008] The social network of the present invention provides a free communication platform between individuals and emergency call centers (911/112/999/066 or whatever the local emergency call number is, anywhere on the globe) enabling a full range of communications options, including texting, sharing photos, live video transfers and video calls, and voice communications services made possible by a smart phone or other similar handheld computing device.
[0009] The service of the present invention does not require any new terminal costs—only a broadband, Internet or wireless connection between the PSAP and the citizen's smart phone or other similar handheld computing device is required.
[0010] The present invention provides a flexible platform and allows the citizen to customize what personal information they desire to be shared in the case of an emergency and well as to whom to notify in case of an emergency. The present invention also allows the PSAP to customize the form and nature of the communications the PSAP is prepared to receive from a citizen in an emergency situation, as well as allowing the PSAP to transfer information to first responders or other emergency organizations or personnel in a real time basis.
[0011] The present invention includes an Application (App) that may be downloaded on any smart phone, other similar handheld computing/communication device and any computer. The App of the present invention provides the exact location of the citizen who requests help by calling, texting, or initiating a video communication. The citizen's location is received by the PSAP over whatever mapping system the PSAP is using.
[0012] In addition to a free service connecting the individual citizen with the emergency call center closest to their location, the platform of the present invention provides citizens and enterprises with a powerful tool to address a wide range of emergency response needs that connect individuals with their health care practitioner, health insurance provider, security services, as well as family, friends, coworkers and neighbors. These applications are available at minimal cost and can be tailored to suit the specific need of the consumer or enterprise using the platform of the present invention. The Emergency Social Network of the present invention provides enterprises providing health care, security, or telematics services with a powerful tool to communicate with customers, insurance companies, patients, and local authorities to share information in an incident.
[0013] The present invention includes a service that addresses one of the most critically needed solutions for citizens and public safety authorities—create an immediate solution to launch next generation emergency call communication capabilities.
[0014] The need exists for a simple means to access emergency call centers that uses the full capability of existing technology which will provide access beyond a “voice-only” communication. At the same time, public safety authorities require the same capabilities to receive and share information with citizens in a crisis or between first responder personnel.
[0015] Additionally, the present invention includes a wide range of revenue apps that address everyday consumer needs to connect with family, friends, and neighbors and enhance communication with health care, security, and insurance services. The present invention offers a wide range of enterprise solutions for organizations and businesses, security, safety, and protection sectors.
[0016] The present invention provides a unique social media. Providing a social network for emergency services, the present invention provides a solution to a basic human need that can be greatly enhanced with existing technology.
[0017] FRESS has the capability of “reverse” emergency broadcast alerts. The emergency broadcast alerts can be done over Bluetooth and/or WiFi through FRESS enabled devices as well all other devices (or selected phones) that have WiFi or Bluetooth enabled. The emergency broadcast alert can be sent to selected phones based on location or category of user (e.g., sent only to police with registered phone numbers).
[0018] The FRESS solution combines “call-in” and “emergency broadcast alerts,” hybrid location technology and algorithms; text, photos and videos; automatic language translation; unique routing capabilities; and cloud capabilities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 depicts an exemplary embodiment of a user interface screen on a mobile telephone, smart phone, or other similar communication device, including tablets, according to one aspect of the present invention.
[0020] FIG. 2 depicts another exemplary embodiment of the user interface screen in FIG. 1 with some features grayed out according to one aspect of the present invention.
[0021] FIG. 3 depicts yet another exemplary embodiment of a user interface screen on a mobile telephone, smart phone, or other similar communication device according to one aspect of the present invention.
[0022] FIG. 4 depicts still another exemplary embodiment of a user interface screen on a mobile telephone, smart phone, or other similar communication device according to one aspect of the present invention.
[0023] FIG. 5 depicts yet another exemplary embodiment of a user interface screen on a mobile telephone, smart phone, or other similar communication device according to one aspect of the present invention.
[0024] FIG. 6 depicts still another exemplary embodiment of a user interface screen on a mobile telephone, smart phone, or other similar communication device according to one aspect of the present invention.
[0025] FIG. 7 depicts yet another exemplary embodiment of a user interface screen on a mobile telephone, smart phone, or other similar communication device according to one aspect of the present invention.
[0026] FIG. 8 depicts a diagram showing the three possible meanings of PSAP due to the present invention.
[0027] FIG. 9 a block diagram of an exemplary embodiment of a system operating in accordance with another aspect of the present invention.
[0028] FIG. 10 depicts a block diagram of an exemplary embodiment of a method operating in accordance with another aspect of the present invention.
[0029] FIGS. 11-13 depict a block diagram of an exemplary embodiment of another method operating in accordance with yet another aspect of the present invention.
DETAILED DESCRIPTION
[0030] FIG. 1 depicts an exemplary embodiment of a user interface screen on a mobile telephone, smart phone, or other similar handheld computing/communication device according to one aspect of the present invention. The invention described herein may be employed on any portable or standalone computing device, such as an IPAD, IPOD, cell phone, smart phone, mobile communication device, personal assistant, mobile computing device, personal computer, Internet enabled appliance, website interface device, tablet PC, user interface to computing device, etc., but is especially useful for use in a mobile telephone device.
[0031] Referring to FIG. 1 , upon pressing the HELP button 101 the user is transferred into HELP menu in the user's native language specified in MY FRESS or by the phones DEFAULT LANGUAGE. As used herein, FRESS refers to the mobile App executing on a smart phone, for example.
[0032] By pushing the QUIT button 102 the FRESS application will QUIT. A warning message will pop-up asking the user to confirm that he wants to QUIT the App. In any case, the App will leave a back-door open for the PSAP to re-establish the connection for 30 minutes. However, all other services in the App will be deactivated, unless the PSAP wants to re-establish them. This enables the PSAP to communicate with the smart phone if the user becomes unable to do so.
[0033] This STATUS FIELD 103 shows the connection status, such as: “Waiting for location . . . ”; “Establish connection, please wait”; “Connected to FRESS”; “No FRESS at your location”; etc. In case “connection” is lost by the carrier—the App will automatically try to re-connect. First, second and third time immediately, then five times with five second intervals, and after that five times with ten second intervals and after that every thirty seconds. Other numbers of times and intervals may be employed without departing from the scope of the present invention.
[0034] By pushing the PUSH TO CALL (PUSH TO TALK) Button 104 the application will automatically connect the user to his closest PSAP. A local database on the phone maintains records of all emergency numbers in the world. Button 104 will be automatically configured to speed-dial the correct number by the location of the device. In case the device is in a location where there is no single emergency number and/or the user has configured a PRIVATE/PERSONAL PSAP and/or the phone detects the user is not in his home country—then the application will give the user options where to call. For example, in an area with no single emergency number, one possible option comprises Police, Fire or EMS. In case of PRIVATE/PERSONAL PSAP, the options will be the PUBLIC PSAP in addition to the options configured in PRIVATE/PERSONAL PSAP. In case the device detects that the user is not in his home country, the option includes the embassy for the user's specified country. These possible options can be separate or combined.
[0035] Pressing the PUSH TO TEXT button 105 allows the user to establish an IM/CHAT with the PSAP. This function will only be available if the user has a FRESS connection (described below) and the PSAP is a FRESS PSAP (see below) that allows texting. Otherwise the Button will be shadowed and unavailable (See FIG. 1 vs. FIG. 2 ).
[0036] FRESS Connection
[0037] A FRESS connection is when the user has established a successful data connection to the FRESS Server, and has successfully been able to send the FRESS minimum data set to the FRESS Server together with its location data.
[0038] There are 3 possible situations for a user that establishes a FRESS connection.
[0039] (1) The user pushes the FRESS icon and does not have sufficient cell phone/wireless coverage to be able to send the FRESS minimum data set to the FRESS server. The user can therefore not establish a successful connection with the FRESS server. This will result in that the FRESS USER will only be able to make a VOICE call (911, 112, 999, 066 or all other emergency call) to the closest PSAP.
[0040] The FRESS button “PUSH TO TALK” on the users phone, will automatically be configured to speed-dial the correct emergency number for the user's area. In case the user is in an area where multiple choices exist, the FRESS application on the user's phone will show these options (example: police, fire-fighters, ambulance, etc.). If the user is outside his country, the FRESS application will also show the user the possibility to speed dial to the closest embassy of his home country.
[0041] The database of numbers to speed dial is built in to the FRESS application installed on the user's phone and therefore independent of a successful FRESS connection to the FRESS server. It will therefore work in any situation, in any area and on any location.
[0042] (2) The user pushes the FRESS icon and successfully sends the FRESS minimum data set to the FRESS server together with the location data of the location in where the user is. But the FRESS server responds that there is no PSAP or other call center in the area with FRESS installed and/or activated. The result will be that the FRESS USER will only be able to make a VOICE call to the closest PSAP. The FRESS button “PUSH TO TALK” on the user's phone, will automatically be configured to speed-dial the correct emergency number for the user's area. In case the user is in an area where multiple choices exist, the FRESS application on the user's phone will show these options (example: police, fire-fighters, ambulance, etc.). If the user is outside his country, the FRESS application will also show the user the possibility to speed dial to the closest embassy of the user's home country.
[0043] The database of numbers to speed dial is built in to the FRESS application installed on the user's phone, and therefore is independent of a successful FRESS connection to the FRESS server. It will therefore work in any situation, in any area and on any location.
[0044] In this scenario, the NON FRESS PSAP can choose to connect to the FRESS webpage, and introduce the IMEI- and/or IMSI- and/or Phone-Number of the user to obtain the FRESS user data set +its location for FREE. Only the PSAP in the area from which the user is calling is able to obtain the information, and only during the time that the user is connected to the FRESS server.
[0045] (3) The user pushes the FRESS icon and successfully sends the FRESS minimum data set to the FRESS server together with the location data of the location in where the user is. The FRESS server responds back that there exists a PSAP in the area of the FRESS USER that has FRESS installed and activated. The FRESS server will then open a tunneled data connection through the FRESS server between the FRESS USER and the closest FRESS PSAP. The result will be that the FRESS USER will be able to use voice, text, image and video to communicate to the FRESS PSAP. However, limitations on what the FRESS USER can use on their own initiative may depend on the FRESS PSAP's policy at that location. The FRESS button “PUSH TO TALK” on the user's phone, will automatically be configured to speed-dial the correct emergency number for the user's area. In case the user is in an area where multiple choices exists, the FRESS application on the user's phone will show these options (example: police, fire-fighters, ambulance, etc.). If the user is outside his country, the FRESS application will also show the user the possibility to speed dial to the closest embassy of the user's home country or other designated number determined by the user.
[0046] The database of numbers to speed dial is built in to the FRESS application installed on the user's phone, and therefore independent of a successful FRESS connection to the FRESS server. It will therefore work in any situation, in any area and on any location. In the case of establishing a successful tunneled data connection between the FRESS server and the closest FRESS PSAP, or other FRESS call center, the FRESS PSAP or other FRESS call center has the possibility to update the user's emergency number to call in case of a voice communication during that session, and/or to be opened directly from the FRESS PSAP/call center side. As used herein, session means a particular data connection at a given point of time, when disconnected from the FRESS server, the default number to call will be restored.
[0047] FRESS PSAP
[0048] A FRESS PSAP is a PSAP with the FRESS PSAP application installed and activated. Meaning the application is launched and has established a successful data connection with the FRESS server.
[0049] Automated Triggering of Emergency Calls:
[0050] Smart phones with FRESS installed will have the capability of automatically triggering alerts when the sensors indicate that conditions have reached a state where help has to be asked for. The type of sensor could be either of the type that is included in the smart phone, such as the accelerometer, or accessories to the smart phone, such as pulsometers and other devices.
[0051] In this way FRESS can be used to permanently monitor conditions of FRESS users, and automatically trigger the necessary connections to public, private and personal safety networks.
[0052] Pressing the PUSH TO VIDEO button 106 allows the user to send real-time video to the PSAP. This function will only be available if the user has a FRESS connection and the PSAP is a FRESS PSAP that allows real-time video. Otherwise the Button will be shadowed and unavailable (See FIG. 1 vs. FIG. 2 ).
[0053] Pressing the PUSH TO VIDEO button 107 allows the user to send a pre-recorded image or live image to the PSAP. This function will only be available if the user has a FRESS connection and the PSAP is a FRESS PSAP that allows reception of an image. Otherwise the button 107 will be shadowed and unavailable (See FIG. 1 vs. FIG. 2 ).
[0054] Pressing the DEMO button 108 allows the user to practice all functions of the App without really connecting to a real PSAP. This demo automatically connects the user to the FRESS DEMO PSAP, where the user can gain practice on how the App works.
[0055] Pressing the MY FRESS button enables the user to input personal data, select a language, enable special conditions and/or configure additional features as PRIVATE PSAP/call center and PERSONAL PSAP/call center. This is the information that is sent to the closest PSAP only, and only when the user hit the FRESS button to ask for HELP. All data is stored on the phone, not on FRESS servers. This is to keep the user's personal information private and secure until an emergency occurs, if any. If none occurs, the user's personal information is never transmitted.
[0056] Turning to FIG. 3 , shown therein is another user display screen according to one exemplary embodiment of the present invention. Pushing the BACK button 301 takes the user back to the App main menu.
[0057] Pushing the HELP button 302 takes the user into the HELP menu for the App “PUSH TO CALL” in the user's native language specified in MY FRESS or by the phones default language.
[0058] The STATUS FIELD 303 shows the call connection status, e.g.: “Calling 112 . . . ”, “Call established”, “Call lost, reconnecting . . . 5 sec . . . ”, or if the user is in the DEMO mode, etc.
[0059] In case “connection” is lost by the carrier, the App will automatically try to re-connect. First, second and third time immediately, then 5 times with 5 second interval, and after that 5 times with 10 second interval and after that every 30 seconds.
[0060] Depending on the user's configuration or location, this SCREEN 304 will change.
[0061] In case the user is in his HOME COUNTRY, and the user's home country has a single emergency number, and the user has not configured a private or personal PSAP. Then the screen will look as in FIG. 3 , directly after pushing PUSH TO CALL in the App's main menu.
[0062] The App will try to establish a normal voice-to-voice communication with the user's closest PSAP, and the user may HANG UP the call by pushing the button 304 .
[0063] Turning to FIG. 4 , shown therein is another user display screen according to one exemplary embodiment of the present invention. In case the user is in a location where there is no single emergency number and/or the user has configured a PRIVATE/PERSONAL PSAP or call center and/or the phone detects the user is not in his home country, the App will give you options where to call, as in FIG. 4 . Once the user selects an option, the App will display a screen as shown in FIG. 3 . This will occur when the user is located in an area with no single emergency number, in which case one option will be Police, Fire or EMS. In case of PRIVATE/PERSONAL PSAP/call center, the options will be the PUBLIC PSAP plus the options configuration selected in PRIVATE/PERSONAL PSAP/call center. In case the App detects the user is out of his home country, the country's embassy telephone number will be given. All of these conditions can be by separate or combined.
[0064] The witness button 405 allows the user to specify that he/she is not the one that needs the emergency, in other words, they are asking for help for someone else. This function will only be available if the user has a FRESS connection and the PSAP is a FRESS PSAP that allows for the witness function. Otherwise the Button 405 will be shadowed and unavailable.
[0065] The status field 406 tells the user if they are a witness or not, and other less important information.
[0066] Turning to FIG. 5 , shown therein is another user display screen according to one exemplary embodiment of the present invention. Pushing the BACK button 501 takes the user get back to the App main menu.
[0067] Upon pushing button 502 , the text that appears in the CHAT BOX will become smaller, whereas pushing button 503 , the text that appears in the CHAT BOX will become bigger.
[0068] Pressing the HELP button 504 takes the user into the HELP menu for the App's “PUSH TO VIDEO” in the user's native language specified in MY FRESS or by the phones default language.
[0069] STATUS FIELD 505 shows the status of the CHAT connection status: “CHAT ESTABLISHED.”, “CHAT STOPPED”, “Connection lost, reconnecting . . . 5 sec . . . ”, or if the user is in the demo mode, etc.
[0070] In case “connection” is lost by the carrier, the App will automatically try to re-connect. First, second and third time immediately, then 5 times with 5 second interval, and after that 5 times with 10 second interval and after that every 30 seconds. All TEXT during the time of lost connection will be cached on the phone and transmitted in the background once connection is re-established.
[0071] In part 506 of the screen is display the TEXT messages sent and received to/from the PSAP. The text will be shown in the SIZE specified by button 502 or 503 . The Size will be stored for future connections. All text received will be translated into the user's native language in case the PSAP has FRESS with translation service into the user's native language. Next to each message sent by the user to the PSAP, a confirmation of delivery will be shown at the end of the sentence.
[0072] In part 507 of the screen, the user can introduce any text message desired to be sent to the PSAP in his native language. The message will be automatically translated into the language of the PSAP. Once the user clicks on this part 507 of the screen, a virtual keyboard will open. In case the phone has a physical keyboard, it could be used as well. To send the message, the user hits the SEND button and/or INTRO on his keyboard.
[0073] Button 508 allows the user to specify that he/she is not the one that needs the emergency, in other words, they are asking for help for someone else. This function will only be available if the user has a FRESS connection and the PSAP is a FRESS PSAP that allows for WITNESS function. Otherwise button 508 will be shadowed and unavailable.
[0074] Status field 509 informs the user if the App is in WITNESS MODE or not, if the PSAP is writing a message back, etc.
[0075] Turning to FIG. 6 , shown therein is another user display screen according to one exemplary embodiment of the present invention. By pushing the back button 601 , the user is taken back to the App main menu.
[0076] By pushing the HELP button 602 , the user is taken to the HELP menu for the App “PUSH TO VIDEO” in his native language specified in MY FRESS or by the phones default language.
[0077] Status field 603 shows the VIDEO connection status: “VIDEO TRANSMITTING.”, “VIDEO STOPPED”, “Connection lost, reconnecting . . . 5 sec . . . ”, or if the user is in demo mode, etc.
[0078] In case “connection” is lost by the carrier, the App will automatically try to re-connect. First, second and third time immediately, then 5 times with 5 second interval, and after that 5 times with 10 second interval and after that every 30 seconds. All video recorded during the time of lost connection will be cached on the phone and transmitted in the background once connection is re-established.
[0079] In part 604 of the screen, the user will receive instructions and or messages from the PSAP. In case the user wants to respond to those messages, the user can just click on the field and the chat window will be open—without losing video connection. The text will be shown in large alphanumerical characters in order to allow the user to point the camera at objects under the camera while reading the text. The messages will scroll slowly to the right or left (language dependent) in case the message does not fit in the text box.
[0080] In part 605 of the screen, the user can see the video that is being sent in real time to the PSAP. In case the user has a cell phone with two cameras (front/back), the user will see a icon 609 in the upper right corner of the video, that by pushing it switches between the cameras.
[0081] The same window 605 can also be used to receive video instructions and/or images from the PSAP.
[0082] Button 606 allows the user to specify that he/she is not the one that needs the emergency, in other words, they are asking for help for someone else. This function will only be available if the user has a FRESS connection and the PSAP is a FRESS PSAP that allows for WITNESS function. Otherwise the Button will be shadowed and unavailable.
[0083] Button 607 allows the user to STOP any transmitting or receiving of a video or image at any time to/from the PSAP.
[0084] Status field 608 tells the user if they are a witness or not, and other less important information.
[0085] Turning to FIG. 7 , shown therein is another user display screen according to one exemplary embodiment of the present invention. Pressing back button 701 takes the user back to the App main menu.
[0086] Pressing the help button 702 takes the user into the help menu for the App “PUSH TO VIDEO” in his native language specified in MY FRESS or by the phones default language.
[0087] Status field 703 shows the image connection status: “TAKE A IMAGE TO SEND”, “IMAGE BEING TRANSMITTED.”, “IMAGE SENT”, “Connection lost, reconnecting . . . 5 sec . . . ”, or if the user is in demo mode, etc.
[0088] In case “connection” is lost by the carrier, the App will automatically try to re-connect. First, second and third time immediately, then 5 times with 5 second interval, and after that 5 times with 10 second interval and after that every 30 seconds. All images taken and selected during the time of lost connection will be cached on the phone and transmitted in the background once connection is re-established.
[0089] In part 704 of the screen, the user will receive instructions and or messages from the PSAP. In case the user wishes to respond to those messages, the user just click on the field and the chat window will be open—without losing video connection. The text will be shown in large alphanumerical characters in order to allow the user to point the camera at objects under the camera while reading the text. The messages will scroll slowly to the right or left (language dependent) in case the message does not fit in the text box.
[0090] In part 705 of the screen, the user can see the view of the camera, the picture taken or the picture selected from his personal gallery.
[0091] In case the user has a cell phone with two cameras (front/back), the user will see a icon 711 in the upper right corner of the camera view, that by pushing it switches between the cameras.
[0092] In case the user wants to take a real time snapshot of the emergency scene, the user hits the button 706 . The image will be shown, and the text of the button will change to “SEND”. If SEND is pushed (on button 706 ), the snapshot taken will be sent to the PSAP.
[0093] In case the user has selected a image from “OPEN GALLERY”, the button 706 will change to SEND. If SEND 706 is pushed, the selected image will be sent to the PSAP.
[0094] Open gallery 707 allows the user to select any image to be sent from the phone's image gallery on the phone.
[0095] Witness button 708 allows the user to specify that he/she is not the one that is need of emergency services, in other words, they are asking for help for someone else. This function will only be available if the user has a FRESS connection and the PSAP is a FRESS PSAP that allows for witness function. Otherwise the witness button 708 will be shadowed and unavailable.
[0096] Status field 709 tells the user if they are a witness or not, and other less important information.
[0097] User's Social Network:
[0098] One aspect of the present invention is that it defines a new concept around the term PSAP, which usually refers to Public Safety Answering Point. Typically, this means the call center where emergency calls are answered and where the dispatch of the emergency services is coordinated.
[0099] The FRESS solution redefines the acronym PSAP, giving it three different meanings:
[0100] 1) Public Safety Answering Point;
[0101] 2) Private Safety Answering Point/call center; and
[0102] 3) Personal Safety Answering Point/call center.
[0103] The three meanings PSAP of are outlined in FIG. 8 .
[0104] The redefinition of PSAP is the backbone on which the structure of the FRESS Emergency Social Network was created. When a FRESS user configures the FRESS data set, one of the fields that is completed includes the people that the user wants alerted if the FRESS button was pressed. This configuration allows users to define the following:
[0105] Public: The way FRESS works with the public safety has been described above.
[0106] Private: Users may define other parties to be alerted in case the FRESS button is pressed.
[0107] Other parties may include, but is not limited to:
[0108] (i) User's physician/nurse practitioner—In case of heart condition, diabetes, epilepsy, allergies, etc.; (ii) User's insurance company—In case of auto accident, theft, etc.; (iii) Private security company—In case of a campus situation; (iv) private security company—in case of travel to dangerous destinations; or (v) a home security company—in case of burglary.
[0109] Personal: FRESS users may want to define next of kin to receive alerts when they press the FRESS button.
[0110] This may be especially useful and needed in the cases, of, but not limited to:
Parents who want to know when their children are in danger. People who want to know when their elderly parents are in danger.
[0113] Configuration of the FRESS button will always alert the Public Safety Answering Point, except in the case where the user expressly chooses that this is not to happen, within the first 5 seconds of launching the FRESS APP. There will be an “opt out” mechanism, by which the Public Safety Answering Point is excluded from the call, after which a menu will appear from which the FRESS user can select the people registered in My FRESS to send the alert to. Basically, this will be a list with radio buttons, in which putting a check mark by the list item will mean those people will receive the alert.
[0114] The “opt out” button is a key feature of the FRESS Emergency Social Network. The user can use FRESS even when the event that is taking place does not warrant a 9-1-1 emergency call.
[0115] PSAP Social Network:
[0116] FRESS allows PSAPs that are equipped with the FRESS interface to create their own Emergency Social Network. Currently, there is very little relevant contact between PSAPs, even neighboring PSAPs. The lack of communication between PSAP occurs in the United States and Europe. This lack of communication and coordination can lead to unwanted outcomes which result in death, etc.
[0117] FRESS allows easy communication and coordination between PSAPs. It also allows events to be passed from one PSAP to another using a simple drag and drop technique. With the rise of IP telephony and where the geographical location of the mobile phone may not be known, this feature could be very useful to a PSAP as the event can be “dragged” and “dropped” onto the PSAP that has jurisdiction in the area where the mobile phone is located.
[0118] When such an event is passed from one PSAP to another, all the event history follows the event. All communications, whether instant messages, video or photos are available to the receiving PSAP, which can then manage the event as it would any other.
[0119] Large Scale Events:
[0120] In the case of large scale crises, PSAPs from around the globe can work together on the same series of events, by simply taking on the identity of the PSAP at the location of the large scale event. This can be incredibly advantageous in this kind of large scale event, in which normally there is a collapse of the local PSAP, unable to attend the incoming calls, be it due to line saturation or operator overload.
[0121] The larger the event, the larger the number of PSAPs around the world that can connect to attend FRESS calls, and the greater the number of people asking for help who can be attended to successfully.
[0122] Even in the case of moderate events, where one PSAP is overloaded due to density of calls, the calls could be attended by the night-shift of a PSAP on the other side of the globe.
[0123] It should be taken into account that dispatch of police, fire, ambulance and other services to deal with these large scale emergencies will always reside in the hands of the local PSAP. Only until such time as they are authorized by the primary PSAP through the FRESS PRO program will the dispatching capabilities become available to additional PSAPs.
[0124] The present invention allows for a PSAP or any call center or command and control center to send emergency broadcast alerts to FRESS enabled devices or non-enabled FRESS devices. The emergency broadcast alerts can be done over Bluetooth and/or WiFi through FRESS enabled devices as well all other devices (or selected phones) that have WiFi or Bluetooth enabled. The emergency broadcast alert can be sent to selected phones based on location or category of user (e.g., sent only to police with registered phone numbers).
[0125] Turning to FIG. 9 , shown therein is a block diagram of a system 90 operating in accordance with one aspect of the present invention. User 91 is a FRESS user. When user 91 presses the FRESS button on his/her phone, the data call (black flows) goes over the local carrier's network 92 to connect to the FRESS cloud 93 over the Internet. The FRESS cloud locates and routes the user to the corresponding PSAP 95 . Voice, text, video and images will be enabled.
[0126] The white arrows show the flow involving a non-FRESS user 94 who makes a regular emergency call. In this case, the voice call is routed by the local carrier 92 to the corresponding PSAP 95 . The white arrows also indicate how FRESS user 91 with no connectivity to the FRESS cloud 93 would be routed to the corresponding PSAP 95 .
[0127] FIG. 10 shows a block diagram of the various steps to implement the method described in the paragraph above in the environment of FIG. 9 .
[0128] FIGS. 11-13 show a more detailed description of the various steps in an exemplary method according to another aspect of the present invention. In element 111 , a user activates FRESS on his/her cellphone (i.e., a calling device) by “pressing” on the FRESS icon on their cellphone, laptop, tablet or pocket computer. FRESS could also be triggered by a third-party/external/independent application or sensor.
[0129] In element 112 , the device on which FRESS has been activated on, checks for any data connectivity (e.g., Wi-Fi, 3G, 4G, GPRS, EDGE, Bluetooth, etc.). In case of data connectivity (Yes), the device tries to establish a connection with the FRESS Cloud. The FRESS cloud is a network of multiple servers connected in mesh and to the Internet. In case a successful connection is established the process continues to element 113 . If Not, the process continues to element 116 .
[0130] In element 113 , the FRESS application on the user's device sends the FRESS MINIMUM DATA SET (FMDS) to the FRESS cloud. Within the FMDS is the location of the calling device. In element 114 , the FRESs cloud checks if the calling device is within an area where a PSAP with FRESS activated exists. If YES, the process continues to element 119 and moves to element 131 in FIG. 13 . If Not, the process continues to element 115 . Also in element 113 , the FRESS cloud establishes a connection between the calling device and the correct PSAP. At the same time, the FMDS is sent to the PSAP. As the connection is done, the calling device gives the option to the user to make a VOICE CALL (see elements 132 - 133 , FIG. 13 ) to the PSAP; SEND LIVE VIDEO (see elements 134 - 135 , FIG. 13 ) to the PSAP; SEND A PICTURE (see elements 136 - 137 , FIG. 13 ) to the PSAP; or OPEN CHAT and TEXT (see elements 138 - 139 , FIG. 13 ) to the PSAP. If nothing is selected, the process stops. Either the USER from the calling device, or the OPERATOR at the PSAP can activate one or more OPTIONS at any time.
[0131] In element 132 , if the USER from the calling device selects the option “PUSH TO CALL”, by pressing that button, the calling device check if the “call” is domestic or not (moves to element 133 , which in turn moves to element 126 of FIG. 12 ).
[0132] Turning to FIG. 12 , if domestic (element 123 )—the correct emergency number to call will be dialed from the calling device.
[0133] If NOT domestic (element 125 )—the correct emergency number to call will be displayed for the user on the calling device, as the user's home country's embassy or consul at the closest location near the calling device.
[0134] If the USER from the calling device selects the option “PUSH TO TEXT” (element 138 ), by pressing that button, the calling device will establish a TEXT CHAT with the PSAP (element 139 ).
[0135] If the USER from the calling device selects the option “PUSH TO IMAGE” or presses send picture (element 136 ), by pressing that button, the calling device will allow the user on the calling device to either take a LIVE picture to be sent to the PSAP or to select a picture from the calling device image gallery (element 137 ).
[0136] If the USER from the calling device selects the option “PUSH TO VIDEO” (element 134 ), by pressing that button, the calling device will establish a LIVE VIDEO STREAM from the calling device's camera to the PSAP (element 135 ).
[0137] The calling devices FMDS is sent and published in a restricted area on the FRESS webpage (element 115 ), and can be accessed and viewed by entering in calling device phone number or IMEI number on the FRESS webpage.
[0138] The information published in the restricted area on the FRESS website will only be accessible during the time the calling device has established connection to the FRESS CLOUD and up to thirty minutes after disconnecting from the FRESS cloud (see element 118 ).
[0139] The user on the calling device can only make use of the “PUSH TO CALL” function, which allows the calling device to establish a VOICE only communication with the closest PSAP.
[0140] If the USER from the calling device selects the option “PUSH TO CALL” (element 132 ), by pressing that button, the calling device check if the “call” is domestic or not (element 122 ).
[0141] If NOT domestic—the correct emergency number to call will be displayed for the user on the calling device (element 125 ), as the user's home country's embassy or consul at the closest location near the calling device. If domestic—the correct emergency number to call will be shown (element 123 ) and dialed from the calling device. The USER on the calling device must agree to establish a call to the proposed number.
[0142] Options
[0143] On the APP side, the FRESS button can have 2 functions—Emergency (any kind) and anonymous reporting, where the button function is the same except that personal information in the data set is filtered out before the data set reaches the PSAP.
[0144] It should be noted that the application can be implemented on any smart phone, tablet or other similar device. Moreover, the present invention could be employed on any mobile device, however, in certain cases the service may be limited for older phones, such as 2G phones.
[0145] The present invention also provides:
a FRESS emergency call number service for 9-1-1, 112, 066, 999, or for any emergency call number worldwide; FRESS PRO—the FRESS emergency service used by first responders (police, fire, EMS); and FRESS Enterprise—very similar to FRESS emergency call number service but customized for clients that will connect into a non-public call center.
[0149] In sum, FRESS technology creates an emergency social network by connecting the mobile device with the call center. The present invention provides the ability to connect the mobile device to a call center, via the FRESS cloud, and other mobile devices, thereby creating quickly and easily an emergency social network. | A mobile application for execution on a handheld computing device stores data regarding connections to public safety answering points with which to share information in an emergency situation and establishes connections with an appropriate public safety answering point upon activation of an emergency button, wherein the connections include voice, text, image and video connections. A user is able to create a list of contacts for a private social emergency response network with which to send previously stored private information in an emergency. In an emergency, the mobile application establishes a platform via which the user and those on the private social emergency response network can share information. The mobile application also sends previously stored private information to those on the list during an emergency. | 7 |
BACKGROUND TO THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to the field of cell culture technology and relates to methods of replicating/cloning cells, preferably cell lines which are important for the production of biopharmaceuticals. The invention also relates to methods of preparing proteins using cells that have been obtained and replicated and compositions which makes it possible to replicate individual cells.
[0003] 2. Background
[0004] The market for biopharmaceuticals for treating humans is growing fast throughout the world. Over 900 biopharmaceuticals are currently being tested in clinical trials with an estimated potential turnover of 50 billion in 2010 (Datamonitor 2007). At present, an ever increasing number of biopharmaceuticals are produced in mammalian cells, as these have the capability for the correct processing and modification of a human protein. The successful production of high yields of biopharmaceuticals in mammalian cells is therefore crucial and depends on the characteristics of the recombinant monoclonal producing cell line that is used in the manufacturing process. In addition the duration of the cell line development is a critical time factor as to how quickly the biopharmaceutical can enter into clinical trials. In view of these aspects there is an urgent need to speed up the process of developing cell lines and make it more efficient.
[0005] For the biotechnological production of biologically active or therapeutic proteins in mammalian cells, so-called biopharmaceuticals, the corresponding mammalian cells are stably transfected with DNA which codes for the biologically active protein (or its subunits). After the transfection process a pool of millions of differently transfected cells is normally obtained. Therefore the crucial step for the preparation of efficient production cell lines is in the selection and replication of cell clones which on the one hand grow very stably and on the other hand show a high specific productivity of therapeutic protein (product formation etc.). As there are millions of different product-expressing cells, it is critical to be able to analyse a plurality of cells individually with a high throughput and using automation in order to be able to sort out suitable candidates (single cell clones) which both grow very robustly and also yield high product titters. This process of single cell isolation and subcultivation is known as cloning or recloning.
[0006] The use of animal cell cultures for producing biopharmaceuticals demands a genotypically and phenotypically homogeneous, i.e. monoclonal cell culture. This is achieved by recloning techniques such as “limited dilution” or by the automated depositing of individual cells by fluorescence activated cell sorting (FACS).
[0007] However, there is the problem of effectively replicating typical recombinant production cells such as mouse myeloma (NS0), hamster ovary (CHO), or hamster kidney cells (BHK), particularly if they are adapted to growth in serum-free suspension cultures, i.e. under modern production-relevant cell culture conditions, after recloning, whereby the cells are individually deposited in microtitre plates, under serum-free culture conditions.
[0008] The reason for this is that cells in vivo are embedded in the tissue matrix and are supplied with secreted auto- and paracrine growth factors by adjacent cells. They are therefore not adapted to isolated growth and die off without stimulation by growth factors if they are not slowly adapted to the new conditions.
[0009] In particular, the use of serum-free or chemically defined media in the recloning step leads to a restricted recloning efficiency, i.e. only a small percentage of the cells deposited survive and grow into a monoclonal cell line.
[0010] The “limited dilution” and FACS recloning techniques currently used are well known in the art.
[0011] In “limited dilution” the cell suspension is serially diluted and the cells are then deposited in a microtitre plate in different numbers of cells per well. In wells containing large numbers of cells, many or all the cells survive as the result of adequate secretion of autocrine growth factors. The fewer cells are seeded per well, the fewer cells survive, so that in this way the dilution can be adjusted so that statistically only one cell survives per well and grows into a monoclonal line. These individual cells clones are detected by visual and/or imaging techniques and the cell clones are grown on in larger culture vessels.
[0012] In FACS technology, a flow cytometer is used to generate single cell clones. For this the cells are placed in a laminar flow and are individually steered into the wells of the microtitre dishes. This ensures that the surviving colonies really are individual clones. Therefore, FACS technology is the preferred method compared with Limited Dilution.
[0013] The use of serum-free or chemically defined media in the recloning step leads to restricted recloning efficiency, i.e. only a few percent of the individually deposited cells grow into a monoclonal cell line.
[0014] At a low recloning efficiency, therefore, a number of microtitre plates have to be filled with single cells in order to obtain the desired number of individual clones, which is time-consuming and expensive (e.g. in terms of media, dishes, etc).
[0015] A low recloning efficiency is particularly disadvantageous if the subsequent analysis of the single cell clones is to be carried out using an automated system. A analysing robot cannot normally distinguish between wells containing living or dead cells and automatically measures all the wells in the microtitre plate. With a recloning efficiency of only 10%, this means that in 90% of cases the robot will analyse an empty well—and will use the same amount of reagent for this as for analysing a living cell clone. In the example here, therefore, 90% of the time and 90% of the material costs are wasted without any data being obtained.
[0016] To solve this problem, in the past, serum (e.g. foetal calf serum, FCS) has often been added to the medium. Serum contains an undefined mixture of different soluble proteins and growth factors which supports the survival and proliferation of cells. For regulatory reasons, however, the use of non-definable additions such as serum is increasingly less tolerated, partly because of the risk of infection with bovine viruses. Totally serum-free production of cell lines is therefore the state of the art from a regulatory point of view.
[0017] Another possible solution is to carry out a “limited dilution” for the recloning. As this method only leads statistically to the production of single cell clones but many clones may also grow in one well, this process has to be repeated several times (usually 2-3 times) to ensure that the cell line obtained really does originate from only a single clone. These repeated cycles involve high labour and time costs which have a negative effect on the costs and timelines required.
[0018] Another approach is the use of “feeder” cells. The name comes from the English word “feed” and refers to a co-cultivation with usually non-dividing cells which serve to supply the desired cells in the culture with nutrients and secreted growth factors. The recloning efficiency can be significantly increased by feeder cells.
[0019] In another approach, recombinant proteins are added to the recloning medium, to promote the survival and growth of the individually deposited cells. Examples of recombinant proteins used are insulin, insulin-like growth factor (IGF), epithelial growth factor (EGF) or human serum albumin (HSA). These additives are obtained as purified proteins or protein solutions and added to the medium. The disadvantages of this method are the costs, the dependency on the availability of the recombinant proteins and their instability. The disadvantages include, inter alia:
the need to store them at −70° C., freeze/thaw cycles lead to inactivation and therefore have to be avoided, rapid loss of activity in solution under cultivation conditions.
[0023] The aim of the present invention is to increase the recloning efficiency in the serum-free FACS-based cloning of production cells.
SUMMARY OF THE INVENTION
[0024] The solution to this technical problem of the reduced recloning efficiency in serum-free, preferably chemically defined and/or insulin-free medium is obtained by the use of transgenic albumin or HSA-producing cells or by the use of medium conditioned by such HSA-producing cells. The HSA is thus not added to the medium from outside as a purified protein but rather is released directly into the recloning medium by living cells.
[0025] The following embodiments are possible:
1. Use of an HSA-producing cell to prepare conditioned medium for die depositing of single cells. 2. Use of HSA-producing cells as feeder cells. In contrast to the use of recombinant HSA which is added to the medium once, the feeder cells in the multiwell plate continuously produce HSA after the depositing of single cells and thus assist the growth of the deposited cells for a longer time than after a single addition of the recombinant protein. 3. Use of HSA-producing cells as host cells for producing biopharmaceuticals. The cells are thus enabled to promote their growth by the secretion of HSA autologously even in the absence of feeder cells and recombinant additives.
[0029] The highest recloning efficiency can preferably be obtained by a combination of these approaches, i.e. by the use of HSA-producing host cells and HSA-conditioned medium. Optionally and depending on the nature of the subsequent analysis process, feeder cells may be used in addition.
[0030] By the use of HSA-producing cells as host or feeder cells or media conditioners the recloning efficiency and hence the quantity of clones obtained can be increased significantly. This effect is observed even at concentrations of less than 200 mg/L HSA, even <100 mg/L in the cloning medium. The activity/effectiveness of secreted HSA on the recloning efficiency is thus significantly higher than that of recombinant HSA, which is usually added in concentrations of 400 mg/L to >2 g/L. A preferred embodiment is the use of HSA-producing cells in insulin-free medium. The positive influence of HSA-producing cells and/or their medium on the recloning efficiency is apparent both in the presence and absence of feeder cells in different media.
[0031] It is also apparent in different cell lines/cell types such as for example hamster and mouse cells, as well as human and various other cell systems.
[0032] The HSA-producing cells used may be both naturally HSA-producing cells (such as human liver cells) and also genetically altered cells of other species.
[0033] A preferred embodiment consists of transgenic HSA-producing production cell lines such as CHO, BHK, NS0, Sp2/0 or Per. C6-cells. A particularly preferred embodiment comprises HSA-producing CHO cells.
[0034] The method described here for increasing the recloning efficiency in serum-free media by the use of HSA-producing cells or medium conditioned thereby results in a more effective clone screening and thereby in a more efficient cell line development process.
[0035] In biopharmaceutical development, the primary goal of recloning is to identify high-producing cell clones. A higher recloning efficiency, through the broader base of clones obtained, and as a result of a normal distribution of the clones in terms of productivity, leads to a higher probability of obtaining high-producing cell clones.
[0036] As fewer cells have to be deposited in dishes at a higher recloning efficiency in order to obtain the same number of living cell clones, there is also a significant saving in both time and effort as well as costs as a result. The process step is thus more economical overall.
[0037] Moreover, the increased recloning efficiency forms the basis for the use of highly efficient automated clone screening methods (screening robot).
[0038] In systems of this kind there is generally no selection of individual wells in the microtitre plate, but all are measured equally, irrespective of whether they contain a living cell population or not. As a result of all the wells in the plate being analysed the number of clones examined increases in direct proportion to the number of emergent clones. A recloning efficiency of only 10% means that 90% of the wells are empty and therefore cannot supply any usable data but are still analysed. In terms of economy, this means that in 90% of cases time and money in the form of reagents are expended without any data being gained. Therefore the efficiency of high throughput automation systems for early clone selection increases proportionally with the number of clones obtained after the depositing of single cells.
[0039] Another advantage of the method described is that the addition of HSA-producing cells as host cells and/or medium conditioners increases the recloning efficiency to a point where there is no need for feeder cells.
[0040] On the one hand this reduces the effort involved in producing and pre-cultivating the feeder cells and at the same time increases the reproducibility of the single cell cloning. In addition it makes it possible to use technologies for visually detecting the number of living cells as a tool for clone analysis. As the amount of product in the culture medium is in linear correlation with the number of producing cells, the technological development seeks to detect both the amount of product and the number of cells, so as to determine from these the highest producing cell clones, i.e. the cell clones with the highest specific productivity.
[0041] As feeder cells are difficult to distinguish visually from the emergent production cells, they are also included in the visual determination of cell numbers, leading to an inaccurate calculation of the total number of cells and hence an imprecise determination of the important parameter of specific productivity. A process without feeder cells is therefore advantageous and represents a preferred embodiment.
[0042] Possible applications for the method described can be found particularly in the production of biopharmaceuticals.
[0043] The increase in the recloning efficiency in the generation of production cells for biopharmaceutical production leads to a higher probability of a highly-productive clone and hence an improved or accelerated product development. The process also increases the economy of this step and also makes it possible to use high-throughput automated clone analysing techniques.
[0044] The addition of recombinant proteins to insulin-containing medium for the purpose of increasing recloning efficiency is indeed described in the prior art (WO2006047380). By contrast, however, the use of secreted albumin or HSA, or medium from albumin- or HSA-producing cells, is explicitly described in the present Patent Application as an alternative and superior possibility. The HSA is not added exogenously to the medium as a recombinant purified protein, but rather the HSA is secreted directly into the recloning medium by the albumin-transgenic cells.
[0045] HSA-producing CHO cells are indeed described in the literature, but there is no description of either the use of HSA-producing cells as host cells for the production of a protein other than HSA, or of their use as feeder cells or as medium conditioners for increasing the recloning efficiency.
DESCRIPTION OF THE FIGURES
[0046] FIG. 1 : POSSIBLE APPLICATIONS OF THE INVENTION
[0047] Schematic representation of the possible embodiments of HSA-producing cells:
(1) for preparing conditioned medium (2) as feeder cells (3) use of HSA-producing cells as host cells for biopharmaceutical production, i.e. the cell that produces the protein of interest additionally secretes HSA and thereby promotes its own growth during recloning.
[0051] These possible applications may be combined in order to increase the recloning efficiency still further.
[0052] FIG. 2 : PREPARATION OF CONDITIONED MEDIUM OF HSA-PRODUCING CELLS IN ORDER TO INCREASE THE RECLONING EFFICIENCY
[0053] (A) This shows the relative recloning efficiency when using fresh recloning medium without any additions (negative control, white) and the relative increase in recloning by the addition of 500 mg/L recombinant HSA (positive control, grey) or 50% conditioned medium from a culture of HSA-producing cells, which is removed from the culture after the stated number of days and added (black bars).
[0054] (B) Tabulated summary of the HSA concentrations measured in the above media. The recloning efficiency is at its maximum when medium conditioned for 2-5 days is used. It is significantly higher than when recombinant HSA is added to the medium, although the HSA concentrations measured in the conditioned medium are lower by a factor of 5-50. Any longer conditioning leads to a reduced recloning efficiency in spite of a higher HSA content in the medium.
[0055] FIG. 3 : INCREASE IN THE RECLONING EFFICIENCY AS A RESULT OF THE USE OF HSA-CONDITIONED MEDIUM
[0056] (A) The influence of HSA-conditioned medium in the presence of feeder cells. This Figure shows the relative recloning efficiency of cells that are individually deposited on 10,000 growth-arrested feeder cells. The negative control shows the recloning efficiency in Boehringer's own medium without any additions (here set at 1), while in the positive control 500 mg/L recombinant HSA had been added to the medium. As a result of the use of conditioned medium of a 2 to 2 day old culture of HSA-producing cells the recloning efficiency can be increased still further. The HSA-concentrations measured in this medium are shown above the bars.
[0057] (B) The influence of the addition of HSA-conditioned media to commercial medium (HyQ SFM 4 CHO medium). The graph shows the recloning efficiency in a medium different from that in (A) without the use of feeder cells. In this medium no individually deposited cell grows into a living culture in the medium without additives. A few cells survive thanks to the addition of recombinant HSA (500 mg/L, dark-grey bars). A higher recloning efficiency on the other hand is achieved by using conditioned medium of HSA-producing cells (light-grey bars). The bars are averages of 3-5 evaluated 96-well plates for each condition; error bars show the standard deviation.
[0058] FIG. 4 : INCREASE IN RECLONING EFFICIENCY BROUGHT ABOUT BY HSA-PRODUCING FEEDER CELLS
[0059] A single cell from a cell population is deposited on either autologous CHO-DG44 feeder cells or transgenic HSA-producing feeder cells. The recloning efficiency using DG44-cells was set at 1. (black bar). The grey bar gives the relative increase in the recloning efficiency when HSA-producing feeder cells are used. The bars indicate the averages of 3 evaluated 96-well plates for each condition.
[0060] FIG. 5 : COMBINATION OF HSA-PRODUCING FEEDER AND HOST CELLS
[0061] This shows the recloning efficiency in batches containing untransfected DG44 cells that have been deposited on autologous feeder cells (1 placed, black), when recloning an HSA-producing cell in the presence of DG44-feeder cells (grey). The combination, i.e. the depositing of an HSA-producing cell on HSA-transgenic feeder cells (white), leads to a further significant increase in the recloning efficiency. The Figure shows the averages of 3 evaluated 96-well plates, the error bars show the standard deviation.
[0062] FIG. 6 : CONCENTRATION-DEPENDENT INCREASE IN THE RECLONING EFFICIENCY AS A RESULT OF THE ADDITION OF RECOMBINANT HSA
[0063] The graph shows the efficiency of the recloning when recombinant HSA is added in the concentrations specified. The maximum efficiency was achieved in this experiment when 1000 mg/L recombinant HSA were added to the recloning medium; this value was set at 100% and the efficiencies measured for the other batches were recorded in relation thereto.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0064] Before the more detailed description of the invention by means of the non-restrictive exemplifying embodiments that follow, it should be pointed out that the use of the indefinite article, for example “a” or “an” and the definite article, namely “the”, includes both the singular and plural of the term in question, unless one of the two forms is explicitly ruled out and reference is made to a particular form (singular or plural). Thus, the term “a cell” automatically includes “a plurality of cells” as well, unless it is explicitly stated that only a single cell is meant. The singular is explicitly meant, for example, where “a” or “one” is supplemented by (1).
[0065] The term “insulin” denotes a growth factor that is secreted by pancreatic beta cells. Insulin is known to the skilled man. Human zinc insulin or recombinant insulin is frequently used in cell culture. The concentration of insulin can be measured in the culture medium using routine experiments such as a commercially obtainable insulin-specific ELISA.
[0066] The term “insulin-free” means that the culture medium does not contain any insulin, particularly any recombinant insulin and no insulin is added to it either.
[0067] Albumin is the most commonly occurring protein in the plasma. It is produced in the liver and contributes to maintaining osmotic pressure in the blood. Albumin binds to nutrients and metabolites and thus assists with their transportation.
[0068] The term “albumin” in the present invention denotes a polypeptide component which has the biological activity of albumin. Albumin generally denotes animal albumin, particularly a mammalian albumin such as for example human, bovine, equine, murine, rat-like and porcine albumin and albumin from birds such as chickens, in particular, etc. Preferably the albumin is human serum albumin (HSA). In the present invention the terms “HSA” and “albumin” are used synonymously, i.e. “HSA” refers both to human albumin and to albumins from other animal species. In the present invention a distinction is made explicitly between recombinant HSA which is added to the culture medium from outside, and “secreted HSA”, which is released into the recloning medium directly, i.e. without purification or separation, by living HSA-producing cells. When reference is made to albumin or HSA secreted directly into the cell culture medium by living albumin-transgenic cells, this means that albumin or HSA is not added from outside as a purified protein.
[0069] The production of recombinant HSA is well known in the prior art and can be carried out e.g. using genetically modified yeasts (U.S. Pat. No. 5,612,197). Recombinant HSA may be obtained commercially from various suppliers, for example from Sigma-Aldrich (Recombinant HSA, Cat. No. A-7223). This is purified protein which can be added to the cultivation medium.
[0070] The data of the present invention show that “secreted HSA” has a significantly higher activity/effectiveness than HSA, as it brings about a substantial increase in the recloning efficiency at significantly lower concentrations.
[0071] The term “significantly lower concentration” means according to the present invention:
a concentration which is at least two times lower compared with recombinant or purified albumin, a concentration which is at least five times lower compared with recombinant or purified albumin, an albumin concentration which is lower by at least factor 2 than that of a comparable culture mixture containing recombinant or purified albumin, an albumin concentration which is lower by at least factor 5 than that of a comparable culture mixture containing recombinant or purified albumin, an albumin concentration which is lower by at least a factor 2 to 100, 2 to 5, 5 to 100, 20 to 100, 5 to 10 than that of a comparable culture mixture containing recombinant or purified albumin, an albumin concentration of less than 200 mg/L, preferably less than 100 mg/L, particularly preferably less than 60 mg/L.
[0078] In contrast to recombinant HSA the secreted HSA is released by HSA-producing cells of a living culture directly into the recloning medium. It may originate from three sources: (a) from HSA-producing cells of a preliminary culture used to prepare conditioned medium, (b) HSA-producing feeder cells, or (3) HSA-secreting host cells (if the individually deposited producing cells have been genetically modified such that they themselves secrete HSA).
[0079] The concentration of HSA can be determined by routine methods such as a commercially obtainable ELISA (e.g. “Human Albumin ELISA Quantitation Kit”, Bethyl Laboratories, Montgomery, Tex.)
[0080] The term “albumin or HSA-transgenic cell”, “albumin- or HSA-producing cell” or “albumin- or HSA-secreting cell” denotes any cell that releases an albumin into the medium. This may either be a cell that naturally secretes albumin (e.g. a liver cell) or a cell that has been genetically modified, for example by the introduction of an albumin- or HSA-expression construction, such that it expresses albumin or HSA and releases it into the medium. A preferred embodiment of the present invention consists of albumin- or HSA-producing mammalian cells, most preferably albumin- or HSA-producing rodent cells, particularly albumin- or HSA-producing CHO- or NS0-cells. The terms such as “albumin- or HSA-transgenic cell”, “albumin- or HSA-producing cell” and “albumin- or HSA-secreting cell” specified are used interchangeably in the present application.
[0081] The “specific productivity” of a cell indicates the quantity of a particular protein that is produced by a cell per unit of time, i.e. that is released into the medium, in the case of secreted proteins. The specific productivity is calculated from the quotient of the concentration of the product in the medium (=titre, determined by ELISA, for example) and the number of producing cells present over the time span under consideration, also known as the “IVC” (integral of the number of living cells over time). The specific productivity is usually given in ‘pcd’ (=pg/cell*day=picograms of secreted protein per cell and per day)).
[0082] The term “cloning/recloning”, “clone/reclone” in connection with cell culture means a technique by means of which a cell population of identical cells can be obtained from an original cell. The term “cell cloning” or “single cell cloning” thus means a process wherein single cells can be identified and isolated from a cell pool with cells of different genotypes and then replicated to form a cell population consisting of a plurality of genetically identical cells. If the cells are deposited individually, i.e. only one (1) cell per culture vessel, and then expanded to form a cell population of identical cells, the process is “direct single cell cloning”. If a number of cells are simultaneously deposited in a culture vessel, expanded to form a cell population and this is divided up into cell populations of identical cells by repeated dilution (=limited dilution), this is described as an “indirect cloning” method.
[0083] “Single clones” or “single cell clones” or “clones” for short are genetically identical cells which originate from one (1) single cell. A cell population consisting of identical cells of the same origin is consequently referred to hereinafter as a “monoclonal cell population”. If during the cultivation of cells of the same origin there are spontaneous changes in the genome, for example mutations and/or translocations, the individual cells of this cell population are still regarded as identical cells for the purposes of the present invention, and the culture is regarded as a monoclonal cell population. By contrast, a pool of stably transfected cells (transfectants) are not cell clones of the same lineage, i.e. they are not a monoclonal cell population, even if genetically identical starting cells are transfected with an identical nucleic acid.
[0084] The term “subclones/subcultures” refers to different generations of cells which are produced from an original cell or original culture by single or multiple passaging of the dividing cells. The words “subclones/subcultures” are used, for example, when identical cells or cell cultures are cultivated and replicated over a number of generations.
[0085] The term “cloning efficiency” or “recloning efficiency” is defined as the percentage of cells which survive, divide and form vital cell populations after being deposited. If for example in a cell sorting operation 100 cells are distributed over 100 culture vessels and if 25 of these 100 individually deposited cells grow to form cultures, the cloning efficiency is 25%.
[0086] By “effective or efficient recloning” is meant a cloning efficiency of at least 10%, preferably at least 20%, more preferably at least 30% and even more preferably at least 40%. According to a particularly preferred embodiment of the present invention the term effective recloning means cloning with an efficiency of at least 50%, preferably at least 60%, most preferably at least 70% and even more preferably at least 80%.
[0087] The term “capable of division/expandable” for the purposes of the present invention describes the potential of a cell/cell population to divide endlessly but at the least over 2, preferably 4, passages. This potential may for example be reduced or destroyed altogether by irradiation with [137] Cs or by mitomycin C treatment.
[0088] The term “derivative/descendant” refers to cells which can be traced back genetically to a particular starting cell and are formed for example by subcultivation (with or without selection pressure) and/or generated by gene manipulation. Re-isolations of cells of the same cell type are also included in the term “derivative/descendant”. Thus, for example, all CHO cell lines are derivatives/descendants of the hamster ovary cells isolated from Cricetulus griseus by Puck et al., 1958, regardless of whether they were obtained by subcultivation, re-isolation or gene manipulations.
[0089] The term “feeder cell” comes from the English word “feed” and refers to a co-cultivation with usually non-dividing cells which serve to supply the desired cells in the culture with nutrients and secreted growth factors. For the preparation, living cells are growth-arrested by irradiation with UV or gamma radiation or treatment with Mitomycin C. The resulting feeder cells live and produce and secrete growth factors but are unable to divide further.
[0090] The term “autologous feeder cell” means that both the feeder cell and the cell which is to be cultivated in the presence of this feeder cell are derived taxonomically from the same origin. If for example the cell to be cultivated is a hamster cell (subfamily Cricetinae ), preferably a cell of the genus Cricetulus or Mesocricetus , for example a CHO or BHK cell, each feeder cell originally isolated from this subfamily is a feeder cell which is autologous to these hamster cells of the subfamily Cricetinae.
[0091] According to a preferred embodiment the term “autologous feeder cell” means that both the feeder cell and the cell which is to be cultivated were derived from the same genus taxonomically or were originally isolated from the same genus (cells from Cricetulus or Mesocricetus ). If for example the cell to be cultivated is a hamster cell of the genus Cricetulus or Mesocricetus , preferably a CHO or BHK cell, each feeder cell originally isolated from the genus in question is an autologous feeder cell in the sense of this invention.
[0092] According to another preferred embodiment an autologous feeder cell is present if the feeder cell and the cell to be cultivated come from the same species, for example Cricetulus griseus or Mesocricetus auratus . According to a particularly preferred embodiment an autologous feeder cell is present if both the feeder cell and the cell to be cultivated come from the same species and have the same tissue tropism (e.g. ovarian cells from Cricetulus griseus —CHO cells).
[0093] According to a particularly preferred embodiment a feeder cell is an autologous feeder cell if both the feeder cell and the cell to be cultivated originate from the same basic cell, for example if both cells were originally CHO-DG-44 cells or descendants of these cells. According to another preferred embodiment the feeder cell confers the same resistances, e.g. to antibiotics, as the cell which is to be cultivated. This is particularly advantageous when the cell deposition is carried out in the presence of a selecting agent, e.g. an antibiotic.
[0094] In one aspect the present invention particularly describes the use of HSA-producing feeder cells for increasing the recloning efficiency. In a preferred embodiment, autologous HSA-producing feeder cells are used.
[0095] The term “limited dilution” denotes an alternative method of recloning. A cell suspension is serially diluted and the cells are then deposited in a microtitre plate in different numbers of cells per well. In wells with high numbers of cells, many or all of the cells will survive as the result of adequate secretion of autocrine growth factors. The fewer cells are seeded per well, the fewer cells survive, which means that the dilution can thus be adjusted so that statistically only one single cell per well survives and grows into a monoclonal line. As this method only leads statistically to the formation of single cell clones, but it is possible for several clones to grow in one well, this process has to be repeated several times (normally 2 to 3 times) in order to ensure that the cell line obtained really is from a single clone.
[0096] By the term “conditioned medium” is meant medium from a culture of living cells. The effect of the conditioned medium is based on its content of growth factors that have been secreted into the medium by the cells of the preliminary culture and have thereby “conditioned” it.
[0097] Accordingly, the term “medium-conditioning cells” or “medium conditioner” refers to cells that are used to prepare conditioned medium.
[0098] In one aspect the present invention describes the use of HSA-producing cells as medium conditioners, so that the conditioned medium thus obtained contains inter alia the HSA secreted by these cells.
[0099] The term “serum” denotes the cell-free component of the blood. Serum contains an undefined mixture of different soluble proteins and growth factors that assist the survival and proliferation of cells. For the cell culture, foetal calf serum (FCS) or bovine serum (FBS) are predominantly used. The usual concentration ranges are 10-20% FCS or FBS as an addition to the cultivation medium.
[0100] The term “serum-free” means culture media and also cultivation conditions which are characterised in that cells are grown in the absence of animal and/or human serum, preferably in the absence of any proteins isolated from serum, preferably in the absence of non-recombinantly produced proteins. Consequently, the term “cells adapted to serum-free conditions” means those cells which can be replicated in the absence of animal or human serum or serum proteins.
[0101] The term “protein-free” means that the culture medium does not contain any animal proteins; proteins isolated from bacteria, yeasts or fungi are not regarded as animal proteins.
[0102] The term “chemically defined” describes a cell culture medium which is serum-free, preferably also protein-free, and which consists of chemically defined substances. Chemically defined media thus consist of a mixture of predominantly pure individual substances. One example of a chemically defined medium is the CD-CHO medium produced by Messrs Invitrogen (Carlsbad, Calif., US).
[0103] The expression “a cell which may be cultivated in suspension” refers to cells which are adapted to growth in liquid cultures (“suspension cultures”) and whose ability to adhere to the surfaces of vessels, for example cell culture dishes or flasks, has been restricted or lost. Cells which are adapted both to serum-free growth and to growth in suspension are referred to as “non-adherent cells adapted to serum-free medium”. If feeder cells are prepared from such cultures, these cells are by definition “non-adherent feeder cells adapted to serum-free medium”.
[0104] The term protein/product of interest refers to biopharmaceutically significant proteins/polypeptides comprising e.g. antibodies, enzymes, cytokines, lymphokines, adhesion molecules, receptors and the derivatives or fragments thereof. However, a protein/product of interest is not restricted to these examples. Generally, all polypeptides that act as agonists or antagonists and/or have a therapeutic or diagnostic use are significant or of interest. Other proteins of interest are for example proteins/polypeptides that are used to alter the properties of host cells within the scope of so-called “Cell Engineering”, such as e.g. anti-apoptotic proteins, chaperones, metabolic enzymes, glycosylation enzymes, and the derivatives or fragments thereof, but are not restricted thereto.
[0105] The term “polypeptides” is used for amino acid sequences or proteins and refers to polymers of amino acids of any length. This term also includes proteins which have been modified post-translationally by reactions such as glycosylation, phosphorylation, acetylation or protein processing. The structure of the polypeptide may be modified, for example, by substitutions, deletions or insertions of amino acids and fusion with other proteins while retaining its biological activity. In addition, the polypeptides may multimerise and form homo- and heteromers.
[0106] By recombinant proteins are meant proteins that are produced by recombinant expression in host cells. Such recombinant proteins are produced under the strictest conditions of purity in order to minimise the risk of contamination. Recombinant proteins are usually produced in suitable host cells such as e.g. yeast cells, animal cells or prokaryotic cells ( E. coli or other bacterial strains) using an expression vector such as for example a plasmid, bacteriophage, naked DNA or a virus, to introduce the recombinant protein into the host cell. Recombinant proteins are usually commercially available in purified form as concentrated protein solutions or in powder form. Recombinant HSA is obtainable for example from various commercial suppliers such as Sigma Aldrich.
[0107] Examples of therapeutic proteins are insulin, insulin-like growth factor, human growth hormone (hGH) and other growth factors, receptors, tissue plasminogen activator (tPA), erythropoietin (EPO), cytokines, e.g. interleukins (IL) such as IL-1, IL-2, IL-3, IL-4, IL-5, IL-6, IL-7, IL-8, IL-9, IL-10, IL-11, IL-12, IL-13, IL-14, IL-15, IL-16, IL-17, IL-18, interferon (IFN)-alpha, -beta, -gamma, -omega or -tau, tumour necrosis factor (TNF) such as TNF-alpha, -beta or -gamma, TRAIL, G-CSF, GM-CSF, M-CSF, MCP-1 and VEGF. Other examples are monoclonal, polyclonal, multispecific and single chain antibodies and fragments thereof such as for example Fab, Fab′, F(ab′) 2 , Fc and Fc′ fragments, light (L) and heavy (H) immunoglobulin chains and the constant, variable or hypervariable regions thereof as well as Fv and Fd fragments (Chamov et al., 1999). The antibodies may be of human or non-human origin. Humanised and chimeric antibodies are also possible.
[0108] Fab fragments (fragment antigen binding=Fab) consist of the variable regions of both chains which are held together by the adjacent constant regions. They may be produced for example from conventional antibodies by treating with a protease such as papain or by DNA cloning. Other antibody fragments are F(ab′)2 fragments which can be produced by proteolytic digestion with pepsin.
[0109] By gene cloning it is also possible to prepare shortened antibody fragments which consist only of the variable regions of the heavy (VH) and light chain (VL). These are known as Fv fragments (fragment variable=fragment of the variable part). As covalent binding via the cysteine groups of the constant chains is not possible in these Fv fragments, they are often stabilised by some other method. For this purpose the variable region of the heavy and light chains are often joined together by means of a short peptide fragment of about 10 to 30 amino acids, preferably 15 amino acids. This produces a single polypeptide chain in which VH and VL are joined together by a peptide linker. Such antibody fragments are also referred to as single chain Fv fragments (scFv). Examples of scFv antibodies are known and described, cf. for example Huston et al., 1988.
[0110] In past years various strategies have been developed for producing multimeric scFv derivatives. The intention is to produce recombinant antibodies with improved pharmacokinetic properties and increased binding avidity. In order to achieve the multimerisation of the scFv fragments they are produced as fusion proteins with multimerisation domains. The multimerisation domains may be, for example, the CH3 region of an IgG or helix structures (“coiled coil structures”) such as the Leucine Zipper domains. In other strategies the interactions between the VH and VL regions of the scFv fragment are used for multimerisation (e.g. dia-, tri- and pentabodies).
[0111] The term diabody is used in the art to denote a bivalent homodimeric scFv derivative. Shortening the peptide linker in the scFv molecule to 5 to 10 amino acids results in the formation of homodimers by superimposing VH/VL chains. The diabodies may additionally be stabilised by inserted bisulphite bridges. Examples of diabodies can be found in the literature, e.g. in Perisic et al., 1994.
[0112] The term minibody is used in the art to denote a bivalent homodimeric scFv derivative. It consists of a fusion protein which contains the CH3 region of an immunoglobulin, preferably IgG, most preferably IgG1, as dimerisation region. This connects the scFv fragments by means of a hinge region, also of IgG, and a linker region. Examples of such minibodies are described by Hu et al., 1996.
[0113] The term triabody is used in the art to denote a trivalent homotrimeric scFv derivative (Kortt et al., 1997). The direct fusion of VH-VL without the use of a linker sequence leads to the formation of trimers.
[0114] The fragments known in the art as mini antibodies which have a bi-, tri- or tetravalent structure are also derivatives of scFv fragments. The multimerisation is achieved by means of di-, tri- or tetrameric coiled coil structures (Pack et al., 1993 and 1995; Lovejoy et al., 1993).
[0115] The term “antibody fusion” or “antibody fusion protein” denotes the fusion/coupling of a protein to an antibody or part of an antibody. In particular these include fusion proteins produced by genetic engineering, in which a therapeutic protein is coupled to the Fc part of an antibody, in order to increase the half-life/stability of the protein in the serum. The term also encompasses antibody fusions consisting of a peptide and an antibody or part of an antibody.
[0116] Preferred host cells for the purposes of the invention are hamster cells such as BHK21, BHK TK − , CHO, CHO-K1, CHO-DUKX, CHO-DUKX B1 and CHO-DG44 cells or derivatives/descendants of these cell lines. Particularly preferred are CHO-DG44, CHO-DUKX, CHO-K1 and BHK21 cells, particularly CHO-DG44 and CHO-DUKX cells. Also suitable are myeloma cells from the mouse, preferably NS0 and Sp2/0 cells and derivatives/descendants of these cell lines.
[0117] Examples of hamster and mouse cells which can be used according to the invention are given in Table 1 that follows. However, derivatives and descendants of these cells, other mammalian cells including but not restricted to cell lines of humans, mice, rats, monkeys, rodents, or eukaryotic cells, including but not restricted to yeast, insect, bird and plant cells, may also be used as host cells for the production of biopharmaceutical proteins.
[0000]
TABLE 1
Known production cell lines
Cell line
Accession number
NS0
ECACC No. 85110503
Sp2/0-Ag14
ATCC CRL-1581
BHK21
ATCC CCL-10
BHK TK −
ECACC No. 85011423
HaK
ATCC CCL-15
2254-62.2 (BHK-21 derivative)
ATCC CRL-8544
CHO
ECACC No. 8505302
CHO-K1
ATCC CCL-61
CHO-DUKX
ATCC CRL-9096
(= CHO duk − , CHO/dhfr − )
CHO-DUKX B1
ATCC CRL-9010
CHO-DG44
Urlaub et al., Cell 33[2], 405-412, 1983
CHO Pro-5
ATCC CRL-1781
Lec13
(Stanley P. et al, 1984).
V79
ATCC CCC-93
B14AF28-G3
ATCC CCL-14
HEK 293
ATCC CRL-1573
COS-7
ATCC CRL-1651
U266
ATCC TIB-196
HuNS1
ATCC CRL-8644
Per. C6
(Fallaux, F. J. et al, 1998)
CHL
ECACC No. 87111906
[0118] According to the invention, recombinant mammalian cells, preferably rodent cells, most preferably murine cells such as NS0 and hamster cells such as CHO or BHK are particularly preferred.
[0119] According to the invention the host cells are preferably established, adapted and cultivated totally under serum-free conditions. Particularly preferably the host cells are additionally established, adapted and cultivated totally in a medium that is not only serum-free but also free from any animal proteins/peptides.
[0120] Examples of suitable nutrient solutions include commercially obtainable media such as Ham's F12 (Sigma, Deisenhofen, DE), RPMI-1640 (Sigma), Dulbecco's Modified Eagle's Medium (DMEM; Sigma), Minimal Essential Medium (MEM; Sigma), Iscove's Modified Dulbecco's Medium (IMDM; Sigma), CD-CHO (Invitrogen, Carlsbad, Calif., USA), CHO—S (Invitrogen), serum-free CHO-Medium (Sigma) and protein-free CHO-Medium (Sigma).
[0121] The term “production cell” or “producer cell” or “production clone” denotes a cell that is used in a process for preparing a protein. In particular this includes genetically modified cells that are used for the industrial production of recombinant proteins. Within the scope of this invention, the term includes in particular genetically modified eukaryotic host cells which express a recombinant protein and are used to prepare this protein. This includes in particular monoclonal cell lines for the production of therapeutic proteins.
[0122] The invention describes a method of cultivating a single cell comprising the following steps: (a) cultivating a cell population, (b) isolating a single cell from the said cell pool and (c) cultivating the said single cell in a conditioned medium, i) which contains albumin, preferably human serum albumin (HSA), which is secreted by living albumin-transgenic cells directly into said medium. In a specific embodiment the present invention describes a process in which the albumin secreted by living albumin-transgenic cells has the same effect on the recloning efficiency as recombinant or purified albumin at a concentration that is significantly lower. The invention describes in particular a process for cultivating a single cell, comprising the following steps: (a) cultivating a cell population, (b) isolating a single cell from said cell pool and (c) cultivating the said single cell in a conditioned medium, i) which contains albumin, preferably human serum albumin (HSA), which is secreted by living albumin-transgenic cells directly into said medium, ii) the albumin secreted by living albumin-transgenic cells achieving the same effect on the recloning efficiency as recombinant or purified albumin at a significantly lower concentration.
[0123] In a specific embodiment the present invention describes a process in which the albumin secreted by living albumin-transgenic cells has the same effect on the recloning efficiency as recombinant or purified albumin at a concentration that is at least two times lower. In a preferred embodiment, the present invention describes a process in which the albumin secreted by living albumin-transgenic cells has the same effect on the recloning efficiency as recombinant or purified albumin at a concentration that is at least five times lower. In a specific embodiment the present invention describes a process in which the albumin concentration in i) is lower by a factor of at least 2, preferably at least 5, than that of a comparable culture mixture containing recombinant or purified albumin. In another specific embodiment, the present invention describes a process in which the single cell in step (b) and (c) expresses a protein of interest.
[0124] In a preferred embodiment step c) is carried out under serum-free conditions, preferably using chemically defined and/or insulin-free medium. In a specific embodiment the present invention describes a process in which in step (c) albumin is present in a concentration of less than 200 mg/L, preferably less than 100 mg/L, particularly preferably less than 60 mg/L. In another specific embodiment the present invention describes a process in which albumin in step (c) ii) is present in a concentration that is lower by a factor of 2 to 100, 2 to 5, 5 to 100, 20 to 100 or 5 to 10, preferably at least in a concentration that is lower by a factor of 5, most preferably at least in a concentration that is lower by a factor of 10.
[0125] In a preferred embodiment the present invention describes a process wherein in step (c) the cell supernatant of living albumin-transgenic cells is added, which is removed between cultivation days 1 to 4. In a particularly preferred embodiment the present invention describes a process wherein in step (c) the cell supernatant of living albumin-transgenic cells is added which is removed on cultivation day 2.
[0126] In another specific embodiment the present invention describes a process wherein the cell supernatant is taken from a cell culture with 1 to 4 million, preferably 1 to 2 million albumin-transgenic cells/ml. In a preferred embodiment of the invention the cell supernatant is taken from a cell culture with 1 to 4 million, preferably 1 to 2 million albumin-transgenic cells/ml and the albumin concentration in i) is lower than that of a comparable culture mixture containing recombinant or purified albumin by a factor of at least 5 to 10, preferably by a factor of at least 10.
[0127] In another preferred embodiment the present invention describes a process wherein the conditioned medium in step c) is produced by the addition of living albumin-transgenic feeder cells. Preferably, at most 50 0000 albumin-transgenic feeder cells/ml are added. Also preferred is a process according to the invention in which the albumin-transgenic feeder cells remain in the medium of step c) continuously for a period of at least 2 weeks. In a preferred embodiment of the invention the conditioned medium in step c) is produced by the addition of living albumin-transgenic feeder cells, in which 50 0000 albumin-transgenic feeder cells/ml or less are added and the albumin concentration in i) is lower that that of a comparable culture mixture containing recombinant or purified albumin by a factor of at least 5 to 100, preferably by a factor of 20 to 100 (preferably also be a factor of more than 100).
[0128] In another preferred embodiment the present invention describes a process wherein the conditioned medium in step (c) is produced by the fact that the single cell from step (b) and (c) is an albumin-transgenic cell. In a particularly preferred embodiment the single cell is transgenic both for albumin and for a gene of interest and the single cell produces both albumin and also at the same time a protein of interest. In a specific embodiment the present invention describes a process wherein in step c)
[0129] a) living albumin-transgenic feeder cells are added or
[0130] b) the cell supernatant of living albumin-transgenic cells, which is removed between days 1 and 4 of cultivation, preferably on day 2 of cultivation, is added.
[0131] The invention also describes a cell which is generated according to one of the processes according to the invention.
[0132] The invention further describes a process for producing a protein of interest in a cell, preferably a CHO cell, preferably under serum-free cultivation conditions, comprising the following steps:
a) producing a cell population that contains a gene of interest that codes for a protein of interest, b) cultivating these cells under cultivation conditions that permit growth of the cells, c) isolating and depositing a single cell in a vessel, e.g. in a 96-well plate, d) cultivating the said single cell in conditioned medium in the presence of
a) cell supernatant of living albumin-transgenic cells, which is taken between the days 1 and 3 of cultivation, preferably on day 2 of cultivation, or b) living albumin-transgenic feeder cells,
e) selecting a cell corresponding to its expression level of the protein of interest, f) harvesting the protein of interest, for example by separating the cell components from the supernatant, and g) purifying the protein of interest.
[0142] In a specific embodiment the present invention describes a process, characterised in that the protein of interest is a recombinant protein, preferably a therapeutic protein, preferably an antibody or an antibody fusion protein or an antibody fragment.
[0143] In a specific embodiment the present invention describes a process, characterised in that the single cell is a hamster or murine cell, preferably a mouse myeloma cell, particularly preferably a CHO or BHK cell or an NSO cell. In another specific embodiment the present invention describes a process, characterised in that the living albumin-transgenic cell comes from the same species as the individually deposited cell. Preferably, the cell is a “Chinese Hamster Ovary” (CHO) cell. More preferably, the cell is a hamster or murine cell, preferably a mouse myeloma cell, particularly preferably a CHO or BHK cell or an NSO cell, depending on the species of the individually deposited cell.
[0144] In a particular embodiment the present invention describes a process, characterised in that it relates to autologous albumin-transgenic cells or feeder cells.
[0145] In another particular embodiment the present invention describes a process, characterised in that the isolation of a single cell in step b) is carried out by “limited dilution” or using a “fluorescence activated cell sorting” (FACS) apparatus.
[0146] In a preferred embodiment the present invention describes a process, characterised in that the cell in step (b) and (c) expresses a protein of interest. In particular the protein of interest is a therapeutic protein, preferably an antibody, an antibody fusion protein or an antibody fragment.
[0147] The invention also describes a protein which is prepared by a process described according to the invention.
[0148] The invention further describes a process for selecting a production cell, using a process according to the invention.
[0149] The invention further describes the use of a production cell according to the invention for biopharmaceutical protein preparation.
[0150] The invention further describes a serum-free conditioned culture medium that makes it possible to cultivate a single cell, containing:
a) cell supernatant of living albumin-transgenic cells, which is taken between days 1 and 4 of cultivation, preferably on day 2 of cultivation, or b) living albumin-transgenic feeder cells for conditioning the medium.
[0153] Preferably, the medium according to the invention contains an albumin concentration of less than 200 mg/L, more preferably less than 100 mg/L, particularly preferably less than 60 mg/L. Preferably, autologous feeder cells are used. In a preferred embodiment the present invention describes a medium, characterised in that the single cell cultivated therein is a CHO cell. Particularly preferably this single cell expresses a protein of interest.
[0154] For putting the present invention into practice, unless stated otherwise, conventional techniques that are generally known to the skilled man from cell biology, molecular biology, cell culture, fermentation technology, etc. are used. The following experimental data are illustrative by nature and are not restrictive.
Experimental Section
Equipment and Methods
Cultivation of the Cells
[0155] The cells CHO-DG44/dhfr −/− (Urlaub et al., 1983) are permanently cultivated as suspension cells in serum-free HyQ SFM 4 CHO medium (HyClone) supplemented with hypoxanthine and thymidine or BI's own medium in cell culture flasks at 37° C. in a damp atmosphere and 5% CO 2 . The cell counts and viability are determined with a CEDEX Cell Counter (Innovatis, DE) or by tryptan blue staining and the cells are then seeded in a concentration of 1-3×10 5 /mL and run every 2-3 days. Recombinant CHO-DG44 are used for the single cell cloning. The cultivation of cloned recombinant cells is carried out analogously to these cells. Again, HyQ medium, Ex-Cell medium (JRH, USA) or BI's own medium without hypoxanthine and thymidine is used as the medium.
[0156] The cells NS0 can be permanently cultivated as suspension cells in serum-free hybridoma medium, animal component-free medium (Sigma, Aldrich, St. Louis, USA) in cell culture flasks at 37° C. in a damp atmosphere and 5% CO 2 . The cell counts and viability can be determined with a CEDEX Cell Counter (Innovatis, DE) or by tryptan blue staining and the cells are then seeded in a concentration of 1−3×10 5 /mL and run every 2-3 days.
Preparation of Feeder Cells by Irradiation
[0157] Suspended CHO-cells (untransfected cells) growing without serum and protein are centrifuged at 180 g for 10 minutes and adjusted to a cell concentration of 1×10 6 /mL in HBSS (Hank's balanced salt solution). Then the cells are irradiated with a radioactive irradiation source (Cs137-irradiator, Gammacell 2000, made by Molsgaard Medical A/S, Denmark) with an energy dose delivery of 4 Gy/min. After the irradiation the cells are seeded with about 10000 cells per well in 96-well microtitre plates in the Ex-Cell medium (JRH, USA) specific for the cells or BI's own medium (e.g. TH-9) and stored at about 37° C. and 5% CO 2 in an incubating chamber atmosphere.
[0158] HSA-producing feeder cells are produced in the same way.
[0159] The process is carried out accordingly with NS0 cells, while the feeder cells are kept/seeded in the particular medium specific for the cells.
Preparation of Conditioned Medium
[0160] The conditioned medium is obtained from the supernatant of an animal cell culture. The cells are put in at a sufficient seeding density and cultivated for 1-7 days. The supernatant is separated from the cells by centrifugation and then sterile-filtered. The filtrate obtained is used as the conditioned medium.
Determination of the has Concentration by ELISA
[0161] The HSA concentration is determined using the Human Albumin ELISA Quantitation Kit made by Bethyl (Cat.-No. E80-129) according to the manufacturer's instructions.
Facs-Based Cell Deposition
[0162] The automatic cell deposition (single or multiple cell deposition) is carried out with a Flow Cytometer (Coulter EPICS Altra (Messrs. Beckman-Coulter, Miami, Fla., USA) fitted with an argon laser (488 nm) using an Autoclone unit. The cells are centrifuged off in the exponential growth phase and taken up in buffer until the required cell concentration is obtained. Then the cells are sorted using the “Hypersort Option” at a speed of 8000-12000 cells/second according to their position in the scattered light. Cells that express a fluorescent protein may alternatively be sorted according to their fluorescence intensity in relation to the intracellularly expressed fluorescence protein. The cells are each individually deposited in 96-well microtitre plates (optionally) provided with feeder cells. During the sorting of CHO cells the cells are deposited in Ex-Cell medium (JRH, USA) or BI's own medium with the corresponding supplements of HSA and preferably IGF or insulin.
[0163] For NS0 cells the cell deposition is carried out accordingly in hybridoma medium, animal component-free medium (Sigma, Aldrich, St. Louis, USA).
Calculating the Recloning Efficiency
[0164] The recloning efficiency is calculated from the quotient of positive wells per plate to total number of wells per plate. The definition of positive wells is those in which there is exactly one clone.
EXAMPLES
Example 1
Preparation of HSA-Producing CHO-Cells
[0165] CHO-DG44 cells growing serum-free in suspension (Urlaub and Chasin, 1980) are transfected with a plasmid which carries an expression cassette for human serum albumin (HSA) and DHFR as selectable markers. Stably transfected HSA-cell pools are produced by subsequent cultivation in HT-free medium. Using an HSA-specific ELISA those pools that secrete most HSA are selected. They are subjected to gene amplification by cultivation in the presence of methotrexate (MTX). By subsequent Limited Dilution HSA-producing cell lines are prepared from the initially heterogeneous cell population and these cells lines are in turn tested for their specific HSA-productivity. These lines are substantially to a further round of gene amplification by cultivation in medium with an elevated MTX concentration, so as to increase the HSA secretion rate further. As MTX can also leads to an reduction in cell growth at the same time, the cell lines obtained are subsequently investigated both for their increased productivity and for their growth properties and the cell line with the highest productivity and good growth is selected. From this cell a cell bank is produced which can be accessed in all future experiments.
Example 2
Increasing the Recloning Efficiency by the Use of Conditioned Medium from HSA-Producing Cells
[0166] One possible embodiment of the present invention consists in the use of HSA-producing cells to increase the recloning efficiency. Before the recloning a culture of HSA-producing cells is started which condition the culture medium over several days, i.e. release growth factors and especially the HSA secreted by them into the medium. On the day of the recloning this conditioned medium is separated from the living HSA-producing cells by centrifugation, filtered (optionally) and added to the recloning medium in a ratio of 1:1.
[0167] In order to determine the optimum duration of the media conditioning, conditioned medium is obtained from a 2, 3, 4, 5, 6 and 7 day old culture and used for the recloning experiment. The positive control used is fresh medium to which 500 mg/L of purified recombinant HSA has been added.
[0168] As can be seen in FIGS. 2A , B, the use of conditioned medium of HSA-producing cells leads to a significant increase in the efficiency of single cells deposition compared with the negative control. By the addition of recombinant HSA (positive control) the recloning efficiency is also increased, but not as much as by the medium of HSA-secreting cells that has been conditioned for 2-5 days. The HSA concentration in the conditioned medium increases continuously over time, yet the recloning efficiency decreases when medium is used that has been conditioned for longer than 5 days. Surprisingly, the greatest increase in efficiency is obtained by means of conditioned medium from day 2, 3 or 4, in which the HSA concentration of 10 to about 60 mg/L is much lower than the concentration of recombinant HSA used in the positive control. This shows that the secreted HSA is active even at low concentrations and compared with recombinant HSA has an effectiveness that is 5 to 50 times higher in relation to the increase in recloning efficiency.
Example 3
Increase in Recloning Efficiency in Different Media
[0169] In order to test whether the observed increase in recloning efficiency by using conditioned medium from HSA-producing cells operates independently of the medium, single cells are recloned in different media: In one batch the single cell is deposited in BI's own medium in the presence of CHO-DG44 feeder cells ( FIG. 3A ), and in another it is deposited in a commercial medium without feeder cells ( FIG. 3B ).
[0170] In both media, the use of the conditioned medium from HSA-secreting cells leads to a significant increase in recloning efficiency, which is both higher than in the negative control than in the positive control, wherein recombinant HSA was added to the recloning medium. In the batch without feeder cells in commercial medium no cells survive in the negative control, but by using the conditioned medium of HSA-producing cells a 5-13% recloning efficiency can be achieved.
[0171] In both experiments it is shown again that the secreted HSA from the conditioned medium acts at significantly lower concentrations and is hence more efficient than HSA added recombinantly to the medium.
Example 4
Increase in the Recloning Efficiency as a Result of HSA-Producing Feeder Cells
[0172] Conditioned medium from a preliminary culture of HSA-producing cells is added to the recloning medium once before the individually deposited cells are seeded. These cells thus receive HSA-containing medium only once at the beginning during the three-week phase of emergence after recloning. HSA-producing feeder cells could by contrast supply the emergent single cell clones continuously with HSA.
[0173] In order to investigate whether the use of HSA-producing feeder cells leads to a further increase in recloning efficiency, CHO-DG44 cells are deposited singly in four 96-well plates with HSA-producing and non-HSA-producing feeder cells. As in the previous example, the recloning medium contains 50% conditioned medium from an HSA-producing preliminary culture. After three weeks the emergent monoclonal cell colonies in each cell culture plate are counted and the recloning efficiency is calculated.
[0174] As shown in FIG. 4 , the recloning efficiency when using HSA-producing feeder cells is significantly higher than in the plates containing normal feeder cells. The increase is about 25%. Accordingly, by combining HSA-conditioned medium and HSA-producing feeder cells it is possible to achieve another significant increase in the recloning efficiency.
Example 5
HSA-Producing Host Cells Show an Increased Recloning Efficiency
[0175] Another possible way of increasing the recloning efficiency might be to use HSA-producing host cells to produce a therapeutic protein. In this way during the recloning the individually deposited producer cells could themselves produce HSA and stimulate themselves via an autocrine loop. To check whether this process actually leads to increased recloning efficiencies, both normal CHO-DG44 cells and HSA-producing cells are individually seeded onto DG44- and HSA-producing feeder cells. After three weeks, the emergent colonies are counted and the recloning efficiency for all three batches is calculated.
[0176] FIG. 5 shows that the recloning efficiency is lowest in the culture dishes with unaltered CHO-DG44 host and feeder cells. If on the other hand HSA-producing cells are recloned, more monoclonal colonies emerge straight away. This shows that the probability of an HSA-producing cell surviving recloning and forming a culture capable of replication is higher than that of a cell that does not secrete HSA.
[0177] The greatest increase in recloning efficiency is obtained by a combination in which an HSA-producing host cell is seeded on HSA-producing feeder cells. This mixture leads to a further increase in the recloning efficiency of more than 40%. Compared with the control mixture without HSA-producing feeder cells there may even be an increase of more than 50%.
Example 6
Increased Recloning Efficiency of NS0-Cells
[0178] The preceding experiments show that the recloning efficiency of hamster cells can be increased by means of secreted human serum albumin. These results would tend to indicate that HSA has a positive effect on recloning efficiency across species.
[0179] To test this hypothesis, murine NS0 hybridoma cells that produce a therapeutic protein are subjected to recloning. They are placed, firstly, in fresh medium, and secondly in medium to which conditioned medium from an HSA-producing CHO cell culture has been added and in a third batch on HSA-producing feeder cells. Compared with recloning in fresh medium or conditioned medium of a cell culture of non-HSA-secreting cells the use of HSA-producing cells has a positive effect on recloning efficiency. This applies both to the use of conditioned medium from HSA-secreting cells and also HSA-producing feeder cells.
[0180] This shows that human HSA which is secreted by hamster cells can assist the recloning of murine cells.
Example 7
Use of Secreted HSA Increases the Recloning Efficiency Of Human Cells
[0181] To set this finding on an even broader base, human HEK293-based production cells are recloned in the presence and absence of conditioned medium of HSA-producing cells.
[0182] Compared with recloning in fresh medium or conditioned medium of a cell culture of non-HSA-secreting cells the use of HSA-producing cells has a positive effect on the recloning efficiency. This applies both to the use of conditioned medium of HSA-secreting cells and also HSA-producing feeder cells.
[0183] It can be concluded from this that the effect of secreted HSA acts on the recloning efficiency of individually deposited cells of several species, i.e. the activity works across species.
Example 8
Increased Recloning Efficiency by HSA-Producing Cells Increases the Probability of the Identification of High-Producing Cells
[0184] The level of the specific productivity of producer cells in a heterogeneous cell population is normal distributed. This means that most of the cells have an average productivity, while a few cells produce a large amount and only a very small percentage produce a very large amount of recombinant product. This fact explains the effort that is expended on cell screening and the identifying of high-producing cells in industrial cell line development programmes. It also means that the likelihood of finding these high producers is directly correlated with the recloning efficiency: the more cells emerge after recloning, the more likely it is that there will be a high-producing cell among them.
[0185] In order to verify this in practice, a heterogeneous population of stably transfected CHO producing cells which secrete a therapeutic protein is subjected to recloning. Some are placed in a recloning medium to which 50% conditioned medium from the parental CHO-DG44 cell has been added (batch 1), and some are placed in 50% conditioned medium from a culture of HSA-producing cells (batch 2).
[0186] As in the previous Examples, more cells grow into clonal cell lines in the batches in which medium from HSA-producing cells was used.
[0187] In the next step 100 clones were selected from the two recloning trials and their productivity was determined by product-specific ELISA. The distribution of the specific productivity over these 100 clones shows a normal distribution in both cases. In the 100 clones that had emerged from the cells that were recloned using medium from HSA-conditioned medium (batch 2), the mean value of this curve has shifted significantly to the right, towards higher productivities. The mean value of the productivity of the 10 highest-producing cells from this batch 2 is higher than that of the 10 highest cell lines from the recloning batch without HSA-producing cells (batch 1). Accordingly the cell line that is selected as the highest-producing clone for the production of the therapeutic protein comes from batch 2.
[0188] This confirms that more cells with higher productivities are indeed obtained from the recloning batch with HSA-producing cells, thus increasing the probability of identifying them. At the same time there is also a greater likelihood of finding the few cells that produce the recombinant protein product in very large amounts and thus make it possible to select and use a high-producing clone for the production. | The present invention refers to the area of cell culture technology and relates to methods for multiplying/cloning cells, preferably cell lines, which are important to the production of biopharmaceuticals. The invention further relates to methods for manufacturing proteins and to the use of cells extracted and multiplied through single cell sorting and to media compositions that enable a multiplication of single cells. Through the use of albumin-producing, preferably HSA-producing, cells as feeder cells for the conditioning of medium or as host cells, the recloning efficiency and thereby the quantity of clones obtained can be significantly increased. A combination of these approaches is also possible. Through the use of albumin-producing, preferably HSA-producing, cells, an increase in the recloning efficiency can be achieved in serum-free and/or insulin-free medium as well, and in different cell types. | 2 |
BACKGROUND OF THE INVENTION
The present invention is concerned with p-nitrophenyl 3-bromo-2,2-diethoxypropionate, of the formula ##STR1## useful in the synthesis of highly functionalized small molecules and heterocycles, particularly pyromeconic acid (2) and 6-methylpyromeconic acid (3). ##STR2## (2) R=R'=H (3) R=CH 3 , R'=H
(4) R=H, R'=CH 3
(5) R=R'=CH 3
Pyromeconic acid and 6-methylpyromeconic acid have particular value in the synthesis of maltol (4, Tate et al., U.S. Pat. No. 3,130,204) and 6-methylmaltol (5, Tate, U.S. Pat. No. 3,468,915), respectively, as well as other valuable 2-substituted pyromeconic acid derivatives (for example, see Tate et al., U.S. Pat. Nos. 3,365,469 and 3,644,635; Brennan et al., U.S. Pat. No. 4,082,717), which are useful in enhancing flavors or aromas, and/or in the inhibition of bacteria or fungi.
SUMMARY OF THE INVENTION
Highly functionalized small molecules that can be chemoselectively manipulated are of great value to the synthetic organic chemist. Of particular interest would be a derivative of a 3-halopyruvic acid in which the acid moiety is activated toward nucleophilic attack. Such a molecule would consist of an alpha-haloketone linked directly to an activated carboxylic acid, and would contain, in effect, three contiguous electro-positive carbon atoms. Clearly, chemoselectively in the reactions of such a molecule with nucleophiles would be difficult to realize, unless a molecule can be found in which each carbon atom can be differentiated. Furthermore, for a synthon of this type to be of general utility, it should be readily available on large scale, and be reasonably stable. We have now discovered a reagent which meets these criteria, viz., p-nitrophenyl 3-bromo-2,2-diethoxypropionate (NPBDP, 1). NPBDP possesses an alpha-bromoketone moiety masked as a ketal, along with an active carboxylic ester. It is readily prepared in large quantities by ketalization of commercially available alpha-bromopyruvic acid, followed by reaction with p-nitrophenyl trifluoroacetate. NPBDP is a crystalline solid of mp 75°-76° C., which can be stored routinely for over a year without decomposition. This work further describes the utility of (1) in the synthesis of highly functionalized small molecules, as well as heterocycles, in particular pyromeconic acid and 6-methylpyromeconic acid.
The present invention should not be so narrowly construed as to be limited to p-nitrophenyl 3-bromo-2,2-diethoxypropionate per se, since numerous equivalent compounds will be obvious to those skilled in the art. Such compounds include, for example, those in which the C-2 ketal group is replaced by one derived from an alternative alcohol, or from a diol; those in which the C-3 bromo group is replaced by an alternative leaving group (i.e., a group subject to similar nucleophilic displacement); and those in which the C-1 p-nitrophenyl group is replaced by a group of similar reactivity.
DETAILED DESCRIPTION OF THE INVENTION
The valuable, new synthetic reagent of the present invention (NPBDP, 1) is readily prepared in large quantities and in high yield from commercially available alpha-bromopyruvic acid.
The ketone group of the bromopyruvic acid is first converted to the ketal, by reaction of that ketoacid with at least two equivalents of ethanol, usually employing a large excess of ethanol which further serves as solvent for the reaction, under substantially anhydrous conditions, in the presence of a strong acid catalyst, e.g. HCl, H 2 SO 4 or an organic sulfonic acid. Alternatively and preferably, the ketal is formed by reacting the bromopyruvic acid with ethyl orthoformate, also usually in excess and serving as the reaction solvent, again in the presence of a strong acid catalyst, preferably sulfuric acid. In either process, temperature is not critical, for example, 0°-50° C. being satisfactory. Since energy costs associated with heating or cooling are avoided, ambient temperature (usually in the range of about 16°-28° C.) is preferred.
In the second stage, the intermediate 3-bromo-2,2-diethoxypropionic acid is reacted with substantially one equivalent of p-nitrophenyl trifluoroacetate, in the presence of at least one equivalent of a tertiary amine, usually in excess. The preferred amine is pyridine, used in sufficient excess to further serve as solvent for the reaction. Temperature is not critical, e.g., 0°-50° C. is satisfactory. For reasons stated above, ambient temperature is preferred.
Although NPBDP contains two potential sites for nucleophilic attack, and both sites have structure suggesting them to be sterically hindered, a wide variety of nucleophiles react readily and exclusively at the active ester. For example, ammonia and acetamide oxime react smoothly with NPBDP to give 3-bromo-2,2-diethoxypropionamide and the corresponding acetamidino ester derivative, respectively. Reaction of NPBDP with the sodium salt of dimethyl malonate affords dimethyl 2-(3-bromo-2,2-diethoxypropionyl)malonate. Even a potent nucleophile such as alphalithioacetonitrile reacts chemoselectively with NPBDP to afford 5-bromo-4,4-diethoxy-3-oxovaleronitrile.
Even though the alpha-bromoketal is inert to intermolecular reaction, intramolecular reactions can occur when bifunctional nucleophiles are employed. Such synthetic utility of NPBDP (1) is illustrated by its use in the synthesis of valuable pyromeconic acid and 6-methylpyromeconic acid: ##STR3## (6) R=CH 3 ( 7) R=H
(8) R=CH 3
(9) R=H
as exemplified below.
Heterocyclic molecules are also derived from the above polyfunctional small molecules, which behave similarly. For example, 5-bromo-4,4-diethoxy-3-oxovaleronitrile is reacted with hydrazine, forming (via hydrazone formation, cyclization and ethanol elimination) 3-cyanomethyl-4-ethoxypyrazole; and acetimido 3-bromo-2,2-diethoxypropionate is cyclized on warming to produce 3-methyl-5-(2-bromo-1,1-diethoxyethyl)-1,2,5-oxadiazole. The latter is deketalized by warming in 95% formic acid to produce the corresponding 3-methyl-5-(2-bromoacetyl)-1,2,5-oxadiazole.
The present invention is illustrated by the following Examples. However, it should be understood that the invention is not limited to the specific details of these Examples.
EXAMPLE 1
3-Bromo-2,2-diethoxypropionate Acid
alpha-Bromopyruvic acid (100 g, 0.60 mole), 240 mL triethyl orthoformate and H 2 SO 4 (4 mL) were combined and the resulting solution stirred 24 hours, then diluted with 1.2 L CH 2 Cl 2 . The organic phase was separated, washed 2×100 mL H 2 O and then 1×100 mL saturated NaCl, dried over Na 2 SO 4 , evaporated and dried in vacuo 4 hours to yield title product as a white solid, 144 g (99%); mp 80°-85° C. This product was of sufficient purity for direct use in the next step. A sample recrystallized from cyclohexane gave mp 91°-92° C.
EXAMPLE 2
p-Nitrophenyl 3-Bromo-2,2-diethoxypropionate
(NPBDP 1)
Title product of the preceding Example (144 g, 0.60 mole), p-nitrophenyl trifluoroacetate (141 g; 0.60 mole), and pyridine (405 mL) were stirred under N 2 for 24 hours, then poured into 2 L H 2 O and extracted 4×500 mL ether. The extracts were combined, washed 5×175 mL 5% NaOH, dried over Na 2 SO 4 , and evaporated to an oil which crystallized on scratching. Recrystallization from hexane gave purified title product as a stable, white crystalline solid; 169 g (77%), mp 75°-76° C.
EXAMPLE 3
Ethyl 2,3-Dihydro-3,3-diethoxy-6-methyl-4-pyrone-5-carboxylate (6)
Under N 2 , NaH (1.06 g, 44 mmole) was stirred in 100 mL dry tetrahydrofuran (THF). A solution of ethyl acetoacetate (5.47 g, 42 mmole) in 20 mL of dry THF was added dropwise over 15 minutes, followed by NPBDP (7.24 g, 20 mmole) in 80 mL dry THF over 5 minutes. The resulting mixture was refluxed for 4 hours, cooled, poured into 400 mL ice water, adjusted to pH 7 with 1 N HBr, and extracted 3×80 mL CHCl 3 . The extracts were combined, dried over Na 2 SO 4 and evaporated to an oil. The oil was chromatographed on 260 g silica gel, using isopropyl ether as eluant. Following elution of less polar ethyl acetoacetate and p-nitrophenol, title product eluted as an oil which distilled in vacuo to yield purified title product; 3.46 g (63%); bp 110°-115° C./0.2 mm.
Anal. Calcd. for C 13 H 20 O 6 : C, 57.34; H, 7.40; Found: C, 57.12; H, 7.28.
Substituting an equivalent amount of ethyl formylacetate for ethyl acetoacetate yields ethyl 2,3-dihydro-3,3-diethoxy-4-pyrone-5-carboxylate (7).
EXAMPLE 4
2-Methyl-5-hydroxy-4-pyrone-3-carboxylic Acid (8)
Under nitrogen, a solution of title product of the preceding Example (3.46 g) is heated in 95% formic acid at 85° C. for 1 hour. The mixture is cooled and evaporated in vacuo to yield present title product.
In like manner, compound (7) of the preceding Example is converted to 5-hydroxy-4-pyrone-3-carboxylic acid (9).
EXAMPLE 5
6-Methylpyromeconic Acid (4)
Title product of the preceding Example (3.0 g, 0.012 mole) is stirred with 12 mL of dimethyl phthalate and heated to 220°-240° C. until evolution of carbon dioxide is complete (about 15 minutes). The mixture is cooled to about 80° C. and fractionally distilled in vacuum at 1-10 mm. Title product is found in fractions distilling below the boiling point of dimethyl phthalate, which is 148° C./10 mm, 132°/5 mm and 100° C./1 mm.
In the same manner, compound (9) of the preceding Example is converted to pyromeconic acid. | p-Nitrophenyl 3-bromo-2,2-diethoxypropionate, useful in the synthesis of highly functionalized small molecules and heterocycles, including pyromeconic acid and 6-methylpyromeconic acid. | 2 |
FIELD OF THE INVENTION
The present invention relates to an optical switch for switching optical signals and a network system provided with the optical switch.
BACKGROUND OF THE INVENTION
Ethernet which works on layer two (including Fast Ethernet, Gigabit Ethernet, and 10 Gigabit Ethernet) has been used in a local area network (LAN). At present, application area of layer-2 Ethernet expands to a metro area network (MAN) and a wide area network (WAN) as well as LAN, as can be seen wide area Ethernet services becoming popular. Further, application of a storage area network (SAN) to a metro area is being discussed. Moreover, since data processing speed has increased as the Internet proliferates, optical interface such as fiber channel for use in Gigabit Ethernet, 10 Gigabit Ethernet and SAN has been standardized. In the near future, it is highly probable that a network using an optical switch becomes popular by use of ultra high-speed interface of 10 Gigabit Ethernet class, in which optical signals are being switched in the form of light.
In an electric switch, the spanning tree protocol (STP) is used to secure network redundancy while avoiding a loop phenomenon. STP is a method of configuring a tree structure in a switching network working on layer 2 , extending to the entire switches in the network while only one route is existent for each of the entire destinations. With this, while a redundant route is secured even in the event of a failure, logical wiring can be determined avoiding network stoppage caused by a packet loop.
In STP, a switch located at the center of the tree is termed root bridge. As center switch, a switch having a minimum bridge ID (identification number) value is selected. In other switches than the root bridge, a root path cost against the root bridge is calculated. Also, a route having the minimum root path cost is set to a forwarding state (a state transmitting data frames), and other routes having greater root path costs than the above is set to a blocking state (a state suspending transmission of data frames). The path cost of a link between each switch is obtained from the link transmission speed. A port in each switch is shifted from a blocking state, through a listening state and a learning state, to a forwarding state. The above each state will be explained in the following FIG. 1 .
FIG. 1 shows a diagram illustrating state transitions in each port of a switch. Each port can take the blocking state, the listening state, the learning state, the forwarding state, and further a disable state. In the blocking state, data traffic is neither transmitted nor received. Namely, data traffic is discarded, and only BPDU (bridge protocol data unit) is received. In the listening state, data traffic is neither transmitted nor received, and the incoming data traffic is discarded, while BPDU is transmitted and received to form an STP tree topology. In the learning state, data traffic is neither transmitted nor received, and the incoming data traffic is discarded. Learning MAC address and generating an MAC address table are performed in this state. Namely, each MAC address provided in the equipment connected to each switch port is retained in this table, correspondingly to each port. When the state is shifted to this learning state, data frames become ready for transfer. In the forwarding state, it becomes possible to transmit/receive both data traffic and BDPU. The disable state is a state other than the above four states, that is, each port stays ineffective or STP is inoperable. Transitions between each state are performed based on each condition corresponding to reference numbers ( 1 ), ( 2 ), ( 3 ), ( 4 ) and ( 5 ) attached to each arrow shown in FIG. 1 . More specifically, the reference number ( 1 ) denotes a case that the port becomes either effective or initialized, the reference number ( 2 ) denotes a case of the port becoming ineffective, the reference number ( 3 ) denotes a case of the port being selected as designated port or root port, the reference number ( 4 ) is a case of the port being selected as blocking port, and the reference number ( 5 ) is a case when a predetermined time (forward delay: time for shifting to the learning state or the forwarding state) has elapsed.
FIGS. 2A , 2 B show diagrams illustrating an exemplary STP tree topology configuration. In a network having physical topology shown in FIG. 2A , logical topology shown in FIG. 2B is structured by exchanging BPDU to determine a route. The procedure for structuring this topology is explained below.
(1) Selecting a Root Bridge
First, a switch having the minimum value of bridge ID (a 64-bit numeral constituted of 16-bit ‘priority’ combined with 48-bit MAC address of each switch) is selected as root bridge.
(2) Selecting Root Ports
In the switches other than the root bridge, a root port, which is a port positioned nearest to the root bridge, is selected. First, a BPDU having a root path cost=0 is transmitted from the root bridge toward switches located downstream. When a switch receives the BPDU, the switch adds the path cost of the port that has received the BPDU, and transfers the new BPDU further to the downstream switches. By repeating the above procedure, each switch receives a plurality of BPDU. The port having received the BPDU including the least root path cost value is selected as root port.
(3) Selecting Designated Ports
All ports in the root bridge are selected as designated ports without exception. Further, among the ports in each segment (where a segment is a link between switches), a port having a shortest route to the root bridge is selected as designated port.
(4) Setting Forwarding Ports
The ports having been selected as root port and designated port are set as forwarding ports.
(5) Setting Blocking Ports
The ports having been selected neither root port nor designated port are set as blocking ports.
Through the above procedure, logical topology having a tree structure (i.e. tree topology) by STP is structured in regard to the network constituted of electric switches.
PROBLEMS TO BE SOLVED BY THE INVENTION
Because opto-electric conversion of ultra high speed signals is highly difficult, an optical switch capable of switching the routes in the form of light without performing opto-electric conversion is a key technology for optical networks. As compared with an electric switch, the optical switch has such features as being free from protocols (Ethernet or Fiber Channel), and capable of passing signals at arbitrary bit rates. Because of these features, the optical switch is considered as a switch having dominant possibility for use in the future network. However, in the optical switch, exchanging BPDU control frames employed in STP has not been taken into account, and therefore it is difficult to implement the STP function. As a result, in a network constituted of a plurality of optical switches, an unintended packet loop may possibly be produced. Furthermore, it is not possible to analyze BPDU even if BPDU is transmitted, because presently the optical switch performs switching without inspecting the contents of BPDU. For the above reason, configuring a tree structure is mainly performed by manual operation, which compels consumption of a large amount of time, as well as human costs.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an optical switch capable of automatic configuration of transmission routes of a tree structure, and a network system constituted of the above optical switch.
In order to attain the above-mentioned object, according to the present invention, there is disclosed a first optical switch having a plurality of ports and being capable of switching optical signal routes in the form of light. The first optical switch includes: a detection means detecting information in regard to a transmission condition of an optical signal passing through each port; and a control means exchanging the above-mentioned information in regard to the transmission condition between each switch, and controlling each port so that a single route is selected from among the plurality of routes on which optical signals are transmitted, based on the difference of the information in regard to the transmission condition between each switch.
In the first optical switch, for example, the information in regard to the transmission condition is optical signal power. A transmission route either having a minimum difference of the information between each switch, or when at least one switch intervenes in the middle of the transmission route, having a minimum accumulation of the differences between each switch, is selected.
In order to attain the above-mentioned object, in a plurality of optical switches each having a plurality of ports and being capable of switching optical signal routes in the form of light, there is disclosed a second optical switch according to the present invention, which includes a detection means detecting information in regard to a transmission condition of an optical signal input into each port; and a control means controlling each port so that a single route is selected from among the plurality of routes on which the optical signals are transmitted, based on the above-mentioned information in regard to the transmission condition of the optical signal detected in each port.
In the second optical switch, for example, the information in regard to the transmission condition is optical signal power, and a transmission route through which an optical signal is input into a port having received the maximum optical signal power is selected.
Preferably, the control means transmits and receives the information in regard to the transmission condition between each switch, using an extended BPDU format having an additional information field in regard to the transmission condition, which is added to the bridge protocol data unit (BPDU) format of the spanning tree protocol (STP). A tree topology with STP is structured through the port control performed by the control means.
Also, the control means transmits and receives the information in regard to the transmission condition via a signal line network different from the network constituting the optical signal transmission routes.
Further, there are disclosed a network system constituted of the above-mentioned optical switch in accordance with the present invention, and a route setting method performed by the optical switch.
The effects of the present invention will be summarized in the following:
In an electric switch, the tree structure is configured using STP. However, in the conventional optical switch, it is not possible to read the signal contents because switching is carried out in the form of light. Therefore, it is not possible to configure the tree structure. According to the present invention, there is provided a method for configuring the tree structure in an optical network by the use of light power (intensity) information. This enables automatic setting of the tree structure in the optical network system, which has been performed through manual operation in the conventional method, and reduction in terms of time and human costs can be achieved. Further, in the event of a failure, failure detection can be attained earlier by monitoring the light power, and as a result, switchover to a redundant route can be achieved faster than in the case when the electric switches are used.
Further scopes and features of the present invention will become more apparent by the following description of the embodiments with the accompanied drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a diagram illustrating state transitions in each port of a switch.
FIGS. 2A , 2 B show diagrams illustrating an exemplary STP tree topology configuration.
FIG. 3 shows an exemplary network configuration (physical topology) constituted of a plurality of optical switches according to an embodiment of the present invention.
FIG. 4 shows a diagram illustrating an internal configuration of an optical switch according to an embodiment of the present invention.
FIG. 5 shows a conceptual diagram of a data plane and a control plane.
FIG. 6 shows a diagram illustrating exemplary control information stored and transmitted on a control plane.
FIG. 7 shows a diagram illustrating a BPDU format in STP for electric switches.
FIG. 8 shows exemplary fields newly added to the BPDU format.
FIG. 9 shows an exemplary configuration of an extended BPDU format according to an embodiment of the present invention.
FIG. 10 shows exemplary frames transmitted and received on a port a 1 .
FIG. 11 shows exemplary frames transmitted and received on a port b 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the present invention is described herein after referring to the charts and drawings. However, it is noted that the scope of the present invention is not limited to the embodiments described below.
According to an embodiment of the present invention, when structuring a logical tree structure of a network constituted of a plurality of optical switches, optical signal power (light intensity) is monitored, and an optical path cost is calculated based on optical power loss, without converting an optical signal transmitting between each optical switch to an electric signal. Based on the calculated optical path cost, logical topology of a tree structure using optical switches is constructed.
FIG. 3 shows an exemplary network configuration (physical topology) constituted of a plurality of optical switches according to the embodiment of the present invention. The network shown in FIG. 3 is constituted of four optical switches OSWa (optical bridge ID: 1), OSWb (optical bridge ID: 2), OSWc (optical bridge ID: 3), and OSWd (optical bridge ID: 4). To these optical switches, electric switches ESWa, ESWb, ESWc and ESWd are connected, respectively. Further, optical switch OSWa has ports a 1 , a 2 , optical switch OSWb has ports b 1 , b 2 , optical switch OSWc has ports c 1 , c 2 , and optical switch OSWd has ports d 1 , d 2 , respectively.
Optical switches OSWa and OSWb are connected by an optical link L 4 having an assumed path cost (optical link path cost) of, for example, 6 (dB). The optical link path cost is a difference of the power loss in the optical link concerned. Similarly, OSWa and OSWc are connected by an optical link L 1 having an assumed link loss of 3 (dB), OSWc and OSWd are connected by an optical link L 2 having an assumed link loss of 4 (dB), and OSWb and OSWd are connected by an optical link L 3 having an assumed link loss of 3 (dB), OSWc and OSWb are connected by an optical link L 5 having an assumed optical link path cost of 4 (dB). Here, each link is constituted of an upward channel and a downward channel. Each link loss shown in FIG. 3 is, for example, an average optical link loss on the upward channel and the downward channel.
FIG. 4 shows a diagram illustrating an internal configuration of an optical switch according to the embodiment of the present invention. As an example, the internal configuration of optical switch OSWa is shown. Other switches have internal configurations similar to the above OSWa. OSWa includes a switch 14 that enables switching of a plurality of input ports 12 and a plurality of output ports 13 . In addition, OSWa includes: an optical branch section 15 by which a portion of optical signals is made to branch at least from either one of input port 12 and output port 13 (branching from the input port is illustrated in the example shown in FIG. 4 ); an optical receiver 16 which receives the optical signal having been made to branch, and measures the light power thereof; and a controller 17 which controls port connection based on the light power measured by optical receiver 16 and the light power information acquired from other switches, and determines an optical signal route. Controller 17 acquires optical signal power information measured in other switches, calculates each path cost of the optical link (optical link path cost) between the switches, and performs port switching control. Here, a paired combination of an input port and an output port shown in FIG. 4 corresponds to each single port shown in FIG. 3 .
In order to configure network tree topology constituted of optical switches, the following are specified in addition to the above-mentioned optical link path cost, and an optical switch path cost.
(i) As to the optical bridge ID of an optical switch, an arbitrary value is settable. With this, an arbitrary one of the plurality of optical switches constituting the network can be defined as optical root bridge. The optical bridge ID is exchanged between each switch using BPDU, using the control plane described later.
(ii) Power difference (link loss: dB) of the optical signal before and after being transmitted through an optical link is defined as optical link path cost.
(iii) A total amount of the optical link path costs of the optical links existent on the route reaching the optical root bridge through which the optical signal passes is defined as optical root path cost.
Under the above specifications, tree topology of the optical switches is configured by the following procedure.
(1) Selecting an optical root bridge
The optical switch of which optical bridge ID is the smallest value is selected as optical root bridge.
(2) Selecting optical root ports
In each optical switch, by measuring the light power of the received optical signal transmitted from the optical root bridge, optical root path costs of the ports in the optical switch concerned are obtained. The port having the least optical root path cost is set as root port.
(3) Setting optical designated ports
The entire ports of the optical root bridge are determined as optical designated ports. Also, among the ports connected to each optical link, the ports having small optical root path costs are determined as optical designated ports.
(4) Setting optical forwarding ports
The optical root port and the entire ports selected as optical designated port are set as optical forwarding ports.
(5) Setting optical blocking ports
The rest of the ports having been neither selected as optical root port, nor determined as optical designated ports are set as optical blocking ports.
With this procedure, a tree topology in the network constituted of optical switches can be configured. Namely, the tree topology throughout the entire network can be configured autonomously using the above-mentioned procedure performed by each optical switch. In order to actualize the configuration procedure of the tree topology, for example, in addition to a data plane for transmitting data in the network in the form of optical signals, a control plane is prepared to transmit optical path costs obtained from light power. The control plane is a network constituted of signal lines physically different from the data plane. On the control plane, power information of the optical signals on the data plane (light power information) is transmitted in the form of electric signals.
FIG. 5 shows a conceptual diagram of the data plane and the control plane. In FIG. 5 , a control plane network is provided corresponding to the data plane network transmitting optical signals through each optical switch OSWa, OSWb, OSWc, OSWd. On this control plane, each controller 17 a , 17 b , 17 c , 17 d (here, suffixes a, b, c, d are added to identify each controller 17 in the switches) of each optical switch OSWa, OSWb, OSWc, OSWd stores light power information on the control plane, and also exchanges light power information with other optical switches.
FIG. 6 shows a diagram illustrating exemplary control information stored and transmitted on the control plane. In FIG. 6 , each controller 17 in the switch has a table (table A, table B, table C, table D) stored in a predetermined memory area, having input power and output power (both upward signal power and downward signal power), and optical link path cost as well, corresponding to each port. Each controller 17 a , 17 b , 17 c , 17 d in each optical switch OSWa, OSWb, OSWc, OSWd exchanges control information stored in each table using extended BPDU, which is an extended format of BPDU used in STP for electric switches, and will be explained later. Corresponding to each arrow shown in FIG. 6 , exemplary control information (light power information) to be exchanged between the switches is shown with respect to both an upward signal and a downward signal.
FIG. 7 shows a diagram illustrating the BPDU format in STP for electric switches. Depending on the BPDU types, values of ‘message type’ are modified. For STP used in electric switches, there are configuration BPDU (message type: ‘00000000’b), and topology change notification (TCN) BPDU (message type: ‘10000000’b).
When configuring tree topology in the network constituted of optical switches, according to the embodiment, it is necessary to assign to each port a value of optical link path cost in each optical switch, prior to configuring tree topology. Therefore, according to the embodiment of the present invention, a new message type is added for this purpose. The name of this new message type is, for example, optical configuration BPDU (message type: other than the values ‘10000000’b and ‘00000000’b, for example, ‘00001000’b). Also, in order to acquire an optical link path cost value, it is necessary to exchange light power information measured in each optical switch. For this purpose, a new field is added in the BPDU format.
FIG. 8 shows exemplary fields newly added to the BPDU format. As shown in FIG. 8 , two fields are added: one is “port input power” which denotes an optical signal power value input to the port, and the other is “port output power” which denotes an optical signal power value output from the port.
FIG. 9 shows an exemplary configuration of an extended BPDU format according to the embodiment of the present invention. In the extended BPDU format, the fields shown in FIG. 8 are added to the BPDU format shown in FIG. 7 . Each optical switches measures light power values on each input/output port, The measured values are inserted into the field values of “port input power” and “port output power”, respectively, and transmitted to other optical switches. Calculation of optical link path cost is performed following transmission and reception of these values.
Taking as an example the optical switch network shown in the above FIG. 3 , exchange of light power information between switches and calculation of the optical link path cost are described below.
First, each optical switch sets the message type value of the extended BPDU format to ‘00001000’b, and transmits the extended BPDU frame to other optical switches. A port a 1 of the switch OSWa and a port b 1 of the switch OSWb are considered in the following description. FIG. 10 shows exemplary frames transmitted and received on the port a 1 , while FIG. 11 shows exemplary frames transmitted and received on the port b 1 . In the switch OSWa, from the information of the reception/transmission light power of the port b 1 , which has been obtained from the switch OSWb, and the information of reception/transmission light power of the port a 1 , which is stored in the memory area of controller 17 of the own switch OSWa, the following calculation results are obtained: The optical link path cost of the link on the transmission side (upward link) is 6 dB, and the optical link path cost of the link on the reception side (downward link) is also 6 dB. In this case, since the optical link path costs on both the transmission side and the reception side are identical, the optical link path cost of this link L 4 becomes 6 dB. When the optical link path cost on the transmission side differs from the optical link path cost on the reception side, for example, the average value is regarded as the optical link path cost of the optical link concerned.
In the switch OSWb also, the similar calculation is performed, and the result is: the optical link path cost on the transmission side is 6 dB, and the optical link path cost on the reception side is 6 dB. From the above results, both the optical transmission/reception power and the optical link path cost value of each transmission/reception port are stored in the switch OSWa and the switch OSWb, respectively. In a similar manner, light power information is exchanged among the entire switches in the network. Thus, a loss in the link connected to each port, namely the optical link path cost, is retained in each switch (refer to table A, table B, table C, table D).
Then, the optical switch, of which optical link path cost of each port has been determined, sets a message type value of the extended BPDU to the value (‘00000000’b) for declaring a configuration BPDU, and performs the aforementioned processing (1) to (5). Thus, logical topology in the optical switch network can be configured.
In the above-mentioned embodiment, by calculating optical link path costs based on light power, a tree structure is configured, in which a transmission route for an optical signal is uniquely determined. However, it may also be possible take an optical signal loss (which is termed optical switch path cost) produced inside each optical switch into consideration, in addition to the optical link path cost. The optical switch itself is also a portion of the optical signal transmission line, and the loss produced while the optical signal is input to the optical switch and output therefrom depends on each switch. Therefore, determining optical signal transmission route in consideration of optical switch path cost, in addition to the optical link path cost, enables more accurate route decision, and configuration of more preferable tree structure as well.
In the above-mentioned embodiment, by measuring the power of the optical signal, configuring the tree structure is performed after each calculates the optical link path cost (and the optical switch path cost) and stores the calculated path cost. However, it is also possible to configure the tree structure without calculating the optical link path cost on a link-by-link basis. More specifically, to determine the routes extending from the root bridge to other switches successively after determining the root bridge, the root bridge outputs optical signals using the entire transmission routes connecting between the root bridge and an object switch for route selection (route selection object switch). The route selection object switch determines the port having received the highest light power as root port. With regard to other ports than the above-determined root port, the light power received on the port of interest is compared with the light power received on the port of other switches being connected to the port of interest via an optical link. The port having higher light power is determined as designated port. The ports other than those having been set as root port and designated port are set as blocking ports. Thus, the tree structure can be configured.
A route switchover of an optical signal transmitted from the optical root bridge and an information exchange of light power measured by an optical switch other than the optical root bridge are performed through exchanging the signal on the control plane by use of the aforementioned extended BPDU.
Further, in the embodiment having been described, the tree topology is configured by calculating the path cost based on the light power. However, it is also possible to adopt any other amount than the light power. For example, by employing a spectrum analyzer in an optical switch, an optical signal-to-noise ratio (OSNR) can be measured in the optical switch. In a system using light for a signal medium, OSNR is an important value to determine the signal quality. From that point of view, it is possible to measure OSNR in the optical switch, and use the measured value as the optical link path cost. By adopting an optical link having a satisfactory OSNR as a signal route, a tree topology of good signal quality and high system reliability can be configured. As other means for path cost evaluation, it may be possible to use a signal bit rate, a type or length of the optical fiber used as transmission medium, the number of opto-electric and electro-optical converters inserted in the middle of the transmission line, etc. It is also possible to use combination of the above two, or more.
Moreover, the embodiment of the present invention may also be applicable when a packet switch having an optical buffer for obtaining the destination of a packet through optical processing is actualized. In this case, operation using the data plane network only becomes possible, not only the two-stage configuration constituted of the control plane and the data plane having been described above. Basic operation thereof is identical to the STP of electric switches. However, as BPDU, the extended BPDU shown in FIG. 9 is adopted instead of the BPDU for electric switches, so that the optical link path cost values calculated from measured light power values are used as indexes for structuring the tree. First, the optical link path cost values are calculated by exchanging the optical configuration BPDU, which are then stored in each memory area of the switch. Next, by exchanging the configuration BPDU, a tree structure is configured. At this time, the optical link path cost obtained through exchanging the optical configuration BPDU is used as path cost. In the case of using such a packet switch, it is possible to apply the method of configuring the tree structure while calculating the optical link path costs, and the method of adopting information other than light power as optical link path cost as described above.
The foregoing description of the embodiments is not intended to limit the invention to the particular details of the examples illustrated. Any suitable modification and equivalents may be resorted to the scope of the invention. All features and advantages of the invention which fall within the scope of the invention a recovered by the appended claims. | The optical switch, having a plurality of ports capable of switching optical signal routes in a network in the form of light, includes a detection means for detecting information in regard to the transmission condition of an optical signal passing through each port; and a control means for exchanging the transmission condition information between each switch and controlling the ports, so as to select one route from among a plurality of routes transmitting the optical signal based on the difference of transmission condition information between the relevant switches. The transmission condition information is the power of the optical signal. When the difference between each switch exists, or when at least one switch intervenes in the middle of the transmission route, by selecting a transmission route which minimizes accumulated differences among the switches, configuring a tree structure conventionally performed through manual operation can be set automatically in an optical network system. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a portable telephone, a diffuser and a lighting device both of which are provided in the portable telephone, in particular to the portable telephone having a back light, and the like which uniformly emit a light on input buttons, the diffuser and the lighting device both of which are provided in the portable telephone.
[0002] In a conventional portable telephone, a light emitting element, such as a light emitting diode (hereunder called LED), and the like is provided, for example, near input buttons, such as numeral keys, or the like. The light emitting element is adjusted to emit a light every time that any one of the input buttons are pushed on by an user. Accordingly, the conventional portable telephone can be used by the user even in the darkness.
[0003] The conventional portable telephone comprises a housing, a plurality of input buttons, a substrate, and a plurality of LEDs each of which is mounted on the substrate and located under a part of the housing between the input buttons. The input buttons are consisting mainly of resins, respectively. Each of the resins includes a diffuser including a diffusing material on which a light from the LED is incident and through which the light is emitted towards an upper side of the input buttons. A surface of the resin defines a lighting surface which transmits or reflects the light from the LED. The conventional portable telephone can be used even in the darkness by driving the LED, when any one of the input buttons are pushed on by an user.
[0004] However, a strength of a light projected from the resin actually becomes smaller as the light becomes remote from the LED. This is not only because the transmission light is fewer than the transmission light at the lighting plane but also because the progressing light is not adjusted to transmit the lighting plane. The strength of the light projected from the resin becomes smaller as the light becomes remote from the LED. As a result, literatures depicted in the input buttons sometimes cannot be seen sufficiently, when the conventional portable telephone is in the darkness. Some proposals are made for solving this problem. For example, numbers of the LEDs are increased. Further, a strength of emitting light in the LED is increased. Moreover, a distance between the LED and the lighting plane is designed to be longer.
[0005] However, in a case that the numbers of the LEDs are increased or that the strength of emitting light in the LED is increased, power consumption of the conventional portable telephone is also increased. Further, in a case that the distance between the LED and the lighting plane is designed to be longer, thickness of the conventional portable telephone sometimes becomes larger.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to provide a compact portable telephone which is capable of preventing a strength of a light projected from a diffuser positioned remote from LED from becoming smaller, without increasing power consumption of the portable telephone.
[0007] Other objects of the present invention will become clear as the description proceeds.
[0008] According to an aspect of the present invention, there is provided a portable telephone comprising: a plurality of input buttons for inputting various indications; at least one light emitting element which emits a light, when any one of a plurality of input buttons is pushed on; at least one diffuser which is located under a plurality of input buttons and which diffuses the light emitted from the light emitting element; the diffuser including: an incidence portion which has a receiving plane positioned near the light emitting element and receiving the light emitted from the light emitting element; and a projecting portion which has a reflecting plane for reflecting the light received by the incidence portion to an upper side of a plurality of input buttons.
[0009] The receiving plane of the incidence portion may be a part of an arc any portions of which has an equal distance from the light emitting element.
[0010] Concave and convex may be formed on a surface of the receiving plane of the incidence portion.
[0011] The light emitting element may be a light emitting diode.
[0012] According to another aspect of the present invention, there is also provided a diffuser located under the input buttons of the portable telephone, wherein the diffuser comprises: an incidence portion which has a receiving plane for receiving a light emitted from the light emitting element; and a projecting portion which has a reflecting plane for reflecting the light received by the incidence portion to an upper side of a plurality of input buttons.
[0013] According to yet another aspect of the present invention, there is also provided a lighting device located near the input buttons of the portable telephone, wherein the lighting device further comprises: at least one light emitting element which emits a light, when any one of a plurality of input buttons is pushed on; at least one diffuser which diffuses the light emitted from the light emitting element; the diffuser further comprising: an incidence portion which has a receiving plane for receiving a light emitted from the light emitting element; and a projecting portion which has a reflecting plane for reflecting the light received by the incidence portion to an upper side of a plurality of input buttons.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a schematic view for partially showing a conventional portable telephone around the input buttons thereof;
[0015] [0015]FIG. 2 is a schematic view for partially showing a back surface of a housing of the conventional portable telephone around the input buttons thereof;
[0016] [0016]FIG. 3 is a sectional view of the housing of the conventional portable telephone around the input buttons thereof seen from the line X 1 to X 2 of FIG. 1;
[0017] [0017]FIG. 4 is a sectional view of the housing of the conventional portable telephone around the input buttons thereof seen from the line Y 1 to Y 2 of FIG. 1;
[0018] [0018]FIG. 5 is an enlarged view for showing one of the input buttons 1 illustrated in FIG. 3, which is located on the right side thereof;
[0019] [0019]FIG. 6 is a luminance distribution diagram of the light from the LED 7 in the conventional portable telephone;
[0020] [0020]FIG. 7 is a schematic view for showing the portable telephone according to the preferred embodiment in which the housing 4 of FIG. 1 is removed;
[0021] [0021]FIG. 8 is a sectional view of the housing of the portable telephone according to the preferred embodiment of the present invention around the input buttons 1 seen from the line X 1 to X 2 of FIG. 1;
[0022] [0022]FIG. 9 is a sectional view of the housing of the portable telephone according to the preferred embodiment of the present invention around the input buttons 1 seen from the line Y 1 to Y 2 of FIG. 1;
[0023] [0023]FIG. 10 is an enlarged view for showing one of the input buttons 1 illustrated in FIG. 8, which is located on the right side thereof;
[0024] [0024]FIG. 11 is a view for showing another example of the resin of the portable telephone according to the preferred embodiment of the present invention;
[0025] [0025]FIG. 12 is a view for showing another example of the resin of the portable telephone according to the preferred embodiment of the present invention;
[0026] [0026]FIG. 13 is a view for showing another example of the resin of the portable telephone according to the preferred embodiment of the present invention; and
[0027] [0027]FIG. 14 is a luminance distribution diagram of the light from the LED 7 in the portable telephone according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring to FIGS. 1 through 6, description is, at first, made about a conventional portable telephone in order to facilitate an understanding of the present invention. FIG. 1 is a schematic view for partially showing a conventional portable telephone around the input buttons thereof. FIG. 2 is a schematic view for partially showing a back surface of a housing of the conventional portable telephone around the input buttons thereof. As illustrated in FIGS. 1 and 2, the conventional portable telephone comprises a housing 4 and a plurality of input buttons 1 , such as numeral keys, or the like.
[0029] [0029]FIG. 3 is a sectional view of the housing of the conventional portable telephone around the input buttons thereof seen from the line X 1 to X 2 of FIG. 1. FIG. 4 is a sectional view of the housing of the conventional portable telephone around the input buttons thereof seen from the line Y 1 to Y 2 of FIG. 1. Besides, as illustrated in FIGS. 3 and 4, the conventional portable telephone further comprises LEDs 7 which are located under a part of the housing 4 between the input buttons 1 . In addition, the input buttons 1 are consisting mainly of resins 8 , respectively. Each of the resins 8 includes a diffuser material on which a light from the LED 7 is incident and through which the light is emitted towards an upper side of the input buttons 1 . A surface of the resin 8 defines an illumination plane 2 which transmits or reflects the light from the LED 7 . Further, the LED 7 is mounted on a substrate 3 .
[0030] [0030]FIG. 5 is an enlarged view for showing one of the input buttons 1 illustrated in FIG. 3, which is located on the right side thereof. Although a light from the LED 7 is illustrated in FIG. 5, refraction of the light is not illustrated therein for convenience of an explanation. In FIG. 5, illustrated is a transmission light 15 at an illumination plane 2 , a transmission light 14 reflected at once on the illumination plane 2 and thereafter transmitting through the illumination plane 2 , a progressing light 13 progressing within a resin 8 , a direct projection plane 10 in which the light from the LED 7 directly reaches the illumination plane 2 , a projection plane 11 of the transmission light 14 and the transmission light 15 , respectively.
[0031] As described above, in the conventional portable telephone, a plurality of LEDs 7 are located between the input buttons 1 . The conventional portable telephone can be used even in the darkness by driving the LED 7 , when any one of the input buttons 1 are pushed on by an user.
[0032] However, the conventional portable telephone has the following problems. FIG. 6 is a luminance distribution diagram of the light from the LED 7 in the conventional portable telephone. A diffuser of the conventional portable telephone includes a diffusing material. However, as illustrated in FIG. 6, a strength of a light projected from the resin 8 actually becomes smaller as the light becomes remote from the LED 7 . This is, as illustrated in FIG. 5, not only because the transmission light 14 is fewer than the transmission light 15 at the illumination plane 2 but also because the progressing light 13 is not adjusted to transmit the illumination plane 2 .
[0033] As mentioned above, the strength of the light projected from the resin 8 becomes smaller as the light becomes remote from the LED 7 . As a result, literatures depicted in the input buttons 1 sometimes cannot be seen sufficiently, when the conventional portable telephone is in the darkness. Some proposals are made for solving this problem. For example, numbers of the LEDs 7 are increased. Further, a strength of emitting light in the LED 7 is increased. Moreover, a distance between the LED 7 and the illumination plane 2 is designed to be longer.
[0034] However, in a case that the numbers of the LEDs 7 are increased or that the strength of emitting light in the LED 7 is increased, power consumption of the conventional portable telephone is also increased. Further, in a case that the distance between the LED 7 and the illumination plane 2 is designed to be longer, thickness of the conventional portable telephone sometimes becomes larger.
[0035] Now, referring to FIGS. 7 through 14 with reference to FIGS. 1 and 2 continued, description will proceed to a portable telephone according to a preferred embodiment of the present invention.
[0036] The portable telephone according to the preferred embodiment of the present invention has a structure similar to that of the conventional one illustrated in FIGS. 1 and 2.
[0037] As illustrated in FIGS. 1 and 2, the portable telephone according to the preferred embodiment of the present invention comprises the input buttons 1 , such as numeral keys, or the like. FIG. 7 is a schematic view for showing the portable telephone according to the preferred embodiment in which the housing 4 of FIG. 1 is removed. In FIG. 7, illustrated are LEDs 7 which are located under a part of the housing 4 between the input buttons 1 . In addition, each of the input buttons 1 includes resin 8 , such as acrylic resin, polycarbonate resin, or the like, respectively. Each resin 8 is consisting of a diffuser having an incidence portion 5 and a projecting portion 6 . The incidence portion 5 receives an incident light from the LED 7 while the projecting portion 6 projects the incident light towards an upper side of the input button 1 .
[0038] Besides, it is alternative that the diffusing material is not included in the resin 8 . Accordingly, variation of design, such as specifications, color tone, or the like can be increased.
[0039] [0039]FIG. 8 is a sectional view of the housing of the portable telephone according to the preferred embodiment of the present invention around the input buttons 1 seen from the line X 1 to X 2 of FIG. 1. FIG. 9 is a sectional view of the housing of the portable telephone according to the preferred embodiment of the present invention around the input buttons 1 seen from the line Y 1 to Y 2 of FIG. 1. Besides, as illustrated in FIGS. 8 and 9, a surface of the resin 8 is an illumination plane 2 through which a light from the LED 7 is transmitted or on which the light from the LED 7 is reflected. Further, the LEDs 7 are mounted on a substrate 3 .
[0040] [0040]FIG. 10 is an enlarged view for showing one of the input buttons 1 illustrated in FIG. 8, which is located on the right side thereof. Although a light from the LED 7 is illustrated in FIG. 10, refraction of the light is not illustrated therein for convenience of an explanation. In FIG. 10, illustrated is a transmission light 15 at an illumination plane 2 , a transmission light 14 reflected at once on the illumination plane 2 and thereafter transmitting through the illumination plane 2 , a progressing light 13 which is progressing within the resin 8 with reflection or diffusion and which transmits through the illumination plane 2 at the projecting portion 6 , a direct projection plane 10 in which the light from the LED 7 directly reaches the illumination plane 2 , a projection plane 11 of the transmission light 14 and the transmission light 15 , respectively.
[0041] Herein, for example, in a case that the resin 8 is consisting of polycarbonate resin, that a distance in a horizontal direction between a center of the LED 7 and a center of the incidence portion 5 is from 1.0 mm to 3.0 mm, and that a distance between an upper surface of the LED 7 and a lower surface of the housing 4 above the LED 7 is from 0.5 mm to 1.5 mm, luminance of the transmission light 15 transmitting through the direct projection plane 10 comes to a desirable strength on a predetermined condition in spite of suppressing light emitting strength of the LED 7 . The predetermined condition is not only that a plane of the incidence portion 5 at the side of the LED 7 has an angle between 15° and 20° against a horizontal plane but also that a plane of the incidence portion 5 at the opposite side has an angle between 35° and 45° against the horizontal plane. Further, in the case that the resin 8 is consisting of polycarbonate resin, that a distance in a horizontal direction between a center of the LED 7 and a center of the incidence portion 5 is from 1.0 mm to 3.0 mm, and that a distance between an upper surface of the LED 7 and a lower surface of the housing 4 above the LED 7 is from 0.5 mm to 1.5 mm, luminance of the progressing light 13 is not reduced on a predetermined condition despite that the progressing light 13 is transmitting through the resin 8 at a position remote from the LED 7 . The predetermined condition is not only that a plane of the projecting portion 6 at the side of the LED 7 has an angle between 10° and 15° against a horizontal plane but also that a plane of the projecting portion 6 at the opposite side has an angle between 15° and 25° against the horizontal plane.
[0042] Next, description proceeds to a path of light in the resin 8 . At first, the incidence portion 5 is formed. The light from the LED 7 is therefore not readily reflected when the light is illuminated on the resin 8 . As a result, the light from the LED 7 is efficiently gathered into the resin 8 . An incident angle into the illumination plane 2 is comparatively small in the light at a side near the LED 7 among the light gathered into the resin 8 . Consequently, the light at the side near the LED 7 is directly projected as the transmission light 15 from the illumination plane 2 to the outside thereof. On the contrary, an incident angle into the illumination plane 2 of the resin 8 is comparatively large in the light at a side remote from the LED 7 among the light gathered into the resin 8 . Consequently, a part or all of the light at the side remote from the LED 7 is reflected on the illumination plane 2 to progress within the resin 8 as the progressing light 13 .
[0043] A part of the progressing light 13 transmits the illumination plane 2 to be projected to the outside of the resin 8 as the transmission light 14 . However, the greater part of the progressing light 13 progress within the resin 8 as the progressing light 13 to be projected, as the transmission light, by the projecting portion 6 from the illumination plane 2 to the outside of the resin 8 . Accordingly, a projecting plane 11 becomes large, as illustrated in FIG. 10.
[0044] In FIG. 10, the incidence portion 5 and the projecting portion 6 are formed by providing concave portions in the resin 8 . However, the incidence portion 5 and the projecting portion 6 may be formed by providing convex portions in the resin 8 , as illustrated in FIG. 11.
[0045] Further, in FIG. 10, an incident plane of the incidence portion 5 into which the light from the LED 7 enters are formed to be a plane. Alternatively, the incident plane may be formed to be a part of an arc any portions of which has an equal distance from the LED 7 in order that the light from the LED 7 may be entered into the resin 8 more efficiently. An example of such a structure is illustrated in FIG. 12. In the structure being illustrated, the incident plane is formed to be a part of a spherical plane.
[0046] Moreover, as illustrated in FIG. 13, minute concave and convex may be formed in the incident plane of the incidence portion 5 into which the light from the LED 7 enters by roughing a surface thereof. In this case, the light from the LED 7 is divided by the minute concave and convex. As a result, luminance of the progressing light 13 can be further prevented from being reduced despite that the progressing light 13 is transmitting through the resin 8 at a position remote from the LED 7 .
[0047] [0047]FIG. 14 is a luminance distribution diagram of the light from the LED 7 in the portable telephone according to the preferred embodiment of the present invention. As illustrated in FIG. 14, luminance of a light projected from the resin 8 becomes substantially uniform in spite of a distance from the LED 7 in the portable telephone according to the preferred embodiment of the present invention. Namely, the luminance of the light projected from the resin 8 becomes substantially uniform, even though the light becomes remote from the LED 7 .
[0048] As described above, the portable telephone according to the preferred embodiment of the present invention comprises a diffuser in which the incidence portion 5 and the projecting portion 6 are formed. The strength of a light projected from the diffuser positioned remote from the LED 7 can be prevented from becoming smaller, even if numbers of the LEDs 7 are not increased, a strength of emitting light in the LED 7 is not increased, a distance between the LED 7 and the illumination plane 2 is not designed to be longer. | In a portable telephone including a plurality of input buttons 1 for inputting various indications, light emitting elements 7 which emit a light, when any one of the input buttons 1 is pushed on, diffusers 8 which are located under a plurality of input buttons 1 and which diffuse the light emitted from the light emitting element 7 , the diffuser 8 has an incidence portion which has a receiving plane positioned near the light emitting elements 7 and receiving the light emitted from the light emitting elements 7 , and a projecting portion 6 which has a reflecting plane for reflecting the light received by the incidence portion 5 to an upper side of a plurality of input buttons 1. | 7 |
[0001] This application claims the benefit of the Korean Application No. P2003-0034082 filed on May 28, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a structure for dispensing an ice in a refrigerator, and more particularly, to a structure for dispensing an ice in a refrigerator, which includes an automated ice-making device for manufacturing pieces of ice and an ice bank for keeping pieces of ice.
[0004] 2. Description of the Related Art
[0005] In general, a refrigerator is divided into a freezing chamber and a chilling chamber. The chilling chamber is maintained at temperature of 3° C. to 4° C., to keep foods or vegetables in a fresh state. The freezing chamber is maintained at a temperature below 0° C., to keep foods in a frozen state.
[0006] Recently, various functions are added to the refrigerator so that a user can use it conveniently. Among them, one function is an automated ice-making device.
[0007] [0007]FIG. 1 is a perspective view showing an example of an automated ice-making device installed in a freezing chamber of a conventional two-door refrigerator, and FIG. 2 is a sectional view taken along the line I-I of FIG. 1.
[0008] As shown, the automated ice-making device 1 includes an ice-making chamber 11 for making pieces of ice, and a water supply part 12 provided at one side of the ice-making chamber 11 to supply water to the ice-making chamber 11 .
[0009] In addition, the automated ice-making device 1 includes a control part 13 accommodating a motor (not shown) at the other side of the ice-making chamber 11 , and an ejector 14 rotatably connected to a shaft of the motor accommodated in the control part 13 to dispense the pieces of ice made in the ice-making chamber 11 to an ice bank 19 .
[0010] A structure of the automated ice-making device 1 will be described below in detail. A coupling part 15 for coupling the automated ice-making device 1 to the freezing chamber of the refrigerator is formed at a rear side portion of the automated ice-making device 1 . The ice-making chamber 11 defining an ice-making space is provided at a body of the automated ice-making device 1 .
[0011] The ice-making chamber 11 is in a hemicylinder shape. Partitioning protrusions 16 for separating and dispensing the pieces of ice are formed at an inner surface of the hemicylinder-shaped ice-making chamber 11 .
[0012] As described above, the motor is installed inside the control part 13 formed at one portion of the ice-making chamber 11 , and the ejector 14 is coupled to the shaft of the motor.
[0013] A shaft of the ejector 14 is formed across a center of the ice-making chamber 11 , and a plurality of ejector pins 14 a are formed at a side surface of a shaft of the ejector 14 . The ejector pins 14 a are formed spaced apart from each other and provided as many as the number of sections partitioned by the partitioning protrusions 16 of the ice-making chamber 11 .
[0014] The ejector pin 14 a is means for dispensing the pieces of ice to the ice bank 19 .
[0015] A slide bar 17 is provided at an upper portion of a front hemicylinder of the ice-making chamber 11 , which is approximately halved on center of the ejector 14 . The pieces of ice slide down the slide bar 17 toward the ice bank 19 . The pieces of ice moved by the ejector pins 14 a are loaded on the slide bar 17 , slide down the slide bar 17 , and then are dropped into the ice bank 19 .
[0016] A heater 18 is attached to a lower surface of the ice-making chamber 11 . In order to transfer the pieces of ice, they must be separated from the inner surface of the ice-making chamber 11 . The heater 18 increases a temperature of the inner surface of the ice-making chamber 11 to melt the pieces of ice, which are fixedly attached to a surface of the ice-making chamber, such that the pieces of ice are easily separated from the ice-making chamber 11 . The separated ice is moved by the ejector 14 and the ejector pins 14 a.
[0017] As shown in FIGS. 3 and 4, such a conventional automated ice-making device is installed inside the refrigerator and generally fixed to rear wall or side wall inside the freezing chamber. Most refrigerators with the automated ice-making device 1 include a dispenser 21 for allowing a user to directly obtain the ices kept in the ice bank 19 without opening a door 2 of the refrigerator.
[0018] Generally, the dispenser 21 is disposed at the door 2 and the automated ice-making device 1 is disposed inside the freezing chamber. Therefore, there are problems that the automated ice-making chamber 1 occupies a large inner space of the freezing chamber 1 . In other words, the automated ice-making device 1 is provided with the ice bank 19 as well as the ice-making chamber 11 , and an ice transfer unit (not shown) for transferring the pieces of ice to the dispenser 21 and an ice crushing part (not shown) are installed in the ice bank 19 , thus occupying a large space of the freezing chamber.
[0019] Since the automated ice-making device 1 and the ice bank 19 occupy about 20% or more of the inner space of the freezing chamber, thus limiting the utilization of the inner space of the freezing chamber.
[0020] Meanwhile, in order to solve the problems, there has been proposed a refrigerator having an automated ice-making device and an ice bank, both of which are installed at a door of a conventional freezing chamber.
[0021] In the above art, the ice transfer unit of the ice bank has an auger installed in a vertical direction and employs a method of moving pieces of ice downwardly. To this end, if the pieces of ice are not discharged for a long time, the pieces of ice are fixedly attached between the augers, thus causing a problem that the augers do not operate.
SUMMARY OF THE INVENTION
[0022] Accordingly, the present invention is directed to a structure for dispensing ice in a refrigerator that substantially obviates one or more problems due to limitations and disadvantages of the related art.
[0023] An object of the present invention is to provide a structure for dispensing an ice in a refrigerator, in which an automated ice-making device and an ice bank are installed at a door of a freezing chamber to thereby enable an effective utilization of the freezing chamber space and prevent a malfunction when transferring pieces of ice.
[0024] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0025] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a structure for dispensing ice in a refrigerator comprises: an ice-making device installed in a door of a freezing chamber; an ice bank storing pieces of ice provided from the ice-making device; an ice transfer unit for transferring the pieces of the ice stored in the ice bank in a width direction; and an ice crushing part for crushing the pieces of the ice transferred by the ice transfer unit.
[0026] Preferably, the ice-making device includes a water-overflow preventing part, and the ice bank is provided at the door of the freezing chamber.
[0027] The ice transfer unit includes a transfer means and a rotating means for rotating the transfer means. Specifically, the transfer means is a spiral auger, and the rotating means is a motor. Preferably, the auger is installed inside the ice bank in a width direction.
[0028] The ice crushing part is formed at one end of the auger and includes a fixed blade and a rotating blade. The rotating blade is coupled to the auger of the ice transfer unit and rotates together with the auger.
[0029] Preferably, an ice discharge opening is provided at a bottom surface of the ice bank in order to discharge pieces of ice and includes a damper for opening/closing the ice discharge opening.
[0030] The ice discharge opening is formed under the ice crushing part and the ice bank is coupled to a dispenser which is formed at the door of the freezing chamber. Preferably, the dispenser includes a large-sized ice selecting part and a small-sized ice selector part.
[0031] Preferably, a control part for controlling the ice transfer unit and the damper is provided.
[0032] In case the large-sized ice selecting part of the dispenser is selected, the control part operates the motor of the ice transfer unit to open the damper, and when the small-sized ice selecting part of the dispenser is selected, the control part operates the motor of the ice transfer unit to close the damper for a predetermined selected time and then open the damper to thereby discharge the ice.
[0033] According to another embodiment of the present invention, the ice discharge opening is provided with a first ice discharge opening and a second ice discharge opening. In this case, there are provided two dampers, i.e., a first damper and a second damper. The first ice discharge opening is formed under the ice transfer unit, and the second ice discharge opening is formed under the ice crushing part.
[0034] A control part for controlling the two dampers and the ice transfer unit is provided. In case the large-sized ice selecting part of the dispenser is selected, the control part operates the first damper to open the first ice discharge opening and operates the second damper to close the second ice discharge opening. Meanwhile, when the small-sized ice selecting part of the dispenser is selected, the control part operates the first damper to close the first ice discharge opening and operates the second ice discharge opening to open the second ice discharge opening.
[0035] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
[0037] [0037]FIG. 1 is a perspective view showing an example of an automated ice-making device 1 and an ice bank, which are attached to a freezing chamber of a conventional two-door refrigerator;
[0038] [0038]FIG. 2 is a sectional view taken along the line I-I;
[0039] [0039]FIGS. 3 and 4 are a schematic plan view and a perspective view of a refrigerator having an automated ice-making device and an ice bank of FIG. 1, respectively;
[0040] [0040]FIG. 5 is a schematic sectional view of an automated ice-making device and an ice bank in a structure for dispensing pieces of ice in a refrigerator according to the present invention;
[0041] [0041]FIG. 6 is a schematic perspective view of the automated ice-making device and the ice bank according to the present invention;
[0042] [0042]FIG. 7 is a sectional view of an ice bank according to another embodiment of the present invention; and
[0043] [0043]FIG. 8 is a perspective view of a refrigerator having the structure for dispensing pieces of ice according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0044] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0045] [0045]FIG. 5 is a schematic sectional view of an automated ice-making device 10 and an ice bank 50 in a structure for dispensing pieces of ice in a refrigerator according to the present invention. FIG. 6 is a schematic perspective view of the automated ice-making device and the ice bank 50 according to the present invention. FIG. 7 is a sectional view of an ice bank 500 according to another embodiment of the present invention.
[0046] As shown in FIGS. 5 and 6, the ice bank 50 is installed at a lower portion of the automated ice-making device 10 . Since the automated ice-making device 10 is formed at a door 2 , water-overflow preventing parts 101 and 102 are formed in order to prevent an overflowing of water in an ice-making chamber according to opening/closing of the door 2 .
[0047] In other words, the first water-overflow preventing part 101 is formed in a panel shape at a position in which the slide bar of the conventional ice-making chamber (refer to FIG. 1) is disposed, and the second water-overflow preventing part 102 is extendedly formed in an arc shape at an opposite side of the first water-overflow preventing part 101 , thereby preventing the overflowing of water according to a movement of the door 2 .
[0048] The ice bank 50 has a storage space in which pieces of ice dispensed from the automated ice-making device 10 are stored. An ice transfer unit 51 and an ice crushing part 53 are installed inside the ice bank 50 .
[0049] The ice transfer unit 51 is means for transferring pieces of ice, which are stored in the ice bank 50 , to an ice discharge opening by operating a lever 21 a of a dispenser 21 for the purpose of eating the pieces of ice.
[0050] The ice transfer unit 51 includes a winding transfer means for directly transferring the pieces of ice, and a rotating means for rotating the transfer means. The transfer means is an auger 513 made of a spiral metal rod or a plastic rod, and the rotating means is a motor 511 .
[0051] A shaft of the motor 511 is coupled to one end of the auger 513 . The auger 513 is a metal construction in which a spiral metal rod is rotatably coupled to the shaft of the motor. The auger 513 can be made of synthetic resin such as plastics, except metal.
[0052] The pieces of ice dropped into the ice bank 50 are placed among the metal rods of the auger 513 . Since the auger 513 is in the spiral shape, the ice disposed inside the auger 513 moves forward if the auger 513 is rotated by the motor 511 .
[0053] The pieces of the ice moving forward are dispensed through the ice discharge opening 56 and dropped into the dispenser 21 coupled to the ice discharge opening 56 .
[0054] According to the present invention, the auger 513 of the ice transfer unit 51 is installed in a width direction, and the ice crushing part 53 is installed in the ice bank 50 together with the ice transfer unit 51 .
[0055] As described in the related art, the pieces of the ices made in the automated ice-making device 10 are formed in hemispherical shapes, thus occupying a large volume. Here, the piece of the ice having the large volume is referred to as “large-sized ice”. People rarely put the large-sized ice in drinking water or food. Instead, after crushing the large-sized ice into the “small-sized” ice, people put the small-sized ice in drinking water.
[0056] The ice crushing part for crushing the large-sized ice into the small-sized ice is installed at the end of the auger 513 and includes a plurality of blades 531 and 532 , such that transferred ice is crushed between the blades 531 and 532 .
[0057] The blades 531 and 532 can perform the crushing function if any one of a rotating blade 531 and a fixed blade 532 is provided. However, it is preferable to provide both the rotating blade 531 and the fixed blade 532 at the same time.
[0058] Preferably, the rotating blade 531 is formed at one end of the auger 513 and thus rotates simultaneously when the auger 513 rotates. In addition, preferably, the fixed blade 532 is installed spaced apart from the rotating blade 531 by a predetermined interval, or it is installed in a circumference direction. In this case, a crushing effect may be improved.
[0059] Ice discharge openings 551 and 552 are formed at a lower portion of the ice bank 50 . One or two ice discharge openings 551 and 552 can be provided. As a first embodiment of the present invention, there are provided two ice discharge openings 551 and 552 .
[0060] As shown in FIG. 6, the first ice discharge opening 551 is formed on a bottom surface of the ice bank 50 under the end portion of the auger 513 transferring the pieces of ice, and the second ice discharge opening 552 is formed on a bottom surface of the ice bank 50 under the ice crushing part 53 .
[0061] The first ice discharge opening 551 is a discharge opening which is opened when a user wants to a large-sized ice. In this case, the piece of ice moving along the auger 513 is dropped into the dispenser 21 before it is transferred to the blades 531 and 532 .
[0062] The second ice discharge opening 552 is a discharge opening which is opened when a user wants a small-sized ice crushed by the ice crushing part 53 . In this case, the pieces of ice are crushed by the blades 531 and 532 and then dropped into the dispenser 21 .
[0063] A first damper 561 is provided at the first ice discharge opening 551 . The first damper 561 is means for opening/closing the first ice discharge opening 501 . A second damper 562 is provided at the second ice discharge opening 552 . The second damper 552 is means for opening/closing the second ice discharge opening 552 .
[0064] A large-sized ice selecting part 211 and a small-sized ice selecting part 212 are formed at the dispenser 21 provided at the door 2 . The large-sized ice selecting part 211 is a part which is selected when a user wants a large-sized ice, and the small-sized ice selecting part 212 is a part which is selected when a user wants a small-sized ice.
[0065] Although not shown, the refrigerator includes a control part for controlling the first damper 561 and the second damper 562 when selecting the large-sized selecting part 211 and the small-sized selecting part 212 .
[0066] Hereinafter, detailed description on functions of the control part will be made.
[0067] If a user selects the large-sized selecting part 211 of the dispenser 21 , the control part operates the first damper 561 to open the first ice discharge opening 551 and operates the second damper 561 to close the second ice discharge opening 552 .
[0068] The control part operates the motor 511 of the ice transfer unit 51 to rotate the auger 513 . According to the rotation of the auger 513 , pieces of the large-sized ice stored in the ice bank 50 are transferred toward the first ice discharge opening 551 . Since the first ice discharge opening 551 is opened by the first damper 561 , the pieces of the large-sized ice are dispensed through the first ice discharge opening 551 and dropped into the dispenser 21 .
[0069] If a user selects the small-sized selecting part 212 of the dispenser 21 in order to obtain the crushed ice, the control part operates the first damper 561 to close the first ice discharge opening 551 and operates the second damper 561 to open the second ice discharge opening 552 .
[0070] The control part operates the motor 511 of the ice transfer unit 51 to rotate the auger 513 . According to the rotation of the auger 513 , pieces of the large-sized ice stored in the ice bank 50 are transferred. Since the first ice discharge opening 551 is closed by the first damper 561 , the pieces of the large-sized ice are transferred to the ice crushing part 53 , not being dispensed through the first ice discharge opening 551 .
[0071] The pieces of the large-sized ice are crushed by the rotating blade 531 and the fixed rotating blade 532 of the ice crushing part 53 and then dropped into the dispenser 21 through the second ice discharge opening 502 .
[0072] Although the embodiment of the present invention shows that the large-sized ice and the small-sized ice are dropped through the different openings by forming two ice discharge openings 551 and 552 , the large-sized ice and the small-sized ice can be discharged using a single ice discharge opening 553 and a single damper 563 .
[0073] In other words, as shown in FIG. 7, the large-sized ice and the small-sized ice can be selectively discharged through a single ice discharge opening 503 .
[0074] As shown, an ice bank 50 according to another embodiment of the present invention includes a single ice discharge opening 553 formed on a bottom surface, and a damper 563 for opening/closing the ice discharge opening 553 .
[0075] If a user selects the large-sized selecting part 211 of the dispenser 21 in order to obtain the large-sized ice, the damper 563 is operated to open the ice discharge opening 553 . Since the ice discharge opening 553 is opened, the large-sized ice transferred through the auger 513 is dropped through the ice discharge opening 553 and then dispensed through the dispenser 21 before it is crushed by the blades 531 and 532 of the ice crushing part 53 .
[0076] If a user selects the small-sized selecting part 212 of the dispenser 21 in order to obtain the small-sized ice, the damper 563 is operated to close the ice discharge opening 553 . Since the ice discharge opening 553 is closed, the large-sized ice transferred through the auger 513 is crushed between the rotating blade 531 and the fixed blade 532 of the ice crushing part 53 .
[0077] After carrying out the crushing operation for a predetermined time, the damper 563 is opened, such that the crushed ice is discharged to the dispenser 21 . The crushing time can be appropriately controlled by the control part. Further, it is possible to obtain a larger amount of the small-sized ice by repeating the above procedures.
[0078] [0078]FIG. 8 is a perspective view of the refrigerator according to the present invention, showing that the automated ice-making device 10 and the ice bank 50 are installed in the door 2 of the refrigerator.
[0079] As shown in FIG. 7, according to the present invention, the automated ice-making device 10 and the ice bank 50 are installed in parallel in a width direction with respect to the freezing chamber door, so that a storage space of the ice bank 50 is expanded. Further, since the auger 513 is installed in the width direction, the auger 513 is lengthened and a space is widened. Therefore, it is possible to prevent a malfunction of the auger, which is caused due to the ice.
[0080] In the refrigerator of the present invention, both the automated ice-making device and the ice bank are installed in the width direction with respect to the freezing chamber door, which does not influence a thickness of the freezing chamber door. Further, compared with the case the ice bank is installed in a length direction, the storage space is widened so that a large amount of ice is stored.
[0081] Furthermore, since the auger of the ice transfer unit is installed in a width direction and there is an affordable space, it is possible to solve the malfunction of the auger due to the ice. A user can selectively eat pieces of ice having different size.
[0082] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | Disclosed is a structure for dispensing ice in a refrigerator, in which an automated ice-making device and an ice bank are installed at a door of a freezing chamber to thereby make its space utilization effectively. The structure of the present invention includes: an ice-making device installed in a door of a freezing chamber; an ice bank storing pieces of ice provided from the ice-making device; an ice transfer unit for transferring the pieces of the ice stored in the ice bank in a width direction; and an ice crushing part for crushing the pieces of the ice transferred by the ice transfer unit. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. Non-Provisional patent application Ser. No. 10/410,481, filed Apr. 9, 2003; now U.S. Pat. No. 7,903,742 which itself claims the benefit of U.S. Provisional Patent Application Ser. No. 60/395,843 filed Jul. 15, 2002; and also U.S. Provisional Patent Application Ser. No. 60/395,874 filed Jul. 15, 2002, and all of which are incorporated by reference herein in their respective entireties.
FIELD OF THE INVENTION
The present invention is directed towards video decoders, and in particular, towards utilization of adaptive weighting of reference pictures in video decoders.
BACKGROUND OF THE INVENTION
Video data is generally processed and transferred in the form of bit streams. Typical video compression coders and decoders (“CODECs”) gain much of their compression efficiency by forming a reference picture prediction of a picture to be encoded, and encoding the difference between the current picture and the prediction. The more closely that the prediction is correlated with the current picture, the fewer bits that are needed to compress that picture, thereby increasing the efficiency of the process. Thus, it is desirable for the best possible reference picture prediction to be formed.
In many video compression standards, including Moving Picture Experts Group (“MPEG”)-1, MPEG-2 and MPEG-4, a motion compensated version of a previous reference picture is used as a prediction for the current picture, and only the difference between the current picture and the prediction is coded. When a single picture prediction (“P” picture) is used, the reference picture is not scaled when the motion compensated prediction is formed. When bi-directional picture predictions (“B” pictures) are used, intermediate predictions are formed from two different pictures, and then the two intermediate predictions are averaged together, using equal weighting factors of (½, ½) for each, to form a single averaged prediction. In these MPEG standards, the two reference pictures are always one each from the forward direction and the backward direction for B pictures.
SUMMARY OF THE INVENTION
These and other drawbacks and disadvantages of the prior art are addressed by a system and method for adaptive weighting of reference pictures in video decoders.
A video decoder and corresponding methods are disclosed for decoding video data for a picture having a plurality of image blocks. The video data including data for an image block of the plurality of image blocks and including at least one reference picture index. The video data is received and includes a single reference picture index for the image block and the data for the image block. The received single reference picture index corresponding to a particular reference picture. The image block is predicted using the particular reference picture corresponding to the single reference picture index and using an offset, determined from a set of offsets, and corresponding to the single received reference picture index. The single received reference picture index determines both the particular reference picture and the offset.
These and other aspects, features and advantages of the present invention will become apparent from the following description of exemplary embodiments, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Adaptive weighting of reference pictures in video coders and decoders in accordance with the principles of the present invention are shown in the following exemplary figures, in which:
FIG. 1 shows a block diagram for a standard video decoder;
FIG. 2 shows a block diagram for a video decoder with adaptive bi-prediction;
FIG. 3 shows a block diagram for a video decoder with reference picture weighting in accordance with the principles of the present invention;
FIG. 4 shows a block diagram for a standard video encoder;
FIG. 5 shows a block diagram for a video encoder with reference picture weighting in accordance with the principles of the present invention;
FIG. 6 shows a flowchart for a decoding process in accordance with the principles of the present invention; and
FIG. 7 shows a flowchart for an encoding process in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention presents an apparatus and method for motion vector estimation and adaptive reference picture weighting factor assignment. In some video sequences, in particular those with fading, the current picture or image block to be coded is more strongly correlated to a reference picture scaled by a weighting factor than to the reference picture itself. Video CODECs without weighting factors applied to reference pictures encode fading sequences very inefficiently. When weighting factors are used in encoding, a video encoder needs to determine both weighting factors and motion vectors, but the best choice for each of these depends on the other, with motion estimation typically being the most computationally intensive part of a digital video compression encoder.
In the proposed Joint Video Team (“JVT”) video compression standard, each P picture can use multiple reference pictures to form a picture's prediction, but each individual motion block or 8×8 region of a macroblock uses only a single reference picture for prediction. In addition to coding and transmitting the motion vectors, a reference picture index is transmitted for each motion block or 8×8 region, indicating which reference picture is used. A limited set of possible reference pictures is stored at both the encoder and decoder, and the number of allowable reference pictures is transmitted.
In the JVT standard, for bi-predictive pictures (also called “B” pictures), two predictors are formed for each motion block or 8×8 region, each of which can be from a separate reference picture, and the two predictors are averaged together to form a single averaged predictor. For bi-predictively coded motion blocks, the reference pictures can both be from the forward direction, both be from the backward direction, or one each from the forward and backward directions. Two lists are maintained of the available reference pictures that may used for prediction. The two reference pictures are referred to as the list 0 and list 1 predictors. An index for each reference picture is coded and transmitted, ref_idx_l 0 and ref_idx_l 1 , for the list 0 and list 1 reference pictures, respectively. Joint Video Team (“JVT”) bi-predictive or “B” pictures allows adaptive weighting between the two predictions, i.e.,
Pred=[( P 0)(Pred0)]+[( P 1)(Pred1)]+ D,
where P 0 and P 1 are weighting factors, Pred 0 and Pred 1 are the reference picture predictions for list 0 and list 1 respectively, and D is an offset.
Two methods have been proposed for indication of weighting factors. In the first, the weighting factors are determined by the directions that are used for the reference pictures. In this method, if the ref_idx_l 0 index is less than or equal to ref_idx_l 1 , weighting factors of (½, ½) are used, otherwise (2, −1) factors are used.
In the second method offered, any number of weighting factors is transmitted for each slice. Then a weighting factor index is transmitted for each motion block or 8×8 region of a macroblock that uses bi-directional prediction. The decoder uses the received weighting factor index to choose the appropriate weighting factor, from the transmitted set, to use when decoding the motion block or 8×8 region. For example, if three weighting factors were sent at the slice layer, they would correspond to weight factor indices 0, 1 and 2, respectively.
The following description merely illustrates the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
Thus, for example, it will be appreciated by those skilled in the art that the block diagrams herein represent conceptual views of illustrative circuitry embodying the principles of the invention. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudocode, and the like represent various processes which may be substantially represented in computer readable media and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” or “controller” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (“DSP”) hardware, read-only memory (“ROM”) for storing software, random access memory (“RAM”), and non-volatile storage. Other hardware, conventional and/or custom, may also be included. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the implementer as more specifically understood from the context.
In the claims hereof any element expressed as a means for performing a specified function is intended to encompass any way of performing that function including, for example, a) a combination of circuit elements that performs that function or b) software in any form, including, therefore, firmware, microcode or the like, combined with appropriate circuitry for executing that software to perform the function. The invention as defined by such claims resides in the fact that the functionalities provided by the various recited means are combined and brought together in the manner which the claims call for. Applicant thus regards any means that can provide those functionalities as equivalent to those shown herein.
As shown in FIG. 1 , a standard video decoder is indicated generally by the reference numeral 100 . The video decoder 100 includes a variable length decoder (“VLD”) 110 connected in signal communication with an inverse quantizer 120 . The inverse quantizer 120 is connected in signal communication with an inverse transformer 130 . The inverse transformer 130 is connected in signal communication with a first input terminal of an adder or summing junction 140 , where the output of the summing junction 140 provides the output of the video decoder 100 . The output of the summing junction 140 is connected in signal communication with a reference picture store 150 . The reference picture store 150 is connected in signal communication with a motion compensator 160 , which is connected in signal communication with a second input terminal of the summing junction 140 .
Turning to FIG. 2 , a video decoder with adaptive bi-prediction is indicated generally by the reference numeral 200 . The video decoder 200 includes a VLD 210 connected in signal communication with an inverse quantizer 220 . The inverse quantizer 220 is connected in signal communication with an inverse transformer 230 . The inverse transformer 230 is connected in signal communication with a first input terminal of a summing junction 240 , where the output of the summing junction 240 provides the output of the video decoder 200 . The output of the summing junction 240 is connected in signal communication with a reference picture store 250 . The reference picture store 250 is connected in signal communication with a motion compensator 260 , which is connected in signal communication with a first input of a multiplier 270 .
The VLD 210 is further connected in signal communication with a reference picture weighting factor lookup 280 for providing an adaptive bi-prediction (“ABP”) coefficient index to the lookup 280 . A first output of the lookup 280 is for providing a weighting factor, and is connected in signal communication to a second input of the multiplier 270 . The output of the multiplier 270 is connected in signal communication to a first input of a summing junction 290 . A second output of the lookup 280 is for providing an offset, and is connected in signal communication to a second input of the summing junction 290 . The output of the summing junction 290 is connected in signal communication with a second input terminal of the summing junction 240 .
Turning now to FIG. 3 , a video decoder with reference picture weighting is indicated generally by the reference numeral 300 . The video decoder 300 includes a VLD 310 connected in signal communication with an inverse quantizer 320 . The inverse quantizer 320 is connected in signal communication with an inverse transformer 330 . The inverse transformer 330 is connected in signal communication with a first input terminal of a summing junction 340 , where the output of the summing junction 340 provides the output of the video decoder 300 . The output of the summing junction 340 is connected in signal communication with a reference picture store 350 . The reference picture store 350 is connected in signal communication with a motion compensator 360 , which is connected in signal communication with a first input of a multiplier 370 .
The VLD 310 is further connected in signal communication with a reference picture weighting factor lookup 380 for providing a reference picture index to the lookup 380 . A first output of the lookup 380 is for providing a weighting factor, and is connected in signal communication to a second input of the multiplier 370 . The output of the multiplier 370 is connected in signal communication to a first input of a summing junction 390 . A second output of the lookup 380 is for providing an offset, and is connected in signal communication to a second input of the summing junction 390 . The output of the summing junction 390 is connected in signal communication with a second input terminal of the summing junction 340 .
As shown in FIG. 4 , a standard video encoder is indicated generally by the reference numeral 400 . An input to the encoder 400 is connected in signal communication with a non-inverting input of a summing junction 410 . The output of the summing junction 410 is connected in signal communication with a block transformer 420 . The transformer 420 is connected in signal communication with a quantizer 430 . The output of the quantizer 430 is connected in signal communication with a variable length coder (“VLC”) 440 , where the output of the VLC 440 is an externally available output of the encoder 400 .
The output of the quantizer 430 is further connected in signal communication with an inverse quantizer 450 . The inverse quantizer 450 is connected in signal communication with an inverse block transformer 460 , which, in turn, is connected in signal communication with a reference picture store 470 . A first output of the reference picture store 470 is connected in signal communication with a first input of a motion estimator 480 . The input to the encoder 400 is further connected in signal communication with a second input of the motion estimator 480 . The output of the motion estimator 480 is connected in signal communication with a first input of a motion compensator 490 . A second output of the reference picture store 470 is connected in signal communication with a second input of the motion compensator 490 . The output of the motion compensator 490 is connected in signal communication with an inverting input of the summing junction 410 .
Turning to FIG. 5 , a video encoder with reference picture weighting is indicated generally by the reference numeral 500 . An input to the encoder 500 is connected in signal communication with a non-inverting input of a summing junction 510 . The output of the summing junction 510 is connected in signal communication with a block transformer 520 . The transformer 520 is connected in signal communication with a quantizer 530 . The output of the quantizer 530 is connected in signal communication with a VLC 540 , where the output of the VLC 440 is an externally available output of the encoder 500 .
The output of the quantizer 530 is further connected in signal communication with an inverse quantizer 550 . The inverse quantizer 550 is connected in signal communication with an inverse block transformer 560 , which, in turn, is connected in signal communication with a reference picture store 570 . A first output of the reference picture store 570 is connected in signal communication with a first input of a reference picture weighting factor assignor 572 . The input to the encoder 500 is further connected in signal communication with a second input of the reference picture weighting factor assignor 572 . The output of the reference picture weighting factor assignor 572 , which is indicative of a weighting factor, is connected in signal communication with a first input of a motion estimator 580 . A second output of the reference picture store 570 is connected in signal communication with a second input of the motion estimator 580 .
The input to the encoder 500 is further connected in signal communication with a third input of the motion estimator 580 . The output of the motion estimator 580 , which is indicative of motion vectors, is connected in signal communication with a first input of a motion compensator 590 . A third output of the reference picture store 570 is connected in signal communication with a second input of the motion compensator 590 . The output of the motion compensator 590 , which is indicative of a motion compensated reference picture, is connected in signal communication with a first input of a multiplier 592 . The output of the reference picture weighting factor assignor 572 , which is indicative of a weighting factor, is connected in signal communication with a second input of the multiplier 592 . The output of the multiplier 592 is connected in signal communication with an inverting input of the summing junction 510 .
Turning now to FIG. 6 , an exemplary process for decoding video signal data for an image block is indicated generally by the reference numeral 600 . The process includes a start block 610 that passes control to an input block 612 . The input block 612 receives the image block compressed data, and passes control to an input block 614 . The input block 614 receives at least one reference picture index with the data for the image block, each reference picture index corresponding to a particular reference picture. The input block 614 passes control to a function block 616 , which determines a weighting factor corresponding to each of the received reference picture indices, and passes control to an optional function block 617 . The optional function block 617 determines an offset corresponding to each of the received reference picture indices, and passes control to a function block 618 . The function block 618 retrieves a reference picture corresponding to each of the received reference picture indices, and passes control to a function block 620 . The function block 620 , in turn, motion compensates the retrieved reference picture, and passes control to a function block 622 . The function block 622 multiplies the motion compensated reference picture by the corresponding weighting factor, and passes control to an optional function block 623 . The optional function block 623 adds the motion compensated reference picture to the corresponding offset, and passes control to a function block 624 . The function block 624 , in turn, forms a weighted motion compensated reference picture, and passes control to an end block 626 .
Turning now to FIG. 7 , an exemplary process for encoding video signal data for an image block is indicated generally by the reference numeral 700 . The process includes a start block 710 that passes control to an input block 712 . The input block 712 receives substantially uncompressed image block data, and passes control to a function block 714 . The function block 714 assigns a weighting factor for the image block corresponding to a particular reference picture having a corresponding index. The function block 714 passes control to an optional function block 715 . The optional function block 715 assigns an offset for the image block corresponding to a particular reference picture having a corresponding index. The optional function block 715 passes control to a function block 716 , which computes motion vectors corresponding to the difference between the image block and the particular reference picture, and passes control to a function block 718 . The function block 718 motion compensates the particular reference picture in correspondence with the motion vectors, and passes control to a function block 720 . The function block 720 , in turn, multiplies the motion compensated reference picture by the assigned weighting factor to form a weighted motion compensated reference picture, and passes control to an optional function block 721 . The optional function block 721 , in turn, adds the motion compensated reference picture to the assigned offset to form a weighted motion compensated reference picture, and passes control to a function block 722 . The function block 722 subtracts the weighted motion compensated reference picture from the substantially uncompressed image block, and passes control to a function block 724 . The function block 724 , in turn, encodes a signal with the difference between the substantially uncompressed image block and the weighted motion compensated reference picture along with the corresponding index of the particular reference picture, and passes control to an end block 726 .
In the present exemplary embodiment, for each coded picture or slice, a weighting factor is associated with each allowable reference picture that blocks of the current picture can be encoded with respect to. When each individual block in the current picture is encoded or decoded, the weighting factor(s) and offset(s) that correspond to its reference picture indices are applied to the reference prediction to form a weight predictor. All blocks in the slice that are coded with respect to the same reference picture apply the same weighting factor to the reference picture prediction.
Whether or not to use adaptive weighting when coding a picture can be indicated in the picture parameter set or sequence parameter set, or in the slice or picture header. For each slice or picture that uses adaptive weighting, a weighting factor may be transmitted for each of the allowable reference pictures that may be used for encoding this slice or picture. The number of allowable reference pictures is transmitted in the slice header. For example, if three reference pictures can be used to encode the current slice, up to three weighting factors are transmitted, and they are associated with the reference picture with the same index.
If no weighting factors are transmitted, default weights are used. In one embodiment of the current invention, default weights of (½, ½) are used when no weighting factors are transmitted. The weighting factors may be transmitted using either fixed or variable length codes.
Unlike typical systems, each weighting factor that is transmitted with each slice, block or picture corresponds to a particular reference picture index. Previously, any set of weighting factors transmitted with each slice or picture were not associated with any particular reference pictures. Instead, an adaptive bi-prediction weighting index was transmitted for each motion block or 8×8 region to select which of the weighting factors from the transmitted set was to be applied for that particular motion block or 8×8 region.
In the present embodiment, the weighting factor index for each motion block or 8×8 region is not explicitly transmitted. Instead, the weighting factor that is associated with the transmitted reference picture index is used. This dramatically reduces the amount of overhead in the transmitted bitstream to allow adaptive weighting of reference pictures.
This system and technique may be applied to either Predictive “P” pictures, which are encoded with a single predictor, or to Bi-predictive “B” pictures, which are encoded with two predictors. The decoding processes, which are present in both encoder and decoders, are described below for the P and B picture cases. Alternatively, this technique may also be applied to coding systems using the concepts similar to I, B, and P pictures.
The same weighting factors can be used for single directional prediction in B pictures and for bi-directional prediction in B pictures. When a single predictor is used for a macroblock, in P pictures or for single directional prediction in B pictures, a single reference picture index is transmitted for the block. After the decoding process step of motion compensation produces a predictor, the weighting factor is applied to predictor. The weighted predictor is then added to the coded residual, and clipping is performed on the sum, to form the decoded picture. For use for blocks in P pictures or for blocks in B pictures that use only list 0 prediction, the weighted predictor is formed as:
Pred= W 0*Pred0 +D 0 (1)
where W 0 is the weighting factor associated with the list 0 reference picture, D 0 is the offset associated with the list 0 reference picture, and Pred 0 is the motion-compensated prediction block from the list 0 reference picture.
For use for blocks in B pictures which use only list 0 prediction, the weighted predictor is formed as:
Pred= W 1*Pred1 +D 1 (2)
where W 1 is the weighting factor associated with the list 1 reference picture, D 0 is the offset associated with the list 1 reference picture, and Pred 1 is the motion-compensated prediction block from the list 1 reference picture.
The weighted predictors may be clipped to guarantee that the resulting values will be within the allowable range of pixel values, typically 0 to 255. The precision of the multiplication in the weighting formulas may be limited to any pre-determined number of bits of resolution.
In the bi-predictive case, reference picture indexes are transmitted for each of the two predictors. Motion compensation is performed to form the two predictors. Each predictor uses the weighting factor associated with its reference picture index to form two weighted predictors. The two weighted predictors are then averaged together to form an averaged predictor, which is then added to the coded residual.
For use for blocks in B pictures that use list 0 and list 1 predictions, the weighted predictor is formed as:
Pred=( P 0*Pred0+ D 0 +P 1*Pred1 +D 1)/2 (3)
Clipping may be applied to the weighted predictor or any of the intermediate values in the calculation of the weighted predictor to guarantee that the resulting values will be within the allowable range of pixel values, typically 0 to 255.
Thus, a weighting factor is applied to the reference picture prediction of a video compression encoder and decoder that uses multiple reference pictures. The weighting factor adapts for individual motion blocks within a picture, based on the reference picture index that is used for that motion block. Because the reference picture index is already transmitted in the compressed video bitstream, the additional overhead to adapt the weighting factor on a motion block basis is dramatically reduced. All motion blocks that are coded with respect to the same reference picture apply the same weighting factor to the reference picture prediction.
These and other features and advantages of the present invention may be readily ascertained by one of ordinary skill in the pertinent art based on the teachings herein. It is to be understood that the teachings of the present invention may be implemented in various forms of hardware, software, firmware, special purpose processors, or combinations thereof.
Most preferably, the teachings of the present invention are implemented as a combination of hardware and software. Moreover, the software is preferably implemented as an application program tangibly embodied on a program storage unit. The application program may be uploaded to, and executed by, a machine comprising any suitable architecture. Preferably, the machine is implemented on a computer platform having hardware such as one or more central processing units (“CPU”), a random access memory (“RAM”), and input/output (“I/O”) interfaces. The computer platform may also include an operating system and microinstruction code. The various processes and functions described herein may be either part of the microinstruction code or part of the application program, or any combination thereof, which may be executed by a CPU. In addition, various other peripheral units may be connected to the computer platform such as an additional data storage unit and a printing unit.
It is to be further understood that, because some of the constituent system components and methods depicted in the accompanying drawings are preferably implemented in software, the actual connections between the system components or the process function blocks may differ depending upon the manner in which the present invention is programmed. Given the teachings herein, one of ordinary skill in the pertinent art will be able to contemplate these and similar implementations or configurations of the present invention.
Although the illustrative embodiments have been described herein with reference to the accompanying drawings, it is to be understood that the present invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one of ordinary skill in the pertinent art without departing from the scope or spirit of the present invention. All such changes and modifications are intended to be included within the scope of the present invention as set forth in the appended claims. | A video decoder, encoder, and corresponding methods for processing video signal data for an image block and a particular reference picture index to predict the image block are disclosed that utilize adaptive weighting of reference pictures to enhance video compression, where a decoder includes a reference picture weighting factor unit for determining a weighting factor corresponding to the particular reference picture index; an encoder includes a reference picture weighting factor assignor for assigning a weighting factor corresponding to the particular reference picture index; and a method for decoding includes receiving a reference picture index with the data that corresponds to the image block, determining a weighting factor for each received reference picture index, retrieving a reference picture for each index, motion compensating the retrieved reference picture, and multiplying the motion compensated reference picture by the corresponding weighting factor to form a weighted motion compensated reference picture. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a United States National Phase application of International Application PCT/DE 2006/001098 and claims the benefit of priority under 35 U.S.C. § 119 of German Patent Application DE 10 2005 030 971.2 filed Jun. 30, 2005, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to a ball and socket joint with sensor means, for example, for an axle system or a wheel suspension of a motor vehicle. Furthermore, the present invention pertains to a process for load measurement on a ball and socket joint as well as to a process for wear measurement on a ball and socket joint.
BACKGROUND OF THE INVENTION
[0003] Ball and socket joints of the type mentioned in the introduction are used, for example, but by no means exclusively, on the chassis or on the wheel suspension of motor vehicles, e.g., as a support joint or guide joint. Ball and socket joints of this class comprise a sensor means, with which forces and loads acting on the ball and socket joint can be determined or measured to a certain extent.
[0004] Ball and socket joints of this type with means for measuring forces and loads are used, for example, on the motor vehicle in order to reliably determine there the forces or bending torques acting on the ball and socket joint during actual driving or also during test driving on the test bench. Such measurements of forces on ball and socket joints in the area of the chassis of a motor vehicle make it possible to infer the dynamic state of a motor vehicle. It is thus possible to achieve, for example, an improvement of the data base for driving safety systems, for example, ESP or ABS. The ball and socket joints of this class can thus be used especially in the sense of improving the driving safety of the motor vehicle.
[0005] A ball and socket joint with force sensor means is known, for example, from DE 101 07 279 A1. The ball and socket joint known from this document is used especially to determine and analyze the force acting in a certain component of a motor vehicle, for example, the axial force present in a track rod because of forces of reaction from the chassis. According to the teaching of this document, provisions are made for this purpose, among other things, for providing a ball and socket joint arranged between different components of the steering linkage with wire strain gauges or piezo pressure sensors in the area of a shaft and for inferring the load on the ball and socket joint and hence the axial forces acting in the steering linkage from the signals of these sensors.
[0006] However, the outfitting of ball and socket joints with such wire strain gauges or piezo sensors arranged in the shaft area is associated with a rather substantial effort. On the one hand, a corresponding surface must be created on the ball pivot for the arrangement, on which the wire strain gauges are then, e.g., to be bonded. In addition, an electric wire connection must also be established in the interior of the ball pivot to an electronic analysis unit, and the electronic analysis unit must be arranged, usually separately from the ball and socket joint in case of sensor elements arranged on the ball pivot, additionally in a protected manner at a suitable site. On the whole, this leads to the rather complicated and hence expensive manufacture of such ball and socket joints provided with load sensors. and, moreover, the exposed sensor system and wiring of such ball and socket joints, arranged at an exposed site, are sensitive and therefore threatened by failures.
[0007] The benefit of the prior-art ball and socket joints with force sensor means is, moreover, limited. Thus, essentially only a force acting in a certain direction can be determined with the prior-art force sensor means. The prior-art ball and socket joints with force sensor means are thus unsuitable for the comprehensive vectorial determination of forces and/or torques, which act on ball and socket joints and on components connected thereto.
[0008] In addition, it is hardly possible in the prior-art ball and socket joints with force sensor means to derive further data on the state especially of the ball and socket joint by means of the force sensor means, beyond the load situation of the ball and socket joint proper. However, since ball and socket joints arranged in the area of the chassis or the steering of motor vehicles are safety-relevant components, whose failure may lead to fatal consequences, especially during driving, it is especially desirable to be also able to obtain data on the instantaneous operating state or state of wear of the ball and socket joint.
SUMMARY OF THE INVENTION
[0009] Against this background, it is the object of the present invention to provide a ball and socket joint with a sensor means, with which ball and socket joint the drawbacks of the state of the art can be overcome. In particular, the ball and socket joint shall make possible the vectorial determination of forces or of loads acting on the ball and socket joint in terms of value and direction in a cost-effective and reliable manner as well as with a high degree of freedom in terms of design. In addition, it shall also be possible to obtain data on the state of wear of the ball and socket joint, so that a possibly imminent failure of a ball and socket joint can be recognized in time and thus prevented.
[0010] This object is accomplished by a ball and socket joint having the features according to the invention. The ball and socket joint according to the present invention comprises, on the one hand, in a manner known per se, a joint housing with a mostly essentially cylindrical interior space, in which the ball shell of the ball and socket joint is in turn arranged. The joint ball of the ball and socket joint is accommodated in the ball shell in a slidingly movable manner. In a likewise known manner, the ball and socket joint comprises, furthermore, a sensor means for measuring forces or loads of the ball and socket joint. However, the ball and socket joint is characterized according to the present invention in that the sensor means is formed by a sensor array, which comprises at least two pressure and force sensors and is placed in the area of the ball shell. The sensors are used to measure the forces or pressing pressures acting between the joint ball and the ball shell.
[0011] This leads to the substantial advantage that, contrary to the state of the art, the entire sensor means is arranged well protected within the joint housing and is rigidly connected to the joint housing or to the ball shell. This already leads to a both robust and reliable and inexpensive construction of the ball and socket joint according to the present invention.
[0012] Unlike in the state of the art, a complicated separate arrangement of the sensor system and the electronic analysis unit with a wiring that may be needed between them through the hollow ball pivot is no longer necessary, but both the sensor system and the electronic analysis unit can rather be arranged together within the joint housing and connected to one another. Even an arrangement of both the sensors and the electronic analysis unit on one and the same common flexible printed circuit board is conceivable and provided. Any mechanical changes on the ball pivot or on the joint ball, by which the stability of the ball and socket joint could be compromised, are no longer necessary, either. The costs that have been associated therewith so far can also be eliminated.
[0013] The arrangement according to the present invention of at least two pressure sensors in the area of the ball shell means in other words that the at least two sensors together with the center of the ball define an at least two-dimensional system of coordinates. Force and pressure signals for at least two different directions in space can thus be determined with the sensors, and the resulting vectorial force that instantaneously acts on the ball and socket joint can in turn be determined from these [signals] by means of a suitable vectorial addition in terms of value and direction in the at least two-dimensional system of coordinates.
[0014] Finally, besides forces, which act on the ball and socket joint from the outside, data on internal forces of the ball and socket joint can additionally also be obtained thanks to the principle of measurement according to the present invention. One can think in this connection, in particular, of the detection of the prestressing force of the ball shell, whose value, decreasing over time, can be used as an indicator of the increasing wear on the ball and socket joint.
[0015] How exactly the at least two sensors of the ball and socket joint are arranged in space is at first irrelevant for the embodiment of the present invention as long as they define, together with the center of the ball, an at least two-dimensional system of coordinates.
[0016] However, provisions are made according to a preferred embodiment of the present invention for the sensor means to be formed by a sensor array comprising the pressure or force sensors, which is placed in the area of the ball shell. The sensors are again used to measure the forces or pressing pressures acting between the joint ball and the ball shell. The three sensors are arranged essentially on an imaginary sensor spherical surface that is concentric to the joint ball such that the plane spanned by the three sensors does not pass through the center of the sensor spherical surface or the joint ball.
[0017] In other words, this means that the three sensors surround the joint ball or the ball shell essentially on an imaginary spherical surface, and the sensors define, together with the center of the ball, a three-dimensional system of coordinates. Force and pressure signals for three different directions in space can thus be determined with the sensors, and the resulting total vectorial force, which instantaneously acts on the ball and socket joint, can in turn be determined from these signals by means of vectorial addition. Complete vectorial determination of the forces acting instantaneously on the ball and socket joint is thus possible in the three-dimensional space.
[0018] According to another, especially preferred embodiment of the present invention, the sensor array comprises eight sensors, which are arranged on at least two mutually different great circles of the imaginary sensor spherical surface. The eight sensors are preferably arranged at the corner points of an imaginary square column inscribed in the sensor spherical surface, i.e., a cuboid with a square base, the vertical axis of the square column coinciding with the longitudinal axis of the ball pivot.
[0019] In other words, this means that the joint ball is surrounded by an array of eight sensors, which is positioned symmetrically in relation to the ball pivot and concentrically to the joint ball.
[0020] The increased number of sensors leads to an increase in the accuracy of measurement and to minimization of inevitable measuring inaccuracies. Furthermore, the symmetrical arrangement of the eight sensors, which preferably coincides with a rectangular Cartesian system of coordinates, makes possible a uniform measuring accuracy practically independently from the direction of action of the load acting in the ball and socket joint, and it facilitates, moreover, the analysis of the measured signals of the individual sensors as well as the conversion of these signals into the resulting total vectorial force in the Cartesian system of coordinates.
[0021] In addition, such an array comprising eight sensors permits the reliable determination of the force actually acting on the ball and socket joint even under difficult conditions. Thus, it is imaginable, for example, that the force acting on the ball and socket joint is so strong that the internal prestressing force within the joint is completely overcome, so that the joint ball is lifted off from the ball shell on the side opposite the direction of the force. Reliable determination of the force acting on the ball and socket joint in terms of value and direction in the three-dimensional space is guaranteed in such a case only if the force acting on the ball and socket joint still also acts on at least three sensors not located on the same great circle even in the state of the joint ball in which it is partially lifted off from the ball shell.
[0022] However, if eight sensors are used in the array described, it is guaranteed that the joint ball is not lifted off from the ball shell in all imaginable loading cases in the area of at least four of the eight sensors. The total vectorial force can thus be reliably determined for every imaginable loading case of the ball and socket joint.
[0023] The present invention is embodied independently from the design of the sensors or the principle of action according to which the sensors operate, as long as the sensors used are suitable for measuring the foreseeably occurring forces or surface pressures. According to preferred embodiments of the present invention, the sensors are designed, however, as wire strain gauges or as piezo sensors. This has the advantage that commercially available and inexpensive sensors can be used.
[0024] Provisions are made, by contrast, according to another, especially preferred embodiment of the present invention, for the sensors to be designed in the form of capacitive sensors. Each of the capacitive sensors preferably now comprises an electrode arranged on the outer side of the ball shell or within the wall of the ball shell, the counterelectrode of the capacitive sensor being formed by the joint ball itself in this case.
[0025] The use of capacitive sensors of such a design is especially advantageous in terms of a simple and robust design and trouble-free operation of the ball and socket joint according to the present invention. The principle of action of the capacitive sensor is that a capacitor, whose capacitance changes with any change in the distance between the electrode and the joint ball, is formed by the electrode arranged in the area of the ball shell, together with the joint ball electrically insulated from that electrode by the material of the ball shell.
[0026] Since the elastic changes in the wall thickness of the ball shell are proportional to the surface pressure acting between the joint ball and the ball shell within broad ranges, the locally instantaneously prevailing surface pressure can be inferred directly and extremely accurately by means of registration of the change in the capacitance of the particular capacitive sensor.
[0027] Further advantages of capacitive sensors are that they operate permanently practically completely without wear, have a simple analysis circuit and require, moreover, only a minimum operating current.
[0028] Provisions are made in this connection according to another embodiment of the present invention for each of the capacitive sensors to comprise two series-connected capacitors. The two capacitors connected in series are formed by two electrodes arranged adjacent to one another on the outer side of the ball shell or within the wall of the ball shell, together with the joint ball, which is free from potential in this case, as the intermediate electrode common to both capacitors.
[0029] This embodiment has the additional decisive advantage that electrical contacting of the joint ball is no longer necessary here. It is rather sufficient to establish an electrically conductive connection between the two electrodes of the capacitive sensor, which are arranged adjacent to one another, and the corresponding analysis circuit, and to monitor the capacitance between the two electrodes arranged adjacent to one another.
[0030] To determine the force acting on the ball and socket joint, the measured force and pressure signals of the sensors of the ball and socket joint are registered in a first process step. The prevailing local forces, pressures and surface pressures are subsequently determined in another process step on the basis of the measured signals of the sensors. The force vector resulting from the local forces, pressures and surface pressures is subsequently determined in the Cartesian system of coordinates in another process step.
[0031] The process according to the present invention has the advantage that the force acting on the ball and socket joint can be detected and measured not only in terms of its value but also in terms of its direction in the three-dimensional space. The measurement of forces on the ball and socket joint in terms of both the value of the force and in terms of the direction of the force with a sensor means that is accommodated entirely in the joint housing and is therefore reliable and robust yields an excellent data base in a simple and reliable manner, for example, in the testing operation, or for driving safety and driver assistance systems of a motor vehicle, for example, for ABS and ESP, but also for advanced vehicle systems, for example, X-by-wire technologies.
[0032] According to a preferred embodiment of the process for load measurement according to the present invention, a prestressing force between the ball shell and the joint ball is also determined as an alternative or in addition to the determination of the force vector acting on the ball and socket joint within the framework of the calculation of the resultant from the sensor signals.
[0033] The calculation of the prestressing force between the ball shell and the joint ball is carried out preferably by means of forming the sum of the signals of sensors of the ball and socket joint that are located opposite each other. The prestressing force can be reliably derived in this manner even in the presence of additional external forces, which may also be variable.
[0034] The determination of the prestressing force in the ball shell of a ball and socket joint is especially advantageous because the value of the prestressing force, which decreases over time, can be used especially as an indicator of the progressive wear of the ball and socket joint, because the ball shell of a ball and socket joint is made usually of a viscoplastic polymer and is subject to both superficial wear because of the relative motion between the ball surface and the ball shell and to a certain relaxation based on creeping motions of the plastic during the service life of the ball and socket joint. Both contribute to the fact that the prestress in the ball and socket joint declines over time, as a result of which the clearance of the joint may also increase, especially under load.
[0035] The value of the prestressing force, which decreases over time, can therefore be used as an indicator of the instantaneous state and the still remaining service life of a ball and socket joint. Furthermore, damage to the ball and socket joint, especially damage to the sealing bellows, with the subsequent penetration of, for example, corrosive salt water into the ball and socket joint, can be inferred, for example, from a prestressing force declining greatly within a short time in a ball and socket joint.
[0036] Against this background, the present invention pertains, furthermore, to a process for wear measurement on a ball and socket joint. The ball and socket joint comprises a sensor array, which is located in the area of the ball shell and comprises at least a pressure or force sensor for measuring the forces or pressing pressures acting between the joint ball and the ball shell.
[0037] To carry out the process for wear measurement according to the present invention on a ball and socket joint, it is first checked in a first process step whether one or more of the conditions “absence of force,” “constancy of force” or “load at standstill of the ball and socket joint,” “predetermined relative position of the ball pivot in the joint housing, which position is suitable for wear measurement” or “absence of motion of the ball and socket joint or of the motor vehicle” is present.
[0038] The more of these conditions are met, the more reliably and accurately can the subsequent measurement be carried out, and the sooner can errors of measurement as a consequence of external effects be avoided.
[0039] The value of the measured force or pressure signals of the sensor array that represent the prestressing force between the ball shell and the joint housing or between the ball shell and the joint ball is subsequently determined in another process step by means of the force sensor means of the ball and socket joint. The value of the wear of the ball and socket joint, which value corresponds thereto, is subsequently calculated in another process step from the measured signals or from the prestressing force determined.
[0040] The determined value of the wear is finally compared to a stored maximum, and a warning is sent if the maximum is exceeded.
[0041] Reliable data can thus be obtained with the process according to the present invention on the foreseeably remaining service life of the ball and socket joint. A possibly imminent failure of the ball and socket joint can also be determined or predicted thanks to the monitoring of the prestressing force or of the wear value of the ball shell according to the present invention. The reliability of operation of the ball and socket joint or of the motor vehicle equipped therewith can be decisively improved in this manner.
[0042] According to a preferred embodiment of the process for wear measurement according to the present invention, the sensor array comprises an even number of, e.g., at least two, pressure or force sensors. The pressure or force sensors are arranged in pairs opposite each other on a diameter line of the joint ball of the ball and socket joint, and the calculation of the wear value is carried out by forming the sum of the measured force or pressure signals of sensors arranged opposite each other.
[0043] The determination of the wear value on a ball and socket joint with the use of the signals of pressure or forces sensors arranged opposite each other is advantageous because a higher accuracy can thus be achieved in respect to the measurement of the prestressing force on the ball shell. Furthermore, the prestressing force can be better distinguished from other forces acting externally on the ball and socket joint as a consequence of forming the sum of the signals of sensors arranged opposite each other. This is linked with the fact that the change in a force acting externally on the ball and socket joint always causes changes in the signals of sensors arranged opposite each other in opposite directions, so that the effect of the external force is automatically eliminated during the formation of the sum of the signals of sensors arranged opposite each other and during the determination of the prestressing force, which is based on this, as well as of the value of the wear.
[0044] The use of the signals of sensors arranged opposite each other to determine the prestressing force and the value of the wear thus makes it possible to make a reliable distinction between whether measured force values are changes in the prestressing force or external forces which act on the ball and socket joint.
[0045] The present invention will be explained in more detail below on the basis of drawings showing only exemplary embodiments. 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
[0046] In the drawings:
[0047] FIG. 1 is a schematic view of the principle of the force breakdown for determining the total vectorial force on a ball and socket joint according to the present invention;
[0048] FIG. 2 is a schematic isometric view of an embodiment of a ball and socket joint according to the present invention;
[0049] FIG. 3 in a schematic isometric view of another embodiment of a ball and socket joint according to the present invention with representation of the total vectorial force;
[0050] FIG. 4 is a schematic view of the longitudinal section of another embodiment of a ball and socket joint according to the present invention with a capacitive force sensor;
[0051] FIG. 5 is an enlarged detail of the capacitive force sensor of the ball and socket joint according to FIG. 4 ;
[0052] FIG. 6 is a longitudinal section of another embodiment of a ball and socket joint according to the present invention with capacitive force sensor in a representation and view corresponding to FIG. 4 ; and
[0053] FIG. 7 is an enlarged view corresponding to FIG. 5 of the capacitive force sensor of the ball and socket joint according to FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] Referring to the drawings in particular, FIG. 1 shows the principle of the force breakdown for the determination of the total vectorial force in a highly schematic longitudinal sectional view. An idealized ball and socket joint shall be considered at first, which maintains a prestressing (prestress/precompression) force due to the manufacture under all operating conditions. In other words, the surface pressure caused by the prestressing force between the joint ball and the ball shell shall always be greater in the idealized ball and socket joint than the surface pressures brought about by operating forces, so that the joint ball will not be lifted off from the ball shell as a consequence of the effect of operating forces.
[0055] Three force or pressure sensors are already sufficient, in principle, under such idealized conditions to determine the operating force acting on the ball and socket joint in terms of both value and direction in the three-dimensional space from the signals of these three sensors. This is true if the three sensors, surrounding the joint ball, are arranged distributed in such a way that the imaginary plane spanned by the three sensors does not pass through the center of the joint ball, because a system of coordinates, whose vectors can be readily converted into vectors of a Cartesian, i.e., rectangular system of coordinates, is already defined now in the three-dimensional space by the sites of the three sensors as well as by the center of the joint ball as a reference point.
[0056] Since it can be assumed in this idealized case that the surface of the joint ball is not lifted off from the ball shell, all three sensors also yield a force component each for every imaginable operating force acting on the ball and socket joint. The operating force F can then be calculated in terms of both value and direction by vectorial addition from these three force components.
[0057] However, eight sensors rather than only three pressure or force sensors are preferably used for several reasons for the reliable and accurate measurement of the vectorial operating force F.
[0058] On the one hand, a higher accuracy of measurement can already be achieved, in principle, with a greater number of sensors, because inevitable static errors of measurement are evened out in this manner. On the other hand, it must also be expected that the idealization, according to which the joint ball is always in contact with the ball shell, does not always coincide with the conditions occurring in practice. Thus, it is realistic to assume that operating forces that are so strong that the surface pressure present between the ball shell and the joint ball is overcome because of the prestress of the ball and socket joint can definitely occur. The joint ball is lifted off from the ball shell in this case in some areas, as a result of which sensors arranged in that area no longer yield usable measured signals.
[0059] While four sensors arranged at the corners of a tetrahedron inscribed in the sensor spherical surface would theoretically already be sufficient to determine the operating force F in terms of both value and direction even in the case in which the ball surface is lifted off from the joint ball in some areas, it proved to be practicable to use not only four but eight pressure or forces sensors for the vectorial determination of the operating force F.
[0060] Namely, these eight sensors can be positioned better, on the one hand, in light of the actual geometric conditions of the joint housing and the ball shell than a tetrahedral array on the ball shell. On the other hand, as was described, a considerably higher accuracy of measurement is achieved with eight sensors than with four sensors, and, finally, the eight sensors can be arranged distributed in such a way that a simplified conversion of the measured signals into a force vector is obtained in the Cartesian system of coordinates.
[0061] If the operating force becomes so strong that the joint ball is lifted off from the ball shell in some areas, the four sensors that yield the strongest measured signal, i.e., the sensors on which the strongest force acts, are preferably used to calculate the force vector.
[0062] The principle of the determination of the force vector of the operating force F will be described at first based on the example of the two-dimensional case for the better understanding of the principle of the determination of the force vector.
[0063] FIG. 1 shows the two-dimensional analogy to a ball and socket joint with a joint ball 1 , a ball shell 2 and a joint housing 3 . Four pressure or force sensors S OL , S OR , S UR and S UL are arranged here between the ball shell 2 and the joint housing 3 . The forces or surface pressures F SOL , F SOR , F SUR and F SUL act on the four sensors S OL , S OR , S UR and S UL .
[0064] To illustrate the force breakdown, on which the determination of the force vector F on the basis of the forces S OL , S OR , S UR and S UL measured by the sensor is based, the introduced force vector F is broken down at first into a force component F ⊥ perpendicular to the longitudinal axis of the ball pivot as well as a force component F ∥ parallel to the ball pivot.
[0065] The two force components F ⊥ and F ∥ , which do not mutually affect each other and are superimposed to one another, generate, all in all in respect to the individual sensors S OL , S OR , S UR and S UL , the forces or surface pressures F SOL , F SOR , F SUR and F SUL , whose components, which go back to the two force components F ⊥ and F ∥ and are thus to be added, are still shown separately in FIG. 1 for the sake of better recognizability. The force components or surface pressures acting on the sensors are always at right angles to the sensor surface, because tangential forces are not registered by the sensors or cannot be transmitted because the joint ball is in sliding contact with the ball shell.
[0066] Strictly speaking, the total force F that is introduced into the ball is not, however, distributed among the forces sensors, because a large part of the force F is absorbed by the surface of the ball shell outside the area of the sensors. The force F thus represents only the total resulting force of the partial forces actually transmitted in the area of the sensors between the joint ball and the ball shell in the example being shown in FIG. 1 . However, this does not compromise the determination of the operating force F actually acting on the ball and socket joint, because the value of the actually acting force F is always proportional to the resultant of the sensor forces. However, such a proportionality factor is determined within the framework of the calibration of the sensor anyway and is thus taken into account.
[0067] The force breakdown in the area of the sensors is shown in FIG. 1 for the two lower sensors S UR and S UL only. However, the same force breakdown applies, in principle, to the two upper sensors S OR and S OL as well.
[0068] The two force components F ⊥ and F ∥ are distributed uniformly between the sensors S UL and S UR considered more specifically in FIG. 1 , so that the force components acting on the sensors are always set, for the sake of simpler understandability, at half of the value of the two force components F ⊥ and F ∥ . However, as was already explained above, the absolute value of the conversion factor between the force components at the sensor and the components F Γ and F ∥ of the actually acting operating force F, which conversion factor is set at ½ here, play at first no role, at any rate for the purpose of the representation of the force breakdown, because the actual value of the conversion factor is set anyway only within the framework of the sensor calibration.
[0069] The force acting on the respective sensors comprises, in principle, three components. These three components are
i. the prestressing force F V , which acts permanently and essentially constantly in parallel to the normals to the sensors after the manufacture of the ball and socket joint (or after the housing cover is rolled onto the joint housing); ii. a proportional part (set at F ∥ /2 here) of the component F ∥ of the total force F, which component is parallel to the ball pivot; and iii. a proportional part (set at F ⊥ /2 here) of the component F ⊥ of the total force F, which component is at right angles to the ball pivot.
Consequently, the two total forces F SUL and F SUR on the two sensors S UL and S UR , which are the lower sensors in the drawing, are obtained at first with the angle α between the axis of the ball pivot and the sensor force directed at right angles to the sensor, which angle is derived from the positioning of the respective sensor at the ball and socket joint, as follows:
[0000]
F
SUL
=
F
V
+
F
2
cos
α
-
F
⊥
2
sin
α
F
SUR
=
F
V
+
F
2
cos
α
+
F
⊥
2
sin
α
[0000] The two sensor forces S SOL , and F SOR for the two sensors S OL and S OR , which are the upper sensors in the drawing, are obtained analogously:
[0000]
F
SOL
=
F
V
-
F
2
cos
α
-
F
⊥
2
sin
α
F
SOR
=
F
V
-
F
2
cos
α
+
F
⊥
2
sin
α
[0000] By adding or subtracting the above equations as well as subsequent resolution according to the force components F ⊥ and F ∥ , the components F ⊥ and F ∥ of the total force F, which components are parallel or at right angles to the ball pivot, can already be subsequently determined from the forces measured by the sensors as follows:
[0000]
F
SUL
=
F
V
+
F
2
cos
α
-
F
⊥
2
sin
α
F
SUR
=
F
V
+
F
2
cos
α
+
F
⊥
2
sin
α
[0000] The upper sign pertains to the upper sensors S OL and S OR and the lower sign to the lower sensors S UL and S UR .
[0073] To determine the angle β between the direction of action of the total force F and the longitudinal axis of the ball pivot,
[0000] F ⊥ =F sin β
[0000] F ∥ =F cos β
[0000] is set according to FIG. 1 .
[0074] If these two equations are divided by each other and the terms determined last for the two components F ⊥ and F ∥ of the total force F are introduced at the same time,
[0000]
sin
β
cos
β
=
∓
cos
α
sin
α
F
SOR
/
SUR
-
F
SOL
/
SUL
F
SOR
/
SUR
+
F
SOL
/
SUL
-
2
F
V
[0000] is obtained. The angle β between the direction of action of the total force F and the longitudinal axis of the ball pivot is obtained from this as follows:
[0000]
β
=
tan
-
1
[
∓
1
tan
α
F
SOR
/
SUR
-
F
SOL
/
SUL
F
SOR
/
SUR
+
F
SOL
/
SUL
-
2
F
V
]
[0000] The value of the total vectorial force F can finally be determined as:
[0000] F =√{square root over (F ⊥ 2 +F ∥ 2 )}
[0000] The total vectorial force F is thus known in terms of both its value and its direction on the basis of the forces measured by the sensors.
[0075] However, the prestressing force F V of the ball and socket joint can additionally also be determined from the forces measured by the sensors. The forces measured by the sensors located diagonally opposite each other, i.e., F SOL and F SUR or F SOR and F SUL , are added up for this, from which double the prestressing force F V is obtained. From this follows
[0000]
F
SOL
+
F
SUR
2
=
F
SUL
+
F
SOR
2
=
F
V
[0000] for the value of the prestressing force F V .
[0076] Since the value of the prestressing force, which decreases over time, depends primarily on the wear of the ball and socket joint, data on the current state of wear of the ball and socket joint can also be obtained, on the basis of the prestressing force F V determined, at any time with the sensor array being shown, besides the vectorial operating force F.
[0077] The prestressing force can be determined reliably only as long as the joint ball has not been lifted off from the ball shell in some areas due to an operating force F introduced from the outside. To ensure contact between the joint ball and the ball shell over the entire area, the measurement of the prestressing force or of the wear of the joint is carried out only when certain boundary conditions are present, for example, always at the torque at which the engine of the motor vehicle is started, or whenever the measured velocity of the vehicle equals zero.
[0078] To make it also possible to determine the component of the total vectorial force F extending in the third dimension of space, on the basis of the force breakdown shown in FIG. 1 for the case of the two-dimensional analogy for the sake of better recognizability, not only the four sensors according to the view in FIG. 1 are used, but, as was already explained above, a total of eight pressure or force sensors are used.
[0079] An example of the array of the eight sensors is schematically shown in FIG. 2 . It can be seen that the eight sensors are arranged at the corners of an imaginary square column, i.e., of a cuboid with a square base, the square column being inscribed in an imaginary sensor spherical surface (not shown) that is concentric to the joint ball, and the vertical axis of the square column coinciding with the longitudinal axis of the ball pivot. A uniform accuracy of measurement is thus obtained for the resultants from the sensor signals for all directions in space, and both the value and the direction of the total vectorial force can be determined in the three-dimensional space by means of comparatively simple trigonometric calculations.
[0080] Viewing FIG. 1 and FIG. 3 together shows that the trigonometric relationships are fully analogous to the two-dimensional example according to FIG. 1 in the three-dimensional case according to FIGS. 2 and 3 . The force breakdown according to FIG. 1 is to be performed separately for the three-dimensional case only twice for the two section planes abcd and abef for the four sensors each contained in them and for the force components F 1 and F 2 , cf. FIG. 3 . Finally, only the resultant F 3D must be formed from the two force components F 1 and F 2 according to the view in FIG. 3 .
[0081] The rectangular triangle ahc (dotted line, with right angle at c) inscribed in the imaginary cuboid abcdefgh defined by the two force components F 1 and F 2 can be used to determine the value of the total resulting force F 3D . According to Pythagoras,
[0000] F 3D =√{square root over (F 1 2 + hc 2 )}
[0000] is true here.
[0082] With the other trigonometric relationship
[0000] hc = eb =F 2 sin β 2
[0000] the value of the total force F 3D in the three-dimensional space is thus obtained as follows:
[0000] F 3D =√{square root over ( F 1 2 +F 2 2 sin 2 β 2 )}
[0000] Both the direction and the length of the force vector F 3D is again determined unambiguously for the three-dimensional case by the value of the force F 3D thus determined as well as by the two angles β 1 and β 2 .
[0083] Besides the representation of the force breakdown, FIG. 3 also shows the arrangement of two of the total of eight pressure or force sensors 6 with the respective feed lines 7 belonging to them. The six other sensors are not visible in the view in FIG. 3 , because they are either in the background of the drawing or are hidden by a component 5 of the joint housing or of the joint housing cover.
[0084] FIGS. 4 through 7 show embodiments of a ball and socket joint according to the present invention with capacitive pressure or force sensors in a highly schematic longitudinal section. The view in FIGS. 4 and 5 pertains to a capacitive sensor 6 , in which one pole is formed by an electrode arranged on the outer side of the ball shell 2 , while the joint ball 1 forms the opposite electric pole.
[0085] The principle of action of the capacitive sensor 6 is that a capacitor 7 , whose capacitance changes with any change in the distance between the electrode of the sensor 6 and the joint ball 1 , is formed by the electrode of the sensor 6 , which electrode is arranged in the area of the ball shell 2 , together with the joint ball 1 , which is electrically insulated from that electrode by the material of the ball shell 2 .
[0086] FIGS. 6 and 7 likewise show a capacitive sensor 6 , which is designed, however, in the form of two capacitors 7 connected in series. The two series-connected capacitors 7 are formed, together with the joint ball 1 , which is free from potential in this case, as an intermediate electrode common to both capacitors 7 , by two electrodes arranged on the outer side of the ball shell 2 .
[0087] The capacitive sensor 6 according to FIGS. 6 and 7 thus has the great additional advantage that unlike in the sensor according to FIGS. 4 and 5 , contacting of the joint ball 1 or of the ball pivot is no longer necessary in this sensor. Rather, only the two feed lines to the two electrodes of the sensor 6 , which electrodes are arranged adjacent to each other, are to be laid.
[0088] The use of capacitive sensors of such a design is advantageous in terms of a simple, robust design and trouble-free operation of the ball and socket joint. Since the elastic changes in the wall thickness of the ball shell 2 are extensively proportional to the surface pressure acting between the joint ball 1 and the ball shell 2 , the surface pressure present locally can be inferred directly and exactly by measuring the capacitance of the sensor.
[0089] Further advantages of such capacitive sensors are especially that such sensors operate practically without wear, make do with a simple analysis circuit and have a lower power consumption.
[0090] Thus, it becomes clear as a result that thanks to the present invention, ball and socket joints or processes for load measurement and for wear measurement on ball and socket joints are provided, with which extremely accurate and reliable determination of the operating state and load state or of the wear of the ball and socket joint is made possible. The present invention makes possible the vectorial determination of forces or of loads acting on the ball and socket joint in a robust and reliable manner. Furthermore, exact data can be obtained on the state of wear of the ball and socket joint, so that an imminent failure of the ball and socket joint can be recognized in time and prevented.
[0091] Thus, the present invention makes a fundamental contribution to the improvement of safety, reliability and failure prevention in ball and socket joints as well as to the expansion of the data base of driver assistance systems, especially where ball and socket joints are used in the area of demanding axle systems and wheel suspensions on the motor vehicle.
[0092] 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 ball and socket joint, a processes for load measurement and for wear measurement is provided, for example, for an axle system of a motor vehicle. The ball and socket joint has a housing ( 1 ), in the essentially cylindrical interior space of which a ball shell ( 2 ) is arranged. The ball ( 3 ) of a ball pivot is slidingly accommodated in the ball shell ( 2 ). The ball and socket joint has a sensor device for measuring forces or loads formed by a sensor array ( 4 ), which is placed in the area of the ball shell ( 2 ) and comprises at least two pressure or force sensors ( 6 ) for measuring forces or pressing pressures acting between the joint ball ( 1 ) and the ball shell ( 2 ). The processes provides permanent monitoring of the operating state and the state of wear of the ball and socket joint, by measuring the prestressing force of the ball shell. | 5 |
FIELD OF THE INVENTION
The present invention relates to a safety apparatus for electric appliances and, in particular, electric stoves.
BACKGROUND OF THE INVENTION
It is common for persons to be interrupted while using electric appliances. They may be interrupted by a ringing of a doorbell, a ringing of a telephone or they may remember a task that they feel they can quickly complete while they wait. A person without memory problems remembers to return to the electric appliance after the interruption has been attended to. A person with a memory problem may not. If a person with a memory problem forgets to return to attend to an electric clothes dryer, it does not present a serious safety problem. However, if the person with a memory problem forgets to return to attend to an electric stove, a fire may result. Some persons with memory problems, realizing the risk, no longer use their stoves. Persons with more pronounced memory problems will continue to cook in an unsafe manner.
Swedish Application 9,102,230 teaches the use of a timing circuit which is coupled to the power supply for an electric appliance. The timer must be set in order for current to flow to the electric appliance. Upon expiration of the time, the flow of current to the electric appliance is cut off. A key activated bypass of the timer is provided for use by persons without memory lose.
The teachings of Swedish Application 9,102,230 are effective to prevent fires. Unfortunately, such teachings do not assist the person with memory loss to complete the task of cooking, preferably without burning the food. In order to remain in their homes persons with memory loss must be able to complete routine household tasks, notwithstanding their memory problems.
SUMMARY OF THE INVENTION
What is required is a safety apparatus for electric appliances that will assist a person with memory problems to complete routine household tasks, such as cooking.
According to the present invention there is provided a safety apparatus for electric appliances which includes sensing means for sensing that an electric appliance is operating. Alarm means are coupled with the sensing means, whereby an alarm is initiated upon the electric appliance operating. Alarm disabling means are provided for disabling the alarm means for a predetermined time interval. In the preferred embodiment the alarm disabling means has a manual reset switch whereby a person supervising the operation of the electric appliance restarts the predetermined time interval.
The safety apparatus, as described above, an alarm sounds to remind the person supervising the use of the electric appliance to return to his or her task. It will also alert the spouse of a memory impaired person, that the electric appliance has been turned on. When the electric appliance is a stove, the task is one of stirring their porridge, turning their meat, and the like. The person supervising the operation of the electric appliance can temporarily disable the alarm by pressing the manual reset switch. There are different alarm means that could be used. The preferred form of alarm means is an audible alarm, as it is easier to catch the attention of a person in the next room with an audible alarm as opposed to flashing lights. A different form of alarm means would have to be used by the hearing impaired. The most practical being a vibration pager that they could carry upon their person. Of course, the benefits of the safety apparatus described are not limited to persons with memory problems. Even persons without memory problems commonly remove a pot from the stove and forget to turn the stove element off. The safety apparatus, as described above, would call them back to the stove if the element was inadvertently left on.
Although beneficial results may be obtained through the use of the invention, as described above, there is always a possibility that the person using the appliance has left his residence or is otherwise out of hearing range of the audible alarm. Even more beneficial results may, therefore, be obtained when switch means are provided for turning off the stove should the alarm disabling means not be reset within a second predetermined time interval. It should be noted that the cutting off of the power to the electric appliance is a matter of last resort. It is preferred that the person using the appliance be assisted by the safety apparatus described in completing the task undertaken.
There are various means for determining whether the electric appliance is in operation. It is preferred that sensors be used to monitor that fact that power is being consumed by the electric appliance. There are various sensors commercially available that will do this by sensing current or voltage.
The teachings of this safety apparatus can be implemented in several ways. An apparatus, as described above, can be incorporated into the manufacture of a new electric appliance and, in particular, a stove. It is also possible to incorporate the safety apparatus in a plug adaptor unit into which the electric appliance is plugged.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, wherein:
FIG. 1 is a perspective view of a plug adaptor unit incorporating the teaching of the present safety apparatus for electric appliances.
FIG. 2 is a block diagram of a preferred embodiment of the safety apparatus for electric appliances.
FIGS. 3a, 3b, 3c are circuit diagrams of the safety apparatus for electric appliances.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment, a safety apparatus for electric appliances generally identified by reference numeral 10, will now be described with reference to FIGS. 1 through 3a, 3b, 3c. The teachings relating to the present invention can easily be incorporated into an electrical appliance. The manner in which safety apparatus 10 can be adapted for use with existing apparatus will now be described.
Referring to FIG. 1, the illustrated embodiment of safety apparatus 10 includes a plug adaptor 12 having a male portion 14 adapted for insertion into a residential electric outlet (not shown) and a female portion 16 adapted to receive a plug from an electric appliance (not shown). Plug adaptor 12 is connected by a conductive wire 18 to a housing 20. Housing 20 has a button form manual reset switch 22, a light 24 and a audio speaker sound grid 26 to allow sound to pass from speakers positioned within housing 20, as will hereinafter be further described.
Referring to FIG. 2, there is illustrated in block form the components that are electrically coupled with plug adaptor 12. A power consumption sensor 28 detects power consumption by the electric appliance to let safety apparatus 10 know that the electric appliance is operating. Power consumption sensor 28 in this case is triggered by current draw. In an application involving an electric stove, it is preferred that sensor 28 have a 3.5 amp threshold to permit operation of the stove clock and lights without activating safety apparatus 10. Apparatus 10 allows the clock and lights to work, while monitoring use of the stove top elements, the oven, or an appliance plugged an electric receptacle on the stoves's control panel. Timing means coupled with sensor 28 play a role in both an alarm means and an alarm disabling means as will hereinafter be further described. In FIG. 2, the timing means are illustrated as a series of blocks representing individual timing circuits 30a, 30, 30c, 30d each of which performs a particular timing function as will hereinafter further be described. Upon receiving a signal from sensor 28 that the electric appliance is consuming power, a number of the timing circuits become active. Timing circuit 30a is connected to light 24, a first speaker 32 and a second speaker 34. Light 24 is illuminated when safety apparatus 10 is first activated and is caused to flash by timing circuit 30a. Similarly, first speaker 32 emits a 3500 hz tone when safety apparatus 10 is first activated and continues to emit such tone as long as safety apparatus 10 is in operation. Beneficial results have been obtained when timing circuit 30a causes light 24 to flash and first speaker 32 emit a tone once per second. Timing circuit 30b is a carry over circuit which causes light 24 to flash and first speaker 32 to emit a tone approximately 15 seconds after current is no longer being sensed. A second speaker 34 serves a primary alarm function emitting a 1000 hz audible alarm tone upon sensor 28 sensing current flow. It is preferred that the audible alarm tone be modulated through the use of an oscillating circuit 36. Light 24, first speaker 32 and second speaker 34 are all connected to alarm disabling means which includes manual reset switch 22 and timing circuit 30c. By pressing manual reset switch 22, timing circuit 30c deactivates light 24, first speaker 32 and second speaker 34 for a first predetermined time interval. Timing circuit 30c works in a manner that is analogous to a "snooze" button on an alarm clock. At the expiration of the first predetermined time interval light 24, first speaker 32 and second speaker 34 will again be operative with first speaker 32 emitting a 3500 hz audible alarm tone and second speaker 34 emitting a 1000 hz audible alarm tone. The first predetermined time interval is, preferably, between 2 and 7 minutes. First speaker 32 and second speaker 34 will continue sounding the audible alarm warning tones until manual reset switch 22 is pressed. An additional feature is the provision of an automatic power cutoff switch 38 coupled to timing circuit 30d. Timing circuit 30d times a second predetermined time interval. If the audible warning tones emitted by first speaker 32 and second speaker 34 are not acknowledged by pressing manual reset switch 22 within the second predetermined time interval, timing circuit 30d will trigger power cutoff switch 38. The second predetermined time interval is, preferably, between 15 and 25 minutes. Every time manual reset switch 22 is pressed, timing circuit 30d is reset. A desirable option is to have an auxiliary output 40. Auxiliary output 40 enables remote monitoring, as will hereinafter be further described.
FIGS. 3a, 3b and 3c, illustrate circuitry underlying the blocks in block diagram FIG. 2. The circuits were made with commercially available components, utilizing a series of gates to implement circuit logic. Referring to FIG. 3a, timing circuit 30c that includes a timing chip U3, resistors R1, R5, R6, R7, Capacitor C3, and a number of gates U2c, U2c, U2d and U4a which are used to implement the circuit logic. Two of the gates, U2c and U2b, are configured as a flip-flop. Resistor R5 and a capacitor C3 are configured to create a resistor/capacitor time delay. Upon power up output Q14 from timer U3 is low, causing output 3 of gate U4a to go high. R5/C3 ensure that timer U3 is enabled during power up in a known condition, this results in a delay that leaves input 9 to gate U2c low. This causes output 10 of gate U2c to go high and output 4 of gate U2b to go low. As a result input 13 into gate U2d is low. Input 12 into gate U2d is, however, high which causes output 11 of gate U2d to be high. A high output at output 11 of gate U2d feeds into input 12 of timing chip U3, to reset timing chip U3. A snooze button 22 effects the operation of timing circuit 30c as will hereinafter be described.
Sensing circuit 28 includes resistor R2, capacitor C2, terminal connections T1.6, T1.7, T1.8 and a gate U1a. Capacitor C2 serves to provide a steady output, notwithstanding the alternating current input. When current flows output 3 of gate U1a goes to high.
Timing circuit 30b includes diode D2, resistor R18, and Capacitor C4. When current flows through timing circuit 30b, capacitor C4 acquires a charge. The use of diode D2 in combination with resistor R18 results in capacitor charging quickly, while discharging relatively slowly. This provides a 15 second carry over as capacitor C4 discharges after the flow of current is terminated.
Gate U1d controls the alarm portion of the circuit. Input 12 of gate U1d comes from output 3 of gate U1a of sensing circuit 28 via timing circuit 30b. Input 13 of gate U1d comes from output 10 of gate U2c of timing circuit 30c. When input 13 is high and input 12 is high, output 11 of gate U1d goes to low initiating the alarm.
The alarm portion of the circuit includes timing circuit 30a, light 24, first speaker 32, second speaker 34 and oscillator 36. Timing circuit 30a includes 555 flasher U8, gates U2a and U4d, resistors R20, R8, and capacitors C15, C19. Capacitor C19 is used to send a pulsing transition signal through to gate U5b which is illustrated in FIG. 3b, and will hereinafter be further described. Gate U5b is configured as a flip flop with gate U5a. Referring to FIG. 3a, gate U2a is used to reset 555 flasher U8. Capacitor C15 is used to create a one or two second delay, which creates an alternative "on" and "off" cycle of current flow to light 24, first speaker 32, and second speaker 34. First speaker 32 is directly connected and emits a tone during the "on" cycle. Gate U4d turns light 24, which is illustrated in FIG. 3c, on and off. The same signal also feeds into oscillator circuit 36 which effects output of second speaker 34. Oscillator circuit 36 includes 555 flasher U7, capacitor C5, resistor R9, gates U4b and U4c. Output from 555 flasher U8 feeds into reset for 555 flasher U7. Capacitor C5 is used to create a 1000 hz tone. Gates U4b and U4c are used to control the power input to second speaker 34.
When snooze button 22 is pressed and then released inputs 12 and 13 of gate U2d go to high, making output 11 of gate U2d go to low starting timing chip U3. When timing chip U3 times out, Q14 of timing chip U3 goes to high, forcing output 10 of gate U2c to high, output 4 of gate U2b to low and output 11 of gate U2d goes to high stopping and resetting timing chip U3. The alarm condition is, of course, only disabled when timing chip U3 is timing. The stopping and resetting of timing chip U3 results in the resumption of the alarm.
A portion of the circuit, identified by reference numeral 40, provides for central monitoring of the use of the electric appliance. Auxiliary output circuit 40 includes gates U1b and U1c. When current is sensed a low signal is sent to gate U1b, when an alarm condition is sensed a high signal is sent to gate U1c. This is a useful function in a seniors residence where the use of the stove in each unit can be monitored from a central location. The monitoring can be accomplished in a number of ways, three of which are illustrated; light emitting diode D4, opto-isolator U9 and relay JWD-171-14.
Referring to FIG. 3b, there is illustrated timing circuit 30d and stove shut off 38. Timing circuit 30d includes timing chips U10, U11, gates U5a, U5b, U5d, U6a, U6b, U6c, U6d, resistors R10, R12, R13, R17 and capacitors C16, C17. Timing chip U10 is a 30 minute timer. Timing chip U11 is a 7.5 minute timer. Output Q14 of timing chip U10 is low, which causes output 3 of gate U6a to go high. R12/C16 ensure that timer U10 is enabled during power up in a known condition, this results in a resistor/capacitor delay after which input 9 to gate U6c also goes to high. When snooze button 22 is pressed, output 4 of gate U6b goes to high, which makes input 13 to gate U6d high. Gate U6d starts and resets timing chip U10. Input 12 to gate U6d comes from the other portion of timing circuit 30d. An alarm condition exists when current is present, but the snooze button has not been pressed. The alarm condition resets and starts timing chip U11 timing. Initially output Q12 of timing chip U11 is low, causing output 11 of gate U5d to go to high. However, after timing chip U11 times out, output Q12 goes to high, causing output 11 of gate U5d to go to low. Capacitor C20 provides for the transition from high to low of input 1 to gate U5a. The presence of current causes input 6 of gate U5b to go to low, causing output 4 of gate U5b to go to high. This makes input 12 into gate U6d high, with input 13 of gate U6d already high, output 11 of gate U6d goes to low resetting and starting timing chip U10. D8 and C21 ensure that timing chip U10 is not running on initial power up.
An alarm condition exists when current is present indicating that the stove is operational and the snooze button has not, as yet been pressed. This alarm condition to input 12 of timing chip U11, resets timing chip U11 and starts the 7.5 minute timer timing down. The presence of current causes input 6 of gate U5b to spike low, causing output 4 of gate U5b to go high. When output 4 of gate U5b goes to high, input 12 of gate U6d goes to high. Input 13 to gate U6d is already high when the stove is on, which causes output 11 of gate U6d to go to low resetting timing chip U10 which starts timing down. Should no further alarm conditions reset timing chip U11, it times out spiking down input 1 to gate U5a causing output 3 of U5b to go to high. This causes output 4 of gate U5b to go to low, resetting timing chip U10. As long as the stove has not been turned off, timing chip U10 will then time down.
If the snooze button 22 is not pressed to reset timing chip U10, the circuit shuts the stove off when timing chip U10 times out. Stove shut off 38 includes gate U5c, resistors R10 and opto-isolators U14 and terminal switches T2.1 and T2.2. When output 4 of gate U6b is high, output 10 of gate U5c is low. When timing chip U10 times out, output Q14 goes to high, causing output 3 of gate U6a to go to low, causing output 10 of gate U6c to go to high and output 4 of gate U6b to go to low. When output 4 of gate U6B goes to low, output 10 of gate U5c goes to high with opto-isolators U14 and terminal switches T2.1 and T2.2 shutting the stove off.
There are a number of different products which stem from this invention. There can be a simple reminder, to remind a keep a person in close proximity to remain on task. There can be a call back feature, to call a person who may be at a distance and alert others in the house, usually the spouse. There can be an automatic shut off feature, that shuts the appliance off should the memory impaired person not respond to a call back within a specified period of time. What features are required depend upon the degree of impairment of the individual. For severely impaired individuals, alerting the spouse or others in the house can be of importance.
It will be apparent to one skilled in that art that a timer may be directly coupled with sensor 28. With this construction the timer, times a predetermined time interval upon receiving a signal from sensor 28. The alarm could be coupled with the timer to provide an audible tone upon receiving a signal from the timer that the predetermined time interval had expired. The timer would have a manual reset switch and would operate substantially as described above. It will also be apparent to one skilled in the art that other modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention as hereinafter defined in the Claims. | A safety apparatus for electric appliances which includes a sensor for sensing that an electric appliance is operating. An alarm coupled with the sensor, whereby an alarm is initiated. A manually operated alarm disabling switch permitting a person supervising the operation of the electric appliance to temporarily disable the alarm for a predetermined time interval. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of patent application having U.S. Ser. No. 09/378,318, filed Aug. 20, 1999, now U.S. Pat. No. 6,780,232, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to the field of transparent coatings for transparent objects such as eyeglass lenses, and refers particularly to a coating compositions having low viscosities and coating compositions producing abrasion-resistant coatings exhibiting high tintability.
BACKGROUND OF THE INVENTION
Transparent plastic materials such as eyeglass lenses are subject to becoming dull and hazy due to scratching and abrasion during use. Polycarbonate eyeglass lenses, for example, are strong and shatter resistant but also are relatively soft and susceptible to scratching. Television screen face plates similarly are made of flexible, shatter resistant plastic materials such as polycarbonate and poly(methylmethacrylate), and these also can be scratched or abraded.
Various coatings have been proposed for eyeglasses and other transparent plastic materials to reduce their propensity to become scratched and abraded. One such composition is shown in U.S. Pat. No. 4,378,250 (Treadway, et al.) granted Mar. 29, 1983. Other coatings are shown in U.S. Pat. No. 5,367,019 (Sawara), U.S. Pat. No. 4,855,180 (Kawamura), U.S. Pat. No. 4,895,767 (Mori et al.) and U.S. Pat. No. 4,719,146 (Hohage et al.) Besides being abrasion resistant, coatings for eyeglass lenses should also be capable of being tinted by treatment with a dye which becomes incorporated in the coating. As a general observation, the tintability of a coating tends to decrease as its hardness and scratch resistance increases, and vice-versa.
Harasta, et al. U.S. Pat. No. 4,426,431 discusses a coating composition referred to as a “hybrid ” system because it employs a solution, in a solvent such as propylene carbonate, of an epoxy compound and a cationic initiator for it, and an acrylic compound and a free radical initiator for it. In general, coating compositions suitable for use in forming protective transparent coatings on eyeglass lenses and the like are provided in solution in a volatile solvent, the solvent serving as a low viscosity vehicle to enable the coating composition to be uniformly spread upon a surface and to accept dye treatments. The solvents that are employed are for the most part organic, and must be used and disposed of carefully.
Perkins et al. U.S. Pat. No. 5,221,560 describes a coating composition containing a polyfunctional, polymerizable non-acrylate functional ether, a radiation-sensitive initiator, and colloidal silica in an amount providing at least 25% by weight of the total solids of the composition, the silica being reacted with a small amount of a hydrolyzed acryloxy-functional or glycidoxy-functional silane.
Treadway, PCT Publication WO 98/39390 describes a coating composition that is substantially free of volatiles and that employs a hydrolysis product of an epoxy-functional silane and also a polymerizable ether. The latter is said to impart tintability to cured coatings of the composition.
U.S. Pat. No. 5,866,262 (Galic et al.) teaches the use of fully hydrolyzed epoxy-functional and imine-functional alkoxysilanes in coating compositions for eyeglass lenses, whereas the previously mentioned U.S. Pat. No. 4,378,250 (Treadway, et al.) teaches that such hydrolysis of epoxy-and imine-functional alkoxysilanes may be less than stoichiometric.
Coating compositions of the type used to provide coatings on such substrates as polycarbonate eye glass lenses desirably are of low viscosity. Moreover, as noted earlier, they desirably are capable, upon curing, of forming surfaces that on the one hand are hard and scratch-resistant and on the other hand are tintable, that is, are capable of readily accepting tinting dyes.
SUMMARY OF THE INVENTION
The present invention provides coating compositions yielding cured coatings that exhibit excellent abrasion-resistance and that readily accept tinting dyes. The compositions preferably are of low viscosity and most preferably are substantially free of volatile solvents.
In one embodiment, a composition of the invention comprises the hydrolysis product of an epoxy-functional alkoxy silane, a curing agent therefor, an ethylenically unsaturated monomer and also an unhydrolyzed epoxy-functional alkoxy silane. The ethylenically unsaturated monomer component desirably comprises an acrylic monomer, preferably an acrylic monomer having an acrylic functionality of not more than two.
I have found that inclusion of an unhydrolyzed epoxy-functional alkoxy silane in the coating composition enables a substantial reduction in the viscosity of the composition to be achieved, without loss of abrasion resistance. Amounts of the unhydrolyzed silane sufficient to significantly reduce viscosity of the coating composition up to about 50% by weight, solids basis, are used.
It has also been found that the tintability of coatings derived from a composition comprising the hydrolysis product of an epoxy-functional alkoxy silane, a curing agent therefor and an ethylenically unsaturated monomer, can be substantially improved by incorporating in the composition a non-reactive polyether surfactant.
Hence, the invention in another embodiment relates to a coating composition comprising the hydrolysis product of an epoxy-functional alkoxy silane, a curing agent therefor, an ethylenically unsaturated monomer, and a non-reactive polyether surfactant in sufficient quantity to improve tintability of a cured coating made from the composition. Tintability is so improved by the addition of the polyether surfactant that the coating composition preferably is free of vinyl ethers and reactive non-silane epoxy ingredients. However, as required, the incorporation in the coating composition of non-silane glycidyl ethers may further improve tintability.
The coating compositions of the invention preferably include a cationic initiator such as a diaryl iodonium hexafluoroantimonate and a free radical initiator to initiate polymerization of the ethylenically unsaturated coating components. The composition may include one or more additional epoxy-functional compounds, acrylic monomers, and other ingredients, including colloids, although preferably the composition is free of silica and most preferably is substantially free of colloids.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In coating compositions of the invention, the epoxy functional alkoxy silane precursor of the at least partially hydrolyzed polymerizable ingredient is preferably an epoxyalkylalkoxysilane of the following structure:
Q—R 1 —Si(R 2 ) m —(OR 3 ) 3-m
wherein R 1 is a C 1 –C 14 alkylene group, R 2 and R 3 independently are C 1 –C 4 alkyl groups and Q is a glycidoxy or epoxycyclohexyl group, and m is 0 or 1. The alkoxy groups are at least partially hydrolyzed to form silanol groups with the release of the R 3 OH alcohol, and some condensation of the silanol groups occurs. Epoxy reactivity is preserved, however. Many epoxy-functional alkoxysilanes are suitable as hydrolysis precursors, including glycidoxymethyl-trimethoxysilane, glycidoxymethyltriethoxysilane, glycidoxymethyl-tripropoxysilane, glycidoxymethyl-tributoxysilane, β-glycidoxyethyltrimethoxysilane, β-glycidoxyethyltriethoxysilane, β-glycidoxyethyl-tripropoxysilane, β-glycidoxyethyl-tributoxysilane, β-glycidoxyethyltrimethoxysilane, α-glycidoxyethyl-triethoxysilane, α-glycidoxyethyl-tripropoxysilane, α-glycidoxyethyltributoxysilane, γ-glycidoxypropyl-trimethoxysilane, γ-glycidoxypropyl-triethoxysilane, γ-glycidoxypropyl-tripropoxysilane, γ-glycidoxypropyltributoxysilane, β-glycidoxypropyl-trimethoxysilane, β-glycidoxypropyl-triethoxysilane, β-glycidoxypropyl-tripropoxysilane, β-glycidoxypropyltributoxysilane, α-glycidoxypropyl-trimethoxysilane, α-glycidoxypropyl-triethoxysilane, α-glycidoxypropyl-tripropoxysilane, α-glycidoxypropyltributoxysilane, γ-glycidoxybutyl-trimethoxysilane, δ-glycidoxybutyl-triethoxysilane, δ-glycidoxybutyl-tripropoxysilane, δ-glycidoxybutyl-tributoxysilane, δ-glycidoxybutyl-trimethoxysilane, γ-glycidoxybutyl-triethoxysilane, γ-glycidoxybutyl-tripropoxysilane, γ-propoxybutyl-tributoxysilane, δ-glycidoxybutyl-trimethoxysilane, δ-glycidoxybutyl-triethoxysilane, δ-glycidoxybutyl-tripropoxysilane, α-glycidoxybutyl-trimethoxysilane, α-glycidoxybutyl-triethoxysilane, α-glycidoxybutyl-tripropoxysilane, α-glycidoxybutyl-tributoxysilane, (3,4-epoxycyclohexyl)-methyl-trimethoxysilane, (3,4-epoxycyclohexyl)methyl-triethoxysilane, (3,4-epoxycyclohexyl)methyl-tripropoxysilane, (3,4-epoxycyclohexyl)-methyl-tributoxysilane, (3,4-epoxycyclohexyl)ethyl-trimethoxysilane, (3,4-epoxycyclohexyl)ethyl-triethoxysilane, (3,4-epoxycyclohexyl)ethyl-tripropoxysilane, (3,4-epoxycyclohexyl)-ethyl-tributoxysilane, (3,4-epoxycyclohexyl)propyl-trimethoxysilane, (3,4-epoxycyclohexyl)propyl-triethoxysilane, (3,4-epoxycyclohexyl)propyl-tripropoxysilane, (3,4-epoxycyclohexyl)propyl-tributoxysilane, (3,4-epoxycyclohexyl)butyl-trimethoxysilane, (3,4-epoxycyclohexyl) butyl-triethoxysilane, (3,4-epoxycyclohexyl)-butyl-tripropoxysilane, and (3,4-epoxycyclohexyl)butyl-tributoxysilane.
A particularly preferred epoxyalkylalkoxysilane is γ-glicidoxypropyl trimethoxy silane due to its wide commercial availability.
Hydrolysis of the epoxy-functional alkoxysilane precursor may occur in an acidic environment, and reference is made to U.S. Pat. No. 4,378,250, the teachings of which are incorporated herein by reference. Hydrolysis of the alkoxy groups liberates the associated alcohol (which may be stripped off) to form silanol groups; these, in turn, are relatively unstable and tend to condense spontaneously. Hydrolysis of the alkoxysilane may but need not be complete, and preferably, the alkoxysilane is reacted with a stoichiometricly sufficient quantity of water to hydrolyze at least 50% of the alkoxy groups and most preferably from about 60% to about 70% of the alkoxy groups. For the hydrolysis of an epoxy-functional trialkoxy silane, good results have been obtained by reacting the silane with a stoichiometricly sufficient quantity of water to hydrolyze two-thirds of the alkoxy groups.
The at least partially hydrolyzed epoxy-functional silane is present in the coating compositions of the invention at a weight concentration (solids basis) of about 10% to about 75%, and preferably about 20% to about 50%.
In addition to the partially or fully hydrolyzed epoxy-functional alkoxy silane, as noted above, the composition desirably includes an effective amount up to about 50% by weight, solids basis, of a non-hydrolyzed, and suitable epoxy-functional alkoxy silanes include the silanes listed above. The non-hydrolyzed epoxy-functional alkoxy silane desirably is present in an amount not less than about 10%, preferably at least about 20%, and most preferably from about 40% to about 50% by weight, solids basis. Preferably, the epoxy-functional alkoxy silane that is included as the non-hydrolyzed component also is employed to make the hydrolyzed component. It should be understood that the hydrolyzed and non-hydrolyzed components may be different and each may utilize one or a blend of different epoxy-functional alkoxy silanes, as desired.
Useful cationic initiators for the purposes of this invention include the aromatic onium salts, including salts of Group Va elements, such as phosphonium salts, e.g., triphenyl phenacylphosphonium hexafluorophosphate, salts of Group VIa elements, such as sulfonium salts, e.g., triphenylsulfonium tetrafluoroborate, triphenylsulfonium hexafluorophosphate and triphenylsulfonium hexafluoroantimonate, and salts of Group VIIa elements, such as iodonium salts such as diphenyliodonium chloride and diaryl iodonium hexafluoroantimonate, the latter being preferred. The aromatic onium salts and their use as cationic initiators in the polymerization of epoxy compounds are described in detail in U.S. Pat. No. 4,058,401, “Photocurable Compositions Containing Group VIA Aromatic Onium Salts,” by J. V. Crivello issued Nov. 15, 1977; U.S. Pat. No. 4,069,055, “Photocurable Epoxy Compositions Containing Group VA Onium Salts,” by J. V. Crivello issued Jan. 17, 1978, U.S. Pat. No. 4,101,513, “Catalyst For Condensation Of Hydrolyzable Silanes And Storage Stable Compositions Thereof,” by F. J. Fox et al. issued Jul. 18, 1978; and U.S. Pat. No. 4,161,478, “Photoinitiators,” by J. V. Crivello issued Jul. 17, 1979, the disclosures of which are incorporated herein by reference.
Other cationic initiators can also be used in addition to those referred to above; for example, the phenyldiazonium hexafluorophosphates containing alkoxy or benzyloxy radicals as substituents on the phenyl radical as described in U.S. Pat. No. 4,000,115, “Photopolymerization Of Epoxides,” by Sanford S. Jacobs issued Dec. 28, 1976, the disclosure of which is incorporated herein by reference. Preferred cationic initiators for use in the compositions of this invention are the salts of Group VIa elements and especially the sulfonium salts, and also the Group VIIa elements, particularly the diaryl iodonium hexaflurorantimonates. Particular cationic catalysts include diphenyl iodonium salts of tetrafluoro borate, hexafluoro phosphate, hexafluoro arsenate, and hexafluoro antimonate; and triphenyl sulfonium salts of tetrafluoroborate, hexafluoro phosphate, hexafluoro arsenate, and hexafluoro antimonate.
A wide variety of ethylenically unsaturated monomers (including oligomers) can be employed in the coating composition of the invention, and acrylic monomers and oligomers, particularly those having acrylic functionalities of not greater than two, are preferred. Useful acrylic compounds for improving adhesion to polycarbonate substrates include both mono and di-functional monomers, but other or additional polyfunctional acrylic monomers may also be included.
Examples of monofunctional acrylic monomers include acrylic and methacrylic esters such as ethyl acrylate, butyl acrylate, 2-hydroxypropyl acrylate, cyclohexyl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate, and the like. Examples of polyfunctional acrylic monomers, including both difunctional and tri and tetrafunctional monomers, include neopentylglycol diacrylate, pentaerythritol triacrylate, 1,6-hexanediol diacrylate, trimethylolpropane triacrylate, tetraethylene glycol diacrylate, 1,3-butylene glycol diacrylate, trimethylolpropane trimethacrylate, 1,3-butylene glycol dimethacrylate, ethylene glycol dimethacrylate, pentaerythritol tetraacrylate, tetraethylene glycol dimethacrylate, 1,6-hexanediol dimethacrylate, ethylene glycol diacrylate, diethylene glycol diacrylate, glycerol diacrylate, glycerol triacrylate, 1,3-propanediol diacrylate, 1,3-propanediol dimethacrylate, 1,2,4-butanetriol trimethacrylate, 1,4-cyclohexanediol diacrylate, 1,4-cyclohexanediol dimethacrylate, pentaerythritol diacrylate, 1,5-pentanediol dimethacrylate, and the like. The acrylic-functional monomers and oligomers desirably are employed at a weight concentration of at least about 10% by weight, preferably from about 10% to about 50%, and most preferably from about 10% to about 25%, all on a solids basis.
As initiators for the ethylenically unsaturated monomers, photoactivated free-radical initiator are preferred, although thermally activated free radical initiators may also be used. Useful photoinitiators for this purpose are the haloalkylated aromatic ketones, chloromethylbenzophenones, certain benzoin ethers, certain acetophenone derivatives such as diethoxyacetophenone and 2-hydroxy-2-methyl-1-phenylpropan-1-one. A preferred class of free-radical photoinitiators is the benzil ketals, which produce rapid cures. A preferred photoinitiator is α,α-dimethoxy-α-phenyl acetophenone (Iragacure™ 651, Ciba-Geigy, disclosed in U.S. Pat. Nos. 3,715,293 and 3,801,329). The most preferred photoinitiator, in accordance with this invention, is 2-hydroxy-2-methyl-1-phenylpropane-1-one (Darocure™ 1173, Ciba-Geigy Corporation). Specific examples of photoinitiators include ethyl benzoin ether, isopropyl benzoin ether, dimethoxyphenyl acetophenone, diethoxy acetophenone, and benzophenone.
In a preferred embodiment, the coating composition is substantially free of volatile solvents and also preferably is free of silica and free of other colloids.
The surfactants useful in the present invention to promote tintability are non-reactive polyethers, and may be water soluble, water dispersible or water insoluble. As used here, “non-reactive” means that the polyether does not significantly participate in the curing reaction involving the epoxy-functional alkoxy silane or the ethylenically unsaturated monomers. A variety of non-reactive polyethers can be employed, including the various poly(alkylene glycol) and poly(alkylene oxide) surfactants, and are chosen for their ability to significantly improve tintability. Preferred polyethers include polyalkylene oxide modified polymers such as polyalkylene oxide modified siloxanes (including polyalkylene oxide modified dimethylsiloxanes and polyalkylene oxide modified heptamethylsiloxanes), the alkoxy polyalkylene oxyethanols, and the substituted polyglycols such as nonylphenol polyethylene glycol. The polyalkylene oxide modified siloxanes may be in liquid or solid form.
Polyalkylene oxide modified polydimethylsiloxanes, as an example, may have the formula:
Me 3 SiO(Me 2 SiO) x [MeSi(PE)O] y SiMe 3
where Me is methyl and PE is —(CH 2 ) 3 O(EO) m (PO) n Z. Here, These surfactants are referred to as “AP” (alkyl-pendant) types. Other polyalkylene oxide modified siloxanes may have the general formula (MeSi) y-2 [(OSiMe 2 ) x/y O—PE] y , where PE is -(EO) m (PO) n R, R being lower alkyl. The latter surfactants are referred to as the “AEB” (alkoxy endblocked) typeIn these general formulas, EO represents ethyleneoxy, PO represents 1,2-propyleneoxy, Z is H or lower alkyl, and x, y, m and n can vary as desired.
A series of polyalkylene oxide modified siloxane surfactants as thus described are available from Witco Corporation under its registered trademark SILWET. Alkoxypolyalkylene oxyethanols, and the substituted polyglycols such as nonylphenol polyethylene glycol, are generally available from Union Carbide Corporation under its registered trademark TERGITOL.
The amount of surfactant to be used in a coating composition is the amount which provides the desired tintability to cured coatings derived from the composition, and this amount may range from a minimum amount—usually a percent or two by weight—that provides noticeable improvement in tintability up to about 10% by weight or more. Amounts of surfactant in the range of about 1% to about 10% by weight of the composition are usually appropriate, and surfactant concentrations of about 4% have given good results.
The invention may be more readily understood by reference to the following illustrative, non-limiting examples. In these examples, tintability is measured as follows: A coated and cured sample is immersed in BPI Black Dye (1% Transmission, Brain Power Inc.) at 95° C.–100° C. for 15 minutes and then rinsed with water and dried. The transmissivity T of the sample is measured spectrophotometrically, and tintability is reported as percentage transmissivity. Resistance to abrasion may be measured by abrading the coated surface of a transparent substrate under predetermined conditions and measuring the haze that is formed as a reduction in light transmissivity. One such testing apparatus is referred to as a Taber Abrader, a product of Byk-Gardner. Abrasion resistance testing with this equipment may be performed in accordance with ASTM D 1044-78. The particular equipment employed for testing coatings referred to below involved a model 5130 Taber abrader equipped with a CS10 abrasive wheel weighted at 500 grams.
EXAMPLE 1
Preparation of Epoxy Base Compositions
Epoxy base #1: A partially hydrolyzed epoxy-functional alkoxysilane is prepared by combining 236 g. of γ-glycidoxypropyltrimethoxysilane, 36 g of water and 0.5 ml of a 1% HCl solution and mixing for 16–20 hours. The resulting product is stripped of volatiles under vacuum.
Epoxy base #2: A second partially hydrolyzed epoxy-functional alkoxysilane is prepared by combining 246 g of epoxy cyclohexylethyltrimethoxysilane, 18 g of water, 20 g of ethanol and 0.2 g of an acidic functional ion exchange resin (CT 275, Purolite Corp.). The mixture is stirred at room temperature for 36–40 hours, and then is stripped of volatiles under vacuum.
EXAMPLE 2
Two coating compositions, labeled A and B, were prepared by blending together the following ingredients, amounts being given in grams. The viscosity of the compositions were measured and compositions were coated on polycarbonate lenses and UV cured using a medium pressure mercury bulb, 250 watts/inch. The coated lenses were subjected to the Taber Abrasion test described above.
Ingredient
A
B
Butane diol diacrylate
8.0
8.0
Cyclohexane dimethanol divinylether
2.0
2.0
Trimethylolpropane triglycidyl ether
7.5
7.5
Epoxy base #1
9.5
5.5
γ-glycidoxypropyltrimethoxysilane (not
0.0
5.0
hydrolyzed)
Triarylsulfonium hexafluorphosphate
0.64
0.66
(Cyracure 6990, Union Carbide)
Triarylsulfonium hexafluoroantimonate
0.64
0.64
(Cyracure 6974, Union Carbide)
2-hydroxy-2-methyl-1-phenyl propan-1-one
0.8
0.8
(Darocure1173, Ciba-Geigy Corporation)
Ebecryl 350 (silicone flow control agent,
0.4
0.4
UCB Chemicals Corp.),
Viscosity, cps
32
11
Taber abrasion, % haze, 200 cycles
11.3–11.6
11.3–11.4
Note should be made that the viscosity of Composition B was approximately one-third the viscosity of comparative Composition A
EXAMPLE 3
Three coating compositions, labeled C, D and E, were prepared by blending together the following ingredients, amounts being given in grams. The viscosity of the compositions were measured and compositions were coated, cured and tested as in Example 2.
Ingredient
C
D
E
Epoxy base #1
7.6
7.6
7.6
Hexane diol diacrylate
6.4
5.2
6.4
Cyclohexane dimethanol divinylether
1.6
1.6
1.6
Epoxy cyclohexylethyl trimethoxy silane
6.0
2.0
4.0
(unhydrolyzed)
Epoxy base #2
0.0
4.0
2.0
1/1 mix of benzophenone and 1-hydroxy
0.6
0.5
0.6
cyclohexylphenyl ketone
Mixed Triarylsulfonium Hexafluoroantimonate
1.2
1.2
1.2
salts, 50% in Propylene Carbonate
(UVI 6974, Union Carbide)
Ebecryl 350
0.2
0.2
0.2
Viscosity, cps
12.0
26
22
Taber abrasion, 200 cycles, % haze
9.8
9.4
9.6
EXAMPLE 4
A base composition was prepared by blending the following ingredients, amounts being given in grams:
Glycidoxypropyltrimethoxysilane, partially hydrolyzed as in 36 Example 1 Glycidoxypropyltrimethoxysilane, unhydrolyzed 50 Hexane diol diacrylate 15 Pentaerythritol triacrylate 5.0 1/1 mix of benzophenone and 1-hydroxy 1.8 cyclohexylphenyl ketone Diaryliodonium hexafluorophosphate (CD 1012, Sartomer Corp) 4.0
The resulting base composition was divided into 10 g aliquots, and to each aliquot was added 0.4 g of one of the surfactants listed below, and the compositions were spin-coated on polycarbonate lenses and cured under UV light to form coating thicknesses in the range of 8 to 10 microns. The tintability of each lens was measured as described above.
Surfactant
Water Solubility
Tintability (% T)
SILWET L-77 (polyalkylene oxide-modified
Dispersible
27.7
heptamethyltrisiloxane, 700 mol. wt., AP type)
SILWET L-722 (polyalkylene oxide-modified
Insoluble
26.2
dimethylsiloxane, 3000 mol. wt., AEB type)
SILWET L-7001 (polyalkylene oxide-modified
Partially soluble
26.2
dimethylsiloxane, 20,000 mol. wt., AP type)
SILWET L-7500 (polyalkylene oxide-modified
Partially soluble
35.4
dimethylsiloxane, 3,000 mol. wt., AP type)
SILWET L-7604 (polyalkylene oxide-modified
Soluble
26.4
dimethylsiloxane, 4,000 mol. wt., AP type)
SILWET L-7607 (polyalkylene oxide-modified
Soluble
27.7
dimethylsiloxane, 1,000 mol. wt., AP type)
SILWET L-7607 (polyalkylene oxide-modified
Insoluble
29.4
dimethylsiloxane, 10,000 mol. wt., AP type)
TERGITOL S-3 (alkyloxypolyethyleneoxyethanol,
Insoluble
26.4
mol. wt. 332)
TERGITOL S-5 (alkyloxypolyethyleneoxyethanol,
Dispersible
28.4
mol. wt. 420)
TERGITOL S-7 (alkyloxypolyethyleneoxyethanol,
Soluble
29.0
mol. wt. 508)
TERGITOL NP-4 (nonylphenol polyethylene glycol
Insoluble
27.0
ether, mol. wt. 396)
TERGITOL NP-6 (nonylphenol polyethylene glycol
Dispersible
33.5
ether, mol. wt. 484)
TERGITOL NP-6 (nonylphenol polyethylene glycol
Dispersible
27.9
ether, mol. wt. 528)
TERGITOL NP-15 (nonylphenol polyethylene glycol
Soluble
27.3
ether, mol. wt. 880)
While preferred embodiments of the invention have been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention or the scope of the appended claims. | A coating composition based upon at least partially hydrolyzed epoxy-functional alkoxy silanes and having particular utility in forming tintable, abrasion resistant coatings on lenses. Incorporation in the composition of a non-hydrolyzed epoxy-functional alkoxy silane provides a desired reduction in viscosity. Incorporation in the composition of a polyether surfactant provides a cured coating of the composition with increased tintability. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to illumination apparatus, and particularly to an arrangement of light reflectors for efficiently using light emitted from a single light source to uniformly illuminate an original. The present apparatus is particularly useful in illuminating originals in a photographic printer, although the apparatus is equally adapted for use with other types of copiers, e.g., electrographic copiers.
2. Description Relative to the Prior Art
Apparatus for illuminating an original generally falls into two categories, each adapted to achieve the same result by a different engineering approach. One approach involves illuminating a slit through which the original is line-imaged by an optical system upon a photosensitive surface. Either the original moves past the illuminated slit or the slit moves over a stationary original to achieve the same result. In both cases the image is built up line by line on the photosensitive surface. The other approach involves illuminating an entire copy plane in which the original is positioned. The latter approach requires at least a momentary phase in the copy cycle when all parts of the original may be simultaneously imaged on the photosensitive surface, i.e., the image of the document is at least momentarily stationary with respect to the photosensitive surface. For example, a short exposure of the original effectively "freezes" motion with respect to a moving photosensitive belt.
Exemplary of the first approach is U.S. Pat. No. 3,982,116 which describes a single light source and an arrangement of mirrors for reflecting light through a slit defined transversely to a copy platen. The mirrors surrounding the light source are designed to converge light rays to a line focus beyond the slit. By placing an original on the platen, and moving the platen relative to the slit, the converging light rays scan the surface of the original.
The second approach is illustrated by copy machines described in each of U.S. Pat. Nos. 3,586,849 and 3,777,135. In each machine, an original is placed upon a transparent support platen mounted relative to an illumination lamp assembly. In order to provide homogeneous illumination, four lamps are orthogonally spaced around each edge of the original. By means of reflectors with compound surfaces (i.e., both planar and curved surfaces), light rays emitted from each lamp are reflected upon the surface of the original such that they overlap and complement rays from the opposing lamp. The light rays reflected from the surface of the original produce image light corresponding to the informational areas on the original. The image light traverses an optical system and exposes the photosensitive surface of a flexible photoconductive belt arranged on a belt assembly.
The application served by these conventional approaches involves substantially opaque material situated in a copier such that light reflects from the opaque surface to a photosensitive surface. Unlike a transparency, which may be illuminated from a light source substantially on the optical axis of the copier, the light source for reflection copying is offset from the optical axis; otherwise the illumination source would block the image from reaching the photosensitive surface. In practice, because uniform illumination is required, it is common to use several light sources. Each source is spaced from one side of the opaque original.
Illumination of an original using a plurality of light sources is a satisfactory approach in some applications. However, in other applications this approach has significant limitations. For example, in a photographic printer where an image is projected from a color print to photosensitive color paper, the spectral characteristics of each lamp must be considered in arriving at proper exposure times and color filtration for a given paper. Not only do many lamps differ initially in spectral distribution, but lamp aging causes the distribution for each lamp to change at an individual rate.
The potential for unwanted color variability therefore increases as the number of light sources increase. Matching the lamps with proper filters to maintain a proper spectral distribution is difficult at best. To worsen matters, the burden is thrown upon the photofinisher rather than the manufacturer. Each light source would require its own set of color filters to control the spectral characteristic of light from that source. The mere number of components that must therefore be matched becomes unmanageable.
U.S. patent application Ser. No. 930,287 in the names of A. M. Boone, J. F. Bloemendaal and A. R. Zanolli, filed concurrently with and assigned to the same assignee as the present application, describes illumination apparatus which effectively reduces the aforementioned problems by providing uniform illumination of an original with a single flash lamp. A pair of parabolic reflectors partially surround the lamp and direct two separate collimated bundles of light toward opposite sides of the original. A planar reflector positioned in the path of each collimated bundle of light intercepts and reflects the collimated light rays upon the original to uniformly illuminate the original from opposite sides.
One problem with illumination apparatus such as described in the copending application Ser. No. 930,287 is that some light emanating directly from the lamp may strike the original without reflecting from any of the reflectors in the system. This condition interferes with uniform illumination of the original and, with certain types of originals, causes specular reflections through the optical system to the photosensitive paper. These reflections show up as blotches on the copy print.
Consequently, the illumination apparatus described in the copending application also included a light baffle positioned between the light source and the original to substantially prevent light rays from passing directly between the source and the original. While the baffle provides the effect desired, a portion of the light energy generated by the lamp is thereby lost to the system.
SUMMARY OF THE INVENTION
The present invention provides apparatus for use in an illumination system for intercepting the otherwise harmful direct rays and diverting them for useful purposes within the system. The potentially harmful rays are generated by an elongated light source positioned in spaced relationship with an object to be illuminated. Light deflector means are positioned between the light source and the object in the path of light rays emanating from the source and directly verging on the object for reflecting the direct rays along a predetermined path. Reflecting means are positioned in the predetermined path in spaced relationship with the object for reflecting the deflected direct rays upon the object, where they contribute with other rays in the illumination system to illuminate the object.
The light deflector means may take the form of a plurality of elongate planar reflecting surfaces juxtaposed in the path of the direct light rays. Each of the juxtaposed surfaces reflects a portion of the direct rays toward the reflecting means.
In the disclosed embodiment, the light deflector is described for use in a photographic printer where the primary illuminating rays are collimated by two elongated parabolic reflecting surfaces positioned on opposite sides of the light source. The illuminating rays emerge as two collimated bundles that are incident upon a pair of planar mirrors on opposite sides of the object. From there the bundles reflect upon and uniformly illuminate the object. Direct rays strike a plurality of elongate planar reflective louvers juxtaposed in their path and reflect to one of the planar mirrors. From there the deflected direct rays reflect upon and contribute to illumination of the object.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention will be described with reference to the figures, wherein:
FIG. 1 is a schematic plan view of the elements of an illumination apparatus as disclosed in copending patent application Ser. No. 930,287:
FIG. 2 is a schematic plan view of a presently preferred embodiment of the invention; and
FIG. 3 is a top elevation taken in perspective to emphasize structural features of the disclosed embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Because illumination apparatus in general are well known, as are photographic and other copying machines, the present description will be directed in particular to elements forming part of, or cooperating more directly with, the present invention. Elements not specifically shown or described may take various forms well known to those skilled in the art.
Referring particularly to FIG. 1, an illumination apparatus is illustrated as substantially described in copending U.S. patent application Ser. No. 930,287, filed Aug. 2, 1978. Portions of that apparatus will be described herein as needed to facilitate an understanding of the present invention. However, the entire application Ser. No. 930,287 is understood to be hereby incorporated into this disclosure by reference. In FIG. 1, the illumination apparatus is illustrated as a component in a copy machine. For purposes of illustration, the copy machine is embodied as a photographic printer for producing copies of photographic prints. As original to be reproduced, such as a planar, rectangular print P, is positioned on a transparent copy platen 2 for casting an image on a photosensitive material 3 through a focusing lens 4. The print P is placed on the copy platen 2, as for example, by hand or by suitable transport apparatus (not shown). Being an opaque copy, the print P is imaged in the printer by means of reflected light. As shown, the reflected light generally follows an optical axis 5 of the printer. Therefore, it is desirable that the illumination apparatus not obstruct reflected light passing along the optical axis 5.
The focusing lens 4 can be of any known design which will produce a sharp image on the photosensitive material 3. As shown in phantom the photosensitive material 3 may be a continuous web of photographic paper transported between a supply reel 6 and a take-up reel 7. The reel may be rotated to advance the paper incrementally in conjunction with the placement, and repeated exposure, of prints on the copy platen 2. Apparatus for producing such cyclical and interlocked motion are well known in the art of copiers generally, and, more particularly in the art of photographic printing. After the entire roll of paper is exposed, the latent images are processed in the usual manner and the individual prints are separated for return to the customer.
The illumination apparatus includes a lamphouse 8 having an elongated light source 9 partially surrounded by two elongated half-parabolic reflectors 10 and 11. The light source preferably comprises a small diameter elongated tubular element, such as for example a Xenon-arc tubular lamp, which is electrically connected to a suitable power source (not shown). The light source is positioned in a suitable support, such as the support 26 illustrated in FIG. 3. Because, as earlier mentioned, the optical axis 5 of the printer optical system must not be obstructed, the lamphouse 8 is canted to one side of the axis 5, as best illustrated in FIG. 1.
A pair of planar reflectors 12 and 13 are provided adjoining the copy platen 2 for diverting light from the lamphouse 8 to the copy platen 2. Being transparent, the platen 2 permits light to substantially transmit through and illuminate the print P. Each mirror 12 and 13 is aluminum coated so that absorption and dispersion is minimized to produce high efficiency diversion of the impinging light rays. The mirrors 12 and 13 are mounted on supporting members 14 and 15, respectively. Each support 14 and 15 is positioned with respect to the copy platen 2 so that at least the area bounded by the print P is fully illuminated by light reflected from each of the mirrors 12 and 13. The amount of inclination of the mirror 12 with respect to the copy platen 2 is a function of the angle of reflection of impinging light rays upon the mirror 12. Similarly the inclination of the mirror 13 depends on the angle of the rays impinging upon it.
The half parabolic reflectors 10 and 11 represent sections of separate parabolic volumes. The parabolic reflectors are so positioned that their focus axes coincide. Since the parabolic surfaces are cylindrical in their lengthwise direction the principal focus is also linear. The light source 9 is placed substantially at the principal focus line of both reflectors. Therefore the length of the source 9 is closely aligned with the linear focus of the half parabolic segments 10 and 11. As is well known, light rays which emanate from a point source at the focus of a parabolic mirror are collimated, i.e., parallel, after they reflect from its source. The light source 9, being nominally at the focus of each of the parabolic mirrors 10 and 11, emits light rays which reflect from each mirror as two separate bundles of substantially parallel rays. The separation of light rays into two bundles is thus effected by the use of two half-parabolic reflectors positioned to have a common focus line. Since the reflectors 10 and 11 are separate, a gap--denoted by reference character 16 is formed between reflectors 10 and 11.
It was found that certain angles of incidence of the light rays caused deleterious effects in the photographic image on the photosensitive material 3. For example, if the angle of light incidence relative to the optical axis 5--as indicated by a reference character 21--is less than about 65°, specular reflection may occur from the surface of the print P and light rays will reflect directly into the optical system through the lens 4 and onto the photosensitive material 3. This effect is particularly pronounced if the print P has a strongly textured surface. These reflections will show up as unwanted bright blotches on the finished copy print. Consequently, the illumination apparatus is designed to bring light rays onto the copy platen 2 at an angle of at least 65°. This angle, and any greater angle, was found to prevent the unwanted specular reflection. Lesser angles increase specular reflection in the case of textured prints; however, such angles may be acceptable if non-textured prints are being illuminated.
Some of the light rays emanate directly from the light source 9 without striking the parabolic reflectors 10 or 11. A portion of these rays strike the planar reflectors 12 or 13 and, because of their angle of incidence, either reflect out of the illumination apparatus or contribute to the illumination of the print P. Those rays illuminating the print P are few compared to the collimated rays and are effectly swamped by the latter so that uniform illumination remains unaffected. Furthermore, the angle at which these rays impinge on the print P is at least 65° relative to the optical axis 5 so that the aforementioned specular reflection is not a problem. However, another portion of these direct light rays verge directly upon the copy platen 2--and therefore the print P--without reflecting from any surface. These rays--shown as a bundle C in FIG. 1--will impinge at an angle substantially less than 65° and therefore cause serious specular reflection from a print P that is strongly textured. For that reason, in copending application Ser. No. 930,287, a light baffle 17 is positioned to block this portion of direct rays from directly striking the copy platen 2.
The direct rays striking the light baffle 17 are either absorbed or reflected harmlessly. Although avoiding the specular reflection problem, such absorption and dispersion of potentially useful light energy decreases the light efficiency of the illumination apparatus. In improving upon the illumination apparatus described in the copending application Ser. No. 930,287, FIG. 2 illustrates a presently preferred embodiment of a modification to the light baffle 17, showing only those rays in the bundle C illustrated in FIG. 1. A light deflector 22 is positioned substantially in place of the light baffle 17, preventing direct impingement of rays on the copy platen 2 while using the intercepted light energy in the system.
The light deflector 22 is composed of a group of elongate, planar, reflective louvers, referred to as deflectors 23A to 23E, that are juxtaposed in the path of light rays radiating from the light source 9 directly toward the print P. Each deflector 23A to 23E has a highly reflective surface facing the light source 9 disposed to efficiently reflect incident light rays. The leading edge (edge closest to the light source 9) of each deflector 23--such as the leading edge 24A of the deflector 23A--is positioned overlapping, or at least substantially in line, with the trailing edge of the adjacent deflector--such as the trailing edge 25B of the deflector 23B. Light rays emanating directly from the source therefore do not pass between the deflectors 23 without striking one of the reflecting surfaces and are thereby prevented from directly striking the copy platen 2. Instead, the light rays are reflected from each reflector 23 to the planar reflector 13, and from there upon the copy platen 2. Importantly, these light rays are directed upon the copy platen 2 at an angle of incidence comparable to that of the collimated bundles of light rays A and B. Therefore, the direct light rays from the source 9 are being used to illuminate the print P without having such an angle of incidence as to cause specular reflection.
Referring now to FIG. 3, the preferred embodiment is illustrated in perspective form. There it is seen that the light deflector 22 is attached to the copy platen 2 by means of a pair of brackets 18 and 19. Each bracket 18 and 19 supports individual deflectors 23 at their respective ends in a spaced relationship best described as analogous to a louver or "venetian blind" shutter. The proper orientation of each reflector 23 can be ascertained by routine manipulation within the capability of those of ordinary skill in this art. In practice an optimum orientation can be selected, and the reflectors 23 are then manufactured in place rather than being adjustable by the user.
The operation of the illumination apparatus can best be described in terms of the light ray pattern illustrated in FIGS. 1 and 2. The bundle A of light rays reflect from the parabolic mirror 11 to the planar reflector 13. From there the rays reflect back across the copy platen 2 and illuminate the print P. The bundle B of light rays reflect from the parabolic mirror 10 to the planar reflector 12. From there the rays reflect back across the copy platen 2 and also illuminate the print P. It will be noted that the light rays in each bundle remain substantially parallel after each reflection. Therefore, light intensity per unit area due to impinging rays from bundles A and B is substantially constant across the length and width of the print P. Furthermore, the intensity pattern of each bundle A and B of light rays substantially complement each other on the face of the copy platen 2--and therefore on the face of print P--making the illumination on the print substantially uniform.
The bundle C of light rays also emanates from the light source 9 and directly bears toward the print P without striking any of the reflectors 10, 11, 12, or 13. These rays instead encounter the louvered reflective surfaces of the deflector 22. Analogous to an ordinary venetian blind that is closed to block direct rays of the sun, the light rays in the bundle C cannot freely pass the deflector 22. Instead, the rays strike the surfaces of the deflectors 23A through E and reflect to the mirror 13. From there the rays reflect back across the copy platen 2 and contribute to illumination of print P. In so doing, the incident angle of the rays in the bundle C have been modified to exceed the critical angle causing specular reflection upon the photosensitive material 3. Thus, a greater amount of light energy than is possible in FIG. 1 is used to illuminate the print P and efficiency is accordingly increased. All this is accomplished without deleterious effect to the image of the print P on the photosensitive material 3.
Also it will be apparent that the disclosed apparatus can be used with various types of originals other than prints, e.g., positive or negative transparencies. Ordinary plain paper originals may be illuminated by this apparatus. While the disclosed illumination apparatus has been described with reference to a photographic printer, it will be apparent to those skilled in the art that it is not limited to this specific application. For example, in FIG. 1 the photosensitive surface 3 could equally well be the photoconductive surface of an electrographic belt assembly. After exposure to the copy original 1, the belt 3 could be advanced through conventional electrographic processing stations, e.g., toning and developing, image transfer, cleaning, charging, etc.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | Light deflection apparatus is provided for use with apparatus for uniformly illuminating a planar original in which light rays emanating from a flash lamp are blocked from directly striking the original. The deflection apparatus includes a plurality of elongated reflective louvers juxtaposed in the path of direct light rays to deflect the rays along a predetermined path. A planar reflector positioned adjacent the original in the path intercepts and reflects the light rays upon and illuminates the original. | 6 |
This is a continuation of application Ser. No. 112,457 filed Oct. 26, 1987 now abandoned.
BACKGROUND OF THE INVENTION
This invention concerns in-ground swimming pools and particular methods of construction.
There are many methods for constructing in-ground pools, just as there are many types of pools themselves. Pools can be constructed of poured-in-place concrete, sprayed concrete, gunite or other such materials, or even of block and mortar. The walls and bottom of the pool are constructed to be water-tight or are lined with a water impervious liner. In terms of durability, a liner is not preferred. The methods of constructing water-tight, non-lined pools vary in difficulty and expense. For example, poured-in-place concrete pools require labor-intensive careful construction of the forms. Uncontrollable factors such as high ground water or untimely rainstorms can cause problems. The sprayed concrete or gunite methods expose workers to the dangers of using the spray gun, require large amounts of material and result in a weaker construction.
Another method of pool construction involves the use of pre-formed sectional panels to form the walls and/or bottom of the pool. This method has a number of advantages. The required excavations can be dug closer to the actual pool dimensions, as the panels are pre-formed and then placed in position. Pre-forming the panels allows mass production and the panels can be formed when weather conditions are optimum at the site or formed at other locations and transported to the site. Curing time for concrete panels is usually less than curing time for poured-in-place walls. Defective panels can be discarded and replaced without affecting the integrity of the entire pool.
The technique of using pre-formed sectional panels in pool construction is well-known. For example, Eichelman et al., in U.S. Pat. No. 1,908,332, teach the use of such panels. The panels are joined laterally by pouring concrete into vertical channels. Bennett, Jr., in U.S. Pat. No. 2,954,645, teaches pre-formed, reinforced panels which are joined to each other by bolts extending through flanges incorporated into each panel. Posnick, in U.S. Pat. No. 3,739,539, teaches the use of thermoplastic panels joined by a solvent weld formed in a removable clamp, followed by poured concrete.
The method of this invention, as well as the sectional panels themselves and the completed pool, are similar to the examples stated above. The invention is novel and distinct in the particular construction of the sectional panels and the method of joining these panels. The construction of the panels enables them to be joined by a simple metal welding operation, an improvement over the usual joining methods which require solvent or concrete to cure before construction of the pool can continue. In addition, no bolts or flanges are exposed to the damaging effects of corrosion, and the stresses between panels are evenly spread along the entire joint rather than focused at particular points. Construction is simplified since the method does not require exacting tolerances for fit and is readily adaptable to variation in shape, size or contour of the desired pool.
BRIEF SUMMARY OF INVENTION
The subject invention involves a method of pool construction comprising the use of specially constructed concrete sectional panels which are welded at the side joints to form a strong, solid, unitary wall. The invention also consists of the uniquely constructed concrete panels themselves and the pool made using such panels under this method. The concrete panels are formed of poured concrete and have reinforcing members running horizontally and vertically. Both lateral ends of the concrete panels culminate in a metal piece formed such that two panels can be placed adjacent, end-to-end, and then welded together along the contacting region of the two metal pieces. The reinforcing members are specially configured to prevent separation or twisting of the end metal pieces away from the concrete portion of the panel. The vertical reinforcing members extend a distance beyond the panel on both the top and bottom, enabling the panel to be interconnected with the pool bottom itself and the horizontal decking surface during final construction of the complete pool structure. The invention is such that pools of any size and shape can be constructed using the method and articles described, including curved or free-form pools.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view from above of the assembled form for receiving concrete to create a sectional panel, illustrating the placement of the angle irons, wooden pieces and reinforcing members.
FIG. 2 is a view of one corner of the assembled form for receiving concrete to create a sectional panel, illustrating the positioning of the reinforcing members.
FIG. 3 is a view of the rear or exterior side of completed sectional panels which have been welded together.
FIG. 4 is a view of the front or interior side of completed sectional panels which have been welded together, showing the vertical reinforcing members bent to accommodate incorporation into the deck and pool bottom.
DETAILED DESCRIPTION OF THE INVENTION
In-ground pool construction using pre-formed sectional panels begins with excavation of a hole slightly larger in area than required for the finished pool, especially along the sides of the pool, to provide room for access to the pool wall sections during assembly. In general, a sectional pool is constructed by excavating the hole, pre-forming the sectional panels for the side wall, assembling the side wall panels into a unitary assemblage, forming the pool bottom to integrally connect with the side wall assemblage, forming the decking portion to integrally connect with the side wall assemblage, and then performing a variety of finishing steps to insure non-leakage and provide a pleasing interior on the surface of the pool.
The invention will be described in terms of flat, rectangular panels, three feet in height, eight feet in length and approximately three and five-eighths inches in thickness, used in the construction of rectangular pools having planar walls, but it is to be expressly understood that the invention can be embodied in any pre-formed panel of differing dimensions and shape necessary to create a sectional pool of curved or free-form shape as well.
The sectional wall-panels are constructed of concrete, reinforcing members and metal end pieces. With reference to FIG. 1, the reinforcing members are reinforcing rods 10 extending both horizontally and vertically within the panel. The reinforcing rods 10 can be of the common steel type, three-eighths inch in diameter, rod-shaped and capable of being bent in a jig to shape. For a finished panel size of three feet vertical and eight feet lengthwise, seven five-foot reinforcing rods are cut to be used as vertical members 11, and four eight-foot reinforcing rods are cut to be used as horizontal members 12. Two three-foot pieces of angle iron 20 (also known as L-bars) are cut for use as the metal and pieces, the angle iron being a right-angle configuration with one side being three inches wide and the other two inches. Four one-foot sections of the reinforcing rods are cut for use as end braces 13.
The two angle irons 20 are placed on a horizontal surface suitable for serving as the bottom of a form-mold for poured concrete. The two angle irons 20 are placed in parallel, eight feet apart, such that the three inch side extends vertically from the surface and the other side of each angle iron 20 rests on the surface and is disposed in the direction of the other angle iron 20. The vertical side of each angle iron 20 will thus form one outer end of each sectional panel 90, and the horizontal side of the angle iron 20 will be planar with the back side of the formed sectional panel 90.
Referring now to FIG. 2, the horizontal reinforcing rods 12 are bent twice at each end such that the last three inch portion 17 of each rod is parallel to the main body of the rod 12, but is disposed off the axis of the main body of rod 12 approximately one and one half inches in the radial direction. Each end of the rod 12 is then welded to the interior of the horizontal side of angle iron 20. The rod 12 is positioned such that the main body of the rod 12, because of the bends at each end, is situated approximately one and one half inches above the horizontal surface. The main body of each rod 12 will thereby occupy a position approximately in the center of each finished three inch panel 90. The four horizontal rods are evenly spaced along the angle irons 20, all parallel to one another, with the top and bottom rods placed approximately four inches from the respective ends of the angle irons 20.
The four reinforcing rod end braces 13 are each bent at a ninety degree angle approximately three inches from one end to form retaining braces for the angle irons 20. The short bent section 15 is welded along the vertical side of the angle iron 20 such that the bent section is parallel to the upper edge of the angle iron but does not extend above it. The longer end of each of these end braces 13 abuts the raised portion of the outermost horizontal reinforcing rods 12 and is welded to said rod along the region of contact 16. This construction prevents the vertical side of the angle iron 20 from bending or pulling away from the finished sectional panel 90 during and after construction of the pool wall.
Referring again to FIG. 1, abutted against the upper end of each angle iron 20 is a piece of cut lumber 30, approximately two inches by four inches and at least eight feet in length. Another similar piece is abutted against the lower end of each angle iron 20. These two pieces of lumber 30, together with the vertical sides of the angle irons 20, form the mold walls for receiving the poured concrete, and define the final size and shape of the sectional panel 90. Evenly spaced along each piece of lumber 30 are seven notches 31 approximately three-eights inch wide and one and one half inches deep. Into these notches 31 are placed the seven vertical reinforcing rods 11 such that each rod extends approximately one foot beyond the lumber 30 on each end. The vertical reinforcing rods 11 and horizontal rods 12 are welded together at their intersections 14 using conventional techniques.
A sufficient amount of wet concrete, approximately eight cubic feet, is now poured over the reinforcing structure in order to completely fill the mold as defined by the angle irons 20 and the pieces of lumber 30. The concrete is smoothed and beveled down at each end so that the edge of the three inch side of the angle iron 20 remains exposed. Upon curing, the wood members 30 are removed and the concrete sectional panel 90 is now ready to be installed. It is most efficient to use a separate mold for each sectional panel 90 and to pour each at the same time.
As described, each sectional panel 90 is approximately eight feet long by three feet high and three and five-eights inch thick. The two lateral ends are composed of the exposed three inch side of angle irons 20. The top and bottom of sectional panel 90 are concrete with one foot sections of the vertical reinforcing rods 11 extending outward.
To install each panel 90, the pool excavation is dug and concrete blocks are placed as footing at the ends of the sectional panels. The sectional panels 90 are placed side by side, as shown in FIG. 3, so that the angle irons 20 of each are in contact along their entire length. A continuous weld using conventional techniques, for example, arc welding, is performed along the contact region of the angle irons 20 facing the exterior of the pool and spot-welding is performed along the interior side. This results in a complete seal between each panel 90 which, after finishing plaster is applied to form a smooth surface, prevents any leakage of water from the pool. Short sections of reinforcing bars may be added as joint bars 18, which are welded between the extended sections of the outermost vertical reinforcing rods 11 of adjacent panels 90 to further stabilize the joints.
Referring now to FIG. 4, the reinforcing rods 11 which extend below the sectional panels are bent inward and can be connected by welding to whatever reinforcing structure is used for the pool bottom. The pool bottom is then poured, which encases the extended reinforcing rods 11 and the bottom of the sectional panels 90, thus securing them in place and creating a unitary surface. The exterior excavation is backfilled and the deck is formed, the reinforcing rods 11 extending from the top of each sectional panel 90 being bent outward to be welded to the reinforcing members of the deck, thus locking in the tops of the sectional panels 90.
It is to be understood that varying the shape of a given pool may require changes of the proportions used as set forth above. The above dimensions are given by way of example only. Likewise, different pool shapes may require the use of angle irons formed at a different angle, to insure that continuous contact is maintained between each end of given sectional panels. Different configurations of the reinforcing rods may also be required for different panel shapes. One skilled in the art could readily substitute equivalent materials without going beyond the scope of this invention, as set forth and defined by the following claims. | An in-ground swimming pool is constructed of sectional panels joined by welding. The panels are formed of poured concrete having lateral ends of metal. Special configuration of internal reinforcing members prevents separation of the metal ends from the concrete body of the sectional panels. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 09/716,783, filed Nov. 20, 2000, now U.S. Pat. No. 6,429,217, which is a divisional of U.S. patent application Ser. No. 09/139,442, filed Aug. 25, 1998, now U.S. Pat. No. 6,479,523, which claims priority to U.S. Provisional Application Ser. No. 60/072,284, filed Jan. 23, 1998 and U.S. Provisional Application No. 60/056,994, filed Aug. 26, 1997.
BACKGROUND OF THE INVENTION
Minimally invasive direct coronary artery bypass (MIDCAB) surgery, both via sternotomy and alternative incisions, is a substantially revolutionary development in surgery for allowing bypass surgery to be conducted on a beating heart. However, beating heart surgery shows an undesirably higher rate of early graft failure than conventional coronary artery bypass procedures using cardiopulmonary bypass and cardioplegia. The technical difficulty of sewing the coronary artery anastomosis on a beating heart is likely an important factor in this difference in outcome between the two techniques. Controlled intermittent asystole (CIA) during brief intervals required for placing anastomotic sutures is suitable for improving the precision of coronary anastomoses performed on a beating heart and reducing graft failure while increasing ease of operation.
Cardiopulmonary bypass (CPB) and chemical arrest using cardioplegia solutions have traditionally provided surgeons with optimal operative conditions: hemodynamic control and cardiac quiescence. This optimal field has contributed to technical success in increasingly complex cardiac surgical operations. However, there has been recent interest in performing coronary artery bypass surgery without either complete cardiopulmonary bypass or cardioplegia. The quality of the distal anastomosis is a primary concern among cardiac surgeons who observe and perform coronary artery bypass graft (CABG) procedures unaided by cardioplegic arrest and cardiopulmonary bypass. Coronary artery bypass graft failure rates reported with minimally invasive direct coronary artery bypass range from 3.8 to 8.9%, while traditional CABG on CPB has a reported anastomotic failure rate of 0.12%. This may reflect a difference in anastomotic precision between MIDCAB and CPB-aided CABG. Although the benefits of avoiding extracorporeal circulation and global cardioplegia in beating heart procedures are important, they do not outweigh the performance of an optimal coronary anastomosis.
The key difference in the anastomotic results between conventional CABG and beating heart CABG is related to achieving elective asystole during construction of the distal anastomosis. Cardiac motion can be minimized during MIDCAB procedures via pharmacologic bradycardia (adenosine, β blockade) and mechanical stabilization using various devices. Although these techniques do improve operative conditions, they only approximate the advantages of elective asystole achieved with CPB and cardioplegia.
Applicants show that a state of controlled intermittent asystole (CIA) is produced off CPB, which provides a major advantage otherwise gained by cardioplegic arrest on CPB. In particular, CIA is achieved using unilateral (or bilateral) vagus nerve stimulation coupled with pharmacologic suppression of electromechanical escape activity.
Applicants demonstrate that elective, controlled intermittent asystole is produced by vagus nerve stimulation after treatment with an acetylcholinesterase inhibitor, a β-adrenergic receptor blocker, or a calcium channel blocker, or combinations thereof.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 Duration of asystole achieved during 60 second vagal stimulation. Lines connect the periods of asystole observed in the non-drug treated and drug treated states in each experimental animal. Drug administration lengthened significantly the period of asystole.
FIG. 2 . Representative left ventricular and aortic pressure tracings during 60 second vagal stimulation in the non-drug treated (A) and drug treated states (B). Dark and open arrows mark the initiation and termination of the vagal impulse, respectively. Before drug treatment, a short pause followed by escape and bradycardia was observed during the 60 second impulse. After drug treatment, prolonged asystole occurred during the 60 second impulse with return of mechanical function after termination. lvp—left ventricular pressure; aop—aortic pressure.
FIG. 3 . Representative left ventricular and aortic pressure tracings during sequential 15 second vagal stimulations in the non-drug treated (A) and drug treated states (B). Dark and open arrows mark the initiation and termination of the vagal impulses, respectively. Before drug treatment, each 15 second stimulation produced a short pause followed by bradycardia, while after drug treatment, asystole lasted the duration of each 15 second stimulation. lvp—left ventricular pressure; aop—aortic pressure.
Abbreviations and Definitions
CABG
Coronary artery bypass graft
CIA
Controlled intermittent asystole
CPB
Cardiopulmonary bypass
MIDCAB
Minimally invasive direct coronary artery
bypass; intended to include any CABG
without the use of global cardioplegia;
synonymous with beating heart surgery,
irrespective of incision
DETAILED DESCRIPTION OF THE INVENTION
Increased acetylcholine activity by acetylcholinesterase inhibition and prevention of electromechanical escape activity by β-adrenergic receptor and calcium channel blockade during vagal stimulation produces a marked potentiation of vagal-induced asystole and a means of achieving CIA. CIA achieved by pharmacologic potentiation of vagal-induced asystole is a suitable technique to facilitate MIDCAB operations. In particular, anastomoses and other complex suturing is facilitated during such controlled asystolic events, a readily appreciated advantage in surgery involving minimally invasive direct coronary artery bypass operations on a beating heart. CIA might have particular advantages in partially or totally endoscopic CABG, and possibly in percutaneous or surgical transmyocardial laser revascularization.
The present invention provides a pharmaceutical composition, comprising an acetylcholinesterase inhibitor, a β-adrenergic receptor blocker, and a calcium channel blocker, said composition useful for performing beating heart surgery. The invention also provides that the composition is useful for controlled intermittent asystole in minimally invasive direct coronary artery bypass surgery. The invention further provides that the compositions can be administered in combination with vagus nerve stimulation. Vagus nerve stimulation can be achieved by direct or indirect electrical stimulation.
In preferred independent embodiments, the acetylcholinesterase inhibitor can be pyridostygmine bromide, the β-adrenergic receptor blocker can be propranolol hydrochloride, and the calcium channel blocker can be verapamil bromide.
The invention also provides a pharmaceutical composition, comprising an acetylcholinesterase inhibitor and a β-adrenergic receptor blocker, said composition useful for performing beating heart surgery. In preferred embodiments, the acetylcholinesterase inhibitor can be pyridostygmine bromide, and the β-adrenergic receptor blocker can be propranolol hydrochloride. The invention also provides that the composition is useful for controlled intermittent asystole in minimally invasive direct coronary artery bypass surgery. The invention further provides that the compositions can be administered in combination with vagus nerve stimulation. Vagus nerve stimulation can be achieved by direct or indirect electrical stimulation.
The invention also provides a pharmaceutical composition, comprising an acetylcholinesterase inhibitor and a calcium channel blocker, said composition useful for performing beating heart surgery. In preferred embodiments, the acetylcholinesterase inhibitor can be pyridostygmine bromide, and the calcium channel blocker can be verapamil bromide. The invention also provides that the composition is useful for controlled intermittent asystole in minimally invasive direct coronary artery bypass surgery. The invention further provides that the compositions can be administered in combination with vagus nerve stimulation. Vagus nerve stimulation can be achieved by direct or indirect electrical stimulation.
The principal challenge of beating heart CABG surgery has been to recreate the advantageous operative conditions of a quiescent operative field provided during conventional CABG with CPB and cardioplegic arrest. A variety of pharmacologic manipulations and mechanical stabilizing techniques assist in performing CABG off pump. These interventions to date minimize, but do not eliminate, cardiac motion. The concept that a state of controlled intermittent asystole improves the conditions for construction of distal coronary artery bypass anastomosis in non-CPB assisted cases was demonstrated by applicant. CIA is defined as operator-initiated and controlled intervals of mechanical cardiac standstill. These intervals may be timed to coincide with placement of sutures in the anastomosis, after which normal cardiac rhythm and hemodynamics are restored while preparations are made for the next successive stitch. Experiments reported by the applicant indicate that the minor bradycardia known to be produced by vagus nerve stimulation is dramatically augmented to function as an electromechanical “on-off switch” by pharmalogical inhibition of acetylcholinesterase and blockade of β-adrenergic receptors and calcium channels. Controlled intermittent asystole may prove equally useful for CPB-assisted cardiac surgery without global cardioplegia.
The chronotropic effects of vagal nerve stimulation have been well described and typically produce an initial pause followed by a “vagal escape” beat and sustained bradycardia during continuous optimal stimulation of the vagus nerve. Cardiac responses to a 60 second vagal stimulation without adjunctive therapy achieved an average pause of 1.6 seconds terminated by vagal escape beats with a 19% reduction in heart rate. Vagus nerve stimulation alone did not produce a controlled period of asystole desired for CIA. In contrast, a triple pharmacologic regimen of e.g, pyridostigmine, propranolol and verapamil inhibited vagal escape, and allowed sustained periods of asystole lasting up to 60 seconds and sequential asystoles of 15 seconds each. Sequential asystoles had no significant hemodynamic consequences.
It is apparent that suppression of the electromechanical escape during vagal stimulation is necessary to produce a sufficient interval of asystole to allow a single stitch to be reliably placed during construction of a distal CABG anastomosis. The negative chronotropic effects of vagal stimulation are produced by acetylcholine release. Acetylcholine activity may be enhanced by inhibition of acetylcholinesterase activity by agents such as pyridostigmine. Additionally, it is known that calcium channel blockade by e.g. verapamil potentiates the negative chronotropic effect of vagus nerve stimulation. Another component in electromechanical escape may be related to increased catecholamine activity in the sympathetic nervous system, triggered by hypotension. Catecholamines increase the rate of diastolic depolarization and decrease the threshold potential. β-adrenergic receptor blockade via e.g. propranolol reduces the effects of catecholamine activity and facilitates suppression of electromechanical escape.
Administration of this combination therapy produced a significant reduction in heart rate and maximum developed ventricular pressure along with an increase in left ventricular end-diastolic pressure, but did not alter mean arterial pressure. There was no apparent fatigue of this pharmacologic effect after sequential stimulations. The animals used for pilot experiments appeared to tolerate this pharmacologic regimen without other adverse hemodynamic side effects, such as acidosis.
The short-term hemodynamic effects of a single prolonged stimulation were found to be substantially insignificant. Likewise the metabolic consequences as detected by pH and changes in base deficit were insignificant.
The pharmacologic regimen used in this investigation sustained the period of vagal-induced asystole for about sixty seconds. This interval would allow more than sufficient time for construction of a distal CABG anastomosis. Animals followed for two hours after administration of drugs displayed responses to vagal stimulation similar to those in the non-drug treated state, confirming reversibility of the drug effects.
An untoward effect of the pharmacologic regimen which requires consideration before clinical application is vagal-induced secretions. All animals displayed significant salivation after initiation of vagal stimulation. However, there were no problems with oxygenation and ventilation due to tracheobronchial secretions in these experiments. Vagal-induced oropharyngeal and tracheobronchial secretions are pertinent in the clinical setting. Additionally, the effects on recurrent laryngeal nerve function require consideration.
Evidence suggests that the long-term effects of this regimen on the vagus nerve are not harmful. Chronic vagus nerve stimulation has been utilized as therapy for intractable seizure disorders without apparent nerve injury or impaired function. Applicants have shown that vagal-mediated chronotropic control at two hours after completion of the experimental protocol was similar to the non-drug treated state.
In summary, controlled intermittent asystole can be achieved by potentiation of vagal-induced asystole via a pharmacologic combination of e.g, propranolol and verapamil for suppression of electromechanical escape and e.g, pyridostigmine for acetylcholinesterase inhibition. Asystole can be reproducibly achieved for prolonged intervals and for shorter multiple sequential intervals using this technique.
Nerve Stimulation
To achieve consistent asystole, applicants have found that nerve stimulation of the right vagus nerve before or after treatment with the pharmacological combinations of the present invention is preferred.
Electrical stimulation is carried out on the right vagus nerve, preferably at a site on the neck. Other suitable locations for vagus nerve stimulation include, but are not limited to, unipolar or bipolar electrical stimulation of the right or left vagus, or both, stimulation of the vagus in the chest after sternotomy, stimulation with a percutaneous catheter or electrode probe in the internal jugular vein, esophagus, or trachea, or combination of these. The nerve stimulator is typically a Grass wire with a single point of contact, but other suitable stimulators include a pair of pacing wires or electrodes placed about 1 cm apart to allow bipolar prodromic stimulation. A single continuous impulse is applied of between about 5 seconds to about 90 seconds, preferably between about 5 seconds and about 15 seconds, to allow a single stitch during surgery. Impulse parameters can readily be varied, e.g, a frequency range of between about 1 Hz and about 500 Hz, preferably between about 20 Hz to about 80 Hz, more preferably about 40 Hz, with an amplitude between about 1 to about 40 volts.
Pharmacologic Potentiation
The acetylcholinesterase inhibitor is also known as a cholinesterase inhibitor. Suitable acetylcholinesterase inhibitors include, but are not limited to tacrine hydrochloride, pyridostigmine bromide, neostigmine methylsulfate, and edrophonium chloride. One preferred acetylcholinesterase inhibitor is pyridostigmine bromide. Acetylcholinesterase inhibitors are administered in a dosage range between about 0.01 mg/kg and about 100 mg/kg, preferably between about 0.1 mg/kg and about 2.0 mg/kg, more preferably about 0.5 mg/kg.
The beta-adrenergic receptor blocker is also known as a beta-adrenergic blocking agent. Suitable beta-adrenergic receptor blockers include, but are not limited to, sotalol HCl, timolol maleate, esmolol hydrochloride, carteolol hydrochloride, propranolol hydrochloride, betaxolol hydrochloride, penbutolol sulfate, metoprolol tartrate, acetbutolol hydrochloride, the combination of atenolol and chlorthalidone, metoprolol succinate, pindolol, and bisoprolol fumarate. One preferred beta-adrenergic receptor blocker is propranolol hydrochloride. Beta-adrenergic receptor blockers are administered in a dosage range between about 0.01 mg/kg and about 100 mg/kg, preferably between about 0.1 mg/kg and about 2.0 mg/kg, more preferably about 80 μg/kg.
Suitable calcium channel blockers include, but are not limited to, nifedipine, nicardipine hydrochloride, diltiazem HCl, isradipine, verapamil hydrochloride, nimodinpine, amlodipine besylate, felodipine, bepridil hydrochloride, and nisoldipine. One prefererred calcium channel blocker is verapamil hydrochloride. Calcium channel blockers are administered in a dosage range of between about 0.001 mg/kg to about 1 mg/kg, preferably between about 0.01 mg/kg and about 0.2 mg/kg, more preferably about 50 μg/kg.
It will be understood that other dosage combinations may be effective. The appropriate dosage is determined by the age, weight, sex, health status of the patient, and may vary with a variety of other factors according to conventional clinical practice.
EXAMPLE 1
Experimental Preparation
The sheep in the examples of the present invention received humane care in compliance with “Principles of Laboratory Animal Care” formulated by the National Society for Medical Research and the “Guide for Care and Use of Laboratory Animals” prepared by the National Academy of Sciences and published by the National Institutes of Health (NIH Publication No. 80-23, revised 1985). The experimental protocol was approved by the Institutional Animal Care and Use Committee of Emory University.
Seven sheep weighing 44 to 45 kg were premedicated with xylazine (0.1 mg/kg) and atropine (0.2 mg/kg) 30 minutes prior to induction of anesthesia with intravenous thiopental (2.2 mg/kg) and lidocaine (2.2 mg/kg). The animals were endotracheally intubated and placed on a volume ventilator with isoflurane for maintenance of anesthesia. Limb leads and precordial lead were placed for electrocardiographic monitoring. The right femoral artery was cannulated for arterial pressure and arterial blood gas monitoring. Tidal volume was adjusted to 10 cc/kg and a rate of 12 breaths per minute, with adjustments made to maintain pH at 7.35-7.45, pO2 greater than 100 mm Hg, and pCO2 between 35-45 mm Hg.
A right cervical incision was performed, the vagus nerve was carefully isolated, and a nerve stimulation probe (Harvard Apparatus, South Natick, Mass.) was placed on the nerve. A median sternotomy was made to expose the heart. A high-fidelity solid-state micromanometer (Millar Inc, Houston, Tex.) was secured in the ascending aorta for aortic blood pressure monitoring. An additional micromanometer was introduced into the left ventricle through the apex for left ventricular pressure monitoring.
EXAMPLE 2
Experimental Protocol
Each animal underwent vagal stimulation before and after drug administration. The pharmacologic regimen consisted of pyridostigmine (0.5 mg/kg) for acetylcholinesterase inhibition, propranolol (80 μg/kg) for β-adrenergic receptor blockade, and verapamil (50 μg/kg) for calcium channel blockade. Vagal stimulation was performed with a nerve stimulator (Grass Instrument Co, Quincy, Mass.) in the monopolar mode at a frequency of 40 Hz, an impulse duration of 0.4 msec, and an amplitude of 2-6 volts. Vagal stimulations were delivered in two regiments: 1) continuous 60 second impulse and 2) sequential 15 second impulses. The continuous 60 second stimulation was designed to determine the longevity of vagal-induced asystole and the physiologic effects of prolonged vagal-induced hypotension. Sequential 15 second vagal stimulations were performed to simulate the suturing intervals required for graft anastomoses and to determine whether cardiac fatigue, electromechanical escape, and physiologic effects occurred under these practical conditions.
EXAMPLE 3
Data Acquisition and Analysis
Electrocardiographic and hemodynamic data were gathered via an analog-to-digital conversion board (Data Translation, Inc, Marlboro, Mass.) and processed, stored, and analyzed via a microprocessor personal 486 computer (Compaq Computer Corp, Houston, Tex.) using interactive proprietary software (Spectrum™, Triton Technology, San Diego, Calif.). The system was configured to collect 4 channels of physiologic data at a frequency of 50 Hz (sufficient for slow-wave waveforms and mean pressure data) over a 200 second period that encompassed the 60 second stimulation or the sequential 15 second train of stimulations. The software allowed subsequent videographic display and analysis of the hemodynamic data.
EXAMPLE 4
Results
Before drug administration, vagal stimulation for 60 seconds produced a brief pause in electromechanical activity (1.6±0.9 seconds) followed by vagal escape and resumption of sinus rhythm with a reduction in heart rate by 19.4±11.9% compared to pre-stimulation heart rate. Similarly, sequential 15 second vagal stimulation performed to stimulate the suturing intervals required for CABG anastomoses produced a short pause (1.1±0.4 seconds) followed by vagal escape and sinus rhythm with a reduction in heart rate of 37±6%.
Administration of the pharmacologic regimen (propranolol, verapamil, pyridostigmine) reduced the heart rate and increased the left ventricular end diastolic pressure, but did not affect the mean arterial pressure or maximum dP/dt as shown in Table 1.
TABLE 1
Hemodynamics before and after drug treatment
Before drugs
After drugs
p value
(mean ± SEM)
(mean ± SEM)
(paired t test)
Heart rate (bpm)
114 ± 4
87 ± 4
0.002
MAP (mm Hg)
84 ± 5
84 ± 5
NS
dP/dt max
3286 ± 232
2847 ± 140
NS
(mm Hg/sec)
LVEDP (mm HG)
3.9 ± 0.5
7.3 ± 0.9
0.005
bpm - beats per minute; dP/dt max - maximum developed left ventricular pressure; LVEDP - left ventricular end diastolic pressure; MAP - mean aortic pressure; NS - not significant; SEM - standard error of the mean; sec - seconds.
After drug administration, 60 second vagal stimulation produced asystole averaging 52±5.6 seconds. The individual responses of the animals before and after drug administration are shown in FIG. 1 . Six animals achieved controlled asystole. Five of these six achieved controlled asystole for greater than 50 seconds. The effects of 60 second vagal stimulation before and after drug treatment in responsive animals are contrasted by representative left ventricular and aortic pressure tracings are shown for a representative experiment in FIG. 2 . Before drug regimen treated, vagal stimulation produced no appreciable change in cardiac rhythm or hemodynamics. In contrast, the triple drug regimen facilitated a consistent asystole and circulatory arrest until the stimulus was withdrawn, after which hemodynamics were rapidly restored to pre-stimulation values. The prolonged asystole and circulatory arrest produced no significant differences in the hemodynamic parameters measured before and after drug-aided 60 second vagal stimulation (Table 2).
TABLE 2
Hemodynamics pre- and post-asystole produced
by 60 second stimulation after drug treatment
Pre-asystole
Post-asystole
p value
(mean ± SEM)
(mean ± SEM)
(paired t test)
Heart rate bpm)
91 ± 8
87 ± 7
NS
MAP (mm Hg)
86 ± 6
92 ± 6
NS
dP/dt max
3032 ± 182
3223 ± 212
NS
(mm Hg/sec)
LVEDP (mmHg)
5.8 ± 1.0
6.0 ± 0.8
NS
bpm - beats per minute; dP/dt max - maximum developed left ventricular pressure; LVEDP - left ventricular end diastolic pressure; MAP - mean aortic pressure; NS - not significant; SEM - standard error of the mean; sec - seconds.
Likewise there was no difference in the parameters measured by arterial blood gases at one and five minutes after the 60 second stimulation compared to pre-stimulation values (Table 3).
TABLE 3
Arterial blood gas data pre-, 1 minute post-, and 5
minutes post-systole produced by 60 second stimulation after drug
treatment
Post-asystole
Pre-asystole
1 minute
5 minutes
(mean ±
(mean ±
(mean ±
p p value
SEM)
SEM)
SEM)
(ANOVA)
pH
7.42 ± 0.03
7.40 ± 0.03
7.42 ± 0.03
NS
PCO 2
41 ± 4
42 ± 4
40 ± 4
NS
(mm Hg)
PO 2
377 ± 87
380 ± 75
390 ± 83
NS
(mm Hg)
HCO 3
26 ± 1
26 ± 1
26 ± 1
NS
(mEq/L)
Base excess
1.2 ± 0.7
1.0 ± 0.4
1.3 ± 0.5
NS
(mEq/L)
ANOVA - one-way analysis of variance with repeated measures; NS - not significant; SEM - standard error of the mean.
Five to six sequential 15 second vagal stimulations in the drug treated state produced consistent and stable asystole (FIG. 3 ). Three of the six animals had a single escape beat during one of the 15 second stimulations. The other three displayed complete asystole during each of the 15 second stimulations. A sustained cardiac rhythm began an average of 5.3±1.8 seconds after termination of each 15 second impulse during which interval a single beat was often observed immediately after withdrawal of stimulation.
While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, it will be understood that the practice of the invention encompasses all of the usual variations, adaptations, and modifications, as come within the scope of the following claims and its equivalents. | A method for indirectly stimulating a vagus nerve of a patient includes the steps of positioning one or more electrodes in the vicinity of the vagus nerve and then actuating the electrode(s) to create an electrical field for stimulating the vagus nerve. Disclosed embodiments include positioning one or more electrodes in the esophagus, trachea, or jugular vein, on the neck of the patient, and combinations thereof. | 0 |
FIELD OF THE INVENTION
This invention relates to a surgical apparatus including a locking device for axially releasably locating an inner surgical tool within an outer sleeve.
BACKGROUND OF THE INVENTION
It has been known in arthroscopic surgical procedures, to enter a surgical site, for example a knee joint, with an elongate entry tool, such as a trocar, sheathed in a snug fitting outer sleeve. Thereafter the entry tool is removed, leaving the entry end of the sleeve at the surgical site and the other end of the sleeve protruding from the patient. Thereafter, one or more additional elongate surgical tools, such as an arthroscope or obturator can, in desired sequence, be alternately inserted through the sleeve to reach the surgical site.
Further, it is known to equip the sleeve for connection to an irrigation liquid source for injecting irrigation liquid therethrough into the surgical site, and for connection to a suction source for removing flowable material from the surgical site.
In each instance, the sleeve, extending into the surgical site, acts as a conduit of access to the surgical site from outside the body of the patient and permits a variety of surgical procedures to be performed without requiring more than the very small incision needed to insert the sleeve.
In prior devices of this type, the outer end of the sleeve is provided with a manually actuable locking device engageable with a connector on the tool for at least axially fixing the tool within the sleeve. However, prior locking devices of which I am aware have not been entirely satisfactory.
In one such prior locking device, a threaded member must be rotated with respect to the sleeve to lock and unlock a tool with respect to the sleeve. However, some surgeons have confused the lock and unlock rotation directions. Further, the threaded member may become slippery during surgery and require extra care to lock and unlock. Further, a surgeon may fail to fully rotate the threaded member and thus need to repeat the rotation.
Accordingly, the objects and purposes of this invention include provision of a locking device for axially releasably locating an inner surgical tool within an outer sleeve, in which it is intended to improve upon prior locking devices, in which locking and unlocking of the tool with respect to the sleeve can be done with one hand, in which locking and unlocking require distinctively different kinds of manipulation and can readily be done without significant training by surgical personnel and despite the presence of liquids or slippery materials on the tool and sleeve, in which the locking is positive and will retain a tool in the sleeve despite feeding of liquid under pressure into a space between the sleeve and tool and toward the wound and despite possible liquid pressure tending to push the tool outwardly out of the sleeve.
Further objects and purposes of the invention will be apparent to persons acquainted with apparatus of this general type upon reading the following specification and inspecting the accompanying drawings.
SUMMARY OF THE INVENTION
A surgical apparatus, in which a locking device releasably secures a surgical tool in a sleeve, comprises a tool receiving sleeve and a lock housing on the sleeve. The lock housing head has an opening through which the tool is insertable into the sleeve. A lock member is actuable for opening the lock housing to release a previously loaded tool or receive a tool. The lock housing is actuable for locking received tool in the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a surgical apparatus embodying the invention.
FIG. 2 is an enlarged, exploded view of the tool lock device of the apparatus of FIG. 1.
FIGS. 3A, 3B and 3C are enlarged fragmentary central cross sectional views each taken on the line 3--3 of FIG. 1 and showing a sequence of positions of parts taken during installation of a tool in the sleeve and tool lock device from which the sleeve extends.
FIG. 4 is an enlarged fragmentary exploded view of a portion of a tool as it approaches the open lock plate of the tool lock device prior to locking.
FIG. 5 is an enlarged exploded view similar to FIG. 4 but with the lock plate in its closed position for locking together the tool and sleeve in their FIG. 1 use position.
FIG. 6 is an enlarged exploded view of the release pin and its spring of FIGS. 4 and 5.
FIG. 7 is an enlarged exploded view of the lock plate unit of FIGS. 4 and 5.
FIG. 8 is a fragmentary elevational view of the locking device of FIG. 1 and substantially taken on the line 8--8 of FIG. 1.
FIG. 9 is a sectional view substantially taken on the line 9--9 of FIG. 8.
FIGS. 10 and 11 are sectional views substantially taken on the line 10--10 of FIG. 3A and 11--11 of FIG. 3C, respectively.
DETAILED DESCRIPTION
A surgical apparatus 10 (FIG. 1), particularly usable in arthroscopic surgery, comprises a hollow, elongate sleeve 11 having a central passage 15. The sleeve 11 includes an elongate hollow sleeve element 12 having a lower end 13 insertable into the tissue of a patient, namely into an inspection or surgical site (not shown) therein.
The sleeve 11 further includes a fitting 14 (FIG. 3C) fixed, as by press fit, over the top of the sleeve element 12. The fitting 14 is hollow and continues the central passage 15 through the sleeve. Stopcocks 16 and 17 (FIG. 1) extend radially and fixedly from the fitting 14, on opposite sides thereof, and are connectable to sources L and S respectively of irrigant liquid and suction, or to other suitable fluid connections. The stopcocks communicate, as generally indicated at 18 (FIGS. 1 and 3C) with the central passage 15 of the sleeve 11. The stopcocks are equipped with valves 20 and 21 manually actuable to open and close communication between the central passage 15 and sources L and S, respectively, and thereby with the surgical site into which the lower end 13 of the sleeve 11 extends during surgery. The central passage 15 continues upward coaxially through the sleeve 11 and its upper end portion widens upwardly to form a widened frustoconical mouth 22 to facilitate downward reception of a tool therethrough.
The sleeve 11 is intended to alternatively receive a variety of tools during the course of a surgical procedure. Examples of tools include a trocar, an arthroscope or an obturator, among others. By way of example, the tool 30 shown in FIGS. 1 and 3C is a trocar.
Each tool 30 has an elongate shank 31 which is installed by inserting its patient engaging, bottom end 32 (FIG. 1) downward into the upward opening, frustoconical mouth 22 of the sleeve 11 and then allowing the tool shank 31 to slide downwardly through the central passage 15 until its patient engaging bottom end 32 reaches substantially the lower end 13 of the sleeve 11 (in the embodiment shown, protruding down and slightly therebeyond). The shank 31 fits within the central passage 15 of the shell 11 closely, but with enough clearance to permit fluid flow in the annular space between the shank 31 and the peripheral wall of the central passage 15. Such flow is axially between the stopcocks 16 and 17 and the lower end 13 of the sleeve 11, for example, to permit irrigant liquid from the source L to travel down the outside of the shank 31 to the surgical site or to allow suction by the source S of flowable materials from the wound site toward the suction source S. In the embodiment shown, the passage 15 and shank 31 are both substantially cylindrical.
Integral with the upper end portion of the shank 31, the tool 30 includes a downward tapering, frustoconical portion 33 (FIG. 3C) for seating snugly and sealingly in the frustoconical mouth 22 when the shank 31 is inserted fully into the sleeve 11.
To lock and unlock the tool 40 with respect to the sleeve 11, a lock device 40 is provided atop the sleeve 11 and interacts between the sleeve 11 and tool 30.
To the extent above described, the surgical apparatus 10 is substantially conventional.
Turning now to aspects of the surgical apparatus 10 more specifically embodying the present invention, the tool 30 includes a cylindrical portion 34 (FIGS. 1 and 3C). Spaced between the ends of the cylindrical portion 34 is an annular lock groove 35. The tool 30 includes a radially enlarged head 36 extending upward integrally and coaxially from the cylindrical portion 34, in spaced relation above the annular lock groove 35. The head 36 is shaped for convenient hand engagement by the user, particularly in inserting the tool 30 into the sleeve 15 and withdrawing same upwardly out of the sleeve.
It may be desired to prevent rotation of the tool 30 with respect to the sleeve 11. To that end, an upstanding, eccentrically located lug 41 (FIG. 1) is engagable with a shallow notch 42 (FIG. 3C) in the bottom peripheral edge of the head 36.
The sleeve 11 includes an upward extension 50 (FIG. 3C) having a lower end portion sealingly fixed by set screws 51 in an upward opening bore 43 in the fitting 14. The extension 50 (or taper housing) thus sealingly continues upward the central passage 15, and indeed, at its upper end, carries the frustoconical mouth 22. In the embodiment shown, it is the interior of the sleeve extension 50 which communicates at 18 with the stopcocks 16 and 17. The snug connection of the sleeve element 12 and sleeve extension 50 in coaxially communicating recesses in the fitting 14 assures a continuous leak-proof liquid or gas communication between the fitting 14 and the lower end 13 of the sleeve element 12.
The snug tapered fit of the installed frustoconical portion 33 of the tool 30 in the frustoconical mouth 22 at the top of the central passage 15 of the sleeve 11 assures that no fluid leakage occurs therebetween, thereby preventing drawing of air downward through the frustoconical mouth 22 into the central passage 15 and further assuring no escape of liquid upward out of the central passage 15 past the frustoconical mouth 22, when the tool 30 is fully installed in and locked into the upper end of the sleeve 11.
The lock device 40 in the preferred embodiment of the invention includes a lock housing 52 (FIGS. 1 and 3C). The lock housing 52 has upper, mid and lower parts respectively defining a substantially cylindrical body 53, a radial flange 54 and a depending tubular skirt 55. The lock housing 52 has a central bore 56 in which is received the upward extension 50 of the sleeve 11. The lower end of the skirt 55 is snugly but slidably received coaxially in an upward opening annular recess 57 (FIG. 3C) in the top of the fitting 14. A coil compression spring 60 (FIGS. 3B and 3C) urges the lock housing 52 downward with respect to the sleeve 11, to bottom the skirt 55 in the annular recess 57 as seen in FIG. 3A. The spring 60 is housed in an annular space 61 (FIG. 3B) defined axially between a downward facing radial step 62 in the upward extension 50 of the sleeve 11 and an upward facing radial step 63 in the central bore 56 of the lock housing 52. The annular space 61 is located axially near the bottom of the body 53 and below the frustoconical mouth 22. The opposing steps 62 and 63 have a radial width somewhat exceeding the radial extent of the spring 60 so that the spring 60 clears the proposed inner and outer cylindrical surfaces of the body 53 and sleeve extension 50 sufficient to enable free telescoping movement of the lock housing 52 on the sleeve extension 50. The spring 60 resiliently bottoms the lower end of the skirt 55 in the annular recess 57 to prevent the lock housing 52 from escaping upwardly off the top of the sleeve 11, and for determining the lowermost position of the lock housing 52, on the upward sleeve extension 50, as shown in FIG. 3A.
Relative rotation between the lock housing 15 and sleeve 11 is prevented as indicated in FIG. 9. More particularly, a radially outwardly facing, axially extending, axially blind groove 64 in the sleeve extension 50 is vertically spaced between the spring annular space 61 and the frustoconical mouth 22. An anti-rotate pin 65 (FIGS. 2 and 9) is inserted through a radial hole 66 in the body 53 of the lock housing 52 and enters the groove 64 to prevent relative rotation between the lock housing 52 and sleeve 11. A set screw 67 is threaded into the outside portion of the hole 66 to prevent non-intended escape of the pin 65 from the groove 64. The top and bottom of the groove 64 may be located to provide an additional or alternative set of limits of vertical displacement of the lock housing 52 on the sleeve 11.
In view of the upward facing step 63 (FIG. 3B), the central bore 56 of the lock housing 52 forms a deep, somewhat enlarged diameter, recess 70 into which the somewhat enlarged diameter top portion 71 (FIGS. 2 and 3C) of the sleeve upward extension 50 is snugly but slidably received.
An undercut groove 72 (FIGS. 1, 2 and 9) extends diametrally across the top of the lock housing body 53. The open top 73 of the groove is of lateral width slightly exceeding the diameter of the recess 70. The undercut groove 72 opens at its opposite ends diametrally through the periphery of the lock housing body 53. The length edges 74 of the undercut portion of the undercut groove 72 are spaced laterally apart a distance substantially exceeding the diameter of the recess 70, as can be seen from FIGS. 2, 10 and 11.
A lock member 75 (FIG. 7) comprises a lock plate 76 having a lock cup 77 at one end thereof. The lock plate 76 is snugly but slidably received diametrally in the undercut groove 72 as indicated in FIGS. 1, 2, 3C and 8-11.
The lock cup 77 depends from one end (the left end in FIG. 3C) of the lock plate 76 in a rigid fashion, extends leftwardly beyond the lock plate 76 and opens rightwardly into the space under the lock plate and along the length direction of the lock plate. With the lock plate 76 extending along the undercut groove as shown in FIGS. 3C, 10 and 11, the cup 77 opens rightwardly toward a radially shallow recess 80 (FIGS. 2, 3C and 10) in the peripheral wall of the lock housing body 53. The recess 80 is generally U-shaped in elevation as seen in FIG. 2 and is sized to laterally receive the lock cup 77 in at least partially recessed relation therein throughout the normal range of lateral movement of the lock plate 76 in the undercut groove 72.
A lock spring 81, here a coil spring of compression type, is compressed diametrally of the lock housing body 53, between the closed leftward end 82 of the lock cup 77 and the opposed upstanding wall of the recess 80, so as to continuously resiliently urge the lock plate 76 leftwardly in FIGS. 3C, 10 and 11, and thereby in the normal direction of withdrawal of the lock plate 76 from the undercut groove 72 during disassembly of the apparatus. The spring 81 is prevented from sliding the lock member 75 leftwardly (FIG. 3C) off the lock housing 52, and indeed the lateral position of the lock plate 76 in the undercut groove 72 is determined, by a release unit 83.
The release unit 83 (FIGS. 3C, 4-6, 10 and 11) comprises a release pin 84 (FIGS. 4-6) comprising a cylindrical base 85 (FIG. 6) which defines the maximum diameter of the pin. Above the cylindrical base 85, the pin 84 has two successive upward facing steps 86 and 87 (FIG. 6) which are separated by medium width part 88 of substantially cylindrical configuration, topped by an upward tapering annular bevel 90. The release pin 84 further comprises a cylindrical narrow width part 91 topped by an enlarged diameter head 92.
The release pin 84 is receivable for its entire length downward into an upward opening blind hole 93 (FIGS. 2 and 3C) in the lock device body 53. The blind hole 93 opens upward through the bottom 94 of the undercut groove 72 adjacent the end thereof furthest from the recess 80. The blind hole 93 is generally centered in the undercut groove 72 and is closely spaced from the recess 70. A coil compression spring 95 is trapped axially between a downward opening recess 96 (FIG. 3C) in the bottom of the release pin 94 and the bottom of the blind hole 93 in the body 53. The spring 95 is sized to continuously urge the release pin 84 upward out of the blind hole 93.
To enable it to coact with the tool 30 and release pin 84, the lock plate 76 has a relatively large diameter hole 100 (FIG. 7) opening therethrough. The hole 100 is laterally centered between the side edges of the lock plate 76 and is nearer to the lock cup 77 than to the opposite end of the lock plate. A notch 101 communicates with the hole 100, is centered between the side edges of the lock plate, and extends from the hole 100 in a direction away from the cup 77. A notch extension 102 (FIG. 7) communicates with and extends beyond the closed end of the notch 101 in a direction away from the cup 75. The notch extension 102 is centered between the side edges of the lock plate 76. The blind end of the notch extension 102 is close to but spaced from the end of the lock plate 76 remote from the cup 77 (the right end in FIG. 7). The lateral widths of the hole 100, notch 101 and notch extension 102 are, respectively, relatively wide, of medium width and of relatively narrow width. The hole 100 is circular and of diameter a bit larger than the diameter of the cylindrical portion 34 of the tool 30 (FIG. 4), so as to allow insertion of the portions 31, 33, 34 and 35 of the tool downward therethrough, in the manner seen, for example, in FIG. 3C. The notch 101 is of lateral width to permit snug but slidable reception therein of the medium width part 88 of the release pin, as shown in FIGS. 3A, 3B, 4 and 10. The notch extension 102 is of width sufficient to snugly but slidably receive the narrow width portion 91 of the release pin 84 as seen, for example, in FIGS. 3C, 5 and 11. The notch extension 102 is too narrow to receive the medium width portion 88 or head 92 of the release pin 84.
OPERATION
The apparatus 10 (FIGS. 2 and 3C) can be assembled as follows. The top of the sleeve element 12 is fixed, as by a press fit or an adhesive or as desired, in the bottom of the fitting 14. The fitting 14 receives the lock housing skirt 55 downward into its annular recess 57 (FIG. 3C). The relaxed spring 60 is dropped into the upfacing recess 70 in the body 53, to rest on the upward facing step 63 (FIG. 3B). The sleeve upward extension 50, with its top portion 71 upward, is then dropped into the recess 70 of body 53 and its step 62 comes to rest upon the top of the spring 60. Set screws 51 affix the sleeve upward extension 50 within the fitting 14. To assure sinking of the skirt 55 to the proper depth in the fitting 14, the skirt 55 preferably has a downward facing step 103 (FIGS. 2 and 3C) which seats upon the bottom of the annular recess 57 in the fitting 14.
The pin 65 and set screw 67 (FIG. 9) are installed in the body 53 with the pin 65 slidably lodged in the groove 64 in the sleeve extension 50, so as to prevent rotation of the sleeve extension 50 within the lock housing body 53.
The release pin spring 95 and release pin 84 are successively dropped into the blind hole 93 (FIG. 3C) in the top of the body 53. The lock plate 76, with the spring 81 captive in the cup 77, is slid (rightwardly in FIG. 3C) into the undercut groove 72 in the body 53. To permit complete insertion of the lock plate 76, the release pin 84 is manually held down with its head 92 below the bottom 94 of the undercut groove 72, thereby allowing the lock plate to slide rightwardly (FIG. 3C) over the top of the release pin 84. Continued rightward sliding of the lock plate 76 brings the notch extension 102 and then the notch 101 over the top of the release pin 84. When the notch 101 is over the top of the release pin, the release pin is allowed to rise into the notch 101 until its lower step 86 hits the bottom of the lock plate 76, as in FIGS. 3A, 3B, 4 and 10. In this position, the release pin 84 prevents leftward (FIG. 3C) escape of the lock member 75 from atop the body 53, and the bottom of the lock plate 76 bears upon the lower step 86 of the release pin 84 to prevent upward escape of the release pin from the body 53.
With the apparatus 40, 11 assembled in the manner above discussed, a tool 30 can be installed therein as follows.
Prior to inserting the tool 30, the lock member 75 is shifted to its open position (with its hole 100 coaxial with the sleeve 11), shown in FIGS. 3A and 10. Then, the bottom end 32 (FIG. 1) of the tool 30 is dropped into the frustoconical mouth 22 of the sleeve central passage 15, until the bottom of the head 36 of the tool 30 comes to rest upon the upward protruding lug 41 (FIGS. 2 and 9). The open lock member 75 permits tool shank 31 and frustoconical portion 33 and the lower cylindrical portion 34 (FIG. 4) to pass downward through the lock plate hole 100. The tool head 36 is then rotated sufficient to bring one of the notches 42 into position above the lug 41 (as in FIG. 8), thereby allowing the tool 30 to drop slightly further into the sleeve central passage 15, indeed until the frustoconical portion 33 of the tool fits sealingly in the frustoconical mouth 22 (FIG. 3C). The annular groove 34 of the tool 30 thus lies in the same radial plane as the lock plate 76. The tool 30 is thus properly vertically located in the sleeve 11 but is not locked therein.
The tool 30 is locked into the lock device 40 and sleeve 11 as follows. With one of the notches 42 receiving the lug 41, the head 36 of the tool 30 can be palmed by the user and the first two fingers of the user's same hand can straddle the skirt 55 and then pull up on the underside of the radial flange 54 of the lock housing 52 to raise the lock housing 52 from its FIG. 3A position to its FIG. 3B position to its FIG. 3C position on the sleeve 11. This compresses the spring 60 and causes the bottom of the tool head 36 to depress the release pin 84 sufficient to drop its medium width portion 88 and bevel 90 below the lock plate 76 (see the transition from FIG. 3B to FIG. 3C and from FIG. 4 to FIG. 5). Thus, the spring 81 is free to displace the lock plate 76 leftward from its FIG. 3B and 10 open position to its FIG. 3C and 11 closed position. This brings the ear-like edges 104 (FIG. 11) of the lock plate 76, where the hole 100 meets the notch 101, into the annular groove 35 in the tool 30, as shown in FIGS. 3C and 11, and thereby prevents the tool 30 from being pulled upward out of the lock housing 52 and sleeve 11.
The lock member 40 is then be released and the spring 60 will push same downward on the sleeve upward extension 50, enough to resiliently urge the lock plate 76 firmly down upon the bottom of the annular groove 35 in the tool 30.
The tool 30 is thus axially and circumferentially locked within the lock device 40 and sleeve 11. This places the apparatus 10 in condition for surgical use.
To remove the tool from the lock device 40 and sleeve 11, it suffices merely to fully push in the lock cup 77, from its FIG. 3C and 5 and 11 position to its FIG. 3B and 4 and 10 position. This brings the notch 101 of the lock plate 76 into occupancy by the release pin 84 and thereby allows the release spring 95 to drive the release pin 84 upward to fill the width of the notch 101 with the medium width part 88 of the release pin 84. Interference between the end of the notch 101 and the medium width portion 88 of the release pin 84 positively holds the lock plate 76 in its open (rightward-most in FIGS. 3B, 4 and 10) position. In this position of the lock plate 76, the hole 100 therein is coaxial with respect to the tool 30. Thus, as a result, the tool can simply be lifted out of the top of the sleeve 11 and the surrounding lock housing 52.
In this way, a succession of tools 30 can be inserted into the holder defined by the sleeve 11 and lock device 40 and held positively therein for appropriate surgical use.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | Surgical apparatus in which a locking device is provided for releasably securing a surgical tool in a sleeve. A lock housing is movable on the sleeve, the lock housing having a through opening through which the tool is insertable to be received into the sleeve. A lock member on said lock housing has a push button actuable for opening the lock housing to reception of the tool through the through opening and into the sleeve. The lock member has means for automatically locking the tool against removal from said lock housing upon release of the push button. A tapered part on the sleeve receives a correspondingly tapered portion of the tool to thereby assure a snug fitting connection of said sleeve with the tool. A hand engageable portion on the lock housing is actuable for pulling the lock housing axially with respect to said sleeve in a direction opposite the direction in which the tool is inserted into the sleeve and for engaging the lock member with a corresponding part of the tool and thereby for positively axially holding together the tapered parts of the sleeve and tool while locking the tool axially with respect to the sleeve. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] (Not Applicable)
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] (Not Applicable)
BACKGROUND OF THE INVENTION
[0003] The present invention relates in general to exposed particulate concrete, and in particular to an improved method for surface-seeding the particulates into the upper surface of the concrete.
[0004] U.S. Pat. No. 4,748,788 entitled SURFACE SEEDED EXPOSED AGGREGATE CONCRETE AND METHOD OF PRODUCING SAME, hereby incorporated by reference in its entirety, discloses a surface seeded exposed aggregate concrete characterized by the use of small, rounded aggregate, such as sand, being broadcast over the upper surface of concrete. The method. disclosed results in a reduction in the size of the aggregate exposed on the surface of concrete compared to other prior art methods. The resultant surface seeded exposed aggregate concrete exhibits an extremely flat exposed aggregate surface suitable for extremely high traffic flooring applications. Additionally, the surface texture and color are able to approximate the surface color and texture of more conventional flooring surfaces, such as stone, granite and marble.
[0005] U.S. Pat. No. 6,033,146 entitled GLASS CHIP LITHOCRETE AND METHOD OF USE OF SAME, hereby incorporated by reference in its entirety, discloses a surface seeded exposed particulate concrete and method for producing same. U.S. Pat. No. 6,033,146 improves upon the surface seeded aggregate concrete and method of making same disclosed in U.S. Pat. No. 4,748,788 by disclosing a method that produces surface seeded particulate concrete that expands the colors and surface texture appearances of concrete surfaces beyond those disclosed in U.S. Pat. No. 4,748,788.
[0006] The patents described above produce surface seeded exposed particulate concrete with desirable characteristics, as evidenced by the use and extensive licensing of such products throughout the United States. However, the application of the surface seeded particulate is a timely process. Furthermore, uniformity of application is difficult to achieve for large surface areas. Typically, it is difficult to achieve a uniform application for surface areas which require broadcasting of particulate beyond a distance of ten feet from the broadcaster.
[0007] Accordingly, there is a need for an improved process for surface-seeding of the particulate into the upper surface of a very large concrete slab.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention specifically addresses and alleviates the problems described above in treating large areas of poured concrete with exposed particulates.
[0009] Aspects of the present invention may be regarded as a surface seeded exposed particulate concrete product and a method of forming the surface seeded exposed particulate concrete product. The surface seeded exposed particulate concrete has a generally flat exposed particulate surface suitable for flooring applications. The particulate may be reactable with a hydrolyzed alkali silica to form an insoluble silicate structure. For example, such a particulate may comprise glass or organic materials, such as sea shells. The alternate may also be a non-reactive particulate. For example, a non-reactive particulate may comprise coarse sand, such as Monterey Aquarium coarse sand.
[0010] The method begins by preparing a subgrade to a desired grade. A concrete mixture is poured over the subgrade. The concrete mixture is screeded to a desired grade which forms a top surface thereof. The top surface of the concrete mixture is finished with a float to seal the top surface and dispose a quantity of cement/fines derived from the concrete mixture at the top surface of the concrete mixture to form an upper surface of cement/fines concrete paste. A quantity of particulate is sprayed upon the upper surface of cement/fines concrete paste. A quantity of particulate is mixed into the cement/fines concrete paste with a float to form an exposed surface of a depth of a mixture of surface-concentrated particulate and cement/fines concrete paste. A surface retarder is applied uniformly over the exposed surface of the surface-concentrated particulate and cement/fines concrete paste. Surface films are washed from the exposed surface. The concrete mixture and paste are cured to form a cured mixture and a cured paste. The exposed surface is then washed to remove surface residue therefrom.
[0011] If the particulate is reactable with a hydrolyzed alkali silica, after the exposed surface is washed, a chemical treatment of hydrolyzed alkali silica solution is applied uniformly over the exposed surface in a quantity sufficient to penetrate only the depth of the surface-concentrated particulate and cement/fines concrete paste. The hydrolyzed alkali silica used with particulates may be a hydrolyzed lithium quartz solution. Applying of chemical treatment may cause penetration of the hydrolyzed alkali metal and silica compound into the upper surface of the concrete mixture through a distance greater than the mean diameter of the particulate.
[0012] Preferably, the particulate has a mean diameter of less than three-eighths of one inch.
[0013] The spraying the quantity of particulate is accomplished using a material gun. The spraying uniformly sprays the quantity of particulate. The spraying includes spraying some of the quantity of particulate a distance of at least twenty feet.
[0014] Applying of the surface retarder may cause penetration of the surface retarder into the upper surface of the concrete mixture through a distance greater than the mean diameter of the particulate.
[0015] The particulate may be sprayed over the upper surface of the concrete mixture at an approximate rate of one pound per square foot of concrete mixture.
[0016] Mixing may comprise using a float in a circular motion to cover the particulate with the cement/fines concrete paste.
[0017] The method may include sponging in a circular motion any areas of the upper surface of the concrete mixture after the mixing and before the applying of the surface retarder.
[0018] The washing of surface film may include applying water to the upper surface of the concrete mixture and lightly brushing the upper surface of the concrete mixture. Preferably, the lightly brushing removes no more than five percent of the particulate from the upper surface of the concrete mixture.
[0019] The washing of the upper surface of the concrete mixture to remove surface residue therefrom may comprise washing the upper surface of the concrete with a mixture of water and muriatic acid.
[0020] The method may include covering the upper surface of the concrete mixture with a vapor barrier after applying of the surface retarder and before washing surface film. The covering the upper surface of the concrete mixture with a vapor barrier may extend for a period of two to twenty-four hours.
[0021] The curing may comprise curing the concrete mixture by use of a fogger or curing the concrete mixture by use of a soaker hose.
[0022] Reinforcement means may be placed upon the prepared subgrade to be disposed within the poured concrete mixture.
[0023] The pouring may comprise mixing the concrete mixture with a color additive.
[0024] After the curing, the method may include altering the surface roughness of the upper surface of the concrete mixture.
[0025] Prior to spraying particulates, the method may include washing with potable water and air drying the particulates.
[0026] The subgrade may be prepared by compacting the subgrade to approximately ninety percent compaction. Preparing the subgrade may include placing a layer of sand between the subgrade and the poured concrete mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These as well as other features of the present invention will become more apparent upon reference to the drawings wherein:
[0028] FIG. 1 is a partial cross-sectional view of the surface seeded exposed particulate concrete of the present invention;
[0029] FIG. 2 is an enlarged partial perspective view of the concrete mixture having the exposed particulate thereon; and
[0030] FIG. 3 is a schematic flow diagram of the manipulative steps utilized in producing the surface seeded exposed particulate concrete of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same, the surface seeded exposed particulate concrete and method of producing the same is pictorially and schematically illustrated. The particulate may be potentially reactive with the concrete mixture 16 . For example, the particulate 18 may comprise glass, such as silica glass, organic materials, such as sea shells of marine animals and mollusk, and other various metals and composite materials. Alternatively, the particulate 18 may be an aggregate that does not react with the concrete mixture. For example, the particulate may comprise coarse sand, such as Monterey Aquarium (Grade) coarse sand. Preferably, the particulate is characterized by having a mean average diameter size of approximately one-eighth inch diameter. The particulate may possess a rounded external surface configuration. Alternatively, the individual particulates may have an angled external surface configuration.
[0032] As is conventional, the initial step in the method of the present invention comprises the preparing of the subgrade to the desired elevation and grade and the compacting of the same to preferably 90% compaction. Subsequently, the subgrade 10 is covered with a one inch minimum thick layer of clean, moist fill sand 12 . The fill sand 12 is not absolutely necessary, but it is highly desirable to control the hydration process of the concrete. Further, in order to increase the resultant strength of the concrete and inhibit subsequent cracking, reinforcement wire mesh or rebar 14 is positioned upon the bed of fill sand 12 .
[0033] With the rebar 14 in place, a concrete mix or mixture 16 is poured over the fill sand 12 and rebar 14 respectively, and as is conventional is poured to approximately a three and one half to four inch thickness. Although variations in the concrete mix 16 are fully contemplated, preferably the mixture 16 comprises 70% sand and 30% three-eighth inch mean diameter particulate combined with a minimum of five sacks of cement, such as Portland cement per cubic yard. Dependent upon individual preferences, various conventional color mixtures may be added to the concrete mix.
[0034] The concrete surface is preferably struck off or screeded to the desired level plane of the concrete surface. However, the mix is preferably not tamped as is conventional, as Applicants have found tamping brings up too many sand fines in most concrete mixes, which would interfere with the subsequent surface seeding of the exposed particulate thereupon. Rather, subsequent to screeding the concrete surface, the surface is floated using a conventional bull float, which may be manufactured of fiberglass, wood, magnesium, or the like. Such floats are characterized by possessing an extremely smooth surface which tends to seal the top surface of the concrete mix 16 and bring out appropriate amounts of cement paste for the subsequent steps of the present invention.
[0035] When the upper surface of the concrete mix 16 is still plastic, small size exposed particulate 18 is sprayed over the top surface of the concrete mix 16 . An industrial sprayer, such as a Goldblat material sprayer or a sand blaster may be used to spray the exposed particulate. Use of such a spraying device allows for the uniform placement of the particulate over large surface areas. For example, the particulate can be uniformly sprayed for distances of about twenty to twenty-four feet from the sprayer as compared to traditional methods of broadcasting the particulate (e.g., manually) which can only achieve uniformity for a distance of about eight to ten feet away from the person broadcasting the particulate.
[0036] Depending on the particulate used, it may be desirable to wash the particulate with potable water and air dry it prior to spraying the particulate on the plastic concrete surface. The particulate 18 should not initially depress below the top surface of the concrete mix 16 but rather, should be sprayed solely to cover the same.
[0037] After the spraying of the particulates 18 , the particulates are then floated into the plastic upper surface of the concrete mix 16 using floats, for example, a fiberglass, wood or magnesium float. The mixing of the particulates 18 with the sand cement paste is critical as it ensures that the particulates 18 are thoroughly adhered or bonded to the top surface of the concrete mix 16 upon resultant curing. Hand sponges may then be used in a rotary fashion to further coat the surface seeded particulates 18 with the sand cement paste of the concrete mix 16 . The entire surface is then finished with steel trowels.
[0038] When the resultant particulate 18 and concrete surface 16 has sufficiently set such that a finger impression not in excess of three-eighths of an inch deep is made upon manually pressing with the fingertips thereupon, a conventional surface retarder, preferably a citric acid based surface retarding agent, is spread to uniformly cover the top surface of the concrete mix 16 . The surface retarder slows down the hydration process of the concrete by penetrating the top surface of the concrete mix to a depth of approximately one-eighth inch.
[0039] After the uniform coverage of the surface retarder thereon, the top surface of the concrete mix 16 is covered with either a plastic sheathing membrane or a liquid evaporation barrier, maintained thereupon for a period of approximately two to twenty-four hours. After about four hours, the surface can usually support a workman without leaving an impression, and the sheathing is removed and the top surface may be loosened with clean wet sponges working in a circular fashion, revealing the top surface of the embedded particulate 18 . The surface is then washed with clean water at low pressure and the heavy latents removed with a soft broom. The washing procedure and light bristle brushing preferably removes no more than five percent of the particulate 18 from the top surface of the concrete mix 16 . Subsequent to the washing, the concrete mix 16 is cured for a minimum of seven days with water only by use of a conventional fogger or soaker hose. Craft paper or liquid membrane cures may be used in place of water as job conditions dictate. Preferably after curing for a minimum of seven days, the surface is subject to conventional power washing using 3,000 PSI water pressure at a temperature of approximately 220° F. A mixture of 10-50% muriatic acid is preferably introduced into the hot water wash. The entire surface is then flushed with clean hot water. Preferably 28 days after the initial concrete placement, the surface is again washed with the high pressure/hot water wash to remove any efflorescence or discoloration from the surface. Sandblasting, acid etching or grinding and polishing may also be used to create texture variations on the surface.
[0040] If the particulate is reactable with a hydrolyzed alkali silica to form an insoluble silicate structure, after the final washing of the concrete, the top surface is treated with a hydrolyzed alkali silica solution, preferably lithium quartz sealer (approximately 12.5% lithium compound by volume). Other members of the alkali family of metals which may be suitable include sodium, potassium, rubidium, sesium, and francium. Other abundant silicone containing materials which may be suitable include feldspars, amphiboles or pyroxenes, and mica. The SINAK HLQ sealer is applied in light even coats using a sprayer or brush to a surface having a temperature between 50°-100° F. The hydrolyzed lithium quartz sealer penetrates the top surface of the concrete mix 16 , again to a depth of approximately one-eighth of an inch. The chemical treatment reacts with the mineral compounds or silicious materials within the concrete mix. The reaction causes formation of an insoluble silicate structure, which acts as a protective barrier, reducing the permeability of the surface to water. Applicant believes that minimizing the addition of moisture over time minimizes the undesired expansion and cracking, even given some chemical reaction in the concrete involving the potentially reactive particulates. Applicant also believes that minimizing the addition of moisture minimizes the scope of the chemical reaction involving the non-inert particulates. Of course, this chemical treatment may be omitted when non-reactive particulates are used.
[0041] The resultant surface seeded exposed particulate concrete besides exhibiting an extremely flat exposed particulate surface suitable for pedestrian and vehicular paving applications, is also not subject to deterioration from the chemical reaction from the non-inert particulates and minerals and silicates found in the concrete mix 16 . The surface texture and color approximates conventional flooring surfaces such as terrazzo, or ceramic tile, and this resemblance may be further accentuated by cutting the concrete surface into rectangular or irregular grids. The present invention comprises a significant improvement in the art by providing surface seeded exposed particulate concrete, wherein a large variety of exposed particulates not necessarily chemically inert may be introduced into the upper cement surface of the concrete mixture.
[0042] Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiment as well as alternative embodiments of the invention will become apparent to one skilled in the art upon reference to the description to the invention. It is therefore contemplated that the appended claims will cover any modifications of the embodiments that fall within the true scope of the invention. | An improved surface seeded exposed particulate concrete and method of making the improved surface seeded exposed particulate concrete is disclosed. Small particulate is sprayed over the upper surface of the concrete. The particulate may be sprayed using a material sprayer. The particulate may be uniformly sprayed to distances exceeding twenty feet. The particulate is mixed into a cement paste derived from the concrete mixture using floats. A surface retarder is then applied to cover the concrete surface. Subsequently, any surface film is washed from the surface of the concrete and the concrete is cured. The result is a surface seeded particulate with an exposed surface that is flat and is suitable for high traffic areas. The resultant surface may resemble stone, granite or marble. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to dispensing, feeding, and/or packaging of materials and more particularly, to dispensing, feeding, and/or packaging of viscous and dense materials.
BACKGROUND INFORMATION
[0002] Pasty materials, suspensions, sealants, cements and adhesives may have one or more of the following properties that make it difficult to dispense, feed and/or package these materials in a batch-wise mode without clogging, contaminating the interior parts of the dispenser, feeder and/or packaging unit. The properties, as mentioned hereinafter, exist in varying combinations, depending on the nature of the material concerned:
[0003] The material can be high in viscosity.
[0004] The visco-elastic ratio of the material may be dominated by the elastic properties at the shear-rate range exercised to make the material flow-out of the dispensing, feeding and/or packaging unit.
[0005] The specific gravity of the material may be relatively high.
[0006] The material may be abrasive.
[0007] The material may be sensitive to the pressure exercised to make the material flow out of the dispensing, feeding and/or packaging unit.
[0008] The material may be shear-rate sensitive at the shear-rate range exercised to make the material flow-out of the dispensing, feeding and/or packaging unit.
[0009] The material can be sensitive to degradation and or deterioration caused by the development of micro-organisms as a consequence of contamination of the interior parts of the dispensing, feeding and/or packaging unit.
[0010] Present equipment for dispensing, feeding and/or packaging of aforementioned materials may incorporate hydraulic pump feeders equipped with a plunger going down in a cylindrical vessel forcing the material to flow into the hole in the center of the plunger, flowing upwards through a tube/pipe either or not equipped with valves. At the end of the tube/pipe the material then flows into the packaging material. The length of the tube/pipe in relationship to the viscosity and the density of the material may cause difficulty removing the material from the tubes/pipes after finishing a batch. This may cause waste of material and/or potential cross-contamination with material in other batches. The process may also cause undesirable compression of the material. This may cause phase separation and/or cold joint formed agglomerates of metal fillers. End results of the process may provide clogged feeder tubes/pipes and/or build up of the pressure in the tubes/pipes resulting in an explosive breakdown of the tubes/pipes.
[0011] The shot size of the pump, which is the result of a preset stroke length of the hydraulic cylinder, has no closed loop control and therefore it is subject to variations in tolerances that quite often are not acceptable for the application.
[0012] Another category of present equipment for dispensing, feeding and/or packaging of aforementioned materials may incorporate hydraulic pump feeders equipped with a plunger going down in a cylindrical vessel providing only slight pressure on the material by its own weight. A scooping device takes a defined quantity of the material and pumps it into a hole in the center of the plunger, forcing the material to flow upwards into a tube/pipe either or not equipped with valves. At the end of the tube/pipe the material then flows into the packaging material. Again, the length of the tube/pipe in relationship to the viscosity and the density of the material may cause difficulty removing the material from the tubes/pipes after finishing a batch. This may cause waste of material and/or potential cross-contamination with material in other batches.
[0013] The process may also cause undesirable compression of the material. This may cause phase separation and/or cold joint formed agglomerates of metal fillers. End results of the process may provide clogged feeder tubes/pipes and/or build up of the pressure in the tubes/pipes resulting in an explosive breakdown of the tubes/pipes.
[0014] Again, the shot size of the pump, which is the result of a preset stroke length of the hydraulic cylinder, also has no closed loop control and therefore it is subject to variations in tolerances that quite often are not acceptable for the application.
[0015] Another category of equipment for dispensing, feeding and/or packaging of aforementioned materials may be constructed with multiple nozzle feeders exercising pressure on the product in an enclosed cylindrical vessel, forcing the material to flow upwards into a number of tubes/pipes either or not equipped with valves. At the end of the tube/pipe the material then flows into the packaging material. Again, the length of the tube/pipe in relationship to the viscosity and the density of the material may cause difficulty removing the material from the tubes/pipes after finishing a batch. This may cause waste of material and/or potential cross-contamination with material in other batches. The process may also cause undesirable compression of the material. This may cause phase separation and/or cold joint formed agglomerates of metal fillers. End results of the process may provide clogged feeder tubes/pipes and/or build up of the pressure in the tubes/pipes resulting in an explosive breakdown of the tubes/pipes.
[0016] Again, the shot size of the pump, which either is the result of a preset stroke length of the hydraulic cylinder or the pneumatic air pressure, has no closed loop control and therefore is subject to variations in tolerances that quite often are not acceptable for the application.
[0017] Another category of equipment for dispensing, feeding and/or packaging of aforementioned materials may incorporate hydraulic presses equipped with a plunger going down in a cylindrical vessel forcing the material to flow into the hole in the center of the bottom of the cylindrical vessel, flowing downward through a tube/pipe. At the end of the pipe a 3-way ball valve is mounted. In its closed position (position 1 ) some material can enter the outlet tube. In position 2 the material will be pressed into a buffer area. In position 3 (at the end of the cycle) the material will be pressed from buffer area into the packaging material. The pressing of the material, in 2 steps, may cause undesirable results. Again, the length of the tube/pipe in relationship to the viscosity and the density of the material may cause difficulty removing the material from the tubes/pipes after finishing a batch. This may cause waste of material and/or potential cross-contamination with material in other batches. The process may also cause undesirable compression of the material. This may cause phase separation and/or cold joint formed agglomerates of metal fillers. End results of the process may provide clogged feeder tubes/pipes and/or build up of the pressure in the tubes/pipes resulting in an explosive breakdown of the tubes/pipes.
[0018] Again, the shot size of the press, which is the result of the length of the tube in the buffer area (position 2 ), has no closed loop control and therefore it is subject to variations in tolerances that quite often are not acceptable for the application. Accordingly, a need exists for a device, method, and system for improving removal of the material from dispensing equipment and reducing undesirable compression of the material.
SUMMARY
[0019] The present invention is a novel device, system, and method or batch-wise preparing and dispensing of material into a packaging unit. The exemplary method may prepare the material in a movable vessel. The vessel may then be positioned underneath a plunger. The plunger may be moved into the vessel and form a seal between walls of the vessel and a rim of the plunger. Pressure may be applied to the material via the plunger. Packaging units may be positioned underneath two or more nozzles exiting from the vessel. The valve of each nozzle may be opened and material dispensed from the vessel into the packaging unit.
[0020] In another exemplary embodiment, the actions of moving the plunger and opening the valves may be controlled by a programmable logic controller. In another exemplary embodiment, successive packaging units may be supplied to each nozzle. In another embodiment, each packaging unit may be weighed after an initial loading and a valve of each nozzle may be opened for a set period of time based on each package weight. In yet another embodiment, each packaged unit may be weighed after an initial loading and a valve of each nozzle opened based on each respective package weight. Embodiments of the invention may have one or more of the following advantages.
[0021] The present invention is not intended to be limited to a system or method that must satisfy one or more of any stated objects or features of the invention. It is also important to note that the present invention is not limited to the exemplary or primary embodiments described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:
[0023] FIG. 1 is a side view of a general embodiment of the equipment for dispensing, feeding and/or packaging according to an exemplary embodiment of the present invention.
[0024] FIG. 2 is a cross-section of the outlet/nozzle according to an exemplary embodiment with a ball valve setting in the bottom of the cylindrical vessel of the present invention.
[0025] FIG. 3 is a cross-section of the outlet/nozzle according to an exemplary embodiment with the flexible tube valve setting in the bottom of the cylindrical vessel of the present invention.
[0026] FIG. 4 is a cross-section of the cylindrical vessel positioned in the front/operator side of the general embodiment of the equipment for dispensing, feeding and/or packaging according to an exemplary embodiment of the present invention.
[0027] FIG. 5 is a cross-section of the cylindrical vessel positioned in the rear/vessel input side and output side of the general embodiment of the equipment for dispensing, feeding and/or packaging according to an exemplary embodiment of the present invention.
[0028] FIG. 6 is a flow chart illustrating an exemplary embodiment for a dispensing, feeding and/or packaging method to be identified and modified according to the present invention.
[0029] FIGS. 7A , 7 B, and 7 C are a cross-section of a vessel being used for preparing and dispensing, feeding and/or packaging according to three different exemplary embodiments of the present invention.
DETAILED DESCRIPTION
[0030] The system may comprise a cylindrical vessel that can be moved into the dispensing, feeding and/or packaging unit on a removable cart or other transport device. The cylindrical vessel includes a bottom with a number of holes in a grid design accommodating the diameter of the cylindrical vessel space needed for the controlling parts as well as evolution in vertical and horizontal pressures caused by the changing level of the column-height of the material.
[0031] The system may be used for dispensing, feeding and/or packaging material or material with high density and viscosity. The material may have a specific gravity between about two to eight. The material may have a dynamic viscosity between about fifteen and four hundred Pascal seconds. The system may be used for dispensing, feeding and/or packaging edible, medicinal, cosmetics and industrial products, for example, but not limited to, silicon, condiments, dental paste, solder paste, adhesives, gels, glues, cement paste and dispersions and/or emulsions.
[0032] The holes may have a diameter in relationship to the viscosity and the visco-elastic ratio, the grain size and the weight percentage of the non-organic pigments, fillers or metal particles. The inlet of the hole may have a v-shaped design limiting the shear rate accelerations when the material is pressed into the outlet.
[0033] In the ball-valve embodiment, the lowest point of the v-shape is the level at the top of the radius of the ball-valve. Every individual hole is opened and closed by a load-cell controlled ball valve. The construction of the bottom enables positioning of the closed ball valve with the top of its radius 3 mm or less under the top-line of the bottom of the cylindrical vessel.
[0034] This construction may assure that the cylindrical vessel can be used for blending as well without the risk of building up single component of non-uniform conglomerates of the blend. The construction may also reduce and/or avoid the stress in the material build up by the acceleration of shear-rates when material passes through the holes in the bottom.
[0035] The mobile, quickly interchangeable mixing cylindrical vessel is entered into the dispensing, feeding and/or packaging station. A hoof-shaped positioning system, moving upward and downward on two servo motor driven spindles, elevates the cylindrical vessel from the rolling cart upward into the feeding position. Bolts may then secure the cylindrical vessel in the feeding position. When the cylindrical vessel is secured in its feeding position, it may be connected to the Programmable Logic Controller (PLC) or other computer controller through a quick-fit plug-in multiple pin connector and snap-lock air supply.
[0036] The plunger may be equipped with a peripheral polymer seal and a valve controlled air inlet/outlet. The air inlet/outlet may be located towards the center of the plunger. When the plunger moves downward in its operating position the air inlet/outlet valve is opened and this device functions as the extractor of any air between the plunger and the material in the vessel. The material may be slightly pressurized by the plunger driven down in a precisely and continuously controlled via a plunger spindle. The plunger spindle may also be driven by a PLC controlled motor. Under minimal and constant pressure the material flows directly through ball valve controlled nozzles into the packaging material. The position of the ball valves at underneath and close to the bottom of the cylindrical vessel may reduce or eliminate any material being pressurized and/or compressed in tubes/pipes. After passing the ball valve, the material flows into the packaging material, for example, jars, cassettes or other packaging without pressure and/or under reduced pressure to move a plunger downwards in a cartridge.
[0037] The outlet design for feeding the material into the packaging units without any feeding tubes and/or pipes allows for quick and thorough cleaning without loss of material or cross contamination between batches. In a flexible tube-valve embodiment, the ball valve may be replaced by a flexible silicon tube-valve enabling instant replacement of the tubes at set intervals or between batches. This specific embodiment enables certification for sanitary fitness for pharmaceutical and food applications or other applications require stricter sanitary conditions. The invention is not limited to a ball-valve or tube-valve; other types of valves may also be used.
[0038] Packaging units may be inserted into an instantly interchangeable tooling device mounted on a slide-in table or other transport device, for example, a conveyor belt or mobile cart. A packaging unit is situated under each load-cell. The load-cells are connected to a controller that controls open/close position of the nozzle valves in the bottom of the cylindrical vessel. The use of instantly interchangeable tooling devices or inserts positioned over the load-cells allows for changeover to different types of packaging without down-time of the feeding equipment. The system facilitates calibration of the load-cells with certified externally calibrated reference weights.
[0039] In the ball-valve embodiment, the system facilitates the filling of cartridges, caulking guns and similar types of packaging, featuring a plunger. When filling these packages through the snout, requiring the plunger to be moved by the inflowing material, a preset counter-pressure can be programmed. This preset pressure automatically is compensated by the controller or computer.
[0040] When the cylindrical vessel is empty the valve on the air/inlet/outlet is opened and the plunger can be moved upwards into its parking position. This construction reduces and/or eliminates many drawbacks of the present state of the art feeding systems as be understood from embodiments described herein.
[0041] Referring to FIGS. 1 and 4 , the system 100 may comprise a sealed top construction connecting four columns. A cylindrical vessel 102 can be moved into the dispensing, feeding and/or packaging unit 104 on a removable cart 106 or other transport device. The cylindrical vessel 102 includes a bottom construction 108 with a number of holes accommodating valves 110 in a grid design within the diameter of the cylindrical. The cylindrical vessel 102 may include enough space for housing the controlling parts, as well as evolution in vertical and horizontal pressures, based on the changing level of the column-height of the material.
[0042] A hoof-shaped positioning system 402 , moving up- and downward on two servo motor driven spindles 112 , elevates the cylindrical vessel 102 from the rolling cart 106 upward into the feeding position. This position may be secured by bolts. When the cylindrical vessel is secured in its feeding position, it may be connected to a PLC controller 114 through a quick-fit plug-in multiple pin connector and snap-lock air supply 116 . This may allow use of multiple cylindrical vessels so that each cylindrical vessel may be connected to the controller 114 during dispensing and packaging.
[0043] The system 100 is not limited to a separate controller 114 that temporarily connects to the cylindrical vessel 102 . In other embodiments, the controller 114 may be incorporated into the cylindrical vessel 102 with each cylindrical vessel 102 having a separate controller 114 . This embodiment may include a connector that allows the controller 114 to gather data from sensors external to the cylindrical vessel 102 .
[0044] A plunger 118 may be equipped with a peripheral polymer seal and a valve controlled air inlet/outlet in the center. When the plunger moves downward in its operating position the valve of the air inlet/outlet is opened and this device functions as the extractor of any air between the plunger and the material in the vessel. The material may be slightly pressurized by the plunger driven down in a precisely and continuously controlled via a plunger spindle 120 . The plunger spindle 120 is driven by PLC controlled motor 502 . Under minimal and constant pressure the material flows directly through the ball valve controlled nozzles into the packaging unit. The position of the ball valves at 3 mm under the bottom of the cylindrical vessel 102 may reduce or eliminate any material being pressurized and/or compressed in tubes/pipes. After passing the valve in each nozzle, the material flows into the packaging unit such as jars and cassettes without pressure and/or under reduced pressure to move a plunger downwards in a cartridge.
[0045] Referring to FIG. 2 , a cross-section of the ball-valve embodiment 200 is shown. The holes 202 have a diameter 204 in relationship to the viscosity and the visco-elastic ratio, the grain size and the weight percentage of the non-organic pigments, fillers or metal particles. The inlet of the hole has a v-shaped design limiting the shear rate accelerations when the material is pressed into the outlet. The lowest point of the v-shape hole 202 is the level as the top of the radius of the ball-valve 206 . Every individual hole is opened and closed by a load cell activating a compressed air driven lever 208 opening or closing the ball valve 206 . The construction of the bottom 210 enables positioning of the closed ball valve with the top of its radius 3 mm under the top-line of the bottom of the cylindrical vessel. The system is not limited to 3 mm. This distance may be increased or decreased depending on the design of the system and intended application.
[0046] In the ball-valve embodiment 200 , the system facilitates the filling of cartridges, caulking guns and similar types of packaging, featuring a plunger. When filling these packages through the snout, requiring the plunger of the cartridge to be moved by the inflowing material, a preset counter-pressure can be programmed. In this case the nozzle 212 is pressed into the snout of the packaging material. The snout is pressed against the flange 214 with a programmable preset force. The controller may automatically compensate for this preset pressure.
[0047] Referring to FIG. 3 , a cross-section of the tube-valve embodiment 300 is shown, the holes 302 have a diameter in relationship to the viscosity and the visco-elastic ratio, the grain size and the weight percentage of the non-organic pigments, fillers or metal particles. The tube-valve may be a flexible silicon tube-valve. The tube-valve may enable replacement of the tubes 304 through loosening the flange 306 and mounting a new tube on a tube setting 308 , at set intervals or between batches. The closing bolt with v-shaped, rounded head is driven by compressed air and controlled by the load-cells through the controller 114 . This embodiment enables certification for sanitary fitness for pharmaceutical and food applications.
[0048] The valve construction may assure that the cylindrical vessel can be used for blending as well without the risk of building up single component of non-uniform conglomerates of the blend and the avoidance of stress in the material build up by the acceleration of shear-rates when material would pass the holes in the bottom. The mobile, quickly interchangeable mixing cylindrical vessel is entered into the dispensing, feeding and/or packaging station. The outlet design for feeding the material into the packaging units without any feeding tubes ands/or pipes allows for quick an thorough cleaning without loss of material or cross contamination between batches.
[0049] Packaging units may be inserted into an instantly interchangeable tooling device mounted on a slide-in table. Every packaging type may be situated over a load-cell. The load-cells are connected to a controller 114 that controls open/close position of the valves 110 in the bottom of the cylindrical vessel. The use of instantly interchangeable inserts positioned over the load-cells allows for changeover to different types of packaging without down-time of the feeding equipment.
[0050] When the cylindrical vessel is empty or packaging complete the valve on the air/inlet/outlet situated on top of the plunger 118 is opened and the plunger 118 can be moved upwards into its parking position. This construction eliminates the drawbacks of the present state of the art feeding systems as described hereinabove.
[0051] Referring to FIG. 6 , an exemplary method for dispensing, feeding and/or packaging material according to the present invention 600 . The dispensing, feeding and/or packaging process is initiated (block 602 ). Is the blending and feeding performed in the same vessel (block 604 A)? If the blending is performed separately (“NO” Branch), the material is blended (block 604 B) and then the vessel 102 is positioned underneath a plunger 118 (block 606 ). If the blending is integrated (“YES” Branch), the material is blended (block 604 B) and different embodiments may incorporate addition steps as will be described with regard to embodiments later herein. The material may be transferred into the vessel 102 (block 606 A), the material may be blended within the vessel 102 in which case the plunger 118 may then be positioned over the vessel 102 (block 606 B) or the plunger 118 maybe connected to the blending tool (block 606 C).
[0052] Once material is prepared (block 604 ) which may involve, for example, adding ingredients, blending, and/or altering the temperature. The plunger 118 is moved into the vessel 102 and forms a seal between walls of the vessel 102 and a rim of the plunger 118 (block 608 ). The plunger 118 may apply pressure to the material by being pressed against a top surface of the material (block 610 ). Packaging units may be loaded underneath two or more nozzles 110 exiting from the vessel 102 (block 612 ). The valves of each nozzle are opened as previous described with regard to the ball-valve and tube-valve embodiments (block 614 ). The material is dispensed from the vessel 102 into the packaging units (block 616 ). This may be accomplished by opening the valves 110 for a set period of time given a set pressure applied by the plunger 118 . The system may also include weight sensors for each packaging unit. The controller may control the valves 110 based on current weight or may dispense material based on estimated time per shot. The system may use successive shots to load each packaging unit. A combination of weight measurements and estimated time per shot may be used to precisely load each packaging unit. The packaging units are removed and new packaging units may be loaded for the next dispensing cycle (block 618 ).
[0053] Referring to FIGS. 7A , 7 B, and 7 C, three different exemplary embodiment of the present invention are described. In the first embodiment 700 A, a separate blending vessel 704 A is used to prepare the material. The prepared material is supplied to the dispensing vessel 702 A. This may be accomplished by dumping the material into the dispensing vessel 702 A or feed the material through pipes/tubes.
[0054] In second embodiment 700 B, the material is prepared and dispensed in the dispensing vessel 702 B. Two tool heads are provided a plunger tool 718 B and a blending tool 720 B. The dispensing vessel 702 B is positioned within the dispensing unit 704 B. The blending tool 720 B is inserted within the dispensing vessel 702 B. Once the blending is complete the plunger tool 718 B is moved into position and inserted into the dispensing vessel 702 B.
[0055] In third embodiment 700 C, the material is prepared dispensed in the dispensing vessel 702 C. Two tool heads are provided a plunger tool 718 C and a blending tool 720 C. The dispensing vessel 702 C is positioned within the dispensing unit 704 C. The blending tool 720 C is coupled to the tool head 722 C and then inserted within the dispensing vessel 702 C. Once the blending is complete the blending tool 720 C is removed from the tool head 722 C and the plunger tool 718 C is coupled to the tool head 722 C. The plunger tool 718 C is then inserted into the dispensing vessel 702 B.
[0056] In fourth embodiment (not shown), the material is prepared dispensed in the dispensing vessel 702 C. A blending tool 720 C is permanently mounted to the tool head 722 C. Once the blending is complete, a plunger tool 718 C is mounted to the bottom of the blending tool 720 C and then inserted within the dispensing vessel 702 C. The plunger tool 718 C is then inserted into the dispensing vessel 702 B. The invention is not limited to the above four exemplary preparing and dispensing embodiments.
[0057] Various changes coming within the spirit of the invention may suggest themselves to those skilled in the art; hence the invention is not limited to the specific embodiment shown or described but the same is intended to be merely exemplary. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principle of the invention, which is not to be limited except by the following claims. | A device, method and system for dispensing of material into a packaging unit is disclosed herein. An exemplary device may have a movable vessel for holding the material prior to dispensing into packing unit. The movable vessel may have walls and a bottom with two or more nozzles extend from the bottom. The nozzles open and close controlling the flow of material from the movable vessel into the packaging unit. The exemplary device may also have a plunger sized to fit within the movable vessel. The plunger provides a seal between a rim of the plunger and the walls of the movable vessel and allows movement in a lateral motion to apply pressure to material within the movable vessel. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation of international application PCT/EP2004/003212, filed 26 Mar. 2004, and which designates the U.S. The disclosure of the referenced application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a apparatus for the melt-spinning of a plurality of strand-like filaments in a yarn forming operation.
For the melt-spinning of synthetic fibers, a melted polymer material is extruded to form a plurality of strand-like filaments. For this, it is necessary that the polymer melt be pressed through nozzle holes. The extrusion, which is also called spinning out, is done by a spinneret which comprises on its underside a plurality of nozzle holes. In practice, several spinnerets of this type are used simultaneously alongside one another in order to extrude several fiber bundles in parallel to one another. For this, the spinnerets are held in a nozzle holder.
In operation, it is necessary that the spinnerets be removed and given maintenance at regular intervals. The removal of the spinnerets is laborious and causes unavoidable downtimes which lead to a loss of production. There is thus the desire to fashion the design of the spinnerets, as well as the connection of the spinnerets to a nozzle holder, in such a way that they can be removed in as simple a manner as possible. Here the leak-tightness of the components must be ensured at all times during operation since the polymer melt is conducted and extended under a high melt pressure.
Apparatus are known from DE 199 35 982 A1, DE 42 36 570 A1, and the corresponding U.S. Pat. Nos. 6,716,016 and 5,387,097, respectively in which the spinnerets or spinneret blocks are secured in place in the nozzle holder in order to make the interface between a melt outlet of the nozzle holder and a melt inlet of the spinneret pressure-tight. For this, a cylindrical seal is secured in place between the melt outlet and the melt inlet. However, apparatus of this type have the basic disadvantage that during operation a deformation of the sealing ring occurs so that a securing in place between the sealing ring and the nozzle holder hinders the loosening of the spinneret. In addition to this, the spinneret must be secured in place against the nozzle holder with high securing forces in order to ensure the sealing function at the interface between the melt outlet and the melt inlet so that correspondingly high de-securing forces are required to loosen the spinneret.
DE 16 60 375 and corresponding U.S. Pat. No. 3,500,499 discloses an apparatus in which the housing and the nozzle plate of the spinneret are held in a receptacle of the nozzle holder in such a manner that they can move relative to one another and in such a manner that the connection between the melt outlet of the nozzle holder and the melt inlet of the spinneret is sealed automatically. However, the movable arrangement of the individual parts of the spinneret has the great disadvantage that the spinneret is not held in the nozzle holder in such a manner that it can be removed as a structural unit. Furthermore, the concept requires an additional sealing point within the spinneret.
It is accordingly an object of the invention to provide a melt spinning apparatus of the type stated initially in such a manner that, on the one hand, the spinneret is held in the nozzle holder in such a manner that it can be loosened easily and, on the other hand, high pressure forces for sealing can be produced between the spinneret and the nozzle holder.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the invention are achieved by the provision of a melt spinning apparatus which comprises a spinneret which comprises a housing which includes a central connecting piece having a melt inlet opening extending therethrough, an annular wall extending radially outwardly from the connecting piece, and a collar extending about the outer periphery of the annular wall. The spinneret further comprises a nozzle plate containing a plurality of nozzle openings and which is mounted to or adjacent the collar of the housing in spaced relation below the annular wall, so as to define a diffuser chamber between said annular wall and the nozzle plate.
The spinneret is mounted within the receptacle of the nozzle holder with the central connecting piece of the housing abutting the inner wall of the receptacle and so that the melt inlet of the housing communicates with the melt outlet of the nozzle holder.
Also, the annular wall of the housing of the spinneret is sufficiently thin and formed of a material to be elastically deformable when a melt is conducted under pressure into the diffuser chamber of the housing and so as to press the central connecting piece of spinneret against the inner wall of the receptacle and seal the melt inlet against the melt outlet.
The invention is distinguished by the fact that the high pressure forces required for sealing only arise and act in the operational state. For this, the annular wall of the housing of the spinneret is formed to be elastic in such a manner that under the action of the melt pressure a deformation of the housing of the spinneret occurs and that the deformation of the housing produces a pressure force for the self-sealing securing in place of the spinneret in the nozzle holder. Thereby the spinneret can be held in the nozzle holder with low securing forces which act only to fix the spinneret in the nozzle holder. Only in the operational state does the melt pressure acting in the spinneret produce a deformation of the housing and thus a self-sealing pressure force.
An additional advantage of the invention is given by the fact that the level of the pressure force for self-sealing securing in place is proportional to the melt pressure. Thus, the connection of the spinneret to the nozzle holder itself remains pressure tight even at the highest melt pressures.
In the case of a particularly advantageous configuration of the invention, the spinneret and the nozzle holder are connected to one another by a securing means which produces a securing force. Therein the securing force produced by the securing means and the pressure force produced by the deformation of the housing have the same direction. Thus, the spinneret can be held in the nozzle holder even with relatively low securing forces or loosened from the nozzle holder with relatively low de-securing forces.
In order, in the case of pre-mounted spinnerets, not to get an adverse effect between the individual parts, such as, for example, the nozzle plate and the housing, the embodiment of the invention is particularly preferred in which the annular wall of the housing has a form and a material which leads to a directionally related deformation under pressure. In particular, a predefined deformation under melt pressure can be achieved by a particular shaping of the housing. Thus, maximum pressure forces can be produced at those sealing points that are to be sealed.
The sealing joints formed between the melt outlet of the nozzle holder and the melt inlet of the spinneret can even be advantageously sealed by the wall of the housing in the area of the melt outlet in such a manner that it is deformable under pressure. The deformation produced by the pressure force thus acts directly on the sealing face formed between the spinneret and the nozzle holder.
To ensure the necessary strength of the housing, the wall of the housing is preferably formed as a thin-walled spherical cap. With this, a maximum deformability is achieved with maximum strength of the housing. In principle however, any shaping of the housing is possible which causes the desired elastic deformation.
The embodiment of the invention in which a sealing ring is disposed between the melt outlet of the nozzle holder and the melt inlet of the housing is distinguished by the fact that even the slightest deformations of the housing lead to a high sealing action.
The apparatus according to the invention is moreover distinguished by a low weight of the spinneret, which leads to an improved handling during mounting and dismounting of the spinneret in the nozzle holder. In addition to this, a reduced expenditure in apparatus is possible due to there being fewer components.
In the following, several embodiments of the apparatus according to the invention are described in more detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 schematically illustrates a cross-section of a first embodiment of the apparatus according to the invention, and
FIG. 2 schematically illustrates a cross-section of another embodiment of the apparatus according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a cross-section of a first embodiment of the apparatus according to the invention is shown in schematic form. The apparatus comprises a nozzle holder 1 which comprises on an underside a downwardly opening receptacle 18 which is configured to receive a spinneret 2 . The nozzle holder 1 usually comprises on the underside several such receptacles (not represented here) to receive several spinnerets. For each receptacle 18 the nozzle holder 1 contains a melt outlet 3 , via which a polymer melt is fed to the spinneret 2 . The nozzle holder 1 , which is also designated as a so-called spinning beam, contains additional melt feeding components such as lines and spinning pumps, which are not represented here.
The nozzle holder 1 is formed in such a manner that it can be heated. Thus, the melt feeding components received by the nozzle holder 1 can be kept at a specified temperature at their walls or the walls of the nozzle holder by a heat transfer medium or by an electrical heating element.
The spinneret 2 comprises a housing 4 and a nozzle plate 10 which is secured on the underside of the housing 4 via the bolts 15 . The nozzle plate 10 comprises a plurality of nozzle openings 11 which serve as the melt outlets. A perforated plate 13 and a filter insert 12 supported on the perforated plate 13 are disposed on the nozzle plate 10 . Within the housing 4 a diffuser chamber 19 is disposed above the filter insert 12 . The diffuser chamber 19 is connected, via a melt inlet 5 in the housing 4 , to the melt outlet 3 of the nozzle holder 1 .
The housing 4 of the spinneret 2 consists essentially of three components. The first component is formed by a connecting piece 9 which is formed in the center and contains the melt inlet 5 . The preferably cylindrical connecting piece 9 is disposed so as to be concentric with the melt outlet 3 of the nozzle holder 1 . Encircling the connecting piece 9 in the form of a ring, a second component of the housing 4 is formed by the annular wall 8 . The wall 8 is formed as a thin-walled spherical cap, the curvature of which essentially forms the diffuser chamber 19 . This component is formed so as to be elastic in such a manner that a deformation under pressure is possible.
A third component of the housing 4 is formed as an external, stable, threaded collar 7 which extends about the periphery of the wall 8 . The threaded collar 7 serves on one side to receive several of the bolts 15 through which the nozzle plate 10 is connected to the housing 4 in a pressure-tight manner and on another side to receive an external thread 20 which is connected to the nozzle holder 1 via a threaded joint 16 .
The spinneret 2 is held in the receptacle 18 of the nozzle holder 1 via the threaded joint 16 . Therein the spinneret 2 is threaded onto the nozzle holder 1 until the housing 4 with the melt inlet 5 abuts the nozzle holder 1 at the sealing face 6 of the melt outlet 3 . The interface between the melt outlet 3 and the melt inlet 5 is sealed in the outward direction by an additional sealing ring 17 . A securing force for the fixation of the spinneret 2 is produced by the threaded joint 16 acting as securing means so that no gap between the housing 4 and the nozzle holder 1 occurs at the sealing face 6 .
In the operational state, a polymer melt is conducted under high pressure from the nozzle holder 1 , via a melt outlet 3 , into the melt inlet 5 and diffuser chamber 19 of the spinneret housing 4 . The melt pressure present within the diffuser chamber 19 acts from inside on the wall 8 of the housing 4 . The wall 8 is formed to be thin in such a manner that a slight elastic deformation is possible. The deformation acting essentially on the wall 8 leads to the connecting piece 9 with the sealing ring 17 being pressed onto the sealing face 6 . The wall 8 is formed to be elastic so that the deformation of the housing is only present under the action of the melt pressure. The pressure force acting on the sealing face due to the deformation leads to a self-sealing securing in place of the spinneret 2 within the receptacle 18 .
It will be noted that the pressure force produced by the deformation has the same direction as the securing force for the spinneret 2 produced by the threaded joint 16 .
Within the diffuser chamber 19 the polymer melt is fed, under the action of the melt pressure, through the filter insert 12 and the perforated plate 13 in order then to be extruded as fine filament strands through the nozzle holes 11 of the nozzle plate 10 . In so doing, the sealing between the nozzle plate 10 and the housing 4 can be achieved by an additional ring seal (not represented here). Along with this, the pressure force for sealing in the outward direction is produced by the bolts 15 which are disposed uniformly on the circumference of the nozzle plate 10 .
In case replacement of the spinneret 2 is required, the feeding of the melt is first discontinued so that within the spinneret 2 , therefore within the diffuser chamber 19 , the melt pressure drops off. With this, the elastic deformation of the housing 4 returns to its original state. The spinneret 2 is only held via the securing force applied by the threaded joint 16 . To loosen the spinneret 2 correspondingly low de-securing forces are needed.
In FIG. 2 another embodiment of the apparatus according to the invention is shown in schematic form. The components with the same function have been given the same reference numbers there.
The nozzle holder 1 is embodied in a manner essentially identical to the foregoing embodiment according to FIG. 1 so that reference can be made to the foregoing description.
The spinneret 2 is formed by the housing 4 , filter insert 12 , perforated plate 13 , and nozzle plate 10 . Here the housing 4 is held with the nozzle plate 10 in a cylindrical threaded sleeve 23 , which is held in the nozzle holder 1 by means of the threaded joint 16 via an external thread 20 . Also, the housing 4 is formed of integral one piece construction which includes a central connecting piece 9 with the melt inlet 5 , the thin wall 8 which encircles the connecting piece 9 , and an encircling supporting collar 21 . A first ring seal 14 . 1 is disposed between the filter insert 12 and the supporting collar 21 of the housing 4 . A second ring seal 14 . 2 is disposed between the perforated plate 13 and the nozzle plate 10 . The nozzle plate 10 is supported on a holding collar 22 at the bottom end of the threaded sleeve 23 .
In the embodiment represented in FIG. 2 , the spinneret 2 is secured in place in the nozzle holder 1 by the threaded joint 16 via the threaded sleeve 23 . Here an encircling sealing ring 17 concentric to the melt inlet 5 is flush with the sealing face 6 of the melt outlet 3 of the nozzle holder 1 . The mounting of the spinneret 2 is accomplished by the threaded sleeve 23 , in so doing with a securing force which produces no significant pressure forces for sealing at the sealing points of the spinneret 2 .
The pressure forces for the self-sealing securing in place of the spinneret 2 are only achieved in the operational state by the deformation of the housing 4 . For this, the polymer melt first reaches, via the melt outlet 3 , the melt inlet 5 , and the diffuser chamber 19 . The melt pressure in the diffuser chamber 19 then causes an elastic deformation of the wall 8 of the housing 4 in such a manner that, due to the deformation of the housing 4 in the direction of the receptacle 18 , via the connecting piece 9 additional pressure forces are built up which lead to the securing in place of the spinneret 2 . Through the use of the seals 14 . 1 , 14 . 2 , and 17 in the joints of the individual parts it is ensured that, in the operational state at the existing melt pressure, a sufficient sealing at the sealing points of the spinneret 2 , as well as the connection between the spinneret and the nozzle holder 1 , is ensured in the outward direction.
The function of the apparatus represented in FIG. 2 is identical to the embodiment according to FIG. 1 . To that extent, reference is made to the foregoing embodiment. Within the diffuser chamber 19 melt pressures of up to 250 bar are reached in the process. To filter the polymer melt, the filter insert 12 is preferably formed by one of the several sieves with different mesh widths. It is however also possible to use, above the perforated plate 13 , a filter insert for a filter granulate having different grain sizes.
The design of the represented embodiments of the apparatus according to the invention, as well as the design of the individual parts, is merely given as an example. The invention subsumes all the apparatus for melt-spinning which comprise the spinnerets, housing, or housing parts which, with pressure present, lead to a deformation and thus to a self-sealing securing in place. The leak-tightness of the nozzle block is thus independent of the pressure force which acts between the spinneret and the nozzle holder for the fixation of the spinneret. Here it is irrelevant whether round, rectangular, or annular spinnerets or nozzle plates are used.
Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | An apparatus for melt spinning a plurality of strand-like filaments through a spinneret, which is mounted within a downwardly open receptacle in a nozzle holder. The spinneret includes a housing which is deformed by the entry of the pressurized polymeric melt into an internal diffuser chamber, so as to press the spinneret against the inner wall of the receptacle and thereby seal the melt inlet of the spinneret against the melt outlet in the receptacle. Thus the high pressure forces required for sealing only arise and are active during the operational state, and the spinneret can be otherwise held in the nozzle holder under a minimal securing force which permits the spinneret to be easily loosened and removed for periodic maintenance. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to audio signal processing. More specifically, reverberation removal is disclosed.
BACKGROUND OF THE INVENTION
[0002] In many situations audio signals are undesirably distorted by reverberations. For example, when a speakerphone is used, the microphone of the speakerphone tends to pick up voices that have been distorted by room reverberations and this can interfere with the ability to comprehend what is being said by the participants of the phone call. In this situation and in others where reverberation is an issue, it would be useful if reverberations could be effectively removed by signal processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Various embodiments of the invention are disclosed in the following detailed description and the accompanying drawings.
[0004] FIG. 1 illustrates signal processing for reverberation removal.
[0005] FIG. 2 illustrates a type of spectro-temporal analysis.
[0006] FIG. 3 illustrates a calculation of the energy in bands as a function of time.
[0007] FIG. 4 illustrates reverberation removal process using delay stability to identify reverberant part of signal within a band.
[0008] FIG. 5 illustrates peak finding and delay determination.
[0009] FIG. 6 illustrates the delay, delay stability, and the gain corresponding to FIG. 5 .
[0010] FIG. 7 illustrates reverberation removal process using a channel with the known characteristic that the channel contains mostly or entirely all of the reverberant part of the signal.
[0011] FIG. 8 illustrates a gain derived non-linearly from energy in a channel with the known characteristic that the channel contains mostly or entirely all of the reverberant part of the signal.
[0012] FIG. 9 illustrates reverberation removal using a known non-reverberant impulse response function and a reverberant impulse response function to remove the non-reverberant portion of the signal.
[0013] FIG. 9A illustrates an embodiment of reverberation removal using onset location and a known reverberant impulse function.
[0014] FIG. 9B illustrates an embodiment of reverberation removal using onset location and a known reverberant impulse function.
[0015] FIG. 10 illustrates a gain function derived from the non-reverberant and reverberant impulse response functions.
[0016] FIG. 11 illustrates a gain derived from knowing the non-reverberant impulse response function and the reverberant impulse response function.
[0017] FIG. 12 illustrates reverberation removal using harmonic responses to derive the reverberant portion of the impulse response function.
[0018] FIG. 13 illustrates reverberation removal derived from harmonic signal information.
DETAILED DESCRIPTION
[0019] The invention can be implemented in numerous ways, including as a process, an apparatus, a system, a composition of matter, a computer readable medium such as a computer readable storage medium or a computer network wherein program instructions are sent over optical or electronic communication links. In this specification, these implementations, or any other form that the invention may take, may be referred to as techniques. In general, the order of the steps of disclosed processes may be altered within the scope of the invention.
[0020] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate the principles of the invention. The invention is described in connection with such embodiments, but the invention is not limited to any embodiment. The scope of the invention is limited only by the claims and the invention encompasses numerous alternatives, modifications and equivalents. Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. These details are provided for the purpose of example and the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.
[0021] Reverberation removal by signal processing audio signals is disclosed. In various embodiments, the signal processing may involve calculating the energy of the audio signals in different frequency bands, filtering the energy over time in each band such that reverberant energy is reduced, identifying the reverberation portion of the signals in each of the bands, establishing a gain function to remove the reverberant portion of the signal in each band, modifying the energy of the audio signals in each band using the gain function, resynthesizing the audio signals from the modified energy signals in each band, combining the processed signals into a single signal, and mixing the processed signals with other signals that mask undesirable processing artifacts.
[0022] FIG. 1 illustrates signal processing for reverberation removal. Original signal A 100 and original signal B 104 are audio signals that are to be processed. In some embodiments, there is only one original signal. In some embodiments, there are two or more original signals. In some embodiments, the audio signals are microphone signals that both are in a space or room together. In some embodiments, the audio signals are recordings of microphone signals that both are in a space or room together. In some embodiments, the audio signals are analog. In some embodiments, the audio signals are digital. In some embodiments, the audio signals are a mixture of digital and analog. Original signal A 100 is first processed by spectro-temporal analyzer 102 , original signal B 104 is first processed by spectro-temporal analyzer 106 . The spectro-temporal analyzer produces signal outputs that indicate the amount of energy in the input signal within frequency bands over time. The spectro-temporal analyzer may be implemented in a number of different ways, including Fourier Transform, Fast Fourier Transform, Gammatone filter banks, wavelet transform, or cochlear models. Particularly useful implementations are the cochlear models described in U.S. patent application Ser. No. 09/534,682 (Attorney Docket No. ANSCP001) by Lloyd Watts filed Mar. 24, 2000 entitled: “EFFICIENT COMPUTATION OF LOG-FREQUENCY-SCALE DIGITAL FILTER CASCADE” and U.S. patent application Ser. No. 10/074,991 (Attorney Docket No. ANSCP006) by Lloyd Watts filed Feb. 13, 2002 entitled: “FILTER SET FOR FREQUENCY ANALYSIS” which are herein incorporated by reference for all purposes. In 108 , reverberation is removed by analyzing the amount of energy within frequency bands in the input signals in order to identify the main part of the signals and reverberant part of the signals and then to suppress the reverberant part of the signals. In some embodiments, the reverberant part of the signal is identified using delay stability between two or more signals. In some embodiments, the reverberant part of the signal is identified using one or more signals known to contain mostly or only reverberant energy. In some embodiments, the reverberant part of the signal is identified by using a known reverberant impulse response function. Using this impulse response function the input signals can be processed to suppress the reverberant part of the signal. In some embodiments, the reverberant part of the signal is deduced from a voice pitch contour derived from the frequency bands with less reverberation and these are then used to suppress the more reverberant part of the signal. In 110 , the temporal audio signal is resynthesized from the separate frequency band signals to create new signal 112 with the reverberant energy significantly suppressed. The resynthesis can be implemented in a number of different ways including inverse Fourier Transform, inverse Fast Fourier Transform, inverse wavelets, or algorithms that reproduce an acoustical waveform from a cochlea model output [described in U.S. Provisional Patent Application No. 60/608,812 (Attorney Docket No. ANSCP013+) filed Sep. 9, 2004 entitled: “SPARSE REPRESENTATION” which is herein incorporated by reference for all purposes.]. In some embodiments, both signal A and signal B are processed to remove the reverberant portion of the signal. In other embodiments, only one signal is used to remove the reverberant portion of the signal. In other embodiments, more than two signals are used to identify the reverberant portion of the signal. In some embodiments, more than two signals are processed to remove the reverberant portion of the signal.
[0023] FIG. 2 illustrates a type of spectro-temporal analysis. In 200 , 204 , and 208 , the input signal is bandpass filtered. In 202 , 206 , and 210 , the energy in each band is then calculated.
[0024] FIG. 3 illustrates a calculation of the energy in bands as a function of time. In 300 , 304 , and 308 , the input signal in each band is rectified. In 302 , 306 , and 310 , the signal from each rectifier is low pass filtered to give the energy in each band.
[0025] FIG. 4 illustrates reverberation removal process using delay stability to identify reverberant part of signal within a band. In step 400 and 402 , within each band the peaks in the energy are located. In step 404 , within each band the delay stability between the peaks in signal A and peaks in signal B are determined. Peak determination can be implemented in a number of ways. If the signals are digital, peaks can be found by searching for samples that have higher values than the previous sample and the next sample. If the signals are analog, peaks can be found by detecting when the derivative of the signal changes sign from positive to negative (positive zero-crossing detector). In step 406 , the gain for each band is determined based on the delay stability. When the delay between the peaks in the two channels is consistent over a period of time, or stable, then the gain for the band is generally set to be high. When the delay between the peaks in the two channels is not consistent over a period of time, or is not stable, then the gain for the band is generally set to be low. In some embodiments, the delays between more than two signals are used to determine the delay stability. In various embodiments, the gain is adjusted based on the measured stability using an appropriately selected function. In some embodiments, the gain is proportional to the delay stability. In other embodiments, the gain is a nonlinear function of the delay stability. In one embodiment, the stability is determined by multiplying each delay by the characteristic frequency of the band, computing the absolute value of the difference between consecutive delays, averaging this quantity over a period of time, adding 1 to this quantity dividing 1 by the result. In step 408 , the two signals in a band are combined and the energy of the combined signals is adjusted using the gain based on the delay stability. In some embodiments, the signals are combined by selecting the larger of the two signals. In some embodiments, the signals are combined by selecting the average of the two signals. In some embodiments, the signals are both processed to remove the reverberant portion of the signals. In some embodiments, derived gain function is applied to the combination of more than two signals.
[0026] FIG. 5 illustrates peak finding and delay determination. Graph trace 500 shows the energy as a function of time for a band of signal A. Graph trace 502 shows the energy as a function of time for the same band of signal B. The delay between peaks is also shown. The delays between the peaks in signal A and the peaks in signal B are mostly the same (delay=d), and so they are mostly consistent. In region 504 of the trace, the delay is not the same (delay=d') and there is also a peak in the band of signal B that does not appear in signal A, and so the delays are mostly inconsistent. In region 504 , the delay is considered not to be stable.
[0027] FIG. 6 illustrates the delay, delay stability, and the gain corresponding to FIG. 5 . Trace 600 illustrates the delay between the peaks in signal A and the peaks in signal B. Trace 602 illustrates the delay stability, or the degree to which the delay stays constant. The delay stability is a function of the delay whose value drops when the average slope of the delay is anything but horizontal. Trace 604 illustrates the gain based on the delay stability. When the delay stability drops, the gain is generally reduced.
[0028] FIG. 7 illustrates reverberation removal process using a channel with the known characteristic that the channel contains mostly or entirely all of the reverberant part of the signal. In step 704 , the gain in each band is determined using the signal energy in a given band from the channel (e.g. signal B as shown) with the known characteristic that the channel contains mostly, or entirely all of the reverberant part of the signal. In some embodiments, the gain is determined by taking the ratio of the energy from signal B to signal A, adding this ratio to 1, and dividing 1 by the result. In other embodiments, the gain is at one constant value except when the energy in signal rises above a threshold at which point the gain is at a lower constant value to suppress the reverberation energy. In step 706 , the gain is used from step 704 to adjust the energy for each band of signal A.
[0029] FIG. 8 illustrates a gain derived non-linearly from energy in a channel with the known characteristic that the channel contains mostly or entirely all of the reverberant part of the signal. Trace 800 is the energy in the channel. Trace 802 shows a gain that is at a constant level when trace 800 is above a threshold and at a lower constant value when trace 800 is below a threshold.
[0030] FIG. 9 illustrates reverberation removal using a known reverberant impulse response function to suppress the reverberant portion of the signal. In step 904 , the energy of each signal band is processed to determine the positions of onsets. Reverberation reduction is achieved by knowing the positions of the onsets in the signal bands and knowing the reverberant response of the room to energy onsets in each frequency band. In some embodiments, the positions of energy onsets can be detected by measuring when the rate of change of the energy exceeds a fixed threshold. In some embodiments, the reverberant impulse response function is measured by examining the impulse response in a frequency band that has reverberation. In some embodiments, the signals in each band can be identified easily as a series of impulses, so that the reverberant portion of the impulse can be easily removed using a gain function. In some embodiments, an inverse filtering using the reverberant portion of the impulse function is implemented.
[0031] FIGS. 9A and 9B illustrate embodiments of reverberation removal using onset location and a known reverberant impulse function. In some embodiments, in order to extract onsets, a filter is applied to the energy output of each frequency. The filter is actually composed of two causal first-order low-pass filters, filter 912 with a shorter time constant (faster) and filter 914 with a longer time constant (slower). These time constants may be dependent on the frequency band. The time constants may be trained ahead of time or may be adapted on-line. Both filters are applied to the energy output function of time for each band 910 , and then the output of the slower filter is subtracted (see 916 ) from the output of the faster filter, and the result is half-wave rectified (see 917 ). In some embodiments, the energy output might be first compressed (e.g., through a logarithm or square-root function) before being filtered. If so, the inverse function is applied after filtering. In 918 , by applying a peak-finding algorithm to the final result, the position of onsets can be estimated (and in 920 used in an algorithm that uses a gain function to suppress energy after onsets). If instead the result is now mixed (see 930 in FIG. 9B ) with the original signal and then resynthesized, onsets will be emphasized and processing artifacts will be less audible, depending on the mixture. The higher the proportion of original signal in the mixture, the less audible will be processing artifacts, but also the more audible will be the reverberation. In some embodiments, after the signal is subtracted (see 916 ) from the output of the faster filter, and the result is half-wave rectified (see 917 ), the signal is resynthesized and then mixed with the original signal.
[0032] FIG. 10 illustrates a gain function derived from the reverberant impulse response functions. Trace 1000 illustrates the non-reverberant impulse. Trace 1002 illustrates the reverberant impulse response function overlaid on the non-reverberant impulse so that the differing portion of the non-reverberant part of the impulse response can be easily identified. Trace 1004 illustrates a gain function derived from the reverberant and non-reverberant impulse response functions designed to suppress reverberant energy.
[0033] FIG. 11 illustrates a gain derived from knowing the non-reverberant impulse and the reverberant impulse response function. Trace 1100 illustrates the energy in a band of the signal. The shaded portion of the trace represents the reverberant portion of the signal. Trace 1102 illustrates a gain function derived to suppress the reverberant portion of the signal.
[0034] FIG. 12 illustrates reverberation removal using voice pitch to derive the reverberant portion of the energy in each frequency band. In step 1204 , harmonic information from signal A in each band 1200 is used to derive the reverberant portion of the impulse response. In some embodiments the reverberant portion of the impulse response function is derived by measuring the voice pitch as a function of harmonics that have little or no reverberation (e.g. higher frequency bands). By projecting this pitch value to the other harmonics (e.g. lower frequencies) and removing the other signals in those bands, the non-reverberant portion of the signal can be suppressed. In step 1206 , a gain function is derived for signals in the different bands to suppress the reverberant portion of the signal energy. In step 1202 , the signal energy is adjusted in each band according to the derived gain function.
[0035] FIG. 13 illustrates reverberation removal derived from harmonic signal information. Traces 1300 illustrate a high harmonic of a signal and its corresponding reverberation where the solid line represents the signal and the dashed line the reverberation. Since the signals are easily distinguished the voice pitch can easily be found. Trace 1302 illustrates the lower harmonic signal where the reverberant and non-reverberant portions of the signal are not easily distinguished from each other. The voice pitch derived from the higher harmonics can be projected to a lower harmonic so that the reverberant part of the signal can be rejected. Trace 1304 illustrates the pitch values derived from higher harmonics projected down to the lower harmonic. Trace 1306 and 1308 illustrate the higher harmonic and the lower harmonic with the reverberation portion of the signal removed.
[0036] Although the foregoing embodiments have been described in some detail for purposes of clarity of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed embodiments are illustrative and not restrictive. | A method of removing reverberation from audio signals is disclosed. The method comprises spectro-temporally analyzing the first audio signal and the second audio signal to derive an energy function of time for a plurality of frequency bands. The method further comprises determining a delay stability between the energy function of time for the first audio signal and the second audio signal in each band, determining a gain function in each band based on the delay stability, adjusting the energy of the first audio signal and the second audio signal using the gain function within each band, and resynthesizing audio signals from the energy in each band of the first audio signal and the second audio signal. | 7 |
This application is a divisional application of U.S. patent application Ser. No. 12/318,679, filed on Jan. 6, 2009, which is a divisional of U.S. application Ser. No. 10/866,120, filed Jun. 14, 2006, now U.S. Pat. No. 7,494,779 the entire contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods for producing complete human antibodies and, more particularly, to a method for producing human antibodies of agonist, antagonist and/or inverse agonist to a biological receptor and the antibodies produced by the same method.
2. Description of Related Art
Generally speaking, drugs must reach specific sites in the body to achieve pharmaceutical effects. Most of these sites are composed of cells that provide target molecules, i.e., receptors, to bind with, or interact with the molecules of drugs. The drug-receptor interaction or binding may lead to either an activation of the receptor, which ultimately results in a biological response; or a blockade of the receptor, which hinder the receptor activation by other drugs or ligands. Pharmacodynamics thus defines an agonist as a drug has the same or similar effect as a group of drugs or ligands. Accordingly, when a drug counteracts the effect of another drug or group of ligands, it is called an antagonist. In the situation where a ligand produces an effect opposite to that of the agonist by occupying the same receptor, it is called an inverse agonist.
Human antibodies have been successfully used for therapeutic drugs against various diseases. These diseases are traditionally infectious diseases, such as infections by respiratory syncytial virus (RSV). Recently, however, antibodies are increasingly used in the therapy of many other disorders, including autoimmune disorders and malignancies like metastastic breast cancer, non-Hodgkin's lymphoma, chronic lymphocytic leukemia and acute myeloid leukemia. Prophylactic use against organ rejection or blood clotting during angioplasty has also been achieved. In general, therapeutically monoclonal antibodies (MAbs) clinically available so far act by binding to ligands, e.g., virus or cytokines, thereby preventing their interactions with the respective receptors and thus blocking unwanted natural effector functions. Other existing receptor-specific monoclonal antibodies have been confined mostly to direct defensive and demolishing mechanisms to receptor-bearing targets such as malignant cells, thereby mediate their death. Although these systems have been extremely effective, they are not readily adapted to resolve more physiologic situation in which receptor-acting antibodies have pharmacodynamical activities.
While yet to be fully available, antibodies with a defined pharmacologic activity have been reported lately. For example, WO 00/32231, U.S. Pat. No. 5,811,097, U.S. Pat. No. 5,855,887 and U.S. Pat. No. 6,051,227 disclose MAbs to mouse CD152 (cytotoxic T lymphocyte antigen-4, CTLA-4) derived from hamsters immunized with a mouse CD152-human IgG1 fusion protein. As CD152 belongs to a groups of immunomodulating receptors that collectively termed as CD28 superfamily and represents a receptor negatively involved in T-lymphocyte co-stimulatory pathways regulating both humoral (antibody-mediated) and cellular immune response, an anti-tumor immune response that shows specificity and memory against the growing tumor was thereafter provoked by injecting antibodies specific for the receptor into mice with tumors (Leach et al., Science 271:1734, 1996). The idea behind this “CTLA-4 (antibody) blockade” approach is that the negative function of CD152 can be blocked with antibodies, therefore acting as antagonists, which may allow the activation or sustenance of residual but effective anti-tumor immunity.
Blocking the negative regulatory role for CD152 inhibition of the immune response provides a novel therapeutic technology, allowing the immune system to recognize and more vigorously attack foreign pathogens and cancers. However, antibodies with murine sequences often elicit immunological responses in the patient (human anti-mouse response) when administered to a human patient. Therefore, it is desirable to prepare fully human antibodies that are void of non-human sequences. By immunizing engineered transgenic mice harboring human immunoglobulin genes, fully human antibodies against CD152 have been reported (see, e.g., WO 00/37504, WO 01/14424, U.S. Pat. Nos. 6,150,584 and 6,682,736). The most exciting conclusion from continuous studies of these anti-CD152 blocking antibodies is the potential for antagonistic antibodies to strengthen the immune response against certain tumors and pathogens, leading to the reduction or elimination of well-established tumors as well as enhancement of antibody reaction to vaccinations.
Being an inhibitory receptor of the CD28 receptor family that plays a key role in regulating T cell activation, agonist binding to CD152 reduces T cell proliferation and cytokine production, resulting in attenuated immune responses. Endogenous agonists include CD80 and CD86 present on antigen-presenting cells (APCs) and CD152 ligation mediates tolerance and anergy. As shown by many and generally accepted, blockade of CD152-agonist interactions, provided by antagonistic antibodies, reduces the inhibition mediated through the CD152 signaling. However, comprehensive receptor-binding drugs should offer activities stopping the binding of the native agent without eliciting a response, i.e., antagonists; but also triggering the same or even opposite events as the native ligand, i.e., agonists or inverse agonists, respectively. In the case of CD152, the use of an agonist would therefore promote organ transplantation and blockade of autoimmune disease by the inhibitory costimulatory pathway. Clearly, it would offer solution to clinical conditions such as allergies, graft versus host disease and graft rejection. On the other hand, both designed and serendipitous inverse agonists could result in medications that display greater efficacy in cancer therapy.
Currently available anti-human CD152 huMAbs only act as antagonistic blocking agents have limited their usefulness in clinical applications. The present invention addresses needs for molecules having varied abilities to preferentially bind to and/or signal through CD152 receptor and methods of screening such molecules for selected and differential manipulation of T cell responses in vitro. Such human antibody molecules would be of beneficial use in a variety of applications, including, e.g., therapeutic and prophylactic treatments and vaccinations. The present invention fulfills these and other needs.
More details about the related prior art in this field can be found in the references listed below:
1. Chin L T, Hinkula J, Levi M, Ohlin M, Wahren B, Borrebaeck C A K. (1994) Site-directed primary in vitro immunization: Production of HIV-1 neutralizing human monoclonal antibodies from sero-negative donors. Immunology 81: 428-34. 2. Chin L T, Malmborg A C, Kristensson K, Hinkula J, Borrebaeck, C A K. (1995) Mimicking the humoral immune response in vitro results in antigen-specific isotype switching by autologous T helper cells. Eur. J. Immunol. 25:657-663. 3. Leach D R, Krummel M F, Allison J P. (1996) Enhancement of antitumor immunity by CTLA-4 blockade. Science. 271:1734-6. 4. Linsley P S, Brady W, Urnes M, Grosmaire L S, Damle N K, Ledbetter J A. (1991) CTLA-4 is a second receptor for the B cell activation antigen B7. J. Exp. Med. 174:561-9. 5. Demotz S, Lanzavecchia A, Eisel U, Niemann H, Widmann C, Corradin G. (1989) Delineation of several DR-restricted tetanus toxin T cell epitopes. T Immunol. 142:394-402.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a simple, effective method for producing human antibodies to a specific receptor, or the specific domains of the receptors without unwanted responses, such as human anti-mouse response (allergic responses).
Another object of the present invention is to provide a simple, effective method for producing agonist, antagonist and inverse agonist to a particular human CD152 receptor with less allergic response.
Another object of the present invention is to provide antibodies for being agonist, antagonist and inverse agonist to a specific receptor, especially to a human CD152 receptor.
Another object of the present invention is to a method for producing human antibodies to a specific receptor, or the specific domains of the receptors with less allergic responses.
Another object of the present invention is to a method for generating human antibodies that recognize at least three different antigenic sites of human CD152.
Another object of the present invention is to provide antigenic conjugate to provoke an antibody response with less allergic potential.
Another object of the present invention is to provide a simple method for identifying the pharmacological effects of an antibody for being agonist, antagonist, or inverse agonist to a receptor in vitro.
Another object of the present invention is to provide a method for constructing and predicting amino acid sequences of epitopes to provoke an antibody response in silico.
To achieve the objects, the method of the present invention for producing human antibodies of agonist, antagonist and/or inverse agonist to a receptor, comprising following steps: (a) defining peptide fragments resembling respective extracellular domains of a receptor by the use of in silico characteristics of the respective extracellular domains of the receptor; (b) optionally defining amino acid sequences of coupled-fragments having the peptide fragments and a T-helper epitope by reassembling or coupling the peptide fragments and the T-helper in silica; wherein at least one T-helper is coupled with a peptide fragment; (c) preparing immunogens having amino acid sequences of the coupled-fragments; (d) stimulating human lymphocytes with the immunogens in vitro; (e) identifying and optionally screening the human lymphocytes that produce antibodies able to recognize the receptor; and (f) collecting the antibodies.
The antigenic conjugate of the present invention comprises coupled-fragments and optionally the induced antibodies thereof that specifically recognize a receptor; wherein the amino acid sequences of the coupled-fragments comprise a T-helper epitope and peptide fragments corresponding to the respective extracellular domains of the receptor.
The method of the present invention for identifying the pharmacological effects of an antibody for being agonist, antagonist, or inverse agonist to a receptor in vitro, comprising following steps: (a) providing human lymphocytes, a mitogen, a ligand, and optionally a polyclonal activator; (b) preparing plural mixtures of ligands and mitogens by adding mitogens or polyclonal activators to separate containers of increasing concentrations of the ligand; (c) providing a first control culture by adding mitogen only, and providing a second control culture by adding a natural agonist of the receptor; (d) inoculating human lymphocytes to the first control culture, the second control culture, and the plural mixtures of ligands and mitogens; (e) determining the degree of the programmed cell death (apoptosis) and/or proliferation in human lymphocytes in each culture and each mixture; and (f) determining the efficacy of the ligand to the receptor by the degree of the programmed cell death (apoptosis) and/or proliferation of mixtures of increasing concentrations of the ligand.
Generally, the present invention provides a method of epitope prediction from an amino acid sequence to find those likely to provoke an antibody response following in vitro stimulation. To this end, the extracellular domain where drugs and natural ligands act on was analyzed by using the following algorithms:
(a) Chou-Fasman indices for the possible location of alpha (α) helices, beta (β) sheets and beta turns; (b) Kyte and Doolittle for hydrophobicity; (c) Karplus and Schulz for flexibility; and (d) Surface probability
The predicted antigenic regions were identified by locations adjacent to β-sheets or α-helical structures and in regions of hydrophilicity and flexibility. Synthetic peptides composed of the predicted antigenic regions and a T-helper epitope from tetanus toxin QYIKANSKFIGITEL (Seq. ID No. 1) (Demotz et al., J. Immunol. 142:394, 1989), were evaluated in vitro by using human peripheral lymphocytes to assess immunological response.
After computer-aided in silica design of peptide-based immunogens was accomplished, lymphocytes from naive human donors are contacted in vitro with the synthetic antigens of interest, and cells that produce antibodies against the antigen are identified. Because the lymphocytes are immunized in vitro rather than in vivo, it is possible to control which antigen, or which part of the antigen, would be recognized by the antibody. Thus, this method is particularly useful in the preparation of antibodies against physiological important receptors such as CD152 that are inherently more difficult to perform immunization. Consistent with this, it has been shown in murine models that CD152-defective mice show extensive and lethal lymphadenopathy with T-cell infiltration of various tissues. Therefore it is impossible, even in principle, to obtain pre-existing antibody, let alone immunizing a human, to CD152 molecule. Accordingly, the present invention also provides a potential means both of percument the human antibody responses and unleaching the responses to nature occurring physiological receptors, which may not be recognized by donors' own immune system in vivo.
Structural analysis showed human CD152 to be most comparable to immunoglobulin superfamily variable domains, with eight β strands providing the framework for three complementary determining region-like loops, CDR1, CDR2 and CDR3. Preferred antigens derived from receptors are the complementary determining regions (CDRs) of CD152, or an immunogenic fragment thereof. More preferably, the immunogen (or antigen) is a peptide comprising one of the CDRs and the QYIKANSKFIGITEL (Seq. ID No. 1) T-helper epitope. In one aspect, the invention provides isolated or recombinant polypeptides comprising an extracellular domain sequence, said extracellular domain sequence having at least about 75% amino acid sequence identity to, or the full length sequence of, at least one of SEQ ID NOs: 2-7, and is not a naturally-occurring extracellular domain sequence because of T-helper epitope conjugation, and wherein said polypeptide has a CDR sequence of CD152.
In another aspect, the invention further provides a method of generating human antibodies that recognize at least three different antigenic sites of human CD152. Thus, by immunizing the lymphocytes with one antigen and screening the immunized lymphocytes with a recombinant CD152 antigen, fully human antibodies recognizing a physiological receptor can be obtained. It is common experience among practitioners in the art to prolong the ability of antibody production from EBV transformed, human antibody-producing cultures by subjected to various further treatments. For example, the cells can be fused with heteromyeloma cells to form trioma cells, which can live a long time and stably produce antibodies. Various available recombinant methods can be applied to allow such antibodies also be produced in bacteria, yeast or mammalian cells.
Accordingly, a further aspect of the invention provides a method of preparing a fully human antibodies recognizing a physiological receptor, comprising:
(a) providing a group of lymphocytes obtained from a naive human donor; (b) immunizing said lymphocytes with computer-aided in silico design antigens in vitro; (c) adding Epstein-Barr virus (EBV) to the immunized lymphocytes; (d) identifying EBV-infected cells that produce the antibody that recognizes the receptor; and (e) screening the antibodies produced in step (d) for the presence of pharmacologic functions.
The method may further comprise the step of removing CD8 + cells and CD56 + cells from said lymphocytes prior to step (b). The CD8 + and CD56 + cells can be removed using any method established in the art. For example, these cells can be removed using antibodies that are specific for CD8 and CD56, respectively. In one embodiment, these antibodies are attached to magnetic beads. Additionally or alternatively, the method may further comprise forming trioma cells or recombinant immunoglobulin, and likewise, their respective fragments from step (d), thereby identifying complete human monoclonal antibodies. Alternatively, polyclonal antibodies can be prepared from a group of antibody-producing cells obtained using the present invention, which are not cultured as individual clones. The antibody preferably recognizes the antigen with a Kd of about 100 nM or less, about 30 nM or less, about 10 nM or less, about 3 nM or less, or about 1 nM or less. The antibody is preferably an IgG antibody, particularly IgG1 and IgG4.
The identifying or screening method may also use other mitogens or polyclonal activators, e.g., concanvalin A (Con A), pokeweed mitogen (PWM), phorbol 12-myristate 13-acetate (PMA) and the superantigen such as staphylococcal enterotoxin A (SEA), to replace or to use in conjugation with PHA therein.
In addition, the invention includes complete human antibodies prepared according to the methods of the invention. In particular, the antibodies can recognize respective specific regions on the extracellular domain of human CD152, such as the CDR regions, and preferably initiate pharmacodynamical effects on human peripheral blood mononuclear cells (PBMC) after engagement. Some such antibodies induce T-cell apoptosis, but do not induce proliferation, similar to that cause by natural agonist, i.e., CD80. In some embodiments, the apoptosis ameliorates and mediocre proliferation appears, which commonly found in an antagonist. Most importantly, other such antibodies modulate T-cell proliferation, but do not induce apoptosis of mitogen-stimulated human PBMC. This antibody may thus probably act as an inverse agonist. Pharmaceutical compositions comprising the antibodies are also provided, which may comprise a pharmaceutically acceptable carrier and/or excipient.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic representation of homodimer configuration of CD152 receptor presented on the surface of a T cell. The relative locations of three immunoglobin CDR-like regions are indicated.
FIG. 1B is the amino acid sequence of human CD152 deduced from cDNA (Seq. ID No. 8) (Genebank accession number L15006, NCBI protein accession number P16410). Asterisks indicate the beginning of the mature peptide, transmembrane region and intracellular region. The CDR1, CDR2, and CDR3-like regions are boxed.
FIGS. 2A , 2 B and 2 C depict respectively hydrophobicity, chain flexibility and surface probability over the CDR1 and adjacent regions of human CD152. FIGS. 2D , 2 E and 2 F illustrate respectively hydrophobicity, chain flexibility and surface probability over the CDR2 and adjacent regions. FIGS. 2I , 2 J and 2 K scheme hydrophobicity, chain flexibility and surface probability over the CDR3 and adjacent regions, respectively, The boxed regions indicate CDR analogous regions with amino acids shown below. The arrows designate predicted strand structures derived from the corresponding residues.
FIG. 3 shows representative reactivity profiles on proliferation (□) and apoptosis (▪) of PHA-stimulated human PBMC. FIGS. 3A , 3 B, 3 C, 3 D and 3 E indicate results obtained from PHA stimulation alone (1.25, 5 and 20 μg/ml), 1.25 μg/ml of PHA with concomitant stimulation with cross-linking CD80 (0.2, 1 and 5 μg/ml), anti-CDR1, anti-CDR2 and anti-CDR3 antibodies (0.1, 1 and 10 μg/ml), respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides methods of preparing fully human antibodies that recognize pharmacologic regions on a pre-determined receptor antigen without relying on human donors that have already been exposed to the antigen. To this end, possible immune active peptides are obtained first from the receptor of interest by using algorithms for epitope prediction and selection. Lymphocytes from naive human donors are immunized in vitro with peptide-based immunogens, and cells that produce antibodies against the receptor are identified and selected. Since the lymphocytes are immunized in vitro rather than in vivo, it is possible to control which antigen, or which part of the receptor, would be recognized by the antibody. A preferred receptor is human CD152, particularly the CDR regions of CD152.
Prior to describing the invention in further detail, the terms used in this application are defined as follows unless otherwise indicated.
A “ligand” is a compound that binds to another molecule, such as a receptor protein.
A “receptor” is a protein interacting with extracellular physiological signals and converting them into intracellular effects.
A “fully (complete) human antibody” is an antibody containing exclusively human sequences.
A “naive human donor” is a human who has not been exposed to an antigen of interest and serves as the source of immune cells or factors. A naive donor does not contain detectable circulating antibodies against the antigen of interest. Typically naïve human donors are healthy, regular blood donors who are consistently screened negative of anti-HIV antibodies.
“Immunize” a cell or an animal with an antigen refers to the action of exposing the cell or the animal to the antigen. The cell or animal can be immunized in any manner that leads to contact between the cell or the animal with the antigen.
“Site-directed in vitro immunization” is an in vitro lymphocyte stimulation process to achieve antibody response to a protein by using a fraction of the protein of interest. It is based on a synthetic heterotope immunogen, which is a peptide containing both T- and B-cell epitopes, that elicited a humoral immune response against the whole protein. Techniques of site-directed in vitro immunization are known in the art. For example, Chin et al., 1994 described the preparation, characterization and use of the technology.
“Treating or ameliorating” a disease or medical condition means reducing or eliminating the symptoms of the disease or medical condition, or slowing down the progress of the disease/medical condition. The reduction is preferably at least about 10%, more preferably at least about 20%, 30%, 40%, 50%, 60%, 70%, 80% or 90%.
“Preventing” a disease or medical condition means taking a measure in a subject who shows no symptoms of the disease or medical condition, wherein, as a result, the subject does not develop the disease/medical condition or develops the disease/medical condition to a lesser extent.
An “effective amount” is an amount of an agent that is sufficient to result in the intended effect. For example, for an antibody used to treat or ameliorate a disease, an effective amount is an amount of the antibody sufficient to reduce or eliminate the symptoms of the disease, or to slow down the progress of the disease.
An “agonist” is called when a ligand has the same or similar effect as another naturally occurring, endogenous ligand or group of ligands.
An “antagonist” is called when a ligand or drug counteracts the effect of an agonist.
An “inverse agonist” is a ligand, which produces an effect opposite to that of the agonist by occupying the same receptor.
“Receptor blockade” is the blocking of the effect of a natural endogenous ligand, e.g., hormone or neurotransmitter, at a cell-surface receptor by a pharmacological antagonist bound to the receptor.
A “sample” is an aliquot or a representative portion of a substance, material, or population. For example, a sample may be a sample of water, sewage, oil, sand, blood, biological tissue, urine or feces.
A “biological sample” is a sample collected from a biological subject, such as an animal, plant or microorganism.
This invention also includes pharmaceutical compositions that contain, as the active ingredient, one or more of the antibodies in combination with a pharmaceutically acceptable carrier or excipients. In preparing the compositions of this invention, the active ingredient/antibody is usually mixed with an excipient, diluted by an excipient or enclosed within such a carrier, which can be in the form of a capsule, sachet, paper or other container. When the pharmaceutically acceptable excipient serves as a diluent, it can be a solid, semi-solid, or liquid material, which acts as a vehicle, carrier or medium for the active ingredient. Thus, the compositions can be in the form of solutions (particularly sterile injectable solutions), tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, emulsions, syrups, aerosols (as a solid or in a liquid medium), ointments containing, for example, up to 10% by weight of the antibody, soft and hard gelatin capsules, suppositories, and sterile packaged powders.
Some examples of suitable excipients include lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, alginates, tragacanth, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, cellulose, sterile water, syrup, and methylcellulose. The formulations can additionally include: lubricating agents such as talc, magnesium stearate, and mineral oil; wetting agents; emulsifying and suspending agents; preserving agents such as methyl- and propylhydroxy-benzoates; sweetening agents; and flavoring agents. The compositions of the invention can be formulated so as to provide quick, sustained or delayed release of the active ingredient after administration to the patient by employing procedures known in the art.
The liquid forms in which the novel compositions of the present invention may be incorporated for administration orally or by injection include aqueous solutions (such as PBS), suitably flavored syrups, aqueous or oil suspensions, and flavored emulsions with edible oils such as corn oil, cottonseed oil, sesame oil, coconut oil, or peanut oil, as well as elixirs and similar pharmaceutical vehicles.
Other suitable formulations for use in the present invention can be found in Remington's Pharmaceutical Sciences.
The following examples are offered to illustrate this invention and are not to be construed in any way as limiting the scope of the present invention. For example, similar research effort can be aimed at other members of the CD28 receptor superfamily such as CD28 and its isoforms (CD28i), inducible costimulator (ICOS), B and T lymphocyte attenuator (BTLA) and programmed cell death 1 (PD-1). Likewise, application can also be made to other receptor families includes ion channels, G-protein coupled receptors, tyrosine kinase-linked receptors and transcription factors.
TABLE 1
Amino acid sequences of peptides in this
invention
SEQ
ID
Peptides
Amino acid sequence
No.
TT
N′-QYIKANSKFIGITEL-C′
1
CDR1 (ext)
N′-EYASPGKATEVRVTV-C′
2
CDR2 (ext)
N′-AATYMMGNELTFLDD-C′
3
CDR3 (ext)
N′-KVELMYPPPYYLGIG-C′
4
TT-CDR1 (ext)
N′-QYIKANSKFIGITELEYASPGKATEVRV
5
TV-C′
TT-CDR2 (ext)
N′-QYIKANSKFIGITELAATYMMGNELTFL
6
DD-C′
TT-CDR3 (ext)
N′-QYIKANSKFIGITELKVELMYPPPYYLG
7
IG-C′
EXAMPLE 1
Preparation of Peptide Antigens
The overall structure of human CD152 protein receptor is represented schematically by FIG. 1A . Amino acid sequence corresponding to human CD152 is shown in FIG. 1B . By incorporating information gained from scientific literatures, the importance of the interrelationships between the CDR3 region and natural CD80 and CD86 ligands has been established. Further evidence suggests that residues locating in the CDR1 region play some role in interaction with CD80/CD86. However, the nature of CDR2 in agonist binding has not yet been fully investigated.
To raise an antibody that can bind native protein, the peptide should also adopt a conformation that mimics its shape when contained within the protein. Therefore, complete sequences derived from the respective CDR1, CDR2 and CDR3 regions are preserved for designing synthetic immunogens. Furthermore, extensions were made to each CDR peptide to comply the combined epitope model as previously described (Chin et al., Immunology 81:428, 1994; Chin et al., Eur, Immunol. 25:657, 1995). As an effective immunogen, the peptide must be selected from an accessible region of the protein if the resulting antibody is to be of use. The most accessible areas will be those parts of the molecule that are exposed or on the outside of the structure. As these regions are in contact with an aqueous environment they are usually hydrophilic. Hydrophobic plots were then established to determine the orientation of extension by using GeneWorks® software (IntelliGenetics, Mountain View, Calif.). Additionally, chain flexibility and surface probability, calculated by using GeneWorks®, over the adjacent regions were also taken into account as secondary parameters for peptide design ( FIG. 2 ).
High scoring CDR peptides from the above stimulation were synthesized and used to prepare combined epitopes in conjugation with the “helper” sequence derived from tetanus toxin encompassing amino acids 830-844 (see peptide “TT”, SEQ ID NO: 1). For example, to generate an immunogen containing both T-cell and B-cell epitopes, peptide “TT” was combined with an extended fragment of CDR1 of human CD152 (peptide “CDR1 (ext) ”, SEQ ID No:2) to form TT-CDR1 (ext) (SEQ ID No:5).
EXAMPLE 2
Generation of Anti-CD152 Human Antibodies
Buffy coats from healthy blood donors, screened negative for HIV-1/2, HTLV-UTI, HCV, HBsAg and containing normal levels of alanine transferase (ALT), were obtained from the Tainan Blood Center, Chinese Blood Services Foundation (Tainan, Taiwan). Peripheral blood mononuclear cells (PBMC) were isolated by density centrifugation (400×g) on FICOLL-PAQUE™ (Amersham Biosciences AB, Uppsala, Sweden). The cells were then washed twice in PBS and collected by 100×g centrifugation.
The obtained PBMC were first magnetically labeled with CD45RO MACS™ microbeads (Miltenyi Biotec, Auburn Calif.) then separated by using a VarioMACS™ (Miltenyi Biotec) instrument. Briefly, the cells were specifically labeled with super-paramagnetic MACS™ microbeads. After magnetic labeling, the cells were passed through a separation column, which was placed in a strong permanent magnet. The magnetizable column matrix served to create a high-gradient magnetic field. The magnetically labeled cells were retained in the column and separated from the unlabeled cells, which passed through. After removal of the column from the magnetic field, the retained cells were eluted. The eluted CD45RO + cells were recovered by 100×g centrifugation and were used immediately. The CD45RO + T cells were cultured in tissue culture flasks at a density of 2×10 6 cells/ml in RPMI-1640 (HyQ™; HyClone, Logan, Utah) supplemented with 1× non-essential amino acids (Life Technologies, Grand Island, N.Y.), 10% human serum, 50 μg/ml gentamycin/kanamycin (China Chemical & Pharmaceutical, Taipei, Taiwan), 50 μM 2-mercaptoethanol and 10 μg/ml pokeweed mitogen (PWM; Sigma Chemicals). After 24 hr incubation, cells were spun down and removed by 400×g centrifugation. Finally, CD45RO + T cell replacing factor, i.e., culture supernatant, was prepared by harvesting the culture supernatant, filtering with a 0.45 mm filter, and stored frozen at −20° C.
Magnetic cell depletion was performed on PBMC to remove cytotoxic cell populations, which inhibit in vitro immunization. Colloidal super-paramagnetic microbeads conjugated to monoclonal anti-mouse CD8 and anti-CD56 antibodies (Miltenyi Biotech) were used as described above. Cytotoxic cell-depleted PBMC, were immunized in vitro using a two-step immunization protocol. Primary immunization was performed by incubating the cells for 6 days in a medium containing 10 nM of the peptide antigens, i.e., TT-CDR1 (ext) , TT-CDR2 (ext) and TT-CDR3 (ext) in media containing 50 μM 2-mercaptoethanol, 10% heat-inactivated human serum, 0.05 ng/ml rIL2 (Calbiochem, San Diego, Calif.), and 25% (v/v) CD45R + T cell replacing factor. On day 7, cells from the primary immunization were harvested and spun through 40% FICOLL-PAQUE™. For secondary immunization, 3×10 7 cells were mixed with the peptide antigen in a flask that had been immobilized overnight with 5 μg/ml of CD40L (CD154; Vinci-Biochem, Vinci, Italy). The cells were cultured for 3-5 days in a medium supplemented with 5% human serum, 50 μM 2-mercaptoethanol and 10 nM peptide antigen.
The in vitro immunized cells were then infected with EBV. Briefly, 10 7 lymphocytes were incubated for 2 hr at 37° C. with occasional resuspension with 1 ml EBV-containing supernatant derived from the EBV-producing marmoset cell line B95-8 (American Type Culture Collection, ATCC CRL 1612; kindly provided by Dr. L.-F. Shu, Tri Services General Hospital, Taipei). The infected cells were seeded at 10 5 /well in 96-well plates together with mytomycin (Kyowa Hakko Kogyo, Toyoko, Japan)-treated PBMC as feeder cells (10 4 /well).
Antigen-specific ELISA was performed by first coating 1 μg/ml BHK cell-expressed recombinant human CD152 (CTLA-4)-muIg fusion protein (Ancell Corporation, Bayport, Minn.), 1 μg/ml monoclonal murine IgG2a (Ancell), 10 μg/well of bovine serum albumin (BSA; Sigma) or tetanus toxoid (ADImmune Corporation, Taichung, Taiwan) onto microtitre plates overnight at room temperature. Culture supernatants were diluted to the desired level in 10 mM sodium phosphate buffer, pH 8.0, containing 0 5 M sodium chloride and 0.1% Tween-20. Coated plates were incubated with diluted culture supernatants, washed, incubated with peroxidase-labeled goat antibodies against human IgG (Zymed Laboratories, So. San Francisco, Calif.) and developed (15 min) by addition of 100 μl of the chromogenic substrate o-phenylaenediamine (OPD) (Sigma). The reaction was stopped after 30 min by adding 1 M sulphuric acid, and the absorbances were read at 490 nm.
EBV-infected lymphoblastoid cells secreting putative anti-CD152 antibodies were identified by solid ELISA as described above. A well containing lymphoblastoid cells was scored as specific antibody-producing if:
(a) the ELISA OD value against recombinant human CD152-muIg fusion protein was at least five times as high as the OD value for the negative control; (b) the reactivity index (RI) was >2, where RI=[OD CD152-muIg −OD medium control against CD152-muIg ]/[OD murine IgG2a −OD medium control against murine IgG2a ].
Wells containing lymphoblastoid cells positive for the above assays were expanded and culture supernatants were collected, quantitated and standardized by ELISA for further study. The reactivity to the corresponding CDR region was confirmed by competitive ELISA using the respective peptide. These cultures were cloned by limiting dilution and cryopreserved.
EXAMPLE 3
Anti-CD152 Antibodies Varied in their Ability to Induce Apoptosis and Proliferation as Compared with Native Agonist
The binding sites of different anti-CD152 human antibodies were confirmed by corresponding synthetic peptides on primary alkyl amine derivatized cellulose membranes (Rapp Polymere GmbH, Tübingen, Germany). To further investigate the pharmacologic effect of different anti-CD152 antibodies and the preferred native agonist, CD80, on cellular growth of human peripheral lymphocytes stimulated in vitro by phytohemagglutinin (PHA), cultures of PBMC were established. Briefly, flat-bottomed 96-well microtitre plates were prepared by adding 50 μl of cell suspension (10 5 cells), 60 μl of medium containing PHA (final concentrations in culture 1.25 μg/ml, Amersham Biosciences AB), 40 μl of autologous plasma and 50 μl of RPMI-1640 medium containing anti-CD152 antibodies or monomeric human CD80-muIg fusion protein (Ancell) at concentrations ranging from 0.2 to 5 μg/ml. For CD80 stimulation, 5 μg/ml goat anti-mouse IgG2a (Southern Biotechnology Associates, Birmingham, Ala.) was added further to provide cross-linked forms of signals. The total culture volume was 200 μl. The cultures were incubated in a humidified atmosphere of 5% CO 2 in air at 37° C. for 96 h. Twenty hours before harvest, 50 μl of medium containing 0.5 μCi of tritiated thymidine (TRA 306, Amersham, specific activity 2 Ci/mol) was added to each well. Cultures were harvested on glass fiber filters with a semi-automatic multiple harvester (PHD, Cambridge Technology Inc.). Cell-bound [ 3 H]-thymidine was determined by counting in an LKB liquid scintillation counter. In some cultures, cell viability was measured at the end of the incubation period by the Trypan Blue dye exclusion test. Identical triplicate cultures were always performed and the median of each triplicate was used in the calculations.
The evaluation of the percentage of apoptosis, cells were centrifuged at 200×g, resuspended in cold 80% ethanol with vigorous mixing to a final density of 1×10 6 /ml. The cells were incubated at 4° C. for a minimum of 30 min. The ethanol-fixed cells were then centrifuged and resuspended in 1 ml of the propidium iodide (PI; Sigma) staining reagent (PBS 0.15 M pH 7.4, 0.1% Triton X-100, 0.1 mM EDTA disodium salt, 50 μg/ml RNase A and 50 μg/ml PI). Samples were stored in the dark at room temperature until analysis, carried out within 24 h. The DNA content of cell nuclei was determined with propidium iodide staining and a FACScan™ cytometer using the Lysis II software (Becton Dickinson, Mountain View, Calif.). Apoptotic cells were determined by flow cytometry to measure the percentage of subdiploid DNA after propidium iodine staining.
We generated a panel of anti-CD152 human antibodies to determine the function of these ligands on human T cells activated by PHA, which yielded mediocre proliferation and apoptosis ( FIG. 3A ). Cross-linking CD80 induced apoptosis with no apparent proliferation observed ( FIG. 3B ). Similarly, antibodies induced by CDR3-containing peptide immunogen also provoked rapid cell death without proliferation, hence confirming an agonist activity ( FIG. 3E ). Stimulation with the CDR1-induced human antibodies significantly reduced, yet did not completely abolish, PHA-triggered cell death ( FIG. 3C ). Surprisingly, when PHA-activated PBMC were incubated with the CDR2-induced human antibodies alone, a high and reproducible cell proliferation was observed, and PHA-caused cell death was completely abolished ( FIG. 3D ). Cell proliferation induced on CD152 triggering by the anti-CDR2 was similar to that seen in 5 ng/ml IL-2-treated cultures and resulted in disappearance of the typical morphological alterations seen in apoptotic cells (e.g., membrane blebbing and disintegration of cells and nuclei into small vesicles).
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 spirit and scope of the invention as hereinafter claimed. | A method for obtaining agonist, antagonist and inverse agonist, to a given physiological receptor is disclosed. For the method, use is made of in silico design synthetic immunogens, which are caused to act in vitro on human lymphocyte-containing cell populations. A preferred receptor is human CD152, particularly the regions of CDR1, CDR2 and CDR3 that elicit antibodies serving as antagonist, inverse agonist and agonist, respectively. Also provided is a method in the treatment of human peripheral lymphocytes for use in the screening of CD152 ligands that yield pharmacological effects. | 6 |
TECHNICAL FIELD
The present invention relates generally to methods of making nonwoven fabrics, and more particularly, to a method of manufacturing a nonwoven fabric exhibiting a durable three-dimensional image, permitting use of the fabric in floor underlayment of laminate floor systems so as to reduce acoustic feedback under normal use (walking) due to sound absorption and leveling of the floating laminate floor system applications.
BACKGROUND OF THE INVENTION
The production of conventional textile fabrics is known to be a complex, multi-step process. The production of fabrics from staple fibers begins with the carding process whereby the fibers ate opened and aligned into a feedstock referred to in the art as “sliver”. Several strands of sliver are then drawn multiple times on a drawing frames to; further align the fibers, blend, improve uniformity and reduce the sliver's diameter. The drawn sliver is then fed into a roving frame to produce roving by further reducing its diameter as well as imparting a slight false twist. The roving is then fed into the spinning frame where it is spun into yarn. The yarns are next placed onto a winder where they are transferred into larger packages. The yarn is then ready to be used to create a fabric.
For a woven fabric, the yarns are designated for specific use as warp or fill yarns. The fill yarns (which run on the y-axis and are known as picks) are taken straight to the loom for weaving. The warp yarns (which run on the x-axis and are known as ends) must be further processed. The large packages of yarns are placed onto a warper frame and are wound onto a section beam were they are aligned parallel to each other. The section beam is then fed into a slasher where a size is applied to the yarns to make them stiffer and more abrasion resistant, which is required to withstand the weaving process. The yarns are wound onto a loom beam as they exit the slasher, which is then mounted onto the back of the loom. The warp yarns are threaded through the needles of the loom, which raises and lowers the individual yarns as the filling yarns are interested perpendicular in an interlacing pattern thus weaving the yarns into a fabric. Once the fabric has been woven, it is necessary for it to go through a scouring process to remove the size from the warp yarns before it can be dyed or finished. Currently, commercial high-speed looms operate at a speed of 1000 to 1500 picks per minute, where a pick is the insertion of the filling yarn across the entire width of the fabric. Sheeting and bedding fabrics are typically counts of 80×80 to 200×200, being the ends per inch and picks per inch, respectively. The speed of weaving is determined by how quickly the filling yarns are interlaced into the warp yarns, therefore looms creating bedding fabrics are generally capable of production speeds of 5 inches to 18.75 inches per minute.
In contrast, the production of nonwoven fabrics from staple fibers is known to be more efficient than traditional textile processes, as the fabrics are produced directly from the carding process.
Nonwoven fabrics are suitable for use in a wide variety of applications where the efficiency with which the fabrics can be manufactured provides a significant economic advantage for these fabrics versus traditional textiles. However, nonwoven fabrics have commonly been disadvantaged when fabric properties are compared to conventional textiles, particularly in terms of resistance to elongation, in applications where both transverse and co-linear stresses are encountered. Hydroentangled fabrics have been developed with improved properties, by the formation of complex composite structures in order to provide a necessary level of fabric integrity. Subsequent to entanglement, fabric durability has been further enhanced by the application of binder compositions and/or by thermal stabilization of the entangled fibrous matrix.
Nonwoven composite structures typically improve physical properties, such as elongation, by way of incorporation of a support layer or scrim. The support layer material can comprise an array of polymers, such as polyolefins, polyesters, polyurethanes, polyamides, and combinations thereof, and take the form of a film, fibrous sheeting, or grid-like meshes. Metal screens, fiberglass, and vegetable fibers are also utilized as support layers. The support layer is commonly incorporated either by mechanical or chemical means to provide reinforcement to the composite fabric. Reinforcement layers, also referred to as a “scrim” material, are described in detail in U.S. Pat. No. 4,636,419, which is hereby incorporated by reference. The use of scrim material, more particularly, a spunbond scrim material is known to those skilled in the art.
Spunbond material comprises continuous filaments typically formed by extrusion of thermoplastic resins through a spinneret assembly, creating a plurality of continuous thermoplastic filaments. The filaments are then quenched and drawn, and collected to form a nonwoven web. Spunbond materials have relatively high resistance to elongation and perform well as a reinforcing layer or scrim. U.S. Pat. No. 3,485,706 to Evans, et al., which is hereby incorporated by reference, discloses a continuous filament web with an initial random staple fiber batt mechanically attached via hydroentanglement, with a second random staple fiber batt then attached to the continuous filament web, again, by hydroentanglement. A continuous filament web is also utilized in U.S. Pat. Nos. 5,144,729; 5,187,005; and 4,190,695. These patents include a continuous filament web for reinforcement purposes or to reduce elongation properties of the composite.
More recently, hydroentanglement techniques have been developed which impart images or patterns to the entangled fabric by effecting hydroentanglement on three-dimensional image transfer devices. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, which is hereby incorporated by reference, with the use of such image transfer devices being desirable for providing a fabric with enhanced physical properties as well as functional dimension.
A three-dimensionally imaged nonwoven fabric must exhibit a combination of specific physical characteristics so as to be beneficial in application as a floor underlayment. For example, when such fabrics are used in flooring underlayment, the fabric must exhibit sufficient durability to withstand application upon abrasive surfaces and yet exhibit a pronounced and resilient three-dimensional pattern so as to provide proper leveling of the floating laminate floor system. Further, three-dimensionally imaged nonwoven fabrics used in industrial applications require sufficient resistance to elongation so as to resist deformation of the image when the fabric is converted into a final end-use article and when used in the final application.
Notwithstanding various attempts in the prior art to develop an acoustic underlayment for pre-finished laminate floor systems, a need continues to exist for a nonwoven fabric, which provides a pronounced image for leveling purposes, as well as sound absorption to reduce acoustic feedback.
SUMMARY OF THE INVENTION
The present invention is directed to a method of forming a nonwoven fabric, which exhibits a pronounced durable three-dimensional image, permitting use of the fabric in floor underlayment of laminate floor systems so as to reduce acoustic feedback under normal use (walking) due to sound absorption and leveling of the floating laminate floor system applications. In particular, the present invention contemplates that a fabric is formed from a precursor web comprising at least one support layer or scrim, whereby when subjected to hydroentanglement on a moveable imaging surface of a three-dimensional image transfer device, an enhanced product is achieved. By formation in this fashion, hydroentanglement of the precursor web results in a more pronounced three-dimensional image, an image that is durable to abrasion and distortion.
In accordance with the present invention, a method of making a nonwoven fabric embodying the present invention includes the steps of providing a precursor web comprising a fibrous matrix. While use of staple length fibers is typical, the fibrous matrix may comprise substantially continuous filaments. In a particularly preferred form, the fibrous matrix comprises staple length fibers, which are carded and cross-lapped to form a precursor web. In one embodiment of the present invention, the precursor web is subjected to pre-entangling on a foraminous-forming surface prior to juxtaposition of a support layer or scrim and subsequent three-dimensional imaging. Alternately, one or more layers of fibrous matrix are juxtaposed with one or more support layers or scrims, then the layered construct is pre-entangled to form a precursor web which is imaged directly, or subjected to further fiber, filament, support layers, or scrim layers prior to imaging.
The present method further contemplates the provision of a three-dimensional image transfer device having a movable imaging surface. In a typical configuration, the image transfer device may comprise a drum-like apparatus, which is rotatable with respect to one or more hydroentangling manifolds.
The precursor web is advanced onto the imaging surface of the image transfer device. Hydroentanglement of the precursor web is effected to form a three-dimensionally imaged fabric. Significantly, the incorporation of at least one support layer or scrim acts to focus the fabric tension therein, allowing for improved imaging of the staple fiber layer or layers, and resulting in a more pronounced three-dimensional image.
Subsequent to hydroentanglement, the three-dimensionally imaged fabric may be subjected to one or more variety of post-entanglement treatments. Such treatments may include application of a polymeric binder composition, mechanical compacting, application of additives or electrostatic compositions, and like processes.
A further aspect of the present invention is directed to a method of forming a durable nonwoven fabric, which exhibits a pronounced and resilient three-dimensionality, while providing the necessary resistance to abrasion and distortion, to facilitate use in a wide variety of industrial applications. The fabric exhibits a high degree of fiber retention, thus permitting its use in those applications in which the fabric is used as an underlayment for various floating floor systems. Further, the support layer or scrim aids in preventing the distortion of the imprinted image upon the application of tension to the composite fabric during routine processing and use.
A method of making the present durable nonwoven fabric comprises the steps of providing a precursor web, which is subjected to hydroentangling. The precursor web is formed into a three-dimensionally imaged nonwoven fabric by hydroentanglement on a three-dimensional image transfer device. The image transfer device defines three-dimensional elements against which the precursor web is forced during hydroentanglement, whereby the fibrous constituents of the web are imaged by movement into regions between the three-dimensional elements and surface asperities of the image transfer device. In the preferred form, the precursor web is hydroentangled on a foraminous surface prior to hydroentangling on the image transfer device. This pre-entangling of the precursor web acts to integrate the fibrous components of the web, but does not impart a three-dimensional image as can be achieved through the use of the three-dimensional image transfer device.
Optionally, subsequent to three-dimensional imaging, the imaged nonwoven fabric can be treated with a performance or aesthetic modifying composition to further alter the fabric structure or to meet end-use article requirements. A polymeric binder composition can be selected to enhance durability characteristics of the fabric or an antimicrobial additive may be used utilized to deter the growth of fungus and mold.
Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of an apparatus for manufacturing a durable nonwoven fabric, embodying the principles of the present invention;
FIG. 2 is a plan view of a three-dimensional image transfer device of the type, referred to as “node”, used for practicing the present invention, with approximate dimension as shown;
FIG. 3 is a top plan photomicrograph of an nonwoven fabric having been imaged using the “node” image transfer device of FIG. 2, produced from a fibrous matrix alone utilizing a backlit light source, the magnification is approximately 10×;
FIG. 4 is a top plan photomicrograph of a nonwoven fabric having been imaged using the “node” image transfer device of FIG. 2, produced in accordance with the present invention, the magnification is approximately 10×;
FIG. 5 is top plan photomicrograph of the same fabric as in FIG. 3, wherein a top-lit light source at an incident angle of 45 degrees was used, the magnification is approximately 10×;
FIG. 6 is a top plan photomicrograph of the same fabric as in FIG. 4, wherein a top-lit light source at an incident angle of 45 degrees was used, the magnification is approximately 10×;
FIG. 7 is a side photomicrograph of the same fabric as in FIG. 3, wherein a top-lit light source at an incident angle of about 90 degrees was used, the magnification is approximately 10×; and
FIG. 8 is a side photomicrograph of the same fabric as in FIG. 4, wherein a top-lit light source at an incident angle of about 90 degrees was used, the magnification is approximately 10×;
DETAILED DESCRIPTION
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated. The present invention is directed to a method of forming a durable three-dimensionally imaged nonwoven suitable for use as acoustic underlayment for pre-finished laminate floor systems wherein the three-dimensional imaging of the fabrics is enhanced by the incorporation of at least one support layer or scrim. Enhanced imaging can be achieved utilizing various techniques. One such technique involves minimizing and eliminating tension in the overall precursor web as the web is advanced onto a moveable imaging surface of the image transfer device, as represented by co-pending U.S. patent application, Ser. No. 60/344,259 to Putnam et al., entitled Nonwoven Fabrics Having a Durable Three-Dimensional Image, and filed on Dec. 28, 2002, which is hereby incorporated by reference. By use of a support layer or scrim, enhanced fiber entanglement is achieved, with the physical properties, both aesthetic and mechanical, of the resultant fabric being desirably enhanced. It is reasonably believed that the internal support of the precursor web provided by the support layer or scrim, as the precursor web is advanced onto the image transfer device, desirably acts to focus tension to the support layer or scrim. Without tension, the fibers or filaments of the fibrous matrix, from which the precursor web is formed, can more easily move and shift during hydroentanglement, thus resulting in improved three-dimensional imaging on the image transfer device. A more clearly defined and durable image is achieved.
With reference to FIG. 1 therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous matrix, which typically comprises staple length fibers, but may comprise substantially continuous filaments. The fibrous matrix is preferably carded and cross-lapped to form a fibrous batt, designated F. In a current embodiment, the fibrous batt comprises 100% cross-lap fibers, that is, all of the fibers of the web have been formed by cross-lapping a carded web so that the fibers are oriented at an angle relative to the machine direction of the resultant web. U.S. Pat. No. 5,475,903, hereby incorporated by reference, illustrates a web drafting apparatus.
A support layer or scrim is then placed in face to face juxtaposition with the fibrous web and hydroentangled to form precursor web P. Alternately, the fibrous web can be hydroentangled first to form precursor web P, and subsequently, at least one support layer or scrim is applied to the precursor web, and the composite construct optionally further entangled with non-imaging hydraulic manifolds, then imparted with a three-dimensional image on an image transfer device.
FIG. 1 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous-forming surface in the form of belt 10 upon which the precursor web P is positioned for pre-entangling by entangling manifold 12 . Pre-entangling of the precursor web, prior to three-dimensional imaging, is subsequently effected by movement of the web P sequentially over a drum 14 having a foraminous-forming surface, with entangling manifold 16 effecting entanglement of the web. Further entanglement of the web is effected on the foraminous forming surface of a drum 18 by entanglement manifold 20 , with the web subsequently passed over successive foraminous drums 20 , for successive entangling treatment by entangling manifolds 24 , 24 ′.
The entangling apparatus of FIG. 1 further includes a three-dimensional imaging drum 24 comprising a three-dimensional image transfer device for effecting imaging of the now-entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 26 which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed.
The present invention contemplates that the support layer or scrim be any such suitable material, including, but not limited to, wovens, knits, open mesh scrims, and/or nonwoven fabrics, which exhibit low elongation performance. Two particular nonwoven fabrics of particular benefit are spunbond fabrics, as represented by U.S. Pat. Nos. 3,338,992; 3,341,394; 3,276,944; 3,502,538; 3,502,763; 3,509,009; 3,542,615; and Canadian Patent No. 803,714, these patents are incorporated by reference, and nanofiber fabrics as represented by U.S. Pat. Nos. 5,678,379 and 6,114,017, both incorporated herein by reference. A particularly preferred embodiment of support layer or scrim is a thermoplastic spunbond nonwoven fabric. The support layer may be maintained in a wound roll form, which is then continuously fed into the formation of the precursor web, and/or supplied by a direct spinning beam located in advance of the three-dimensional imaging drum 24 .
Manufacture of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the fibrous matrix, which can include the use of staple length fibers, continuous filaments, and the blends of fibers and/or filaments having the same or different composition. Fibers and/or filaments are selected from natural or synthetic composition, of homogeneous or mixed fiber length. Suitable natural fibers include, but are not limited to, cotton, wood pulp and viscose rayon. Synthetic fibers, which may be blended in whole or part, include thermoplastic and thermoset polymers. Thermoplastic polymers suitable for blending with dispersant thermoplastic resins include polyolefins, polyamides and polyesters. The thermoplastic polymers may be further selected from homopolymers; copolymers, conjugates and other derivatives including those thermoplastic polymers having incorporated melt additives or surface-active agents. Staple lengths are selected in the range of 0.25 inch to 10 inches, the range of 1 to 3 inches being preferred and the fiber denier selected in the range of 1 to 22, the range of 1.2 to 6 denier being preferred for general applications. The profile of the fiber and/or filament is not a limitation to the applicability of the present invention.
EXAMPLES
Comparative Example 1
Using a forming apparatus as illustrated in FIG. 1, a nonwoven fabric was made by providing a precursor web comprising 100 weight percent polyester fibers. The web had a basis weight of 3 ounces per square yard (plus or minus 7%). The precursor web was 100% carded and cross-lapped, with a draft ratio of 2.5 to 1.
Prior to three-dimensional imaging of the precursor web, the web was entangled by a series of entangling manifolds such as diagrammatically illustrated in FIG. 1 . FIG. 1 illustrates disposition of precursor web P on a foraminous forming surface in the form of belt 10 , with the web acted upon by an entangling manifold 12 . The web then passes sequentially over a drum 14 having a foraminous forming surface,for entangling by entangling manifold 16 , with the web thereafter directed about the foraminous forming surface of a drum 18 for entangling by entanglement manifold 20 . The web is thereafter passed over successive foraminous drums 22 , with successive entangling treatment by entangling manifolds 24 ′, 24 ′. In the present examples, each of the entangling manifolds included 120 micron orifices spaced at 42.3 per inch, with the manifolds successively operated at 100, 300, 700, and 1300 pounds per square inch, with a line speed of 45 yards per minute. A web having a width of 72 inches was employed.
The entangling apparatus of FIG. 1 further includes a three-dimensional imaging drum 24 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. The entangling apparatus includes a plurality of entangling manifolds 26 , which act in cooperation with the three-dimensional image transfer device of drum 24 to effect patterning of the fabric. In the present example, the imaging manifolds 26 were successively operated at 2800, 2800, and 2800 pounds per square inch, at a line speed which was the same as that used during pre-entanglement. A performance or aesthetic modifying composition can optionally be applied to the imaged fabric at 30 , with the fabric then dried on drying cans 32 .
The three-dimensional image transfer device of drum 24 was configured as a so-called “node” image, as illustrated in FIG. 2 .
Images of the comparative material are presented in FIGS. 3, 5 , and 7 .
Example 1
A three-dimensionally imaged nonwoven fabric was manufactured by a process as described in Comparative Example 1, wherein in the alternative, and in accordance with the present invention, a lighter 1.5 ounce per square yard polyester staple fiber web was juxtaposed with a 1.5 ounce polyester spunbond web of approximately 2.0 denier. The staple fiber web/spunbond web layered matrix was then subjected to equivalent hydraulic pressures as described in Comparative Example 1.
Images of the improved material of the present invention are presented in FIGS. 4, 6 and 8 .
With reference to FIGS. 3 through 8, it is apparent that the imaged nonwoven fabrics made in accordance with the present invention exhibit greater three-dimensional image clarity and are more pronounced than the image imparted to equivalent basis weight materials without the support layer or scrim. The more pronounced three-dimensional images further result in increased bulk, as is depicted in the comparison of FIG. 7 and FIG. 8 . Imaged nonwoven fabrics, such as Example 1, further exhibit a significantly reduced performance, resulting in improved image retention during mechanical processing and use.
The material of the present invention may be utilized as a sound absorbent underlayment as well as provide for leveling of various floor systems, including floating laminate floor systems, and other end use products where a three-dimensionally imaged nonwoven fabric can be employed. Other end uses include; fabrication into acoustic wall systems, automotive applications, wet or dry hard surface wipes, which can be readily hand-held for cleaning and the like, protective wear for industrial uses, such as gowns or smocks, shirts, bottom weights, lab coats, face masks, and the like, and protective covers, including covers for vehicles such as cars, trucks, boats, airplanes, motorcycles, bicycles, golf carts, as well as covers for equipment often left outdoors like grills, yard and garden equipment, such as mowers and roto-tillers, lawn furniture, floor coverings, table cloths and picnic area covers.
From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims. | The present invention is directed to a method of forming a nonwoven fabric, which exhibits a pronounced durable three-dimensional image, permitting use of the fabric in floor underlayment of laminate floor systems so as to reduce acoustic feedback under normal use (walking) due to sound absorption and leveling of the floating laminate floor system applications. In particular, the present invention contemplates that a fabric is formed from a precursor web comprising at least one support layer or scrim, whereby when subjected to hydroentanglement on a moveable imaging surface of a three-dimensional image transfer device, an enhanced product is achieved. By formation in this fashion, hydroentanglement of the precursor web results in a more pronounced three-dimensional image, an image that is durable to abrasion and distortion. | 3 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.