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The present invention relates to a cleaning device for cleaning outlet ports or the like and/or outlet spouts or the like in soda recovery boilers or the like. The invention also relates to a cleaning tool for use in the cleaning device as well as two methods of using the cleaning device.
PRIOR ART
Liquid soda that is tapped from a soda recovery boiler usually passes at least one outlet port and an outlet spout located under the same. The soda running out of the boiler has a temperature of approx. 1000° C. and, upon contact with air, a part of the soda solidifies and forms a solid “covering” in the port and the spout. Solidified soda blocks the flow and it occurs that lumps are to pass in the spout as well as that liquid soda splashes out in the boiler room. The usual way today to prevent that solidified soda blocks the flow is to clean outlet ports and outlet spouts manually at regular intervals by means of long levers. This work is heavy and risky.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a cleaning device that is efficient in cleaning. A second object of the present invention is to provide a cleaning device that is useful for automatic cleaning. A third object of the present invention is to provide a cleaning tool for use in the cleaning device. A fourth object of the present invention is to provide methods to use the cleaning device that give the intended cleaning effect and simultaneously require minimal manual effort.
Thus, the invention comprises a cleaning device for cleaning outlet ports or the like and/or outlet spouts or the like in soda recovery boilers or the like, the cleaning device comprising at least one connecting rod. At least one front tool part is found, mounted on said connecting rod.
The cleaning device may comprise at least one rear tool part, mounted on said front tool part.
Said front tool part may in turn comprise at least one first cleaning part and at least one first holder part with bracket, said first cleaning part having a shape and size that closely connects to the corresponding shape and size of an outlet port or the like that is to be cleaned, so that said first cleaning part, if required, can be inserted into the outlet port and clean the same from solidified soda, cinder or the like.
Said first cleaning part may be in the shape of a hollow cylinder open in the ends, which cylinder has an essentially circular or oval cross-section. At least one slot may be present in the envelope surface of said cylinder. Said slot may run in the longitudinal direction of the cylinder, from one end to the other of the cylinder and through the entire length thereof, whereby said first cleaning part gets radially resilient properties.
Said rear tool part may in turn comprise at least one second cleaning part and at least one second holder part with bracket, said second cleaning part having a shape and size that closely connects to the corresponding shape and size of the interior of an outlet spout or the like that is to be cleaned, so that said second cleaning part, if required, can be inserted into the outlet spout and clean the same from solidified soda, cinder or the like. Said second cleaning part may comprise at least one flange-like scraping device, which upon cleaning scrapes in the outlet spout.
Said second holder part may be articulately connected to said first holder part. Said first holder part may be connected to the front part of said connecting rod. Said connecting rod may be connected to a drive mechanism enabling automatic operation of the cleaning device in a way decided beforehand.
Thus, the invention also comprises a cleaning tool for use in the cleaning device according to the above. The cleaning tool comprises at least one front tool part for mounting on a connecting rod.
The cleaning tool may comprise at least one rear tool part, mounted on said front tool part.
Said front tool part may in turn comprise at least one first cleaning part and at least one first holder part with bracket, said first cleaning part having a shape and size that closely connects to the corresponding shape and size of an outlet port or the like that is to be cleaned, so that said first cleaning part, if required, can be inserted into the outlet port and clean the same from solidified soda, cinder or the like. Said rear tool part may in turn comprise at least one second cleaning part and at least one second holder part with bracket, said second cleaning part having a shape and size that closely connects to the corresponding shape and size of the interior of an outlet spout or the like that is to be cleaned, so that said second cleaning part, if required, can be inserted into the outlet spout and clean the same from solidified soda, cinder or the like.
Thus, the invention also comprises a method of using the cleaning device according to the above for cleaning outlet ports or the like in soda recovery boilers or the like. The method comprises the steps of
(A) directing the cleaning device against an outlet port or the like that is to be cleaned and in that connection locating a front end of a first cleaning part essentially right opposite said outlet port,
(B) inserting said first cleaning part into said outlet port sufficiently far in order to clean the port from occurring solidified soda, cinder or the like, and
(C) bringing back said first cleaning part entirely from said outlet port.
Thus, the invention also comprises a method of using the cleaning device according to the above for cleaning outlet spouts or the like in soda recovery boilers or the like. The method comprises the step of
(D) bringing the cleaning device along an outlet spout or the like that is to be cleaned and in such a way that a first cleaning part and/or a second cleaning part will run in the outlet spout essentially through the entire length thereof and hence clean the spout from occurring solidified soda, cinder or the like.
The cleaning device can be brought along said outlet spout in such a way that said second cleaning part also will run past the lower end of the outlet spout, said second cleaning part also cleaning around said lower end and under the spout in an area closest to said lower end, possible beard-like formations in the form of solidified soda, cinder or the like being removed. The cleaning device can be operated automatically by means of a drive mechanism.
LIST OF DRAWINGS
FIG. 1 shows, in a perspective view, a cleaning tool according to the invention included in a cleaning device according to the invention.
FIG. 2 shows, in a side view, the tool according to FIG. 1 .
FIG. 3 a shows, in a view from above, the tool according to FIG. 1 .
FIG. 3 b shows, in a view from below, the tool according to FIG. 1 .
FIG. 4 shows, in a section along the line A-A in FIG. 2 , a front part of the tool according to FIG. 1 .
FIG. 5 shows, in a section along the line B-B in FIG. 2 , a rear part of the tool according to FIG. 1 .
FIG. 6 shows, in a side view from a first side, a connecting rod and a drive mechanism intended for use with the tool in FIG. 1 and included in a cleaning device according to the invention.
FIG. 7 shows, in a side view from a second side, the connecting rod and the drive mechanism according to FIG. 6 .
FIG. 8 a shows, in a side view, a starting position in cleaning by means of the tool according to FIG. 1 .
FIG. 8 b shows, in a side view, a first operation position in cleaning by means of the tool according to FIG. 1 .
FIG. 8 c shows, in a side view, a second operation position in cleaning by means of the tool according to FIG. 1 .
DESCRIPTION OF EMBODIMENTS
From FIGS. 1-3 is evident how two parts of a cleaning tool according to the invention included in a cleaning device according to the invention appear and are assembled, viz. a front tool part 1 a - d , 3 , 6 and a rear tool part 2 a - d . The front tool part 1 a - d , 3 , 6 comprises a first cleaning part 1 a , a first holder part 1 b with bracket 1 c and a first strut 1 d . The first holder part 1 b and bracket 1 c are provided by two elongated arms A 1 and A 2 . The rear tool part 2 comprises a second cleaning part 2 a , a second holder part 2 b with bracket 2 c and a second strut 2 d . The second holder part 2 b and bracket 2 c are provided by two elongated arms A 3 and A 4 . The front tool part 1 a - d , 3 , 6 and the rear tool part 2 a - d are articulatedly interconnected with each other around the axle journals 3 that are fixedly connected to the first cleaning part 1 a via the first holder part 1 b . An adjustment device 4 enables adjustment of the desired angle between the first and second holder parts 1 b and 2 b . In the first holder part 1 b , there are, in the bracket 1 c , holes 5 for bolts or the like for mounting the first holder part 1 b on a connecting rod or the like.
From FIG. 4 is evident that the first cleaning part 1 a is in the form of a hollow cylinder open in the ends, which cylinder has an oval cross-section, the section being seen from the front. The shape of the cross-section is adapted to the shape of the outlet port 11 that is to be cleaned and the length of the cylinder is adapted to the depth of the same outlet port 11 , i.e., usually the wall thickness of the boiler. Two reinforcements 6 are found on the inside of the cylinder, one on each side of a slot 7 in the otherwise continuous cross-section shape. Furthermore, from the figure the first strut 1 d , the first holder part 1 b and the axle journals 3 are evident, which all are included in the front tool part 1 a - d , 3 , 6 .
From FIG. 5 is evident how the second cleaning part 2 a appears in profile immediately behind a section that is seen from the front. By the presence of a slot 8 , the second cleaning part 2 a is divided into two flange-like downward-directed scraping devices 2 a . The length of the second holder part 2 b is adapted to the length of the outlet spout 12 that is to be cleaned.
In the cleaning device according to the invention, the first holder part 1 b is, via the bracket 1 c thereof, in any known way—for instance by screw joint, bolt joint, rivet joint, welding and/or brazing—mounted on a connecting rod 9 . From FIGS. 6 and 7 is evident how the connecting rod 9 in turn is connected to a drive mechanism 10 , which enables automatic operation of the cleaning device in a way decided beforehand. The drive mechanism 10 is of a previously known type.
Here, a suitable method of using the cleaning device according to the invention in cleaning an outlet port 11 with the appurtenant subjacent outlet spout 12 in connection with a soda recovery boiler 13 will now be accounted for more closely, and in connection with the FIGS. 8 a - c.
First, the drive mechanism 10 is brought to direct the cleaning device against an outlet port 11 that is to be cleaned and in that connection locate the front end of the first cleaning part 1 a right opposite said outlet port 11 , see FIG. 8 a , wherein it should be observed that in the respective FIGS. 8 a - c , for the sake of clarity, only the front tool part 1 a - d , 3 , 6 and the rear tool part 2 a - d of the cleaning device have been drawn-in, which parts together constitute said cleaning tool.
Then, the drive mechanism 10 is brought to insert the first cleaning part 1 a in said outlet port 11 sufficiently far in order to entirely clean the port 11 from occurring solidified soda, cinder or the like, see FIG. 8 b , which shows the introduction of the course of events. The cleaning takes place mechanically by the exterior shape of the first cleaning part 1 a closely connecting to the interior shape of the outlet port 11 , and accordingly occurring solidified soda, cinder or the like being “peeled” off from the interior walls of the outlet port 11 . By the presence of the slot 7 , the exterior shape of the first cleaning part 1 a is somewhat flexible, i.e., the exterior wall in the cleaning part 1 a may spring somewhat in the radial direction. In this way, the first cleaning part 1 a may compensate for certain variations in the shape of the outlet port 11 and it is avoided that the first cleaning part 1 a is caught in the outlet port 11 in the event that cinder and solidified soda have formed thicker layers than normally in the outlet port 11 . The slot 7 also contributes to decreasing the risk of soda being caught on the first cleaning part 1 a and comes with it back after accomplished cleaning of the outlet port 12 .
Then, the drive mechanism 10 is brought to bring back said first cleaning part 1 a entirely from said outlet port 11 and subsequently the drive mechanism 10 is brought to bring the cleaning device along the appurtenant outlet spout 12 that is to be cleaned and in such a way that the first cleaning part 1 a and the second cleaning part 2 a will run in the outlet spout 12 through the entire length thereof from above and down and hence clean the spout 12 from occurring solidified soda, cinder or the like, see FIG. 8 c . This takes place in such a way that the first cleaning part 1 a cleans an upper part of the spout 12 and the second cleaning part 2 a simultaneously cleans a lower part of the spout 12 , wherein an overlapping can take place so that an intermediate part of the spout 12 is cleaned by the first cleaning part 1 a as well as the second cleaning part 2 a . The second cleaning part 2 a will also run past the lower end of the outlet spout 12 at the end of the spout, the second cleaning part 2 a also cleaning around the lower end of the spout 12 and under the spout 12 in an area closest the lower end thereof, possible beard-like formations in the form of solidified soda, cinder or the like being removed also there.
The drive mechanism 10 comprises a control system that may be maneuvered automatically via a timer or manually from a maneuvering room. The control system may comprise one or several computers.
Said front tool part 1 a - d , 3 , 6 and rear tool part 2 a - d are manufactured from stainless acid-proof steel or another suitable material that resists corrosive environment and high temperature.
In the cleaning device according to the invention, the first holder part 1 b does not need, via the bracket 1 c thereof, to be fixedly mounted on the connecting rod 9 but may be movably, for instance articulatedly, mounted. In that connection, some kind of known locking device may be present in order to, for a shorter or longer time, fix the holder part 1 b with the bracket 1 c in a desired position in relation to the connecting rod 9 . The first holder part 1 b with the bracket 1 c may alternatively be made integrally with the connecting rod 9 .
Instead of being mounted on the front tool part 1 a - d , 3 , 6 , the rear tool part 2 a - d may be mounted directly on the connecting rod 9 and anywhere along the length thereof. The rear tool part 2 a - d may alternatively be mounted on the front tool part 1 a - d , 3 , 6 as well as directly on the connecting rod 9 . The rear tool part 2 a - d may alternatively be made integrally with the front tool part 1 a - d , 3 , 6 and/or the connecting rod 9 .
The cleaning device according to the invention may also be used by hand, i.e., without help from the drive mechanism 10 , the connecting rod 9 having the front tool part 1 a - d , 3 , 6 and/or the rear tool part 2 a - d hence being handled entirely manually and as an alternative to a simple manual lever.
The invention is not limited to the embodiments shown here but may be varied within the scope of the appended claims.
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The present invention relates to a method of using a cleaning device for cleaning outlet ports ( 11 ) or the like and/or outlet spouts ( 12 ) or the like in soda recovery boilers ( 13 ) or the like, the cleaning device comprising at least one connecting rod ( 9 ). The cleaning device has at least one front tool part ( 1 a - d, 3, 6 ), mounted on said connecting rod ( 9 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 10/965,129, filed Oct. 14, 2004.
BACKGROUND
[0002] The present invention relates to a phase change memory.
[0003] Phase change memories use a class of materials that have the property of switching between two phases having distinct electrical characteristics, associated with two different crystallographic structures of the material and variations thereof, such as an amorphous, disordered phase and a crystalline or polycrystalline, ordered phase. The two phases are hence associated to resistivities of considerably different values where the more disordered phases are higher in resistivity and the crystalline phases are lower in resistivity.
[0004] Currently, the alloys of elements of group VI of the periodic table, such as Te or Se, referred to as chalcogenides or chalcogenic materials, can be used advantageously in phase change memory cells. The currently most promising chalcogenide is formed from an alloy of Ge, Sb and Te (Ge 2 Sb 2 Te 5 ), which is now widely used for storing information on overwritable disks and has also been proposed for mass storage.
[0005] In the chalcogenides, the resistivity may vary by two or more orders of magnitude when the material passes from the amorphous (more resistive) phase to the crystalline (more conductive) phase, and vice versa.
[0006] Phase change can be obtained by locally increasing the temperature. Below 150° C., both the phases are relatively stable, although there is some tendency over a period years at 150C for the reset amorphous state to crystallize, thereby lowering its resistance. Starting from an amorphous state, and rising the temperature above 200° C., there is a rapid nucleation of the crystallites and, if the material is kept at the crystallization temperature for a sufficiently long time, it undergoes a phase change and becomes crystalline. To bring the chalcogenide back to the amorphous state, it is necessary to raise the temperature above the melting temperature (approximately 600° C.) and then rapidly cool off the chalcogenide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic diagram of one embodiment of the present invention;
[0008] FIG. 2 is a current-voltage curve for one embodiment of the present invention;
[0009] FIGS. 3-10 are cross-sections through a semiconductor device according to a first embodiment of the invention, in subsequent manufacturing steps, taken along line 10 - 10 of FIG. 12 ;
[0010] FIG. 11 shows a cross-section through the device of FIG. 12 , taken along line 11 - 11 of FIG. 14 ; and
[0011] FIG. 12 is a plan view of the device of FIGS. 10 and 11 .
DETAILED DESCRIPTION
[0012] In a phase change memory using chalcogenic elements as storage elements, memory cells are arranged in rows and columns to form an array, as shown in FIG. 1 . The memory array 1 of FIG. 1 comprises a plurality of memory cells 2 , each including a memory element 3 of the phase change type and a selection element 4 . The memory cells 2 are interposed at cross-points of rows 6 (also called word lines) and columns 5 (also called bit lines).
[0013] In each memory cell 2 , the memory element 3 has a first terminal connected to an own word line 5 and a second terminal connected to a first terminal of its own selection element 4 . The selection element 4 has a second terminal connected a bit line 6 . In another solution, the memory element 3 and the selection element 4 of each cell 2 may be exchanged in position.
[0014] A binary memory may be formed by an array of cells including a switch element called “ovonic threshold switch” (also referred to as an OTS hereinafter), connected in series with a memory element called “ovonic memory switch” (OMS). The OTS and the OMS may be formed adjacent to each other on an insulating substrate, connected through a conducting strip. Cells are coupled between a row and a column of a memory array and the OTS may function as a selection or access device 4 .
[0015] The OMS is formed by a chalcogenic semiconductor material having two distinct metastable phases (crystalline and amorphous) associated with different resistivities, while the OTS may be built with a chalcogenic semiconductor material having a single phase (generally amorphous, but sometimes crystalline) with two distinct regions of operation associated with different resistivities. If the OTS has a higher resistance than the OMS, when a memory cell is to be read, a voltage drop is applied to the cell that is insufficient to trigger the OMS when the latter is in its higher resistance condition (associated with a digital “0” state), but is sufficient to drive the OTS and OMS into their low resistance condition when the OMS is already in its low resistance condition (associated with a digital “1” state).
[0016] An OTS may have the characteristic shown in FIG. 2 . An OTS has a high resistance for voltages below a threshold value Vth. When the applied voltage exceeds the threshold value Vth, the switch begins to conduct at a substantial, constant, low voltage and presents a low impedance. When the current through the OTS falls below a holding current I H , the OTS goes back to its high-impedance condition. This behavior may be symmetrical and may occur also for negative voltages and currents.
[0017] A phase change memory device comprises a chalcogenic material and a resistive electrode, also called a heater. In fact, from an electrical point of view, the crystallization temperature and the melting temperature are obtained by causing an electric current to flow through the chalcogenide material and its resistive electrode in contact or close proximity with the chalcogenic material. In this way, the chalcogenic material is heated by Joule effect in the electrode and by current/voltage and Joule effect in the chalcogenide.
[0018] In particular, a voltage/current pulse of a suitable length (corresponding to the crystallization time) and amplitude (corresponding to the crystallization temperature) may be applied to crystallize the chalcogenic material. The chalcogenic material changes state, switching to a lower resistivity, more crystalline state (also called the set or “1” state). Vice versa, a shorter voltage/current pulse, such as 20 nanoseconds of suitable amplitude (corresponding to the melting temperature) melts the chalcogenic material, cooling it down rapidly and then quenching it in the amorphous phase.
[0019] Memory regions, for example in the form of strips of a chalcogenic material, may directly contact heating regions. In order to reduce the area of the memory cells, a mold layer of a further dielectric material, such as silicon nitride, is first formed on the dielectric layer housing the resistive material. Then a metallic, semi-metallic or semiconductor glue layer (e.g. of Ti or TiSiN) is deposited, which adheres to the mold layer. After narrow slits have been opened in the mold layer and in the glue layer to expose the heating regions, a chalcogenic layer is deposited on the mold layer, thus filling the slits and contacting the heating regions. The glue layer reduces detachment of the chalcogenic layer. In fact, the chalcogenic layer does not adhere tightly to dielectric materials, and would easily delaminate in subsequent process steps, especially those involving a thermal stress (annealing, oxidation, barrier and metallic layer deposition).
[0020] However, the use of the metallic/semi-metallic/semiconductor glue layers is not free from limitations. First of all, glue layers may involve a surface cleaning treatment by sputter etch before deposition of the chalcogenic layer. During this step, especially when metallic or semi-metallic glue layers are used, reflected power may impair efficiency and yield. In fact, sputter etch processes and machines are normally optimized for treatment of dielectric layers, so that they are not suitable for different materials.
[0021] Moreover, the stack formed by the mold layer, the glue layer and the chalcogenic layer may need a further etch to define connection lines (bit lines) for the memory cells. Problems involved in etching stacks comprising both metallic/semi-metallic/semiconductor layers and dielectric layers are well-known. In particular, several etching agents must be used, because the materials forming the stack are only selectively removed. Hence, the connection lines or whatever structures are to be formed often have irregular profiles and unpredictable dimensions, and are insufficiently reproducible. Etching thick metal layers is difficult as well. In addition, the thickness of the glue layer may be substantiated relative to the thickness of connection lines or structures.
[0022] With reference to FIG. 3 , a semiconductor wafer 10 , including a substrate 11 , is initially subject to the usual steps to form circuitry components and any element to be integrated into the substrate 11 . For example, decoding components may be integrated in the substrate 11 .
[0023] Then, the wafer 10 is covered by an insulating layer 12 . Row lines 13 (e.g., of copper) are formed on top of the insulating layer 12 , insulated from each other by a first dielectric layer 14 . The row lines 13 (word lines) may be formed by first depositing the first dielectric layer 14 , removing the dielectric material where the row lines 13 are to be formed, and then filling the resulting trenches with copper (Cu). Any excess copper is removed from the surface of the wafer 10 by chemical mechanical polishing (CMP), all pursuant to a damascene process.
[0024] Thereafter, an encapsulating structure is formed as indicated in FIG. 4 . The encapsulating structure may be formed by depositing, in sequence, a first nitride layer 18 and a first oxide layer 19 and then selectively removing the first nitride layer 18 and the first oxide layer 19 down to the surface of the first dielectric layer 14 as shown in FIG. 5 . Thus, for each row line 13 , an opening 20 is formed which extends at least in part on top of the row line 13 . An opening 20 may extend along the whole respective row line 13 or along only a part thereof, in which case a plurality of openings 20 extend in alignment with each other along each row line 13 .
[0025] Then, a spacer layer (e.g., of silicon nitride) is deposited and etched back. Thus, the horizontal portions of the spacer layer are removed, and only vertical portions 21 thereof, extending along the vertical walls of the opening 20 , are left. These vertical portions 21 join the first nitride layer 18 laterally to the openings 20 and form, with the first nitride layer 18 , a protective region 22 . Thus, the structure of FIG. 5 is obtained, wherein the protective region 22 together with the first oxide layer 19 form an encapsulating structure.
[0026] Thereafter, as shown in FIG. 6 , a heater layer 23 is deposited and stabilized. For example, TiSiN may be used, which conformally covers the underlying structure. One vertical wall of the heater layer 23 extends onto and makes contact with a respective row line 13 . Subsequently, a sheath layer 24 (e.g., of silicon nitride) and a second dielectric layer 25 are deposited. The second dielectric layer 25 may be deposited by Sub Atmospheric Chemical Vapor Deposition Undoped Silicon Glass (USG), High Density Plasma USG, or Plasma Enhanced Chemical Vapor Deposition USG to completely fill the openings 20 to complete the encapsulating structure in some embodiments.
[0027] In practice, the sheath layer 24 and the protective region 22 may isolate the heater layer 23 from the first and second oxide layers 19 , 25 to reduce oxidation of the heater material.
[0028] The structure is then planarized by chemical mechanical polishing to remove all portions of the second dielectric layer 25 , the sheath layer 24 , and the heater layer 23 extending above the openings 20 as shown in FIG. 7 . Then, a gluing substance 26 , which in one embodiment may include silicon, is implanted in the wafer 10 to form first and second surface glue regions 19 a , 25 a in respective superficial portions of the first and, respectively, the second oxide layers 19 , 25 . The concentration of the implanted gluing substance 26 in the first and second surface glue regions 19 a , 25 a , where it penetrates, may be between 10 16 and 10 23 atoms/cm 3 in some embodiments.
[0029] The addition of the gluing substance 26 with a controlled superficial concentration improves the capability of dielectric materials, such as silicon dioxide, to adhere to chalcogenides. In practice, the implanted gluing substance 26 makes the surfaces of the first and the second oxide layer 19 , 25 suitable for adhesion to a chalcogenic layer which is to be subsequently deposited thereon. Other gluing substances than Si may be implanted as well, such as As, Sb, Ge, B, In, Ti, P, Mo and W. After implantation, the surface 11 a of the wafer 11 , which is mostly of dielectric material, may undergo a pre-deposition cleaning treatment by sputter etch.
[0030] Next, an OMS/OTS (Ovonic Memory Switch/Ovonic Threshold Switch) stack may be deposited as indicated in FIG. 8 . In detail, a first chalcogenic layer 27 (e.g., Ge 2 Sb 2 Te 5 ), a first barrier layer 28 (e.g., TiAlN), a second chalcogenic layer 29 (e.g., As 2 Se 3 ) and a second barrier layer 30 (e.g., TiAlN) are deposited. The previously implanted gluing substance 26 causes the first chalcogenic layer 27 to tightly adhere to the first and the second surface glue region 19 a , 25 a , and the adhesion surface may be sufficiently wide to withstand any thermal or mechanical stress in subsequent manufacturing steps.
[0031] The above materials are only indicative, and any chalcogenic material suitable to store information depending on its physical state (for first chalcogenic layer 27 ) and to operate as a selector for second chalcogenic layer 29 ) may be used. Storage elements 27 ′ are formed at mutual contact areas 37 of the heating layer 23 and the first chalcogenic layer 27 (see also FIGS. 11 and 12 ).
[0032] Then, the first chalcogenic layer 27 , the first barrier layer 28 , the second chalcogenic layer 29 and the second barrier layer 30 are defined ( FIG. 9 ) to form so called “dots” 31 at the intersections of the rows and columns of the matrix. The dots 31 may extend along the length of a column 1 .
[0033] Then a sealing layer 32 (e.g., of silicon nitride) and an interlayer dielectric 33 (e.g., of silicon dioxide) are deposited as indicated in FIG. 9 .
[0034] Finally, the wafer 10 is subjected to CMP to planarize the structure and column lines and vias are formed, for example, using a standard dual damascene copper process. The interlayer dielectric 33 and the first dielectric layer 14 (as well as the sealing layer 32 and the bottom of the protective region 22 , where present) are etched in a two-step process to form vias openings 35 (extending down to the row lines 13 ) and column trenches 36 (extending down to the dots 31 ). The two etching steps may be carried out in any sequence. Then, a metal material (e.g. Cu) is deposited that fills the via openings 35 ( FIG. 11 ) and the column trenches 36 , forming vias 40 and column lines 41 a . Furthermore, row line connections 41 b are also formed. Thus the structure of FIGS. 10-12 is obtained.
[0035] As clearly visible from FIGS. 10-12 , the heater layer 23 form heaters or resistive elements having substantially box-like shapes with a first vertical elongated wall 23 a (on the left, in the drawings) extending approximately above the midline of the respective row line 13 and a second vertical elongated wall 23 b (on the right) extending on top of the first oxide layer 19 . Each first vertical elongated wall 23 a forms a wall-shaped heater that contacts the respective dots 31 along a line (contact area 37 indicated by a hatching in FIG. 12 ) and is shared by all the dots 31 aligned on a single row line 13 , while the second vertical elongated wall 23 b has no function. The electrical connection of all the dots 31 along a same row line through the wall-shaped heater 23 does not impair the operation of the memory device, since the second chalcogenic material 29 of the dots 31 form an OTS or selection element allowing addressing only the dots 31 connected to both the row line 13 and the column line 41 a that are addressed.
[0036] In particular, the problems caused by the poor adhesion between chalcogenic and dielectric materials may be reduced, in some embodiments, by adding the gluing substance to the dielectric layers, namely at superficial regions thereof, before depositing the chalcogenic layer. Moreover, problems involved in etching stacks comprising both metallic or semi-metallic layers may be reduced in some embodiments. Thus, stacked structures having regular profiles and predictable dimensions may be made in some cases.
[0037] The phase change memory cells manufactured according to the present invention may also be compact. Their thickness may be reduced, because the gluing may be accomplished inside the dielectric layers arranged under the chalcogenic layer, instead of using deposited glue layers.
[0038] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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A phase change material is formed over a dielectric material. An impurity is introduced into the dielectric to improve the adherence of said dielectric to said phase change material.
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CLAIM OF PRIORITY
The present application claims the benefit of and incorporates by reference U.S. Provisional Application No. 61/675,529 filed Jul. 25, 2012, entitled “SPRING WINDING DEVICE FOR USE WITH OVERHEAD DOORS.”
FIELD OF THE INVENTION
The present invention relates to a spring winding device, such as for use in pretensioning a counterbalance spring used with an overhead door.
BACKGROUND OF THE INVENTION
Conventionally, a torsion spring counterbalancing mechanism may be used with an overhead door to counterbalance a weight of the overhead door when moving the overhead door during between an open position and a closed position. When the torsion spring counterbalancing mechanism is installed, one or more springs forming a portion of the torsion spring counterbalancing mechanism need to be pretensioned with an amount of counterbalancing force. Further, following initial installation, adjustment of the amount of counterbalancing force may be necessary to repair or replace the torsion spring counterbalancing mechanism.
A conventional method used to adjust the amount of counterbalancing force in one or more springs forming a portion of the torsion spring counterbalancing mechanism may be dangerous. Winding rods are typically inserted into a spring end cone, a rotational force is applied to the one or more springs, the spring end cone is disengaged from a torsion shaft, and the amount of counterbalancing force is one of increased and decreased. When a first winding rod is inserted in the spring end cone, the rotational force may be applied to the one or more springs. Using a second winding rod and an iterative process, the one or more springs may be wound or unwound. Such a process may be dangerous, as the winding rod will rotate quickly when the one or more springs are pretensioned and the winding bar is unrestrained.
To reduce such a danger, it is known in the prior art to employ a spring winder having a worm drive gear engaged with a worm wheel to adjust the amount of counterbalancing force. The worm wheel is fitted about a center portion of the torsion shaft and the worn drive gear is rotated to adjust the amount of counterbalancing force in the one or more springs. However, when the one or more springs are pretensionsed, the worm wheel may tilt or move along its axis as it resists the counterbalancing force. When the worn wheel tilts or moves along its axis, the worn drive gear may become disengaged or misaligned, rendering such a spring winder inoperable.
It is also known in the prior art to locate the spring winder having the worm drive gear engaged with the worm wheel at an end of the torsion shaft to militate against movement of the worm wheel. In such an arrangement a separate spring winder is employed for each spring, and the spring winder is subject to a thrust force of the spring. Balancing the thrust force of the spring may extend a service life of the spring significantly. Further, in such an arrangement, non-conventional cable drums are employed to house a portion of the spring winder. The spring winder having the worm wheel at an end of the torsion shaft increases a cost and a complexity of the counterbalancing mechanism while decreasing a service life of the one or more springs.
It would be advantageous to develop a spring winding device that does not require pretensioning using winding rods, maintains rigidity and alignment when a counterbalancing force is applied, and decreases a cost and a complexity of a counterbalancing mechanism the spring winding device is incorporated in.
SUMMARY OF THE INVENTION
Presently provided by the invention, a driveline including a continuously variable transmission that is inexpensive, compact, may be configured for a wide range of torque distributions, and able to adjust a drive ratio has surprisingly been discovered.
In one embodiment, the present invention is directed to a spring winding device for a counterbalancing mechanism. The spring winding device comprises a support bracket, a worm gear, and a drive gear. The worm gear is rotatably coupled to the support bracket and includes a mount portion for coupling a first end cone thereto. The drive gear is rotatably disposed adjacent the support bracket and is drivingly engaged with the worm gear. A rotation of the drive gear causes the worm gear to rotate within the support bracket.
In another embodiment, the present invention is directed to a counterbalancing force adjustment device for a counterbalancing mechanism. The counterbalancing force adjustment device comprises an anti-rotation device and a spring winding device. The anti-rotation device comprises an elongate member and a bumper portion. The bumper portion is coupled to the elongate member. The spring winding device comprises a support bracket, a worm gear, and a drive gear. The worm gear is rotatably coupled to the support bracket. The worm gear includes a mount portion for coupling a first end cone thereto. The drive gear is rotatably disposed adjacent the support bracket. The drive gear is drivingly engaged with the worm gear. The anti-rotation device is drivingly engaged with a second end cone to militate against a rotation thereof. A rotation of the drive gear causes the first end cone to rotate with the worm gear, causing an amount of counterbalancing force stored in a torsion spring coupled to the first end cone and the second end cone to be adjusted.
In another embodiment, the present invention is directed to a method of adjusting an amount of force stored in a pair of springs of a counterbalancing mechanism. The method comprises the steps of providing a first spring disposed about a shaft, the first spring and shaft forming a portion of the counterbalancing mechanism, the first spring drivingly engaged with the shaft at a first end thereof; providing a second spring disposed about the shaft, the second spring and shaft forming a portion of the counterbalancing mechanism, the second spring drivingly engaged with the shaft at a first end thereof; providing a spring winding device for the counterbalancing mechanism, the spring winding device comprising a rotatable portion for coupling a second end of the first spring and a second end of the second spring thereto; and adjusting the amount of force stored in the pair of springs of the counterbalancing mechanism simultaneously by rotating the rotatable portion of the spring winding device.
In another embodiment, the present invention is directed to a method of adjusting an amount of force stored in a spring of a counterbalancing mechanism. The method comprises the steps of providing the spring disposed about a shaft having a keyway formed therein, the spring and shaft forming a portion of the counterbalancing mechanism, the spring drivingly engaged with the shaft at a first end thereof through the use of a keyed mounting cone, the keyed mounting cone able to be moved along the keyway of the shaft; providing a spring winding device for the counterbalancing mechanism, the spring winding device comprising a rotatable portion for coupling a second end of the first spring and a second end of the second spring thereto; and adjusting the amount of force stored in the counterbalancing mechanism by rotating the rotatable portion of the spring winding device, wherein in response to the amount of force stored in the counterbalancing mechanism being adjusted, a position of the keyed mounting cone moves along the shaft as a length of the spring changes.
In another embodiment, the present invention is directed to a method of adjusting an amount of force stored in a spring of a counterbalancing mechanism. The method comprises the steps of providing the spring disposed about a shaft, the spring and shaft forming a portion of the counterbalancing mechanism, the spring drivingly engaged with the shaft at a first end thereof; providing a spring winding device for the counterbalancing mechanism, the spring winding device comprising a support bracket, a worm gear rotatably coupled to the support bracket, the worm gear including a mount portion for coupling a second end of the spring thereto, and a drive gear rotatably disposed adjacent the support bracket, the drive gear drivingly engaged with the worm gear, wherein a rotation of the drive gear causes the worm gear to rotate within the support bracket; providing an anti-rotation device comprising an elongate member and a bumper portion, the bumper portion coupled to the elongate member; drivingly engaging the anti-rotation device with the first end of the spring; releasing the first end of the spring from driving engagement with the shaft; adjusting the amount of force stored in the counterbalancing mechanism by rotating the drive gear; drivingly engaging the first end of the spring with the shaft; and releasing the anti-rotation device from driving engagement with the first end of the spring.
Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.
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 when considered in the light of the accompanying drawings in which:
FIG. 1 is a perspective view of a spring winding device according to an embodiment of the present invention;
FIG. 1A is a side view of an end cone and a torsion shaft according to another embodiment of the present invention;
FIG. 2 is a perspective view of the spring winding device shown in FIG. 1 ;
FIG. 3 is a perspective view of the spring winding device shown in FIG. 1 ;
FIG. 4 is a perspective view of the spring winding device shown in FIG. 1 ;
FIG. 5 is a perspective view of a gear shroud used with the spring winding device shown in FIG. 1 ;
FIG. 6 is a perspective view of an anti-rotation device according to an embodiment of the present invention;
FIG. 7 is a perspective view of an anti-rotation device according to another embodiment of the present invention;
FIG. 8 is a perspective view of an anti-rotation device according to another embodiment of the present invention;
FIG. 9 is a perspective view of an anti-rotation device according to another embodiment of the present invention;
FIG. 10 is a perspective view of an anti-rotation device according to another embodiment of the present invention; and
FIG. 11 is a perspective view of the spring winding device shown in FIG. 1 including the gear shroud shown in FIG. 5 , the spring winding device being used with the anti-rotation device shown in FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless the claims expressly state otherwise.
FIGS. 1 , 2 , 3 , 4 and 11 illustrate a spring winding device 10 according to an embodiment of the invention. The spring winding device 10 forms a portion of a counterbalancing mechanism (partially shown) for an overhead door (not shown) and preferably comprises a support bracket 12 , a flanged worm gear 14 , a drive gear assembly 15 , and a gear shroud 16 (shown in FIGS. 5 and 11 ). As shown, the spring winding device 10 is mounted above the overhead door placed in a closed position. As a non-limiting example, the overhead door may be a residential garage door.
The counterbalancing mechanism also includes two torsion springs 17 and a torsion shaft 18 . Each of the torsion springs 17 include a first end cone 19 and a second end cone 20 fixed to opposing ends of the torsion spring 17 . Each of the first end cones 19 as shown is known in the art as a winding cone, and may be coupled to the torsion shaft 18 using at least one set screw 21 . Each of the second end cones 20 as shown is known in the art as a stationary cone, and is coupled to the flanged worm gear 14 using at least one fastener. The spring winding device 10 is disposed about the torsion shaft 18 , which also forms a portion of the counterbalancing mechanism. The torsion shaft 18 is a conventional torsion shaft, and is well known in the art.
As shown in FIGS. 1 and 11 , the torsion shaft 18 is a torsion shaft having a keyway 22 formed therein. The keyway 22 formed therein may be disposed through a keyed end cone 19 ′ having a key 23 formed thereon, shown in FIG. 1A . The keyed end cone 19 ′ having the key 23 is drivingly engaged with the keyway 22 of the torsion shaft 18 . The keyed end cone 19 ′ is able to be moved along a length of the torsion shaft 18 while maintaining driving engagement with the torsion shaft 18 . The keyed end cone 19 ′ is able to move along the torsion shaft 18 as an amount of counterbalancing force stored in each of the torsion springs 17 coupled thereto is adjusted. It is understood that when the amount of counterbalancing force stored in each of the torsion springs 17 is adjusted, a length of each of the torsion springs 17 changes. In response to the length of each of the torsion springs 17 changing, each of the keyed end cones 19 ′ moves along the torsion shaft 18 . The keyed end cone 19 ′ having the key 23 formed thereon eliminates a need for an anti-rotation device when an amount of counterbalancing force stored in each of the torsion springs 17 is adjusted. The keyed end cone 19 ′ militates against a binding that may occur to the torsion springs 17 if the amount of counterbalancing force stored in each of the torsion springs 17 is adjusted without allowing the length of each of the torsion springs 17 to change.
The support bracket 12 is a L-shaped member mounted to a wall 24 above a frame (not shown) for the overhead door. The support bracket 12 includes a mounting portion 25 and a main portion 26 . A retaining portion 27 is coupled to the support bracket 12 . A drive gear assembly aperture 28 , a flanged worm gear fastening perforation 29 , and a plurality of mounting apertures 30 are formed through the main portion 26 and the mounting portion 25 . A portion of an outer peripheral edge of the main portion 26 and a portion of an outer peripheral edge of the retaining portion 27 define a torsion shaft perforation 32 . The support bracket 12 is preferably formed by stamping and bending a sheet metal such as steel; however, it is understood that the support bracket may be formed with other processes from other materials.
The mounting portion 25 has a rectangular shape and includes at least two mounting apertures 30 formed therethrough. As most clearly shown in FIG. 2 , the mounting apertures 30 may be circular apertures or elongate apertures. A plurality of fasteners, such as screws, bolts, or the like, is disposed through the mounting apertures 30 and couple the support bracket 12 to the wall 24 . It is understood that the mounting portion 25 may include a bracket adjustment device (not shown). The bracket adjustment device allows a position of the support bracket with respect to the wall 24 to be adjusted. The bracket adjustment device facilitates installation and service of the counterbalancing mechanism the spring winding device 10 forms a portion of.
The main portion 26 is an elongate portion of the support bracket 12 and includes the drive gear assembly aperture 28 formed therethrough. As most clearly shown in FIG. 3 , the drive gear assembly aperture 28 is substantially rectangular in shape and also defines an alignment tab 34 and a drive gear retention tab 36 . Alternately, the drive gear assembly aperture 28 may be any other shape. The alignment tab 34 is an elongate member bent away from and substantially orthogonal to a surface of the main portion 26 . The drive gear retention tab 36 is an elongate member bent away from and substantially orthogonal to a surface of the main portion 26 . The drive gear retention tab 36 is formed adjacent the alignment tab 34 and is bend in an opposing direction with respect to the alignment tab 34 . At least one flanged worm gear fastening perforation 29 is formed through the main portion 26 . The flanged worm gear fastening perforation 29 is an elongate perforation; however, it is understood that that flanged worm gear fastening perforation 29 may have another shape. As mentioned hereinabove, a portion of the outer peripheral edge of the main portion 26 partially defines the torsion shaft perforation 32 . The torsion shaft perforation 32 is substantially circular in shape.
The retaining portion 27 is a member coupled to the main portion 26 . As shown in FIGS. 1-3 and 11 , the retaining portion 27 is coupled to the main portion 26 using a plurality of rivets disposed through perforations formed through the main portion 26 and the retaining portion 27 ; however it is understood that the retaining portion 27 may be coupled to the main portion 26 using any conventional fastener. As mentioned hereinabove, a portion of the outer peripheral edge of the retaining portion 27 partially defines the torsion shaft perforation 32 . The retaining portion 27 is preferably formed by stamping and bending a sheet metal such as steel; however, it is understood that the support bracket 12 may be formed with other processes from other materials.
The flanged worm gear 14 is a disposed between the main portion 26 and the retaining portion 27 , through the torsion shaft perforation 32 . When not coupled to the support bracket 12 , the flanged worm gear 14 is a rotatable portion of the spring winding device 10 . The flanged worm gear 14 includes a gear portion 38 and a first end cone mount portion 40 . A support recess 42 is formed between the gear portion 38 and the first end cone mount portion 40 . A torsion shaft aperture 44 is formed through the flanged worm gear 14 . The flanged worm gear 14 is formed by casting and machining a metal; however, it is understood that other processes may be used to form the flanged worm gear 14 .
The gear portion 38 is a disc shaped member having a toothed outer edge 46 . The toothed outer edge 46 of the gear portion 38 is in driving engagement with the drive gear assembly 16 . A plurality of set perforations 48 are formed through the gear portion 38 . Each of the set perforations 48 may be aligned with the flanged worm gear fastening perforation 29 when the flanged worm gear 14 is rotated about a gear portion axis. A fastener 49 is disposed through the flanged worm gear fastening perforation 29 and one of the set perforations 48 to couple the flanged worm gear 14 to the support bracket 12 . As shown in FIGS. 1 , 2 , 3 , 4 and 11 , the fastener 49 is a fastener having threads corresponding to threads formed in the set perforations 48 ; however, it is understood that the fastener 49 may be any conventional fastener. The gear portion axis is substantially coincident to an axis of the torsion shaft 18 . At least two cone mounting perforations 50 are formed in a second end cone mount portion 51 . The second end cone mount portion 51 comprises two protuberances extending away from the gear portion 38 ; however, it is understood that the second end cone mount portion 51 may comprise other shapes or that the gear portion 38 may not include the second end cone mount portion 51 . Preferably, the cone mounting perforations 50 are threaded, however, it is understood that the cone mounting perforations 50 may be configured for any type of fastener.
The first end cone mount portion 40 is a flanged shape member spaced apart from the gear portion 38 . As most clearly shown in FIG. 3 , the first end cone mount portion 40 includes a hollow central cylindrical portion 52 and two radially extending protuberances 54 . At least two cone mounting perforations 56 are formed in the radially extending protuberances of the first end cone mount portion 40 . Preferably, the cone mounting perforations 56 are threaded, however, it is understood that the cone mounting perforations 56 may be configured for any type of fastener.
As shown in FIGS. 1-3 and 11 , when the counterbalancing mechanism including the spring winding device 10 is in an installed condition, each of the second end cones 20 is coupled to the end cone mount portion 40 and the second end cone mount portion 51 using fasteners inserted through each of the second end cones 20 and into the cone mounting perforations 50 , 56 . Alternately, it is understood that the second end cones 20 may be integrally formed with the gear portion 38 or coupled to the gear portion 38 in any other conventional manner.
The support recess 42 is a recess between the gear portion 38 and the two radially extending protuberances 54 . A portion of the first end cone mount portion 40 having a reduced diameter defines the support recess 42 . When the flanged worm gear 14 is disposed in the support bracket 12 , at least a portion of the main portion 26 and the retaining portion 27 enter and rotatably support the flanged worn gear 14 . A width of the support recess 42 is slightly greater than a thickness of the main portion 26 and the retaining portion 27 , permitting the main portion 26 and the retaining portion 27 to be disposed therein. The width of the support recess 42 militates against a substantial axial deviation of the flanged worm gear 14 within the support bracket 12 .
The drive gear assembly 16 is coupled to the main portion 26 of the support bracket 12 . The drive gear assembly 16 includes a drive gear housing 58 and a drive gear 60 . The drive gear housing 58 is coupled to the main portion 26 and the drive gear 60 is rotatably disposed in the drive gear housing 58 . As shown in FIGS. 1 , 2 , 3 , 4 and 11 , the drive gear assembly 16 includes a single drive gear; however, it is understood that the drive gear assembly may include two or more drive gears arranged in a gear train to facilitate adjusting an amount of counterbalancing force in one or more torsion springs.
The drive gear housing 58 is a member formed by casting and machining a metal such as steel; however, it is understood that the drive gear housing 58 may be formed with other processes from other materials. The drive gear housing 58 is disposed in the drive gear assembly aperture 28 and coupled to the main portion 26 . A first drive gear slot 62 and a second drive gear slot 64 are formed in opposing portions of the drive gear housing 58 . The first drive gear slot 62 and the second drive gear slot 64 align and rotatably support the drive gear 60 when the spring winding device 10 is assembled. As most clearly shown in FIGS. 3 and 4 , a plurality of mounting perforations corresponding to mounting perforations formed through the main portion 26 receive rivets to couple the drive gear housing 58 to the main portion 26 . However, it is understood the drive gear housing 58 may be coupled to the main portion 26 in any conventional manner. The drive gear housing 58 also includes an alignment tab 66 extending from a remaining portion of the drive gear housing 58 . When the drive gear housing 58 is coupled to the main portion 26 , the alignment tab 66 is disposed through the drive gear assembly aperture 28 and supported by the main portion 26 . When the drive gear housing 58 is coupled to the main portion 26 , a portion of the drive gear housing 58 is disposed against the alignment tab 34 , as shown in FIGS. 2 and 3 .
The drive gear 60 is a threaded member rotatably disposed in the drive gear housing 58 . When the spring winding device 10 is assembled, at least one thread 68 formed in the drive gear 60 is in driving engagement with the toothed outer edge 46 of the flanged worm gear 14 . The drive gear 60 includes two annular journals 70 which are disposed in the drive gear slots 62 , 64 and militate against axial movement of the drive gear 60 with respect to the drive gear housing 58 . A drive end 72 of the drive gear 60 is disposed adjacent an outer surface of the drive gear housing. As most clearly shown in FIG. 4 , the drive end 72 includes a hexagonal shaped protuberance for drivingly engaging a driving tool (not shown); however, it is understood that the drive end 72 may include other features formed therein for engaging other drive tools. When the driving tool is engaged with the drive end 72 and the driving tool is rotated, the drive gear 60 rotates and the at least one thread 68 applies a force to the toothed outer edge 46 of the flanged worm gear 14 , causing the flanged worm gear 14 to rotate within the support bracket 12 . When the drive gear 60 is disposed in the drive gear housing 58 , a second end 74 of the drive gear 60 is disposed adjacent to or abuts the drive gear retention tab.
As shown in FIGS. 5 and 11 , the gear shroud 16 is a ring shaped member coupled to the support bracket 12 . The gear shroud 16 is formed from a plastic using a molding process; however, it is understood that the gear shroud 16 may be formed from other materials using other processes. The gear shroud 16 has a substantially L-shaped cross-section and encloses at least a portion of the flanged worm gear 14 . Further, it is understood that the gear cover may enclose at least a portion of the drive gear assembly 16 . It is also understood that the gear cover may form a portion of a torsion spring cover (not shown). The gear shroud 16 includes a plurality of shroud fasteners 76 and a drive gear protuberance 78 . The gear shroud 16 militates against debris from collecting on or within the toothed outer edge 46 , the drive gear housing 58 , the drive gear 60 . Further, the gear shroud 16 militates against an entanglement that may occur between a foreign object, the toothed outer edge 46 , and the drive gear 60 .
Each of the shroud fasteners 76 is a hollow, bifurcated protuberance having a barbed end. Each of the shroud fasteners correspond to a shroud perforation 80 formed in one of the main portion 26 and the retaining portion 27 of the support bracket 12 . An elastic deformation of each of the shroud fasteners 76 allows each of the shroud fasteners 76 to be disposed in the shroud perforation 80 , coupling the gear shroud 16 to the support bracket 12 .
The drive gear protuberance 78 is a portion of the gear shroud 16 extending away from a remaining portion of the gear shroud 16 . The drive gear protuberance 78 has a substantially rectangular shape; however, it is understood that the drive gear protuberance 78 may have other shapes or may be formed separate from the remaining portion of the gear shroud 16 . When the gear shroud 16 is coupled to the support bracket 12 , the drive gear protuberance 78 is disposed adjacent or abuts the drive gear housing 58 .
FIG. 6 illustrates an anti-rotation device 100 for use with each of the first end cones 19 . The anti-rotation device 100 may be used with the spring winding device 10 when the counterbalancing mechanism is installed or serviced. The anti-rotation device 100 is coupled to each of the first end cones 19 to resist a torque applied to the first end cones 19 when a tension of the torsion spring 17 is adjusted during installation or service of the counterbalancing mechanism. When the tension of the torsion spring 17 is adjusted during installation or service of the counterbalancing mechanism, the anti-rotation device 100 permits the first end cones 19 to move along the torsion shaft 18 to accommodate changes in length of the torsion spring 17 that occur during adjustment of the tension of the torsion spring 17 . As shown in FIGS. 1 , 2 , and 11 , the counterbalancing mechanism comprises two torsion springs, disposed on opposite sides of the spring winding device 10 , and would require the use of two anti-rotation devices 100 to install or service the counterbalancing mechanism. FIG. 11 illustrates an anti-rotation device 100 ″″ according to another embodiment of the invention being used to install or service the counterbalancing mechanism.
As shown in FIGS. 1 , 2 , and 6 - 11 , the first end cone 19 includes apertures 102 formed therein oriented transversely to a torsion shaft aperture 104 . The first end cone 19 includes four apertures 102 formed therein, the apertures 102 spaced apart equally. The at least one set screw 21 is threadingly disposed in the first end cone 19 for coupling the first end cone 19 to the torsion shaft 18 . The first end cone 19 is a conventional winding cone, and is well known in the art.
The anti-rotation device 100 includes a main body 108 , an arm member 110 , and a first cone pin 112 . The arm member 110 and the first cone pin 112 are adjustably disposed within the main body 108 . When the anti-rotation device 100 is coupled to the first end cone 19 , the anti-rotation device 100 is in driving engagement therewith.
The main body 108 is a L-shaped member the arm member 110 and the first cone pin 112 are adjustably disposed within. The main body 108 includes a first leg 114 , a second leg 116 , a second cone pin 118 , and at least one arm member fastener 120 . An arm member perforation 122 is formed through the first leg 114 and a cone pin perforation 124 is formed through the second leg 116 . The main body 108 is formed by casting and machining a metal; however, it is understood that other processes may be used to form the main body 108 .
The first leg 114 is an elongate member having a rectangular cross section. The arm member perforation 122 is formed lengthwise through the first leg 114 and has a diameter which permits the arm member 110 to be disposed therethrough. The at least one arm member fastener 120 is threadingly disposed in a perforation that intersects the arm member perforation 122 . When the at least one arm member fastener 120 is driven to engage the arm member 110 disposed in the arm member perforation 122 , the arm member 110 is coupled to the main body 108 . The second cone pin 118 extends outwardly from the first leg 114 and is coupled thereto in any conventional manner. A diameter of the second cone pin 118 substantially corresponds to the apertures 102 of the first end cone 19 .
The second leg 116 is an elongate member having a rectangular cross section. The second leg 116 is oriented transversely to the first leg 114 . The cone pin perforation 124 is formed through the second leg 116 transverse to the second cone pin 118 and has a diameter which permits the first cone pin 112 to be disposed therethrough. The first cone pin 112 is disposed through the cone pin perforation 124 and extends outwardly from the second leg 116 and is removably coupled thereto by a head 126 of the first cone pin 112 and a pin 128 removably disposed through a perforation in the first cone pin 112 ; however, it is understood that the first cone pin 112 may be removably coupled to the second leg 116 in any conventional manner. The first cone pin 112 includes a plurality of perforations formed therethrough, which permit a length of the first cone pin 112 extending through the cone pin perforation 124 to be adjusted by moving a location of the pin 128 . A diameter of the first cone pin 112 substantially corresponds to the apertures 102 of the first end cone 19 .
The arm member 110 is an elongate member having a shaft portion 130 and a bumper portion 132 . The shaft portion 130 has a circular cross section and is rotatably coupled to the bumper portion 132 at a first end thereof. The shaft portion 130 is formed by forging a metal; however, it is understood that other processes may be used to form the shaft portion 130 . The bumper portion 132 is a disc shaped member rotatably coupled to a distal end of the shaft portion 130 . At least a portion of the bumper portion 132 is formed from a resilient material, such as rubber. However, it is understood that the bumper portion 132 may have other shapes and may be formed from other materials.
FIG. 7 shows an alternative embodiment of the anti-rotation device 100 . Similar structural features of the anti-rotation device 100 include the same reference numeral and a prime (′) symbol.
An anti-rotation device 100 ′ includes a main body 208 , an arm member 210 , and a first cone pin 112 ′. The arm member 210 and the first cone pin 112 ′ are adjustably disposed within the main body 208 . When the anti-rotation device 100 ′ is coupled to the first end cone 19 , the anti-rotation device 100 ′ is in driving engagement therewith.
The main body 208 is a L-shaped member the arm member 210 and the first cone pin 112 ′ are adjustably disposed within. The main body 208 includes a first leg 214 , a second leg 116 ′, a second cone pin 118 ′, and an arm member pin 234 . An arm member perforation 222 is formed through the first leg 214 and a cone pin perforation 124 ′ is formed through the second leg 116 ′. The main body 208 is formed by casting and machining a metal; however, it is understood that other processes may be used to form the main body 208 .
The first leg 214 is an elongate member having a rectangular cross section. The arm member perforation 222 is formed lengthwise through the first leg 214 and has a diameter which permits the arm member 210 to be disposed therethrough. An arm member fastening slot 236 is formed in the first leg 214 , the arm member fastening slot 236 intersecting the arm member perforation 222 . The arm member fastening slot 236 is V-shaped; however, it is understood that other shapes may be used. The arm member pin 234 is disposed in the arm member fastening slot 236 and through one of a series of perforations formed in a shaft portion 230 of the arm member 210 to couple the arm member 210 to the main body 208 . The second cone pin 118 ′ extends outwardly from the first leg 214 and is coupled thereto in any conventional manner. A diameter of the second cone pin 118 ′ substantially corresponds to the apertures 102 of the first end cone 19 .
The second leg 116 ′ is an elongate member having a rectangular cross section. The second leg 116 ′ is oriented transversely to the first leg 214 . The cone pin perforation 124 ′ is formed through the second leg 116 ′ transverse to the second cone pin 118 ′ and has a diameter which permits the first cone pin 112 ′ to be disposed therethrough. The first cone pin 112 ′ is disposed through the cone pin perforation 124 ′ and extends outwardly from the second leg 116 ′ and is removably coupled thereto by a head 126 ′ of the first cone pin 112 ′ and a pin 128 ′ removably disposed through a perforation in the first cone pin 112 ; however, it is understood that the first cone pin 112 ′ may be removably coupled to the second leg 116 ′ in any conventional manner. The first cone pin 112 ′ includes a plurality of perforations formed therethrough, which permit a length of the first cone pin 112 ′ extending through the cone pin perforation 124 ′ to be adjusted by moving a location of the pin 128 ′. A diameter of the first cone pin 112 ′ substantially corresponds to the apertures 102 of the first end cone 19 .
The arm member 210 is an elongate member having the shaft portion 230 and a bumper portion 132 ′. The shaft portion 230 has a circular cross section and is rotatably coupled to the bumper portion 132 ′ at a first end thereof. The shaft portion 230 includes a plurality of perforations formed therethrough, which permit a length of the shaft portion 230 extending through the arm member perforation 222 to be adjusted by moving a location of the arm member pin 234 . The shaft portion 230 is formed by forging and machining a metal; however, it is understood that other processes may be used to form the shaft portion 230 . The bumper portion 132 ′ is a disc shaped member rotatably coupled to a distal end of the shaft portion 230 . At least a portion of the bumper portion 132 ′ is formed from a resilient material, such as rubber. However, it is understood that the bumper portion 132 ′ may have other shapes and may be formed from other materials.
FIG. 8 shows an alternative embodiment of the anti-rotation device 100 . Similar structural features of the anti-rotation device 100 include the same reference numeral and a double prime (″) symbol.
An anti-rotation device 100 ″ includes two main bodies 340 and an arm member 110 ″. The arm member 110 ″ is adjustably disposed within the main bodies 340 . The main bodies are opposingly disposed on the arm member 110 ″. When the anti-rotation device 100 ″ is coupled to the first end cone 19 , the anti-rotation device 100 ″ is in driving engagement therewith. The anti-rotation device 100 ″ is coupled to the first end cone 19 by moving each of the main bodies 340 along the arm member 110 ″.
Each of the main bodies 340 is a U-shaped member the arm member 110 ″ is adjustably disposed within. The main body 340 includes a fastening portion 342 , a central portion 344 , a cone pin 346 , at least one arm member fastener 348 , and an arm member perforation 350 . The main body 340 is formed by casting and machining a metal; however, it is understood that other processes may be used to form the main body 340 .
The fastening portion 342 is an elongate member having a rectangular cross section. The arm member perforation 350 is formed lengthwise through the fastening portion 342 and has a diameter which permits the arm member 110 ″ to be disposed therethrough. The at least one arm member fastener 348 is threadingly disposed in a perforation that intersects the arm member perforation 350 . When the at least one arm member fastener 348 is driven to engage the arm member 110 ″ disposed in the arm member perforation 350 , the arm member 110 ″ is coupled to the main body 340 . The fastening portion 342 includes an alignment protuberance 352 and an alignment recess 354 .
The alignment protuberance 352 has a rectangular cross-section and extends from the fastening portion 342 in a manner substantially parallel to the arm member perforation 350 . The alignment recess 354 is formed in the fastening portion 342 and has a substantially rectangular cross-section. A shape of the alignment recess 354 corresponds to at least a portion of the alignment protuberance 352 . When two of the main bodies 340 are opposingly disposed on the arm member 110 ″, the main bodies may be positioned so that the alignment protuberances 352 and alignment recesses 354 respectively engage one another, militating against relative rotational movement therebetween about the arm member 110 ″.
The central portion 344 is an elongate member having a rectangular cross section. The central portion 344 is oriented transversely to the fastening portion 342 . The cone pin 346 extends from a distal end of the central portion 344 .
The cone pin 346 is integrally formed with the central portion 344 , has a substantially circular cross-section and extends outwardly from the central portion 344 and is substantially parallel to the fastening portion 342 . Alternately, the cone pin 346 may be coupled to the central portion 344 in any conventional manner. A diameter of the cone pin 346 substantially corresponds to the apertures 102 of the first end cone 19 .
FIG. 9 shows an alternative embodiment of the anti-rotation device 100 . Similar structural features of the anti-rotation device 100 include the same reference numeral and a triple prime (′″) symbol.
An anti-rotation device 100 ′″ includes an adjuster body 456 , a support body 458 , and an arm member 410 . The arm member 410 is adjustably disposed within the adjuster body 456 and the support body 458 . When the anti-rotation device 100 ′″ is coupled to the first end cone 19 , the anti-rotation device 100 ′″ is in driving engagement therewith. The anti-rotation device 100 ′″ is coupled to the first end cone by moving the arm member 410 through an adjuster perforation 460 and by disposing an adjuster fastener 462 through the adjuster body 456 .
The adjuster body 456 is a U-shaped member the arm member 410 is adjustably disposed within. The adjuster body 456 includes a primary portion 464 and a secondary portion 466 . The adjuster body 456 is formed by coupling the primary portion 464 to the secondary portion 466 with a plurality of fasteners; however, it is understood that the adjuster body may be unitarily formed.
The primary portion 464 is a L-shaped member. The primary portion 464 includes the adjuster perforation 460 formed therein at a first distal end and a perforation for receiving the adjuster fastener 462 formed therein at a second distal end. The adjuster perforation 460 includes a thread formed thereon, which is engaged with a corresponding thread formed on a shaft portion 468 of the arm member 410 .
The secondary portion 466 is a L-shaped member. The secondary portion 466 includes a cone pin 470 extending therefrom at a first distal end and a perforation for receiving the adjuster fastener 462 formed therein at a second distal end. The cone pin 470 is coupled to the secondary portion 466 and has a substantially circular cross-section and extends outwardly from the secondary portion and is substantially coincident with the shaft portion 468 of the arm member 410 . Alternately, the cone pin 470 may be coupled to the secondary portion 466 in any conventional manner. A diameter of the cone pin 470 substantially corresponds to the apertures of the first end cone.
The support body 458 is a L-shaped member. The support body 458 is coupled to the primary portion 464 at a first distal end and includes a perforation formed therethrough for receiving the shaft portion 468 at a second distal end. The perforation formed through the support body 458 is substantially aligned with the adjuster perforation 460 . The support body 458 is preferably welded to the primary portion 464 ; however, it is understood that the support body 458 may be integrally formed with the primary portion 464 or coupled thereto in any conventional manner.
The arm member 410 is an elongate member having the shaft portion 468 and a bumper portion 132 ′″. The shaft portion 468 is a threaded rod and is rotatably coupled to the bumper portion 132 ′″ at a first end thereof. A diameter of the shaft portion 468 substantially corresponds to the apertures 102 of the first end cone 19 and a second end thereof may be disposed in the apertures 102 . The shaft portion 468 is threadingly disposed through the adjuster perforation 460 and may be secured thereto with a fastener such as a nut, for example. The shaft portion 468 is formed by forging a metal; however, it is understood that other processes may be used to form the shaft portion 468 . The bumper portion 132 ′″ is a disc shaped member rotatably coupled to a distal end of the shaft portion 468 . At least a portion of the bumper portion 132 ′″ is formed from a resilient material, such as rubber. However, it is understood that the bumper portion 132 ′″ may have other shapes and may be formed from other materials.
FIG. 10 shows an alternative embodiment of the anti-rotation device 100 . Similar structural features of the anti-rotation device 100 include the same reference numeral and a quadruple prime (″″) symbol.
The anti-rotation device 100 ″″ includes two main bodies 540 and an arm member 110 ″″. The arm member 110 ″″ is adjustably disposed within the main bodies 540 . The main bodies are opposingly disposed on the arm member 110 ″″. When the anti-rotation device 100 ″″ is coupled to the first end cone 19 , the anti-rotation device 100 ″″ is in driving engagement therewith. The anti-rotation device 100 ″″ is coupled to the first end cone 19 by moving each of the main bodies 540 along the arm member 110 ″″.
Each of the main bodies 540 is a L-shaped member the arm member 110 ″″ is adjustably disposed within. The main body 540 includes a fastening portion 542 , a central portion 544 , a cone pin 546 , and at least one arm member fastener 548 . The main body 540 is formed by casting and machining a metal; however, it is understood that other processes may be used to form the main body 540 .
The fastening portion 542 is a substantially cylindrical shaped body defining an arm member perforation 550 therethrough. The arm member perforation 550 has a diameter which permits the arm member 110 ″″ to be disposed therethrough. The at least one arm member fastener 548 is threadingly disposed in a perforation that intersects the arm member perforation 550 . When the at least one arm member fastener 548 is driven to engage the arm member 110 ″″ disposed in the arm member perforation 550 , the arm member 110 ″″ is coupled to the main body 540 .
The central portion 544 is an elongate member having a rectangular cross section. The central portion 544 is oriented transversely to an axis of the fastening portion 542 . The cone pin 546 extends from a distal end of the central portion 544 .
The cone pin 546 is integrally formed with the central portion 544 , has a substantially circular cross-section and extends outwardly from the central portion 544 and is substantially parallel to the axis of the fastening portion 542 . Alternately, the cone pin 546 may be coupled to the central portion 544 in any conventional manner. A diameter of the cone pin 546 substantially corresponds to the apertures 102 of the first end cone 19 .
In use, the spring winding device 10 and the anti-rotation device 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ are used to adjust an amount of counterbalancing force in one or more torsion springs 17 forming a portion of the torsion spring counterbalancing mechanism. FIG. 11 illustrates the anti-rotation device 100 ″ being used to adjust an amount of counterbalancing force in one or more torsion springs 17 .
First, one of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ is coupled to each of the first end cones 19 . The cone pins 112 , 118 , the cone pins 112 ′, 118 ′, the cone pins 346 of each of the main bodies 340 , the cone pin 470 and the second end of the shaft portion 468 , or the cone pins 546 of each of the main bodies 540 are respectively disposed in the apertures 102 of each of the first end cones 19 to drivingly engage the first end cone 19 with one of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″. By adjusting one of the first cone pin 112 , 112 ′, each of the arm member fasteners 348 , the adjuster fastener 462 and the shaft portion 468 , or each of the arm member fasteners 548 , each of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ may be coupled and drivingly engaged with one of the first end cones 19 . Further, it is understood that a length of the arm member 110 , 210 , 110 ″, 410 , 110 ″″ may be adjusted based on an amount of counterbalancing force stored in the torsion springs 17 or an amount of counterbalancing force to be stored in the torsion springs 17 .
Next, the fastener 49 coupling the flanged worm gear 14 to the support bracket 12 is removed. The fastener 49 is removed from one of the set perforations 48 of the gear portion 38 and the flanged worm gear fastening perforation 29 of the main portion 26 . Preferably, the fastener 49 is disposed through the flanged worm gear fastening perforation 29 and engaged with a thread formed in one of the set perforations 48 ; however, it is understood that other fasteners, such as a nut and a bolt, may be used.
Next, the at least one set screw 21 of each of the first end cones 19 are adjusted to disengage the first end cone 19 from the torsion shaft 18 . When the first end cones 19 are disengaged from the torsion shaft 18 , the amount of counterbalancing force stored in the torsion springs 17 is applied to the anti-rotation device 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ engaged with each of the first end cones 19 . As a result, the bumper portion 132 , 132 ′, 132 ″, 132 ′″, 132 ″″ of each of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ contacts the wall 24 or the overhead door to resist the amount of counterbalancing force stored in the torsion springs 17 .
Next, the amount of counterbalancing force stored in the torsion springs 17 is adjusted using the spring winding device 10 . The amount of counterbalancing force stored in the torsion springs 17 may be increased or decreased by rotating the drive gear 60 . When the driving tool engaged with the drive end 72 of the drive gear 60 is rotated, the drive gear 60 rotates and the at least one thread 68 applies a force to the toothed outer edge 46 of the flanged worm gear 14 , causing the flanged worm gear 14 to rotate within the support bracket 12 . The second end cones 20 , which are coupled to the flanged worm gear 14 , rotate in response to rotation of the drive gear 60 and the amount of counterbalancing force stored in the torsion springs 17 is adjusted simultaneously. As shown in FIGS. 1-3 and 11 , the spring winding device 10 is used to adjust the amount of counterbalancing force stored in two torsion springs 17 . Depending on a direction the drive gear 60 is rotated, the amount of counterbalancing force stored in the torsion springs 17 may be increased or decreased. It is understood that at least one of the flanged worm gear 14 and the support bracket 12 may be fitted with a device (not shown) for counting a number of rotations made by the flanged worm gear 14 during the process used to adjust the amount of counterbalancing force stored in the torsion springs 17 . Such a device facilitates properly adjusting the amount of counterbalancing force stored in the torsion springs 17 .
The anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ are able to move with respect to the torsion shaft 18 as the amount of counterbalancing force stored in each of the torsion springs 17 coupled thereto is adjusted. It is understood that when the amount of counterbalancing force stored in each of the torsion springs 17 is adjusted, a length of each of the torsion springs 17 changes. In response to the length of each of the torsion springs 17 changing, the bumper portion 132 , 132 ′, 132 ″, 132 ′″, 132 ″″ of each of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ rotates about the arm member 110 , 210 , 110 ″, 410 , 110 ″″ against the wall 24 and the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ and the first end cones 19 move along the torsion shaft 18 . The anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ militate against a binding that may occur to the torsion springs 17 if the amount of counterbalancing force stored in each of the torsion springs 17 is adjusted without allowing the length of each of the torsion springs 17 to change.
Once a desired amount of counterbalancing force stored in the torsion springs is obtained, the flanged worm gear 14 is coupled to the support bracket 12 . The fastener 49 is disposed through the flanged worm gear fastening perforation 29 of the main portion 26 and into one of the set perforations 48 of the gear portion 38 and the fastener 49 is tightened to militate against relative movement from occurring between the flanged worm gear 14 and the support bracket 12 .
Next, the at least one set screw 21 of each of the first end cones 19 are adjusted to engage each of the first end cones 19 with the torsion shaft 18 , allowing the amount of counterbalancing force stored in the torsion springs 17 to be applied to the torsion shaft.
Lastly, each of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ coupled to the first end cones 19 is removed. By reversing the above procedure used to couple the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ to the first end cones 19 , the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ are removed from the first end cones 19 , and the process used to adjust the amount of counterbalancing force in one or more torsion springs 17 is completed.
Further, it is understood that the spring winding device 10 and a pair of the keyed end cones 19 ′ may also be used to adjust an amount of counterbalancing force in one or more torsion springs 17 forming a portion of the torsion spring counterbalancing mechanism. In use, the spring winding device 10 and the keyed end cones 19 ′ are used to adjust an amount of counterbalancing force in one or more torsion springs 17 forming a portion of the torsion spring counterbalancing mechanism, without the use of one of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″.
First, the at least one set screw 21 of each of the keyed end cones 19 ′ are adjusted to disengage the keyed end cones 19 ′ from the torsion shaft 18 . When the keyed end cones 19 ′ are disengaged from the torsion shaft 18 , each of the keyed end cones 19 ′ is able to be moved along a length of the torsion shaft 18 while maintaining driving engagement with the torsion shaft 18 .
Next, the amount of counterbalancing force stored in the torsion springs 17 is adjusted using the spring winding device 10 . The amount of counterbalancing force stored in the torsion springs 17 may be increased or decreased by rotating the drive gear 60 . When the driving tool engaged with the drive end 72 of the drive gear 60 is rotated, the drive gear 60 rotates and the at least one thread 68 applies a force to the toothed outer edge 46 of the flanged worm gear 14 , causing the flanged worm gear 14 to rotate within the support bracket 12 . The second end cones 20 , which are coupled to the flanged worm gear 14 , rotate in response to rotation of the drive gear 60 and the amount of counterbalancing force stored in the torsion springs 17 is adjusted simultaneously.
In response to the amount of counterbalancing force stored in the torsion springs 17 being adjusted, each of the keyed end cones 19 ′ move along the torsion shaft 18 as a length of each of the torsion springs 17 coupled thereto is adjusted. The key 23 of each of the keyed end cones 19 ′ move along keyway 22 of the torsion shaft 18 in response to an axial force generated by the amount of counterbalancing force stored in the torsion springs 17 being adjusted. When the amount of counterbalancing force stored in the torsion springs 17 is increased, the length of each of the torsion springs 17 decreases, and each of the keyed end cones 19 ′ move along the torsion shaft 18 towards the spring winding device 10 . When the amount of counterbalancing force stored in the torsion springs 17 is decreased, the length of each of the torsion springs 17 increases, and each of the keyed end cones 19 ′ move along the torsion shaft 18 away from the spring winding device 10 .
Once a desired amount of counterbalancing force stored in the torsion springs is obtained, the flanged worm gear 14 is coupled to the support bracket 12 . The fastener 49 is disposed through the flanged worm gear fastening perforation 29 of the main portion 26 and into one of the set perforations 48 of the gear portion 38 and the fastener 49 is tightened to militate against relative movement from occurring between the flanged worm gear 14 and the support bracket 12 .
Lastly, the at least one set screw 21 of each of the keyed end cones 19 ′ are adjusted to fix each of the keyed end cones 19 ′ with respect to the torsion shaft 18 . When the keyed end cones 19 ′ are fixed to the torsion shaft 18 , each of the keyed end cones 19 ′ is unable to be moved along a length of the torsion shaft 18 .
The keyed end cone 19 ′ having the key 23 formed thereon eliminates a need for one of the anti-rotation devices 100 , 100 ′, 100 ″, 100 ′″, 100 ″″ when an amount of counterbalancing force stored in each of the torsion springs 17 is adjusted.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiments. 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.
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A spring winding device, a counterbalancing force adjustment device for a counterbalancing mechanism, and a method of adjusting an amount of force stored in a spring of a counterbalancing mechanism are provided. The spring winding device includes a support bracket, a worm gear, and a drive gear. The worm gear is rotatably coupled to the support bracket and includes a mount portion for coupling a first end cone thereto. The drive gear is rotatably disposed adjacent the support bracket and is drivingly engaged with the worm gear. A rotation of the drive gear causes the worm gear to rotate within the support bracket. The spring winding device does not require pretensioning using winding rods, maintains rigidity and alignment when a counterbalancing force is applied, and decreases a cost and a complexity of the counterbalancing mechanism.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of co-pending application Ser. No. 09/463,252 filed on Jan. 21, 2000, which, in turn, is a 371 of PCT/US97/12800 which was filed on Jul. 21, 1997.
FIELD OF THE INVENTION
The present invention relates generally to improvements in surgical devices, and more particularly to an improved adjustable retractor, and a retractor with a liner and integral drape therefor for preventing contamination of incised cavity walls of various thicknesses during surgery.
BACKGROUND OF THE INVENTION
The sides of an open incision, as well as matter such as body parts and fluids passing through the incision during surgery, are inherently susceptible to cross-contamination by infectious microorganisms or like matter. Therefore, extreme care is required to insure that any exposed fluids or tissues are completely isolated from each other.
Various designs have been proposed and utilized to prevent transmission of indigenous and exogenous contaminants to healthy viscera from infectious tissues or fluids. U.S. Pat. No. 5,524,644 by Berwyn M. Crook, filed Jun. 9, 1995, describes an incision liner and retractor device which can be installed in an incision, incrementally adjusted in place to form-fit a wide range of cavity wall thicknesses, and retract the sides of the incision apart for better access to the abdominal cavity. It employs a flexible impermeable liner of pliable plastic material with opposite ends terminating at inner and outer resilient O-rings. The inner O-ring is inserted in the cavity by squeezing it through the incision and allowing it to expand around the inner edge of the incision. The outer O-ring is then rolled down over the portion of the liner extending out of the incision until it is tight against the outer rim of the incision and the remaining portion is drawn taut and contiguous with the incision sides. The outer O-ring is generally oblong in cross-section to provide a positive gripping surface for the fingers to roll the outer O-ring more easily, especially when the liner or the surgeon's gloves are slippery.
In many instances, a surgical drape may be first placed over the patient's body before the incision liner and retractor device is installed. This combination further reduces the risk of cross-contamination between the open cavity and the skin around the incision, especially if an organ is brought outside the abdominal cavity to perform surgery on it. However, since the liner and drape are not integrally connected, there is no assurance that the drape may not slide from beneath the outer O-ring and leave the patient's skin exposed in a most vulnerable region immediately adjacent to the incision.
Some prior art surgical protectors address this problem to a limited degree. For instance, U.S. Pat. No. 3,397,692 to Creager, Jr. et al. discloses an incised surgical device in which a resilient ring cemented around the rim of a central aperture in a drape is squeezed together and expanded in the cavity to grip the incised edge of the peritoneum. The drape is bunched together where it passes through the incision and then spreads out over the body surface in radially diminishing wrinkles. U.S. Pat. No. 4,188,945 to Wenander similarly provides a surgical cloth with a semi-rigid thread hemmed in around a central aperture. A portion of the cloth around the aperture is gathered together and inserted in an incision, and then enlarged under the incision edge by increasing the length of thread around the aperture. Like the surgical device of Creager, Jr. et al., a wrinkled surface is created in the incision and around the operating site. Consequently, neither device provides a relatively smooth surface in the incision and around the wound where extracted viscera may be placed nor positive retraction of the sides of the incision. In addition, there is no means for preventing external portions of the drape from slipping in and out of the incision with movement of the surgeon's hand.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved surgical retractor liner and integral drape which prevent exposure to cross-contamination by infectious fluids and solids between an incised cavity and the skin around the incision.
Another object of the invention is to provide a surgical retractor liner and integral drape assembly which interfaces smoothly and contiguously with the sides of an incision and with the skin around the incision.
Still another object of the invention is to provide a retractor liner with integral drape which can be easily installed and adjusted in place to fit a wide range of cavity wall thicknesses.
A further object is to provide a retractor liner which will positively insulate an incision from exposure to indigenous and exogenous contaminants and positively retract the sides of the incision for a wider opening to the cavity.
A further object of the present invention to provide a relatively low cost surgical retractor liner of simplified design which can be easily installed in a wound and adjusted in place to form fit a wide range of cavity wall thicknesses for protection against harmful contaminants.
SUMMARY OF THE INVENTION
These and other objects and aspects of the invention are accomplished in one embodiment by a surgical retractor liner and integral drape which can be inserted in an incision and incrementally adjusted tightly in place in the cavity wall and on the surrounding skin to prevent cross-contamination with body fluids and solids during surgery. It includes a flexible plastic film retractor liner impervious to microorganisms with opposite ends terminating at inner and outer resilient O-rings. The inner O-ring is installed in the incision by squeezing opposite sides together, inserting it through the incision and allowing it to expand around the inner edge of the incision. The length of the retractor liner is selected to allow a portion to extend out of the incision for rolling down until it is tight against the outer edge of the incision and retracts the sides of the incision for widening the opening. A flexible plastic film skirt fixed at one end around the outer O-ring, and coaxial with the retractor liner, tapers outwardly toward the inner O-ring with the other end sealingly joining the rim of a centrally located aperture in a flexible drape. The extended length of the skirt is at least as long as the portion of the retractor liner fully extending out of the incision when the inner O-ring is expanded against the inner edge. This assures that the drape completely adheres to the surface around the incision and remains fixed in place by the retractor liner and by adhesive patches fixed to the drape. The size of the drape is sufficient to cover the area around the operating site and to prevent it from exposure to any contaminating fluids and tissue.
In another embodiment, the retractor liner comprises a flexible liner of thin substantially elastic material, separate from the drape, secured at opposite open ends around resilient inner and outer O-rings.
In both embodiments, the outer O-ring in cross-section is generally circular with opposed flat sides in planes generally transverse to the extended length of the liner for restoring the outer O-ring to its preformed configuration when turned about the circumferential axis of rotation of the ring. The flat sides also provide gripping surfaces for manually turning the outer O-ring with greater ease, especially when the liner or the surgeon's gloves are slippery. The retractor liner may be constructed in a single liner length with different circumferences for accommodating a wide range of incision sizes and cavity wall thicknesses.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and advantages of the invention will become more apparent from the following description of the preferred embodiments when taken in conjunction with the accompanying drawings wherein:
FIG. 1 represents a perspective top view of one embodiment of a surgical retractor liner and integral drape device according to the invention;
FIG. 2 is a side view partially in cross-section of a portion of the embodiment of FIG. 1;
FIG. 3 is an enlargement in cross section of an upper portion of the embodiment shown in FIGS. 1 and 2;
FIG. 4 is a view in radial cross section of an alternate embodiment of an O-ring for use in the upper portion of the assembly shown in FIG. 3; and
FIGS. 5A and 5B are schematic illustrations of the device in two stages of installation in an incision;
FIG. 6 is an isometric view of another embodiment of a retractor liner according to the invention, in a fully extended state and with portions cut away;
FIG. 7 is a view in longitudinal cross-section of an outer end of the retractor liner of FIG. 6;
FIGS. 8A and 8B is a schematic representation in longitudinal cross-section of the retractor liner of FIG. 6 partially installed in a surgical wound; and
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference characters designate like or corresponding parts throughout the several views, there is shown in FIG. 1 a surgical retractor liner and integral drape device 10 comprising an incision retractor liner 12 of uniform circumference along its length coaxially extending through a skirt 14 and a central aperture 16 a in a drape 16 .
As best seen in FIG. 2, retractor liner 12 and skirt 14 have adjacent upper ends which wrap around an outer O-ring 18 and overlap at annular edges 12 a and 14 a (FIG. 3) and seal to each other and to the outer side skirt 14 . A lower end portion of retractor liner 12 wraps around an inner O-ring 20 and overlaps at an annular edge 12 b and seals to the outer side of retractor liner 12 ; whereas a lower end of skirt 14 is sealed around the perimeter of aperture 16 a . Retractor liner 12 is essentially uniform in circumference along a central longitudinal axis defined by the extended length of the liner. Skirt 14 is coaxial with retractor liner 12 and tapers outwardly to aperture 16 a.
Outer O-ring 8 is generally oblate in cross-section with opposed upper and lower flat chordal sides 18 a and lab substantially normal to the extended length of retractor liner 12 . Sides 18 a and 18 b are located equidistant from, and on opposite sides of, the centroid of the radial cross-section through O-ring 18 . The oblate shape provides an over-center snap action when O-ring 18 is rolled about itself onto retractor liner 12 and skirt 14 for incrementally shortening the upper ends and for resisting unrolling after being shortened.
Inner O-ring 20 is entirely circular in cross-section, but may have a similar cross-section as O-ring 18 for incrementally shortening the lower end of retractor liner 12 .
FIG. 4 illustrates in radial cross-section an alternate embodiment of an outer O-ring 18 . The upper and lower sides 18 a and 18 b taper outwardly from opposite sides of a plane normal to the extended length of liner 12 thereby allowing O-ring 18 to be turned with less resistance around its annular axis due to the lesser mass near the inner circumference O-ring 18 . This structure is particularly desirable for large diameter rings having relatively large diameter cross-sections.
The materials for making assembly 10 are selected to insure stability when installed. One preferred material for retractor liner 12 , skirt 14 and drape 16 is a substantially inelastic heat-sealable 3-mil polyolefin plastic film, such as Saranex™ film 2050 by The Dow Chemical Company. Another preferred material for liner 12 and skirt 14 is a substantially elastic heat-sealable 2-mil polyurethane film, such as Dureflex® PT6100S by Deerfield Urethane, Inc.
The polyurethane material has been found to provide certain advantages not available with the Saranex™ polyolefin material. For instance, the elastic polyurethane material takes up any lengthwise adjustment which cannot be fully accommodated by the incremental adjustments made by rolling the O-ring 18 ′. In addition, the elastic polyurethane provides a better retraction function along the edges of the incised wound. This is believed due, at least in part, to the better wound edge margin gripping action resulting from the axial take-up of the elastic polyurethane.
The difference between the non-elastic polyolefin material and the elastic polyurethane may be seen from a test wherein five 1″×3″ specimens of each of these materials were stretch tested at room temperature (+75° F.) and permanent deformation (deflection) calculated from its load vs. displacement curve. The average deflection of the polyolefin film was approximately 0.354 inch/inch, while the polyurethane specimen deflection averaged approximately 0.167 inch/inch.
O-rings 18 and 20 are preferably preformed of an elastomeric medical-grade polyurethane of sufficient hardness to retain the rings expanded in place around the inner and outer rims of the incision. The O-ring material must be compliant enough to allow the fingers to turn the outer O-ring 18 over 180° around its annular axis from the preformed configuration. They may be color-coded with different colors, such as white and blue, for easier recognition of the correct O-ring to be inserted in an incision.
Drape 16 may be adhered directly to the skin of the patient or to an underlying drape by an adhesive spread over the underside of the drape, or by adhesive patches 22 at selected locations on the underside of the drape. The size of drape 16 is selected to provide effective protection from exposure to infectious fluids and tissue in the vicinity of the incision.
The length of a fully extended retractor liner 12 is typically around 150 mm to accommodate most wall thicknesses at the incision. An assortment of liner and O-ring diameters are provided to accommodate different lengths of incisions, and the personal preference of the surgeon. U.S. Pat. No. 5,524,644, supra, discloses a table of liner and O-ring diameters available for different incision lengths, and its disclosure is incorporated by reference herein. The urethane O-rings are typically in the range of 50-90 Shore A durometers.
The diameter of an upper length of skirt 14 , in a relaxed state before stretching around O-ring 18 and sealing it at edge 14 a , corresponds substantially to the diameter of retractor liner 12 . The remaining lower portion tapers outwardly to the diameter of aperture 16 a which is slightly larger than the diameter of retractor liner 12 to allow clearance for retractor liner 12 to be stretched into contact with the outer rim of the incision. The length of skirt 14 must not be shorter than retractor liner 12 by an amount greater than the thickness of the wall at the incision. If the difference were greater, the drape will not adhere completely to the skin immediately adjacent to the incision. Of course, if the difference is less than the wall thickness, the lower end of skirt 14 will merely bunch up around the uninserted portion of retractor liner 12 and roll onto O-ring 18 but still provide a satisfactory seal. Typically, the thickness of abdominal walls ranges between 25 mm and 75 mm. Therefore, for an overall liner length of 150 mm, an effective skirt length should not be shorter by more than 25 mm, namely an overall length of 135 mm.
A typical installation of the retractor liner and integral drape assembly 10 is illustrated in two stages in FIGS. 5A and 5B. In FIG. 5 a , retractor liner 12 is inserted into an incision in the abdominal wall A with the inner O-ring 20 expanded against the inner rim of the incision and drape 16 adhered to the skin, or to an underlying drape not shown. In this installation skirt 14 is shorter than retractor liner 12 by a difference slightly less than the thickness of the abdomen wall, thereby causing skirt 14 to bunch up around fully extended retractor liner 12 . In FIG. 5B, the upper end of the assembly containing O-ring 18 is rolled down over the outside of skirt 14 , abuts the top of drape 16 with skirt 14 drawn taut against the incision, and retracts the sides of the incision to widen the opening. Drape 16 is thusly positively anchored against slipping out from under the rolled down portions of liner 12 and skirt 14 .
Referring now to FIG. 6, an adjustable retractor device 110 includes a thin relatively elastic liner 112 , uniform circumference along its length and impervious to solids and fluids containing bacteria and other harmful contaminants.
As best seen in FIG. 7, the upper end portion 112 a of the liner 112 wraps around outer O-ring 118 and terminates in an annular edge portion 112 c sealed around the outer side of liner 112 . At least one O-ring, such as the O-ring 118 , is generally oblate in cross-section having opposed flat chordal side surfaces 118 a and 118 b which are transverse, i.e. substantially normal, to the liner central longitudinal axis defined by the extended length of liner 112 , as shown in FIGS. 6-8 b . As shown, the chordal surfaces 118 a and 118 b are located equidistant from, and on opposite sides of, the centroid of the cross-section. The surfaces 118 a and 118 b provide surface means for purposes to be described.
Inner O-ring 120 is secured to lower end portion 112 b in the same manner as O-ring 118 , except the configuration in cross section is entirely circular. If desired, both O-rings may have the same cross-sectional shape as O-ring 118 to provide reversibility to the retractor liner device 110 .
The oblate shape of the O-ring 118 provides stability in a plane perpendicular to the longitudinal axis of the liner 112 and provides an over center snap action when rolled about itself and the liner, thereby providing incremental shortening in predetermined increments and resistance to lengthening after shortening.
The materials and dimensions of adjustable surgical device 10 are selected to ensure stability when installed. A preferred elastic material suitable for liner 112 is a 2-mil polyurethane film, such as Dureflex® PT61005 supra. It is produced in seamless tubular form or by a flat sheet in a cylindrical form with the meeting margins along the side overlapped and sealed. A nominal liner length suitable for minimally invasive surgery is typically around 150 mm. Liner diameters will vary according to wound length as will be discussed.
Outer and inner O-rings 118 and 120 are preferably preformed of an elastomeric medical grade material of sufficient hardness to retain O-rings 118 and 120 expanded in place around the inner and outer edges of the wound. Like O-ring 18 , the material must be compliant enough to allow O-ring 118 to be turned by the fingers over 180 degrees around its annular axis from the preformed configuration. Urethane is therefore the preferred elastomeric material. When the O-rings are of different configurations, the O-rings are preferably color-coded with different colors, such as white and blue, for aiding in recognizing the correct end of the protector to be inserted in the wound.
The inside circumferences of O-rings 118 and 120 generally correspond to the outside circumference of liner 112 . By way of example, a urethane O-ring 118 for use with a liner 110 mm (4.33 inches) in diameter has a diameter across the transverse cross section of about 7.94 mm ({fraction (5/16)} inch) with a distance between parallel flat sides 118 a and 118 b of approximately 6.10 mm (0.240 inch). O-ring 120 has a diameter of its circular cross-section of about 7.94 mm ({fraction (5/16)} inch). Of course, the sizes of the O-rings and liners will vary according to wound size and wound wall thickness, and the personal preference of the surgeon will affect the choice of size for a particular surgical procedure.
The following table sets forth a preferred relation between incision length and liner and O-ring and liner diameters. It also sets forth the preferred cross-sectional diameters for each O-ring, it being understood that O-ring 18 has opposed flats and is, therefore, oblate and not circular in cross-section.
O-Ring
Incision
Liner Diameter
Cross Sectional
Length (mm)
(mm)
Diameter (mm)
10
30
5.15
20
30
5.15
30
60
7.13
40
60
7.13
50
80
7.52
60
80
7.52
70
110
7.92
80
110
7.92
90
110
7.94
100
130
9.53
110
130
9.53
120
150
11.11
130
150
11.11
140
170
12.70
150
170
12.70
160
190
14.29
170
190
14.29
180
210
15.88
190
210
15.88
200
230
15.88
The durometers of the O-rings set forth in the above table should be in a range of 50 to 90 Shore A. The preferred material is urethane, but silicone could be used with some loss of stability after installation and adjustment. The best stability is achieved by using a material having a high modulus of elasticity with a ring, as manufactured; having a minimum of residual stresses and strains. The size of the flats affects both gripability for adjustment and stability after adjustment, since the larger the size of flats for a given O-ring cross-sectional diameter, the less stability that exists. By way of example, a preferred flat width for an O-ring having a cross-sectional diameter of 7.94 mm ({fraction (5/16)} inch) is 6.10 mm (0.240 inches). It is expected that with increasing diameters each flat width should increase proportionately based on a formula: W=xD where W is the width of the flat; D is the diametrical cross-section of the O-ring; and x is a constant equal to 0.85 for a urethane ring having a hardness within the ranges stated.
In using the adjustable surgical device in a minimally invasive abdominal surgical procedure, the abdomen is routinely prepared with antiseptics and dried; the site for the incision is traced on the abdomen and covered with a surgical drape; and a muscle-split is made at the site through the peritoneum. As illustrated in FIGS. 8A and 8B, retractor and liner 110 is placed in wound W 1 by squeezing inner O-ring 120 into a tight oblong shape and inserting it lengthwise through the incision and letting it expand inside the peritoneum around the inner edge of the wound. Outer end portion 112 a is gripped by the thumb and fingers at flat sides 118 a and 118 b of outer ring 18 (FIG. 7) and turned outwardly, in opposite directions shown by arrows A, rolling liner 112 on the O-ring until it abuts the outer edge of the wound W 1 as shown in FIG. 8 B. However, as a result of the elasticity of the liner material, any lengthwise adjustment not accommodated by the incremental. adjustments causes the part of liner 112 in the wound between O-rings 118 and 120 to be thereby drawn into contiguous contact with the edge margins of wound W 1 and hence with the wound walls to provide a self-retaining protective barrier during surgery which is impervious to contaminating solids and fluids. If desired, the protector 10 can also be pre-adjusted prior to insertion, or partially pre-adjusted.
Some of the many advantages and novel features of the invention should now be readilapparent. For example, the invention provides an improved liner and drape device which prevents exposure between an incised cavity and the skin around the incision to cross-contamination by infectious fluids and tissue. The assembly is positively anchored in place around the operating site by the installed liner, smoothly interfaces against the sides of the incision and the surrounding skin, and retracts the sides of the incision for a wider opening. It can be easily installed in an incision and adjusted in place to fit a wide range of cavity wall thicknesses as well as provide positive insulation of an incision and surrounding skin from indigenous and exogenous contaminants.
A relatively simple and inexpensive surgical retractor liner is provided for protecting wounds from exposure to contamination. It can be quickly and easily installed in a wound and adjusted in place to form-fit a wide range of cavity wall thicknesses, and it stays in place after insertion. A fewer number of combinations of sizes of protectors are needed to accommodate a variety of incision sizes and cavity wall thicknesses.
Of course, it will be understood that various changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.
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A surgical retractor liner and integral drape suitable for inserting in an incision and adjusting in place to prevent cross-contamination during surgery between the incised cavity and the surrounding skin of the patient. In one embodiment, a flexible elastic liner impervious to microorganisms has resilient inner and outer rings at opposite ends for holding the liner firmly in the incision. The outer ring is rolled down over itself drawing the liner taut and contiguous in the incision. In another embodiment, a skirt is sealingly joined at the outer ring and tapers outwardly and sealingly joins to a drape around a central aperture therein. The inner ring is inserted and expanded against the inner edge of the incision, and the outer ring is rolled down over the liner and skirt to draw the liner taut in the incision and to retract the sides of the incision while positively anchoring the drape in place around the area of the incision. In another embodiment, a lengthwise incrementally and automatically adjustable wound protector and retractor is provided.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] In one of its aspects, the present invention relates to a foam article. In another of its aspects, the present invention relates to a vehicular seat element. In yet another of its aspects, the present invention relates to a trim cover material particularly adapted for application to a foam element.
[0003] 2. Description of the Prior Art
[0004] Foam articles are well known in the art.
[0005] Further, it is known to construct form articles from a foam element to which is applied a cover material that sometimes is termed as a “trim cover” in the art. The use of a trim cover applied to a foam element has gained widespread acceptance in the automotive industry. The trim cover can have a finished surface made of vinyl, cloth, leather and the like. The foam element is typically made from an isocyanate-based foam such as polyurethane. Of course, it is possible to construct the foam element from a cellular matrix material such as horse hair and the like.
[0006] In vehicular applications, it is common to employ foam articles in the seat of the vehicle. Typically a vehicular seat comprises two general elements. These are the seat bottom and the seat back. It is common for these elements to include a frame member coupled to the foam element and covered, at least partially, by the trim cover.
[0007] In recent years, the automotive industry has strived to improve the so-called “fit and finish” of all interior vehicular components, particularly the vehicle seats. In practice, this means striving to produce vehicular seats having narrower width channels or trenches and improving the overall appearance of the seat by creating a tighter fit between the trim cover and the foam element. A useful analogy is to consider striving to produce a vehicle seat where a trim cover fits the foam element “like a glove”.
[0008] As will be described below, the desire of the automotive industry to produce such improved foam articles has lead to a variety of problems during manufacture of the articles. Particularly, a significant amount of additional material and/or labour is required to produce such articles. In some cases, even with additional labour and/or material, it is still difficult to attain the goals set by the automotive industry.
[0009] Accordingly, it would be desirable to have a foam article which has an improved “fit and finish” appearance and can be made without significantly increasing the amount of labor and/or material costs required to produce the article.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to obviate or mitigate at least one of the above-mentioned disadvantages of the prior art.
[0011] It is another object of the present invention to provide a novel foam article.
[0012] It is yet another object of the present invention to provide a novel vehicular seat element.
[0013] It is yet another object of the present invention to provide a novel trim cover useful for the production of a foam article such as a vehicular seat element.
[0014] Accordingly, in one of its aspects, the present invention provides foam article comprising:
[0015] a foam element;
[0016] a trim cover comprising a finished outer layer; and
[0017] a slip layer interposed between the foam element and the trim cover, the slip layer comprising a material having a kinetic coefficient of friction with respect to the foam element of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM9206P.
[0018] In another of its aspects, the present invention provides a vehicular seat element comprising:
[0019] a foam element;
[0020] a trim-cover comprising a finished outer layer; and
[0021] a slip layer interposed between the foam element and the trim cover, the slip layer comprising a material having a kinetic coefficient of friction with respect to the foam element of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM9206P.
[0022] In yet another of its aspects, the present invention provides a trim cover comprising a finished outer layer and an inner layer, the inner layer comprising a material having a kinetic coefficient of friction with respect to the a foam element of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM9206P.
[0023] Thus, the present inventor has discovered that it is possible to produce a foam article having improved “fit and finish” without the need to significantly increase the cost of labour and/or materials. More specifically, it has been discovered that the use of a trim cover with an inner layer comprising a material with a prescribed kinetic coefficient of friction with respect to the foam element allows for the use of tighter fitting trim covers resulting in the production of a foam article with improved “fit and finish”. The inner layer of the trim cover comprises a material having a kinetic coefficient of friction with respect to the foam element of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM9206P (the text of GM9206P is reproduced in the present application in the Appendix). The present foam article is particularly useful in vehicular applications such as in a vehicular seat element (e.g., one or both of a seat bottom and a seat back). Alternatively, the present foam article can be used in non-vehicular applications or in vehicular applications other than seat elements. The present foam article is particularly useful in applications where a foam element is completely or almost completely covered by a trim cover and the intent is to have a foam article with improved “fit and finish” or craftsmanship—e.g., an article having a tight fitting trim cover applied thereto.
[0024] The slip layer may be secure to the foam element or to the trim cover. Alternatively, the slip layer may be non-secure with respect to either of the foam element or trim cover. Preferably, the slip layer is secured to the trim cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Embodiments of the present invention will be described with reference to the accompanying drawings, wherein like reference numerals denote like parts, and in which:
[0026] FIGS. 1 - 4 illustrate production of a foamed article using a conventional approach; and
[0027] FIGS. 5 - 8 illustrate production of a preferred embodiment of the present foamed article.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Prior to describing the preferred embodiments of the present invention, a description of a prior art approach for producing a covered foam article is provided to facilitate understanding the problems associated with the prior art.
[0029] Thus, with reference to FIGS. 1 - 4 , a conventional process for application of a trim cover to a foam element is set out.
[0030] Initially, a foam element 10 is provided. Foam element 10 may be produced in a mold or other conventional device. Typically, foam element 10 is made from an isocyanate-based foam such as a polyurethane foam. In the illustrated embodiment, foam element 10 is in the shape of a seat back typically used in the vehicular application.
[0031] As shown, foam element 10 has molded therein a U-shaped trench 15 .
[0032] In an initial step in the process, a spray dispensing device 20 (or other equivalent device) is used to dispense an adhesive 25 primarily in trench 15 of foam element 10 .
[0033] Next, a metal frame element 30 is moved in the direction of arrow A and placed in trench 15 of foam element 10 .
[0034] With reference to FIG. 2, once frame element 30 is position in trench 15 of foam element 10 , frame element 30 contacts adhesive 25 and is secured to foam element 10 .
[0035] With reference for FIG. 3, a trim cover 35 is disposed above the combination of frame element 30 and foam element 10 . It is known in the art to incorporate an inner layer (not shown) or slip sheet in trim cover 35 . This inner layer or slip sheet may comprise one or more of the following: foam, angel hair, polymer layers and the like. The inner layers or slip sheets used to date have a relatively high kinetic coefficient of friction with respect to foam element 10 . As shown, trim cover 35 is initially inverted so that the inner surface thereof is exposed. Next, trim cover 35 is lowered onto foam element 10 (having frame element 30 secured thereto) in the direction of arrow B. Once an upper surface 40 of trim cover 35 contacts foam element 10 trim cover 35 is “rolled” or otherwise moved such that an opening 50 of trim cover 35 is in alignment with a bottom portion 55 of foam element 10 . It should be noted that there are devices in the art which can perform the step illustrated in FIG. 3. Since these devices are conventional, they will not be discussed further herein.
[0036] It is worthwhile to note that the use of adhesive 25 to secure frame element 30 to foam element 10 is done primarily for the purpose of securing frame element 30 in place during the covering step illustrated in FIG. 3. In other words, the use of adhesive 25 is not required to secure frame element 30 to foam element 10 after production and installation of the vehicle seat.
[0037] With reference to FIG. 4, the covered foam article produced from FIG. 3 is shown. As illustrated, a portion C of foam element 10 protrudes from trim cover 35 . The reason for this is as follows. When it is desired to produce a covered foam article having improved “fit and finish” qualities, trim cover 35 becomes a much tighter fit with respect to foam element 10 . The result of using a conventional device to apply trim cover 35 to foam element 10 , as shown in FIG. 3, is protrusion of portions C from trim cover 35 (e.g., due to upper surface 40 of trim cover 35 not contacting an upper surface 45 of foam element 10 prior to “unrolling” of trim cover 35 ). Thus, it becomes necessary to employ one or more individuals to manually pull or finesse trim cover 35 in the direction of arrow D to finish the covering step and the production of the covered foam article.
[0038] Thus, it will be seen from the above description that the prior art technique of producing a covered foam article necessitates the use of extra materials (adhesive 25 to secure frame element 30 to foam element 10 during the cover step) and labour (one or more individuals to pull trim cover 35 in the direction of arrow D to cover protrusion of portion C of foam element 10 ).
[0039] With reference to FIGS. 5 - 8 , a particularly preferred embodiment of the present foam article will be described. Thus, with reference to FIG. 5, there is illustrated a preferred embodiment of a trim cover 35 a useful to produce the present foam article. Thus, trim cover 35 a comprises an outer layer 60 , an intermediate layer 45 and an inner layer 70 .
[0040] Outer layer 60 of trim cover 35 a is conventional and can be made of any desirable material such as cloth, vinyl, leather and the like. Intermediate layer 65 is optional. If present, intermediate layer 65 preferably comprises a foam, more preferably an isocyanate-based foam, most preferably a polyurethane foam.
[0041] Intermediate layer 65 may be secured to outer layer 60 in a conventional manner. For example, it is possible to secure intermediate layer 65 to outer layer 60 using an adhesive or similar material. Alternatively, it is possible to flame laminate, hot roll laminate, adhesive laminate or otherwise secure intermediate layer 65 to outer layer 60 . Inner layer 70 is provided and may be secured to intermediate layer 65 or the combination of outer layer 60 and intermediate layer 65 using any of the means discussed above. Alternatively, inner layer 70 may be sewn (or otherwise mechanically fastened) to the combination of outer layer 60 and intermediate layer 65 .
[0042] Inner layer 70 is comprised of a material having a kinetic coefficient of friction with respect to foam element 10 of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM 9206P (see the Appendix hereto). Preferably, inner layer 70 comprises a material having a kinetic coefficient of friction with respect to foam element 10 of less than about 0.73, more preferably in the range of from about 0.50 to about 0.73, more preferably in the range of from about 0.55 to about 0.73, more preferably in the range of from about 0.60 to about 0.70, more preferably in the range of from about 0.50 to about 0.65, when measure pursuant to ASTM D1894-00 using the conditions set out in GM 9206P.
[0043] Preferably, inner layer 70 comprises a polymer material, more preferably a polyester, a polypropylene or a mixture of a polyester and a polypropylene. It is possible to incorporate in the polymer material an additive or slip agent which serves to confer to inner layer 70 sufficient smoothness to provide a kinetic coefficient of friction with respect to foam element 10 of less than about 0.75 as set out above.
[0044] Preferably, inner layer 70 is constructed to be in the form of a non-woven scrim.
[0045] A suitable such material is available from Alhstrom Corporation as Grade 27500 Scrim.
[0046] With reference to FIG. 6, frame element 30 is placed in trench 15 of foam element 10 —the use of an adhesive to secure frame element 30 in place is not required. Trim cover 35 a is inverted in a manner similar to that illustrated in FIG. 3 and lowered over foam element 10 in the direction of arrow B. Thereafter, trim cover 35 a is applied to cover foam element 10 in the same manner as described above. Due to the selection of inner layer 70 to have the prescribed coefficient of friction with respect to the foam element set out above, it is possible to “unroll” trim cover 35 a over foam element 10 without misaligning frame element 30 and without resulting in having a portion of foam element 10 protrude from the opening of trim cover 35 a.
[0047] Thereafter, a pair of bottom flaps 37 in trim cover 35 a may be folded and sealed to complete production of the covered foam element.
[0048] Thus, the use of trim cover 35 a allows for facilitating the production of a covered foam element having improved “fit and finish” or craftsmanship without the requirement of using additional materials such as adhesives and/or additional labour as described above with reference to FIGS. 1 - 4 . Such improved craftsmanship may be manifested in one or more of: production of foam articles with reduced occurrence of visible wrinkling of the trim cover; the ability of use tighter fitting trim covers; the production of parts having the appearance of relatively straight seams; the production of parts where the seams are aligned in the finished product; and/or facilitation of finessing the product (if required) during post-covering operations. Other advantages will be apparent to those of skill in the art having the present specification in hand.
[0049] While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.
[0050] All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.
APPENDIX
COEFFICIENTS OF FRICTION OF SOFT TRIM MATERIAL
GM9206P
[0051] 1. SCOPE This procedure is used to determine the coefficients of friction of materials using ASTM D1894, Method A or B.
[0052] NOTE: If a strain gage is used to determine the friction, slightly higher results will be obtained because of the pulleys.
[0053] 2. Equipment Required
[0054] 2.1 Surface Friction Tester. Custom Scientific Instrument Model #CS-152S, 13 Wing Drive, Cedar Knolls, N.J. 07927.
[0055] 2.1.1 Weight of sled, 300 g (foam coated)
[0056] 2.1.2 Speed of moving plane, 300 mm/minute
[0057] 2.2 Humidity cabinet
[0058] 2.3 Clean, white, cheesecloth
[0059] 2.4 Chlorothane, 9981224
[0060] 2.5 Pressure sensitive tape, double backed
[0061] 2.6 Polyethylene bag
[0062] 2.7 Teflon cloth (NOTE: Teflon cloth was replaced with a sample of foam (i.e., equivalent to the foam element discussed above) having the following dimensions: 3×12×½)
[0063] 3. Test Procedure
[0064] 3.1 Before testing, condition all samples to be tested in the humidity cabinet at 21 C. and 50% RH for a period of 4 h. After conditioning, samples may be stored in the polyethylene bag for a maximum for a period of 1 h.
[0065] 3.1.1 On the moving plane of the testing machine, place the sheet of teflon using the pressure sensitive tape.
[0066] 3.1.2 Clean the surface of the teflon with the chlorothane and cheesecloth. Wipe the cleaned surface with a dry piece of cloth to make sure that no residue remains.
[0067] NOTE: This should be done 4 h prior to any testing, preferably at the end of each days usage to provide ample time to dry.
[0068] 3.1.3 On the underside of the sled, on top of the foam, place a 64×64 mm piece of pressure sensitive tape.
[0069] 3.1.4 Place a precut 64×100 mm sample, uncoated side, against the tape on the underside of the sled allowing the flap to be wrapped around the front edge of the sled and attached to the metal with a piece of tape.
[0070] 3.1.5 Place the sled with the sample attached on the teflon cloth, coated side down, and start the machine.
[0071] 3.1.6 Three tests will be conducted on the same piece of coated material and the average of the three tests will be the amount of friction found in grams
[0072] NOTE: Static readings will not be used and should be disregarded when averaging the results.
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A foam article comprising: a foam element; and a trim cover comprising a finished outer layer and an inner layer in contact with the foam element, the inner layer comprising a material having a kinetic coefficient of friction with respect to the foam element of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM9206P. The foam article is advantageously suited for use in a vehicular application such as a car seat (seat bottom, seat back and the like). The invention allows for the production of improved quality products while mitigating and obviating the need for additional material and/or labour costs.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. Ser. No. 10/559,024, filed Apr. 13, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a garment or garments incorporating a functional electrical or electronic circuit. Preferably, the invention relates to the incorporation into a garment of a breathable, porous, flexible fabric circuit for use as a heater. The garment may include a thermally activated chemical delivery system. The circuit may be used as an electrical interconnect (electro-conductive) system with or without electronic devices, e.g. as a keypad or keyboard.
[0004] 2. Related Art
[0005] A primary function of garments designed for outdoor sports and leisure activities such as mountaineering, hiking, potholing, motorcycling, etc., is thermal protection, particularly from cold weather conditions. Similarly, such thermal protection is important in many work-wear applications (e.g. seamen, workmen, delivery personnel, refrigeration plant operators, airport workers, etc.) where, potentially, staff may be exposed to cold conditions for prolonged periods. Conventionally, protection from the cold has been achieved by incorporating within garments low-convection fabric structures capable of entrapping still air to provide thermal insulation (e.g. waddings or battings). The thermal insulation achieved by such structures is principally a function of fabric thickness: the insulation increases with fabric thickness. Therefore, existing garments with high thermal insulation can be thick and bulky and may have limited conformability. This can restrict the mobility and comfort of the wearer in use, which is disadvantageous.
[0006] The designs of various active heating systems capable of evolving heat in response to an energy input are known. These systems involve incorporating materials into fibres or films, coatings and laminated structures and specify the use of (for example); phase change materials, metals and exothermic materials. The incorporation of electrical heating systems within garments has also been described in the prior art and include continuous metallised fabric (GB-A-2092868), woven carbonised filament (U.S. Pat. No. 6,172,344 and GB-A-2336514) and insulated conductive yarn (U.S. Pat. No. 6,501,055) heating elements.
SUMMARY OF THE INVENTION
[0007] The present inventor has realised that there is a need for a breathable flexible heater which is capable of being incorporated into a garment. Typically, such incorporation should not compromise the flexibility or conformability of the garment. Ideally, such a heater could be capable of forming part of the garment assembly rather than being “bolted-on”, which is a cumbersome approach. Preferably, the heater system should also allow the garment to maintain its vapour management characteristics (e.g. breathability) and not interfere with other performance characteristics that govern the functionality of the garment in use (e.g. air permeability, wind and waterproofing). Preferably, the heating of the garment can be applied locally only to those areas of the garment that require heating. Preferably also, regulation of the heater element temperature is enabled.
[0008] Accordingly, in a first aspect, the present invention provides a flexible heater system for incorporation into a garment. Typically, the heater can be incorporated as a lining into the garment without complicating the design of the garment and without significantly interfering with other aspects of the garment's functionality.
[0009] Preferably, the heater system includes a porous metallised fabric heater element. The advantage of this is that the microclimate of the garment to which the heater system is to be applied will be substantially unaffected by the presence of the heater system when the heater system is not in operation. Of particular importance to the microclimate of a garment is the breathability of the garment, i.e. the ability for water vapour to pass from the wearer of the garment, through the garment to the outside surface of the garment.
[0010] Typically, the heater element is formed by photochemical etching of porous metallised fabric.
[0011] Details of the construction, manufacture and heating performance of a suitable flexible, porous etched metallised fabric heater are described in WO03/053101, the content of which is incorporated by reference in its entirety. WO03/053101 claims priority from UK Patent Application No. 0228999.9, filed 14 Dec. 2001.
[0012] Preferably, the porous etched metallised fabric heater element with an appropriate track pattern is encapsulated in or laminated between layers of a suitable continuous polymer to produce a waterproof, flexible heater element. The thickness of the heater element is preferably less than 1 mm. The heater element may be connected to a portable battery so as to be powered to deliver significant thermal energy to the wearer.
[0013] In a preferred embodiment, the heater element is formed into a laminate by applying a breathable face fabric to the heater element.
[0014] The width, length and shape of the etched track pattern can be selected from a wide range in order to optimise the heater element performance or to provide differential heating.
[0015] In use, the heater element may be controlled to regulate the rate of heating and/or the maximum heat output. Suitable temperature regulation can be achieved either manually by the wearer or via a suitable control device. Suitable control devices may incorporate a surface mounted thermistor. Alternatively, temperature regulation can be achieved by limiting the resistance of the heater itself.
[0016] Ensuring that the heater element is thin and flexible allows minimisation of stiffening or reduction in conformability of the garment. Garments containing the heater element may be deformed, bent and packed for storage. Garments containing the heater element may also be washed (e.g. machine washed or hand washed) without removing the heater element from the garment. Such heater elements are able to retain their electrical heating function after such treatments.
[0017] It is intended that the heater element can be incorporated into existing garments, e.g. by the garment manufacturer, without the need for major modifications to the construction and/or design of such existing garments.
[0018] Preferably, the heater element is incorporated into a laminated structure. The laminated structure may include, in addition to the heater element, an outer face fabric (e.g. a woven fabric of man-made fibres). The laminated structure may further include an inner lining fabric. The inner lining fabric may be a woven, knitted, nonwoven or mesh fabric.
[0019] Typically, lamination of the fabrics into the laminated structure is carried out using known processes. Preferably, thermoplastic adhesives in the form of meltblown webs, grids, mesh structures and/or films are used. Particle binders can also be applied by spraying or coating onto one or more of the surfaces to be laminated. The laminate may be produced by calendaring or pressing at an appropriate temperature or using any other known technique.
[0020] The laminated structure may include a breathable film or membrane that is substantially impervious to liquid water (e.g. rainwater) but which allows water vapour to pass through.
[0021] The heater element may be laminated to the required fabrics (e.g. the face fabric) using a thermoplastic web material. Such materials are typically fibrous and have a high degree of open porosity. Typical thermoplastic webs soften when heated (e.g. to around 130.degree. C.). Pressure may be applied to speed up the softening of the material. Typically, the thermoplastic web material is located between the heater element and the face fabric. The arrangement is then heated and pressed so that the thermoplastic web is softened and deformed so as to adhere the heater element to the face fabric to form a laminate. For example, an industrial ironing process may be used to laminate the heater element and face fabric in this way.
[0022] The heater element may be incorporated into a drop-liner for a garment.
[0023] The heater element may be incorporated in a detachable liner for a garment.
[0024] The present inventor has realised that the present invention may have a further advantage over known garments. It is preferred to incorporate functional chemicals into an laminate structure according to an embodiment of the invention or into a garment for use with the laminate structure, said functional chemicals being ones that are capable of being initiated by operation of the heater element.
[0025] Preferably, the invention provides heat-activatable agents for release due to heat generated by the heater element.
[0026] The chemicals (or agents) of interest include antimicrobials (for suppressing or killing microbiological activity, e.g. bacteria), insect repellants (for repelling insects such as mosquitoes etc.), fragrances and perfumes.
[0027] In a preferred approach, the chemicals (or agents) of interest are microencapsulated in microcapsules. Suitable microcapsules are those that melt at a particular initiation temperature. Alternative microcapsules are those that allow diffusion of the active chemicals through their walls to effect a slow release mechanism within the garment. By appropriate temperature control, the heater element in the garment may then be used to initiate the delivery of such active chemicals or agents.
[0028] It will be understood that by the encapsulation of various active chemicals and the use of microcapsules having different thermal characteristics, the timing of the delivery of each chemical can be controlled as required. Normally, the microencapsulated components will not form part of the heater element itself. Instead they will typically be contained within other layers of the laminate structure e.g. the inner fabric layer. The release of the chemicals is typically achieved using the heater, which is preferably adjacent to the layer containing the microencapsulated components. The breathability of the fabric heater assists the circulation of the released functional chemicals.
[0029] The operation of the heater element may be controlled in such a way so as to provide a time-varying heating profile to the garment.
[0030] Furthermore, the present inventor has realised that the tracks of the flexible metallised fabric can be used as electrical interconnects in a functional circuit to be incorporated in a garment. In this way, the invention can be used as an electrical interconnect between circuit components.
[0031] Accordingly, in another aspect, the present invention provides a breathable garment flexible electrical interconnect formed from porous metallised fabric, for use in a garment.
[0032] Preferred or optional features of the heater element are also preferred or optional features for the electrical interconnect, where appropriate.
[0033] In adapting the invention for this use, the heater element set out above need not be operated as a heater in use, i.e. the heat generated by the tracks of the metallised fabric need not be significant enough to provide significant heat to the garment. Thus, the present invention may provide a garment incorporating a functional electrical circuit. The circuit may include active and/or passive components, e.g. LEDs. These may be fixed to the tracks of the circuit using solder, conductive adhesive or other known conductive attachment techniques. Materials having desired electronic properties may be applied to the metallised fabric in order to create discrete electronic components. For example, resistive or dielectric materials may be applied in this way, giving rise to a textile circuit having useful functional circuit properties. For example, such a textile circuit may be built into a garment to provide a keypad, e.g. for a mobile phone, or a keyboard or other data entry or control device.
[0034] In a still further aspect, the invention provides a fabric electronic device for data entry or control, incorporating an electrical interconnect as set out above.
[0035] Preferably, the device is configurable between a storage configuration and a use configuration by unrolling.
[0036] In any of the aspects of the invention set out above, the flexible metallised fabric may be shaped so as to provide terminals for electrical connection of tracks formed on the fabric at an elongate flexible tail portion of the fabric. In this way, the functional part of the shape (e.g. the heater element part or the complex circuitry tracks) may be connected to a suitable power supply via the terminals at the tail portion. This avoids the need for conventional wires to be trailed through the garment from the power supply to the fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Preferred embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0038] FIG. 1 shows a schematic cross-sectional view of a laminated fabric according to an embodiment of the invention.
[0039] FIG. 2 shows a schematic cross-sectional view of a laminated fabric according to another embodiment of the invention.
[0040] FIG. 3 shows a schematic plan view of a laminated fabric according to an embodiment of the invention but without an inner fabric layer.
[0041] FIG. 4 shows a schematic cross-sectional view of a laminated fabric according to another embodiment of the invention.
[0042] FIG. 5 a schematic cross-sectional view of a laminated fabric according to another embodiment of the invention.
[0043] FIG. 6 shows a schematic layout of tracks for a first layer for a fabric keypad according to an embodiment of the invention.
[0044] FIG. 7 shows a schematic layout of tracks for a second layer for a fabric keypad, to be used in conjunction with the layer of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] FIG. 1 shows a laminated fabric structure 10 having three layers. Heater element layer 14 is sandwiched between face fabric layer 12 and inner fabric layer 16 .
[0046] FIG. 2 shows an alternative laminated fabric structure having four layers. Heater element layer 14 is sandwiched between breathable film or coating 18 and inner fabric layer 16 . Face fabric layer 12 is disposed on breathable film 18 .
[0047] FIG. 3 shows a schematic plan view of a laminated fabric according to an embodiment of the invention but without an inner fabric layer 16 . One corner of the limited structure is shown turned over to expose the face fabric layer 12 . Breathable layer 18 is disposed on the back surface of face fabric layer 12 . Heater element layer 14 is located on the breathable layer. Inner fabric layer 16 is not shown for the sake of clarity.
[0048] A suitable power supply (not shown) for the heater is supplied by Mpower Batteries Limited, consisting of 2.times.3.6 V lithium ion batteries. Suitable control circuitry is also available from the same source. See also the control circuitry disclosed in WO 03/039417.
[0049] The conductive track pattern of the heater element is shown in FIG. 3 . The way in which a metallised fabric may be used to create a suitable heater element will now be described.
[0050] The heater element is formed by taking a nickel coated polyester woven fabric and cutting it to the desired shape for the garment of interest. A suitable material is the commercially available metallised fabric Metalester (Registered Trade Mark), a woven electroless nickel plated polyester mesh. Such fabrics are available with a variety of thread thicknesses, thread spacings, type of weave and weight of nickel. Threads may typically have a diameter within the range 24 to 600 micrometers (microns), a thread count of between 4 and 737 per cm, and a metal coating of varying weight per square metre.
[0051] Suitable fabrics may be coated with a continuous layer of metal after manufacture, for example by sputtering, by chemical reduction or by electro-deposition, which results in total encapsulation of all the threads of the mesh in metal. In an alternative mesh, the individual warp and weft threads may be metallised prior to fabric production, for example by sputtering, by chemical reduction or by electro-deposition.
[0052] After selecting the desired metallised fabric and cutting it to the required shape, the desired track pattern is then photochemically etched from the fabric. This is done by first designing and generating a suitable phototool, in a way well known to the skilled person. Next, the fabric is mounted onto a hinged frame of brown styrene board, so that the otherwise flimsy fabric can be more readily handled. The fabric is then cleaned with a commercial surface cleaning agent to assist in the adhesion of the photoresist. Then, the photoresist is applied, typically by dip-coating the fabric into a liquid photoresist to ensure application of the photoresist to all parts of the fabric by immersion.
[0053] Next, the fabric is exposed to a suitable image pattern of ultraviolet light from the phototool. This image is developed. The unrequired metal is then progressively etched away. Then, the photoresist is removed to leave the required metallic track shape for the heater element. These steps will be clear to the skilled person. The metallic track is indicated by reference numeral 14 in FIG. 3 .
[0054] In the embodiment of the invention shown in FIG. 1 , the flexible heater element is combined into a laminated structure 10 by thermal adhesion. The laminate consists of the outer face fabric 12 , which is typically a woven fabric composed of man-made fibres, the heater element 14 and the inner lining fabric 16 , which ordinarily may be a woven, knitted, nonwoven or mesh fabric.
[0055] Lamination is achieved using conventional processes. Preferably, thermoplastic adhesives in the form of meltblown webs, grids, mesh structures and films are used. Particle binders can also be applied by spraying or coating on to one or more of the surfaces to be laminated. The laminate is produced by calendaring or pressing at an appropriate temperature or using any other known technique.
[0056] A suitable thermoplastic web material is the melt-spun interlining material Vilene (registered trade mark) U25 supplied by Freudenberg Nonwovens Interlining Division (part of Freudenberg Vliesstoffe KG). The U25 grade is made from 100% polyamide and has a random web structure and a weight of 25 grams per square metre. The material softens and fuses when heat is applied at about 130.degree. C. for about 10 seconds with a pressure of 15-30 N/cm.sup.2. The web has a high degree of open porosity and so allows the lamination between the face fabric and the heater element to give rise to a breathable structure.
[0057] In some protective garments a breathable film/membrane or coating is incorporated to prevent the penetration of liquid water and wind. At the same time, this film is intended to allow the passage of water vapour from the wearer to the outside environment to improve comfort. Commonly, this breathable film is applied to the back of the face fabric as shown in FIG. 2 or is laminated between the face fabric and the inner lining. In such garments, the heater element is incorporated between the breathable membrane/coating and the inner lining.
[0058] FIG. 4 shows a laminated structure 22 according to another embodiment of the invention. Similar features to those shown in the other drawings are given the same reference numerals for the sake of clarity. The structure of FIG. 4 is intended for use as a drop-liner within a garment. The heater element 14 is laminated to the inner fabric layer 16 . An air gap 13 is provided between the heatable inner lining 20 and the outer face fabric 12 and breathable membrane 18 by only loosely attaching the inner lining 20 (i.e. not over its entire surface) to the outer face fabric and breathable membrane.
[0059] It is also contemplated that the outer face fabric 12 need not have a breathable membrane.
[0060] FIGS. 1, 2 , 3 and 4 show garment systems where the linings may not be designed to be removable and the heater element is fully integrated within the lining fabrics. In some garments it is advantageous to have a removable or detachable lining to allow them to be interchanged with others depending on weather conditions or removed for washing for example. Such inner linings may often be fixed in to the garment using a zip, mounted around the circumference of the inner lining.
[0061] In another embodiment, the heater element is laminated to the inside of the inner lining, which may be a woven, knitted, nonwoven or mesh structure, as shown in FIG. 5 . This laminated structure is intended to be removable using any commonly used fixation system such as a zip fastener or a hook-and-loop system. The inner lining fabric may be a fleece or pile fabric depending on the design and intended use of the garment.
[0062] It will be understood that whilst specific examples are provided, other laminated, drop and mid-liner combinations are possible in garments and these are within the spirit and scope of the present invention.
[0063] In a further embodiment, functional chemicals are incorporated into the laminated structure or the garment. The functional chemicals can be initiated by the heat generated by the heater element. Such chemicals include antimicrobials (to suppress or kill microbiological activity), insect repellants (to repel mosquitoes etc.) fragrances and perfumes. In a preferred approach such chemicals are microencapsulated in microcapsules, which melt at a particular initiation temperature or others, which allow diffusion of the active chemicals through their walls to effect a slow release mechanism within the garment. By appropriate temperature control, the heater element in the garment is then used to initiate the delivery of such active chemicals.
[0064] It will be understood that by the encapsulation of various active chemicals and the use of microcapsules having different thermal characteristics, the timing of the delivery of each chemical can be controlled as required. Normally, the microencapsulated components will not form part of the heater element itself rather they will be contained within other layers of the garment e.g. the face fabric layer. The release of the chemicals is however achieved using the heater, which is preferably situated next to the layer which incorporates the microencapsulated components.
[0065] For the specific example of a microencapsulated insect repellent, the microcapsules of US-A-20030124167 are incorporated into the face fabric layer.
[0066] Suitable materials for encapsulating suitable agents include lipids such as wax, paraffin, tristearin, stearic acid, monoglycerides, diglycerides, beeswax, oils, fats and hardened oils.
[0067] Suitable perfumes and fragrances are known. These may be encapsulated in wax, for example.
[0068] Microencapsulated fragrances are available from Celessence International, of Hatch End, Pinner, Middlesex, HA5 4AB, UK.
[0069] In another embodiment, the invention is extended to create a garment which incorporates an electro-conductive circuit. Active and passive components are mounted to the fabric circuit track using solder or a conductive adhesive or similar attachment systems. In addition, electronic materials e.g. resistive or dielectric materials can be applied to the fabric circuit to create discrete components thus allowing a complete functional electronic circuit board to be made. The invention utilises a porous, etched fabric circuit as described above. The resulting electro-conductive textile circuit can be incorporated in to a garment in a similar manner as described in relation to FIGS. 1-5 to improve functionality and to enable the control of associated equipment for example, mobile phone keypads, military applications etc.
[0070] FIG. 6 shows a schematic layout of conductive tracks for a first layer for a fabric keypad according to an embodiment of the invention. The metallised fabric layer 30 is photochemically etched to produce the track layout shown and then cut to the required shape. Tracks 32 follow a known layout between contact pads 34 . Tracks 32 lead to terminals 38 on flexible tail portion 36 . The tail portion 38 shown in this drawing is short, but it will be clear to the skilled person that the formation of a significantly longer tail portion is easily accomplished in the light of the present disclosure.
[0071] Thicker tracks 40 are also formed. These provide electrical connections for LEDs (not shown) to be connected between adjacent tracks, e.g. at location 42 .
[0072] FIG. 7 shows a schematic layout of tracks for a second layer for a fabric keypad, to be used in conjunction with the layer of FIG. 6 . The metallised fabric layer 50 is photochemically etched to produce the track layout shown and then cut to shape. Tracks 52 follow a known layout between contact pads 34 . Tracks 32 lead to terminals 58 on flexible tail portion 56 .
[0073] When assembled into the fabric keypad device, the first layer 30 is laid over the second layer 50 with a spacer layer (not shown) located between them. As will be seen from FIGS. 6 and 7 , the overlaying of the layers brings corresponding contact pads into register with each other. The second layer is covered by another fabric layer having key designations printed on it, e.g. by thermostatic printing (registered trade mark). Pressure applied to a particular key by a user's finger pushes contact pad 52 into electrical contact with contact pad 32 through a corresponding hole through the spacer layer, completing a circuit. This circuit completion is recognised by suitable known control means, and the function corresponding to that key is carried out in a known way. For example, in the case of a TV remote control, a suitable signal is sent from the TV remote control corresponding to the key pressed. Alternatively, in the case of a mobile phone keypad, a number signal is sent to a display device. Alternatively, in the case of a keyboard, a signal corresponding to the key depressed is sent to a computer or other data manipulation device.
[0074] Of course, the flexible electrical interconnect need not be used in a garment. It may be produced as an independent device, e.g. as a roll-up keyboard or the like. Given the disclosure of the flexible device for incorporation in a garment, the skilled person will be able to produce such an independent device.
[0075] The above embodiments have been described by way of example. Modifications of these embodiments, further embodiments and modifications thereof will be apparent to the skilled person and as such are within the scope of the invention.
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Disclosed is a breathable heater element for a garment or for the lining of a garment such as an outdoor jacket, e.g. a waterproof jacket. The heater element is formed from porous metallised fabric such a nickel plated woven polyester fabric by photochemical etching of a suitable track pattern onto the metallised fabric. The formed heater element is then laminated into a lining. The material of the lining may be impregnated with microencapsulated functional chemicals such as fragrances, perfumes, antimicrobials or insect repellents. The microcapsules release their contents on activation due to heat generated by the heater element.
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BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates generally to the manufacture of polyester resins, and to preforms and hot-fill bottles and other containers manufactured therefrom.
[0003] (2) Description of the Prior Art
[0004] Polyethylene terephthalate (PET) bottles and other containers are widely used for foods and beverages because of their optical clarity, ease of blow molding, gas barrier properties, heat resistance, mechanical strength, and price. To form the resin into containers, the polyester resin is typically first shaped by injection molding into a thick-walled preform, typically in the shape of a tube with a threaded opening, or finish end, at the top. A container is then produced by stretch blow molding the heated preform in a mold having a cavity of the desired container shape. The preform is expanded to fill the mold by rapidly stretching it mechanically in the axial direction while simultaneously forcing air into the heated preform to expand it radially. The resultant containers are acceptable for use in packaging liquids that have a fill temperature at about room temperature.
[0005] However, filling of such containers with liquid that is at an elevated temperature, usually as a result of pasteurization or sterilization, tends to soften the container, causing shrinkage and distortion. Accordingly, an additional annealing step is required to heat treat or heat-set containers used in the packaging of heated liquids. Heat setting is normally effected by briefly annealing the container in a heated mold, which may be the same or different from the mold used during the blow-molding step.
[0006] For example, hot fill containers may be formed using a heat-setting mold having a temperature of 110° C. to 170° C., preferably from about 130° C. to 150° C. A preform is first heated to above its softening temperature, and inserted into the mold. Air is then blown into the interior of the preform with an inserted rod as the preform is elongated. Normally, the air is blown in two stages, a primary or pre-blow stage in which the preform is expanded to the general shape of the container, followed by a secondary or high blow stage at an increased force to ensure that the preform conforms to the interior dimensions of the heated mold. In this secondary stage, the fully expanded container is held against the wall of the heated mold for a brief period, e.g., 0.5 to 0.8 second, so that the polyester undergoes some degree of crystallization, which increases the resin's thermal stability and reduces the tendency of the container to shrink or distort. Heat setting permits filling of the containers with liquids having a temperature of up to about 100° C. without significant shrinkage or distortion.
[0007] However, this additional annealing or heat-setting step significantly lengthens the time required to make a container, resulting in reduced productivity and higher costs. Thus, to meet the demands for high-speed production, it is necessary to use a polyester resin that has an increased rate of crystallization. Rapid crystallization of polyester resins, however, tends to result in preforms and containers that have a hazy or cloudy appearance, rendering the containers aesthetically unacceptable for the packaging of liquids for human consumption.
[0008] Thus, there is a continuing need for a method of increasing the crystallization rate of polyester resins enabling the rapid production of hot-fill bottles with an acceptable optical clarity. There is similarly a need for a polyester resin suitable to achieve this objective, and for preforms and hot-fill polyester containers exhibiting these properties.
SUMMARY OF THE INVENTION
[0009] Commonly assigned U.S. patent application Ser. No. 10/017,420, filed Dec. 13, 2001, describes the production of polyester bottles from polyester resin that has incorporated therein from about 0.001 wt. % (10 ppm) to about 0.1 wt. % (1000 ppm), and preferably from about 0.005 wt. % (50 ppm) to about 0.05 wt. % (500 ppm), of BaSO 4 having an average particle size of from 0.1 micron to 2.0 micron, and preferably from about 0.2 micron to about 1.0 micron. Incorporation of BaSO 4 of this particle size in this quantity has been found to significantly reduce bottle-to-bottle friction, i.e., the sticking of polyester bottles to each other as they move along a conveyor, resulting in improved production efficiencies. This reduction in bottle-to-bottle friction is due to the increased roughness from the presence of these larger size particles of BaSO 4 adjacent the bottle surface.
[0010] In accordance with the present invention, it has been found that a different and unrelated advantage, namely an increase in crystallization without a noticeable increase in haziness, can be achieved by incorporating a different amount of BaSO 4 with a different average particle size into the polyester resins.
[0011] More specifically, it has been found that the crystallization rate, and thereby the production rate, of hot-fill polyester bottles and other containers can be increased without causing visually discernable haze in the bottles, by incorporating up to about 250 ppm, and preferable from about 40 ppm to about 50 ppm, of BaSO 4 having an average particle size of less than 0.1 micron into the polyester resin used in manufacture of the containers.
[0012] It will be understood by one skilled in the relevant art that many factors affect formation of visually discernable haze in the manufacture of polyester containers, the preform wall thickness being a factor of primary significance. For example, under the same conditions, a preform wall thickness of about 4 mm may not exhibit visually discernable haze, while a preform of an otherwise identical composition manufactured under the same conditions may exhibit visually discernable haze when the wall thickness is about 6 mm. Presence of haze in the preform will necessarily result in haze in a container made from the preform. Thus, when determining the desired amount of BaSO 4 to use in a given polyester composition, one skilled in the art will take into account the wall thickness of the preform. Accordingly, a container with a thinner wall, e.g., a 4 mm wall, may contain up to 250 ppm BaSO 4 , while containers with a 6 mm wall may be limited to no more than 40-50 ppm BaSO 4 in the composition.
[0013] Other factors to be taken into account in determining the amount of BaSO 4 to use in the composition include the conditions used in molding the preform, as well as the container design, and the conditions under which the container is manufactured, in particular the amount of time that the container is annealed. For example, if a container with greater resistance to shrinkage and distortion is required, the manufacturer may prolong the annealing time, which will improve these properties by increasing the percentage of crystallization. However, the likelihood of an increase in haziness is proportional to the increase in crystallization. Therefore, a lesser amount of BaSO 4 may be needed if a greater annealing time is employed.
[0014] The present invention is generally useful with the various polyester polymers normally used on the manufacture of clear bottles, such as beverage containers having a volume of, e.g., 8 to 12 oz. up to about 1 to 2 liters, or more. Polyester compositions are generally prepared by the esterification of a diacid and a diol, and may also be prepared by the transesterification of a diester, such as dimethyl terephthalate, and a diol, followed by polycondensation. Transesterification catalysts such as the acetates of zinc, manganese, cobalt, sodium and calcium can be employed individually or in combination, while polycondensation catalysts include antimony compounds (such as antimony acetate, antimony oxides), germanium compounds, and titanium compounds. The commonly used diacid is terephthalic acid, while the normal diol is ethylene glycol. Copolyesters can be formed with the two or more diacids or diols. Representive examples of substitute diacid components are isophthalic acid, adipic acid, 2,6-naphthalene dicarboxylic acid, etc. A substitute diester is dimethyl 2,6-naphthalene dicarboxylate. Representative examples of substitute diol components are diethylene glycol, 1,4-butanediol, cyclohexanedimethanol, 1,3-propandiol, etc. The specific reaction conditions for polyester production are well known in the art and are not per se a part of the present invention.
[0015] These polyester compositions used for bottles are normally produced by melt phase polymerization, followed by solid-state polymerization. Generally speaking, after the melt phase polymerization, the intrinsic viscosity (I.V.) reaches a level of about 0.5 to 0.7. Higher I.V. levels are not practically achievable by melt phase polymerization without degradation of the polymer. In order to raise the I.V. to the level normally used for bottles, the melt phase product is first pelletized and the temperature is lowered to room temperature. The pellets are then further polymerized by solid-state polymerization by heating with a nitrogen blanket at about 200° C. to increase the I.V. to 0.7 to 1.1, preferably 0.72 to 0.88.
[0016] The polyester compositions used to prepare the preforms and bottles of the present invention are preferably prepared by incorporating the BaSO 4 during the melt phase. A slurry may be formed of BaSO 4 and ethylene glycol, and milled to ensure a uniform dispersion of BaSO 4 /ethylene glycol without any agglomeration. Preferably, the BaSO 4 should not exceed 75% by wt. of the slurry. This slurry is added into the melt phase polymerization process, preferably at the esterification stage. An amount of slurry sufficient to achieve the desired percentage of BaSO 4 is used. Alternatively, the BaSO 4 can be added into the TA/EG slurry, added directly to the polymer melt at the end of the polycondensation process, added into the extruder during the injection molding of the preform, or made into a master batch of BaSO 4 and PET via a compounding process, and then adding the master batch to the extruder.
[0017] In selecting the appropriate size and quantity of BaSO 4 , an average particle size of 0.1 micron and above should be avoided, since it has been found that only particle sizes below 0.1 micron have a significant nucleation effect in the polyester, and therefore the desired increase in crystallization rate. Further, unlike the invention described in the above co-pending application in which the features are attributable to the physical characteristics of the BaSO 4 , permitting the addition of up to 1000 ppm BaSO 4 , the upper limit of BaSO 4 used in the present polyester resins should not exceed about 250 ppm in order to avoid noticeable haziness with these smaller diameter particles.
[0018] In the preferred embodiment, the polyester/BaSO 4 compositions are first formed into hollow preforms by injection molding. The preform is generally in the form of a closed end cylinder with a closed end and an open threaded, or finish, end, with a volume equal to about {fraction (1/15)}th to about {fraction (1/30)}th of the volume of the final bottle. The preforms, after cooling, are normally conveyed or shipped to another location, where they are heated to 90-140° C., normally by infrared lamps, and biaxially stretched, e.g., by blow molding, to the shape of the final bottle.
[0019] The BaSO 4 -containing polymers can be used to manufacture a variety of bottle shapes, and the actual bottle shape is not a critical feature of the invention, although as noted previously the bottle shape is relevant in determining the amount of BaSO 4 used. Examples of hot-fill containers contemplated by the present invention are bottles used in the packaging of juices and sauces.
[0020] Various additives commonly used in clear polyester bottles can also be used in the polyester compositions, so long as haziness does not result. Such optional additives include thermal stabilizers, light stabilizers, dyes, pigments, plasticizers, antioxidants, lubricants, effusion aids, residual monomer scavengers, and the like.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE I
[0021] The effect on crystallization of polyester resin of a small amount (40 ppm) of BaSO 4 having an average particle size of less than 0.1 micron is shown by the following comparison with the same polyester resin without added BaSO 4 :
TABLE 1 40 ppm 0 ppm IV (dl/g) 0.781 0.799 L-value (−) 79 80 b-value (−) −3.6 −3.3 Tg (° C.) 82.2 82.4 Cp (J/g) 0.32 0.31 Tc (° C.) 181.2 188.7 Hc (J/g) 30 18.7 Tm (° C.) 252.2 250.7 Hm (J/g) 27.2 19.8 Tcc (° C.) 155.5 155.1 Hcc (J/g) 14.3 5.1
[0022] In the above table: IV=intrinsic viscosity; L-value=whiteness index; b-value=yellowness index; Tg=glass transition temperature; Cp=heat capacity; Tc=crystallization peak temperature during heating; Hc=crystallization energy during heating; Tm=melting temperature; Hm=energy absorbed during melting; Tcc=crystallization peak temperature of cooling curve; and Hcc=crystallization energy released during cooling. The higher crystallization rate of the resin containing 40 ppm BaSO 4 is shown by the lower Tc, and the higher Tcc, He and Hcc.
[0023] The attached graph compares the peak crystallization time of the above resins at different temperatures as determined by differential scanning colorimetry.
EXAMPLE II
[0024] Samples of polyester resin containing 100 ppm BaSO4 (Sample A) and 50 ppm BaSO4 (Sample B) were first dried at 300° F. for about 5-6 hours, and then formed into 1-liter heat-set bottle preforms having a weight of 49 g and a finish opening diameter of 43 mm. The haziness of Sample A, particularly in the thickest part of the preform (5.3 mm), was determined to be unacceptable for bottle production due to visually discernable haze. It is believed that the haziness is caused by too much crystallization. Sample B at the same wall thickness and produced under the same conditions, was determined to have acceptable clarity. Sample B was then blown into 1-liter bottles that were evaluated by testing for shrinkage and ovality. The degree of shrinkage determines any changes in diameter, height and volume. Ovality indicates how the bottle retains its round shape after hot filling. By industry standards, an acceptable hot-filled bottle has shrinkage of less than about 3.0% and a change in ovality of less than about 0.100 inch.
[0025] The following shrinkage percentages were observed as different sections along the bottle when the bottles were filled with liquid at the specified temperatures (average of 10 measurements):
TABLE 3 Position 185° F. 190° F. 195° F. 200° F. Height 0.10 0.21 0.37 0.40 Upper Bell 1.23 1.67 1.95 2.52 Lower Bell 1.66 2.42 3.06 4.28 Upper Bumper 1.10 1.63 2.10 3.04 Lower Bumper 1.54 2.29 2.91 4.07 Volume 1.42 2.00 2.47 3.57
[0026] The following changes in ovality (inch) were noted along the bottle length at the specified temperatures (average of 10 measurements):
TABLE 4 Position 185° F. 190° F. 195° F. 200° F. Upper Bell 0.022 0.021 0.027 0.028 Lower Bell 0.020 0.019 0.023 0.031 Upper Bumper 0.018 0.025 0.027 0.037 Lower Bumper 0.011 0.011 0.014 0.029
[0027] The bottles were also top-load tested. Empty bottles were tested to simulate loading that the bottles might experience during filling. Filled bottle testing to simulate loading that the bottles might experience when stacked. As indicated by the following table, the bottles had a maximum top load of 66.6 lbs. at 0.16 in. displacement, and a filled top load of 81.3 lbs. These values compare favorably with acceptable industry values:
TABLE 5 Test Displacement at Max. Load (in.) Load at Max. Load (lbf) No. Empty Bottle Hot-Filled Bottle Empty Bottle Hot-Filled Bottle 1 0.155 0.240 66.52 80.75 2 0.171 0.282 70.63 83.89 3 0.162 0.261 63.49 81.15 4 0.166 0.295 69.58 83.68 5 0.156 0.235 64.48 75.03 6 0.158 0.266 64.70 83.52 Avg. 0.161 0.263 66.57 81.34
EXAMPLE III
[0028] Polyester resin with 40 ppm BaSO4 was air dried at 160° C. for 4 hours, and then formed into 60.75 g preforms of acceptable clarity at injection temperatures in the range of 260° C. to 290° C. Preforms formed by injection molding at 280° C. were stretch blow molded into 1.5L bottles on a Krupp Corpoplast LB01E stretch blow-molding machine. It was determined that bottles with acceptable clarity, shrinkage and deformation could be produced within the preform skin temperature range of from 99° C. to 119° C., with the optimal temperature being 117° C. Shrinkage and deformation was measured after filling the bottles with water at 88° C. Bottle shrinkage was determined to be 2.47%, while change in ovality was 0.035% at the diameter of the lower bell.
EXAMPLE IV
[0029] Polyester resin samples containing 0 ppm, 250 ppm and 500 ppm of BaSO 4 were formed into 48 g preforms having an average wall thickness of 0.16 in. (4.06 mm). Cooling times of 4, 7 and 11 seconds, and extrusion temperature of 515° F., 535° F. and 560° F., were used to test the processability of the different resins. Bottles were produced from the preforms on a Cincinnati Milacron RHB-L laboratory blow molder, equipped with a 1.5 liter bottle mold. The molder was also equipped with a Milacron Spectrawave oven utilizing 650-watt quartz lamps.
[0030] During the tests, the primary blow pressure was set at 140 psi and the secondary blow pressure was set at 420 psi. After being heated by the infrared lamps, the equilibrium time before blowing was set for 10 seconds. The primary delay time was set at 0.5 second. The skin temperature of the preform was controlled by adjusting the oven residence time within the range of 130 to 260 seconds. The properties of the resultant preforms and bottles are set forth in the following tables.
TABLE 6 0 ppm Cond. 1 Cond. 2 Cond. 3 Cond. 4 Cond. 5 Extruder Temp (F.) 560 560 560 530 515 Nozzle Temp (C.) 280 280 280 280 260 Cooling Water Temp (.F) 50 50 50 50 50 Cooling Time (sec) 11 7 4 11 11 Preform Clear Clear Clear Hazy Hazy (light) (heavy) Bottle 260 Hazy (light) (various heating 240 Clear Clear Clear Hazy Pearl times) (sec) (light) (heavy) 220 Clear Clear Clear Clear Pearl (moderate) 200 Clear Clear Clear Clear Pearl (moderate) 180 Clear 170 Clear side Pearl bottom 160 Bottle failed
[0031] [0031] TABLE 7 250 ppm Cond. 1 Cond. 2 Cond. 3 Cond. 4 Cond. 5 Extruder Temp (F.) 560 560 560 530 515 Nozzle Temp (C.) 280 280 280 280 260 Cooling Water Temp (F.) 50 50 50 50 50 Cooling Time (sec) 11 7 4 11 11 Preform Clear Clear Clear Clear Hazy then hazy (heavy) Bottle 240 Hazy Hazy Hazy Hazy Pearl (various heating (moderate) (heavy) (heavy) (heavy) (failure) times) (sec) 220 Clear Clear Clear Hazy Pearl (light) (heavy) 200 Clear Clear Clear Clear Pearl (moderate) 180 Clear 160 Clear 140 Pearl (light) 130 Bottle failed
[0032] [0032] TABLE 8 500 ppm Cond. 1 Cond. 2 Cond. 3 Cond. 4 Cond. 5 Extruder Temp (F.) 560 560 560 530 515 Nozzle Temp (C.) 280 280 280 280 260 Cooling Water Temp (F.) 50 50 50 50 50 Cooling Time (sec) 11 7 4 11 11 Preform Clear Hazy Hazy Hazy Hazy (light) (moderate) (light) (heavy) Bottle 240 Hazy Hazy Hazy (various heating (heavy) (heavy) (heavy) times) (sec) 220 Hazy Hazy Hazy (light) (moderate) (moderate) 200 Clear Hazy Hazy (light) (light) 180 Clear 160 Clear 150 Pearl (light) 140 Bottle failed
[0033] The above data demonstrates that factors such as extruder temperature, nozzle temperature, and cooling time have a significant affect on the properties of the preforms and bottles, even when the same resin is used to produce a bottle preform having the same wall thickness. Based on the above data, it is concluded that up to about 250 ppm of BaSO 4 may be successfully used in the hot fill polyester bottle resins, with a sufficient operating window for commercial feasibility, when producing bottles from preforms having an average wall thickness of about 4 mm.
[0034] Certain modification and improvements will occur to those skilled in the art upon a reading of the foregoing description. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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Hot-fill polyester bottles and other containers characterized by an absence of visually discernable haze are manufactured from a polyester polymer containing up to about 250 ppm, and preferably from about 40 ppm to about 50 ppm, of a uniformly dispersed barium sulfate having an average particle size of less than about 0.1 micron. The polymer may be first formed into a preform, which may have an average wall thickness of from about 4 mm to about 6 mm, that is subsequently blown into the desired container configuration.
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FIELD OF THE INVENTION
[0001] The present invention relates to ironing boards and more specifically to ironing board covers with a bag or pouch attached to the cover to hold articles.
BACKGROUND
[0002] Ironing board covers in the present state of the art provide a surface on which garments, linens and the like can be pressed. Typical covers provide a smooth padded surface for ironing. The top material of the cover is usually heat resistant or insulated so that heat from the iron is reflected back into the garment being pressed, and not transferred to the ironing table beneath the cover. The underside of the cover may comprise padding and/or a slip-resistant material that keep the cover stationary on an ironing table as an iron slides over the cover.
[0003] Ironing boards are generally limited in size to provide a portable ironing surface that can be stored easily. When the ironing board is collapsed for storage, other accessories, such as spray starch, also need to be stored. Accordingly, it is desirable to have a storage container associated with the ironing table such that the ironing table and accessories can be readily stored.
SUMMARY OF THE INVENTION
[0004] With the foregoing in mind, the present invention provides an ironing table cover that holds accessories. The cover includes a sheath that fits around an ironing board. A pouch attached to the sheath holds accessories while the cover is on the ironing board or when the cover is detached from the ironing board. When the cover is on the ironing board, the pouch holds accessories within convenient reach of a person using the ironing board.
[0005] The pouch is attached to the sheath using any conventional fastener. In one embodiment of the invention, the pouch is fixed to the sheath. The pouch may also be detachable from the sheath, and may be detachable from the sheath at one or more places. The pouch may be manufactured in several forms, including a pocket integrally connected to the cover or a mesh bag.
DESCRIPTION OF THE DRAWINGS
[0006] The foregoing summary as well as the following description will be better understood when read in conjunction with the figures in which:
[0007] [0007]FIG. 1 is a perspective view of an ironing board cover with a pouch, in accordance with the present invention.
[0008] [0008]FIG. 2 is a top view of the ironing board cover in FIG. 1 attached to an ironing table, said table being represented by dashed lines.
[0009] [0009]FIG. 3 is a bottom view of the ironing board cover in FIG. 1.
[0010] [0010]FIG. 4 is a perspective view of an alternative embodiment of an ironing board cover, showing a pouch detached from the cover.
[0011] [0011]FIG. 5 is a fragmentary perspective view of another alternative embodiment of an ironing board cover showing a cylindrically-shaped pocket attached to the cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Referring to FIGS. 1 - 3 in general, and to FIGS. 1 and 2 specifically, a cover 10 for covering an ironing board is shown. The cover 10 includes a fabric sheath 12 adapted to fit around the perimeter of an ironing board. A pouch 20 is located at one end of cover 10 and holds one or more articles, such as a bottle of spray starch, iron-on patches or other accessories. In use, cover 10 attaches to an ironing board and holds articles in the pouch so that a person using the ironing board can easily reach the articles while ironing.
[0013] Referring now to FIG. 1, the cover 10 is shown attached to an ironing table 5 . Cover 10 may be used with standard ironing tables or with table-top ironing boards. As shown in FIG. 1, cover 10 is configured to conform with the shape of an ironing board 7 on ironing table 5 . In particular, the sheath 12 is adapted to fit over ironing board 7 . Sheath 12 preferably includes a securing means to hold the cover 10 firmly on board 7 .
[0014] The ironing table 5 includes an ironing board 7 supported by a pair of legs 8 . The legs are pivotable so that the board can be collapsed for storage as shown in FIG. 1 in phantom. When the legs are extended as shown in FIG. 1, there is a gap between the legs and the board 7 . When the table is collapsed, the legs are adjacent the table so that there is no significant gap between the board and the legs. Preferably, the pouch 20 is configured and positioned so that the pouch and its contents do not extend into the gap, which would interfere with folding the ironing table. More specifically, referring to FIGS. 1 and 2, the pouch is attached to the top surface of the cover 10 , and configured so that it does not hang below the ironing board 7 between the legs and the ironing board.
[0015] Referring now to FIGS. 1 and 2, cover 10 will be described in greater detail. Sheath 12 comprises a generally rectangular end 16 and a tapered end 18 that generally conforms to the shape of the ironing board. Preferably, the perimeter dimensions of sheath 12 are slightly larger than perimeter dimensions of ordinary ironing boards, so that cover 10 can easily fit around the ironing board. In addition, corner edges of sheath 12 are preferably rounded to conform to the shape of the ironing board. Referring now to FIG. 3, the edge of sheath 12 folds inwardly toward the interior of the sheath so as to form an opening 13 on the underside of cover 10 . Sheath 12 is adapted to slip over the edges of ironing board 7 , such that the board is received into opening 13 beneath the sheath, as shown in FIG. 1.
[0016] Referring now to FIGS. 1 and 2, a bag or pouch 20 is attached to one end of sheath 12 . Preferably, pouch 20 is attached to sheath 12 at rectangular end 16 . Pouch 20 may be manufactured in several configurations. For example, pouch 20 may comprise a generally rectangular piece of heat-resistant material attached on three sides to sheath 12 . The fourth side of pouch 20 is left unattached to the sheath 12 so as to form a pocket on top of the sheath. Alternatively, pouch 20 may comprise a bag-like enclosure attached to sheath 12 as shown in FIGS. 1 and 2. The bag 20 can be formed of numerous materials, including but not limited to clear or opaque plastic or vinyl. In FIG. 1, bag 20 is shown as a mesh bag.
[0017] Referring now to FIGS. 1 and 2, bag 20 has a bottom side 27 that attaches to sheath 12 and a top side 29 that faces upwardly when the bag 20 and sheath are attached to ironing board 7 . The top side 29 has a slit or opening 25 that provides access inside the bag. A closure 26 on the bag 20 operates to open and close opening 25 . Closure 26 may be of any type known in the art, including but not limited to a zipper, hook and loop connects, a snap connection or a button connection. In FIG. 1, closure 26 is shown as a zipper connection. Preferably, the materials used to form bag 20 are sufficiently heat-resistant to resist melting or damage when they come in contact with a hot iron.
[0018] As stated earlier, sheath 12 preferably includes a securing means 14 to hold the cover 10 firmly on board 7 . The securing means 14 may comprise any conventional material, such as an elastic band or a draw string connected to the perimeter of opening 13 . Referring now to FIGS. 1 and 3, the securing means 14 comprises a draw string. A pair of terminal ends 15 on drawstring 14 protrude from the cover 10 at tapered end 18 . Terminal ends 15 are operable to expand or contract opening 13 when the ends are pulled or released. After sheath 12 is fitted around the edges of ironing board 7 , tension applied to terminal ends 15 tightens drawstring 14 to contract opening 13 and tighten the cover 10 around ironing board 7 . Release of tension from drawstring 14 loosens sheath 12 around ironing board 7 to allow removal or adjustment of cover 10 . The adjustable nature of drawstring 14 allows sheath 12 to fit around most ironing boards.
[0019] Pouch 20 is attached to sheath 12 using any common fastener or method of assembly known in the art. For example, the pouch 20 may be fixed to sheath 12 using stitching or a layer of adhesive. Alternatively, pouch 20 may be removably attached to sheath 12 using fasteners such as snap connections or hook and loop fasteners, such as velcro. Referring to FIG. 4, the pouch 20 is shown in connection with hook and loop type connectors for releasably connecting the pouch to the sheath 12 . In FIG. 4, pouch 20 is shown detached from hook and loop connector 19 on sheath 12 . Connector 19 includes a hook connector 21 fixed to the bag 20 and a loop connector 23 A fixed to the sheath 12 . Alternatively, loop connector 23 A may be fixed to the bag 20 and hook connector 21 fixed to sheath 12 .
[0020] It is not uncommon for plastic components in hook and loop connections to collect lint or other fibrous material. This may occur if the plastic strip 21 rubs against garments or articles containing a heavy amount of lint. A significant amount of lint may accumulate on hook connector 21 if it is fixed to the sheath. In particular, if hook connector 21 is fixed to the sheath and cover 10 is used while bag 20 is detached, the plastic strip may grab onto garments or linens as they are ironed. Lint that accumulates on plastic strip 21 can prevent velcro connection 19 from working properly. Therefore, it may be desirable to place the hook connector 21 on the bottom side 27 of bag 20 rather than on the sheath.
[0021] Connector 19 is positioned so that pouch 20 rests on top of ironing board 7 when the cover 10 is attached over the board. In this way, pouch 20 remains on top of table 5 , as opposed to hanging over an edge of the table, so that the person ironing can easily reach the pouch without walking around the table.
[0022] Occasionally, the person ironing may desire to remove the pouch from the top of ironing board 7 so that an item can be pressed on the entire ironing board surface. This may occur, for example, where large drapes are being ironed. Pouch 20 and its contents may present an irregular surface that is not suitable for ironing. Although removal of pouch 20 increases the amount of work space that can be used for ironing, the advantages of having the pouch are sacrificed when the pouch is removed. As a result, it is desirable to have a pouch 20 that can be attached to multiple sections of an ironing board 7 and not just the top surface.
[0023] In FIG. 4, the cover is shown with multiple hook and loop fasteners for attaching the pouch at multiple locations. Specifically, a pair of loop connectors 23 A, 23 B are shown attached to sheath 12 . Loop connectors 23 A is configured to connect with pouch 20 on the top of ironing board 7 . Loop connectors 23 B is configured to connect with pouch 20 on the side of ironing board 7 , allowing the pouch to hang off of the side of the ironing board so that the entire surface of the board can be used for ironing.
[0024] In the previous figures, the pouch is illustrated as a flat pouch. However, alternate pouch configurations can be used. For instance, FIG. 7 illustrates an alternate pouch configuration in which the pouch 120 is generally cylindrically-shaped, extending across the table 105 . To firmly secure the pouch and prevent it from floppy or rolling, preferably the pouch is attached to the cover 110 by two spaced apart rows of stitching 122 that are generally parallel. Similarly, the pouch can be attached to the cover by two spaced apart rows of hook and loop fasteners, or other connectors. The ends of the pouch 120 are closed, and an opening in the side permits access to the interior of the pouch. Preferably, a zipper 125 or other closure mechanism is provided for closing the side opening.
[0025] The terms and expressions which have been employed are used as terms of description and not of limitation. There is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof. It is recognized, however, that various modifications are possible within the scope and spirit of the invention. Accordingly, the invention incorporates variations that fall within the scope of the following claims.
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An article of manufacture is provided for covering ironing boards. The article is comprised of an ironing board cover and a pouch attached to the cover. The pouch may be a pocket or a bag-like enclosure for holding accessories. In one embodiment, the bag is fixed to the cover. The bag may also be detachable from the cover, and may be detachable from one or more locations on the cover.
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BACKGROUND
Various types of frames, such as for doors, windows, or the like for houses or other buildings, have been developed. A frame construction may utilize species of wood, such as fir, pine or poplar. Window or door frames are normally exposed to environmental factors, such as moisture, typically resulting in structural deterioration. A number of influences may include: microbial rot, insect infestation, water damage or other environmental factors. Deterioration of the wood frame is undesirable.
BRIEF DESCRIPTION OF THE DRAWINGS
Claimed subject matter is particularly pointed out and distinctly claimed in the concluding portion of the specification. However, both as to organization or method of operation, together with objects, features, or advantages thereof, it may be better understood by reference to the following detailed description if read with the accompanying drawings in which:
FIG. 1 is an isometric view of one embodiment of a frame;
FIG. 2 is a cross-sectional view of a portion of the frame of FIG. 1 , taken along the line 2 - 2 ;
FIG. 3 is a cross-sectional view of the frame of FIG. 1 , taken along the line 3 - 3 ; and
FIG. 4 is a flow chart of an embodiment of a method of constructing or manufacturing a frame.
DETAILED DESCRIPTION
In the following detailed description, numerous specific details are set forth to provide a thorough understanding of claimed subject matter. However, it will be understood by those skilled in the art that claimed subject matter may be practiced without these specific details. In other instances, methods, apparatuses or systems that would be known by one of ordinary skill have not been described in detail so as not to obscure claimed subject matter.
Reference throughout this specification to “one embodiment” or “an embodiment” may mean that a particular feature, structure, or characteristic described in connection with a particular embodiment may be included in at least one embodiment of claimed subject matter. Thus, appearances of the phrase “in one embodiment” or “an embodiment” in various places throughout this specification are not necessarily intended to refer to the same embodiment or to any one particular embodiment described. Furthermore, it is to be understood that particular features, structures, or characteristics described may be combined in various ways in one or more embodiments. In general, of course, these and other issues may vary with the particular context of usage. Therefore, the particular context of the description or the usage of these terms may provide helpful guidance regarding inferences to be drawn for that context.
Likewise, the terms, “and” and “or” as used herein may include a variety of meanings that also is expected to depend at least in part upon the context in which such terms are used. Typically, “or” if used to associate a list, such as A, B or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B or C, here used in the exclusive sense. In addition, the term “one or more” as used herein may be used to describe any feature, structure, or characteristic in the singular or may be used to describe some combination of features, structures or characteristics. Though, it should be noted that this is merely an illustrative example and claimed subject matter is not limited to this example.
Various types of frames, such as for doors, windows, or the like for houses or other buildings, have been developed. A frame construction may utilize species of wood, such as fir, pine or poplar. However, as mentioned previously, environmental factors may result in deterioration or decay of these varieties of wood, which is typically undesirable.
In one potential embodiment, frame members may be made up of smaller pieces of wood finger jointed together. In general, frame members constructed of finger joined or jointed wood may be less costly compared to frame members constructed of a solid lumber of comparable dimensions. Therefore, typically, resulting assembled wood frames are less costly to manufacture. Frames may likewise be generally primed and painted so that finger joints are typically not visible and, therefore, do not typically detract from appearance of a finished product.
As mentioned, however, a frame, such as for a building or the like, e.g., a window or door frame, for example, is normally exposed to environmental factors. Thus, for example, moisture may result in wood deterioration or damage. A number of influences may include: microbial rot, insect infestation, water damage or other environmental factors.
Various frame constructions have been developed in an attempt to address decay or deterioration of a wood frame. For example, pressure-treated wood may be employed. However, in general, pressure-treated wood may not be suitable. Compounds utilized to treat wood may interfere with paint, for example. Likewise, extruded wood-based products have been employed. Examples are described in U.S. Pat. Nos. 5,873,209; 5,661,943; 6,122,882; and 6,446,410. However, for these approaches, dissimilarity of materials used in separate portions of a frame may result in potential issues regarding application of primer or paint. That is, paint or primer may not adhere or may provide a perceived difference in produce appearance as a result of dissimilarity of materials. USPTO Provisional application No. 60/887,256, filed on Jan. 30, 2007, entitled DOOR FRAME HAVING DURABLE WOOD PORTIONS discloses a door frame and other products having upper wood portions and lower portions of dissimilar wood varieties where the lower portions are made of various slow growing conifer species, such as Cedar and Cyprus. These species of trees are known for slow growth and longevity, including the callitropsis nootkatensis , which is known to grow for 2000 years, reaching a harvestable maturity at approximately 30-40 years. Use of wood products originating from slow growing tree species, such as Alaska Yellow Cedar a.k.a. callitropsis nootkatensis , or other species in the Cedar or Cyprus families, generally associated with old growth forests, may be costly or result in social or environmental concerns. Cedar and Cyprus trees tend to be desirable for construction, resulting historically in high-demand, over-harvesting, higher costs, and environmental over consumption. Consequently, a product which relies upon wood products derived from these species may be subject to availability or cost fluctuation and potentially a host of other social or political factors as well. Additionally, identification of a product in the marketplace utilizing Cedar, Cyprus or other species associated with old growth forests, as an element of manufacture, may result in a negative public perception of the product itself.
One aspect of an embodiment in accordance with claimed subject matter comprises a plurality of frame members that are joined together to form a wood frame, such as for a door or window, for example. For example, FIG. 2 illustrates a portion of the embodiment of FIG. 1 in which frame members are finger jointed together. A wood frame, for example, may include an upper portion made of a wood species, such as fir, pine or other similar fast growing, inexpensive wood material. A lower portion of the wood frame may comprise a bamboo composite. An embodiment of a process or method for manufacture of blocks of bamboo composite is described in more detail below.
A bamboo composite may provide a variety of advantages. For example, it may provide resistance to wood deterioration or decay; however, paint or primer may adhere in a manner so that if joined with dissimilar woods, a difference in appearance may not be perceptible or barely so. Likewise, bamboo may be more available, less costly and not result in old growth forest environmental concerns in comparison with other wood varieties, such as Cypress or Cedar. Upper portions of a frame may be relatively inexpensive, thereby reducing overall cost of the frame. A bamboo composite in this embodiment may be used in the lower portions of the frame. A lower may be more heavily exposed to moisture or the like that may otherwise lead to decay of the wood frame. However, a bamboo composite may provide resistance to decay. In addition to door or window frames, other components that may have exposure to environmental factors, such as siding, exterior trim, or the like may also be constructed using a combination of fast growing, inexpensive wood material and a bamboo composite.
An embodiment of a wood frame is provided for purposes of illustration. For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the embodiment shown in FIG. 1 . However, it is to be understood that various alternative orientations are likewise possible. It is also to be understood that specific structures or processes shown in the attached drawings and described in this specification are simply provided as illustrative embodiments. Hence, specific dimensions or other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting.
A wood frame 101 is illustrated in FIG. 1 . Wood frame 101 includes upright side frame members 102 and 103 , and an upper frame member 104 extending between and interconnecting side frame members 102 and 103 . Side frame members 102 and 103 , and upper frame member 104 , include a plurality of individual upper pieces of wood that are connected together at finger joints, such as 106 . Upper pieces of wood 105 may be made of a wood material, such as fir or the like, used for constructing frames or other wood structures of houses, for example. Although wood species of this type, e.g. fir, pine or poplar, are relatively low cost and provide structural strength, these varieties or species of wood generally provides less weather or decay resistance than may be desirable for some situations.
In addition to upper pieces of wood 105 , upright side frames 102 and 103 may also include a bamboo composite 110 connected to an adjacent upper piece of wood 105 by a finger joint 109 , again, as illustrated in FIG. 2 , for example. Lower pieces of wood 110 may comprise bamboo composite, which may be resistant to decay, rot, insect damage or other degradation due to moisture or other weather or environmental conditions. Of course, virtually any suitable joint configuration may be utilized to interconnect upper pieces of wood 105 to lower pieces of wood 110 . For example, dovetails, dowels, mechanical connectors, or virtually any other connection arrangement may also be utilized.
For an embodiment, lower wood pieces 110 may comprise a bamboo composite. Details regarding a process or method of manufacture of an embodiment of a bamboo composite are now provided, referring to FIG. 4 . It is of course appreciated that any shape or size of wood frame element may be manufactured. Lower wood pieces 110 are provided merely for illustration purposes. Likewise, claimed subject matter is not limited in scope to the method or process embodiment provided below. For example, other process operations in addition to the process operations below or as alternatives to particular process operations below may be employed. Likewise, in other embodiments, variations in the order of process operations described may also be possible.
FIG. 4 is a flow chart of one embodiment of a method or process for making a bamboo composite, such as in blocks, for use in a wood frame. It is noted that quantities provided below are provided for purposes of illustration and are not meant to limit the scope of claimed subject matter. For example, initially, at box 440 , raw bamboo logs may be cut to a desired standard length, such as a length of 30 inches for example. At box 450 , standard length bamboo logs may be split lengthwise into strips or stickers of a particular width, such as a width of 1.5 inches, for example. It is noted that adjustment for bamboo log diameter to achieve a desired width may be appropriate. At box, 460 , bamboo stickers may be planed, such as by a planning machine, so that the stickers achieve consistent proportions e.g., rectangular. At box 470 , bamboo stickers may be steamed, such as through placement in an industrial steam oven capable of maintaining a pressure of around 8 kg/cm3 temperature of approximately 100 degrees for about two hours. This steaming process may reduce sugar or other organic contaminants through carbonization. At box 480 , carbonated stickers may be kiln dried in the range of approximately 70-80 degrees for about 170 hours or until moisture content is reduced to around 7-10%. At box 490 , the stickers may be acclimatized for approximately 110 hours prior to further processing.
At box 485 , bamboo stickers may be assembled or composed into bamboo composite blocks. For example, a glue or similar material may be employed on the surface of the stickers. At box 495 , bamboo composite blocks may be hot pressed at a temperature of around 100 degrees, a side pressure of about 10 kgs/cm2, and top pressure of about 20 kgs/cm2, for a period of approximately 1 minute per millimeter in thickness.
As discussed above, the upper pieces of wood 105 may comprise a wood other than a bamboo composite. For example, fir or other woods, such as radiator pine, eastern white pine, ponderosa pine, elliotis pine, or other pines, poplars, or other fast growth species may be employed. It will be understood that suitable examples of wood for the upper pieces of wood 105 are not limited to these species. These examples of wood species or varieties are intended to be illustrative rather than exhaustive. Likewise, the upper pieces may also comprise a manufactured or composite wood derived from a combination of wood materials processed to form a rectangular wood block suitable for milling and joining. For example, upper frame members may be assembled from smaller pieces of wood materials in accordance with, for example, a process of manufacturing described by U.S. patent application Ser. No. 11/506,377, titled “Composite Frame for an Opening,” filed on Aug. 18, 2006, by D. Todd Lemons, and assigned to the assignee of the currently claimed subject matter. Of course, it is appreciated that claimed subject matter is not limited in scope to employing an approach described in the foregoing patent application. Rather, it is provided here for illustrative purposes.
Depending at least in part upon the particular frame, lower wood pieces 110 may vary in height. For example, without limitation, a height of about 4 inches to about 10 inches may be employed, but may be as large as approximately 24 inches or as small as approximately 1 inch may be employed. Likewise, if desired, a plurality of pockets (not shown) may be formed to accommodate door hinges, for example.
With further reference to FIG. 3 , frame elements 105 and 110 may generally have a flat outer surface 311 , and inner surfaces 312 and 313 , with a transverse surface 314 extending between inner surfaces 312 and 313 to form a stop. End surfaces 315 and 316 extend between outer surface 311 , and inner surfaces 312 and 313 , respectively. In general, upper frame member 104 may have a cross-sectional shape that is substantially the same or similar to the cross-sectional shape of side frame members 102 and 103 . However, it will be understood that the cross-sectional shape of frame elements 105 and 110 may vary depending upon the particular type of frame or other component that is being fabricated. Likewise, frame members need not have identical cross-sectional shapes. For example, a frame member of a garage door frame may generally have a cross-sectional shape configured to accommodate a garage door, and window frames may a cross-sectional shape to accommodate a particular type of window.
The following describes one embodiment of a process for joining upper and lower frame elements. As discussed previously, finger joints are cut into an upper frame element to match finger joints cut into a lower frame element, in this embodiment, a bamboo composite. The frame elements may be joined by a thermosetting polymer, such as, for example, an epoxy. A composite comprising joined upper and lower elements results which may be milled to specification. Surface imperfections may be filled and sealed. As described in more detail below, a variety of coatings and sealants may be applied, typically to a frame, such as 101 .
Surfaces 311 - 316 of frame members 102 , 103 , and 104 may be treated on all exposed surfaces using, in at least one embodiment, a process that includes a: sealant coating, a bridge coat, a cellcoat, and a coating of paint primer. A sealant coating may prepare the wood by penetrating on a cellular level to reduce water penetration. A bridge coating may be applied to create a surface to which a cellcoat may bond. A cellcoat may bond with a bridge coat to create a durable surface resistant to intrusion by water or insects. Likewise, an application of primer paint may prepare frame members 102 , 103 , and 104 for painting to provide a finished appearance In general, a frame 101 may be painted after it is installed in a building, but it may alternately be pre-painted prior to installation.
Upper pieces of wood 105 and lower pieces of wood 110 typically are intended to exhibit similar properties with respect to absorption or adherence of primer and paint, such that a durable, substantially uniform coating over a frame results. This provides a substantially uniform appearance without special treatments. Likewise, frame elements or pieces 105 and 110 may tend to retain a similar appearance over time.
An advantage of an embodiment of a process as previously described, for example, is ready availability of materials. Upper elements may be derived from fir, pine or other fast growing and renewable forest crops which may be replanted, grown, and harvested for a similar purpose in as few as 10-20 years. Similarly, bamboo typically has a 6 year harvest cycle. A combination of these renewable wood products may result in a finished material appealing to consumers interested in durable, cost-efficient, and environmentally sustainable products that reduce demand to harvest old growth forests. In the context of this application, the term “renewable product” or “renewable wood product” refers to a wood product made from wood having a harvest cycle such that the anticipated life of the product is at least as long or greater than the harvest cycle. Under normal conditions, the projected life of a frame may be estimate to be at 25-40 years under normal conditions, whereas the wood may regenerate in as few as 10 years. Therefore, for the frame embodiment described, for example, the resulting product comprises a renewable wood product.
A frame or other component manufactured in accordance with claimed subject matter may be cost-effective and weather resistant. Use of a bamboo composite may address use of dissimilar frame materials. A frame or other components manufactured in accordance with claimed subject matter may be highly durable, cost-effective and renewable.
In the preceding description, various aspects of claimed subject matter have been described. For purposes of explanation, systems or configurations were set forth to provide an understanding of claimed subject matter. However, claimed subject matter may be practiced without those specific details. In other instances, well-known features were omitted or simplified so as not to obscure claimed subject matter. While certain features have been illustrated or described herein, many modifications, substitutions, changes or equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications or changes as fall within the true spirit of claimed subject matter.
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A method of processing bamboo to produce bamboo composite blocks for use in a wood frame. The method includes forming rectangular bamboo stickers, wherein a rectangular bamboo sticker comprises of consistent dimensions as to at least one other of the rectangular bamboo stickers, steaming the rectangular bamboo stickers, kiln drying the rectangular bamboo stickers, and acclimatizing the rectangular bamboo stickers. The method also includes assembling the rectangular bamboo stickers to form bamboo composite blocks, and hot pressing the bamboo composite blocks.
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RELATED APPLICATIONS
This application corresponds to PCT/EP2013/000807, filed Mar. 15, 2013, which claims the benefit of German Application No. 10 2012 005 429.9, filed Mar. 16, 2012, the subject matter of which is incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for determining the temperature of a substrate, in particular a semiconductor substrate, as well as to an apparatus and a method for thermally treating substrates, in particular semiconductor substrates.
In the art, different apparatuses and methods for thermal treatment of substrates are known, as well as apparatuses for determining the temperature of a substrate during a thermal treatment thereof.
A known method for the thermal treatment of semiconductor substrates includes for example heating the substrate by means of electromagnetic radiation, which is emitted by lamps, such as tungsten halogen lamps. It is known to determine the temperature of the semiconductor wafer via a radiation detector directed onto the substrate for controlling the temperature of the thermal treatment. Since the radiation detector, however, typically not only detects radiation which is emitted from the semiconductor wafer but also radiation which is reflected by the semiconductor wafer or is transmitted there through, a differentiation of these different fractions of the radiation is required for determining the temperature.
For such a differentiation, U.S. Pat. No. 5,318,362, describes the so called Ripple technique, in which a frequency is impressed into the lamp radiation via a respective excitation of the lamp. This was initially achieved by utilizing the AC frequency of the power supply and this technique was refined over time and different frequencies were impressed. Changes in the temperature of the semiconductor wafer occur substantially slower in comparison to the impressed frequency. Thus, the radiation emitted by the semiconductor wafer due to its own temperature does not contain the frequency impressed onto the lamp radiation and may thus be differentiated there from.
For determining the temperature of the substrate with this technique, initially the emissivity of the substrate has to be determined and subsequently the temperature. The degree of emissions or emissivity of an object may depend on its temperature or process reactions and may change during the thermal treatment. Such a change may be gradual or erratic, and the change may be reversible or may be permanent. In particular, erratic changes may lead to an error in the determination of the temperature, if the change is detected too slowly or not at all. Calibration of an emissivity measurement is often difficult, since stable references are lacking. Furthermore, the emissivity of an object may also depend on the surroundings and may be different on the inside of a reactor compared to the outside thereof.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an apparatus and a method for the thermal treatment of substrates, which, independent of the emissivity of the substrate, allows a radiation based determination of the temperature.
In accordance with the invention, this object is achieved by an apparatus for determining the temperature of a substrate in accordance with claim 1 and method for the thermal treatment of substrates in accordance with claim 10 . Further embodiments of the invention will be come clear from the respective dependent claims and the following description.
In accordance with the invention, an apparatus for determining the temperature of a substrate, in particular of a semiconductor substrate during the heating thereof by means of at least one first radiation source, comprises: a first radiation detector, which is directed onto a first surface area of the substrate, which surface area faces towards the at least one radiation source, such that radiation emitted by the substrate and a first proportion of radiation of the at least one radiation source, which is reflected at the substrate, falls onto the first radiation detector, and a second radiation detector, which is directed onto a second surface area of the substrate, which second surface area faces to the at least one radiation source, such that radiation emitted by the substrate and optionally a second proportion of radiation of the at least one radiation source, which is reflected at the substrate, falls onto the radiation detector, wherein the first and second proportions of the radiation of the first radiation source, which is reflected at the substrate, which fall onto the respective radiation detectors, are different, and wherein the first and second surface areas are substrate areas having in substance the same temperature. Furthermore, a temperature determination unit is provided, which is capable of determining the temperature of the substrate directly by means of a power or radiation intensity of the first radiation source and the radiation detected by the first and second radiation detectors. Using two radiation detectors enables a direct determination of the temperature of the substrate by means of the detected radiation without knowing the emissivity of the substrate. The first and second radiation detectors may be formed by a single detector which is alternatively supplied with radiation coming from the substrate and having a first proportion of radiation reflected at the substrate and radiation coming from the substrate having a second proportion of radiation reflected at the substrate, wherein the second proportion may be zero or may approach zero.
Preferably, at least a third radiation detector is provided, which is directed onto the at least one first radiation source, in order to determine the radiation intensity of the first radiation source.
In one embodiment of the invention, the first and second surface areas are arranged in substance on a common circle with respect to a center point of the substrate. The term in substance as used herein encompasses all areas, which at least overlap in the area of the common circle, even if these areas are not centered with respect to the circle. This is supposed to ensure that the surface areas have in substance the same temperature. This may also be achieved by having the first and second surface areas arranged directly adjacent to each other or having the first and second surface areas at least partially overlapped. Preferably, the apparatus comprises at least one optical element, which influences the proportion of the radiation of the at least one radiation source, which is reflected at the substrate, wherein the at least one optical element may for example be an aperture and/or a filter. At least one optical element may be allocated to each radiation detector, wherein the optical elements may define different opening angles for a field of view of the radiation detectors and/or may be arranged at different distances from the substrate, in order to influence the proportion of the radiation of the at least one radiation source which is reflected at the substrate and reaches the respective radiation detector.
The apparatus may comprise at least one filter, which is arranged between at least one radiation source of a plurality of first radiation sources and the substrate, in order to filter out the radiation of the at least one radiation source, which is within the range of the measurement wave length of the radiation detector, before the radiation of the at least one radiation source impinges upon the substrate,
In one embodiment the at least one first radiation source is a lamp, in particular a rod lamp.
The inventive method for thermally treating substrates, in particular semiconductor wafers, comprises: heating the substrate by means of a first radiation, which is emitted by at least a first radiation source, wherein the radiation of the first radiation source is directed onto a first side of the substrate and is at least partially reflected thereby. A first radiation coming from a first surface area of the first side of the substrate is detected, wherein the detected first radiation comprises at least a first substrate-radiation portion and a first reflection-radiation portion, wherein the first substrate-radiation portion consists of radiation emitted by the substrate due to its own temperature, and wherein the first reflection-radiation portion consists of radiation of the first radiation source, which is reflected at the substrate.
Furthermore, a second radiation is detected, which comes from a second surface area of the first side of the substrate, wherein the detected second radiation comprises at least on second substrate-radiation portion and a second reflection-radiation portion, wherein the second substrate-radiation portion consists of radiation emitted by the substrate due to its own temperature and the second reflection-radiation portion consists of radiation of the at least one first radiation source which is reflected at the substrate. The first and second surface areas are areas which comprise in substance the same temperature of the substrate, and the first and second reflection-radiation portions differ. On the basis of the first and the second detected radiations and the drive power of the at least one first radiation source and/or a radiation intensity of the same, the temperature of the substrate is determined. This is again possible directly using the previously mentioned values without first determining the emissivity of the substrate.
Preferably, the first and second radiations are detected with different radiation detectors, in order to enable simultaneous detection. However, they could also be detected in an alternate manner with the same radiation detector.
For homogenizing the substrate temperature in a rotation manner, the substrate is rotated around an axis extending in substance perpendicular to the first side, wherein the first and second surface areas are located in substance on a common circle of rotation with respect to a center point of the substrate. It is also possible—with or without rotation of the substrate—that the first and second surface areas are directly adjacent to each other or at least partially overlap.
In one embodiment, the first and/or second reflection-radiation portion is influenced by at least one optical element located between the substrate and the radiation detector for detecting the detected radiation.
In one embodiment, in the radiation path between the at least one radiation source of a plurality of first radiation sources and the substrate, radiation in the range of the measuring wave length of the radiation detector is filtered out before the radiation of the at least one radiation source falls onto the substrate, in order to influence the detected reflection-radiation portion.
Preferably, using a radiation detector, which is directed on the at least one first radiation source, the radiation intensity coming from the at least one radiation source is detected, wherein the result of this detection is used when determining the temperature of the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in more detail herein below with reference to the drawings. In the drawings:
FIG. 1 is a schematic side sectional view through an apparatus for thermally treating semiconductor wafers;
FIG. 2 is a schematic top view onto a semiconductor wafer;
FIG. 3 ( a ) to ( c ) are schematic side views of different arrangement possibilities for a substrate pyrometer with respect to a bank of lamps;
FIG. 4 ( a ) is a curve of the expected progression of a pyrometer signal versus the radiation of the wafer due to its own temperature;
FIG. 4 ( b ) is a curve, showing the expected progression of a pyrometer signal versus the drive power of heating lamps, the emitted radiation of which falls into the pyrometer by means of reflection at a wafer;
FIGS. 5 ( a ) and 5 ( b ) are curves showing the expected progression of a pyrometer signal versus the temperature of a wafer, wherein the pyrometer detects both temperature radiation of the wafer as well as radiation of the heating lamps reflected at the wafer, the heating lamps being driven with a constant lamp power, wherein FIG. 5 ( a ) shows the expected progression of the pyrometer signal at a lamp power of 5% and FIG. 5 ( b ) shows the expected progression of the pyrometer signal at a lamp power of 50%;
FIG. 6 is a curve of the expected working temperatures of a pyrometer as a function of the lamp power; and
FIG. 7 shows different curves of the expected working temperatures of a pyrometer as a function of the lamp power, wherein the different curves are based on detecting different portions of reflected radiation of the heating lamps at the pyrometer.
DESCRIPTION OF EMBODIMENTS
In the following description, terms such as above, below, left and right and similar expressions refer to the figures and are not to be seen in a limiting manner, even though they may refer to a preferred embodiment. The term “in substance” with respect to angles and arrangements is supposed to encompass deviations up to 10%, preferably up to 5% unless other indications are given. The term “in substance” when referring to other values is supposed to encompass deviations up to 10%, preferably up to 5%, unless other indications are made.
FIG. 1 shows a schematic side section view of an apparatus 1 for the thermal treatment of semiconductor wafers W. The apparatus 1 comprises a housing 2 having an interior space, which inter alia forms a process chamber 3 . The process chamber 3 is bounded on its upper and lower side by wall elements 5 and 6 , respectively and on its sides by the housing 2 . Above the wall element 5 a lamp chamber 7 is provided within the housing 2 . The lamp chamber 7 may have a mirrored surface and a heating source in the form of several lamps 8 may be provided. Below the wall element 6 another lamp chamber 9 similar to lamp chamber 7 is provided, in which a heat source in the form of several lamps 10 is provided.
The side walls of the process chamber 3 may also have a certain mirror effect for at least a portion of the electromagnetic radiation occurring within the process chamber 3 . Furthermore, at least one of the side walls of the process chamber 3 has a process chamber door (not shown) for loading and unloading the semiconductor wafers W. Furthermore, gas inlets and gas outlets (not shown) for the process chamber 3 may be provided.
Within the process chamber 3 a substrate holder 12 having supports 13 is provided, onto which the semiconductor wafer W is placed. The substrate holder 12 is connected to a rotation mechanism, in order to rotate a semiconductor wafer W received on the substrate holder 12 around an axis, which is in substance perpendicular to the upper surface of the semiconductor wafer W. Hereby, as is known in the art, temperature differences on the semiconductor wafer are to be balanced. Within the process chamber 3 a compensation ring which radically surrounds the semiconductor wafer is provided as is known in the field of RTP-systems.
The wall elements 5 and 6 , which bound the process chamber 3 on the top and the bottom are made of quartz and are in substance transparent to the radiation of the lamps 8 and 10 , respectively.
The lamps 8 and 10 may be so-called flash lamps, which are typically operated in a flash mode, or tungsten halogen lamps, which are typically operated in a continuous mode. The lamps may also be arranged in a different manner and it is also possible to combine the above mentioned lamp types or to combine the above with other lamp types. In particular, it is also possible to dispense with the lamps 10 and to provide only an upper lamp chamber 7 having lamps 8 or to dispense with the upper lamp chamber 7 and the lamps 8 and to only provide the lower lamp chamber 9 having lamps 10 .
The apparatus 1 further comprises a first pyrometer, which is directed onto the upper side of the semiconductor wafer W, which is called the first substrate pyrometer 20 in the following, as well as a second pyrometer, which is directed onto the upper side of the semiconductor wafer W, which will be called the second substrate pyrometer 21 in the following. Furthermore, a third pyrometer, which is directed onto at least one of the lamps 8 is proved, which will be called the lamp pyrometer 25 in the following. Optionally, a pyrometer may be provided which is directed onto the back side of the semiconductor wafer W, i.e. a pyrometer which is directed onto the side of the semiconductor wafer W opposite to the lamps 8 , in order to allow a transmission of radiation through the semiconductor wafer W to be taken into account.
The first substrate pyrometer 20 and the second substrate pyrometer 21 are directed onto the upper side of the semiconductor wafer W in such a manner, that they are directed onto surface areas 20 a , 21 a having the same temperature. When having a rotating semiconductor wafer W, the first and second surface areas 20 a , 21 a may lay in substance on a common circle of rotation with respect to a center point of the semiconductor wafer W. Hereby, the term in substance is supposed to encompass an at least partial overlap of the surface areas 20 a , 21 a in a direction of rotation. Such an arrangement is for example shown in the view of FIG. 2 . The surface areas 20 a , 21 a could also be arranged directly adjacent to each other or in an overlapping manner in order to ensure that the semiconductor wafer W has the same temperature in the surface areas 20 a , 21 a.
In accordance with FIG. 1 , the first substrate pyrometer 20 and the second substrate pyrometer 21 are shown such that they extend into the upper lamp chamber and are directed in a perpendicular manner from above onto the semiconductor wafer W. It would also be possible to mount the first and second substrate pyrometers on a side of housing 2 and to direct the same onto the semiconductor wafer W from the side. For example, the first and second substrate pyrometers 20 , 21 could also be directed onto the upper side of the semiconductor wafer W via a light guide, which could extend in a shielded manner into or through the lamp chamber 7 and a corresponding opening in the upper wall 5 .
The first and second substrate pyrometers 20 , 21 are thus capable of detecting radiation coming from the semiconductor wafer W. This radiation coming from the substrate includes radiation emitted by the substrate, which is called substrate-radiation in the following, as well as typically radiation coming from the lamps 8 , which are reflected at the semiconductor wafer W, which radiation is called reflection-radiation in the following. The radiation detected at the respective first and second substrate pyrometers 20 , 21 differs with respect to the composition of the portions of the substrate-radiation and the reflection-radiation. This may be achieved in different manners, as will be explained herein below with respect to FIG. 3 . Hereby it is possible, that the portion of the reflection-radiation, which is measured at one of the substrate pyrometers 20 , 21 is zero or almost zero.
In accordance with FIG. 1 , the lamp pyrometer 25 is shown extending into the upper lamp chamber and being directed from above in a perpendicular manner onto one of the lamps 8 of the upper bank of lamps. It would also be possible, to mount the lamp pyrometer 25 on a side of the housing 2 and to direct the same from the side onto one of the lamps 8 .
FIGS. 3 a to c show schematic side views of different alternatives of arranging the substrate pyrometers 20 , 21 and the lamp pyrometer 25 with respect to the semiconductor wafer W and the lamps 8 of the upper bank of lamps.
In all of the alternatives, the substrate pyrometers 20 , 21 are directed onto the upper side of the semiconductor wafer W through a gap between adjacent lamps 8 of the upper bank of lamps hereby, the substrate pyrometers 20 , 21 are each arranged such that in substance no direct radiation of the lamps 8 can be detected, which may for example be achieved by a corresponding opening of an aperture of the substrate pyrometers 20 , 21 . In the different alternatives, a field of view of the substrate pyrometers 20 , 21 is indicated by a dashed line.
In each alternatives, furthermore the lamp pyrometer 25 is directed onto a lamp 8 which is adjacent to substrate pyrometer 20 so that the lamp pyrometer 25 may detect radiation of a lamp 8 , which via reflection may also be detected by substrate pyrometer 20 , as will be explained in more detail herein below.
In the alternative according FIG. 3 a the substrate pyrometer 20 has a field of view on the semiconductor wafer W, which is defined by an opening angle α and the distance of the substrate pyrometer 20 to the semiconductor wafer W. The opening angle α is chosen with respect to the position of the substrate pyrometer 20 such that a single reflected radiation of the lamps 8 , which are arranged adjacent to the substrate pyrometer 20 may fall into the substrate pyrometer 20 and is detected hereby.
The substrate pyrometer 21 has a field of view on the semiconductor wafer W, which is defined by an opening angle β and the distance of the substrate pyrometer 21 to the semiconductor wafer W. The opening angle β is chosen with respect to the position of the substrate pyrometer 21 such that no radiation of the lamps 8 may fall into the substrate pyrometer 21 via a single reflection. In explaining the above alternative, only a single reflection of the lamp radiation is taken into consideration. Obviously, via multiple reflections (further) lamp radiation may fall into the respective substrate pyrometer 20 , 21 . This may, however, in substance be neglected in the following, since the corresponding portion of the radiation, which enters the substrate pyrometer 20 or 21 via multiple reflections is relatively small.
As will be clear from the above explanation and FIG. 3 a , the substrate pyrometers 20 , 21 measure in substance the same substrate-radiation but different portions of the reflection-radiation. At the substrate pyrometer 21 in substance no or only a very small portion of reflection-radiation is measured, while at the substrate parameter 20 , depending on the intensity of the lamps 8 , a substantial portion may be measured.
In the alternative according to FIG. 3 b , the substrate pyrometers 20 , 21 each have a field of view on the semiconductor wafer W, which is defined by the same opening angle 13 but different distances of the substrate pyrometers 20 , 21 to the semiconductor wafer W. The substrate pyrometer 20 is arranged with a larger distance with respect to the top surface of the semiconductor wafer W than the substrate pyrometer 21 . Hereby it is possible, that radiation of the lamps 8 may fall into the substrate pyrometer 20 via a single reflection, while this is not possible with respect to substrate pyrometer 21 , as shown in FIG. 3 b . Thus, it is again possible that the substrate pyrometers 20 , 21 measure the same substrate-radiation but different portions of the reflection-radiation.
FIG. 3 c shows a further alternative of arranging the substrate pyrometers 20 , 21 . In this alternative the substrate pyrometers 20 , 21 each have a field of view of the semiconductor wafer W which is defined by the same opening angle α and the same distances of the respective substrate pyrometers 20 , 21 to the semiconductor wafer. Thus, the same portions of reflection-radiation would fall into the respective substrate pyrometers 20 , 21 . In the vicinity of the substrate pyrometer 21 , however, the lamps 8 are surrounded by a filter element, which filters the lamp radiation in the range of the measuring wave length of the substrate pyrometer 21 . Thus, generally reflection-radiation of the lamps 8 may fall into the substrate pyrometer 21 , but this radiation is outside of the measuring wave length range of the substrate pyrometer 21 , such that the substrate pyrometer 21 detects a different portion of reflection-radiation compared to the substrate pyrometer 20 .
In operation, an evaluation circuit (not shown) may be connected to the substrate pyrometers 20 , 21 and the lamp pyrometer, which may directly determine the temperature of the semiconductor wafer W from the detected radiations, as will be explained in more detail herein below. Furthermore, also the emissivity of the semiconductor wafer W may be determined on the basis of the detected radiations.
During operation, the semiconductor wafer W is heated via the lamps 8 and optionally via the lamps 10 . The substrate pyrometers 20 , 21 detect the radiation coming from the semiconductor wafer W, which, as explained above, contains the substrate-radiation and where applicable the reflection-radiation. Furthermore, the detected radiation may also contain transmission components, which, however, are not taken into consideration in the following description. The lamp pyrometer 25 detects the lamp radiation of at least one of the lamps 8 . The lamp radiation may optionally comprise a modulation as is known in the art, in order to make it distinguishable from the substrate-radiation. Such a modulation is not needed for temperature determination, but it may provide additional information.
The typical pyrometric temperature measurement is based on measuring the intensity of the thermal radiation of an object at a predetermined wave length. For a black body radiator having the temperature T, the thermal radiation power P bb which is emitted from an area dA within the wave length range between λ and λ+dλ in the entire half space is given by the Planck formula:
dP
bb
(
T
,
λ
)
dAd
λ
=
C
1
λ
5
(
e
c
2
/
(
λ
T
)
-
1
)
wherein
C
1
=
2
π
hc
2
=
3
,
742
*
10
8
W
µ
m
4
m
2
and
C
2
=
hc
k
=
14388
µ
mK
For a real object, the radiation is less than the radiation of a black body radiator:
dP ( T , λ ) d λ = ɛ ( T , λ ) dP bb ( T , λ ) d Ad λ
wherein ε represents the emissivity of the object, wherein 0<ε<1. This is dependent on the wave length and the angle of view and also often changes with the temperature of the object. Furthermore, it may also be dependent on the situation such that the emissivity of an object in a reflecting chamber may for example be higher compared to the same object in a free space.
For a temperature measurement of an object based on its radiation at a certain wave length, typically the emissivity of the object at the wave length and the angle of view onto the object have to be known. The direct emissivity at a wave length is the same as the direct absorption at the wave length in accordance with Kirchhoff's law such that ε=1−ρ−τ, wherein ρ is the reflectivity and τ is the transmissivity.
In the apparatus of the above referenced type, the substrate pyrometer 20 measures substrate-radiation as well as reflection-radiation. Assuming that no directed lamp radiation may fall into the substrate pyrometer, multiple reflections are not taken into consideration and at the measuring wave length of the substrate pyrometer 20 no transmission occurs, the signal S 20 of the substrate pyrometer 20 may be represented as follows:
S 20 =aεP bb ( T )+ bρL ( P )
wherein P bb (T) is the black body radiation corresponding to the wafer temperature T in accordance with the Planck's formula, ε is the emissivity of the wafer surface and L(P) is the lamp radiation at the measuring wave length, when the lamps are operated with a predetermined power P. ρ is the reflectivity of the wafer surface and a and b are constants, which depend on the field of view of the pyrometer, the chamber geometry and other parameters.
Without transmissivity, the reflectivity is ρ=1−ε, such that the pyrometer signal may be represented as follows:
S 20 =aεP bb ( T )+ b (1−ε) L ( P )=( aP bb ( T )− bL ( P ))ε+ bL ( P )
When assuming in the above referenced apparatus that the lamps 8 are tungsten halogen lamps and the substrate pyrometer has a measuring wave length of 2.3 μm, then the influence of the substrate-radiation and the reflection-radiation in the signal of the substrate pyrometers may be represented as shown in FIG. 4( a ) and FIG. 4( b ) . Here FIG. 4( a ) shows the progression of the pyrometer signal versus the temperature of the wafer for the substrate-radiation alone (lamps off) and FIG. 4( b ) shows the progression of the pyrometer signal versus the lamp power in percentage for the pure reflection-radiation (wafer temperature=0). Both, FIGS. 4( a ) and 4( b ) show the progression for different emissivities ε of a semiconductor wafer W.
The FIGS. 5( a ) and 5( b ) show the expected progression of the pyrometer signals versus the temperature of the wafer, detecting both, the substrate-radiation as well as the reflection-radiation. Here, FIG. 5( a ) shows the expected progression of the pyrometer signal at a lamp power of 5% and FIG. 5( b ) shows the expected progression of the pyrometer signal at a lamp power of 50%, each for respective different emissivities ε of a semiconductor wafer W.
As can be seen at the crossings of the curves in FIGS. 5( a ) and 5( b ) , for each lamp power, there is a wafer temperature, at which the pyrometer signal is independent of the emissivity ε of the semiconductor wafer W. These crossings define the working temperature of a pyrometer and the temperature may be expressed as follows:
aP bb ( T P ( P ))= bL ( P )
At this temperature, the pyrometer signal is:
S=bL ( P )= aP bb ( T P ( P ))
FIG. 6 shows a curve of working temperatures of a pyrometer as a function of the lamp power. Each time the wafer temperature crosses this curve and a corresponding lamp power P, the temperature is directly known without knowing the emissivity ε of the semiconductor wafer.
In the field, typically the lamp power P is not the one holding the semiconductor wafer W at a constant temperature T P . Thus, different lamp powers for a process operation on the one side and a measurement on the other side would be advantageous. It would for example be possible for a measurement to rapidly but continuously change the lamp power. Hereby, the point could be determined, at which the lamp power and the pyrometer signal match the line according to FIG. 6 , which would allow a direct temperature determination. Subsequently, the lamp power could again be controlled for normal process operation. If such change of the lamp power is possible fast enough, without influencing the temperature of the semiconductor wafer, a direct temperature measurement using only one substrate pyrometer would be possible.
Preferably, both of the above described substrate pyrometers 20 , 21 are used for a temperature measurement, wherein the different portions of the measured reflection-radiation allow a direct temperature measurement, as described herein below.
FIG. 7 shows different curves of the working temperature (corresponding to FIG. 6 ) of a pyrometer for different portions of the reflection-radiation at a constant substrate-radiation. The upper curve shows the working temperature for the normally expected reflection-radiation. The lower curve corresponds to a reduction of the expected reflection-radiation by the factor 2.5 and 10, respectively.
Two substrate pyrometers, which detect different portions of reflection-radiation with a constant substrate-radiation allow a direct temperature determination on the different curves of the respective working temperatures. Furthermore, a weighted sum of two pyrometer signals, which contain in a known manner different portions of reflection-radiation may be used, to emulate a virtual pyrometer, which has a working point at the current wafer temperature.
Mathematically the pyrometer signals of the substrate pyrometers 20 , 21 may be expressed as follows:
S 20 =a 20 εP bb ( T )+ b 20 (1−ε) L ( P )
and
S 21 =a 21 εP bb ( T )+ b 21 (1−ε) L ( P )
Here, S 20 is the pyrometer signal of the substrate pyrometer 20 , a 20 is a constant, which takes into consideration an amplification factor of the wafer radiation at the substrate pyrometer 20 , and b 20 is a constant, which takes into consideration an influence of the reflection-radiation at the substrate pyrometer 20 . Correspondingly, S 21 is the pyrometer signal of the substrate pyrometer 21 , a 21 is a constant, which takes into consideration an amplification factor of the wafer radiation at the substrate pyrometer 21 , and b 21 is a constant, which takes into consideration an influence of the reflection-radiation at the substrate pyrometer 21 . The influence of the reflection-radiation is determined by the portions of substrate-radiation and reflection-radiation, which as is known differ at the substrate pyrometers.
Rearranging the above formulas leads to:
P
bb
(
T
)
=
(
b
21
S
20
-
b
20
S
21
)
L
(
P
)
a
21
S
20
-
a
20
S
21
+
(
a
20
b
21
-
a
21
b
20
)
L
(
P
)
and
ɛ
=
1
-
a
21
S
20
-
a
20
S
21
(
a
21
b
20
-
a
20
b
21
)
L
(
P
)
For these formulas there is always one solution, as long as both substrate pyrometers detect a signal which is not zero and contains different portions of the reflection-radiation. Hereby the calculated emissivity is an in-Situ emissivity, which is only valid within the chamber and within the linear model.
In reality, the pyrometer signals S 20 and S 21 will also be influenced by other factors, which are not shown in the above equation. Furthermore, multiple reflections of the lamp radiation, which may fall into the pyrometer, can also influence the equation. Furthermore, a simple relationship between the lamp power and the expected lamp radiation is not necessarily exact when the lamp power changes rapidly. Therefore, it may be advantageous to directly determine the lamp radiation, which may be achieved by the lamp pyrometer 25 . Instead of the lamp power, the measurement of the lamp pyrometer may be incorporated into the above equations. This measurement may also be supported by a model, which is based on the lamp power, in order to take into consideration influences of more distant lamps.
The curves of the working temperatures according to FIG. 6 are based on a simple model and the real curves will differ from the shown ones. Rather than enhancing the model, it may be advantageous to determine the curves by a calibration routine. Here, different calibration runs with at least two wafers having different emissivities are required. A calibration run consists of a sequence of different constant lamp powers or preferably constant lamp radiation, which is measured by the lamp pyrometer.
A constant lamp power or lamp radiation leads to the wafer asymptotically approaching an equilibrant temperature. This equilibrant temperature is higher than the working temperature of the pyrometer for high lamp power or lamp radiation and is lower than the working temperature of the pyrometer for lower lamp power or lamp radiation. If one starts at a low wafer temperature and a high lamp power or lamp radiation, the wafer temperature will cross the curve according to FIG. 6 . Reducing the lamp power or lamp radiation now leads to the wafer temperature falling below the curve according to FIG. 6 . A sequence may be set in which the temperature crosses the curve multiple times at different positions, in order to obtain the complete curve. If this sequence is run with both wafers (having different emissivities), the real position of the curve of the working temperatures may be determined.
This calibration may be performed for both substrate pyrometers if they have different working temperatures. As previously mentioned, the real temperature of the wafer will seldom lay on one of the calibrated curves of working temperatures. However, a virtual pyrometer S v may be emulated by a weighted sum of the two pyrometers signals as follows:
S v =αS 20 +(1−α) S 21
For each virtual pyrometer, which is determined by the value of α, a respective calibration of the curve of the working temperatures may be performed in a corresponding manner, as was done for the real pyrometer. This would appear to be advantageous for a limited number of virtual pyrometers. For the real temperature measurement, the temperature values which are not covered by the curves may then be obtained by interpolation of the curves of the working temperatures.
The invention was previously described with respect to preferred embodiments of the invention without being limited to these embodiments. For example, more than two substrate pyrometers may be used or a single substrate pyrometer may be used, wherein for example via a movable aperture, the field of view on the semiconductor wafer and thus, the portion of the reflection-radiation, which falls into the substrate pyrometer may be constantly changed in a known manner. Hereby, two pyrometers having different portions of reflection-radiation are simulated. It is also possible to provide two pyrometers, which from different positions are directed onto the same area of the substrate, such that one of the pyrometers will see the reflected image of the lamp on the substrate surface, while the other will not. In three dimensions this can also be achieved at the same opening angle and the same angle of incidence onto the substrate surface. The two surface areas of the substrate may in this case be exactly the same such that it is ensured, that the surface areas both have the same temperature and the same emissivity even without rotation. In a further alternative for arranging the pyrometers, one of the pyrometers may be directed onto the substrate through a tube, which may optionally be at least partially reflective, wherein the tube extends to a position close to the substrate surface. At a suitable (small) opening angle of the pyrometer, the pyrometer is thus moved optically closer to the substrate. A pyrometer having a tube and one parameter having no tube, for example arranged on a common circle of radiation then forms the required combination of different portions of reflection-radiation. These embodiments are explicitly to be covered by the following claims.
The features of individual embodiments may freely be combined with or exchanged with features of the other embodiments, as long as they are compatible. In particular, an apparatus may be formed, the alternative of arranging the substrate pyrometers with different opening angles, different distances to the wafer and/or filters may be combined.
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An apparatus and a method for determining the temperature of a substrate, in particular of a semiconductor substrate during the heating thereof by means of at least one first radiation source are disclosed. A determination of the temperature is based on detecting first and second radiations, each comprising radiation emitted by the substrate due to its own temperature and radiation emitted by the first radiation, which is reflected at the substrate and at least one of a drive power of the first radiation source and the radiation intensity of the first radiation source.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application Ser. No. 60/694,477 filed Jun. 28, 2005, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to substituted [1,4]-diazepanes that are CXCR3, receptor antagonists. The compounds, and pharmaceutically acceptable salts thereof, are useful for the treatment of disorders that are mediated by CXCR3 function.
BACKGROUND OF THE INVENTION
[0003] Chemokines are cytokines that play an important role inflammatory and immune response. Chemokines are divided into four major groups (CXC, CC, C and CX3C) based on the structural separation of conserved cysteine residues within the peptide sequence. CXC and, CX3C (all of which display four conserved cysteine residues) display one and three amino acid residues, respectively, between the first and second conserved cysteine residues whereas the CC chemokines display sequential cysteine residues. C chemokines exhibit only two conserved cysteine residues (the second and fourth cysteine residues, within other groups) (Murphy et al, Pharmacol. Rev. 2000, 52, 145).
[0004] Chemokine receptors are members of the super family of G-protein coupled receptors (GPCR's) having seven transmembrane-spanning regions. The natural chemokine ligands for CXCR3, Mig (monokine induced by interferon-γ/CXCL9), IP-10 (interferon-inducible protein 10/CXCL10) and I-TAC (interferon-inducible T cell a chemoattractant/CXCL11), are thought to play a key role in directing activated T cells and other cell types (such as NK cells) to sites of inflammation.
[0005] The CXCR3 receptor has been implicated in Th1 cell-mediated inflammation; CXCR3 is one of the most abundant chemokine receptors on Th1 cells (reviewed in Annunziato et al, Eur Cytokine Netw. 1998, 9, 12). Consequently, inhibition of chemokine function via CXCR3 may be useful for the treatment of a number of disorders relating to T cell-mediated function, including inflammatory bowel disease, multiple sclerosis, rheumatoid arthritis, and diabetes, as well as in the prevention of allograft rejection. CXCR3-bearing T-lymphocytes are enriched in inflamed intestinal tissue (Papadakis K. et al, Inflammatory bowel diseases 2004, 10, 778; Yuan et al, Inflammatory bowel diseases 2001, 7, 281) and CXCR3 ligands IP-10 and Mig are expressed in inflamed tissues in mucosal immune, responses (Singh et al, Journal of Interferon and Cytokine Research 2003, 23, 591). Antibodies against IP-10 have been shown to inhibit inflammation in two mouse models of colitis (Sasaki et al, European Journal of Immunology 2002, 32, 3197; Singh et al, Journal of Immunology 2003, 171, 140). Blockade of IP-10 was also effective against disease symptoms and T-cell proliferation in two animal models of multiple sclerosis (mouse hepatitis virus infection and experimental allergic encephalomyelitis (EAE); reviewed in Tsunoda et al., Mult. Scler. 2004, 10, 26 and Arimilli et al, Immunol. Rev. 2000, 177, 43). CXCR3 plays a role in insulin-dependent diabetes (reviewed in Arimilli et al, Immunol Rev. 2000, 177, 43) and CXCR3 ligands secreted by pancreatic beta cells are chemoattractants for infiltrating T-cells in insulitis. (Frigerio et al, Nat. Med. 2002, 8, 1414). Both CXCR3 (Motoki et al, Modern Rheumatology, 2003, 13, 114; Lande et al, Journal of Immunology 2004, 173, 2815; Qin et al, Journal of Clinical Investigation 1998, 101, 746) and its ligands (Patel et al, Clinical Immunology 2001, 98, 39) are upregulated in synovial fluid and/or peripheral blood in rheumatoid arthritis. Allograft survival is prolonged in acute graft rejection models in CXCR3- or IP-10-deficient mice or in the presence of antibodies directed against the receptor or IP-10 (Hancock et al, J. Exp. Med. 2000, 192, 1515; Hancock et al, J. Exp. Med. 2001, 193, 975; Baker et al, Surgery 2003, 134, 126; the potential uses of CXCR3 antagonists for prevention of graft rejection are reviewed in Vincenti et al, Am. J. Transplant 2002, 2, 898).
[0006] In addition to its role in inflammation, CXCR3 has been implicated in angiogenesis and its role has been reported to be either angiogenic or angiostatic. Postischemic neovascularization is decreased in CXCR3-deficient mice (Waeckel et al, Circulation-Research 2005, 96, 576). However, the receptor has more often been observed to have an angiostatic effect (Luster et al, J. Exp. Med. 1995, 182, 219; Strieter et al, J. Biol. Chem., 1995, 270, 27348; Arenberg et al, J. Leukoc. Biol. 1997, 62, 554; reviewed in Rosenkilde and Schwartz, APMIS 2004, 112, 481) and expression of the receptor in endothelial cells is cell cycle-regulated (Romagnani et al, J. Clin. Invest. 2001, 107, 53).
SUMMARY OF THE INVENTION
[0007] In one aspect, the invention relates to a genus of CXCR3 inhibitors sharing the general formula I:
[0000]
[0000] wherein:
R 1 is substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted aryl, substituted or unsubstituted arylcycloalkyl substituted or unsubstituted heteroaryl, substituted or unsubstituted heterocycle, substituted or unsubstituted arylalkyl, substituted or unsubstituted sulfur or oxygen heteroarylalkyl;
R 2 is H;
X is CO—, or (CO)—NH—;
[0008] R 3 is substituted or unsubstituted C2-C6 alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted heterocycle substituted or unsubstituted arylalkyl substituted or unsubstituted heteroarylalkyl;
Y is H, C(O)—, CON—, or C(O)NH—; and
[0009] R 4 is H, or substituted or unsubstituted alkyl,
wherein R 3 is not pyridine when R 1 is alkyl.
[0010] In another aspect, the invention relates to a method of treating a condition associated with CXCR3 function comprising administering to a subject in need of such treatment a therapeutically effective amount of a compound of formula I
[0000]
[0000] wherein:
R 1 is substituted or unsubstituted alkyl substituted or unsubstituted cycloalkyl, substituted or unsubstituted aryl, substituted or unsubstituted arylcycloalkyl substituted or unsubstituted heteroaryl, substituted or unsubstituted heterocycle, substituted or unsubstituted arylalkyl, substituted or unsubstituted sulfur or oxygen heteroarylalkyl;
R 2 is H;
X is CO—, or (CO)—NH—;
[0011] R 3 is substituted or unsubstituted C2-C6 alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted-heterocycle, substituted or unsubstituted arylalkyl, substituted or unsubstituted heteroarylalkyl;
Y is H, C(O)—, CON—, or C(O)NH—; and
[0012] R 4 is H, or substituted or unsubstituted alkyl,
wherein R 3 is not pyridine when R 1 is alkyl
or a pharmaceutically acceptable salt thereof.
[0013] Such conditions include inflammatory bowel disease, multiple sclerosis, rheumatoid arthritis, diabetes and allograft rejection.
[0014] In another aspect, the invention relates to pharmaceutical compositions comprising a pharmaceutically acceptable carrier and compounds of formula I, including pharmaceutically acceptable salts thereof, in any stereoisomeric form, or a mixture of any such compounds in any ratio. The compositions may comprise an additional anti-inflammatory agent.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In the description that follows, certain conventions will be followed as regards the usage of terminology including the abbreviations and definitions described below unless otherwise stated:
Ac—Acetyl BSA—Bovine Serum Albumin Boc—tert-butoxycarbonyl Boc 2 O—tert-butoxycarbonic anhydride C—carbon c—cyclo δ—Nuclear Magnetic Resonance chemical shift referenced to tetramethylsilane DCE—1,2-dichloroethane DCM—dichloromethane=methylene chloride=CH 2 Cl 2 DIPEA—Diisopropylethylamine DMAP—4-Dimethylamino pyridine DMF—N,N-Dimethylformamide DMSO—Dimethyl sulfoxide EDC—1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride Et—Ethyl EtOAc—Ethyl acetate Et 3 N—Triethylamine FLIPR—Fluorometric Imaging Plate Reader, Molecular Devices 1 H NMR—Proton Nuclear Magnetic Resonance HATU—O-(7-Azobenzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate HBSS—Hanks Balanced Salt Solution HEPES—4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid Hexanes—HPLC grade isomeric hexanes HOBt—Hydroxybenzotriazole i—so IP-10—interferon-inducible protein 10/CXCL10 I-TAC—interferon-inducible T cell a chemoattractant/CXCL11 LCMS—Liquid Chromatography Mass Spectroscopy m—-meta Me—Methyl MeOH—Methanol Mig—monokine induced by interferon-γ/CXCL9 min—minutes n—normal N—Nitrogen NMR—Nuclear Magnetic Resonance NaCNBH 3 —Sodium cyano borohydride Na(OAc) 3 BH—Sodium triacetoxy borohydride o—-ortho p—-para Ph—Phenyl r.t.—room temperature sat.—saturated s—secondary t—tertiary TFA—Trifluoro acetic acid THF—Tetrahydrofuran
DEFINITIONS
[0063] “Alkyl” refers to C1-C10 substituted, branched, unsubstituted and linear hydrocarbons potentially substituted at any of the C1-C10 positions. Examples of alkyl groups include but are not limited to methyl, ethyl, n-propyl, i-propyl, n-butyl, t-butyl- and t-butyl, pentyl, hexyl, octyl and the like.
[0064] “Cycloalkyl” refers to C3-C10 substituted or unsubstituted cyclic hydrocarbons potentially substituted at any of the C3-C10 positions. “Cycloalkyl” includes groups involving cyclic hydrocarbon functionality as a substitution of an alkyl group. Examples of cycloalkyl groups include but are not limited to c-propyl, c-butyl, c-pentyl, c-hexyl, and the like.
[0065] “Alkoxy” refers to alkoxy groups from 1 to 8 carbon atoms of a straight, branched, cyclic configuration and combinations thereof. Examples of alkoxy groups include, but are not limited to methoxy, ethoxy, propoxy, isopropoxy, cyclopropyloxy, and the like.
[0066] Halogen includes F, Cl, Br, and I, with F and Cl as the preferred groups.
[0067] “Aryl” refers to C6-C14 substituted or unsubstituted unsaturated aromatic carbocycle containing single or multiple rings. Examples of aryl groups include, but are not limited to phenyl, napthyl, biphenyl and the like.
[0068] “Arylalkyl” refers to an alkyl containing an aryl ring. Examples of arylalkyl groups include, but are not limited to benzyl, phenethyl, phenylpropyl, phenylbutyl and the like. Arylalkyl groups can be substituted or unsubstituted. Substitution can be incorporated at positions within the aryl segment of arylalkyl, the alkyl segment of arylalkyl, and combinations thereof.
[0069] “Heteroaryl” refers to C3-C10 aryl ring(s) containing one or more heteroatoms selected from nitrogen, oxygen and sulfur, within the ring(s) in a heteroaromatic system. Heteroaryl can be monocyclic or poly cyclic, with monocyclic and bicyclic preferred. Rings can be substituted or unsubstituted. Examples of ring substituents include but are not limited to alkyl, substituted alkyl, cycloalkyl, alkoxy, aryl, heteroaryl, heterocycle, carbonyl, carboxy, NO 2 , halogen, hydroxy, cyano, benzyl, phenoxy, naphthyloxy, aryloxy, benzyloxy and the like.
[0070] “Heterocycle” refers to a C3-C10 aromatic or non aromatic ring systems comprising monocyclic or poly cyclic ring systems containing one or more heteroatoms selected from nitrogen, oxygen and sulfur, within the ring(s). Rings can be substituted or unsubstituted.
[0071] “Heteroarylalkyl” refers to an alkyl containing a heteroaryl ring. Examples of heteroarylalkyl groups include, but are not limited to furfuryl, thiophene methyl, thiophene ethyl, pyridine methyl, pyridine ethyl and the like. The term oxygen or sulfur heteroarylalkyl refers to groups in which the heteroaryl ring contains an oxygen or sulfur but not nitrogen, for example, furanylalkyl and thiophenealkyl. Heteroarylalkyl can be present as different isomers, for example, but not limiting, 2-, 3- and 4-pyridine methyl heteroarylalkyl groups can be substituted or unsubstituted. Substitution can be incorporated at positions with in the aryl segment of heteroarylalkyl, the alkyl, segment of heteroarylalkyl, and combinations thereof.
[0072] Arylcycloalkyl refers to an aryl group fused to a cycloalkyl group, the two having two atoms in common. Substitution can be incorporated at positions within the aryl segment of arylcycloalkyl, the alkyl segment of arylcycloalkyl, and combinations thereof.
[0073] Groups that are termed to be “substituted” may be substituted in any manner with single or multiple substituents in such a way that the substitution does not adversely affect the desired activity of compounds of type I. Examples of substitution are detailed in the detailed description of the invention and examples, and may include but are not limited to alkyl, cycloalkyl, alkoxy, alkylaryl, aryl, heteroaryl, alkylheteroaryl, heterocycle, carbonyl, sulfonyl, carboxy, carboxyamido, amino (primary, secondary and tertiary, alkylamino, dialkylamino, arylamino, diarylamino, arylalkylamino, diarylalkylamino, heteroarylamino, diheteroarylamino, heteroarylalkylamino, diheteroarylalkylamino, alcohol, acyl, aroyl, heteroaroyl, nitro, cyano, keto, halogen, haloalkyl (for example trifluoromethyl), haloalkoxy (for example trifluoromethoxy), amino acyl, amino aroyl.
[0074] Some of the compounds described herein may contain one of more asymmetric centers and may thus give rise to enantiomers, diastereomers, and other stereoisometric forms which may be defined in terms of absolute stereochemistry as (R) or (S). The present invention is meant to include all such possible enantiomers and diastereomers and mixtures thereof. Optically active (R) and (S) isomers may be prepared using chiral synthons or chiral reagents, or resolved using conventional techniques
[0075] “Pharmaceutically acceptable salt” as used herein, refers to a composition involving a salt prepared from a pharmaceutically acceptable non-toxic organic or inorganic acid or base, including hydrates thereof. Pharmaceutically acceptable salts are known in the art.
[0076] The present invention provides substituted diazepanes as CXCR3 antagonists. Preferred compounds of the invention are found in the class of substituted diazepane carboxamides of the formula
[0000]
[0077] in which Y is C(O)NH, X is CO— and R 2 is H. Exemplary compounds are shown in Table 1. Details with respect to synthesis and analysis of the compounds of the invention are provided below.
Analysis
[0078] Analysis of the compounds of the invention was performed by analytical HPLC according to one of two methods:
[0079] Method A employed a Waters Millenium 2690/996PDA separations system employing a Phenomonex Luna 3u C8(2) 50×4.6 mm analytical column. The aqueous acetonitrile based solvent gradient involves;
[0080] 0-1 min—Isocratic 5% of (0.05% TFA/acetonitrile);
[0081] 1 min-7 min—Linear gradient of 5-90% of (0.05% TFA/acetonitrile);
[0082] 7 min-9 min—Isocratic 90% of (0.05% TFA/acetonitrile);
[0083] 9 min-10 min—Linear gradient of 90-5% of (0.05% TFA/acetonitrile);
[0084] 10 min-12 min—Isocratic 5% of (0.05% TFA/acetonitrile).
[0085] Flow rate=1 mL/min.
[0086] Method B entailed analysis by a Millenium 2690/996PDA separations system employing a Phenomenex Columbus 5u c18 column 50×4.60 mm analytical column. The aqueous acetonitrile based solvent gradient involves;
[0087] 0-0.5 min—Isocratic 10% of (0.05% TFA/acetonitrile);
[0088] 0.5 min-5.5 min—Linear gradient of 10-90% of (0.05% TFA/acetonitrile):
[0089] 5.5 min-7.5 min—Isocratic 90% of (0.05% TFA/acetonitrile);
[0090] 7.5 min-8 min—Linear gradient of 90-10% of (0.05% TFA/acetonitrile);
[0091] 8 min-10 min—Isocratic 10% of (0.05% TFA/acetonitrile).
[0092] Flow rate=0.4 mL/min.
[0093] Mass Spectroscopy was conducted using Thermo-electron LCQ classic.
[0094] Liquid Chromatography Mass Spectroscopy was conducted using a Waters Millenium 2690/996PDA linked Thermo-electron LCQ classic.
[0095] 1 H NMR spectroscopy was conducted using a Varian 300 MHz Gemini 2000 FTNMR.
[0000]
TABLE 1
Mass Spec.
HPLC
Example
Structure
Found
(Minutes/method)
1
532 [M + H]
6.46 min/A
2
572 [M + H]
6.79 min/A
3
546 [M + H]
6.67 min/A
4
562 [M + H]
7.03 min/A
5
457 [M + H]
5.95 min/A
6
562 [M + H]
6.87 min/A
7
562 [M + H]
7.07 min/A
8
568 [M + H]
7.05 min/A
9
548 [M + H]
6.75 min/A
10
584 [M + H]
7.21 min/A
11
630 [M + H]
7.81 min/A
12
616 [M + H]
7.53 min/A
13
582 [M + H]
7.24 min/A
14
582 [M + H]
7.18 min/A
15
612 [M + H]
7.23 min/A
16
534 [M + H]
6.76 min/A
17
616 [M + H]
7.28 min/A
18
574 [M + H]
7.10 min/A
19
588 [M + H]
7.12 min/A
20
602 [M + H]
7.27 min/A
21
528 [M + H]
6.68 min/A
22
579 [M + H]
6.19 min/A
23
583 [M + H]
7.16 min/A
24
498 [M + H]
6.25 min/A
25
607 [M + H]
7.02 min/A
26
582 [M + H]
7.13 min/A
27
600 [M + H]
7.29 min/A
28
486 [M + H]
6.23 min/A
29
548 [M + H]
6.80 min/A
30
528 [M + H]
6.65 min/A
31
600 [M + H]
7.30 min/A
32
467 [M + H]
6.53 min/A
33
560 [M + H]
7.00 min/A
34
566 [M + H]
6.94 min/A
35
583 [M + H]
7.76 min/A
36
566 [M + H]
6.93 min/A
37
630 [M + H]
7.77 min/A
38
548 [M + H]
6.94 min/A
39
560 [M + H]
7.03 min/A
40
608 [M + H]
6.54 min/A
41
618 [M + H]
7.40 min/A
42
600 [M + H]
7.42 min/A
43
545 [M + H]
6.13 min/A
44
616 [M + H]
7.56 min/A
45
574 [M + H]
7.20 min/A
46
526 [M + H]
6.59 min/A
47
573 [M + H]
6.73 min/A
48
568 [M + H]
7.44 min/A
49
544 [M + H]
7.74 min/A
50
588 [M + H]
6.92 min/A
51
566 [M + H]
6.97 min/A
52
572 [M + H]
6.89 min/A
53
583 [M + H]
5.61 min/A
54
644 [M + H]
8.12 min/A
55
548 [M + H]
6.90 min/A
56
569 [M + H]
7.51 min/B
57
618 [M + H]
7.43 min/A
58
562 [M + H]
7.11 min/A
59
560 [M + H]
6.95 min/A
60
527 [M + H]
5.18 min/A
61
554 [M + H]
6.28 min/A
62
582 [M + H]
7.29 min/B
63
571 [M + H]
5.08 min/A
64
582 [M + H]
7.16 min/A
EXPERIMENTAL
[0096] Compounds of type I can be synthesized by means of conventional organic synthesis employing solid-phase and solution phase chemistries. By way of illustration, but not limitation, the synthesis of compounds of type I is detailed in schemes 1 and 2.
[0000]
[0000]
Solid-Phase Synthesis of Compounds of Type I
[0097] Compounds of type I can be synthesized on solid-phase in five steps from 4-(4′-formyl-3′-methoxy)phenoxybutyric acid functionalized amino methyl terminated polystyrene resin utilizing commercially available 4-nitro-3-fluoro benzoic acid (Scheme 1). Reductive alkylation onto the formyl group of the acid labile linker, followed by amide formation with 4-nitro-3-fluoro benzoic acid provides the carboxamide. Fluoro displacement with an excess of homopiperazine to provide the N-aryl[1,4]-diazepane is followed by urea formation with an isocyanate or an N-carbamoyl chloride, carbamate formation with a chloroformate, amide formation with an anhydride or an acid chloride. Tin chloride mediated nitro-reduction and subsequent N-derivatization of the resulting primary aniline with an acid chloride to provide the amide or reductive alkylation to provide the amino derivative or urea formation with an isocyanate provides compounds of type I. Ligand cleavage from the solid support is achieved using TFA in CH 2 Cl 2 , allowing compound purification by flash chromatography or preperative HPLC.
Solid-Phase Synthesis—General Procedures
[0098] For solid-phase reactions it is often desirable to think of the amount of solution reagents in terms of concentrations rather than equivalents. For this reason, reagent concentration is generally provided in the following experimental protocols. All shaking is performed with a wrist-action shaker. The size of shaking vessels typically employed is 20 mL (small) or 100 mL (medium). Each washing cycle is carried out with 12 mL of solvent for small shaking vessels or 60 mL of solvent for medium vessels over 5-10 minutes unless otherwise stated. All solvents used for reactions and washings are HPLC grade unless otherwise stated. Reactions which require heating are performed in scintillation vials with Teflon-lined screw caps. These are placed in an oil bath. Upon reaction completion, the resin in the scintillation vial is transferred to a glass shaking vessel and washed. The resin-bound ligand can be removed by acid cleavage with TFA/CH 2 Cl 2 .
Intermediate 1 (I-1)—General Procedure A—Acylation with 4-(4′-formyl-3′-methoxy)phenoxybutyric acid
[0099]
[0100] To a solution of 2.86 μg (12.0 mmol, 0.2 M, 4.0 eq.) of 4-(4′-formyl-3′-methoxy)phenoxybutyric acid and 1.84 g (12.0 mmol, 0.2 M, 4.0 eq.) of HOBt.H 2 O in 60 mL of DMF was added 3.75 mL (24.0 mmol, 0.4 mL, 8.0 eq.) of DIC. The resulting solution was stirred for 20 min at 25° C. This solution was added to a medium shaking vessel containing 3.8 g (˜0.8 mmol/g, 3.0 mmol, 1.0 eq.) aminomethyl terminated Polystyrene. The mixture was shaken for 17 h at 25° C. The shaking vessel was then drained and the resin was washed with DMF (1×), CH 2 Cl 2 (1×), DMF (2×), CH 2 Cl 2 (2×), CH 3 OH (2×) and CH 2 Cl 2 (2×).
Intermediate 2 (I-2)—General Procedure B—Reductive Amination
[0101]
[0102] To a suspension of 0.6 g (40.8 mmol, 0.48 mmol, 1.0 eq.) of resin-bound o-methoxybenzaldehyde (I-1) in 12 mL of 1,2-dichloroethane (DCE) was added 4.8 mmol (0.4 M, 10.0 eq.) of a primary amine. The resin suspension was shaken for 15 sec and 1.0 g (4.8 mmol, 0.4 M, 10.0 eq.) of sodium triacetoxyborohydride was added. The suspension was shaken for 16 h at 25° C., venting the reaction vessel periodically during the first 1 h. The vessel was then drained, and the resin was washed with CH 3 OH (1×), CH 2 Cl 2 (2×), CH 3 OH (1×), CH 2 Cl 2 (2×), Cl 3 OH (1×), CH 3 OH (1×30 min) and CH 2 Cl 2 (2×).
Intermediate 3 (I-3)—General Procedure C—N-Acylation with 3-nitro-4-fluoro benzoic-acid
[0103]
[0104] To 0.6 g (˜0.7 mmol/g, 0.4 mmol, 1.0 eq.) of resin-bound secondary amine (I-2) in 10 mL of DMF was added 0.46 g (2.5 mmol, 0.25 M, ˜3.5 eq.) of 3-nitro-4-fluoro benzoic acid and 0.95 g (2.5 mmol 0.25 M, ˜3.5 eq.) of HATU. A portion of 0.87 mL (5.0 mmol, 0.5 M, ˜7 eq.) of, N,N-diisopropylethylamine was added and the mixture was shaken at 25° C. for 16 h. The vessel was drained and the resin was washed with DMF (2×), CH 2 Cl 2 (1×), DMF (1×), CH 2 Cl 2 (2×), CH 3 OH (2×) and CH 2 Cl 2 (2×).
Intermediate 4-(I-4)—General Procedure D—N-Arylation with homopiperazine
[0105]
[0106] To 0.6 g (˜0.7 mmol/g, 0.4 mmol, 1.0 eq.) of resin-bound aryl fluoride (I-3) in 10 mL of DMF was added 0.5 g (5 mmol, 0.5 M, ˜7 eq.) of homopiperazine and the mixture was shaken at 25° C. for 16 h. The vessel was drained and the resin was washed with DMF (2×), CH 2 Cl 2 (1×), DMF (1×), CH 2 Cl 2 (2×), CH 3 OH (2×) and CH 2 Cl 2 (2×).
Intermediate 5 (I-5)—General Procedure E—N-Derivatization—Urea Formation
[0107]
[0108] To 0.6 g (˜0.7 mmol/g, 0.4 mmol, 1.0 eq.) of resin-bound secondary amine (I-4) in 10 mL of CH 2 Cl 2 was added 2.5 mmol (0.25 M, ˜3.5 eq.) of an isocyanate and the mixture was shaken at 25° C. for 16 h. The vessel was drained and the resin was washed with CH 2 Cl 2 (1×), DMF (1×), CH 2 Cl 2 (2×), CH 3 OH (2×) and CH 2 Cl 2 (2×).
Intermediate 6 (I-6)—General Procedure F—Nitro Reduction
[0109]
[0110] To 0.6 g (˜0.7 mmol/g, 0.4 mmol, 1.0 eq.) of resin-bound nitro compound (I-5) was added 10 mL of a 2 M solution of tin (II) chloride dihydrate in DMF and the mixture was shaken at 25° C. for 36 h. The vessel was drained and the resin was washed with DMF (2×), CH 2 Cl 2 (1×), DMF (1×), CH 2 Cl 2 (2×), CH 3 OH (2×) and CH 2 Cl 2 (2×).
Intermediate 7 (I-7)—General Procedure G—N-Derivatization—Amide Formation
[0111]
[0112] To 0.6 g (˜0.7 mmol/g, 0.4 mmol, 1.0 eq.) of resin-bound aniline (I-6) in 10 mL of CH 2 Cl 2 was added 0.87 mL (5.0 mmol, 0.5 M, ˜7 eq.) of N,N-diisopropylethylamine and 2.5 mmol (0.25 M, ˜3.5 eq.) of an acid chloride. The mixture was shaken at 25° C. for 16 h. The vessel was drained and the resin was washed with CH 2 Cl 2 (1×), DMF (1×), CH 2 Cl 2 (2×), CH 3 OH (2×) and CH 2 Cl 2 (2×).
Intermediate 8 (I-8)—General Procedure H—Acid Cleavase
[0113]
[0114] To 0.2 g of resin bound diazepane (I-7) in a scintillation vial was added 10 mL of 50% v/v TFA/CH 2 Cl 2 , and the resulting resin suspension was stirred at rt for 2 h. The resin was removed by filtration and the solvent removed in vacuo. The residue was purified by preparative HPLC.
Solution-Phase Synthesis
[0115] Compounds of type I can be synthesized in five steps from commercially available 4-nitro-3-fluoro benzoic acid (Scheme 2). Activation of the carboxyl group as the acid chloride is followed by amide formation with an amine to provide the carboxamide. Fluoro displacement with an excess of homopiperazine to provide the N-aryl[1,4]-diazepane is followed by urea formation with an isocyanate or an N-carbamoyl chloride, carbamate formation with a chloroformate, amide formation with an anhydride or acid chloride. Nitro-reduction and subsequent N-derivatization of the resulting primary aniline with an acid chloride to provide the amide or reductive alkylation to provide the amino derivative or urea formation with an isocyanate to provide the urea results in the formation of compounds of type I. Analogous compounds of type I can be synthesised using similar experimental procedures.
Intermediate 9 (I-9)—Procedure I: N-|2-(2,4-Dichloro-phenyl)-ethyl|-4-fluoro-3-nitro-benzamide
[0116]
[0117] To a solution of 5.0 g (27.0 mmol, 1.0 eq) of 3-nitro-4-fluoro benzoic acid in 100 mL of CH 2 Cl 2 at 0° C. was added 4.7 mL (54.0 mmol, 2.0 eq.) of oxalyl chloride and 100 μL (1.3 mmol, 0.05 eq.) of DMF. The resulting solution was stirred at 0° C. for 1 h, allowed to warm to room temperature and stirred for an additional 16 h. The solvent was removed in vacuo to provide 3-nitro-4-fluoro benzoyl chloride. The crude acid chloride was dissolved in 150 mL of CH 2 Cl 2 and cooled to 0° C. A portion of 8.1 mL (54.0 mmol, 2.0 eq.) of 2-(2,4-dichlorophenyl)ethyl amine was added over 10 min, and the mixture stirred at 0° C. for 20 min. The reaction mixture was diluted with 300 mL of CH 2 Cl 2 , washed with 100 mL of 1M HCl, 80 mL of sat. NaHCO 3 , dried (Na 2 SO 4 ) and the solvent removed in vacuo to provide 9.5 g (26.6 mmol, 98%) of 1-9 as a yellow solid. (δ H , 300 MHz, CDCl 3 ) 3.02 (t, 2H), 3.70 (q, 2H), 6.25 (bt, 1H), 7.10-7.40 (m, 4H), 8.04 (m, 1H), 8.39 (dd. 1H); ESI, 562 └M+H┘.
Intermediate 10 (I-10)—Procedure J: 4-|1,4|Diazepan-1-yl-N-|2-(2,4-dichloro-phenyl)-ethyl|-3-nitro-benzamide
[0118]
[0119] To a solution of 9.5 g (26.6 mmol. 1.0 eq.) of I-9 in 100 mL of DMF at 0° C. was added a solution of 8.1 g (79.8 mmol 3.0 eq.) of homopiperazine in 50 mL of DMF. The resulting red solution was stirred at 0° C. for 15 min and 150 mL of water added. The mixture was extracted with 3×100 mL of diethyl ether and the combined organic extracts were washed with 100 mL of sat. brine, dried (Na 2 SO 4 ) and the solvent removed in vacuo to provide crude I-10, (δ II , 300 MHz, CDCl 3 ) 1.95 (m, 2H), 2.91 (m, 2H), 3.03 (m, 4H), 3.29 (m, 2H), 3.46 (m, 2H), 3.66 (m, 2H), 6.22 (bt, 1H), 7.04 (d, 1H), 7.16 (m, 2H), 7.77 (dd, 1H), 8.06 (d, 1H).
Intermediate 11 (I-11)—Procedure K: 4-{4-└2-(2,4-Dichloro-phenyl)-ethylcarbamoyl|-2-nitro-phenyl}-|1,4|diazepane-1-ethly urea
[0120]
[0121] To a solution of 11.6 g (26.2 mmol, 1.0 eq.) of I-10 in 150 mL of CH 2 Cl 2 was added 2.1 mL (29.3 mmol, 5.0 eq.) of ethyl isocyanate. The resulting solution was stirred at 25° C. for 30 min. The solvent was removed in vacuo to provide 10.5 g (20.6 mmol, 78% from I-9) of I-11 as a yellow solid. (δ II , 300 MHz, CDCl 3 ) 1.05 (t, 3H), 1.95 (m, 2H), 3.02 (t, 2H), 3.18 (dq, 2H), 3.32 (m, 2H), 3.42 (m, 4H), 3.65 (m, 4H) 4.37 (bt, 1H), 6.43 (bt, 1H), 7.02 (d, 1H), 7.16 (m, 3H), 7.36 (m, 1H), 7.77 (dd, 1H), 8.05 (d, 1H)
Intermediate 12 (I-12)—Procedure L: 4-{2-Amino-4-└2-(2,4-dichloro-phenyl)-ethylcarbamoyl|-phenyl}-|1,4|diazepane-1-ethly urea
[0122]
[0123] A solution of 7.8 g of sodium hydrosulfite (tech grade, ˜38 mmol, 3 eq.) and 2.5 g of sodium bicarbonate (29.7 mmol, 2.2 eq.) in 100 mL of water was added to a solution of 7.0 g of I-11 in 150 mL of 2:1 v/v p-dioxane/methanol at 0° C. over 10 min. The resulting suspension was allowed to warm to room temperature and stirred for an additional 30 min. The mixture was diluted with 250 mL of water and extracted with 3×150 mL of EtOAc. The combined organic extracts were dried (Na 2 SO 4 ), the solvent removed in vacuo and the residue purified by flash column chromatograph (EtOAc to 10% MeOH/EtOAc) to provide 4.5 g (9.4 mmol, 68%) of I-12 as a white solid. (δ II , 300 MHz, CDCl 3 ) 1.08 (t, 3H), 1.98 (m, 2H), 3.03 (m, 6H), 3.26 (dq, 2H), 3.53 (t, 2H), 3.62 (m, 4H), 4.02 (bs, 2H), 4.35 (t, 1H) 6.14 (bt, 1H), 6.92 (m, 2H), 7.15 (m, 3H), 7.40 (s, 1H).
Intermediate 13 (I-13)—General Procedure M: N-Derivatization
[0124]
[0125] To a solution of 100 mg (0.21 mmol, 1.0 eq.) of I-12 in 2 mL of CH 2 Cl 2 was added 72 μL of triethylamine (0.52 mmol, 2.5 eq.) and catalytic DMAP. A portion of 0.25 mmol (1.2 eq.) of an acid chloride was added and the resulting solution stirred at 25° C. for 1.5 h. The mixture was diluted 30 mL of CH 2 Cl 2 , washed with 10 mL of sat. NaHCO 3 , dried (Na 2 SO 4 ) and the solvent removed in vacuo. The residue was purified by flash column chromatography (EtOAc to 10% MeOH/EtOAc) to provide I-13.
Intermediate 14 (I-14)—Procedure N: 4-Fluoro-3-nitro-benzoic acid methyl ester
[0126]
[0127] To a solution of 5.0 g (27.0 mmol, 1.0 eq) of 3-nitro-4-fluoro benzoic acid in 100 mL of CH 2 Cl 2 at 0° C. was added 4.7 mL (54.0 mmol, 2.0 eq.) of oxalyl chloride and 100 μL (1.3 mmol, 0.05 eq.) of DMF. The resulting solution was stirred at 0° C. for 1 h, allowed to warm to room temperature and stirred for an additional 16 h. The solvent was removed in vacuo to provide 3-nitro-4-fluoro benzoyl chloride. The crude acid chloride was dissolved in 150 mL of MeOH at 0° C. and the mixture stirred for 20 min. The solvent was removed in vacuo to provide 9.5 g (26.6 mmol, 98%) of 4-Fluoro-3-nitro-methyl benzoate (I-14) as a white solid. (δ H , 300 MHz, CDCl 3 ) 3.97 (s, 3H), 7.36 (dd, 1H), 8.30 (m, 1H), 8.73 (dd, 1H).
Intermediate 15 (I-15)—Procedure O: 4-[1,4]Diazepan-1-yl-3-nitro-benzoic acid methyl ester
[0128]
[0129] To a solution of 5.0 g (25.1 mmol, 1.0 eq.) of I-14 in 50 mL of DMF was added a solution of 12.6 g (125 mmol, 5.0 eq.) of homopiperazine in 100 mL of DMF. The resulting red solution was stirred at room temperature for 15 min and 150 mL of water added. The mixture was extracted with 3×100 mL of diethyl ether and the combined organic extracts were washed with 100 mL of sat. brine, dried (Na 2 SO 4 ) and the solvent removed in vacuo to provide 6.5 g of crude I-15 as a yellow oil. (δ H , 300 MHz, CDCl 3 ) 1.85 (m, 2H), 2.85 (m, 2H), 3.03 (m, 2H), 3.32 (m, 2H), 3.48 (m, 2H), 3.85 (s, 3H), 7.00 (d, 1H), 7.94 (dd, 1H), 8.36 (d, 1H), 8.39 (dd, 1H).
Intermediate 16 (I-16)—Procedure P: 4-(4-Ethylcarbamoyl-[1,4]diazepan-1-yl)-3-nitro-benzoic acid methyl ester
[0130]
[0131] To a solution of 6.5 g (23.3 mmol, 1.0 eq.) of I-15 in 200 mL of CH 2 Cl 2 was added 2.1 mL (29.3 mmol, 1.25 eq.) of ethyl isocyanate. The resulting solution was stirred at 25° C. for 30 min. The solvent was removed in vacuo to provide 8.5 g (24.3 mmol, 97% two steps) of I-16 as a deep yellow oil. (δ H , 300 MHz, CD Cl 3 ) 1.04 (t, 3H), 1.95 (m, 2H), 3.20 (dq, 2H), 3.36 (m, 2H), 3.46 (m, 4H), 3.63 (m, 2H), 3.83 (s, 3H), 4.37 (t, 1H), 7.03 (d, 1H), 7.94 (d, 1H), 8.32 (d, 1H).
Intermediate 17 (I-17)—Procedure Q: 3-Amino 4-(4-ethylcarbamoyl-[1,4]diazepan-1-yl)-benzoic acid methyl ester
[0132]
[0133] A solution of 17.7 g of sodium hydrosulfite (tech grade, ˜86 mmol, ˜5 eq.) and 5.7 g of sodium bicarbonate (67.6 mmol, 4.0 eq.) in 75 mL of water was added to a solution of 5.9 g (16.9 mmol, 1.0 eq.) of I-16 in 150 mL of p-dioxane at room temperature, over 15 min. The resulting suspension was stirred for an additional 30 min. The mixture was diluted with 200 mL of water and extracted with 3×150 mL of EtOAc. The combined organic extracts were dried (Na 2 SO 4 ), the solvent removed in vacuo and the residue purified by flash column chromatography (EtOAc to 10% MeOH/EtOAc) to provide 4.2 g (13.1 mmol, 78%) of I-17 as a white solid. (δ H , 300 MHz, CDCl 3 ) 1.12 (t, 3H), 1.98 (m, 2H), 3.10 (m, 4H), 3.30 (dq, 2H), 3.56 (t, 2H), 3.65 (m, 2H), 3.82 (s, 3H), 4.02 (s, 2H), 4.35 (t, 1H), 6.98 (d, 1H), 7.36 (s, 1H), 7.37 (dd, 1H).
Intermediate 18 (I-18)—Procedure R: 3-(3-Chloro-benzoylamino)-4-(4-ethylcarbamoyl-[1,4]diazepan-1-yl)-benzoic acid methyl ester
[0134]
[0135] To a solution of 1.56 g (4.87 mmol, 1.0 eq.) of I-17 and 1.62 mL (11.67 mmol, 2.4 eq.) of triethylamine in 25 mL of CH 2 Cl 2 was added 10 mg (cat.) of DMAP followed by 0.74 mL (5.85 mmol, 1.2 eq.) of 3-chlorobenzoyl chloride. The resulting mixture was stirred at room temperature for 1 hour and 50 mL of CH 2 Cl 2 added. The organic solution was washed with 50 mL of water, 20 mL of sat. NaHCO 3 , dried (Na 2 SO 4 ), and the solvent removed in vacuo. The residue purified by flash column chromatography (80% EtOAc/hexanes to EtOAc) to provide 1.2 g (2.61 mmol, 54%) of I-18. (δ II , 300 MHz, CDCl 3 ) 1.12 (t, 3H), 1.98 (m, 2H), 3.10 (m, 4H), 3.30 (dq, 2H), 3.56 (t, 2M, 3.65 (m, 2H), 3.82 (s, 3H), 4.02 (s, 2H), 4.35 (t 1H), 6.98 (d, 1H), 7.36 (s, 1H), 7.37 (dd, 1H). E.I. └M+H┘ 459.
Intermediate 19 (I-19)—Procedure S: 3-(3-Chloro-benzoylamino)-4-(4-ethylcarbamoyl-|1,4|diazepan-1-yl)-benzoic acid
[0136]
[0137] A solution of 0.21 g (8.7 mmol, 4.0 eq.) of lithium hydroxide in 10 mL of water was added to a solution of 1.0 g (2.18 mmol, 1.0 eq.) of I-18 in 10 mL of THF and the mixture stirred at 60° C. for 16 h. the mixture was cooled to room temperature and 50 mL of water added. The aqueous phase was acidified to pH 5 with 1M HCl. The product vas extracted into 3×50 mL EtOAc, the combined organic extracts dried (Na 2 SO 4 ), removed in vacuo to provide 0.83 g (1.9 mmol, 86%) of I-19 as a white solid. (δ II , 300 MHz. CDCl 3 ) 1.12 (t, 3H), 1.92 (m, 2H), 3.06 (m, 2H), 3.20 (m, 2H), 3.30 (q, 2H), 3.53 (t 2H), 3.68 (m, 2H). 7.15 (d, 1H), 7.48 (m, 2H), 7.77 (dd, 1H), 7.80 (d, 1H), 7.95 (t, 1H), 8.81 (d, 1H), 9.35 (bs, 1H). E.I. └M+H┘ 445.
Intermediate 20 (I-20)—Procedure T: Amide Formation
[0138]
[0139] To a solution of 30 mg (0.07 mmol, 1.0 eq.) of I-19, 11 mg (0.08 mmol, 1.1 eq.) of HOBt and 15 mg (0.08 mmol, 1.1 eq.) of EDC in 2 mL or CH 2 Cl 2 was, added 0.22 mmol (3.0 eq.) of an amine and the mixture stirred at room temperature for 2 h. The mixture was diluted with 20 mL of EtOAc, and washed with 10 mL of 1M HCl, 10 mL of sat. NaHCO 3 , and 10 mL of sat. NaCl. The organic phase was dried (Na 2 SO 4 ), and the solvent removed in vacuo. The residue purified by flash column chromatography or preperative HPLC to provide I-20.
Representative Examples
4-(4-((4-fluorophenethyl)carbamoyl)-2-benzamidophenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0140]
[0141] (δ II , 300 MHz, CDCl 3 ) 1.21 (t, 3H), 2.12 (m, 2H), 3.02 (t, 2H), 3.16 (m, 2H), 3.22 (m, 2H), 3.39 (dq, 2H), 3.75 (m, 6H), 4.58 (bt, 1H) 6.68 (bt, 1H), 7.08 (t, 2H), 7.36 (m, 3H), 7.64 (m, 2H), 7.76 (dd, 1H), 8.00 (dd, 1H), 8.92 (d, 1H), 9.50 (bs, 1H); ESI, 532 └M+H┘.
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(furan-4-carboxamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0142]
[0143] (δ H , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.12 (m, 2H), 3.09 (m, 4H), 3.28 (m, 2H), 3.42 (dq, 2H), 3.74 (m, 2H), 3.80 (m, 4H), 4.47 (bt, 1H) 6.50 (bt, 1H), 6.83 (d, 1H), 7.40 (m, 3H), 7.53 (s, 1H), 7.64 (m, 1H), 7.79 (dd, 1H), 8.21 (d, 1H), 8.83 (d, 1H), 9.04 (bs, 1H); ESI, 572 └M+H┘
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(cyclopropanecarboxamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0144]
[0145] (δ H , 300 MHz, CDCl 3 ) 1.00 (m, 2H), 1.11 (m, 2H), 1.24 (t, 3H), 2.01 (m, 1H), 2.13 (m, 2H), 3.12 (t, 2H), 3.21 (m, 4H), 3.42 (dq, 2H), 3.64 (t, 2H), 3.79 (m, 4H), 4.60 (bt, 1H) 6.56 (bt, 1H), 7.25 (m, 3H), 7.46 (d, 1H), 7.74 (dd, 1H), 8.72 (d, 1H), 8.84 (bs, 1H); ESI, 546 [M+H]
(+/−)-4-(2-(3-chlorobenzamido)-4-((2-phenylpropyl)carbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0146]
[0147] (δ H , 300 MHz, CDCl 3 ) 1.25 (t, 3H), 1.48 (d, 3H), 2.12 (m, 2H), 3.15 (m, 5H), 3.40 (dq, 2H), 3.58 (m, 1H), 3.71 (t, 2H), 3.80 (m, 2H), 3.88 (m, 1H), 4.45 (t, 1H) 6.37 (bt, 1H), 7.40 (m, 5H), 7.65 (m, 4H), 7.84 (dt, 1H), 8.05 (m, 1H), 8.83 (d, 1H), 9.48 (bs, 1H); ESI, 562 [M+H].
4-(2-(3-chlorobenzamido)-4-(isopropylcarbamoyl)phenyl)-acetyl-1,4-diazepane
[0148]
[0149] (δ H , 300 MHz, CD 3 OD) 1.38 (d, 6H), 2.05 (m, 2H), 2.10 and 2.22 (2s, 3H), 3.28 (m, 2H), 3.40 (m, 2H), 3.80 (m, 4H), 4.30 (m, 1H), 7.39 (m, 1H), 7.70 (m, 3H), 8.01 (m, 1H), 8.12 (m, 1H), 8.25 (dd, 1H); ESI, 457 [M+H].
4-(4-(((+/−)trans-2-phenylcyclopropyl)carbamoyl)-2-(3,5-difluorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0150]
[0151] (δ H , 300 MHz, CDCl 3 ) 1.27 (t, 3H), 1.45 (m, 3H), 2.15 (m, 2), 2.32 (m, 1H, 3.20 (m 3H), 3.26 (m, 2H), 3.40 (dq, 2H), 3.70 (t, 2H), 3.83 (m, 2H), 4.48 (t, 1H) 6.73 (bd, 1H), 7.15 (tt, 1H), 7.40 (m, 6H), 7.53 (m, 2H), 7.86 (dd, 1H), 8.85 (d, 1H), 9.48 (bs, 1H); ESI, 562 [M+H].
4-(2-(3-chlorobenzamido)-4-((3-phenylpropyl)carbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0152]
[0153] (δ H , 300 MHz, CDCl 3 ) 1.26 (t 3H), 2.12 (m, 4H), 2.85 (t 2H), 3.20 (m, 2H), 3.28 (m, 2H), 3.41 (dq, 2H), 3.62 (q, 2H), 3.73 (t, 2H), 3.81 (m, 2H), 4.45 (t 1H), 6.40 (bt, 1H), 7.35 (m, 6H), 7.65 (m, 2H), 7.79 (dd, 1H), 7.87 (dt, 2H), 8.91 (d, 1H), 9.52 (bs, 1H); ESI, 562 [M+H].
4-(4-((4-chlorobenzyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0154]
[0155] (δ H , 300 MHz, CDCl 3 ) 1.21 (t 3H), 2.13 (m, 2H), 3.18 (m, 2H), 3.24 (m, 2H), 3.71 (dq, 2H), 3.71 (t, 2H), 3.80 (m, 2H), 4.52 (bt, 1H) 4.71 (d, 2H), 6.87 (bt, 1H), 7.38 (m, 5H), 7.61 (m, 2H); 7.82 (dd, 2H), 8.00 (dd, 1H), 8.97 (d, 1H), 9.50 (bs, 1H); ESL 568 [M+H].
4-(4-((4-chlorophenethyl)carbamoyl)-2-benzamidophenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0156]
[0157] (δ H , 300 MHz, CDCl 3 ) 1.21 (t, 3H), 2.08 (m, 2H), 3.02 (t, 2H), 3.15 (m, 2H), 3.25 (m, 2H), 3.38 (dq, 2H), 3.72 (m, 6H), 4.58 (bt, 1H), 4.71 (d, 2H), 6.72 (bt, 1H), 7.27 (m, 6H), 8.00 (dd, 1H), 8.92 (d, 1H)) 9.50 (bs, 1H); ESI, 548 [M+H].
4-(2-(3-chlorobenzamido)-4-((naphthalen-1-ylmethyl)carbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0158]
[0159] (δ H , 300 MHz, CDCl 3 ) 1.23 (t, 3H), 2.12 (m, 2H), 3.17 (m, 2H), 3.23 (m, 2H), 3.39 (dq, 2H), 3.72 (t, 2H), 3.80 (m, 2H), 4.41 (bt, 1H), 5.22 (d, 2H), 6.63 (bt, 1H), 7.60 (m, 7H), 7.82 (dt, 2H), 7.97 (m, 3H), 8.22 (d, 1H), 9.47 (bs, 1H); ESI, 584 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-isopropyl-1,4-diazepane-1-carboxamide
[0160]
[0161] (δ H , 300 MHz, CDCl 3 ) 1.21 (d, 6H), 2.12 (m, 2H), 3.17 (m, 4H), 3.24 (m, 2H), 3.71 (t, 2H), 3.80 (m, 1H), 4.31 (bd, 1H), 6.48 (bt, 1H), 7.35 (m, 3H), 7.51 (d, 1H), 7.62 (m, 2H), 7.78 (dd, 1H), 7.84 (d, 1H), 8.02 (d, 1H), 8.90 (d, 1H), 9.52 (bs, 1H); ESI, 630 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(4-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0162]
[0163] (δ II , 300 MHz, CDCl 3 ) 1.21 (t, 3H), 2.04 (m, 2H), 3.12 (t, 4H), 3.23 (m, 2H), 3.38 (dq, 2H), 3.68 (m, 6H), 4.56 (bt, 1H), 6.60 (bt, 1H), 7.35 (m, 3H), 7.48 (s, 1H), 7.62 (d, 2H), 7.75 (dd, 1H), 7.95 (d, 2H), 8.89 (d, 1H), 9.49 (bs, 1H); ESI, 616 └M+H┘.
4-(4-((4-chlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0164]
[0165] (δ H , 300 MHz, CDCl 3 ) 1.23 (t, 3H), 2.12 (m, 2H), 3.71 (t, 2H), 3.18 (m, 2H), 3.24 (m, 2H), 3.40 (dq, 2H), 3.80 (m, 6H), 4.49 (bt, 1H), 6.52 (bt, 1H), 7.35 (m, 5H), 7.62 (m, 2H), 7.77 (dd, 2H), 7.83 (d, 1H), 8.02 (d, 1H), 8.87 (d, 1H), 9.53 (bs, 1H); ESI, 582 ℑM+H┘.
4-(4-((2-chlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0166]
[0167] (δ H , 300 MHz, CDCl 3 ) 1.23 (t, 3H), 2.12 (m, 1H), 3.18 (m, 6H), 3.40 (dq, 2H); 3.71 (t, 2H), 3.80 (m, 4H), 4.52 (bt, 1H), 6.59 (bt 1H), 7.35 (m 5H), 7.62 (m, 2H), 7.77 (dd, 1H), 7.83 (d, 1H), 8.02 (d, 1H), 8.87 (d, 1H), 9.53 (bs, 1H); ESI, 582 └M+H┘.
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-methoxybenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0168]
[0169] (δ H , 300 MHz 9, CDCl 3 ) 1.22 (t 3H), 2.12 (m, 2H), 3.16 (m, 4H), 3.22 (m, 2H), 3.39 (dq, 2H), 3.72 (t, 2H), 3.80 (m, 4H), 4.00 (s, 3H), 4.52 (bt, 1H), 6.61 (bt, 1H), 7.21 (dd, 1H), 7.30 (m, 3H), 7.52 (m, 4H), 7.79 (dd, 1H), 8.92 (d, 1H), 8.87 (d, 1H), 9.50 (bs, 1H); ESI, 612 [M+H].
4-(4-(benzylcarbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0170]
[0171] (δ H , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.15 (m, 2H), 3.18 (m, 2H), 3.25 (m, 2H), 3.39 (dq, 2H), 3.72 (t, 2H), 3.80 (m, 4H), 4.58 (bt, 1H), 4.78 (d, 2H), 6.79 (bt, 1H), 7.40 (m, 6H), 7.60 (m, 2H), 7.82 (m, 2H), 8.02 (d, 1H), 8.96 (d, 1H), 9.53 (bs, 1H), ESI 534 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(2-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0172]
[0173] (δ H , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.05 (m, 2H), 3.16 (m, 6H), 3.37 (dq, 2H), 3.61 (t, 2H), 3.72 (m, 2H), 3.79 (q, 2H), 4.47 (bt, 1H), 6.61 (bt, 1H), 7.38 (m, 3H), 7.58 (m, 4H), 7.78 (dd, 1H), 7.88 (dd, 1H), 8.97 (d, 1H), 9.40 (bs, 1H); ESI, 616 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(thiophene-2-carboxamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0174]
[0175] (δ H , 300 MHz, CDCl 3 ) 1.23 (t 3H), 2.18 (m, 2H), 3.18 (m, 4H), 3.24 (m, 2H), 3.41 (dq, 2H), 3.80 (m, 6H), 4.50 (bt, 1H), 6.52 (bt, 1H), 7.38 (m, 4H), 7.50 (d, 1H), 7.69 (d, 1H), 7.80 (m, 2H), 8.84 (d, 1H), 9.39 (bs, 1H); ESI, 588 └M+H┘.
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-methyl-1,4-diazepane-1-carboxamide
[0176]
[0177] (δ H , 300 MHz, CDCl 3 ) 2.13 (m, 2H), 2.91 (d, 3H), 3.19 (m, 4H), 3.24 (m, 2H), 3.71 (t, 2H), 3.80 (m, 4H), 4.58 (bq, 1H), 6.58 (bt, 1H), 7.38 (m, 2H), 7.50 (d, 1H), 7.64 (m, 2H), 7.75 (dd, 2H), 7.83 (dd, 1H), 8.02 (d, 1H), 8.88 (d, 1H); 9.50 (bs, 1H); ESI 602 [M+H].
4-(2-benzamido-4-((3-phenylpropyl)carbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0178]
[0179] (δ H , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.08 (m, 4H), 2.81 (t, 2H), 3.15 (m, 2H), 3.23 (m, 2H), 3.39 (dq, 2H), 3.59 (q, 2H), 3.70 (t, 2H), 3.78 (m, 2H), 4.60 (bt, 1H), 6.62 (bt, 1H), 7.38 (m, 6H), 7.62 (m, 3H), 7.76 (dd, 1H), 8.00 (d, 2H), 8.92 (d, 1H), 9.53 (bs, 1H); ESI 528 [M+H].
4-(2-(3-chlorobenzamido)-4-(3,4-dimethoxyphenethylcarbamoyl)phenyl)acetyl-1,4-diazepane
[0180]
[0181] (δ H , 300 MHz, CD 3 OD) 2.03 (m, 2H), 2.08 and 2.22 (2s, 3H), 2.95 (t, 2H), 3.30 (m, 2H), 3.66 (t, 2H), 3.75 (t 2H), 3.82 (m, 4H) 3.86 (s, 3H), 3.89 (s, 3H), 6.95 (m, 3H), 7.38 (m, 1H), 7.70 (m, 3H), 8.00 (m, 1H), 8.12 (m, 1H), 8.30 (dd, 1H); ESI 579 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-cyanobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0182]
[0183] (δ H , 300 MHz, CDCl 3 ) 1.10 (t, 3H), 2.97 (m, 2H), 3.06 (m, 4H), 3.15 (m, 2H), 3.25 (m, 2H), 3.57 (t, 2H), 3.67 (m, 4H), 4.36 (t, 1H), 6.32 (t 1H), 7.19 (m, 2H), 7.27 (m, 1H), 7.38 (d, 1H), 7.68 (m, 2H), 7.83 (m, 1H), 8.07 (m, 1H), 8.23 (m, 1H), 8.72 (d, 1H), 9.43 (bs, 1H); ESI, 607 [M+H].
4-(4-((3-chlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0184]
[0185] (δ II , 300 MHz, CDCl 3 ) 1.25 (t, 3H), 2.14 (m, 2H), 3.05 (m, 2H), 3.19 (m, 2H), 3.28 (m, 2H), 3.40 (dq, 2H), 3.72 (t, 2H), 3.81 (m, 4H), 4.43 (t, 1H), 6.50 (t, 1H), 7.26 (m, 1H), 7.40 (m, 5H), 7.65 (m, 2H), 7.79 (dd, 1H), 7.86 (dt, 1H), 8.05 (m, 1H), 8.89 (d, 1H), 9.51 (bs, 1H); ESI, 582 └M+H┘.
4-(4-((4-chloro-2-methylphenethyl)carbamoyl)-2-(4-fluorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0186]
[0187] (δ II , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.10 (m, 1H), 3.12 (m, 4H), 3.22 (m, 2H), 3.38 (dq, 2H), 3.64 (t, 2H), 3.76 (m, 4H), 4.60 (t, 1H), 6.67 (t, 1H), 7.30 (m, 5H), 7.48 (d, 1H), 7.75 (dd, 1H), 8.00 (m, 2H), 8.86 (d, 1H), 9.47 (bs, 1H); ESI, 600 └M+H┘.
4-(2-(3-chlorobenzamido)-4-(isopropylcarbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0188]
[0189] (δ II , 300 MHz, CDCl 3 ) 1.24 (t, 3H), 1.40 (d, 6H), 2.10 (m, 2H), 3.16 (m, 2H), 3.24 (m, 2H), 3.40 (m, 2H), 3.72 (m, 2H), 3.81 (m, 2H), 4.40 (m, 1H), 4.65 (bt, 1H), 6.33 (d, 1H), 7.38 (t, 1H), 7.62 (m, 2H), 7.80 (m, 2H), 8.00 (s, 1H), 8.86 (s, 1H), 9.55 (bs, 1H); ESI, 486 └M+H┘.
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-isobutyramidophenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0190]
[0191] (δ II , 300 MHz, CDCl 3 ) 1.24 (t, 3H), 1.38 (d, 6H), 2.12 (m 2H), 2.80 (m, 1H), 3.18 (m, 6H), 3.42 (dq, 2H), 3.64 (m, 2H), 3.78 (m, 4H), 4.56 (bt, 1H), 6.48 (d, 1H), 7.25 (m, 3H), 7.50 (d, 1H), 7.77 (dd, 1H), 8.68 (bs, 1H), 8.82 (d, 1H); ESI, 486 [M+H].
4-(2-benzamido-4-(4-methylphenethylcarbamoyl)phenyl)-N-ethyl-1,4-diazepane-4-carboxamide
[0192]
[0193] (δ H , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.12 (m, 2H), 2.42 (s, 3H), 3.00 (t, 2H), 3.18 (m, 2H), 3.23 (m, 2H), 3.40 (dq, 2H), 3.70 (t, 2H), 3.78 (m, 4H), 4.58 (bt, 1H), 6.52 (bt, 1H), 7.22 (s 4H), 7.39 (m, 2H), 7.70 (m, 4H), 8.02 (dd, 1H), 8.94 (d, 1H), 9.52 (bs, 1H); ESI, 528 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-fluorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0194]
[0195] (δ H , 300 MHz, CDCl 3 ) 1.22 (t 3H), 2.10 (m, 2H), 3.18 (m, 4H), 3.22 (m, 2H), 3.38 (dq, 2H), 3.68 (t, 2H), 3.78 (m, 4H), 4.58 (bt, 1H), 6.61 (bt, 1H), 7.38 (m, 3H), 7.46 (d, 2H), 7.61 (m, 2H), 7.74 (m, 3H), 8.86 (d, 1H), 9.48, (bs, 1H); ESI, 600 [M+H].
1-(2-(4-(ethylcarbamoyl)-1,4-diazepan-1-yl)-5-(isopropylcarbamoyl)phenyl)-3-phenylurea
[0196]
[0197] (δ H , 300 MHz, CDCl 3 ) 1.27 (t, 3H), 1.36 (d, 6H) 1.98 (m, 2H), 3.15 (m, 2H), 3.36 (m, 2H), 3.42 (m, 2H), 3.59 (m, 2H), 3.80 (m, 2H), 4.38 (m, 1H), 5.09 (t, 1H), 6.43 (d, 1H), 7.18 (m, 2H), 7.40 (m, 2H), 7.75 (d, 2H), 8.10 (s, 1H), 8.80 (s, 1H), 9.60 (bs, 1H); ESI 467 [M+H].
4-(2-(3-chlorobenzamido)-4-((2,3-dihydro-1H-1-inden-1-yl)carbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0198]
[0199] (δ H , 300 M CDCl 3 ) 1.26 (t, 3H), 2.10 (r, 3H), 2.83 (m, 1H), 3.06 (m, 1H), 3.20 (m, 3H), 3.19 (m, 2H), 3.29 (m, 2H), 3.41 (dq, 2H), 3.72 (t, 2H), 3.81 (m, 2H), 4.46 (t, 1H), 5.84 (q, 1H), 6.63 (d, 1H), 7.35 (m, 4H), 7.47 (m, 1H), 7.63 (m, 2H), 7.85 (m, 2H), 8.02 (m, 1H), 8.92 (d, 1H), 9.50 (bs, 1H); ESL 560 [M+H].
4-(4-((2-fluorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0200]
[0201] (δ H , 300 MHz CDCl 3 ) 1.25 (t, 3H), 2.13 (m, 2H), 3.12 (t, 1H), 3.03 (m, 2H), 3.19 (m, 2H), 3.28 (m, 2H), 3.40 (dq, 2H), 3.72 (t, 2H), 3.80 (m, 4H), 4.47 (t, 1H) 6.53 (bt, 1H), 7.20 (m, 2H), 7.38 (m, 3H), 7.65 (m, 2H), 7.78 (dd, 1H), 7.86 (dt, 1H), 8.04 (m, 1H), 8.90 (d, 1H), 9.51 (bs, 1H); ESI, 566 [M+H].
4-(4-((4-fluorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0202]
[0203] (δ H , 300 MHz, CDCl 3 ) 1.26 (t, 3H), 2.15 (m, 2H), 3.03 (m, 2H), 3.319 (m, 2H), 3.28 (m, 2H), 3.41 (dq, 2H), 3.72 (t, 2H), 3.80 (m, 4H), 4.46 (t, 1H) 6.48 (bt, 1H), 7.14 (t, 2H), 7.35 (m, 3H), 7.64 (m, 2H), 7.78 (dd, 1H), 7.86 (dt, 1H), 8.03 (m, 1H), 8.89 (d, 1H), 9.51 (bs, 1H); ESL 566 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-propyl-1,4-diazepane-1-carboxamide
[0204]
[0205] (δ H , 300 MHz, CDCl 3 ) 1.02 (t, 3H), 1.62 (q, 2H), 2.12 (m, 2H), 3.18 (m, 4H), 3.26 (m, 4H), 3.71 (m, 2H), 3.80 (m, 4H), 4.57 (bt, 1H), 6.52 (bt, 1H), 7.35 (m, 3H), 7.52 (s, 1H), 7.61 (m, 2H), 7.78 (m, 1H), 8.82 (m, 1H), 8.03 (m, 1H), 8.92 (d, 1H), 9.53 (bs, 1H); ESI, 630 [M+H].
4-(4-(((+/−)-trans-2-phenylcyclopropyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0206]
[0207] (δ H , 300 MHz, CDCl 3 ) 1.26 (t, 3H), 1.43 (m, 3H), 2.15 (m, 2H), 2.32 (m, 1H), 3.20 (m, 2H), 3.28 (m, 2H), 3.41 (dq, 2H), 3.72 (t, 2H), 3.82 (m, 2H), 4.46 (t, 1H), 6.75 (bs, 1H), 7.35 (m, 6H), 7.65 (m, 2H), 7.87 (m, 2H), 8.04 (m, 1H), 8.90 (d, 1H), 9.54 (bs, 1H); ESL 560 [M+H].
4-(4-((3,4-dimethoxyphenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0208]
[0209] (δ H , 300 MHz, CDCl 3 ) 1.25 (t, 3H), 2.15 (m, 2H), 3.03 (m, 2H), 3.19 (m, 2H), 3.28 (m, 2H), 3.43 (m, 2H), 3.72 (t, 2H), 3.80 (m, 4H), 3.98 (s, 6H), 4.50 (bt, 1H) 6.65 (bt, 1H), 6.95 (m, 3H), 7.30-8.20 (m, 6H), 8.90 (d, 1H) 9.51 (bs, 1H); ESL, 608 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3,5-difluorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0210]
[0211] (δ H , 300 MHz, CDCl 3 ) 1.23 (t, 3H), 2.18 (m, 2H), 3.16 (m, 4H), 3.22 (m, 2H), 3.42 (dq, 2H), 3.71 (t, 2H), 3.80 (m, 4H), 4.60 (bt, 1H) 6.68 (bt, 1H), 7.18 (dt, 3H), 7.38 (m, 3H), 7.52 (m, 3H), 7.79 (dd, 1H), 8.80 (d, 1H), 9.46 (bs, 1H); ESI, 618 [M+H].
4-(4-((2,4-dichloropenethyl)carbamoyl)-2-(2-fluorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0212]
[0213] (δ H , 300 MHz, CDCl 3 ) 1.23 (t, 3H), 2.18 (m, 2H), 3.16 (m, 6H), 3.40 (dq, 2H), 3.71 (t, 2H), 3.80 (m, 4H), 4.60 (bt, 1H) 6.64 (bt, 1H), 7.30 (m, 4H), 7.42 (m, 2H), 7.63 (m, 1H), 7.76 (dd, 1H), 8.35 (dt, 1H), 9.00 (d, 1H); ESI, 600 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-1,4-diazepane
[0214]
[0215] (δ H , 300 MHz CDCl 3 ) 1.83 (m, 2H), 3.05 (m, 8H), 3.20 (t, 2H), 3.67 (q, 2H), 6.34 (bt, 1H), 7.22 (m, 3H), 7.36 (d, 1H), 7.45 (d, 1H), 7.52 (m, 1H), 7.65 (dd, 1H), 7.85 (m, 1H), 8.03 (m, 1H), 8.73 (m, 1H), 9.82 (bs, 1H); ESI, 545 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0216]
[0217] (δ H , 300 MHz, CDCl 3 ) 1.12 (t, 3H), 2.00 (m, 2H), 3.05 (m, 4H), 3.13 (m, 2H), 3.26 (m, 2H), 3.58 (t, 2H), 3.67 (m, 4H), 4.33 (t, 1H), 6.32 (t, 1H), 7.20 (m, 2H), 7.25 (m, 1H) 7.38 (d, 1H), 7.48 (m, 1H), 7.54 (m, 1H), 7.64 (dd, 1H), 7.73 (m, 1H), 7.90 (m, 1H), 8.77 (d, 1H), 9.38 (bs, 1H); ESI, 616 [M+H].
(+/−)-4-(2-(3-chlorobenzamido)-4-((1,2,3,4-tetrahydronaphthalen-1-yl)carbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0218]
[0219] (δ H , 300 MHz, CDCl 3 ) 1.26 (t, 3H), 2.10 (m, 6H), 2.95 (m, 2H), 3.18 (m, 2H), 3.27 (m, 2H), 3.40 (dq, 2H), 3.71 (t, 2H), 3.82 (m, 2H), 4.45 (t, 1H), 5.03 (m, 1H) 6.64 (d, 1H), 7.25 (m, 3H), 7.42 (m, 2H) 7.62 (m, 2H), 7.85 (m, 2H), 8.01 (t, 1H), 8.90 (d, 1H), 9.49 (bs, 1H); ESI, 574 [M+H].
4-(4-(((+/−)(-trans-)-2-phenylcyclopropyl)carbamoyl)-2-benzamidophenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0220]
[0221] (δ H , 300 MHz, CDCl 3 ) 1.23 (t, 3H), 1.40 (m, 3H), 2.10 (m, 2H), 2.30 (m, 1H), 3.18 (m, 2H), 3.24 (m, 2H), 3.40 (dq, 2H), 3.74 (t, 2H), 3.80 (m, 2H), 4.53 (t, 1H), 6.80 (d, 1H), 7.35 (m, 6H), 7.65 (m, 3H), 7.82 (dd, 1H), 8.02 (d, 2H), 8.96 (d, 1H), 9.54 (bs, 1H); ESI, 526 └M+H┘.
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(isoxazole-5-carboxamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0222]
[0223] (δ II , 300 MHz CDCl 3 ) 1.24 (t, 3H), 2.14 (m, 2H), 3.18 (m, 4H), 3.22 (m, 2H), 3.43 (dq, 2H), 3.78 (m, 4H), 3.91 (m, 2H), 4.52 (bt, 1H), 6.42 (bt, 1H), 7.19 (d, 1H), 7.30 (m, 3H), 7.52 (d, 1H), 7.79 (dd, 1H), 8.54 (d, 1H), 7.84 (d, 1H), 9.85 (bs, 1H); ESI, 573 └M+H┘.
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(thiophene-4-carboxamide)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0224]
[0225] (δ H , 300 MHz, CDCl 3 ) 1.23 (t 3H), 2.10 (m, 2H), 3.15 (m, 4H), 3.25 (m, 2H), 3.43 (dq, 2H), 3.72 (t, 2H), 3.78 (m, 4H), 4.54 (bt, 1H), 6.58 (bt, 1H), 7.35 (m, 3H), 7.48 (d, 1H), 7.56 (m, 1H), 7.62 (m, 1H), 7.77 (dd, 1H), 8.14 (d, 1H), 8.86 (d, 1H), 9.85 (bs, 1H); ESI, 588 └M+H┘.
4-(4-((3-fluorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0226]
[0227] (δ II , 300 MHz, CDCl 3 ) 1.26 (t, 3H), 2.14 (m, 2H), 3.06 (t, 2H), 3.18 (m, 2H), 3.28 (m, 2H), 3.41 (dq, 2H), 3.72 (m, 2H), 3.81 (m, 4H), 4.46 (t, 1H), 6.50 (t, 1H), 7.05 (r, 2H), 7.16 (d, 1H), 7.40 (m, 2H), 7.62 (m, 2H), 7.78 (dd, 1H), 7.85 (dt, 1H), 8.03 (m, 1H), 8.89 (d, 1H), 9.51 (bs, 1H); ESI, 566 ┌M+H┐.
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(furan-2-carboxamido)phenyl)-N-ethyl-1,4-diazepine-1-carboxamide
[0228]
[0229] (δ H , 300 MHz, CDCl 3 ) 1.24 (t. 3H), 2.20 (m, 2H), 3.12 (4H), 3.22 (m, 2H), 3.41 (dq, 2H), 3.80 (m, 6H), 4.59 (bt, 1H), 6.58 (bt, 1H), 6.70 (dd, 1H), 7.38 (m, 4H), 7.46 (d, 1H), 7.67 (d, 1H), 7.75 (dd, 1H), 8.86 (d, 1H), 9.60 (bs, 1H); ESI, 572 └M+H┘.
4-(4-((2,4-dichlorophenethyl)carbamoyl-2-(isonicotinamido)phenyl)-N-ethyl-1,4-diazepan-1-carboxamide
[0230]
[0231] (δ II , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.10 (m, 2H), 3.19 (m, 4H), 3.28 (m, 2H), 3.38 (dq, 2H), 3.71 (t, 2H), 3.79 (m, 4H), 4.43 (bt, 1H), 6.43 (bt, 1H), 7.38 (m, 3H), 7.51 (d, 1H), 7.80 (d, 1H), 7.83 (d, 2H), 8.92 (d, 1H); 8.99 (d, 2H), 9.63 (bs, 1H); ESL 583 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-butyl-1,4-diazepane-1-carboxamide
[0232]
[0233] (δ H , 300 MHz, CDCl 3 ) 1.02 (t, 3H), 1.43 (m, 2H), 1.62 (m, 2H), 2.12 (m, 2H), 3.18 (m, 4H), 3.24 (m, 2H), 3.37 (m, 2H), 3.71 (t, 2H), 3.79 (m, 4H), 4.51 (bt, 1H), 6.53 (bt, 1H), 7.38 (m, 3H), 7.50 (d, 1H), 7.78 (dd, 1H), 7.82 (d, 2H), 8.02 (d, 1H), 8.84 (d, 2H), 9.53 (bs, 1H); ESL, 644 [M+H].
4-(2-(3-chlorobenzamido)-4-(phenethylcarbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0234]
[0235] (δ H , 300 MHz, CDCl 3 ) 1.24 (t, 3H), 2.12 (m, 2H), 3.04 (t, 2H), 3.18 (m, 2H), 3.24 (m, 2H), 3.39 (dq, 2H), 3.71 (t, 2H), 3.80 (m, 4H), 4.54 (bt, 1H), 6.54 (bt, 1H), 7.40 (m, 6H), 7.62 (m, 2H) 7.77 (dd, 1H), 7.84 (dt, 2H), 8.02 (d, 1H), 8.86 (d, 2H), 9.52 (bs, 1H); ESI, 548 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-(3,4-difluorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0236]
[0237] (⊕ H , 300 MHz, CDCl 3 ) 1.22 (t, 3H), 2.10 (m, 2H), 3.14 (m, 4H), 3.24 (m, 2H), 3.39 (dq, 2H), 3.70 (t, 2H), 3.78 (m, 4H), 4.57 (bt, 1H), 6.56 (bt, 1H), 7.35 (m, 3H), 7.44 (m, 2H), 7.72 (m, 2H), 7.91 (dt, 2H), 8.82 (d, 1H), 9.44 (bs, 1H); ESI, 618 [M+H].
4-(4-((4-methylphenethyl)carbamoyl)-2-(3-chlorobenzamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0238]
[0239] (δ H , 300 MHz, CDCl 3 ) 1.27 (t, 3H), 2.13 (m, 2H), 2.45 (s, 3H), 3.02 (t, 2H), 3.18 (m, 2H), 3.27 (m, 2H), 3.41 (dq, 2H), 3.72 (m, 2H), 3.81 (m, 4H), 4.44 (t, 1H), 6.40 (t, 1H), 7.39 (m, 4H), 7.65 (m, 2H), 7.78 (dd, 1H), 7.87 (dt, 1H), 8.05 (m, 1H), 8.90 (d, 1H), 9.51 (bs, 1H); ESL, 562 [M+H].
4-(2-(3-chlorobenzamido)-4-((2,3-dihydro-1H-inden-2-yl)carbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0240]
[0241] (δ H , 300 MHz, CDCl 3 ) 1.25 (t, 3H), 2.12 (m, 2H), 3.08 (dd, 2H), 3.17 (m, 2H), 3.26 (m, 2H), 3.40 (dq, 2H), 3.55 (dd, 2H), 3.71 (t, 2H), 3.82 (m, 2H), 4.45 (t, 1H), 5.06 (m, 1H), 6.72 (d, 1H), 7.35 (m, 3H), 7.62 (m, 3H), 7.82 (m, 3H), 8.03 (m, 1H), 8.84 (d, 1H), 9.49 (bs, 1H); ESI, 574 [M+H].
4-(4-((+/−)(trans-2-phenylcyclopropyl)carbamoyl)-2-(isonicotinamido)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0242]
[0243] (δ H , 300 MHz, CDCl 3 ) 1.23 (t, 3H), 1.40 (m, 3H), 2.10 (m, 2H), 2.30 (m, 1H), 3.20 (m, 2H), 3.26 (m, 2H), 3.38 (dq, 2H), 3.70 (t, 2H), 3.30 (m, 2H), 4.48 (t, 1H), 6.80 (d, 1H), 7.35 (m, 6H), 7.84 (m, 3H), 8.90 (d, 1H), 8.98 (d, 2H), 9.63 (bs, 1H); ESI 527 [M+H].
4-(2-(3-chlorobenzamido)-4-((2-(thiophen-2-yl)ethyl)carbamoyl)phenyl-N-ethyl-1,4-diazepane-1-carboxamide
[0244]
[0245] (δ H , 300 MHz, CDCl 3 ) 1.22 (t 3H), 2.14 (m, 2H), 3.19 (m, 2H), 3.23 (m, 2H), 3.38 (dq, 2H), 3.72 (t, 2H), 3.81 (m, 4H), 4.44 (t, 1H), 6.52 (t, 1H), 7.01 (d, 1H), 7.07 (dd, 1H), 7.28 (dd, 1H), 7.38 (m, 1H), 7.60 (m, 2H), 7.78 (dd, 1H), 7.84 (dd, 1H), 8.02 (d, 1H), 8.92 (d, 1H), 9.52 (bs, 1H); ESL 554 [M+H].
4-(2-(3-chlorobenzamido)-4-(isoquinolin-5-ylcarbamoyl)phenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0246]
[0247] (δ H , 300 MHz, CDCl 3 ) 1.25 (t, 3H), 2.18 (m, 2H), 3.24 (m, 2H), 3.32 (m, 2H), 3.41 (m, 2H), 3.74 (t, 2H), 3.85 (m, 2H), 4.48 (t, 1H), 7.48 (d, 1H), 7.65 (m, 2H), 7.78 (t, 1H), 7.87 (m, 2H), 7.99 (m, 2H), 8.08 (m, 1H), 8.34 (d, 1H), 8.71 (m, 2H), 9.26 (d, 1H), 9.41 (s, 1H), 9.55 (bs, 1H); ESI, 571 [M+H].
4-(4-((2,4-dichlorophenethyl)carbamoyl)-2-benzamidophenyl)-N-ethyl-1,4-diazepane-1-carboxamide
[0248]
[0249] (δ H , 300 MHz, CDCl 3 ) 1.10 (t, 3H), 2.00 (m, 2H), 3.05 (m, 4H), 3.15 (m, 2H), 3.28 (dq, 2H), 3.59 (t, 2H), 3.66 (m, 4H), 4.28 (t, 1H), 6.32 (t, 1H), 7.25 (m, 3H), 7.38 (d, 1H), 7.54 (m, 3H), 7.65 (dd, 1H), 7.89 (m, 2H), 8.82 (d, 1H), 9.40 (bs, 1H); ESL 582 [M+H].
[0000] The functional antagonists of the chemokine receptor CXCR3 disclosed above were identified based on the inhibition of both calcium mobilization and T-cell chemotaxis in response to stimulation with I-TAC. In addition, the compounds were shown to be non-cytotoxic.
CXCR3 FLIPR® Assays:
[0250] ACXCR3 cDNA clone, (sequence as listed in Genbank, accession number BD 195161) and chimeric G protein Gqi5, were used to construct a stably transfected HEK293 cell line using co-transfection protocols known to those of skill in the art. HEK293/CXCR3 G qi5 cells were seeded at 10,000 cells (25 μL) per well in poly (D-lysine)-treated 384-well plates (Costar, black clear-bottom cell culture-treated) 24-48 hours prior to the assay. Culture medium was removed and replaced with 25 μL of 50% cell culture medium/50% Calcium Plus Dye (Molecular Devices)/2.5 mM probenecid (Sigma). For dye loading, plates were incubated for 30 minutes at 37° C./5% CO 2 , followed by equilibration to room temperature for 30-90 min. Test compounds were diluted in 20 μL HBSS/20 mM HEPES, pH7.5/1% DMSO/0.1% BSA/2.5 probenecid. 12.5 μL test compound (or as controls, CXCL11/I-TAC to 40 nM or buffer alone, also with 1% DMSO) was added in the FLIPR® 384 to dye-loaded cells. 12.5 μL ITAC (R&D Systems), in HBSS/20 mM HEPES, pH 7.5/0.1% BSA, was then added to the cells/test compound, to a final concentration of 40 nM, and fluorescence measured once per second over the first minute, followed by an additional two minutes of one measurement/two seconds. All FLIPR® pipette tips were presoaked in 1% BSA prior to use in order to reduce adsorption of ligand.
CXCR3 Radioligand Binding Assay:
[0251] ( 125 I) CXCL10/IP-10 (NEN) at 25 nM was allowed to bind at 25° C. to crude HEK293/CXCR3 Gqi5 membrane preparations in 50 mM HEPES, pH 7.5, 5 mM MgCl 2 , 1 mM CaCl 2 , 0.5% BSA, 1% DMSO in the presence of test compounds. Reactions were filtered through 0.3% polyethyleneimine-blocked MAFCNOB filter plates (Millipore) and washed three times with ice-cold 50 mM HEPES, pH 7.5, 0.5 M NaCl, 0.1% BSA. 1 μM unlabeled CXCL9/Mig (Peprotech) was used to define nonspecific binding.
Cytotoxicity Assay
[0252] 20,000 HEK293/CXCR3 Gqi5 cells were seeded in clear 96-well tissue culture-treated plates in 50 μL, in culture medium without DMSO. 50 μL of the test compounds, (serially diluted in medium/2% DMSO) or Triton X-100/2% DMSO as a control were added, followed by incubation for 24 hours at 37° C./CO 2 . 10 uL WST-1 reagent (Roche) were added and plates incubated at 37° C. until color developed. After agitation of the plates for 5 minutes, absorbance at 450 nm was measured.
Formulations
[0253] While it may be possible for the compounds of the present invention to be administered as the raw chemical, it is preferable to present them as a pharmaceutical composition. According to a further aspect, the present invention provides a pharmaceutical composition comprising a compound of formula I or a pharmaceutically acceptable salt or solvate thereof, together with one or more pharmaceutically acceptable carriers thereof and optionally one or more other therapeutic ingredients, as discussed below. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
[0254] The formulations include those suitable for oral, parenteral (including subcutaneous, intradermal, intramuscular, intravenous and intraarticular), rectal and topical (including dermal, buccal, sublingual and intraocular) administration. The most suitable route may depend upon the condition and disorder of the Recipient. The formulations may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of bringing into association a compound of the invention or a pharmaceutically acceptable salt or solvate thereof (“active ingredient”) with the carrier which constitutes one or more accessory ingredients. In general, the formulations are prepared by uniformly and intimately bringing into association the active ingredient with liquid carriers or finely divided, solid carriers or both and then, if necessary, shaping the product into the desired formulation.
[0255] The term “pharmaceutically acceptable salt” refers to salts prepared from pharmaceutically acceptable non-toxic acids or bases including inorganic acids and bases and organic acids and bases. When the compounds of the present invention are basic, salts may be prepared from pharmaceutically acceptable non-toxic acids. Including inorganic and organic acids. Suitable pharmaceutically acceptable acid addition salts for the compounds of the present invention include acetic, benzenesulfonic (besylate), benzoic, camphorsulfonic, citric, ethenesulfonic, fumaric, gluconic, glutamic, hydrobromic, hydrochloric, isethionic, lactic, maleic, malic, mandelic, methanesulfonic, mucic, nitric, pamoic, pantothenic, phosphoric, succinic, sulfuric, tartaric acid, p-toluenesulfonic, and the like. When the compounds contain an acidic side chain, suitable pharmaceutically acceptable base addition salts for the compounds of the present invention include metallic salts made from aluminum, calcium, lithium, magnesium, potassium, sodium and zinc or organic salts made from lysine, N,N′-dibenzylethylenediamine, chloroprocaine, choline, diethanolamine, ethylenediamine, meglumine (N-methylglucamine) and procaine.
[0256] Formulations of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The active ingredient may also be presented as a bolus, electuary or paste. A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a hinder, lubricant, inert diluent, lubricating, surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide sustained, delayed or controlled release of the active ingredient therein.
[0257] Formulations for parenteral administration include aqueous and non-aqueous sterile injection solutions which may contain anti-oxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient. Formulations for parenteral administration also include aqueous and non-aqueous sterile suspensions, which may include suspending agents and thickening agents. The formulations may be presented in unit-dose of multi-dose containers, for example sealed ampules and vials, and may be stored in a freeze-dried (lyophilized) condition requiring only the addition of a sterile liquid carrier, for example saline, phosphate-buffered saline (PBS) or the like, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules and tablets of the kind previously described.
[0258] Formulations for rectal administration may be presented as a suppository with the usual carriers such as cocoa butter or polyethylene glycol. Formulations for topical administration in the mouth, for example buccally or sublingually, include lozenges comprising the active ingredient in a flavored basis such as sucrose and acacia or tragacanth, and pastilles comprising the active ingredient in a basis such as gelatin and glycerin or sucrose and acacia. It should be understood that in addition to the ingredients particularly mentioned above, the formulations of this invention may include other agents conventional in the art having regard to the type of formulation in question, for example those suitable for oral administration may include flavoring agents.
[0259] Preferred unit dosage formulations are those containing an effective dose, as recited below, or an appropriate fraction thereof, of the active ingredient. The compounds of the invention may be administered orally or via injection at a dose from 0.001 to 2500 mg/kg per day. The dose range for adult humans is generally from 0.005 mg to 10 g/day. Tablets of other forms of presentation provided in discrete units may conveniently contain an amount of compound of the invention which is effective at such dosage or as a multiplex of the same, for instance, units containing 5 mg to 500 mg, usually around 10 mg to 200 mg.
[0260] The compounds of formula (I) are preferably administered orally or by injection (intravenous or subcutaneous). The precise amount of compound administered to a patient will be the responsibility of the attendant physician. However, the dose employed will depend on a number of factors, including the age and sex of the patient, the precise disorder being treated, and its severity. Also, the route of administration may vary depending on the condition and its severity.
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CXCR3 inhibitors of formula
are disclosed. Inhibition of CXCR3 activation is useful for treating disorders resulting from CXCR3-associated T-cell mediated function, such as inflammatory bowel disease, multiple sclerosis, rheumatoid arthritis and diabetes, as well as in the prevention of allograft rejection. N-ethyl-1,4-diazepane-1-carboxamides in which R 1 is substituted or unsubstituted arylalkyl and R 3 is substituted or unsubstituted aryl are particularly preferred.
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The present invention relates to a water purification device and, more particularly, to a two-stage reverse-osmosis water purification device including a prefilter to remove impurities from the water that would otherwise have a detrimental effect on the longevity and efficiency of the reverse-osmosis filter element.
There has been a growing concern over the contamination of drinking water, extending even to water provided from municipal water supplies. Consequently, homeowners have taken a variety of measures to ensure an adequate supply of safe, clean drinking water, ranging from buying bottled water to installing water purification systems in their homes. While a variety of different types of home water purification systems are available (e.g., sediment filters, deionization systems, ion exchange/water softening systems, distillation systems, and activated carbon systems), systems utilizing reverse-osmosis filtration have proven superior in removing almost all types of pollutants with the greatest convenience and at reasonable expense. See, e.g., U.S. Pat. No. 3,542,199, which is herein incorporated by reference. A reverse-osmosis water purification device works, in general, by forcing water under pressure through a semipermeable membrane that permits water to pass through but is impermeable to certain impurities such as nitrates, heavy metals and salts, chemical fertilizers, and bacteria and viruses.
Water quality varies widely depending upon geographical location, and there has been a need to provide a single reverse-osmosis water purification system that works well with a minimal amount of servicing over a large range of locations, i.e., a system that will work uniformly well to purify tap water of widely varying quality. However, certain characteristics of the various materials used for reverse-osmosis filter membranes differ significantly. For example, cellulose acetate, a common reverse-osmosis membrane, is not bacteria-resistant (i.e., the bacteria commonly found in water use the cellulose acetate for food). Consequently, cellulose acetate membranes are generally used only where the water is chlorinated, which kills the bacteria. Further, cellulose acetate filter membranes are preferably used only with cold water having a low pH (less than 8). Certain other all-purpose membranes are bacteria-resistant, but are not usable with hard water. Polyamide filter membranes are usable under a greater variety of conditions than other membranes because they are resistant to bacteria and are effective through a wide range of temperatures and pHs. However, polyamide membranes are chlorine-degradable, but will function effectively for a reasonable period of time to produce quantities of drinking water sufficient for family use, provided the filter membrane is only exposed to low concentrations of chlorine (approximately 0.1-0.2 ppm of chlorine in the water that is forced through the reverse-osmosis membrane).
Activated carbon is known to adsorb chlorine. However, over time, the activated carbon becomes saturated with chlorine and its pores clogged with sediment carried in the water so that its effectiveness in removing chlorine from the water is drastically reduced. Activated carbon prefilters have been used in water purification systems which are mounted under the counter, where size constraints are not a great concern and large amounts of carbon can be used so as to provide a reasonable service-free life for the prefilter before the carbon becomes saturated with chlorine and clogged with sediment. Conversely, with over-the-counter water purification units (e.g., water purification units that either rest on the countertop or that "hang-on" or are affixed directly to the water faucet so as to be supported thereby), the size of the unit is a major factor affecting its acceptability to consumers. This size limitation has prevented the use of an amount of activated carbon sufficient to reduce the chlorine content of the water to a level of approximately 0.1-0.2 ppm for a reasonable amount of time, e.g., six months to a year, before becoming saturated with chlorine or, more likely, clogged with sediments, at which time the user must replace the prefilter.
Accordingly, it is a principal object of the present invention to provide an over-the-counter reverse-osmosis water purification system which is effective under a wide variety of water conditions and has a reasonable service life before replacement of the filter elements is required.
More particularly, it is an object to provide such a water purification system that, despite being required to use relatively small amounts of activated carbon due to size restrictions associated with over-the-counter systems, is able to effectively reduce the chlorine content of the water to a level that provides a reasonable service life for the reverse-osmosis filter membrane, while also having a similarly reasonable service life for the activated carbon prefilter.
These objects, as well as others that will become apparent upon reference to the following detailed description and accompanying drawing, are provided by a water purification system having a first pressure vessel containing a reverse-osmosis filter and a second separate pressure vessel containing an activated carbon prefilter operatively connected upstream of the first pressure vessel by means of a common header. The activated carbon prefilter includes a particulate trap upstream of the activated carbon to trap sediment carried in the unpurified water. The particulate trap is compressible under the operational water pressures attained when the trap becomes clogged with sediment to crack or break away the particles clogging the trap from the surface thereof, thus permitting flow to continue through the trap into the activated carbon and, subsequently, through the reverse-osmosis filter element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a water purification system embodying the instant invention secured to the nozzle of a faucet;
FIG. 2 is a cross-sectional view of the inventive water purification system showing the flow path of the water through the system;
FIG. 3 is an exploded cross-sectional perspective view of the prefilter shown in FIG. 2; and
FIG. 4 is a bottom view of the particulate trap shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to the figures of the drawing, which are by way of illustration and not limitation, there is seen a preferred embodiment of a "hang-on" type over-the-counter water purification system, generally indicated by 10, embodying the present invention. (To aid in the description of the water purification system 10, "downstream" will be used to indicate the direction of flow of water through the system during purification, while "upstream" indicates a direction through the system opposite the flow.) The system 10 includes a common header 11 which receives tap water through an inlet 12 (see FIG. 2) and directs it sequentially (as indicated by the numerous arrows) through filter elements contained in pressure vessels 14 and 15 that are screwed into the header 11, after which the pure water exits the header 11 at 16. The header 11 of the system 10 may be directly mounted to the nozzle 18 of a faucet 19 overlying a basin or sink 20, the interior of the inlet 12 of the header 11 being threaded at 21 to receive an adapter 22 to secure the header 11 to the nozzle 18. The adapter 22 may include a quick-disconnect coupling (not shown) of a known design to permit fast and simple attachment and removal of the system 10 with respect to the nozzle 18. Alternatively, the system 10 may be supported on the countertop adjacent the faucet 19 by a stand (not shown), the inlet 12 of the header 11 being connected to the nozzle 18 by a length of flexible tubing (also not shown) so that tap water may be introduced into the system 10.
After unpurified tap water enters the header 11, it is directed through a channel 24 in the header to the pressure vessel 14 having a compartment within which there is an activated carbon prefilter 25. After exiting the prefilter 25 at outlet 26, the water flows downstream through a channel 28 to enter the pressure vessel 15 having a compartment within which a reverse-osmosis filter element 29 is located. Purified water that passes radially inward through the filter element 29 exits an outlet 30 on the filter element 29 and reenters the header 11 to flow through a channel 31 to the outlet 16 of the header 11.
The reverse-osmosis filter element 29 is well-known in the art and includes a semipermeable membrane 32 spirally wrapped about a tubular core 34 in conjunction with a porous material (not shown) as described in U.S. Pat. No. 3,367,504, which is herein incorporated by reference. Specifically, the filter element 29 includes an envelope formed by a porous material in between two layers of a reverse-osmosis semipermeable membrane, with the envelope being spirally wound about the support core 34 with a separator grid separating adjacent envelopes. In practice, the filter element includes at least about 10 sq. cm of semi-permeable membrane surface area per cu. cm of volume of the filter element 29. The core 34 is closed at its lower end 35, but is open at its upper end 30, which is sealed with respect to the header 11 by means of an elastomeric O-ring gasket 36. The filter element 29 is sealed with respect to the pressure vessel 15 by means of a chevron-type seal 38 so that, during operation, water entering the pressure vessel 15 from the prefilter 25 from channel 28 is forced downwardly through the separator grid of the filter element 29, where a portion of the water permeates through the membrane and travels spirally inward through the porous material and into the support core 34 through the perforations 34a therein. This water is substantially free from impurities and flows upwardly through the filter outlet 30 and channel 31 to exit the system 10 through a swivel connection 39. As illustrated, the swivel connection 39 is sealed with respect to the header by means of an O-ring gasket 40 and includes a projecting tubular portion 44 with radial retaining ribs 42 for securing a length of flexible tubing 44 thereto. The tubing 44 extends to a separate reservoir (not shown) in which the purified water is collected and stored until needed.
The portion of the water entering the pressure vessel 15, but not permeating through the membrane and flowing into the support core 34, flows axially downwardly through the separator grid of the filter element 29, carrying all the impurities that do not pass through the membrane 32 to the bottom of the pressure vessel 15, where the water and impurities are discharged from the pressure vessel 15 through a capillary tube 45 into the sink 20. The capillary tube 45 extends through an opening 46 in the pressure vessel 15 and, due to its length and small diameter, provides resistance to flow therethrough to maintain the desired water pressure in the pressure vessel 15 which is sufficient to force a portion of the water entering the pressure vessel 15 through the semipermeable reverse-osmosis membrane 32. Thus, the flow rate is controlled by use of the capillary tube 45, which is held in place by an elastic ring 48 that serves as a sealing gasket at the opening 46 where the tube exits the pressure vessel housing. The ring 48 engages the exterior of the capillary tube 45 just inside of the pressure vessel 15, being located in a frustoconical seat 49 centered about the opening 46. An increase in pressure within the vessel 15 forces the elastic ring 48 into tighter contact with the tube 45 and frustoconical seat 49 to increase the seal to prevent untreated water from leaking from vessel 15. The amount of blowdown flow is controlled by the size of the inside diameter and the length of the capillary tube 45. The inside diameter will be about 0.5 mm and its length will be about 25 to 50 centimeters long. The tubing may also be coiled and placed inside the pressure vessel 15 except for the outlet end extending a short distance through the wall, or it can extend almost entirely outside as shown in FIG. 2.
In order to ensure that the amount of chlorine in the water entering the reverse-osmosis filter element 29 is sufficiently low so that the filter element 29 efficiently functions to provide an adequate supply of pure drinking water to an average-sized family over a period of six months to a year before replacement of the filter element 29 is required, unpurified tap water is initially passed through the activated carbon prefilter 25 supported in the pressure vessel 14. The prefilter 25 comprises a thin plastic cylindrical housing 50 having a recessed, bottom web 51 integral therewith and having perforations 51a. The cylinder 50 is filled with between approximately 60 to 150 grams, preferably about 80 grams, of activated carbon preferably having a particulate size between about approximately 0.5 mm and about 0.05 mm and a pore size of approximately 200 microns. Typically this amount of carbon will be used with a filter 29 having between about 250 and 2500 sq. cm. of membrane. To retain the activated carbon in the housing 50 and to prevent carbon fines from being carried into the reverse-osmosis filter 29, a porous polypropylene retaining disk 52 is placed within the housing 50 downstream of the activated carbon. After the housing 50 is filled with carbon, the retaining disk 52 is placed in the open upper end of the housing 50, which is then closed with a plastic top 54 ultrasonically welded to the housing 50. The retaining disk 57 may have a pore size of approximately 200 microns. The top 54 includes a raised central outlet port 55 received in a seat 56 in the header 11. The seat 56 is in fluid communication with the channel 28, and the carbon prefilter 25 is sealed with respect to the seat 56 by means of an O-ring gasket 58 received in a groove 59 on the exterior of the raised outlet port 55. Accordingly, no water may exit the pressure vessel 14 and enter the channel 28 leading to the reverse-osmosis filter element 29 without first passing through the carbon prefilter 25.
In keeping with the invention, means is provided for preventing the activated carbon in the prefilter 25 from becoming clogged with sediment or particulates carried in the unpurified tap water, thus preventing the activated carbon from becoming prematurely ineffective in its primary function of removing chlorine from the water, and consequently resulting in early end excessive chlorine degradation of the reverse-osmosis filter element 29. To this end, a particulate trap 60 in the form of a ring-shaped sponge is located within the pressure vessel 14 upstream of the activated carbon prefilter 25. The sponge 60 is preferably made of polyester and has a pore size less than that of the activated carbon in order to inhibit the entry of particulates into the housing 50 that could clog the pores in the activated carbon. As illustrated, the particulate trap sponge 60 is in the form of a disk or ring, sized in diameter to fit snugly on the exterior of the housing within the recess defined by the housing 50 and the bottom web 51. The sponge 60 has a central aperture 61 which is received upon an outwardly-extending cylindrical projection 62 on the bottom of the web 51 to positively locate the sponge with respect to the housing. While the central portion of the projecting member 62 is hollow, there are no perforations in the bottom web in the area circumscribed by the projection 62 so that all water flowing into the housing 50 must pass through the particulate sponge 60.
Over time, particulate matter will collect on the bottom exposed surface of the particulate trap sponge 60, restricting flow into the prefilter 25 and, consequently, reducing the rate at which water is purified by the system 10. However, as the pressure differential across the sponge 60 increases due to the clogging with sediment, the pressure will compress the sponge 60, cracking away from the surface of the sponge at least a portion of the caked-on sediment, thus opening additional pores through which water may flow through the perforations 51a in web 51 in the prefilter 25 and increasing the flow rate through the system 10. To encourage the particulate sponge 60 to deform when subjected to a pressure differential due to clogging of the particulate trap 60 with sediment, the sponge 60 is formed with a plurality of recesses or apertures 64 in the surface 65 between its radially inner and outer edges 66, 67, respectively. The recesses 64 extend only partially through the sponge 60 and serve to enhance the radial compression of the sponge 60 to effectively open up cracks in the sediment that may be caked onto the sponge. While the illustrated sponge 60 has a series of apertures 64, any holes, slots, concentric rings, etc. in the sponge 60 that permit radial pressure, as well as axial pressure, to act on the sponge will work equally well.
Eventually, the amount of sediment trapped by the sponge 60 will be sufficient to completely compress or collapse the sponge 60 against the support web 51, thus slowing down and eventually stopping the flow of tap water through the sponge 60. However, at such a time it is likely that the activated carbon in the entire prefilter 25 will still be able to adsorb chlorine from the tap water that passes therethrough. Accordingly, the entire prefilter 25 does not need to be replaced, but only the sponge 60 is cleaned. The system 10 can be restored to satisfactory operating conditions simply by unscrewing the pressure vessel 14 from the header 11 to remove the prefilter 25 from the pressure vessel, and then removing the sponge 60 from its recess and washing off the mud. The sponge 60 is then replaced onto the housing 50, and the prefilter 25 and pressure vessel are reassembled onto the header 11. Thus, even if the tap water contains large amounts of sediments that may require frequent simple cleaning of the particulate sponge 60, the activated carbon within the prefilter 25 can be used to nearly the full extent of its useful life as regards its primary function of removing chlorine.
To provide an example of the effectiveness of the above-described system, polyamide reverse-osmosis filter elements of the type used in the present invention, when subjected to tap water having approximately 1.5 ppm chlorine, have an "on-line" life of only between about 17 to 33 days during which the filter will reject 90 percent or more of most impurities. Operating the reverse-osmosis filter under such conditions would require replacing the filter element at least monthly--a frequency far too great to be suitable for home use. It is calculated that, if the level of chlorine in the tap water were approximately 0.2. ppm, an "on-line" life of from 100 to 250 days could be expected for the reverse-osmosis membrane. In the illustrated system, in order to produce between 3 and 6 gallons per day of purified water, the tap water flow rate to the system must be between approximately 40 to 160 ml per minute. At such a range of flow rates, an activated carbon prefilter of approximately 80 grams of activated carbon and having a particle size between approximately 200 to 1,000 microns, will remove between approximately 90-plus to 99-plus percent of the chlorine in the tap water having 1 ppm of chlorine. The particulate activated carbon is packed into the housing 50 so that it occupies about 150 cc of space, and in this condition, the effective "pore size" of the passageways through this packed particulate mass average about 200 microns. With the activated carbon being able to adsorb approximately 0.7 grams of chlorine for each gram of carbon, it is calculated that the 80 grams of carbon should be able to remove approximately 56 grams of chlorine, which corresponds to a flow of 1 ppm chlorine tap water at a rate of 160 ml per minute for 240 days. Accordingly, an activated carbon prefilter of the size contemplated by the present invention would, for a sufficiently long period of time, serve to reduce the chlorine in the water to be treated by the reverse-osmosis filter to a level that would provide a satisfactory "on-line" life for the reverse-osmosis filter membrane.
However, in addition to the chlorine, tap water may carry up to approximately 1 ppm of particulates or sediment. At a flow rate of 160 ml per minute, it is calculated that up to 38 grams of sediment could be deposited on the activated carbon in the prefilter over a period of six months. If such an amount of sediment were to cake on the activated carbon, it would significantly reduce the ability of the activated carbon to adsorb chlorine and thus impair its effectiveness. Thus, absent the above-described prefilter including a particulate trap means, an over-the-counter reverse-osmosis water purification system with a chlorine degradable membrane and having a reasonable service life could not be obtained.
Thus an over-the-counter purification system utilizing a reverse-osmosis filter is provided which is able to effectively reduce the chlorine content of the water to a level that provides a reasonable service life for the chlorine-degradable reverse-osmosis filter membrane, while using only relatively small amounts of activated carbon consistent with such over-the-counter environment. While the invention has been described in terms of the preferred embodiment, there is no intent to limit the invention to the same. On the contrary, it is intended to cover all equivalents and modifications within the scope of the appended claims.
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A water purification system having a first pressure vessel containing a reverse-osmosis filter and a second separate pressure vessel containing an activated carbon prefilter operatively connected in series and upstream of the first pressure vessel by means of a common header. The activated carbon prefilter includes a particulate trap upstream of the activated carbon to trap sediment carried in the unpurified water. The particulate trap is compressible under operational water pressures attained in the system when the trap becomes clogged with sediment, which serves to crack or break away from the surface thereof particle accumulations clogging the trap, permitting flow to continue through the trap into the activated carbon and, subsequently, through the reverse-osmosis filter element.
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BACKGROUND OF THE INVENTION
This application claims the benefit of U.S. Provisional Patent Applications Ser. No. 60/399,436 filed on Jul. 31, 2002, the entire disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
The invention relates generally to radiation sensors and, more particularly, to a UV radiometer that includes a collection unit with an attenuator having an entrance with one multi-stage input opening or plural input openings, or with at least one cavity for attenuating optical radiation, a detector and electronics to measure UV dose and UV irradiance applied to products and materials in a UV curing system or in other UV exposure systems.
BACKGROUND OF INVENTION AND DESCRIPTION OF PRIOR ART
In measuring of UV or other light irradiance and cumulative dose inside of UV chambers as well as in UV curing systems or in any UV emitting environment as from an output of UV light guides, the performance and efficiency of, e.g., a UV curing system, can be distorted due to contamination and degradation of UV lamps.
In the prior art, several UV radiometers have been developed for portable and stationary devices. U.S. Pat. No. 5,514,871 and U.S. Pat. No. 6,278,120 describes radiation sensors for measuring levels of ultraviolet intensity. They were developed for measuring high intensity radiation and have similar design for optical attenuation, which result in a large overall size because several optical elements are needed to be placed in a linear fashion, i.e., with a detector immediately following an attenuation device and directed toward a radiation source. U.S. Pat. No. 5,382,799 describes a radiation sensor for measuring levels of ultraviolet intensity which has a smaller size of the attenuator but the attenuation device requires several distinct parts, such as a diffuser window, one or more Teflon® diffusers, an aperture plate separated from the Teflon® diffuser by an O-ring, a cut glass filter, a spacer, etc., which result in challenges for reproducibility of the desired attenuation. U.S. Pat. No. 5,497,004 describes a radiation sensor with an attenuator made of a quartz glass. This sensor requires one or several discrete steps of attenuation conducted via complex elements, such as a dispersive element comprises a quartz glass having interior boundary surfaces, and an optical filter for visible light, to achieve appropriate attenuation.
There are several variants of optical attenuators described in the U.S. Pat. No. 6,167,185, U.S. Pat. No. 6,351,329, U.S. Pat. No. 6,292,616, U.S. Pat. No. 6,404,970, which share the same deficiencies as described previously.
There is a need for a compact radiation sensor with high radiation tolerance and less frequent calibration to maintain and monitor the level of UV irradiation and dose received from the light emitting device and level of exposure to the materials inside an exposure unit.
SUMMARY OF INVENTION
It is an object of the present invention to improve optical sensor designs for measuring UV radiation, especially with in a UV curing system.
It is another object of the present invention to improve the performance of radiation sensors using an attenuator with a high level of attenuation, which protects the UV detector from degradation after exposure of the radiation sensor to high doses of UV radiation.
It is a further object of the present invention to provide a way for ease of calibration of the sensor during manufacturing and subsequent calibration efforts.
It is also an object of the present invention to improve radiation sensor tolerance and extend a time period between calibration using information about temperature and total accumulated dose during the sensor operation.
Other objects and advantages of the present invention may be seen from the following detailed description
In accordance with the present invention, the radiation sensor has multiple attenuators to receive a high level of attenuation, a small sized detector unit and allows for ease of adjustment for the sensitivity of different detectors. Preferably, the radiation sensor has a multi-cavity attenuator, which has inside means for adjusting and filtering radiation. The radiation sensor has a micro controller, which allows for correcting an output signal if it is affected by detector aging, optical part solarization or temperature.
The radiation sensor, according to the present invention, includes one or more simple and efficient filters made of plastic plates for correction of the spectral sensitivity of different photodiodes used therein.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and additional features and characteristics of the present invention will become more apparent from the following detailed description considered with reference to the accompanying drawings in which like reference numerals designate like elements and wherein:
FIG. 1 shows the front view of one embodiment of an assembled radiation sensor with a multi-cavity attenuator according to the present invention.
FIG. 2A shows the back view with a closed lid of the embodiment of a radiation sensor depicted in FIG. 1 .
FIG. 2B shows the back view of one embodiment of an open lid of the embodiment of a radiation sensor depicted in FIG. 1 .
FIG. 2C shows the back view of another embodiment of an open lid of the embodiment of a radiation sensor depicted in FIG. 1 reconfigured to work with a surface mount photodiode.
FIG. 3 snows a schematic diagram of one embodiment of a radiation sensor according to the present invention.
FIG. 4 shows a multi-cavity attenuator with a detector according to the present invention.
FIG. 5A shows an adjustable multi-cavity attenuator with a detector according to the present invention.
FIG. 5B shows a multi-cavity attenuator with an improved cosine response according to the present invention.
FIG. 5C shows a multi-cavity attenuator with more than one secondary cavity according to the present invention
FIG. 6 shows an embodiment of a UV sensor for sensing radiation density (irradiance) from different light guides according to the present invention.
FIG. 7A shows another embodiment of a UV sensor for sensing radiation density (irradiance) from different light guides according to the present invention.
FIG. 7B shows a UV sensor according to the present invention with an inserted 3 mm light guide.
FIG. 7C shows a UV sensor according to the present invention with an inserted 5 mm light guide.
FIG. 7D shows a UV sensor according to the present invention with an inserted 8 mm light guide.
FIG. 8 shows an operation sequence of a radiation detector according to the present invention.
FIG. 9A shows a perspective view of the adjustable insert depicted in FIG. 5A ; and FIG. 9B shows a perspective view of the insert depicted in FIG. 5B .
FIG. 10 shows a spatial response of the multi-cavity attenuators depicted in FIG. 5A and FIG. 5B .
FIG. 11 shows a spectral correction of G5842 photodiode using a 1.6 mm polyester plate.
FIG. 12 shows a spectral correction of G6262 photodiode using a 3 mm polycarbonate plate.
DETAILED DESCRIPTION OF THE INVENTION
A radiation sensor according to the present invention is an optical electronic device for measuring UV irradiance from high intensity UV sources. One of the embodiments of the radiation sensor optimized for using in UV curing chambers comprises a housing, a housing lid, an attenuator, a detector, a preamplifier, an amplifier, a controller with an analog to digital converter, one or several push buttons, memory, a display, batteries and a power supply. The front view of the radiation sensor is shown in FIG. 1 . A housing 1 has a display 2 and a Power button 3 and a Mode button 4 . The back view of the radiation sensor is shown in FIG. 2A . The housing 1 has dimensions of 100 mm×100 mm×12 mm and is closed with a lid 56 . There is a thermo isolative material under the lid that protects any electronics inside from excessive heat during operation. The lid 56 is secured with screws 57 and has a window 5 . The view of the radiation sensor without lid is shown in FIG. 2B . The housing 1 holds a printed circuit board 34 A and batteries 18 . The printed circuit board 34 A has an opening in the center with an adjustable insert 32 . The opposite side of the adjustable insert 32 is fixed inside of an attenuator 6 . The attenuator 6 is shown with a thin line as it is located under the printed circuit board 34 A and secured with screws 30 A through holes in the printed circuit board 34 A. A photodiode 34 is inserted in the attenuator 6 through another opening on the printed circuit board 34 A. The printed circuit board 34 A has a reserved place for soldering a surface mount photodiode 34 B. As the embodiment shown in FIG. 2C , the printed circuit board 34 A has only the photodiode 34 B installed thereon. To work with the photodiode 34 B the same attenuator 6 is rotated around the insert 32 and secured with screws 30 A in a second position as shown in FIG. 2C . For some embodiments, both photodiodes 34 , 34 B are installed and the attenuator is modified to have one first cavity and two secondary cavities associated with both photodiode 34 , 34 B. The photodiode 34 or the surface mounted photodiode 34 B can be a silicon carbide UV A, UV B, or UV C photodiode, a GaAsP UV photodiode, an AlGaN UV photodiode, and a GaN UV photodiode.
The radiation sensor, according to the present invention, can work with one or several photodiodes having a traditional package or surface mount package. The embodiment with several photodiodes allows receiving information about irradiance in several spectral ranges.
The schematic diagram of the radiation sensor according to the present invention is shown in FIG. 3 . The radiation sensor has an attenuator 6 , a detector 7 (e.g., a photodiode), a preamplifier 8 , a scaling amplifier 9 , a controller 10 with an analog to digital converter 11 and an internal temperature sensor 12 , a Power pushbutton 3 , a Mode pushbutton 4 , a memory 13 , a RS-232 means 14 , a RS-232 connector 15 , an external temperature sensor 16 , a digital display 2 , batteries 18 , a power supply 19 , a real time clock 58 , etc. There is a connector 59 reserved for connecting an outside temperature sensor 59 A to be placed outside of the radiation sensor to measure an actual temperature inside of a UV chamber.
The design of a multi-cavity attenuator, according to the present invention, is shown in FIG. 4 . The lid 120 has an entrance aperture 121 (diameter of 3 mm) with a window 122 . The printed circuit board 126 A has a hole under the window 122 to let light enter inside of the first cavity 124 (a cylindrical hole with a 5 mm diameter and a 7.5 mm depth) of an attenuator body 123 made of fluoropolymer or metal (such as aluminum or stainless steel) to scatter and redirect the light inside the first cavity 124 . The window 122 comprises a sapphire plate which has extremely high resistance to scratching. For some embodiments the window 122 is made as a positive lens to correct a spatial response of a radiation sensor. The attenuator body 123 is attached to the printed circuit board 126 A with screws 123 A and has a second cavity 125 (a cylindrical hole with a 8.5 diameter and a 7.5 mm depth), which directs scattered and attenuated light to a photodiode 126 . The internal surface of the first and second cavities comprises a machined surface of fluoropolymer or metal without any reflective or absorptive coatings. In case of a metal attenuator body, the machined surface is preferably polished to provide multiple reflection with low attenuation after each reflection. The radiation entered into the first cavity 124 is reflected, scattered and redirected therein, and only portion of it (less than 1%) enters into the second cavity 125 . There is a hole 123 C (diameter of 2 mm) in the wall 123 B (of 2 mm thick) between the first cavity 124 and the second cavity 125 . The radiation entered into the second cavity 125 is reflected, scattered and redirected therein such that it is again attenuated in more than 200 times. The size of the hole 123 C is chosen to obtain an appropriate total attenuation of attenuator because the amount of radiation that pass from the first cavity into the second cavity is approximately proportional to the surface area of the hole 123 C. Such a multi-cavity design provides of attenuator with a high level of attenuation and a small size so as to reduce the size of a radiation sensor comprising the attenuator.
The invention provides a compact, stable, resistant to high level of irradiance sensor which can be easily expanded to have many UV ranges. For example, one central cavity with input window can be surrounded with several (2, 3, 4, 5, 6 . . . ) cavities having photodetectors with different UV ranges.
Prior art radiation detectors do not use cavity to attenuate radiation. Usually, the walls of the prior art cavity walls do not reflect light, such as being made black or having a size and orientation that the radiation follows from an inlet to a filter or a diffuser and to output as a collimated beam. On the other hand, the invention is designed with cavity walls of a high reflection rate such that the radiation hits walls many times.
An adjustable attenuator with a detector is shown in FIG. 5A . The lid 127 has an entrance aperture 128 (diameter of 3 mm) with a window 129 . The printed circuit board 134 A has a hole under the window 129 to let light enter inside of the first cavity 131 of an attenuator body 130 . The attenuator body 130 is attached to the printed circuit board 134 A with screws 130 A and has a second cavity 133 , which directs scattered and attenuated light to the photodiode 134 . An optical filter 135 A is placed in front the photodiode 134 . There is a hole 130 C in the wall 130 B between the first cavity 131 and the second cavity 133 . The first cavity 131 (a cylindrical hole with a 5 mm diameter and a 7.5 mm depth) has an adjustable insert 132 made as a brass tube polished inside and having an outside diameter 5 mm, an inner diameter 4 mm, and a 7.5 mm length. The adjustable insert 132 can be moved to change the open area of the hole 130 C to obtain an appropriate total attenuation of attenuator. FIG. 9A shows a perspective view of the adjustable insert 132 . The adjustable insert 132 has two notches 132 A on its upper end to rotate the insert with a screwdriver for an adjustment. On its lower end, it has a cut segment 1 32 B. By orientating the adjustable insert 132 differently relative to the hole 130 C, different amount of radiation will pass from the first cavity 124 into the second cavity 125 . In this embodiment, the interior surface of the insert 132 works as reflective surface of the first cavity 124 . After adjustment, the insert 132 is secured with a screw 132 A. The multi-cavity attenuator with such an adjustable insert operates in a much broader range of UV irradiance (e.g., from 100 W/cm2 to 0.5 W/cm2) and measures more accurately. For example, radiation sensors with maximum range 10 W/cm2 and 1 W/cm2 need different attenuation to bring an output signal from the photodiode into the optimal range in which the photodiode works lineally and without saturation.
The effects of a radiance incidence angle on a detector output is very important for many applications where light sources are different for calibration and for real measurements. An ideal irradiance detector has an angular response, which can be described as a cosine function of the angle of incidence. The proximity of the measured angular response to the theoretical cosine function shows the quality of a detector. The example of a theoretical cosine response in Polar and Cartesian Coordinates are shown in the International Light Measurement Handbook published by International Light, Inc. (Newburyport, Mass.) A multi-cavity attenuator with an improved cosine response is shown in FIG. 5B . The lid 160 has a window 161 . A fluoropolymer tape 162 (e.g., a white PTFE tape according to Mil.Spec.T-27730A, minimum of 99% Polytetrafluoroethylene, made by McMaster-Carr, Chicago, Ill.) is secured a sapphire plate 166 to the window 161 with a washer 163 . The sapphire plate 166 has a first portion with a diameter approximately equal to a diameter of a hole of the lid 161 and a second portion with a diameter smaller than the diameter of the hole of the lid 161 . The printed circuit board 165 has a hole under the window 161 to let light enter inside of the first cavity 167 (a cylinder with a 5 mm diameter and a 7.5 mm deep) of an attenuator body 164 made of a fluoropolymer. The fluoropolymer has no absorption in visible and UV range and it is temperature resistant. It has white color and provides good diffuse reflection. The attenuator body 164 is attached to the printed circuit board 165 with screws 164 A and has a second cavity 168 (a cylinder of a 8.5 mm diameter and a 7.5 mm deep) which directs scattered and attenuated light to the photodiode 173 . The UV radiation from the first cavity 167 penetrates to the second cavity 168 through the semi transparable wall 164 B of 0.2–5 mm thick between them. The first cavity 167 has an insert 171 made as a brass tube polished inside. The insert 171 has an outside diameter 5 mm, an inner diameter 4 mm, and a 5 mm length. The insert is secured with a screw 172 . FIG. 9B shows a perspective view of the insert 171 . The length of the insert 171 and the thickness of the wall 1 64 B between the cavities are chosen to obtain an appropriate total attenuation of attenuator. The attenuator body 164 is wrapped with a layer of another fluoropolimer tape 169 and then with a layer of aluminum foil 170 . The fluoropolimer tape 19 and the aluminum foil 170 increase uniformity of a UV light field inside the first cavity and the second cavity to protect the fluoropolimer body from contamination and mechanical stress. The multi-cavity attenuator with a fluoropolimer tape directly under the window has a spatial response close to cosine as shown in FIG. 10 .
Another embodiment of a multi-cavity attenuator with more than one secondary cavity is shown in FIG. 5C . The lid 180 has a window 181 . A fluoropolymer tape 182 is secured near the window 181 with a washer 183 . The printed circuit board 185 has a hole under the window 181 to let light enter inside of the first cavity 187 (a cylinder with a 5 mm diameter and a 7.5 mm deep) of an attenuator body 184 made of a fluoropolymer. The attenuator body 184 is attached to the printed circuit board 185 with screws 184 A and has two secondary cavities 188 , 189 (cylindrical holes of a 5 mm diameter and a 7.5 mm deep) which directs scattered and attenuated light to photodiodes 190 and 191 having different spectral ranges of sensitivity. The UV radiation from the first cavity 187 penetrates to both of the secondary cavities 188 , 189 through the semi transparable wall 184 B and 184 C of 0.2–5 mm thick between them. The attenuator body 184 is wrapped with a layer of another fluoropolimer tape 192 and then with a layer of aluminum foil 193 . The photodiodes 190 , 191 connected to an electrical schematic and work simultaneously to provide data about the irradiance in two different spectral ranges. In other embodiments, a multi-cavity attenuator has several secondary cavities therein, e.g. four secondary cavities connected to the front, back, right and left sides of the first cavity, each of which is associated with one respective photodiode, one respective optical filter or plastic correction filter. A radiation sensor with such embodiments measures irradiance in all spectral ranges important for specific application. In other embodiments, more than four small diameter secondary cavities are associated with the first cavity.
One embodiment of a UV sensor with an attenuator for measuring of the irradiance from UV light guides is shown in FIG. 6 . An attenuator body 236 is made of metal and covered with a layer of a fluoropolimer tape 236 A and an aluminum foil 236 B. The attenuator body 236 has a main cavity 237 , several channels for inserting light guides with different diameters. Each channel has a beginning bigger diameter(e.g., 238 A, 239 A, 240 A ) equal to the outer diameter of a corresponding light guide, for example 10 mm, 7 mm and 5 mm, to accommodate light guides with optical diameters of 8 mm, 5 mm and 3 mm respectively. Another section of each channel has a diameter slightly smaller (e.g., 238 B, 239 B, 240 B) than outer diameter of the light guide, for example 9 mm, 6 mm and 4 mm, so as not to restrict radiation from the light guides of 8 mm, 5 mm and 3 mm. The channel parts 238 B, 239 B, 240 B are made with a polished surface and serve as a first cavity of a multi-cavity attenuator. The radiation enters the channel parts 238 B, 239 B, 240 B from the light guide. For example, an 8 mm light guide 254 is shown. The radiation gets first attenuation after reflection and scattering inside of the channel and through the end of the channel then enters into the main cavity 237 . Walls of the main cavity 237 reflects and scatters the radiation and deliver it to the UV photodiode 243 placed in a mortise of the attenuator body 236 . For some embodiments without enough attenuation, there is a scattering device 241 (with a 12 mm diameter) made of (1) an opal glass or a fluoropolimer film and (2) a UV long pass filter, which corrects a spectral range of UV photodiode 243 to have a specified spectral sensitivity.
An embodiment of a UV sensor with a multi-cavity attenuator for measuring of the irradiance from different UV light guides is shown in FIG. 7 . An attenuator body 244 is made of metal and has a variable diameter channel 244 A having a 5 mm length of a 5 mm diameter, a 7.5 mm length of a 7 mm diameter, and a 7.5 mm length of a 10 mm diameter and a main cavity 244 B (a cylinder with a 4 mm length and a 15 mm diameter). A photodiode cover 245 has an opal glass insert 246 and a printed circuit board 249 with a photodiode 248 . The photodiode cover 245 and the printed circuit board 249 are attached to the attenuator body 244 with screws 250 and 251 . The variable diameter channel 244 A provides stable fixation for accommodating light guides with different diameters. FIG. 7B shows the UV radiation sensor with a 3 mm light guide 252 inserted in the channel of the attenuator body 244 . FIG. 7C shows the UV radiation sensor with a 5 mm light guide 252 inserted in the channel of the attenuator body 244 . FIG. 7D shows the UV radiation sensor with a 8 mm light guide 252 inserted in the channel of the attenuator body 244 . The attenuator body 244 has a polished internal surface in the main cavity 244 B and on the first two smaller diameter portions of the variable diameter channel 244 A. As shown in FIG. 7B , for the 3 mm light guide, only one section of the main cavity serves as an attenuator. For the 5 mm light guide, two sections of the main cavity serve as an attenuator, and for the 8 mm light guide, three sections of the main cavity serve as an attenuator The depth of each step in the variable diameter channel is chosen to provide an appropriate attenuation for each diameter of a corresponding light guide. Such a UV radiation sensor with a variable diameter light guide channel and with several stages of attenuation as a single or multi-cavity attenuator, opal glass, a fluoropolimer film provides portable and efficient sensor for main industrial devices with UV light guides.
The attenuator design according to the invention also works for visible light or other wave length. The ones for UV A, UV B, UV C, visible, or their combination are used as examples. The dimensions for visible light or other wave length can be two times less or three times more.
An operation sequence of a radiation detector according to the present invention is shown in FIG. 8 . At the beginning the radiation detector is in a Sleeping mode 101 . After the POWER button 3 (see FIG. 3 ) is pressed a Setting mode 102 is activated and the controller 10 checks a voltage of batteries 18 and retrieves data of the last run of the measurements from the memory 13 . If the battery voltage is lower than a limit, a warning LOW BATTERY will be shown at the display 2 . After the Setting mode 102 is done, the display 2 works in Mode “1” in which the results of the last measurement from the memory 13 are shown on the display 2 . In FIG. 1 , the first line of the display shows the total dose in Joules per Centimeter Square (e.g., 3.82 J/cm 2 ) and the second line shows the maximum irradiance during last run in Watts per Centimeter Square (e.g., 0.630 W/cm 2 ). After pressing the MODE button 4 the display 2 is switched from the Mode “1” into the Mode “2”. In the Mode “2,” the display 2 shows the maximum irradiance during the last run in Watts per Centimeter Square and time in seconds for the time when this maximum irradiance was detected. Pressing the MODE button 4 again, the display 2 is switched from the Mode “2” into the Mode “3”. In the Mode “3,” the display 2 shows the maximum temperature during the last run in degrees of Celsius and time in seconds for the time when this maximum temperature was detected. Pressing the MODE button 4 again returns the display 2 into the Mode “1”. If digits and units of measurement on the display 2 during the Modes “1”, “2” and “3” are not blinking, the data on the display are taken from the memory 13 . During the Modes “1”, “2” and “3,” the analog to digital converter (A/D converter) 11 in the controller 10 (see FIG. 3 ) periodically measures outputs of the scaling amplifier 9 to check for the presence of UV radiation.
If the level of UV irradiance I C exceeds a threshold I TR (I C >I TR ), the controller 10 automatically starts the Mode “4”. In this mode, the controller 10 constantly measures the outputs of the scaling amplifier 9 with the amplified output (×10). If the amplified output comes close to saturation, the controller 10 uses non-amplified output (×1). Using of two outputs increases the dynamic range of the radiation detector and allows measuring irradiance from 20 W/cm 2 to 0.001 W/cm 2 . The controller 10 continuously integrates irradiance data to find a cumulative dose from the beginning of the current run and shows results of current measurement on the display 2 . The first line of the display shows the dose in Joules per Centimeter Square and the second line shows the current irradiance during last run in Watts per Centimeter Square. Digits and units of measurement on the display during the modes “4” are blinking, that serves an indication that data on the display are results of running measurements. The controller 10 operates with the real time clock 58 and continuously saves in the memory 13 all data about the dose, the maximum irradiance together with time stamped data about momentarily levels of irradiance and temperature from temperature sensors.
In the Mode “4,” if the POWER button 3 or the MODE button 4 is pressed, the controller 10 stops running measurements, saves new data in the memory 13 , renew data about total cumulative dose measured since the last calibration, and activates the Mode “5” in which the results of the new measurement are shown on the display 2 . The first line of the display shows the total dose in Joules per Centimeter Square and the second line shows the maximum irradiance during new run in Watts per Centimeter Square. After pressing the MODE button 4 , the display 2 is switched from the Mode “5” into the Mode “6”. In the Mode “5,” the display 2 shows the maximum irradiance during new run in Watts per Centimeter Square and time in seconds for the time when this maximum irradiance was detected. By pressing the MODE button 4 again, the display 2 is switched from the Mode “6” into the Mode “7”. In the Mode “7,” the display 2 shows the maximum temperature during a new run in degrees of Celsius and time in seconds for the time when this maximum temperature was detected. By pressing the MODE button 4 again, the display 2 is returned into the Mode “5”. In the Modes “5”, “6” and “7,” digits on display are not blinking and units of measurement are blinking, that serves an indication that data on the display are results of the new run. To start manually a new run of measurements during any mode of operation the MODE button 4 should be pressed and hold. To turn off the radiation sensor during any mode of operation, the POWER button 3 should be pressed and hold.
The detector can be adjusted and calibrated such that a certain irradiance signal should give a predetermined current. The detector is adjusted and calibrated by using regulate means to transfer maximum radiation, putting a light guide with a standard known irradiance (which is measured with an independent calibrated sensor), reading an output of the radiation detector, and using the regulate means to transfer radiation to have a predetermined output signal. Accordingly, the detector is calibrated and ready for measurement. It has a specified sensitivity and an output current under the maximum irradiance which will not exceed allowed a current limit.
The radiation sensor according the present invention has a RS-232 means 14 comprising a RS-232 line driver and a RS-232 connector 15 . Any calibration information can be verified and corrected directly from a computer through a RS-232 port. After the radiation sensor finishes a current measurement, the RS-232 port is used to download an irradiance and temperature profile from the memory 13 .
The controller 10 also measures temperature signals from an internal temperature sensor 12 , an external temperature sensor 16 , and an outside temperature sensor 59 A that can be connected to the connector 59 . The internal temperature sensor 12 is a part of the controller 10 and monitors the controller temperature. The external temperature sensor 16 monitors the temperature in the radiation sensor housing near the UV detector. Those two sensors are used to start a sound signal if either temperature comes close to the safe limit and to turn off the power supply 19 if either temperature exceeds the set level to protect electronics. The controller 10 uses data from the external temperature sensor 16 to apply correction factors to the current readings of the A/D converter so as to compensate for a zero shift and a variation of sensitivity of the detector 7 , the preamplifier 8 and the scaling amplifier 9 . Compensation coefficients are stored in the memory 13 for continuously correcting the irradiance measurements during operation.
In some embodiments, the radiation sensor has an optical filter 135 A inside of the attenuator 130 (see FIG. 5A ) to correct a spectral sensitivity of the photodiode 134 . For example a cheap GaAsP UV photodiode Model No. G5842 made by Hamamatsu Photonics K.K. (Shizuoka Pref., 430-8587, Japan) has a spectral response range from 260 nm to 400 nm and cannot be used as sensor for the UV A range without spectral correction with a long pass filter. A glass or interference optical filter can be used but they are expensive and usually have big dimensions. According to the present invention, a small polyester plate with thickness of 1 m to 4 mm can be used together with the GaAsP G5842 photodiode to detect light of 320 nm to 400 nm that corresponds to the UV A range. FIG. 11 shows a spectral correction of a G5842 photodiode using a 1.6 mm polyester plate. A detector sensitivity for each specific wavelength is defined as a ratio of the detector output signal (e.g. output current for photodiodes) to irradiance level at the detector input, assuming that only narrow band radiation of this specific wavelength is present. Relative sensitivity for each wavelength is defined as a ratio of the detector sensitivity for this wavelength to the maximum detector sensitivity. The curve “a” shows the relative sensitivity of the G5842 photodiode without correction. The curve “b” shows the relative sensitivity of the photodiode with an additional 1.6 mm polyester plate for correction. The polyester plate absorbs radiation with a wavelength shorter than 320 nm forming consequently a sensitivity that corresponds to the UV A range (320–400 nm). Under the UV radiation, the polyester plate gradually changes transmission. The lifetime of the detector with the polyester long pass filter can be extended with a correction coefficient applied to the results of current measurements. The radiation sensor, after each run, renews data about the total cumulative dose measured after last calibration and the controller 10 applies a correction factor to compensate for variation in the detector sensitivity. Same correction methods are used if the detector changes its sensitivity after exposure to the UV radiation.
In some embodiments, the radiation sensor uses a cheap GaAsP photodiode G6262 by Hamamatsu with a spectral response range from 300 nm to 580 nm. The spectral response of the photodiode can be corrected with a long pass filter to make a detector for a visible light. FIG. 12 shows a spectral correction of a G6262 photodiode using a 3 mm polycarbonate plate. The curve “a” shows the relative sensitivity of the G6262 photodiode without correction. The curve “b” shows the relative sensitivity of the photodiode with an additional 3 mm polycarbonate plate for correction. The polycarbonate plate absorbs radiation with wavelength shorter than 320 nm forming consequently a sensitivity that corresponds to the visible light range (400–580 nm). A glass or interference optical filter can be used, but they are expensive and usually have big dimensions. According to the present invention, a small polycarbonate plate with thickness of 1 m to 4 mm can be used together with the GaAsP G6262 photodiode to detect light of 400 nm to 580 nm.
Both embodiments in FIGS. 11–12 described above use a cheap photodiode together with a small cheap plastic plate inside of the second cavity of the multi-cavity attenuator to form the spectral curve “b”. This solution provide a cheap, compact and reliable alternative to an expensive silicon carbide photodiode (SiC) which has an internal interference optical filter for UV A and to a bulky silicon (Si) photodiode with a glass or external interference optical filter. The outside temperature sensor 59 A is optionally connected to the connector 59 . The outside temperature sensor 59 A may be a microchip digital temperature sensor, e.g., Model No. LM 74 made by National Semiconductor (Santa Clara, Calif.) The temperature sensor 59 A is located on the small printed circuit board and protected from direct UV light with an aluminum foil. The aluminum foil serves as substrate for materials used in UV curing procedure, such as paint, glue or compound. The radiation sensor with the outside temperature sensor 59 A provides information of a real temperature profile that is very important for optimization of the technological procedure since the efficiency of the UV activation can be different for different temperatures and real temperature varies for different optical properties of the materials used. The outside temperature sensor 59 A may be made as a disposable unit to be replaced with a new sensor after each run or can be made as printed circuit board with the sensor having a disposable aluminum cover.
The radiation sensor according to the present invention is especially efficient for measuring high levels of UV irradiance in UV A, UV B and UV C ranges. It operates up to 20 W/cm 2 in UV A and UV B ranges and to 2 W/cm 2 in UV C and visible ranges. Such levels of irradiance are present in some UV curing equipment and at the output of some UV illuminating systems with UV light guides. The embodiment in FIG. 6 is optimized for using with UV light guides having different diameters. One of light guides is inserted in a channel that corresponds its diameter. Light from the UV light guide enters the main cavity 237 through the cylindrical channels 238 B, 239 B or 240 B. Each of the cylindrical channels 238 A, 239 A or 240 A has a different depth of an enlarged diameter so as to stop the end of the light guide at the different distance from the channel end. After initial scattering and reflection in a cavity between a light guide end and an end of the cylindrical channel, the radiation enters main cavity 237 . After the scattering and reflection in main cavity 237 , the radiation is additionally attenuated with the scattering device 241 and passes through the UV long pass filter 242 to the detector 243 . The lengths and positions of the channels 238 B, 239 B, 240 B are chosen to obtain on the photodiode 243 an irradiance level corresponding to the irradiance level at the outputs of the respective light guide. For example, if the light guides deliver light beams to an identical UV power but with different cross sections, the irradiance is inversely proportional to the surface of the cross section. Therefore, the channel for the light guide with a bigger diameter is made longer and placed at the bigger distance from the photo detector 243 .
A more compact embodiment for a UV sensor with a light guide holder is shown in FIG. 7A , which works in a similar way. The attenuator body 244 has a main cavity 244 A and a cylindrical channel with sections of different diameters 244 B. FIG. 7B shows a UV sensor with inserted 3 mm light guide. FIG. 7C shows a UV sensor with inserted 5 mm light guide. FIG. 7D shows a UV sensor with inserted 8 mm light guide. Light from the UV light guide enters the cylindrical channel. After initial scattering and reflection in the channel, the radiation enters the main cavity 244 A. After the scattering and reflection in main cavity 244 A, the radiation is additionally attenuated with the opal glass 246 and passes through a fluoropolimer film 247 to the photodiode 248 . The length of the parts with different diameters are chosen to obtain on the photodiode 248 an irradiance level that corresponds to the irradiance level at the outputs of the light guides.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification by taking UV as an example. However, the invention, which is intended to be protected, is not limited to the particular light or embodiments disclosed. The embodiments described herein are illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents that fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby.
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The invention provides a radiation sensor including a housing, an attenuator with at least one cavity for attenuating optical radiation, and a detector, as well as an optical attenuator including an attenuator body, an entrance with one multi-stage input opening or plural input openings, and means for transferring radiation inside of the attenuator body and then to a detector. The invention further provides methods for using the radiation sensor or the optical attenuator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is entitled to the benefit of French Patent Application No. 0511846 filed on Nov. 23, 2005.
FIELD OF THE INVENTION
The invention relates to a method of fabricating a lug on a structural element of composite material, in particular a connecting rod.
BACKGROUND OF THE INVENTION
Connecting rods are known that comprise a hollow body of composite material, e.g. obtained by winding filaments around a mandrel, or indeed by winding a ply of woven fibers.
The thickness of the hollow body is obtained by winding an appropriate number of turns.
Composite material connecting rods are also known in which the solid body is made by stacking plies.
It is also known to provide extensions, either from the wall of the hollow body or from the solid body that serve to become the lugs of coupling forks. After the body has been polymerized, it suffices to pierce holes in the extensions and possibly to cut them to shape in order to obtain the lugs.
Nevertheless, the thickness of the lugs obtained in that way is the same as the thickness of the wall of the hollow body or the thickness of the solid body. Unfortunately that thickness is not necessarily sufficient. The state of the art is illustrated by the following patent documents: FR 2 060 049, DE 37 26 340, FR 2 705 610, U.S. Pat. No. 5,279,892, U.S. Pat. No. 6,036,904.
OBJECT OF THE INVENTION
An object of the invention is to propose a novel method of producing one or more lugs on a structural element of composite material.
BRIEF DESCRIPTION OF THE INVENTION
To achieve this object, the invention provides a method of fabricating a lug on a structural element of composite material made at least locally out of a stack of primary plies of composite fibers defining at least one extension for forming the lug, the method including the step of separating the primary plies at least in the extension and of inserting intermediate plies between the primary plies.
Thus, the thickness of the extension is no longer tied to the thickness of the structural element. In particular the extension can be made thicker in order to obtain a lug of suitable thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood in the light of the following description given with reference to the figures in the accompanying drawings, in which:
FIG. 1 is a perspective view of a connecting rod obtained by the method of the invention;
FIG. 2 is a face view of a cut-out pattern for fabricating a connecting rod of the invention;
FIG. 3 is a section on line III-III through the body of the FIG. 1 connecting rod;
FIG. 4 is a fragmentary view of the FIG. 1 pattern seen edge-on;
FIG. 5 is a section view on line V-V of FIG. 1 ; and
FIG. 6 is a diagrammatic view of a fabric comprising a plurality of bonded-together plies suitable for use in implementing the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 , the method of the invention serves to obtain a completely composite connecting rod 100 comprising a tubular body 102 with two forks 103 , each comprising two facing lugs 104 .
According to a particular aspect of the invention shown in FIG. 2 , an initial step lies in cutting out a pattern 110 from a fiber fabric, a carbon fiber fabric in this example, which pattern 110 has a central portion 111 with two opposite edges 112 and has four extensions 113 projecting therefrom, comprising two extensions at each end of the central portion 111 , on either side of an axis of symmetry 114 of the pattern.
The fiber fabric is preferably obtained from a so-called “2.5 D” weave, comprising a plurality of primary plies having weft fibers interconnected by warp fibers that extend from one primary ply to another in order to bond the primary plies together. Such bonding between the primary plies enables them to be secured to one another, while allowing for relative sliding between the primary plies while the pattern is being shaped.
In this respect, the preferred fabric is the fabric described in patent document FR 2 759 096, and described below with reference to FIG. 6 . The fabric comprises a basic weave that is constituted:
firstly by at least twenty-eight weft fibers 1 to 28 organized in at least eight columns C 1 to C 8 each extending in the thickness direction E of the fabric, and disposed in a staggered configuration with alternation between columns C 2 , C 4 , C 6 , C 8 having at least three superposed weft fibers spaced apart at a predetermined pitch P, and columns C 1 , C 3 , C 5 , C 7 having at least four superposed weft fibers spaced apart by the same pitch P, the weft fibers 1 to 28 extending to define at least seven primary plies N 1 to N 7 ; and secondly, by at least twelve warp fibers 29 to 40 disposed in at least four parallel planes P 1 , P 2 , P 3 , P 4 that are offset in the weft fiber direction, each plane containing three superposed parallel warp fibers arranged in each of these planes as follows:
a first warp fiber (respectively numbered 29 , 32 , 35 , 38 ) connects the topmost warp fiber ( 1 , 8 , 15 , 22 ) of a four-weft fiber column (C 1 , C 3 , C 5 , C 7 ) to an upper intermediate weft fiber ( 16 , 23 , 2 , 9 ) of a four-weft fiber column (C 5 , C 7 , C 1 , C 3 ) that is spaced apart from the preceding column by at least two pitch steps P, the first warp fiber returning over a top end weft fiber ( 1 , 8 , 15 , 22 ) of a four-weft fiber column (C 1 , C 3 , C 5 , C 7 ) that is spaced apart from the first column by at least four pitch steps P; a second warp fiber (respectively numbered 30 , 33 , 36 , 39 ) connecting a top intermediate weft fiber ( 2 , 9 , 16 , 23 ) of a four-weft fiber column (C 1 , C 3 , C 7 ) to a lower intermediate weft fiber ( 17 , 24 , 3 , 10 ) of a four-weft fiber column (C 5 , C 7 , C 1 , C 3 ) that is spaced apart from the preceding column by at least two pitch steps P, the second warp fiber returning over an upper intermediate weft fiber ( 2 , 9 , 16 , 23 ) of a four-weft fiber column (C 1 , C 3 , C 5 , C 7 ) that is spaced apart from the first column by at least four pitch steps P; and a third warp fiber (respectively numbered 31 , 34 , 37 , 40 ) connecting a lower intermediate weft fiber ( 3 , 10 , 17 , 24 ) of a four-weft fiber column (C 1 , C 3 , C 5 , C 7 ) to the bottommost weft fiber ( 18 , 25 , 4 , 11 ) of a four-weft fiber column (C 5 , C 7 , C 1 , C 3 ) spaced apart from the preceding column by at least two pitch steps P, the third warp fiber returning over a lower intermediate weft fiber ( 3 , 10 , 17 , 24 ) of a four-weft fiber column (C 1 , C 3 , C 5 , C 7 ) that is spaced apart from the first column by at least four pitch steps P.
The positions of the parallel warp fibers ( 29 , 30 , 31 ; 32 , 33 , 34 ; 35 , 36 , 37 ; 38 , 39 , 40 ) are offset longitudinally by one pitch step P from one plane to another. Continuous lines represent the warp fibers 29 , 30 , 31 of plane P 1 , short dashed lines represent the warp fibers 23 , 33 , 34 of plane P 2 , chain-dotted lines represent the warp fibers 35 , 36 , 37 of plane P 3 , and finally long dashed lines represent the warp fibers 38 , 39 , 40 of the plane P 4 . The offset can be seen particularly clearly.
Returning to FIG. 2 , the pattern 110 is cut out from said fabric in such a manner that the weft fibers extend along the axis of symmetry 114 of the pattern 110 .
According to a particular aspect of the invention, the pattern 110 is then rolled up to form a tube by bringing its edges 112 close together. As shown diagrammatically in FIG. 3 , the plies of the fabric slide relative to one another, with sliding being zero on the axis of symmetry 114 and at its maximum in the vicinity at the edges 112 , such that the edges take on a chamfered shape.
The edges 112 are then placed against one another. Preferably, the end face of one of the edges 112 bears against the inside face of the pattern 110 so that the thickness of the resulting tube is substantially constant in the join zone.
Since the edges 112 are not parallel in this example, a tubular portion is obtained that is conical in shape. However it would be possible to obtain a cylindrical tubular portion in the same manner by cutting the pattern 110 to have edges 112 that are parallel.
According to a particular aspect of the invention, as shown in FIG. 4 , the warp fibers are removed from the ends of the extensions 113 in order to separate the primary plies formed by the weft fibers. This produces primary plies N 1 to N 7 (seen edge-on and represented by thick lines) that can be spaced apart from one another. Intermediate plies 116 (represented by fine lines with only one intermediate ply being given a reference) are inserted between adjacent primary plies so that the fibers constituting the intermediate plies 116 extend obliquely, preferably at 45° relative to the weft fibers making up the primary plies N 1 to N 7 .
The intermediate plies 116 are preferably disposed in such a manner as give the extensions 113 thickness that varies progressively so as to reach an end thickness that is constant and substantially twice that of the fabric. To do this, intermediate plies 116 are inserted of lengths that increase with increasing distance from the center of the extension 113 .
Transverse fibers 117 are then introduced across the primary plies N 1 to N 7 and the intermediate plies 116 in order to reinforce the ends of the extensions 113 (the transverse fibers are represented by dashed lines, with only one of them carrying a reference in the figure. This gives a three-dimensional structure to said end that is particularly strong and that prevents the plies from sliding one on another. The transverse fibers are preferably inserted by stitching.
The pattern fitted with its intermediate plies is shaped on a mandrel (not shown). Thereafter, using the conventional resin transfer molding (RTM) technique, resin is diffused between the fibers of the pattern and of the intermediate plies.
The overlapping edges 112 are thus bonded together by the resin. The overlapping chamfers provide a larger bonding area between the two edges 112 such that the join (visible in FIG. 1 ) is very strong and makes the connecting rod suitable for withstanding stresses both in tension and in compression.
This produces a strong tubular body with two arms of increased thickness at each end formed by the extensions, said arms extending facing each other in pairs. It then remains to cut the arms to shape and to pierce them in order to transform them into the lugs 104 . This produces the connecting rod shown in FIG. 1 that is made entirely out of composite material.
Preferably, and as shown in FIG. 5 , the lugs are each provided with a pair of rings 120 , each pair comprising a first ring 121 having a cylindrical portion 122 extending in the hole in one of the lugs 104 , together with a collar 123 extending against one of the flanks of the lugs 104 , and a second ring 125 having a cylindrical portion 126 extending tightly inside the cylindrical portion 122 of the first ring 121 , together with a collar 127 that bears against the end of said cylindrical portion 122 . The length of said cylindrical portion 122 is preferably very slightly shorter than the width of the lug 104 so that the lug is lightly clamped between the collars 123 and 127 .
Such a connecting rod is advantageously used for constituting folding braces or stays for landing gear. Such braces comprise two connecting rod elements that are hinged together and that work essentially in traction and compression, such that the connecting rod of the invention can advantageously be used in such an application. In addition, it is known that such braces or stays can also be subjected to impacts, e.g. from stones thrown up by the tires. The “2.5 D” fabric used is specifically well-known for its high resistance to impacts and to delamination.
Dimensioning has shown that the saving in weight compared with metal braces or stays is significant. Furthermore, manufacturing time is considerably shortened.
The invention is not limited to the description above, but on the contrary covers any variant coming within the ambit defined by the claims.
In particular, although the use of a particular fabric is described with reference to FIG. 6 , it is possible to use a similar fabric having a larger number of primary plies, or indeed to use other fabrics that allow primary plies to slide relative to one another. Such a fabric can be obtained by superposing primary plies and stitching them together loosely.
In order to reinforce the edge-to-edge join, it is possible to stitch the two edges together before polymerization.
Although the method of the invention is associated with a connecting rod, the method of the invention can be applied equally well to any other structural element made of composite material.
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The invention provides a method of fabricating a lug on a structural element of composite material made at least locally out of a stack of primary plies of composite fibers defining at least one extension for forming the lug. The method includes the step of separating the primary plies at least in the extension and of inserting intermediate plies between the primary plies.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority of Korean Patent Application No. 10-2011-0007510 filed on Jan. 25, 2011, which is incorporated by reference in their entirety herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an active array antenna apparatus capable of controlling a radio frequency (RF) polarization in real time, and more particularly, to a general antenna apparatus capable of environmentally and temporally controlling polarization resources necessary for wireless communication in order to improve communication quality and increase communication capacity.
2. Related Art
A wireless terrestrial/satellite communication system generally transmits/receives data information through antennas using a predetermined frequency. Here, as an important element for transmitting and receiving signals in the wireless terrestrial/satellite communication system, antennas are present at an end of the wireless terrestrial/satellite communication system. These antennas should be configured to efficiently transmit and receive electromagnetic waves. Therefore, the research and development of the antenna has been actively conducted.
A significantly number of antennas are present. However, as a generally used high frequency antenna, there are a dipole antenna, a monopole antenna, a patch antenna, a horn antenna, a parabolic antenna, a helical antenna, a slot antenna, and the like. These antenna are applied and used in various forms according to a communication distance and a service area.
As necessary resources of the wireless terrestrial/satellite communication system, there are frequency, polarization, space, and direction. In the present and the future, a frequency resource, which is the most important resource for wireless communication, has been exhausted due to an increase in kinds of wireless communication services. In addition, a multiple input multiple output (MIMO) communication technology has been necessarily demanded due to an increase in bandwidth of a service. An object of this MIMO communication technology is to increase communication capacity by performing independent multi-channel transmission using multiple antennas. However, most satellite communication/mobile communication terminal or relay/base station antennas for MIMO communication have currently used the defined fixed polarization. In this antenna system structure using the fixed polarization, it is expected that service quality is deteriorated to an interference problem between services, or the like, caused by an increase in a service and an increase in a bandwidth in the future. In order to overcome this problem, an antenna technology of improving service quality and increasing service capacity by temporally variably controlling the polarization of the antenna so as to be appropriate for wireless environment and system requirement had been demanded.
In the future, due to saturation (depletion) of the wireless communication, elastic application/utilization of new radio resources such as a polarization, a space, a direction, or the like, has been absolutely required.
SUMMARY OF THE INVENTION
The present invention provides a general active array antenna apparatus capable of environmentally and temporally controlling an RF polarization of a wireless communication antenna apparatus in order to improve quality of wireless communication services and increase communication capacity thereof in the future.
In an aspect, a transmission antenna apparatus is provided. The transmission antenna apparatus includes: a signal distributing unit distributing a plurality of input signals to generate independent signals; a channel inputting unit inputting each of the independent signals to a corresponding channel; a multi channel unit including a plurality of channels to which the independent signals are input; and a dual polarization antenna unit generating and transmitting a dual polarization, wherein the multi channel unit adjusts phases and/or amplitudes of the independent signals for each of the channels to which the independent signals are input and intersects and combines the phase and/or amplitude adjusted independent signals with respect to the plurality of input signals to generate a plurality of combined independent signals, and wherein the dual polarization antenna unit transmits each of the plurality of combined independent signals input from the multi channel unit as orthogonal components of the dual polarization.
The adjustment of the phases and/or the amplitudes of the independent signals for each of the channels may be temporally controlled.
The dual polarization antenna unit may include a plurality of dual polarization antenna elements, wherein the dual polarization antenna element has an orthogonal intersecting structure or an orthogonal intersecting dipole structure and simultaneously generates a plurality of independent orthogonal polarizations based on the structures.
The plurality of input signals may be two different input signals, the signal distributing unit may distribute two independent signals from each of the two different input signals, the multi channel unit may attenuate and remove one of independent signals configuring the combined independent signals, for each of the two different input signal, and the dual polarization antenna unit may transmit two combined independent signals of which one is attenuated and removed as each of orthogonal components of the orthogonal polarizations.
The signal distributing unit may receive two input signals to distribute each of two independent signals, the multi channel unit may attenuate and remove one of two independent signals configuring the combined independent signals, and the dual polarization antenna unit may transmit two combined independent signals of which one is attenuated and removed as each of orthogonal components of the orthogonal polarizations.
The channel inputting unit may intersect and input independent signals distributed from the plurality of input signals with respect to each of the channels of the multi channel unit.
A weight for the phase and/or the amplitude may be added to each of the channels to which the independent signal is input to adjust the phase and/or the amplitude of the independent signal.
The transmission antenna apparatus may further include a monitoring/controlling unit provided at a separate position from the signal distributing unit, the channel inputting unit, the multi channel unit, and the dual polarization antenna unit, wherein the monitoring/controlling unit controls the adjustment of the phase and/or the amplitude of the independent signal and selects an independent signal to be attenuated and removed.
The control of the adjustment of the phase and/or the amplitude of the independent signal and the selection of the independent signal to be attenuated and removed may be performed in a base station apparatus connected to the antenna apparatus.
In another aspect, a reception antenna apparatus is provided. The reception antenna apparatus includes: a dual polarization antenna unit receiving a dual polarization signal; a multi channel unit including a plurality of channels to which each of orthogonal components of the dual polarization signal is input; a signal combining unit combining signals with each other, wherein the multi channel unit distributes independent signals having different characteristics in each of the orthogonal components to input the distributed independent signals for each of the channels and adjusts and outputs phases and/or amplitudes of the independent signals for each of the channels, and wherein the signal combining unit combines signals having the same characteristics among the independent signals output from the multi channel unit with each other.
In another aspect, a method for transmitting a signal using a dual polarization antenna is provided. The method includes: distributing each of a plurality of input signals as a plurality of independent signals; inputting each of the plurality of independent signals to a corresponding channel; adjusting phases and/or amplitudes of the independent signals for each of the channels to which the independent signals are input; intersecting and combining the phase and/or amplitude adjusted independent signals with respect to the plurality of input signals to generate combined independent signals; and inputting and transmitting each of the combined independent signals as orthogonal components of a dual polarization antenna.
The adjustment of the phases and/or the amplitudes of the independent signals may be temporally controlled.
The plurality of input signals may be two different input signals, in the distributing, two independent signals may be distributed from each of the two different input signals, in the adjusting, one of independent signals configuring the combined independent signals may be attenuated and removed for each of the two different input signal, and in the transmitting, two combined independent signals of which one is attenuated and removed may be input as each of the orthogonal components of the dual polarization antenna.
In the distributing, two independent signals may be distributed from each of two input signals, in the adjusting, one of the two independent signals configuring the combined independent signals may be attenuated and removed, and in the transmitting, two combined independent signals of which one is attenuated and removed may be input as each of the orthogonal components of the dual polarization antenna.
In the adjusting, a weight for the phase and/or the amplitude may be added to each of the channels to which the independent signal is input to adjust the phase and/or the amplitude of the independent signal.
In another aspect, a method for receiving a signal using a dual polarization antenna is provided. The method includes: receiving a dual polarization signal; distributing independent signals having different characteristics in each of the orthogonal components; inputting the distributed independent signals for each of a plurality of channels adjusting phases and/or amplitudes of the independent signals for each of the channels; and combining signals having the same characteristics among the phase and/or amplitude adjusted independent signals with each other.
In the present invention described above, the antenna, which is all kinds of antennas including two input and output terminals and capable of forming a dual polarization, includes a unit antenna element, an array antenna, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram schematically showing a configuration of a passive array antenna apparatus used for a base station antenna according to the related art.
FIG. 2 is a diagram schematically describing that different polarizations are transmitted through real time scheduling in a polarization control active array antenna apparatus according to the present invention.
FIG. 3 is a diagram schematically showing an example of a configuration of a real time RF polarization control active array antenna apparatus according to an exemplary embodiment of the present invention.
FIG. 4 is a diagram schematically showing a configuration of a real time RF polarization control active array antenna apparatus and an example of a configuration of an interface for the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention.
FIG. 5 is a diagram schematically showing a configuration of an active array to antenna element in the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention.
FIG. 6 is a diagram schematically showing an example of a configuration of a multi active channel unit.
FIG. 7 is a diagram schematically showing a coaxial wiring relationship of a polarization reconstruction combining unit according to the exemplary embodiment of the present invention and an example of a configuration of a power distributing/combining unit.
FIG. 8 is a diagram schematically showing a configuration of a baseband/modem polarization control active array antenna apparatus.
FIG. 9 is a flow chart schematically showing an operation of a system including the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention in a transmission mode.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
The present invention relates to an active array antenna apparatus for controlling an RF polarization in real time and a method for transmitting and receiving a signal using the same. In the active array antenna apparatus for controlling an RF polarization in real time according to an exemplary embodiment of the present invention, each antenna element has an active array antenna element form and also has an antenna structure capable of generating an orthogonal dual polarization. In addition, each antenna element includes two input or output terminals, and signals input or output through two terminals may have independent controlled amplitudes and phases. Here, the amplitude and phase control of two orthogonal component signals may be performed by an analog or digital polarization control apparatus.
The polarization control apparatus may include an analog active part, a digital signal processing unit, or the like, therein according to a configuration of an antenna system. The polarization control apparatus is connected to an end orthogonal dual polarization antenna, and may be controlled by or communicate with an antenna main controlling unit performing a polarization control.
Hereinafter, the present invention will be described with reference to the accompanying drawings. In describing the present invention, a description for portions obvious to those skilled in the art will be omitted in order not to obscure the gist of the present invention. In addition, the same reference numerals will be used to describe the same components through the accompanying drawing for convenience of explanation and understanding.
It is to be noted that each of terms described below is used only in order to help the understanding of the present invention and each manufacturing company or study group may use different terms for the same use.
In addition, it is noted that each component of the antenna system described in the present description may be applied to all of transmission and reception and uplink transmission and downlink transmission.
FIG. 1 is a diagram schematically showing a configuration of a passive array antenna apparatus used for a base station antenna according to the related art.
The passive array antenna apparatus includes a passive array antenna 100 , a remote head unit (RRH) 140 , a donor unit 150 , and a baseband base station apparatus 160 . The passive array antenna 100 includes a plurality of passive antenna array elements 110 and a feed circuit 120 combining or distributing power for the plurality of passive antenna array elements 110 . The remote head unit 140 includes high output amplification, low noise amplification, frequency conversion, and digital to optical signal conversion devices. The passive array antenna 100 and the remote head unit 140 may be connected to each other by a simple coaxial cable. The donor unit 150 connected to the base station apparatus 160 and the remote head unit 140 may be connected to each other by an optical cable.
The antenna apparatus according to the related art does not include a real time polarization conversion function and a beam forming/beam scan function and has low antenna efficiency and low system power efficiency due to feed loss of the feed circuit 120 .
FIG. 2 is a diagram schematically describing that different polarizations are transmitted through real time scheduling in a polarization control active array antenna apparatus according to the present invention. Referring to FIG. 2 , a real time RF polarization control active array antenna apparatus proposed in the present invention provides a function of performing transmission and reception while changing the polarization according to real time scheduling, unlike the antenna apparatus according to the related art. For example, a linear polarization 1 (P LP1 ) may be generated during Δt 1 , a linear polarization 2 (P LP2 ) may be generated during Δt 2 , and a circular polarization 1 (P CP1 ) may be generated during Δt 3 , from the array antenna apparatus.
FIG. 3 is a diagram schematically showing an example of a configuration of a real time RF polarization control active array antenna apparatus according to an exemplary embodiment of the present invention. The real time RF polarization control active array antenna apparatus includes an active array antenna apparatus 3000 , a monitoring and controlling unit 3800 , a donor unit 150 , and a baseband base station apparatus 160 . The active array antenna apparatus 3000 includes a plurality of active antenna array elements 3100 , a multi active channel unit 3200 providing functions of a remote head unit, that is, a transmission high output amplification function, a reception low noise amplification function, and a function capable of an amplitude and a phase of active channels, and an uplink and downlink frequency conversion and digital to optical signal conversion device (not shown). The active array antenna apparatus 3100 and the donor unit 150 may be connected to each other by an optical cable.
The real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention may provide a real time polarization conversion function and a three dimensional beam forming/three dimensional beam scan function, and also provide significantly high antenna efficiency and high system power efficiency since it has an active feed structure.
Hereinafter, a configuration of the active array antenna apparatus 3000 will be described in detail. Here, for convenience of explanation, a time division duplex (TDD) type WiMAX (or Wibro) system will be described as an example of a system according to the exemplary embodiment of the present invention.
FIG. 4 is a diagram schematically showing a configuration of a real time RF polarization control active array antenna apparatus 3000 and an example of a configuration of an interface for the real time RF polarization control active array antenna apparatus 3000 according to the exemplary embodiment of the present invention.
The donor unit 150 and the baseband base station apparatus 160 may be installed inside a house, and the active array antenna apparatus 3000 except for the monitoring/controlling unit 3800 may be installed outside the house.
The real time RF polarization control active array antenna apparatus 3000 includes an active array antenna element 3100 , a multi active channel unit 3200 , a polarization reconstruction combining unit 3300 , a power distributing/combining unit 3400 , an antenna controlling unit 3500 , a frequency converting/digital to optical converting unit 3600 , and a power supplying unit 3700 . Here, the monitoring/controlling unit 3800 may be installed inside the home so as to be independently interfaced with the donor unit 150 .
The active array antenna element 3100 may include N 1 horizontal array elements and N 2 vertical array elements. The N 1 horizontal array elements may provide horizontal beam forming and beam scan functions, and the N 2 vertical array elements may provide vertical beam forming and beam scan functions. Here, for convenience of explanation, a structure in which eight antenna elements are arranged in each of two layers, for example, a case in which two horizontal array elements and eight vertical array elements are arranged will be described as an example of the present invention.
FIG. 5 is a diagram schematically showing a configuration of an active array antenna element 3100 in the real time RF polarization control active array antenna apparatus 3000 according to the exemplary embodiment of the present invention.
Referring to FIG. 5 , left vertical array antenna elements 3110 include eight antenna elements, and right vertical array antenna elements 3120 also include eight antenna elements. The left vertical array antenna elements 3110 and the right vertical array antenna elements 3120 may be disposed, having an interval of d x therebetween. An array interval between the vertical array antenna elements may be determined according to unique characteristics of an applied antenna element and have an influence on horizontal beam forming and beam scan characteristics.
Each antenna element may have a structure of orthogonal intersecting antenna elements DE 1 and DE 2 or a structure of orthogonal intersecting dipole elements. For example, the antenna element may have two input terminals I 1 and I 2 so as to provide two orthogonal components E x and E y . Therefore, in the case of allowing each antenna element to correspond to users receiving a communication service through the RF polarization control active array antenna according to the exemplary embodiment of the present invention, it is possible to perform a polarization control based on each user.
Two independent signals are combined with each other and input to each input terminal. For example, a signal M 11 +M 21 may be input to the input terminal 1 I 1 , and a signal M 12 +M 22 may be input to the input terminal 2 I 2 . Here, signals M 11 and M 12 are coherent signals branched from an input signal M 1 and each having an amplitude and a phase that may be mutually controlled. In addition, signals M 21 and M 22 are also coherent signals branched from an input signal M 2 and each having an amplitude and a phase that may be mutually controlled.
Two independent signals are combined with each other by a multi active channel unit 3200 to be described below.
FIG. 6 is a diagram schematically showing an example of a configuration of a multi active channel unit 3200 . The multi active channel unit 3200 includes two layers and includes eight multi active channel sub units arranged in each of the two layers, that is, a total of sixteen multi active channel sub units 3210 to 3217 and 3220 to 3227 . Each of the multi active channel sub units includes four active channels corresponding to four input signals M 11 , M 12 , M 21 , and M 22 and outputs two signals M 11 +M 21 and M 12 +M 22 corresponding to the inputs I 1 and I 2 of each antenna element.
In a transmission mode, each of the multi active channel sub units 3210 to 3217 and 3220 to 3227 has an output interfaced with the antenna element of the antenna element arrays 3110 and 3120 and an input interfaced with the polarization reconstruction coaxial wiring combining unit 3300 . In a reception mode, each of the multi active channel sub units 3210 to 3217 and 3220 to 3227 has an input interfaced with the antenna element of the antenna element arrays 3110 and 3120 and an output interfaced with the polarization reconstruction coaxial wiring combining unit 3300 .
Each of the multi active channel sub units 3210 to 3217 and 3220 to 3227 includes two end filters BPF 1 and BPF 2 , four RF channel switches SW 1 to SW 4 , two transmission high output amplifiers HPA 1 and HPA 2 , two low noise amplifiers LNA 1 and LNA 2 , two power distributers/combiners PDC 1 and PDC 2 , and vector signal controlling units 3210 a and 3220 a.
The vector signal controlling units 3210 a and 3220 a include four digital phase shifters PS 1 to PS 4 and fourth digital power attenuators ATT 1 to ATT 4 .
Here, the end filters BPF 1 and BPF 2 serve to suppress out-of-band signals.
The four RF channel switches SW 1 to SW 4 may be simultaneously synchronized and selected so as to provide a transmission and reception channel selection function. Here, a synchronization control signal (T-sync signal) is provided from the base station apparatus.
The transmission high output amplifiers HPA 1 and HPA 2 provide a function of high-output amplifying a transmission signal at the time of a transmission channel mode. In addition, at the time of a reception channel mode, power of the transmission high output amplifiers is blocked, thereby making it possible to protect the reception low noise amplifiers LNA 1 and LNA 2 . Here, the high output amplifiers may also be blocked through the RF channel switches SW 1 to SW 4 .
The reception low noise amplifiers LNA 1 and LNA 2 provide a function of low-noise amplifying a reception signal at the time of the reception channel mode. In addition, at the time of the transmission channel mode, power of the low noise amplifiers is blocked, thereby making it possible to protect the low noise amplifiers from the high output signal leaked and input from the high output amplifiers. Here, the low noise amplifiers may also be blocked through the RF channel switches SW 1 to SW 4 .
The power distributers/combiners PDC 1 and PDC 2 provide a function of combining two transmitted independent input signals M 11 and M 21 with each other at the time of the transmission channel mode. The power distributers/combiners PDC 1 and PDC 2 provide a function of distributing two received independent input signals M 11 and M 21 at the time of the reception channel mode.
The vector signal controlling units 3210 a and 3220 a may include four digital phase shifters PS 1 to PS 4 and fourth digital power attenuators ATT 1 to ATT 4 .
The four digital phase shifters PS 1 to PS 4 may adjust phases of the respective active channels. Here, the digital phase shifters adjust the phases of the respective channels with respect to the input signal to allow two orthogonal component signals transmitted to the antenna element to have a phase difference of 90 degrees, thereby making it possible to generate a circular polarization.
The four digital power attenuators ATT 1 to ATT 4 may adjust amplitudes of the respective active channels. Here, channels for signals to be transmitted among channels to which signals are input may also be selected through the digital power attenuators. For example, attenuation is maximally applied to one of signals input to each channel to remove or minimize a corresponding signal, thereby making it possible to select a desired channel among the channels to which the signals are input.
The adjustment of the amplitudes and/or the phases through the vector signal controlling units 3210 and 3220 a is performed by the antenna controlling unit 3500 . The amplitude and/or the phase of the active channel is controlled through the antenna controlling unit 3500 , thereby making it possible to perform real time polarization reconstruction, beam forming and beam scan, initial phase compensation, and the like. The antenna controlling unit 3500 receives various control signals from the monitoring/controlling unit 3800 to transfer a control command to the multi active channel unit 3200 . The monitoring controlling unit 3800 may be configured separately from the antenna apparatus 3000 , and a user/manager may control parameters on transmission of the antenna apparatus through the monitoring/controlling unit 3800 as described below.
FIG. 7 is a diagram schematically showing a coaxial wiring relationship of a polarization reconstruction combining unit according to the exemplary embodiment of the present invention and an example of a configuration of a power distributing/combining unit.
An intermediate portion of FIG. 7 shows a coaxial wiring relationship of the polarization reconstruction combining unit 3300 . Referring to FIG. 7 , the polarization reconstruction combining unit 3300 provides a function of replacing an RF wiring in order to reconstruct two signals and transmission and reception polarizations. For example, referring to FIG. 7 , the polarization reconstruction combining unit 3300 allows two independent RF signals M 11 and M 21 to be input to two left channels configuring the multi active channel sub unit 3210 and allows two independent RF signals M 12 and M 22 to be input to two right channels configuring the multi active channel sub unit 3210 .
A lower end portion of FIG. 7 shows an internal configuration of the power distributing/combining unit 3400 .
Referring to FIG. 7 , the power distributing/combining unit 3400 includes two 1-8 way power distributers/combiners 3420 and 3421 and sixteen 2-8 way power distributers/combiners 3410 to 3471 . The power distributing/combining unit 3400 distributes power of two independent input signals to output each 32 (a total of 64) signal, at the time of the transmission channel mode. Similarly, the power distributing/combining unit 3400 distributes power of each 32 (a total of 64) input signal to output two independent signals, at the time of the reception channel mode.
Hereinafter, again referring to FIG. 4 , the real time RF polarization control active array antenna apparatus 3000 according to the exemplary embodiment of the present invention will be additionally described.
The antenna controlling unit 3500 of FIG. 4 receives various control signals from the monitoring/controlling unit 3800 to transfer a control command to the multi active channel unit 3200 . Here, as the control signals input from the monitoring/controlling unit 3800 , there are an amplitude and/or phase control signal, a power turn on/off control signal, a beam forming and beam scan control signal, a polarization control signal, and the like.
The antenna controlling unit 3500 may also collect status information of each of the 16 multi active channel sub units 3210 to 3217 to 3220 to 3227 to transfer the status information to the monitoring/controlling unit 3800 and may transfer a synchronization control (T Sync) signal received from the frequency converting/digital to optical converting units 3600 to each of the 16 multi active channel sub units 3210 to 3217 and 3220 to 3227 . Here, the antenna controlling unit 3500 , the multi active channel unit 3200 , and the monitoring/controlling unit 3800 may communicate with each other in, for example, a RS232C serial communication (38, 400 bps, half duplex) scheme.
The frequency converting/digital to optical converting unit 3600 includes two frequency converting units 3610 and 3620 , a local oscillator 3630 synchronized with an external reference frequency (for example, 10 MHz) (for example, a phase locked loop (PLL) type local oscillator), and a digital to optical converter 3640 . The frequency converting/digital to optical converting unit 3600 performs digital to optical interfacing with the donor unit 150 and provides a frequency conversion function and a function of converting a digital optical signal into an RF signal and/or amplifying and transmitting the digital optical signal. The digital to optical converter 3640 separates the independent signals, for example, M 1 and M 2 , received from the donor unit and supplies each of the separated signals to the frequency converting units 3610 and 3620 .
The power supplying unit 3700 of FIG. 4 converts alternate current (AC) power into direct current (DC) power to supply the DC power to each active unit, for example, the antenna controlling unit 3500 , the frequency converting/digital to optical converting unit 3600 , the multi active channel unit 3200 , and the like. The power supplying unit 3700 supplies power to each channel configuring the sub units of the multi active channel unit 3200 , thereby making it possible to increase power efficiency.
The monitoring/controlling unit 3800 of FIG. 4 may be installed inside the home, separately from the antenna apparatus 3000 , and communicate with the donor unit 150 through a universal serial bus (USB) terminal in the RS232C serial communication (38, 400 bps, half duplex) scheme. In addition, the monitoring/controlling unit 3800 may passively control the synchronization control (T Sync) with respect to an uplink and a downlink.
The monitoring/controlling unit 3800 may communicate with the antenna controlling unit 3500 in the RS232C serial communication (38, 400 bps, half duplex) scheme. Therefore, the monitoring/controlling unit 3800 may provide a function of controlling the amplitude and/or the phase control, a function of controlling the power turn on/off, a function of controlling the beam forming and/or beam scan, a function of controlling the polarization reconstruction, a function of collecting the status information (a power level, a temperature, or the like) of each 16 sub unit, and a function of setting a monitor, a TDD guide offset, a TDD receive-to-transmit transition gap (TDD RTG), a TDD transmit-to-receive transition gap (TDD TTG), or the like, of the multi active channel unit 3200 .
In contrast with the donor unit of the base station system according to the related art, the donor unit 150 has a modified firmware so that it is interfaced with the monitoring/controlling unit 3800 .
FIG. 8 is a diagram schematically showing a configuration of a baseband/modem polarization control active array antenna apparatus according to another exemplary embodiment of the present invention.
In the exemplary embodiment of FIG. 8 , the distributing/combining function of the power distributing/combining unit 3400 , the function of the polarization reconstruction combining unit 3300 , and the functions of the digital power attenuators ATT 1 to ATT 4 and the digital phase shifters PS 1 to PS 4 of the multi active channel sub units 3210 to 3217 and 3220 to 3227 in the exemplary embodiment of FIGS. 4 to 7 may be performed in a baseband/modem unit 8000 positioned at the donor unit or the baseband base station apparatus. Therefore, in the exemplary embodiment of FIG. 8 , an active array antenna apparatus 7000 performs a function required for transmitting and receiving signals in addition to the above-mentioned functions.
The baseband/modem unit 8000 includes a demultiplexer (DEMUX) unit 8100 distributing digital signals in terms of transmission, a vector signal controlling unit 8200 control amplitudes and phases of the distributed digital signals, and a multiplex (MUX) unit 8300 combining the amplitude and/or phase controlled digital signals with each other. Two independent input data M 1 data and M 2 data pass through the vector signal controlling unit 8200 and are then combined with each other.
Next, the combined signals pass through the active array antenna apparatus 7000 and are then input to a single orthogonal dual polarization antenna element 3110 in order to simultaneously generate two independent orthogonal polarizations. Here, the two dual polarizations may be generated by controlling weighting factors (complex factors controlling the amplitude and the phase) W 11 , W 12 , W 21 , and W 22 .
In addition, in order to obtain an array gain, at the time of use of the array antenna, the input signals may be distributed and used by the number of array antennas in the active array antenna apparatus 7000 or the baseband/modem unit 8000 .
FIG. 9 is a flow chart schematically showing an operation of a system including the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention in a transmission mode.
A plurality of independent signals M 1 and M 2 are input from a base station to an antenna apparatus (S 910 ). The independent signals input to the antenna apparatus is subjected to optical to digital conversion and is subjected to sync control and frequency conversion if needed.
The independent signals M 1 and M 2 are distributed as each element independent signal (S 920 ).
Each of the independent signals M 1 and M 2 is distributed as a plurality of independent signals M 11 and M 12 , and M 21 and M 22 . The independent signals M 11 and M 12 are first and second independent signals distributed from the independent signal M 1 . The independent signals M 21 and M 22 are first and second independent signals distributed from the independent signal M 2 .
The distributed independent signals are input to each of the channels (S 930 ). Each of the channels corresponds to each of the independent signals in a one-to-one scheme, and each of the independent signals may be input to each of the channels.
Amplitudes and/or phases of the independent signals passing through each channel are adjusted (S 940 ). The amplitudes and/or the phases of the independent signals may be controlled for each channel.
In order to control the amplitudes and/or the phases of each of the independent signals, a attenuator and a phase shifter may be used for each channel. In addition, in order to control the amplitudes and/or the phases of each of the independent signals, each of the weighting factors W 11 , W 12 , W 21 , and W 22 may be added to each of the independent signals. Here, the weighting factors, which are complex factors, adjust the amplitudes and the phases of each of the independent signals.
The amplitude and phase controlled independent signals are combined with different independent signals to form a dual polarization (S 950 ). A single independent signal is combined with a different kind of independent signal as represented by Equation. 1.
E 1= M 11′+ M 21′
E 2= M 12′+ M 22′ [Equation 1]
Where M 11 ′, M 12 ′, M 21 ′, and M 22 ′ indicate phase and/or amplitude controlled independent signals, and E 1 and E 2 indicate orthogonal component signals (polarization signals) input to each intersecting structure in a single antenna element having an orthogonal intersecting structure or an orthogonal intersecting dipole structure.
Here, when the M 1 and the M 2 are the same signal, the antenna apparatus according to the exemplary embodiment of the present invention transmits the same signal.
Here, when the M 1 and the M 2 are the different signals, the antenna apparatus according to the exemplary embodiment of the present invention is a MIMO system and may obtain a transmission diversity effect. For example, when the M 21 ′ and M 12 ′ are removed through the attenuator, a single antenna may transmit two independent signals orthogonal to each other. Even in the case in which the M 1 and the M 2 are the different signals, only signals on one sides such as M 11 and M 12 or M 21 and M 22 are removed, thereby making it possible to selectively transmit only the same signal.
Two polarizations E 1 and E 2 are transmitted through the antenna element (S 960 ).
The present invention may also be applied to a system including a real time RF polarization control active array antenna apparatus in a reception mode.
In the case of the system the real time RF polarization control active array antenna apparatus in the reception mode, operations in the transmission mode described in FIG. 9 are reversely applied to received polarization signals, thereby making it possible to obtain the independent signals.
Although the TDD type WiMAX (or Wibro) system has been described as an example of the system according to the exemplary embodiment of the present invention for convenience of explanation, the present invention is not limited thereto. That is, the spirit of the present invention may be applied to various systems. For example, the spirit of the present invention may also be applied to a FDD type WiMAX (or Wibro) system by excluding the switches SW 1 to SW 4 in the exemplary embodiment of FIG. 6 and may also be applied to a long term evolution (LTE) system.
In contents described in the present specification, work performed in a communication network may be performed during a process of controlling the communication network and transmitting data in a system (for example, a server, a base station, or the like) managing the communication network or be performed in a terminal coupled to the communication network.
With the antenna apparatus according to the exemplary embodiments of the present invention, the polarization control adapted for a real time or long term wireless communication environment change is performed, polarization characteristics of the antenna are provided for each of wireless communication environment adaptation sector user groups, thereby making it possible to improve communication service quality and increase communication capacity.
In addition, according to the exemplary embodiments of the present invention, a wireless electric wave may be efficiently and optimally operated and utilized so as to be adapted for the future various services and complex wireless environment. In addition, a technology in which a wireless communication environment adaptation real time polarization control technology and a MIMO signal processing technology are combined with each other in order to transmit data at a high speed may be widely applied to the next generation mobile communication base station/relay array antenna system.
Further, in the present invention, “comprising” a specific configuration will be understood that additional configuration may also be included in the embodiments or the scope of the technical idea of the present invention.
In the above-mentioned exemplary system, although the methods have described based on a flow chart as a series of steps or blocks, the present invention is not limited to a sequence of steps but any step may be generated in a different sequence or simultaneously from or with other steps as described above. Further, it may be appreciated by those skilled in the art that steps shown in a flow chart is non-exclusive and therefore, include other steps or deletes one or more steps of a flow chart without having an effect on the scope of the present invention.
The above-mentioned embodiments include examples of various aspects. Although all possible combinations showing various aspects are not described, it may be appreciated by those skilled in the art that other combinations may be made. Therefore, the present invention should be construed as including all other substitutions, alterations and modifications belong to the following claims.
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The present invention relates to a general active array antenna apparatus capable of environmentally and temporally controlling radio frequency (RF) polarization resource necessary for wireless communication in order to improve communication quality and increase communication capacity. The antenna according to the present invention has a form of an active array antenna element, wherein each active array antenna element has a structure in which it may generate orthogonal dual polarizations and includes two input terminals and output terminals. An end orthogonal dual polarization antenna is connected to a polarization control apparatus that may process analog or digital signals, and the polarization control apparatus is controlled by or communicate with an antenna main controlling apparatus performing a polarization control algorithm. Ultimately, an object of this antenna apparatus is to improve communication quality and increase communication capacity.
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This application is a continuation of U.S. Pat. application Ser. No. 07/670,432, filed Mar. 18, 1991, now abandoned.
FIELD OF THE INVENTION
This application is directed to rearranged taxol compounds, and more particularly is directed to taxol derivatives with an opened oxetane ring, taxol derivatives in which the oxetane ring is opened and the A-ring is contracted, and taxol derivatives with a contracted A-ring.
BACKGROUND OF THE INVENTION
The naturally occurring diterpenoid taxol has great potential as an anti-cancer drug, and has shown activity in several tumor systems. Background information on taxol, the mechanisms of taxol's biological activity, and the synthesis of water soluble derivatives from taxol, are described in copending U.S. application Ser. No. 07/573,731, filed Aug. 28, 1990 now U.S. Pat. No. 5,059,699 . All references cited herein are incorporated by reference as if reproduced in full below.
Taxol is in short supply and is relatively expensive. Further, total synthesis of taxol is quite difficult due to the bridged bicyclic portion of the taxane ring structure Therefore, it is highly desirable to find taxol derivatives with similar biological activities, which lend themselves to easier total synthesis than taxol.
There is also a need for a method to quickly determine the biological activities of new compounds or pharmaceutical compounds having bioactivities or structures similar to taxol. The short supply and expense of taxol makes impractical the use of taxol as a standard in determining the bioactivities of other compounds; thus, it is highly desirable that a range of other standards with known biological activities be available to determine the bioactivity of taxol derivatives and other compounds relative to taxol. Useful standards should be derivatives of taxol, or the standards should be compounds which have similar structures to taxol, but which are more readily available or which can be synthesized easier than taxol. At present, some derivatives, which do not exhibit the same high biological activity as taxol, are thrown away; this waste would be eliminated by a method which uses taxol derivatives, which have significantly less biological activity than taxol, as standards in bioactivity testing, rather than utilizing more taxol, which is already in short supply and very expensive.
Thus, there is a need for taxol derivatives having a range of in vivo and in vitro activities, and there is a need for taxol derivatives or compounds having similar biological activities to taxol which are capable of easier total synthesis than taxol.
OBJECTS OF THE INVENTION
Thus, it is a primary object of the present invention to synthesize taxol derivatives having varying in vitro and vivo activities for use as standards in determining the bioactivity of other compounds in comparison to taxol.
It is a further object of the present invention to synthesize derivatives of taxol, having similar in vivo activities, which are capable of easier total synthesis than taxol.
SUMMARY OF THE INVENTION
These and other objects of the present invention are accomplished through synthesis of compounds useful for the aforementioned purposes and objectives. In a preferred embodiment, taxol is treated with mesyl chloride to prepare a taxol derivative with a contracted A-ring, which has comparable activity to taxol in a tubulin depolymerization assay, and which shows cytotoxicity against KB cells in a cell culture assay. In an alternate preferred embodiment, taxol is treated with triethyloxonium tetrafluoroborate (Meerwein's reagent) to produce a taxol derivative with an opened oxetane ring. In another alternate preferred embodiment, reaction of taxol with acetyl chloride yields a taxol derivative in which the oxetane ring is opened and the A-ring is contracted. All of the aforementioned products show in vivo activity in KB cell culture assays. Further, the preferred compounds have different in vivo activities, which makes them ideal to form a range of standards for biological testing of other compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generalized representation of a taxol compound structure.
FIG. 2 is a generalized representation of a taxol compound with an opened oxetane ring.
FIG. 3 is a generalized representation of a taxol compound having a contracted A-ring and an opened oxetane ring.
FIG. 4 is a generalized representation of a taxol compound with a contracted A-ring.
FIG. 5 is a representation of structure of an acetonide of taxol.
FIG. 6 is an alternate generalized representation of a taxol compound.
FIG. 7 is a generalized representation of the hydrogenated form of the compound illustrated in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, the structure of taxol (1) is represented when R1 is C(O)CH 3 , R2 is OH, R3 is H, and R4 is H. The derivatives of taxol discussed herein are represented in FIGS. 1-7, with specific structure variables R1-R7, defined in Table I below. For the sake of convenience, structures will be referred to by the structure numbers provided in Table I.
TABLE I______________________________________Variable Definitions For Structures DiscussedHerein And Illustrated In FIGS. 1-7Structure FIG.Number Number Variable Definitions______________________________________(1) 1 R1 = C(O)CH.sub.3, R2 = OH, R3 = H, R4 = H(2) 1 R1 = C(O)CH.sub.3, R2 = H, R3 = OH, R4 = H(3) 1 R1 = H, R2 = H, R3 = OH, R4 = H(4) 2 R1 = C(O)CH.sub.3, R2 = OH, R3 = H, R4 = H, R5 = H R6 = H, R7 = C(O)CH.sub.3(5) 2 R1 = C(O)CH.sub.3, R2 = OC(O)CH.sub.3, R3 = H, R4 = C(O)CH.sub.3, R5 = H, R6 = H, R7 = C(O)CH.sub.3(6) 2 R1 = C(O)CH.sub.3, R2 = OC(O)CH.sub.3, R3 = H, R4 = C(O)CH.sub.3, R5 = OC(O)CH.sub.3, R6 = H, R7 = C(O)CH.sub.3(7) 3 R1 = C(O)CH.sub.3, R2 = OC(O)CH.sub.3, R3 = H, R4 = C(O)CH.sub.3, R5 = OC(O)CH.sub.3, R6 = OH, R7 = OC(O)CH.sub.3(8) 7 R1 = C(O)CH.sub.3, R2 = OC(O)CH.sub.3, R3 = H, R4 = C(O)CH.sub.3, R5 = OC(O)CH.sub.3, R6 = OH, R7 = OC(O)CH.sub.3(9) 4 R1 = C(O)CH.sub.3, R2 = OSi(CH.sub.2 CH.sub.3).sub.3, R3 = Si(CH.sub.2 CH.sub.3).sub.3(10) 4 R1 = C(O)CH.sub.3, R2 = OH, R3 = H(11) 6 R1 = C(O)CH.sub.3, R2 = OSi(CH.sub.2 CH.sub.3).sub.3, R3 = OH, R4 = Si(CH.sub.2 CH.sub.3).sub.3(12) 5 R1 = C(O)CH.sub.3, R2 = C(O)CH.sub.3(13) 6 R1 = C(O)CH.sub.3, R2 = OSi(CH.sub.2 CH.sub.3).sub.3 , R3 = OSO.sub.2 CH.sub.3, R4 = Si(CH.sub.2 CH.sub.3).sub.3______________________________________
Due to the complexity of the taxol structure, and the incomplete understanding of the relationship between the taxol structure and its activity, it was difficult or impossible to predict how derivatives of taxol would behave; further, the complexity of the taxol structure made prediction of reaction product structures equally difficult. The present invention overcomes these problems through the synthesis of taxol derivatives with a contracted A-ring (FIG. 4), with a contracted A-ring and an opened oxetane ring (FIG. 3), or with an opened oxetane ring (FIG. 2), which retain in vivo activity, although at different levels than taxol.
The taxol derivative having a contracted A-ring structure, otherwise known in a preferred embodiment as A-Nortaxol (10), is easier to perform total synthesis of than taxol since the bridged bi-cyclic portion of the diterpenoid structure has been fused. Further, it has been discovered that A-Nortaxol has an in vitro activity very close to that of taxol in a tubulin depolymerization assay. Thus, A-Nortaxol (10) can be used in a similar fashion to taxol (1).
It is believed that the oxetane ring (the D-ring in taxol (1)) is susceptible to ring-opening by reaction with electrophilic reagents, so initial experiments were performed using zinc bromide as an electrophile to attempt to open the oxetane ring on taxol. Taxol (1) was combined with zinc bromide in methanol at ambient temperature, but the oxetane ring was not opened, and the taxol simply underwent epimerization of the C-7 hydroxyl group and cleavage of the 10-acetyl group to yield 7-epitaxol (2) and 10-deacetyl-7-epitaxol (3).
The relatively mild conditions created by zinc bromide in methanol were selected because it was believed that the more vigorous conditions created by other electrophiles and other solvents may result in taxol derivatives without any substantial biological activity due to destruction of part or all of the bioactive portions of the molecule. However, it was surprisingly discovered that treatment of taxol with different electrophilic groups resulted in rearrangement of different portions of the taxol structure, and that some of the various products retained in vivo activity. More specifically, reaction of taxol with the strong electrophile triethyloxonium tetrafluoroborate (Meerwein's reagent) resulted in a taxol derivative (4) with an opened oxetane ring. Reaction of taxol with acetyl chloride yielded a product (7) in which the oxetane ring was opened, but the A-ring was contracted. Treatment of the protected taxol (11) with mesyl chloride, followed by deprotection, resulted in a taxol derivative with a contracted A-ring alone, A-Nortaxol (10).
It was also surprisingly discovered that these rearranged taxol derivatives (4), (7), and (10) all retain varying degrees of in vivo activity, as determined by KB cell culture assays. A-Nortaxol (10) also showed very similar activity to taxol in a tubulin depolymerization assay, and showed higher in vivo activity than the acetyl chloride product (7) and the Meerwein product (4). Thus, the range of activity shown by the taxol derivatives of the present invention make them ideal for use as standards in biological testing. Further, A-nortaxol (10) and the acetyl chloride product (7) are easier to perform synthesis on than taxol since the A and B rings are fused in the products rather than bridged (note that the bridge bond between A and B rings in taxol is extremely difficult to synthesize). Thus, the present invention includes a method, which is highly useful to researchers in determining the activity of compounds in comparison to taxol (1) and taxol derivatives; the method has an additional advantage, since it is not necessary to use the limited and expensive supply of taxol as a control or standard.
In a preferred process, new compounds or production line pharmaceutical compounds, which must be tested to ensure bioactivity in comparison to taxol, are subjected to bioactivity evaluation in parallel with standards utilizing compounds (4), (7), and (10). Since the relative bioactivities of products (4), (7), and (10) are known (in comparison to one another as well as to taxol), the relative bioactivity of the compound being tested to taxol can be determined in a reliable fashion. Thus, in addition to the in vivo activity of compounds (4), (7), and (10), which makes the compounds useful as cytotoxic agents, they are also useful in extending the limited supply of taxol. This is because the method of the present invention replaces taxol with new compounds in testing other compounds which are used as cytotoxic agents in general, or, which are used as anti-cancer or anti-leukemic drugs in humans.
METHODS AND MATERIALS
Specific reaction methods are described in more detail in the following non-limiting examples. The methods used herein are generally described in the Journal Of Organic Chemistry, 51, pp. 797-802 (1986). Low resolution mass spectrometry data were obtained on a VG 7070 E-HF mass spectrometer. Exact mass measurements were performed at the Midwest Center for Mass Spectrometry, NSF Regional Instrumentation Facility (Grant Che-8211164). The term "standard work-up" in the following non-limiting examples includes extraction with a suitable solvent (usually ethyl acetate or methylene chloride), washing the extract with water, drying over magnesium sulfate or sodium sulfate, and evaporation in vacuo. All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Other methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention.
EXAMPLE 1
Taxol (1) was reacted with zinc bromide, ZnBr 2 as follows: 100 mg taxol (0.117 mmol) was combined with 3.3 g ZnBr 2 (0.4 mmol) in 10 ml CHCl 3 :MeOH(1:4) and stirred for 24 hours at 40° C. Water was added to the mixture, and the standard work-up (as defined above in "Methods") yielded a white solid. The solid was purified by chromotography to obtain two compounds, which were identified as 7-epi-taxol (2) and 10-deacetyl-7-epitaxol (3) by comparison to published data (see Journal of Natural Products, 49, pp. 665-669 (1986), and Journal of Natural Products, 44, pp. 312-319 (1981); compounds (2) and (3) have been previously described by McLaughlin et. al. in Journal of Natural Products, 44, pp. 312-319 (1981). Thus, it was necessary to try more vigorous reaction conditions to open the oxetane ring, despite the risk that the more vigorous conditions would cause other portions of the taxol structure to be altered to an extent that the resulting compound would lack any substantial bioactivity.
EXAMPLE 2
Taxol (1) was reacted with Meerwein's reagent as follows: A solution of taxol in dichloromethane was prepared by adding 100 ml taxol (0.117 mmol) to dry dichloromethane. The taxol solution in dichloromethane was cooled and stirred while 200μl triethyloxonium tetrafluoroborate (1 M in CH 2 Cl 2 ) was added drop-wise from a freshly opened bottle. These conditions were maintained for 3? minutes, at which time the reaction was quenched with 3 ml of ethereal HCl (1:2 mixture of 1N HCl:ether) followed by stirring for 10 minutes. Standard workup gave a crude solid, which was further purified by flash chromotography and PTLC to yield 53 mg (51%) of a taxol compound with a opened oxetane ring (4) (The "Meerwein product"). NMR, MS, and IR (KBr) were performed on a sample of the Meerwein product (4) and its melting point was determined, with the characterization data and NMR data presented in Tables II and III below:
TABLE II______________________________________Characterization Data For Product (4)(Resulting From Reaction Of Taxol With Meerwein's Reagent)______________________________________Melting Point 160-164° C. (amorphous solid)IR (KBr) cm.sup.-1 1745(s), 1670(m), 1535(w), 1505(w), - 1474(w), 1395(m), 1120(m), 1080(m), 1060(m)MS(FAB) m/z 872 (MH.sup.+, 100), 854 (MH.sup.+, H.sub.2 O)High-resolution calculated (MH.sup.+) 872.3493;mass spectrum observed 872.3463______________________________________
TABLE III______________________________________NMR Data for Reaction Product OfTaxol With Meerwein's Reagent, C.sub.47 H.sub.54 NO.sub.15 (4)Carbon Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.56 (d,6) 3 4.03 (3,6) 5 3.70 (br s) 6 .sup.a 7 4.49 (dd 4,11)10 5713 6.01 (br dd, 4,11)14 2.45 (dd, 11,16) 3.08 (dd, 4,16)1516 1.12 (s)17 1.12 (s)18 2.10 (s).sup.b19 1.22 (s)20 3.85 (ABq, 11 Δv.sub.AB = 86) 2' 4.70 (br s) 3' 5.92 (dd, 2,9)NH 7.19 (br d,9)OAc 1.65 (s) 2.25 (s)2-OBz 8.03 (m) 7.3-7.6 (m).sup.c3'-NBz 8.03 (m) 7.3-7.6 (m).sup.c3'-Ph 7.3-7.6 (m).sup.cOH 3.91 (s)______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks
EXAMPLE 3
The Meerwein product (4) was acetylated as follows: 5 mg of the Meerwein product (4) (0.0057 mmol) was dissolved in 100μl of pyridine, and 300μl of acetyl chloride (excess) was added to the solution; the solution was kept at room temperature for 30 minutes, and warmed to 60° C. for one hour, followed by quenching with water. Standard work-u yielded crude material which was purified on PTLC to yield 3 mg (55%) of chromatographically homogeneous 2',7-diacetyl-D-seco-taxol (5). Structure was confirmed with 1 H NMR.
EXAMPLE 4
2',7-diacetyl-D-seco-taxol (5) was acetylated as follows: 8 mg 2',7-diacetyl-D-seco-taxol (5) (0.008 mmol) was dissolved in 750μl tetrahydrofuran (THF) and to this solution dicyclohexylcarbodiimide (5 mg, 2.5 eq) 4μl acidic anhydride (5 eq) and a catalytic amount of pyrrolidino pyridine were added. The stirred solution was heated to 60° C. for 7.5 hours, the solvent was then evaporated and the residue extracted into ethyl acetate. Standard work-up yielded a crude mixture which was purified by PTLC with 1% MeOH/CHCl 3 to yield 3 mg (38% yield at 63% conversion) of 2',5,7-triacetyl-D-seco-taxol (6). Characterization data is presented in Table IV and NMR data is presented in Table V below.
TABLE IV______________________________________Characterization Data For2', 5, 7-Triacetyl-D-Seco-Taxol (6)______________________________________IR cm.sup.-1 1740(s), 1720(s), 1676(m), 1625(s), 1225(s)MS(FAB)m/z 998(MH.sup.+, 13) 980(MH.sup.+, 12) 936(6) 848(23),(relative 650(100).intensity)______________________________________
TABLE V______________________________________NMR Data For 2', 5, 7-Triacetyl-D-Seco-Taxol (6)Carbon Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.63 (d,5) 3 4.04 (d,5) 5 5.26 (m).sup.c 6 a 7 5.43 (br d, 9)10 6.42 (s)13 6.03 (m)14 2.40 (dd, 9,15) 3.07 (dd, 5,15)1516 1.13 (s)17 1.11 (s)18 2.24 (s)19 1.38 (s)20 4.01 (ABq, 12 Δv.sub.AB = 57) 2' 5.26 (m).sup.c 3' 6.12 (dd,3,1O)NH 7.20 (br d,9)OAc 1.98 (s), 2.13 (s), 2.16 (s), 2.19 (s), 2.20 (s)2-OBz 8.20 (m)3'-NBz 7.8 (m)3'-Ph 7.2-7.6 (m).sup.cOH______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks
EXAMPLE 5
The Meerwein product (4) was then treated with 2,2-propane as follows: 6 mg of the Meerwein product (4) (0.007 mmol) and 200μl 1 2,2-dimethoxypropane was combined in 500μl dry dichloromethane along with a catalytic amount of p-dry toluenesulfonic acid, and stirred for one hour. Standard workup yielded a crude product, which was further purified by PTLC to obtain 6 mg (95%) of pure acetonide (12) (FIG. 5). The structure of the acetonide (12) was confirmed by 1 H NMR and by mass spectrometry; MS(FAB) m/z (relative intensity): 916 (MNa + , 100), 855 (MNa + --HOAc--H, 25), 832 (MNa + --CH 3 CO--C 3 H 5 , 50) 761(40). 1 H NMR data is presented in Table VI below.
TABLE VI______________________________________NMR Data for Acetonide (12) Of The Meerwein Product (4)Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.34 (d,8) 3 3.06 (d,8) 5 4.34 (m) 6 6.sub.ax 1.95 (ddd 5,11,15).sup.b 6.sub.eq 2.36 (ddd) 2,5,15) 7 4.48 (dd,5,11)10 6.38 (d,2)13 5.68 (d,2)14 2.57 (AB part of ABX, 9, 14 Δv.sub.AB = 62)1516 4.67 (s), 4.75 (s)17 1.63 (s)18 1.67 (s).sup.b19 1.62 (s)20 4.15 (ABq, 12, Δv.sub.AB = 26) 2' 4.50 (d,3) 3' 5.60 (dd,3,8)NH 6.98 (br d,8)OAc 1.83 (s), 2.17 (s)2-OBz 8.10 (m) 7.3-7.4 (m).sup.c3'-NBz 7.73 (m) 7.3-7.4 (m).sup.c3'-Ph 7.3-7.4 (m).sup.cOHOther 1.30 (s).sup.d 1.33 (s)______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks .sup.d signals of the methyl groups of the acetonide
EXAMPLE 6
Taxol (1) was reacted with acetyle chloride under the following conditions: 200 mg taxol (0.23 mmol) was dissolved in 2 ml acetyle chloride, and the solution was refluxed for one hour. The reaction was quenched with ice water and ethyl acetate, and stirred for 30 minutes. Standard work-up yielded a white solid. Recrystallization of the white solid from ethyl acetate and hexanes yielded acetylated A-Nor-D-seco-taxol (7) (See FIG. 3) as white needles (156 mg, 68%). Characterization data for acetylated A-Nor-D-seco-taxol (7) is provide in Table VII and NMR data is provided in Table VIII below.
TABLE VII______________________________________Characterization Data For Acetylated A-Nor-D-seco-taxol______________________________________(7)Melting Point 140-142° C.IR(CHCl.sub.3) cm.sup.-1 1750(s), 1660(m), 1606(m), 1372(m), 1282(m), 1156(m)MS(FAB)m/z 1002(MNa.sup.+, 35), 676(MNa.sup.+ -side-chain, 15), 616 (675-HOAc, 30), 554(676-PhCOOH, 20), 494(616-PhCOOH, 30), 411(24), 3722(4), 177(100)High resolution calculated for C.sub.53 H.sub.57 NO.sub.17 Na(MNa.sup.+) = 1002.3524;mass spectrum observed 1002.3557______________________________________
TABLE VIII______________________________________NMR Data For Acetylated A-Nor-D-seco-taxol (7)Carbon Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.35 (d,7) 3 3.54 (d,7) 5 5.28 (br s) 6 a 7 5.54 (dd,4,13)10 6.38 (s)13 5.67 (t,7)14 2.64 (m)1516 4.69 (s), 4.82 (s)17 1.62 (s)18 1.82 (s)19 1.53 (s)20 4.15 (ABq, 12 Δv.sub.AB = 55) 2' 5.52 (d,2) 3' 6.02 (dd,2,9)NH 7.03 (d,9)OAc 1.85 (s), 2.00 (s), 2.13 (s), 2.17 (s), 2.22 (s)2-OBz 7.93 (m), 7.2-7.9 (m).sup.c3'-NBz 7.85 (m) 7.2-7.9 (m).sup.c3'-Ph 7.2-7.9 (m).sup.cOH 3.75 (s)Other______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks
EXAMPLE 7
The Meerwein product (4) was treated with acetyle chloride as follows: 50 mg of the Meerwein product (4) (0.057 mmol) was dissolved in CHCl 3 ; 3 mg pyrrolidinopyridine (an amount sufficient to catalyze the reaction) and excess acetyle chloride (5eq) were added to the solution. Excess triethylamine was then added dropwise to the stirred solution at room temperature. A red color developed, which disappeared when more acetyl chloride was added; additional triethylamine and acetyl chloride were added until a single major product was obtained. The reaction was stopped after a total reaction time of 5 hours by addition of 3 ml of water and stirring for 30 minutes. Standard work-up was followed with an additional wash with 3N HCl. The mixture of products was subjected to PTLC to obtain the major component as 10 mg of a white solid (18%). 1 H NMR, mass spectrometry, and infrared spectrometry confirmed that this compound was identical to the acetyl product of Example 6, acetylated A-Nor-D-seco-taxol (7)
EXAMPLE 8
The acetylated A-Nor-D-seco-taxol (7) was hydrogenated to its dihydro derivative (8) (FIG. 7) as follows: 24 mg of the acetyl chloride product (7) (0.023 mmol) was dissolved in 2.5 ml ethyl acetate, and hydrogenated over Pd/H 2 . After 24 hours, the catalyst was filtered off, and the solvent was evaporated to yield a crude solid, which consisted of product and unreacted starting material; the unreacted starting material was not separable from the product. The crude product was dissolved in methylene chloride and treated with 5 mg m-chloroperbenzoic acid (58%) at room temperature for 3 hours; this converted the starting material to its separable epoxide. The solvent was evaporated and the residue subjected to PTLC with 4% MeOH/CHCl 3 to yield 8 mg pure hydrogenated product (8) (35%) along with 11 mg of a mixture of diastereomeric epoxides. The hydrogenated product (8) was recrystallized from ethyl acetate and hexanes. Characterization data is presented in Table I below and NMR data is presented in Table IX below.
TABLE IX______________________________________Characterization data forHydrogenated Acetylated A-Nor-D-Seco-Taxol (8)______________________________________Melting Point 148-150° C.IR (KBr) cm.sup.-1 1740(s), 1720(m), 1640(m), 1220(m), 910(m)MS(FAB) m/z 1004(MNa.sup.+, 100), 962(MNa.sup.+ -C.sub.3 H.sub.6, 10),(relative 944(MNa.sup.+ -HOAc, 15)intensity)______________________________________
TABLE X______________________________________NMR Data For HydrogenatedAcetylated A-Nor-D-Seco-Taxol (8)Carbon Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.17 (d,8) 3 3.68 (d,8) 5 4.94 (br d, 11) 6 a 7 5.54 (dd,5,11)10 6.36 (s)13 5.72 (m)14 2.48 (AB part of ABX, 14, 16 Δv.sub.AB 32 65)15 1.60 (m)16 0.76 (d, 7)17 0.78 (d, 7)18 1.83 (s)19 1.53 (s)20 4.11 (ABq, 11 Δv.sub.AB = 78) 2' 5.40 (d,3) 3' 5.95 (dd,3,8)NH 7.02 (d,8)OAc 1.17 (s), 1.18 (s), 2.00 (s), 2.13 (s), 2.17 (s)2-OBz 7.91 (m), 7.2-7.6 (m).sup.c3'-NBz 7.83 (m) 7.2-7.6 (m).sup.c3'-Ph 7.2-7.6 (m).sup.cOHOther______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks
EXAMPLE 9
Taxol was reacted with imidazole and triethylsilylchloride as follows: 238 mg of solid imidazole (10 eq) was added to a solution of 200 mg taxol (0.234 mmol) in 2.5 ml DMF; 196μl triethylsilylchloride (10 eq) was then added to the stirred solution while the solution was at room temperature, followed by warming the solution to 45°-50° C.. After 2 hours, the solution was diluted with water, and extracted with ethyl acetate. The crude solid obtained after evaporation of the solvent was purified on a silica gel flash column to yield 242 mg (96%) of pure 2',7-bis (triethylsilyl)taxol (11) (FIG. 6). Characterization data is presented in Table XI and NMR data is presented in the Table XII below.
TABLE XI______________________________________Characterization Data For2',7-bis(triethylsilyl)taxol (11)______________________________________Melting Point 122-123° C.IR cm.sup.-1 1740(s), 1720(s), 1660(s), 1640(m), 1240(s), 810(m)MS(FAB) m/z 1104(MNa.sup.+, 100), 1003(30), 981(MNa.sup.+ -(relative PhCOOH, 10)intensity)______________________________________
TABLE XII______________________________________NMR Data l For 2,',7-bis(triethylsilyl)taxol (11)Carbon Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.71 (m) 3 3.88 (d,6) 5 4.94 (br d, 11) 6 a 7 4.48 (dd,6,14)10 6.44 (s)13 6.20 (m)14 a1516 1.22 (s)17 1.18 (s)18 2.02 (s)19 1.70 (s)20 4.27 (ABq, 11 Δv.sub.AB = 63) 2' 4.71 (d, 3) 3' 5.71 (m)NH 7.12 (d,9)OAc 2.17 (s), 2.55 (s)2-OBz 8.12 (m) 7.2-7.5 (m).sup.c3'-NBz 7.79 (m) 7.2-7.5 (m).sup.c3'-Ph 7.2-7.5 (m).sup.cOHOther 0.48 (6H,m).sup.c 0.57 (6H,m) 0.81 (9H,t,8) 0.91 (9H,t,8)______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks
EXAMPLE 10
2',7-bis(triethylsilyl)taxol (11) was treated with triethylamine and mesyl chloride (methane sulfonyl chloride) as follows: 30 mg of 2',7-bis(triethylsilyl)taxol (II) (0.028 mmol) was added to 3 ml of dry methylene chloride, and cooled to -15° C. under argon. 600μl of triethylamine (154 eq) was added, followed by addition of 300μl of mesyl chloride (138 eq) in 1 ml methylene chloride, with the additions made over a 5 minute period. The mixture was allowed to warm to -5° to 0° C., and this temperature was maintained for a total reaction time of 2.5 hours, at which time 50% conversion of the starting material to 2',7-bis(triethylsilyl)-A-Nortaxol (9) (FIG. 4) was observed. The solution was cooled again to -15° C., and 1 ml triethylamine and 500μl mesyl chloride were added; this latter procedure was repeated one additional time. The reaction was then stopped by adding 2 ml triethylamine, 5 ml water, and 5 ml ethyl acetate. Standard work-up yielded crude material, which was purified by PTLC to give 6 mg (20%) of 2',7-bis(triethylsilyl)-A-Nor-taxol (9) (FIG. 4) along with 2 mg starting material and 2 mg 7-triethylsilyl-A-Nor-taxol. It is believed that the mesylate (13) (FIG. 6) is formed as an intermediate between (11) and (9). Mass spectrometry data, m/z, are as follows: 1086(MNa + , 45), 1064(MH + , 75), 1005(MH + --OAc, 25), 975(MH + --OAc--CH 2 O, 15) 963(MH + --OAc-C 3 H 6 , 15) 820(MH + --PhCOOH,PhCONH 2 --H, 100). NMR data is presented in Table XIII below:
TABLE XIII______________________________________NMR Data For 2',7-bis(triethylsilyl)-A-Nor-taxol (9)Carbon Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.54 (d,8) 3 3.53 (d,8) 5 5.02 (d,8) 6 1.90 (m) 7 4.53 (dd,8,5)10 6.39 (s)13 5.81 (br t,7)14 2.40 (m)15 2.60 (m)16 4.66 (s), 4.75 (s)17 1.65 (s)18 1.62 (s)19 1.73 (s)20 4.15 (ABq, 12) Δv.sub.AB = 26) 2' 4.60 (d,2) 3' 5.64 (dd,2,11)NH 7.15 (d,11)OAc 2.02 (s), 2.40 (s)2-OBz 8.01 (m) 7.2-7.5 (m).sup.c3'-NBz 7.70 (m) 7.2-7.5 (m).sup.c3'-Ph 7.2-7.5 (m).sup.cOHOther 0.38 (6H,m).sup.e 0.60 (6H,m) 0.75 (9H,t, 8) 0.90 (9H,t, 8)______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks .sup.e signals of the ethyl groups of the TES groups
EXAMPLE 11
2',7-bis(triethylsilyl)-A-Nor-taxol (9) was treated with pyridinium hydrofluoride as follows: 67 ml 2',7-pyridinium bis(triethylsilyl)-A-Nor-taxol (9) (0.07 mmol) was dissolved in 1 ml dry THF under argon. The solution was cooled to 0° C. and 100μl pyridinium hydrofluoride (70% in pyridine) was added. After 3 hours the cooling bath was removed, and the reaction was allowed to proceed for an additional 45 hours at room temperature. The reaction was quenched with 2 ml aqueous pyridine (10% v/v pyridine). Standard work-up resulted in a crude solid which was purified by PTLC with 8% MeOH/CHCl 3 , as the eluent. A-nor-taxol (10) was obtained as a white solid in 55% yield (29 mg). (Note that deprotection of the silyl ether (9) yielded a mixture of products when tetrabutylammonium fluoride was used instead of pyridinium hydrofluoride.) Mass spectrometry data, n/z (relative intensity), as follows: 836(MH + , 100), 776(MH + -HOAc, 30), 551(836-side-chain-H, 10), 307(20); High resolution mass spectrum calculated for C 47 H 50 NO 13 (MH + ) was 836.3282, observed 836.3272. 1 H NMR is presented in Table XIV below.
TABLE XIV______________________________________.sup.1 H NMR Data For A-Nor-Taxol (10)Carbon Position .sup.1 H Shift (PPM from TMS) Coupling Hertz______________________________________ 2 5.49 (d,8) 3 3.48 (d,8) 5 5.04 (d,8) 6 1.86 (dd,11,15); 2.59 (ddd,8,9,15) 7 4.63 (dd,9,11)10 6.32 (s)13 5.71 (m).sup.c14 2.04 (dd,8,13) 2.42 (dd,13,6)1516 4.69 (br s) 4.76 (br s)17 1.59 (s)18 1.61 (s)19 1.64 (s)20 4.24 (ABq, 8, Δv.sub.AB = 34) 2' 4.67 (d,2) 3' 5.71 (dd,11,2).sup.cNH 6.89 (d,11)OAc 2.17 (s), 2.36 (s)2-OBz 8.10 (m) 7.2-7.6 (m).sup.c3'-NBz 7.66 (m) 7.2-7.6 (m).sup.c3'-Ph 7.2-7.6 (m).sup.cOHOther______________________________________ .sup.a peak concealed under signals from methyl group .sup.b determined by decoupling experiment .sup.c overlapping peaks
BIOLOGICAL TESTING OF TAXOL DERIVATIVES
Taxol (1) the Meerwein product (4), the acetyl chloride product (7), and A-nor-taxol (10) were tested in KB cell culture assays. All of the samples showed in vivo activity as shown in Table XV below (note that an ED 50 (μg/ml) of less than 4.0 indicates in vivo activity). Taxol has been shown to have great potential as an anti-cancer drug, so that these compounds can be used in a similar fashion to taxol as cytotoxic agents.
TABLE XV______________________________________Bioactivity of Modified Taxols In KB Cell CultureCompound ED.sup.50 (μg/ml) cell culture______________________________________Taxol (1) 0.00001Meerwein product (4) 2.3Acetyl Chlorideproduct (7) 2.5A-Nortaxol (10) 2.0______________________________________
Taxol (1), the Meerwein product (4), the acetyl chloride product (7), and A-Nor-Taxol (10) were also subjected to tubulin depolymerization assays with the results presented in Table XVI below.
TABLE XVI______________________________________In Vitro Activity In Tubulin Depolymerization Assay ID.sub.50 (μM) in tubulinCompound depolymerization assay______________________________________Taxol (1) 0.3Meerwein product (4) >6.3A-Nortaxol (10) 0.9______________________________________
Note that A-Nor-Taxol (10) has an activity which is very similar to taxol in the tubulin depolymerization assay. Since the A-Nor-Taxol (I0) structure has a fused A-ring, A-Nor-Taxol (10) is a more likely candidate for total synthesis than taxol. Further, because A-Nor-taxol has been found to be cytotoxic, and to have an in vitro activity close to taxol's in a tubulin depolymerization assay, it is believed that A-Nor-taxol (10) may have bioactivity mechanisms very similar to taxol's (1).
With reference to Table XV, note that the in vivo activity of A-Nor-Taxol (10), the Meerwein product (4), and the acetyl chloride product (7) are 2.0, 2.3, and 2.5 respectively. This range of in vivo activities makes these compounds useful as standards for testing other compounds, eliminating the need for taxol standards. Since, the relative in vivo activity of these compounds is now known, the bioactivity of an unknown compound can be determined with respect to these compounds without having to refer to any published data or without use of taxol as a standard.
A preferred process for testing the bioactivity of unknown compounds, or for testing taxol-derived pharmaceuticals, includes treatment of an unknown sample in a bioactivity test, and simultaneous treatment under the same conditions of at least one, preferably of all three, of the following products: A-Nor-Taxol (10), the Meerwein product (4), and the acetyl chloride product (7). By comparison of results for the unknown sample with the results for the products (4), (7), and (10), the in vivo activity of the unknown can be determined.
Due to the bioactivity demonstrated for some of the compounds of the present invention, it is believed that compounds (4)-(12) will be useful directly as, or as intermediates for, antineoplastic, antileukemic and anticancer prodrugs or drugs, and their use as such is considered to be a part of the present invention.
Contemplated equivalents of the rearranged taxol compounds of the present invention include rearranged taxol compounds having a contracted A-ring, an opened oxetane ring, or a contracted A-ring and an opened oxetane ring, which have one or more side chain or ring substituents substituted with a non-interfering group (e.g., a substituted group which does not seriously alter the desirable properties of the rearranged taxol compounds of the present invention), such as, but not limited to, substitution of --H, --OH, --OR, --NR, --Ar, --OC(O)CH 3 , Ph--I--, PH--N--, or ═O for another non-interfering moiety.
From the above teachings, it is apparent that many modifications and variations of the present invention are possible. It is therefore to be understood that the invention may be practiced otherwise than as specifically described.
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In a preferred embodiment, taxol is treated with mesyl chloride to prepare a taxol derivative with a contracted A-ring, which has comparable activity to taxol in a tubulin depolymerization assay, and which shows cytotoxicity against KB cells in a cell culture assay. In an alternate preferred embodiment, taxol is treated with triethyloxonium tetrafluoroborate (Meerwein's reagent) to produce a taxol derivative with an opened oxetane ring. In another alternate preferred embodiment, reaction of taxol with acetyl chloride yields a taxol derivative in which the oxetane ring is opened and the A-ring is contracted. All of the aforementioned products show in vivo activity in KB cell culture assays. Further, the preferred compounds have different in vivo activities, which makes them ideal to form a range of standards for use in biological testing of other compounds.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is related to the application of Varian S.p.A. (Ser. No. 12/343,961) entitled “CENTRIPETAL PUMPING STAGE AND VACUUM PUMP INCORPORTING SUCH PUMPING STAGE”
FIELD OF THE INVENTION
The present invention relates to a spiral pumping stage for vacuum pump. More particularly, the present invention relates to an improved spiral molecular pumping stage and to a vacuum pump comprising the pumping stage.
BACKGROUND OF THE INVENTION
Molecular drag pumping stages produce pumping action by momentum transfer from a fast-moving surface (moving at speed comparable to thermal speed of the molecules) directly to gas molecules. Generally, these pumping stages comprise a rotor and a stator cooperating with each other and defining a pumping channel therebetween. Collisions of gas molecules in the pumping channel with the rotor rotating at a very high speed cause gas in the channel to be pumped from the inlet to the outlet of the channel itself.
With reference to FIG. 1 , between 1920-1930 Karl Manne Georg Siegbahn developed a molecular pumping device 10 , wherein the pumping action is obtained through the cooperation of a rotor disk 20 having smooth surfaces integral with a rotating shaft 30 with a pair of stator bodies 40 , 50 , each facing a rotor disk surface and provided with a corresponding spiral-shaped groove 60 open towards the respective surface of the rotor disk and defining therewith a corresponding pumping channel.
The Siegbahn patent GB 332,879 discloses an arrangement of the above-mentioned kind. The gas to be pumped, entering through an inlet 70 at the outer periphery of each pumping groove, flows in both spiral channels in centripetal direction, i.e. from the outer periphery towards the center of the pumping grooves, as indicated by arrows CP. In this case two spiral pumping channels in parallel are to be considered; the gas flows in both channels in centripetal direction.
According to Siegbahn, in order to control the resistance of the gas pumped through the spiral channels 60 , the cross-section area of these channels is reduced from the outer periphery of the stator bodies towards their center, in accordance with the reduction of the tangential speed of the disk, in the direction of the gas flow.
U.S. Pat. No. 6,394,747 (M. Hablanian) discloses a vacuum pump having reduced overall size and weight utilizing for this purposes a pair of Siegbahn-type pumping stages connected in series rather than in parallel.
According to U.S. Pat. No. 6,394,747 disclosure, a rotor disk having smooth surfaces is placed between a first stator disk and a second stator disk. Each stator disk is provided with a spiral groove open towards the respective surface of the rotor disk and defining therewith a corresponding pumping channel. At the beginning, the gas to be pumped flows between the first stator disk and the rotor disk in centrifugal direction, from the center to the outer periphery of the rotor disk, and then between the second stator disk and the rotor disk in centripetal direction, i.e. from the outer periphery to the center of the rotor disk.
The cross-section area of the groove defining the pumping channel in the first stator disk, where the gas flows in centrifugal direction, is reduced from the center to the outer periphery, while the cross-section area of the groove defining the channel in the second stator disk, where the gas flows in centripetal direction, is reduced from the outer periphery to the center. In this way the cross-section area of the grooves is always reduced in the direction of the flow and in this way, the U.S. Pat. No. 6,394,747 aims at optimizing both the pumping speed and the compression ratio.
In known Siegbahn-type pumping stage, having the above-mentioned geometric configuration generates the risk of internal compressions and successive re-expansions and corresponding power losses, especially in applications with important flow rates. Therefore, the main object of the present invention is to provide a spiral pumping stage for vacuum pump, which allows to overcome the above-mentioned drawback and to reduce power losses, especially when several stages are connected in series. This and other objects are achieved by a spiral pumping stage as claimed in the appended claims.
SUMMARY OF THE INVENTION
A pumping stage according to the present invention comprises a spiral pumping channel that is designed so that the volumetric channel speed (L/s), given by the product of the channel cross-section area and half the rotor velocity normal to the aforesaid area, is substantially constant throughout the pumping channel.
The pumping stage comprises a stator body having at least one spiral channel on a first surface, the cross-section area of this channel is reduced from the center to the outer periphery of the body so as to maintain the product of the channel cross-section area and the rotor velocity normal to the aforesaid area (i.e. the internal gas flow velocity) constant, irrespective of whether the gas flows through the channel in a centripetal or centrifugal direction.
According to a preferred embodiment of the invention, the pumping stage comprises a stator body having at least one spiral channel on a first surface, wherein the gas flows in a first direction, and at least one further spiral channel on its opposite surface, wherein the gas flows in a second direction opposite to the first direction, the cross-section area of both these channels is reduced from the center to the outer periphery of the disk so as to maintain the constant internal channel speed. Thus, the variation of the cross-section area of the grooves defining the spiral channel of the pumping stage stator body is designed on the grounds of purely geometrical reflections, independently from the advancing direction of the gas flow.
It is evident to the person skilled in the art that the above-mentioned structural feature, in addition to reducing power losses, also constitutes a remarkable advantage with respect to simplicity and cost reduction during the manufacturing process, since all the stator bodies can be made identical, except for the winding direction of the spiral, without regard to whether they are used in centripetal or centrifugal pumping stages.
Advantageously, the pumping stage according to the invention can be used in a vacuum pump in combination with other pumping stages, of the same kind or of a different kind. For example, the pumping stage can be provided downstream of a plurality of turbomolecular axial pumping stages. Also, the pumping stage according to the invention can be provided upstream of a Gaede pumping stage and/or regenerative pumping stage.
According to first preferred application of the invention to a vacuum pump, a plurality of pumping stages are connected in series so that the gas flows through the pumping stages in centripetal and centrifugal direction alternately.
According to a second preferred application of the invention to a vacuum pump, a plurality of pumping stages are connected in parallel so that the gas to be pumped flows through these channels in parallel in centrifugal direction.
According a third preferred application of the invention to a vacuum pump, a plurality of pumping stages are connected in parallel so that the gas to be pumped flows through these channels in parallel in centripetal direction.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and features of the invention will be evident from the detailed description of some preferred embodiments of the invention, given by way of non-limiting example, with reference to the attached drawings, wherein:
FIG. 1 is a cross-sectional view of a known Siegbahn-type pump;
FIG. 2 a is a perspective view of a stator body of a pumping stage according to the present invention;
FIG. 2 b is a cross-sectional view of a first pumping stage incorporating the stator body of FIG. 2 a;
FIG. 2 c is a cross-sectional view of a first pumping stage incorporating the stator body of FIG. 2 a;
FIG. 3 is a cross-sectional view of a vacuum pump according to a first embodiment of the present invention;
FIG. 4 is an enlarged view of a detail of the vacuum pump of FIG. 3 ;
FIG. 5 is a cross-sectional view of a vacuum pump according to a second embodiment of the present invention;
FIG. 6 is a cross-sectional view of a vacuum pump according to a third embodiment of the present invention;
FIG. 7 is a perspective view of a stator body of a pumping stage for different embodiments of the vacuum pump according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 2 a though 2 c , the pumping stage comprises a rotor disk 7 , 7 ′ having smooth surfaces cooperating with a stator body 1 , which is provided with a plurality of spiral channels 3 a , 3 b , 3 c , 3 d , on the surface facing said rotor disk 7 , 7 ′. These spiral channels are connected in parallel and separated from each other by corresponding spiral ribs 5 a , 5 b , 5 c , 5 d.
The cross-section area σ of channels 3 a , 3 b , 3 c , 3 d is reduced from the center to the outer periphery of disk 1 , i.e. as the distance R from the center of stator body 1 increases. More particularly, as known, the rotor velocity V T =ωR is reduced concordantly with radius R from the outer periphery towards the center of the stator body.
According to the invention, the cross-section area σ of channels 3 a , 3 b , 3 c , 3 d varies so that, the volumetric channel speed S is constant, according to which
S=V n ×σ=constant (1)
wherein V n is half the rotor velocity normal to area σ.
More particularly, according to a preferred embodiment of the invention, the shape of the spiral channels of the stator body 1 is defined so that along each spiral channel the following condition is always satisfied:
S = 2 πω H ( R ) R 2 ⅆ R R ⅆ ϕ 1 + [ ⅆ R R ⅆ ϕ ] 2 = CONSTANT ( 2 )
wherein ω=V T /R is the rotor angular velocity;
H(R) is the height of the channel, possibly variable as a function of R; φ is the winding angle of the channel spiral.
It will be evident to an expert in the field that a spiral pumping stage whose channel has a shape determined by the values of R and φ, which—although they do no represent an exact solution of the equations (1) and (2)—are in any case a good approximation thereof, still falls within the scope of protection of the present invention. In particular, a spiral pumping stage wherein R and φ have a deviation not higher than ±10% with respect to the exact solution of the equations (1) and (2) set forth above or has a channel speed S which is CONSTANT within a deviation of ±10% along the channel itself, allows to effectively reach the objects of the present invention.
According to a first order approximation of the above equation and in order of the manufacturing simplification for a channel with constant height H, the channel shape is defined by:
S
=
2
πω
R
ⅆ
R
ⅆ
ϕ
=
CONSTANT
.
(
3
)
By integration, it is obtained
R 2 - R 1 2 R 2 2 - R 1 2 = ϕ ϕ o ,
wherein R 1 and R 2 are the inner radius and the outer radius of the stator channel, respectively; and φ 0 is the overall winding angle of the spiral (360° in the example of FIG. 2 a ). Therefore, as stated above, by maintaining the volumetric channel speed constant, the risk of internal expansions or compressions is avoided and the power losses are limited.
With reference to FIGS. 2 b and 2 c , the geometrical configuration of the pumping stage according to the invention is advantageously independent from the flow direction of the gas to be pumped, since it is defined by the cited mathematical law, whichever the gas flow direction is.
FIG. 2 b shows a pumping stage where the gas flows through the channel in a centripetal direction. The pumping stage comprises a gas inlet 6 at or close to the outer periphery of the stator body 1 and a gas outlet 8 at or close to the center of the stator body, so that the gas to be pumped flows through channels 3 a , 3 b , 3 c , 3 d in a centripetal direction, as indicated by arrow CP. According to the invention, the cross-section area of said channels is reduced from the center to the outer periphery of the stator body so that the internal volumetric channel speed is constant along the pumping stages and the equation (1) or (2) or (3) is satisfied.
FIG. 2 c shows a pumping stage where the gas flows through the channel in a centripetal direction. The pumping stage comprises a gas inlet 6 ′ at or close to the center of the stator body 1 and a gas outlet 8 ′ at or close to the outer periphery of the stator body, so that the gas to be pumped flows through channels 3 a , 3 b , 3 c , 3 d in a centrifugal direction, as indicated by arrow CF. As in the pumping stage shown in FIG. 2 b , the cross-section area of these channels is reduced from the center to the outer periphery of the stator body so that the internal volumetric channel speed is constant along said pumping stages and the equation (1) or (2) or (3) is satisfied.
Comparing embodiments shown in FIGS. 2 b and 2 c , it is evident that the stator bodies can be made identical irrespective of whether they are intended to be used in centripetal or centrifugal pumping stages.
With reference to FIGS. 3 and 4 a vacuum pump P is shown according to the present invention. Vacuum pump P comprises an inlet for the gas to be pumped at lower pressure, an outlet for the pumped gas at higher pressure and a plurality of pumping stages provided between said inlet and said outlet. More particularly, it comprises: a first region A at low pressure provided with a plurality of turbomolecular axial pumping stages connected in series; a second region B at intermediate pressure provided with a plurality of spiral pumping stages according to the invention; and a third region C at high pressure provided with one or more Gaede pumping stages (which can possibly be followed or replaced by regenerative stages).
More particularly, the intermediate region B of the vacuum pump P comprises one or more centripetal pumping stages 301 a , 301 b , 301 c according to the invention (three in the example shown in FIG. 3 ) connected in series with as many centrifugal pumping stages 303 a , 303 b , 303 c according to the invention, alternated with the centripetal stages.
With reference to FIG. 4 , a first centripetal pumping stage S 1 and a second centrifugal spiral pumping stage S 2 according to the invention connected in series are shown in detail.
To this aim, a stator body 11 is provided on both surfaces 11 a , 11 a ′ with spiral channels 13 a , 13 b , 13 c , 13 d and 13 a ′, 13 b ′, 13 c ′, 13 d ′, separated by corresponding spiral ribs 15 a , 15 b , 15 c , 15 d and 15 a ′, 15 b ′ 15 c ′, 15 d ′, respectively.
A first rotor disk 17 having smooth surfaces is located opposite to a first surface 11 a of the stator 11 and cooperates therewith for forming a first pumping stage S 1 according to the invention. A second rotor disk 17 ′ having smooth surfaces is located opposite to a second surface 11 a ′ of the stator 11 and cooperates therewith for forming a second pumping stage S 2 according to the invention.
The gas, coming from an inlet 21 placed at the outer periphery of the first pumping stage S 1 flows through the first pumping stage S 1 in centripetal direction (as indicated by arrow CP), passes through the passage 23 provided at or close to the center of said stator body 11 that connects the two stages S 1 and S 2 and then flows through the second pumping stage S 2 in centrifugal direction (as indicated by arrow CF), successively exiting through an outlet 25 placed at the outer periphery of the second pumping stage S 2 .
With reference again to FIG. 3 , it is evident that the inlet 21 can put a turbomolecular pumping stage or a previous centrifugal spiral pumping stage or a pumping stage of other kind in the region A in communication with the first pumping stage S 1 of the region B. The same way, the outlet 25 of the last pumping stage of the region B can put the pumping stage S 2 in communication with a successive pumping stage according to the invention or with a Gaede pumping stage or even with a regenerative pumping stage or with a pumping stage of other kind in the region C.
As described above, according to the invention, the cross-section area of channels 13 a , 13 b , 13 c , 13 d of the first pumping stage S 1 and of channels 13 a ′, 13 b ′, 13 c ′, 13 d ′ of the second pumping stage S 2 is reduced from the center to the outer periphery of the stator body 11 and varies so that the internal pumping speed is constant along the pumping stages S 1 and S 2 and the condition of equation (1) or (2) or (3) is satisfied.
FIG. 5 shows a second embodiment of a vacuum pump P′ according to present invention. The pump P′ comprises: a first region A′ at low pressure that is provided with a plurality of centrifugal pumping stages connected in parallel (five in the example shown in FIG. 5 ); a second region B′ at intermediate pressure that is provided with a plurality of pumping stages according to the invention connected in series; and a third region C′ at high pressure that is provided with one or more Gaede pumping stages (which can possibly be followed or replaced by regenerative stages).
More particularly, the second region B′ at intermediate pressure of vacuum pump P′ comprises one or more centripetal pumping stages 501 a , 501 b , 501 c according to the invention (three in the example shown in FIG. 5 ) connected in series with as many centrifugal pumping stages 503 a , 503 b , 503 c according to the invention, alternated with said centripetal stages.
Regarding the first region A′ at low pressure, for obtaining the centrifugal pumping stages 505 a , 505 b , 505 c , 505 d , 505 e connected in parallel, the wall of the central cavity D′ of the rotor E′ comprises radial through-holes F′, so that the gas arriving from inlet G′ penetrates inside the cavity D′ of the rotor E′, passes through the through-holes F′ and is subdivided between the several pumping stages of this first region A′, being successively collected in a collector defined by holes H′.
With reference to FIG. 5 , a further region can be provided upstream to the first region A′. This further region, for example, may comprise a plurality of turbomolecular axial pumping stages. In this case, the outlet of the last turbomolecular stage is connected to the inlet G′ of the pumping stages of the first region A′.
FIG. 6 shows a third embodiment of a vacuum pump P″ according to the present invention. The pump P″ comprises: a first region A″ at low pressure, provided with a plurality of pumping stages according to the invention connected in parallel (five in the example shown in FIG. 6 ); a second region B″ at intermediate pressure, provided a plurality of pumping stages according to the invention connected in series; and a third region C″ at high pressure, provided with one or more Gaede pumping stages (which can possibly be followed or replaced by regenerative stages).
More particularly, the second region B″ at intermediate pressure of vacuum pump P″ comprises one or more centripetal pumping stages 601 a , 601 b , 601 c according to the invention (three in the example shown in FIG. 6 ) connected in series with as many centrifugal spiral pumping stages 603 a , 603 b , 603 c according to the invention, alternated with said centripetal stages.
In the first region A″ being at low pressure, the wall D″ of the rotor E″ comprises one or more radial through-holes F″ and is closed on its upper side by a closing member J″, so as to define a collector for the gas. The gas arriving from the inlet G″ passes through the radial through-holes H″ suitably formed in the wall of the stators of the pumping stages 605 a , 605 b , 605 c , 605 d , 605 e is subdivided among the several pumping stages of the first region A″, flows through these pumping stages in centripetal direction and converges into the cavity D″ of the rotor E″, from which it enters successively the region B″ at intermediate pressure of the pump P″, through a centrifugal pumping stage 607 a.
With reference to FIG. 6 , a further region can be provided upstream to the first region A″, the further region may comprise, for example, a plurality of turbomolecular axial pumping stages. In this case, the outlet of the last turbomolecular stage is connected to the inlet G″ of the pumping stages of the first region A″.
From embodiments shown in FIGS. 3 , 5 and 6 , it is evident to the person skilled in the art that the pumping stages can be made substantially identical in structure (except for the spiral winding direction), not depending on the direction of the gas flow whether the gas to be pumped flows through them in centripetal or centrifugal direction. This feature remarkably simplifies the manufacturing of the pumps with a corresponding reduction of their manufacturing costs.
With reference to FIG. 7 , a stator 21 of a pumping stage that is particularly suitable for applications of the kind of the one shown in FIG. 5 or 6 , where a pair of pumping stages are defined on opposite surfaces of the same stator and are connected in parallel. In this case, instead of providing separate channels on the opposite surfaces of the stator body, it is possible to provide a stator body 21 comprising an outer ring 27 that carries cantilever curved vanes 25 a , 25 b , 25 c , 25 d , 25 e , 25 f defining there between corresponding spiral channels 23 a , 23 b , 23 c , 23 d , 23 e , 23 f . The stator body 21 can be located between two rotor disks having smooth lo surfaces and cooperate therewith for forming a pair of either centripetal or centrifugal spiral pumping stages according to the invention connected in parallel through which the pumped gas flows.
It is evident that the described examples and embodiments are in no way limiting. Many modifications and variants are possible without departing from the scope of the invention as defined by the appended claims.
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A molecular spiral-type vacuum pumping stage comprises a smooth surfaces rotor disk cooperating with a stator body. The stator body comprises a plurality of spiral channels on at least one surface facing the rotor disk. The cross-section area (σ) of these channels are reduced from the center to the outer periphery of the stator body so that the condition is satisfied according to which the internal channel speed, i.e. the product of the channel cross-section area and half the rotor velocity normal to the aforesaid area, is constant throughout the channels. Due to this arrangement, it is possible to avoid the risk of internal compression or re-expansions, this limiting the power losses. The present invention also refers to a vacuum pump comprising at least one pumping stage as described above.
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BACKGROUND
[0001] In many gas wells, inflowing fluid passes through a sand screen which filters out particulates from the inflowing gas. Generally, the flow rate of the inflowing gas is very high such that any sand production can cause substantial erosion of components in a gas well completion. The sand production is controlled with sand screens employed either as stand-alone screens or in combination with a surrounding gravel pack. However, the velocity of the inflowing gas often can exceed an erosion velocity which causes erosion of the sand screen and ultimate failure of the sand screen. Once the sand screen fails, the risk of erosion arises with respect to other elements of the completion. Use of gravel packing may limit the velocity of particulates; however gravel packs are not necessarily uniform along the entire sand screen, resulting in high, erosive flow rates through poorly packed regions.
SUMMARY
[0002] In general, the present invention provides a technique for filtering sand; distributing a flow of fluid; e.g. distributing an inflow of gas or condensate; and limiting the potential for erosion of completion components in a wellbore. By way of example, the technique is useful in production applications, but the technique also can be used in fluid injection applications, e.g. gas injection applications. The technique employs a base pipe and a sand screen surrounding the base pipe. The base pipe comprises a plurality of flow restriction elements deployed in a selected pattern along the base pipe to provide a desired distribution of flowing fluid. The pattern of flow restriction elements also maintains a flow rate of the flowing fluid below an erosive flow rate across the entire sand screen.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
[0004] FIG. 1 is a schematic illustration of one example of a sand screen assembly deployed in a well, according to an embodiment of the present invention;
[0005] FIG. 2 is a partial cross-sectional view of the sand screen assembly taken generally across an axis of the sand screen assembly, according to an embodiment of the present invention;
[0006] FIG. 3 is a partial cross-sectional view taken generally in an axial direction through a wall of the sand screen assembly, according to an embodiment of the present invention;
[0007] FIG. 4 is a partial cross-sectional view of an alternate example of the sand screen assembly taken generally across an axis of the sand screen assembly, according to another embodiment of the present invention;
[0008] FIG. 5 is a partial cross-sectional view taken generally in an axial direction through a wall of an alternate example of the sand screen assembly, according to another embodiment of the present invention;
[0009] FIG. 6 is a schematic illustration of one embodiment of the flow restriction elements, according to an embodiment of the present invention;
[0010] FIG. 7 is a partial cross-sectional view of an alternate example of the sand screen assembly taken generally across an axis of the sand screen assembly, according to another embodiment of the present invention;
[0011] FIG. 8 is a partial cross-sectional view taken generally in an axial direction through a wall of an alternate example of the sand screen assembly, according to another embodiment of the present invention; and
[0012] FIG. 9 illustrates one example of a flow profile along a sand screen when fluid inflow is controlled by flow restriction elements, according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0013] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0014] The present invention generally relates to a system and methodology for filtering sand from flowing fluid, such as from inflowing gas in a gas production well. As explained in greater detail below, the system and methodology also enable a desired distribution of the flowing fluid across the sand screen while keeping the flow rate of the flowing fluid below an erosion flow rate to protect the sand screen from degradation.
[0015] According to one embodiment, a well system is provided with one or more sand screen assemblies coupled into a completion and deployed downhole into a gas well. Each sand screen assembly comprises a base pipe surrounded by a sand screen which filters particulates from an inflowing stream of gas during gas production. The base pipe beneath the sand screen is equipped with a plurality of flow restriction elements through which the inflowing gas moves to an interior of the base pipe after passing through the sand screen.
[0016] The flow restriction elements are sized and distributed to provide a controlled pressure drop and to eliminate regions of high flow velocity along the sand screen. The flow velocity is restricted to a rate below an erosion rate of the sand screen to prevent degradation and failure of the sand screen during gas production. The flow restriction elements may be arranged in a variety of patterns to provide the controlled pressure drop and thus the controlled flow rate through the sand screen. For example, multiple flow restriction elements may be evenly distributed along the base pipe to provide an evenly distributed inflow of gas and a consistent pressure drop along the sand screen. However, other patterns of the flow restriction elements also may be selected to create a desired flow control, e.g. a desired variation in pressure drop and/or flow rate along the sand screen.
[0017] Referring generally to FIG. 1 , one schematic example of a well system 20 for use in a well 22 is illustrated. Well 22 may comprise a production well for producing a desired fluid, e.g. gas or oil; or well 22 may comprise an injection well for injecting a desired fluid, e.g. gas or water. The well system 20 is designed to enable filtering of flowing fluid during production (or injection) of fluid from the well 22 . In this particular example, well system 20 may comprise a well completion 24 , e.g. a gas production well completion, deployed downhole into a wellbore of well 22 . The completion 24 may be deployed downhole via a conveyance 26 , such as coiled tubing, production tubing, or another suitable conveyance. Depending on the specific application, well 22 may comprise a wellbore 28 which is cased or lined with a casing 30 having perforations 32 to enable fluid communication between a surrounding reservoir/formation 34 and the wellbore 28 . However, completion 24 may be employed in open wellbores or in a variety of other wellbores, environments and wellbore configurations designed to maximize retrieval of the desired hydrocarbon based fluid, e.g. gas. The completion 24 also may be designed for fluid, e.g. gas, injection applications.
[0018] Well completion 24 potentially includes many types of devices, components and systems. For example, the well equipment may comprise a variety of artificial lift systems, sensor systems, monitoring systems, and other components designed to facilitate production operations, servicing operations, and/or other well related operations. In the example illustrated, well completion 24 further comprises a sand screen assembly 36 .
[0019] The sand screen assembly 36 has a sand screen 38 designed to filter sand from gas or other fluid flowing across the sand screen 38 . During gas production, for example, gas flows into wellbore 28 from formation 34 and passes through sand screen 38 which filters out sand while allowing the remaining gas to pass into completion 24 . The sand screen 38 may be used in cooperation with and/or be positioned between other components of the well completion 24 . Additionally, the sand screen assembly 36 may comprise a base pipe 40 positioned such that the sand screen 38 is mounted to surround the base pipe 40 .
[0020] Completion 24 also may comprise one or more isolation devices 42 , e.g. packers, positioned to enable selective isolation of a specific well zone associated with the sand screen assembly 36 . It should be noted that well completion 24 may further comprise additional sand control assemblies 36 and isolation devices 42 to isolate and control fluid flow, e.g. gas flow, from (or to) other well zones of the reservoir/formation 34 .
[0021] In FIG. 1 , wellbore 28 is illustrated as a generally vertical wellbore extending downwardly from a surface location 44 . Additionally, completion 24 is illustrated as deployed downhole into the generally vertical wellbore 28 beneath surface equipment 46 , such as a wellhead. However, the design of wellbore 28 , surface equipment 46 , and other components of well system 20 can be adapted to a variety of environments. For example, wellbore 28 may comprise a deviated, e.g. horizontal, wellbore or a multilateral wellbore extending from surface or subsea locations. The well completion equipment 24 also may be designed for deployment into a variety of vertical and deviated wellbores drilled in a variety of environments.
[0022] Referring generally to FIG. 2 , one embodiment of sand screen assembly 36 is illustrated. In this embodiment, base pipe 40 comprises a plurality of flow restriction elements 48 , and sand screen 38 is mounted around base pipe 40 and the plurality of flow restriction elements 48 . The flow restriction elements 48 are designed to allow gas flow through a sidewall 50 of base pipe 40 and into an interior 52 of the base pipe for production to a desired location. The plurality of flow restriction elements 40 are arranged in a desired, predetermined pattern to provide a controlled pressure drop across the base pipe 40 , and thereby to provide a controlled flow rate of inflowing gas through sand screen 38 . The flow restriction elements 48 also may be employed for use with other fluid, e.g. condensates, oil or water, flowing at a high flow rate into or out of the base pipe 40 during production or injection applications.
[0023] Various sizes, densities and patterns of flow restriction elements 48 may be located along the base pipe 40 which is positioned radially beneath the surrounding sand screen 38 . The sizes, densities and patterns of flow restriction elements 48 are selected according to the environment, downhole pressures, quality of the formation, presence of a surrounding gravel pack, and other environmental parameters. The size, density and arrangement of the flow restriction elements 48 establish the desired pressure drop along the base pipe 40 and also serve to sufficiently reduce the flow velocity of the gas or other fluid below an erosion flow rate. In specific applications, the arrangement of flow restriction elements 48 is selected to reduce the flow rate of inflowing gas (and particulates carried with the inflowing gas) to a rate which does not cause erosion along any region of the surrounding sand screen 38 . In many applications, the flow restriction elements 48 are evenly distributed along the base pipe 40 to provide a constant pressure drop along the base pipe 40 and an evenly distributed inflow of gas. However, the size, density and pattern of the restriction elements 48 also may be varied along the base pipe 40 in a predetermined manner to provide a controlled variation of pressure drop and/or flow rate of, for example, inflowing gas.
[0024] In FIGS. 2 and 3 , cross-sectional views of portions of one specific embodiment of the sand screen assembly 36 are illustrated. In this embodiment, the flow restriction elements 48 comprise small holes or orifices 54 extending in a generally radial direction through sidewall 50 of base pipe 40 . The orifices 54 have a diameter selected according to the parameters of the downhole application, e.g. gas production application, so as to sufficiently reduce the rate of flowing fluid below an erosion rate of sand screen 38 . In many applications, the size of orifices 54 is in the range of one to five times the size of the slot openings/passages through the surrounding sand screen 38 . For example, if sand screen 38 is designed with screen openings, e.g. pore or slot openings, approximately 0.25 mm in diameter, the diameter of orifices 54 may be selected in the 0.3 mm to 1.0 mm range. However, formation parameters, e.g. particle size, and other downhole factors may encourage use of smaller or larger orifices 54 . The pattern of orifices 54 can be used to significantly reduce flow area through the base pipe 40 and to spread the flowing fluid over a desired perforation pattern. Consequently, the desired pressure drop occurs as fluid moves through sidewall 50 of base pipe 40 . The total inflow area created by the sum of flow restriction elements 48 is calculated to give the desired pressure drop and flow rate reduction along the base pipe.
[0025] The inflow area provided by flow restriction elements 48 is a function of perforation/orifice diameter and the number of orifices 54 . To achieve an even distribution of the flowing fluid, e.g. inflowing gas, as desired in some embodiments, many small holes may be created through sidewall 50 of base pipe 40 in a consistent or even pattern. This type of pattern through the base pipe 40 creates an even gas inflow pattern toward and through the sand screen 38 .
[0026] In the embodiment illustrated, sand screen 38 comprises a plurality of layers 56 designed to facilitate both filtering and flow through the sand screen 38 . Depending on the well environment and other downhole factors, the actual type and number of layers can vary substantially. However, several types of sand screens 38 comprise an internal drainage layer 58 surrounded by a filter media layer 60 . Alternate and/or additional layers also may be provided.
[0027] In FIGS. 4 and 5 , another embodiment of sand screen assembly 36 is illustrated as having sand screen 38 positioned over base pipe 40 . In this embodiment, each flow restriction element 48 comprises a nozzle 62 in the form of an insert which is inserted into a corresponding perforation or opening 64 formed radially through sidewall 50 . The nozzle inserts 62 may be secured in their corresponding openings 64 by a variety of mechanisms. For example, the nozzle inserts 62 may be threaded into or press fit into corresponding openings 64 . The nozzle inserts 62 also may be tapered or conical to facilitate frictional engagement when press fit into corresponding opening 64 . It should be noted that in other embodiments, the nozzles 62 may be formed in sidewall 50 without creating separate inserts received in corresponding openings.
[0028] In the embodiment illustrated, each nozzle insert 62 comprises a passage 66 through which inflowing gas is routed through sidewall 50 and into the interior 52 of base pipe 40 . As described with respect to the previous embodiment, the size of each passage 66 as well as the number and pattern of inserts 62 may be calculated to achieve the desired pressure drop across the base pipe 40 and also the desired reduction in velocity of flowing fluid, e.g. inflowing or outflowing gas, to a flow rate below an erosion rate of the sand screen 38 . The nozzle inserts 62 also may be formed from an erosion resistant material, such as a hardened material, carbide material, or other suitable material.
[0029] Referring generally to FIG. 6 , the nozzles 62 may be designed with flow passages 66 each having an expanded portion 68 downstream of a passage entry opening 70 . By way of example, the expanded portion 68 may be designed as a tapered region with a taper having an increasing diameter in the direction of flowing fluid. The expanded portions 68 help prevent plugging of passages 66 if particles pass through screen openings 72 , e.g. slots or pores, of sand screen 38 . In this design, the entry opening 70 provides the desired flow area, but this region only extends a short length to help prevent plugging.
[0030] By choosing nozzles 62 having passages equal to or slightly larger than screen openings 72 of the sand screen 38 , a self-healing effect is achieved. If the sand screen 38 undergoes any erosion, as illustrated by the widened screen opening 72 on the right side of FIG. 6 , a particle 74 is able to pass through and plug the corresponding nozzle 62 . The plugged passage 66 reduces the fluid flow flux in this area and reduces or eliminates any further erosion. Consequently, the diameter/area of passages 66 may be selected based on formation particle size to make sure the particles are able to plug the passage 66 in the event of regional failure of sand screen 38 . In some applications, passages 66 may be smaller than screen opening 72 but then the nozzles are subject to unwanted plugging due to fines passing through the sand screen 38 .
[0031] To further improve this self-healing effect, the drainage layer 58 of the sand screen 38 may be separated into several compartments. The compartmentalization may be achieved by placing inserts or other types of flow blocking members in the axial flow channels of the drainage layer 58 to prevent movement of particles 74 in an axial direction along an exterior of the base pipe 40 . Preventing particles 74 from flowing axially or tangentially along an outer surface of the base pipe 40 ensures that a significant portion of the sand screen will not fill with sand even if a small part of the sand screen 38 is eroded. By way of example, the inserts or flow blocking members may comprise a ring in the drainage layer, a segment between structural members, e.g. between axial rods, of the sand screen, a shim placed between wrappings of the screen, or other suitable members designed to compartmentalize the screen and thus prevent any substantial transverse flow of fluid and particulates.
[0032] Referring generally to FIGS. 7 and 8 , another embodiment of sand screen assembly 36 is illustrated as having sand screen 38 positioned around base pipe 40 . In this embodiment, each flow restriction element 48 comprises a small tube 76 disposed between an outer surface of the base pipe 40 and the surrounding sand screen 38 . In one example, multiple tubes 76 are oriented generally longitudinally between a drainage layer of the sand screen 38 and the outer surface of base pipe 40 , as best illustrated in FIG. 8 . Additionally, each tube 76 is routed to and coupled with the corresponding hole 54 extending through sidewall 50 .
[0033] With respect to embodiments of the present erosion prevention system, such as those embodiments discussed above, the size of the passages/flow areas through the flow restriction elements is designed for optimal flow performance. However, various embodiments also may be constructed to provide the self-healing effects discussed above. Generally, each flow restriction element 48 provides a flow connection to the interior 52 of base pipe 40 and acts as a drain for inflowing fluid, e.g. gas, entering the sand screen 38 . As a result, the gas flow approaching sand screen assembly 36 tends to converge towards these drainage points.
[0034] The focusing effect of the flow may be controlled, at least somewhat, by the slot/opening density of the sand screen 38 and/or by the cross-sectional configuration of the drainage layer 58 , as illustrated schematically in FIG. 9 which provides an example of a flow profile 78 across the sand screen 38 . With relatively small areas open to flow through the sidewall 50 of base pipe 40 versus a relatively large cross-sectional area of the drainage layer 58 /sand screen 38 , a more even flux is achieved with respect to fast flowing fluid, e.g. inflowing gas, approaching the sand screen assembly 36 . As the fluid enters the slot opening 72 of the sand screen 38 , a small pressure drop occurs. Additionally, a small pressure drop occurs as a fluid flows longitudinally/transversely within the sand screen 38 toward a flow restriction element 48 of base pipe 40 . To achieve a small flux variation, the sand screen assembly 36 may be designed so the pressure drop through the screen opening 72 is of a similar order of magnitude as the pressure drop along the drainage layer 58 over the distance between distant flow restriction elements 48 .
[0035] Desired patterns of flow restriction elements 48 may be selected and designed based on optimization of peak flow velocity versus average flow velocity. Knowledge of the peak flow velocity and the average flow velocity is used to design flow restriction element density and flow area to ensure the velocity approaching sand screen 38 stays below an erosion velocity, thereby reducing or preventing erosion of the sand screen 38 .
[0036] The overall well system 20 may be constructed to accommodate a variety of flow filtering applications in a variety of well environments while limiting or preventing erosion of the screen and other completion components. Accordingly, the number, type and configuration of components and systems within the overall system may be adjusted to accommodate different applications. For example, the size, number and configuration of the sand screen assemblies may vary from one application to another along the completion equipment. Additionally, many types of flow restriction elements and arrangements of those elements may be employed as dictated by the overall design of gas production equipment and by downhole environmental conditions. The base pipe configuration and the sand screen configuration also may be adjusted according to the specific application and environment. The sand screen assemblies and their erosion control elements may be combined into many types of well completions utilized in production and/or servicing operations. Also, the types and arrangements of other downhole equipment used in conjunction with the one or more sand screen assemblies may be selected according to the specific well related application in which the sand screen assemblies are employed.
[0037] Although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Accordingly, such modifications are intended to be included within the scope of this invention as defined in the claims.
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A technique enables an improved filtering of sand, a desired distribution of produced or injected fluid, and a reduction in erosion of completion components positioned in a production or injection well. The technique employs a base pipe and a sand screen surrounding the base pipe. The base pipe comprises a plurality of flow restriction elements arranged in a selected pattern along the base pipe to provide a desired distribution of the fluid flowing into or out of the sand screen. The pattern of flow restriction elements also maintains a flow rate of the flowing fluid below an erosive flow rate across the entire sand screen.
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[0001] The present invention relates to a drive device having an electric machine, a planetary gear, a differential, and an operative connection between a drive shaft of the electric machine and a first sun wheel of the first planetary gear, the first sun wheel being in toothed engagement with first planet wheels which are in toothed engagement with a stationary first annulus gear and are rotatably mounted on a first planet carrier, which is rotatably fixedly connected to a differential cage of the differential.
BACKGROUND
[0002] Such a drive device is described in DE 198 41 159 C2. The electric machine in the form of an electric motor is connected to a classic bevel differential gear with the aid of a simple planetary gear. The rotor shaft is provided with a toothing at the end which forms the sun wheel of the planetary gear. The differential cage of the bevel differential gear at the same time is the planet carrier for the planets of the planetary gear which are in toothed engagement with the sun wheel and a stationary annulus gear. The planet carrier is rotatable about the main axis of the drive device. The axle drive bevel gears of the differential are connected to output shafts to which the torques introduced into the differential are distributed via the compensating gears, starting from the planet carrier. Such drive devices have a very compact design and require little installation space.
SUMMARY OF THE INVENTION
[0003] It is an object of the present invention to create a drive device having a variable drive concept.
[0004] The present invention provides that the operative connection between the planetary gear and the drive shaft is a second planetary gear. The second planetary gear is formed by at least one second sun wheel, by a second set of planet wheels, by a second planet carrier, and by a second annulus gear. The input of the operative connection is the second sun wheel. The second sun wheel is rotatably fixedly connected to the drive shaft about the rotational axis of the drive shaft for this purpose and is in toothed engagement with the second planet wheels. The second set of planet wheels is rotatably mounted on planetary pins at a radial distance from the main axis of the drive device, the planetary pins being fixed on the second planet carrier.
[0005] The second planet wheels are in toothed engagement with the internal toothing of the second annulus gear, which may be held in a stationary manner. Within the meaning of the present invention, “may be held in a stationary manner” shall mean that the second annulus gear may be held rotatably fixedly with respect to a housing, for example a housing of the drive device, relative to the main axis of the drive device, but may also be enabled again so as to rotate about the main axis.
[0006] The second planet carrier of the second planetary gear and the first sun wheel of the first planetary gear are rotatably fixedly connected to each other about the rotational axis of the drive shaft. The first sun wheel is the input of the first planetary gear.
[0007] The rotational axis of the drive shaft is the main axis of the drive device which centrally extends axially through the drive device, and is thus also the rotational axis of the first planet carrier, of the second planet carrier, of the first annulus gear, and of the second annulus gear.
[0008] According to the present invention, an engageable and disengageable rotary joint is provided between the second sun wheel and the second annulus gear. When the rotary joint between the second sun wheel and the second annulus gear is engaged, a relative rotation of the annulus gear with respect to the sun wheel and a relative rotation of the sun wheel with respect to the annulus gear are precluded. The function of the second planetary gear is suspended. In this operating state, the rotational speeds and torques at the first sun wheel correspond to those at the drive shaft. When the rotary joint between the second sun wheel and the second annulus gear is disengaged, the further planetary gear is in effect. The rotational speeds and torques at the first sun wheel in this case deviate from those at the drive shaft due to the action of the second planetary gear.
[0009] Such a system according to the present invention allows the drive device to be operated in at least two operating states, making its use more variable.
[0010] One embodiment of the present invention provides for the second annulus gear to be fixable in a stationary manner with the aid of at least one brake. The brake is a disk or multi-disk brake, or a band brake, for example. Rotations of the second annulus gear may be decelerated with the aid of the brake from a maximum rotational speed to the rotational speed value of zero in relation to the surroundings.
[0011] A further embodiment of the present invention provides for the engageable and disengageable rotary joint between the second sun wheel and the second annulus gear to be producible with the aid of at least one clutch. The clutch is a multi-disk clutch, for example, or a synchronous clutch having conical friction rings. During engagement of the clutch, differences in the rotational speeds between the second annulus gear and the second sun wheel may be reduced from maximum values when the clutch is disengaged all the way to the relative rotational speed value of zero when the clutch is fully engaged.
[0012] The deceleration of the annulus gear is preferably accompanied by a synchronous disengagement of the clutch. The enabling of the annulus gear is accompanied by a synchronous engagement of the clutch, as is provided in one embodiment of the present invention. In this way, at least two operating states may be implemented, the brake being released synchronously with the clutch being engaged in a first operating state. In a second operating state, the clutch is disengaged synchronously with the brake being applied. Moreover, a third operating state is provided, in which both the clutch is disengaged and the annulus gear is enabled by the brake so as to be freely rotatable. In this operating state, no drive power is delivered to the differential.
[0013] The brake and the clutch may be operated separately and independently from each other using different operating devices.
[0014] One embodiment of the present invention provides for a joint operating device for the brake and the clutch, whereby the drive device, including the brake and the clutch, has a very compact and accordingly installation space-saving design. This operating device allows the brake and the clutch to be synchronously operated at the same time to shift the different operating states.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will be described in greater detail hereafter based on two exemplary embodiments.
[0016] FIG. 1 shows a schematic illustration of a drive device 1 longitudinally along the main axis 2 of the drive device 1 .
[0017] FIG. 2 shows a schematic illustration of a drive device 20 longitudinally along main axis 2 of drive device 20 .
DETAILED DESCRIPTION
[0018] Drive device 1 includes an electric machine 3 and has a first planetary gear 4 and a differential 5 . An operative connection is established via a second planetary gear 6 between a drive shaft 3 a of electric machine 3 , which is a rotor shaft 3 a, and a first sun wheel 4 a of first planetary gear 4 .
[0019] First sun wheel 4 a is in toothed engagement with first planet wheels 4 b which are in toothed engagement with a stationary first annulus gear 4 d and are supported thereon. Planet wheels 4 b are rotatably mounted on a first planet carrier 4 c.
[0020] Planet carrier 4 c is rotatably fixedly connected to a differential cage 5 a of differential 5 , so that differential cage 5 a may be rotatably driven about main axis 2 together with planet carrier 4 c . Differential 5 is a planet differential in this case, whose differential cage 5 a is a planet carrier 5 a . However, as an alternative, the differential may also be a classic bevel differential gear having a differential cage, compensating gears and output wheels. Compensating gears 5 b and 5 c of the planet differential are formed by two sets of planet wheels 5 b and 5 c. In each case, a planet wheel 5 b and a planet wheel 5 c are in toothed engagement with each other. Moreover, planet wheels 5 b are in toothed engagement with an output wheel 5 d, which in planetary gear 5 is a sun wheel 5 d , and planet wheels 5 c are in toothed engagement with an output wheel 5 e, which in planetary gear 5 is a sun wheel 5 e. Sun wheels 5 d and 5 e are connected in each case to an output shaft 8 and 9 . Output shaft 9 is oriented coaxially to main axis 2 . Output shaft 8 is situated concentrically to rotor shaft 3 a, so that its rotational axis corresponds to main axis 2 .
[0021] Second planetary gear 6 is formed of a second sun wheel 6 a, second planet wheels 6 b, a second annulus gear 6 d, and a second planet carrier 6 c. Second sun wheel 6 a is in toothed engagement with second planet wheels 6 b. Planet wheels 6 b are rotatably mounted on planet carrier 6 c and are in toothed engagement with second annulus gear 6 d. Second planet carrier 6 c is connected to first sun wheel 4 a. Second sun wheel 6 a is rotatably fixedly connected to drive shaft 3 a, so that second sun wheel 6 a is rotatably driveable about main axis 2 .
[0022] An engageable and disengageable rotary joint 10 is formed between second sun wheel 6 a and second annulus gear 6 d. Rotary joint 10 is composed of a clutch K 2 and a brake B 1 . A first clutch element 11 a is connected to sun wheel 6 a in that first clutch element 11 a is rotatably fixedly connected to drive shaft 3 a and may be driven by the same. A second clutch element 11 b is fixed concentrically to main axis 2 on second annulus gear 6 d and is rotatably with the same about main axis 2 relative to first clutch element 11 a . Clutch elements 11 a and 11 b may be connected to each other with the aid of an operating device, which is not shown in greater detail, in a form-locked and/or frictionally engaged manner, whereby the clutch K 2 formed of clutch elements 11 a and 11 b is engageable. The form lock between clutch elements 11 a and 11 b may be suspended again by the operating device and clutch K 2 may thus be disengaged.
[0023] Second annulus gear 6 d may be held on a housing 13 in a stationary manner with the aid of a brake B 1 so that it cannot be rotated about main axis 2 . Brake B 1 is formed of a first brake element 12 a, which is fixed on housing 13 , and a second brake element 12 b, which is fixed on second annulus gear 6 d rotatably about the main axis.
[0024] Second clutch element 11 b and second brake element 12 b are formed together on a disk 14 and have mutually concentric linings 14 a and 14 b.
[0025] In the system described at the outset, annulus gear 6 d may be enabled by releasing brake B 1 , so that clutch K 1 may be engaged and thus a rotatably fixed connection may be established between annulus gear 6 d and sun wheel 6 a. After clutch K 1 has been disengaged, annulus gear 6 d may be fixed with respect to the surroundings 16 with the aid of brake B 1 . These shifting processes are preferably seamless.
[0026] FIG. 2 shows a schematic illustration of a drive device 20 longitudinally along main axis 2 of drive device 20 .
[0027] As drive device 1 according to FIG. 1 , drive device 20 includes electric machine 3 , first planetary gear 4 , and differential 5 . An operative connection is established via a second planetary gear 6 between a drive shaft 3 a of electric machine 3 , which is a rotor shaft 3 a, and a first sun wheel 4 a of first planetary gear 4 . The design and the structure of drive devices 20 and 1 are identical regarding planetary gears 4 and 6 and differential 5 . Drive device 20 differs from drive device 1 illustrated in FIG. 1 only by rotary joint 7 .
[0028] Rotary joint 7 is engageable and disengageable and is formed between second sun wheel 6 a and second annulus gear 6 d. Rotary joint 7 is composed of a clutch K 2 and a brake B 1 . A first clutch element 15 a is connected to sun wheel 6 a in that first clutch element 15 a is rotatably fixedly connected to drive shaft 3 a and may be driven by the same. A second clutch element 15 b is at least rotatably fixed concentrically to main axis 2 on second annulus gear 6 d, but is displaceable axially to this annulus gear and is rotatable with the same about main axis 2 relative to first clutch element 15 a. Second clutch element 15 b, which has a friction lining 18 situated concentrically to main axis 2 , is illustrated in a neutral position. Clutch elements 15 a and 15 b are connectable to each other in a frictionally engaged manner with the aid of a linearly acting actuator A, whereby clutch K 2 formed of clutch elements 15 a and 15 b is engageable upon movements of actuator A in the figure to the left. The frictional engagement between clutch elements 15 a and 15 b may be suspended again by movements of actuator A to the right side, and clutch K 2 may thus be disengaged.
[0029] Second annulus gear 6 d may be held in a stationary manner with respect to surroundings 16 with the aid of a brake B 1 so that it is not rotatable about main axis 2 . Brake B 1 is formed of a brake element 17 , which is fixed on surroundings 16 , and second clutch element 15 b, which is rotatably connected to second annulus gear 6 d about main axis 2 , but is axially displaceable relative to this annulus gear with the aid of actuator A. For a frictional engagement with the second clutch element, brake element 17 is provided with a friction lining 19 situated concentrically to main axis 2 . The frictional engagement may be established by a movement of actuator A in the figure to the right, and thus by a displacement of second clutch element 15 b to the right, and may be suspended again by a displacement to the left.
[0030] Due to the system described at the outset, clutch K 1 is engaged, and synchronously therewith brake B 1 is released, during a displacement of second clutch element 15 b in the figure to the left, which means that a rotary joint is established between drive shaft 3 a and thus second sun wheel 6 a and annulus gear 6 d, while brake B 1 , which has held annulus gear 6 d on the surroundings, is released at the same time. Upon displacement of second clutch element 15 b in the figure to the right, clutch K 1 is disengaged, and synchronously therewith brake B 1 is applied, which means that the rotary joint between annulus gear 6 d and sun wheel 6 a is suspended, and annulus gear 6 d is fixed on the surroundings at the same time.
REFERENCE NUMERALS
[0031]
[0000]
1
drive device
2
main axis
3
electric machine
3a
drive shaft/rotor shaft
4
first planetary gear
4a
first sun wheel
4b
first planet wheel
4c
first planet carrier
4d
first annulus gear
5
differential
5a
differential cage/planet carrier
5b
compensating gear/planet wheel
5c
compensating gear/planet wheel
5d
output wheel/sun wheel
5e
output wheel/sun wheel
6
second planetary gear
6a
second sun wheel
6b
second planet wheel
6c
second planet carrier
6d
second annulus gear
7
rotary joint
8
output shaft
9
output shaft
10
rotary joint
K1
clutch
11a
first clutch element
11b
second clutch element
B1
brake
12a
first brake element
12b
second brake element
13
Housing
14
Disk
14a
Lining
14b
Lining
K2
Clutch
15a
first clutch element
15b
second clutch element
16
surroundings
A
Actuator
17
brake element
18
friction lining
19
friction lining
20
drive device
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A drive device ( 1, 20 ) including an electric machine ( 3 ), a first planetary gear ( 4 ), a differential ( 5 ) and an operative connection between a drive shaft ( 3 a ) of the electric machine ( 3 ) and a first planetary pinion ( 4 a ) of the first planetary gear ( 4 ), said first planetary pinion ( 4 ) engaging with the first planet wheels ( 4 b ) which engage with a stationary first ring gear ( 4 ) and which are rotationally mounted on a first planet carrier ( 4 c ) which is connected in a rotationally fixed manner to a differential cage ( 5 a ) of the differential.
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GOVERNMENT CONTRACT
The United States Government has rights in this invention pursuant to Contract No. N00014-76-C-0619 awarded by the Department of the Navy.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to direct current dynamoelectric machines and, more particularly, to a machine with circumferentially segmented magnets.
The present invention is closely related to and is an improvement on the subject matter of copending application Ser. No. 891,564 by Mole et al, filed Mar. 29, 1978 and assigned to the present assignee, now U.S. Pat. No. 4,185,216, issued Jan. 22, 1980. The full disclosure of said copending application is herein incorporated by reference.
In the copending application there is described a dynamoelectric machine in which magnetic fields are developed by field windings placed in longitudinally running recesses in a cylindrical stator and energized so as to provide radial magnetic fields in polar regions between the field windings. Stator conductors are placed in slots in the polar regions. The rotor carries longitudinal conductors on its surface positioned to cut the radial magnetic fluxes, and current collecting means are provided at both ends of the machine to make electrical contact with both ends of the rotor conductors. The current collecting means is connected to the stator conductors to complete the electrical circuit of the machine. The concepts described in the copending application have been successfully demonstrated with confirmation that a machine can be produced of smaller size and weight and lower cost, or of higher power output, by the circumferentially segmented magnetic configuration as opposed to axially segmented magnet homopolar machines as are described in Mole, Pat. No. 4,041,337, issued Aug. 9, 1977. The circumferentially segmented magnet configuration makes it more practical to use brushes for current collection and adequate magnetic fields can be provided without resort to excessively bulky field coils or the complication and expense of superconducting magnets.
There remains an interest in the art to provide machines having high power density in more simplified structural configurations, particularly insofar as the minimization of electrical current collecting brushes is concerned. Applications of particular interest include ship propulsion motors and generators and other such applications where high power density machines are required.
In the copending application, embodiments of circumferentially segmented magnet machines are disclosed that generally require a large number of current collecting brushes. Each conductor of the rotor passing through the active zone requires a brush set at each end, with each set sized to carry full winding current. The situation is not appreciably improved by using brushes contacting a plurality of rotor bars simultaneously since the currents are subdivided among the bars but not among the brushes. Therefore, multiple turn windings on the rotor cannot be used to reduce the number of brushes and maintain the same power level. Fundamentally, what is needed to develop a higher voltage is that the number of passes of conductors through the active zone and the number of effective brush sets must be increased. In machines of this general character, it is the case that machine efficiency is greatly influenced by the numbers of brushes employed because of the large friction producing surface area and the large contact drop loss at each brush-conductor interface. Designs with smaller brush area are therefore desirable to result in machines whose efficiency is more determined by torque producing conductors rather than by losses of brushes. Also with fewer brush sets, the voltage gradient along the circumference of the commutator may be reduced.
The approach taken by the present invention to solutions of the foregoing problems is to use a novel magnetic geometry in the stator structure of the circumferentially segmented magnet machine that allows the rotor to have fixed interconnections between pairs of rotor conductors or bars. This reduces the number of required brushes and their associated losses. The stator comprises a field winding in a circumferentially segmented array generally in accordance with the copending application providing active zones and null zones. The magnetic core of the stator, however is also segmented such as by providing a gap or a non-magnetic spacer between stator iron portions of adjacent pole segments. The non-magnetic region, located in a null zone, ensures the magnetic isolation of one pole segment from the next. The magnetic configuration of the machine is such that the north magnetic poles of two adjacent pole segments are located adjacent to one another, separated by a null zone. The south poles of two adjacent segments are located diametrically opposite to the two adjacent north poles. There may be any even number of pole segments in the machine. When more than two segments are used, the polarity of additional poles alternates as one proceeds circumferentially from the two adjacent north poles to the two adjacent south poles. The field windings are located in the null zones and are interconnected so as to generate the magnetic field configuration described.
Stator conductors are located in slots in the active zones, connected in circuit with the brushes, to provide mmf to compensate the rotor mmf. This minimizes undesirable voltage gradients in the active zone and assists current switching at the end of the active zone and minimizes circulating current between parallel rotor conductor circuits.
The rotor is constructed generally in accordance with the embodiments of the copending application in that there are a plurality of longitudinally running, circumferentially spaced, rotor conductor bars on its outer periphery, preferably as an air gap winding although a winding in slots may also be employed. Significantly, the rotor conductors have fixed interconnections at their ends that create a series path through a plurality of the rotor conductors that are spaced a pole distance apart. The fixed interconnections are selectively provided with current collector bars for contacting the associated brushes. Brushes need be located only between two adjacent north poles and two adjacent south poles of the stator. When the current enters one brush, it splits with half going in opposite circumferential directions to rotor bar sets in different active zones. The currents pass circumferentially through end connections to rotor bars under the adjacent pole until the opposite brush set is reached. While it is possible to arrange the conductors with their brushes at only one end of the machine, it is preferred that the arrangement be such as to provide brushes on both ends of the machine, while still minimizing the numbers of required brushes as opposed to the embodiments of the copending application. This permits at all times that the conductors which are totally within the active zones of the stator magnetic field carry current.
Breaking down the elements of the basic arrangement in accordance with the invention, one finds the following characteristics:
(a) The stator has windings and a magnetic core structure providing a sequence of active and null zones around the circumference. Some even number of pole segments are provided, with twice that number of active zones. For example, considering a four pole segment machine, each active zone may encompass about 30° and each null zone about 15°; a 90° stator quadrant, beginning at one active zone, thus comprises 30° active, 15° null, 30° active, and 15° null zones in sequence and a single location within one active zone is displaced about 45° from a single corresponding location in the next active zone. A pair of north poles are adjacent each other, with a null zone between them, and a pair of south poles are adjacent each other with a null zone between. (All angles referred to are mechanical, rather than electrical, unless the context makes clear otherwise.)
(b) The number of rotor conductors is preferably large so each bar subtends only a small angle. Normally, this means a significantly larger number of rotor conductors than active zones. For example, sixty-four conductors may be provided for a machine as referred to in (a) which has four pole segments and eight active zones; and the rotor conductors are substantially uniformly spaced around the rotor (e.g. at a given rotor position, two thirds of the conductors are in active zones.)
(c) In the stationary structure, at least one brush pair is provided for contacting rotor bars that are in the two adjacent north poles of the field and in the two adjacent south poles.
(d) The rotor conductors are interconnected into a number of series sets each comprising conductors displaced from each other substantially by the 45° displacement of stator active zone locations. In a sixty-four bar example with eight active zones, eight bars spaced a pole distance may be connected in two four-bar series sets, the two sets being directly parallel by the brushes. A collector bar is provided at each interconnected pair of bars.
(e) The brush set contacts diametrically opposite positions of a series set of rotor bars while the bars of that set are located in active zones; the voltage generated therefore is that developed across the series set rather than a single bar or plurality of parallel bars.
In addition to the above, two brush sets may be used, one at each end of the machine, with the rotor bars interconnected in sets having staggered collector bars at each end. The rotor bars themselves may be disposed on the rotor in a single layer or in two layers of individually insulated bars.
Furthermore, winding conductors may be placed in parallel under the brushes so long as the parallel connected windings are within the active zone. The winding voltage may be increased by using multiple turns per pole which means that the turns that are closed under like poles do not add to the voltage of the machine so that there is an advantage to using a larger number of poles to minimize the effect of cancelled voltages.
Therefore, it can be seen that by the provision of the stator with non-magnetic spacers between adjacent pole segments and each pole segment having two active zones separated by a null zone that the rotor bars can be interconnected to achieve high power density and reduced current collection requirements.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic transverse view of a dynamoelectric machine embodying the invention;
FIG. 2 is a diagrammatic developed view of a portion of a rotor, such as that of FIG. 1, showing an arrangement of conductor bars and brushes;
FIG. 3 is a diagrammatic transverse view of a rotor in accordance with a further embodiment of the invention;
FIG. 4 is a diagrammatic developed view of a portion of a rotor surface showing an arrangement of conductors and brushes in accordance with an embodiment of the present invention; and
FIG. 5 is a diagrammatic view of a stator structure in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is shown and described embodied in a four pole-segment machine, although it will be understood that the machines in accordance with this invention may have any number of pole-segments of an even number and that such machines can be operated equally well as either generators or motors.
Referring to FIG. 1, the machine has a generally tubular stator member 10 with a cylindrical inner surface 12. A rotor 14 is disposed within the stator 10 with an air gap 13 therebetween. The mechanical arrangement of the rotor and stator and their associated elements may be generally in accordance with the description of the above referred to copending application.
The stator 10 comprises magnetic material of which all or part may be laminated. A plurality of circumferentially spaced, longitudinally extending recesses 18 are provided in the stator surface 12. Field windings 20 are disposed in the recesses 18 and extend longitudinally of the machine with end connections at the ends of the machine by circumferentially extending end turns to complete the field coil. The field windings are made up of a suitable number of conductors extending longitudinally through the recesses 18 and insulated from the magnetic core material 11. Cooling ducts for any suitable coolant can be incorporated in the field windings as desired.
The field windings 20 are connected to a source of direct current excitation, in such a manner that the direction of current flow provides magnetic fields as illustrated by reference numeral 30 extending radially across the air gap 13 between the stator and rotor. This creates a number of poles proceeding in the sequence north N1, south S1, north N2, south S2, south S3, north N3, south S4, north N4. The magnetic flux paths define polar regions in which the radial flux is concentrated into active zones 26 and inactive or null zones 28. The active zones are those in which the radial flux is concentrated while the null zones are those in which there is no radial flux except a minor amount of leakage flux.
Field coils 20 are only shown very schematically in FIG. 1. What is significant is that the field coils, or any alternative employing permanent magnets, be arranged to create the magnetic fields as illustrated and described. Merely by way of further example, FIG. 5 is included to show a more specific coil arrangement for generating the required fields. In FIG. 5, magnetic core sections 11 each have a longitudinally running recess accommodating a pair of coil halves, each half of a different coil, and a pair of half coils are also located between the two core sections 11 on the right and on the left sides of the drawing. In this arrangement, no coil elements are located in the upper and lower null regions 17. Each pair of coil halves of like reference number, such as 20A, form a complete coil so that with the gaps or non-magnetic spacers 17 the full pole complement results.
Referring again to FIG. 1, stator conductors 32 are also provided which are included in the electrical circuit of the machine. The conductors 32 are placed in longitudinal slots in the pole face regions and may be of insulated copper bars or other suitable conductors. Any desired or necessary number of conductors 32 may be provided in each pole face.
Alternate ones of the field windings 20 are each provided with magnetic material 11 at their outer periphery to permit completion of the flux path around that coil portion. Th other alternate set of excitation windings 20 are each provided at their outer periphery with a non-magnetic spacer 17 or gap so that there is no flux path around that portion of the winding.
At least the outer periphery of the rotor 14 is of magnetic material, preferably laminated to reduce eddy current losses. Rotor conductors 36 of insulated conductor bars of any suitable type, preferably stranded or made up of a suitable number of wires or other conductors, transposed as necessary and formed into generally rectangular insulated bars, are disposed on the exterior rotor surface to provide an air gap winding, although a slot winding may also be used. The conductors 36 are held in place on the rotor surface in any suitable manner such as described in the copending application. The ensuing description will include more detailed examples of numbers of rotor bars and their interconnection.
FIG. 2 shows rotor conductor bars 36 and their interconnection into a series set. First and second bars 36A and 36B have the connection (and a current collector 37) at one end of the machine, second and third bars 36B and 36C have connection at the other end of the machine, and so on over the circumferential periphery of the rotor. What this does is provide a continuous series path through all of the rotor bars in which adjacent bars will, when their end connection or collector bars are contacted by a brush, carry current in the same direction which then proceeds in opposite directions around the circumference of the rotor.
The configuration as shown in FIG. 2 with the north and south poles (N1, S1, etc.) corresponds to a particular relationship to the stator poles at a given rotational position of the rotor. As seen, brushes B1 and B2 are located between the two adjacent north pole (N1 and N4) conductors and at two adjacent south pole (S2 and S3) conductors; the uppermost and lowermost positions on the transverse view of FIG. 1. The current, indicated by arrows, enters one brush B1 and splits, going in opposite circumferential directions to rotor bars in different active zones. The currents pass circumferentially through end connections to rotor bars under the adjacent pole until the opposite brush B2 is reached, thus completing the current path.
FIG. 2 is representative of one of several series sets of rotor conductors, each set comprising conductors spaced by a distance substantially equal to the spacing of the stator active zones, about 45° for the stator as shown in FIG. 1. The other series sets include bars located physically a few degrees from each other and from those of the set shown. As the rotor rotates, its commutator end, which has the current collector bars 37, advances in relation to the fixed brushes and each series set successively contacts the brushes. The series set of bars 36A through 36H as shown in FIG. 2 is indicated by reference numerals on FIG. 1.
The stator conductors 32 of FIG. 1 are interconnected at their ends to each other and to the brush sets to form series paths through the active zones for current in opposite direction to that carried by the rotor conductors in the same zones, in order to complete the electrical circuit.
A further embodiment of the invention will be described in reference to FIGS. 3 and 4. FIG. 3 illustrates a full complement of rotor conductors or bars which in this example are sixty-four in number. The rotor bars are disposed on the rotor in two concentric circles. For convenience as well as clarity, the bars are consecutively numbered in each of the two circles. Bars 1 through 32 are in the outer circle and bars 1' through 32' are in the inner circle. These numbers, as well as the numbers of the more centrally illustrated circle of collector bars, sequentially numbered 1 through 32, are not to be confused with any reference numerals that are applied elsewhere to the drawing.
First, it should be understood that the double layer illustration of rotor bars is primarily to facilitate an understanding of the interconnections of the bars and not necessarily to show that the bars need be located in two layers. General considerations that influence the physical layout of bars include: the desirability of a large number of bars each spanning a minimal angle of the rotor circle, utilizing the full circumference while maintaining adequate insulation levels between bars; a bar cross-section that has a low aspect ratio of its two orthogonal dimensions; a square cross-section or 1:1 ratio being the most preferred but not critical; and, of course, a structure amenable to convenient, economical fabrication. Hence, it may be desirable in some instances to provide the same number of bars shown (sixty-four) in a single layer rather than two layers.
It should also be understood that the arrangement of bars as shown in FIG. 3 in a double layer, or in a single layer, does not limit the ability to interconnect them to only one arrangement. The bars as shown in FIG. 3 may be interconnected in the form illustrated in FIG. 2, requiring brushes only at one end. However, the set of bars may alternatively be connected as shown in FIG. 4, to be described, which employs a brush set at each end of the machine.
In FIG. 3, the two circles of bars are numbered to locate a bar having an unprimed number (such as bar 1) in a first pole position (about at the center of N4) while the corresponding prime numbered bar (e.g., 1') is in the same relation to the next pole (N1), when the rotor is at a given rotational position in relation to magnetic field of the stator. If a single layer of bars were used, with a lower aspect ratio than that illustrated, the bar sequence around the rotor may proceed in the manner 1, 30', 2, 31', 3, 32', 4, 1', etc. with substantially the same results.
In accordance with FIG. 4, bars numbered as shown in FIG. 3 are selectively interconnected at their ends in the following manner:
______________________________________Bars Interconnected At One Machine End______________________________________1 and 1', connected to the collector bar 12 and 2', connected to the collector bar 232 and 32', connected to the collector bar 32______________________________________
That is, at one end, bar x (where 1≦x≦32) and bar x' are interconnected at collector bar x; and bars x and x' are physically displaced one pole pitch.
At the second end of the machine, where the rotor bars appear the same and a second circle of collector bars would be provided, the connections are, for this example:
______________________________________Bars Interconnected At Second Machine End______________________________________1 and 25'2 and 26'32 and 24'______________________________________
That is, at the second end bar x is connected to bar (x+24)' and the connected bars are physically displaced one pole pitch in the opposite circumferential direction.
The result of these interconnections is to form distinct counter-rotating series current paths through the bars. For example, when the rotor is at the position shown in FIG 3, current (indicated by arrows on FIG. 4) may enter brush B1' (at the end of the machine not illustrated in FIG. 3,) and divide into bars 5 and 29'. The current path through bar 5 continues through bars 5', 13, and 13' around the machine 180° to brush B2' where it is collected. The current path through bar 29' proceeds, in the opposite circumferential direction, through bars 29, 21', and 21 to brush B2'.
Another pair of counter-rotating currents is provided between brushes B1 and B2. Current introduced at B2 divides into bars 17 and 17'. The path through bar 17 continues through bars 9', 9, and 1' to brush B1. The path through bar 17' continues through bar 25, 25' and 1 to brush B1.
The sixteen bars illustrated in FIG. 4 are one of four sets of the total sixty-four bars. For example, a second set interconnected the same way and in the next position from the set shown comprises bars 12', 16, 8', 12, 4', 8, 32', 4, 28', 32, 24', 28, 20', 24, 16' and 20.
Generalizing from the foregoing examples, one may see that:
(1) The stator is provided with windings and a magnetic pole structure to provide a circumferential sequence of a plurality of active and inactive (null) polar regions in which the active polar regions are uniformly spaced by the null regions from each other.
(2) The stator winding creates active pole orientations such that one pair of north poles (e.g. N1 and N4) are adjacent and one pair of south poles (e.g. S2 and S3) are adjacent with intermediate poles alternating in polarity.
(3) Current collection means (e.g. brushes B1 and B2) are located in the stationary structure to contact rotor bars that are in the adjacent pairs of north and south poles (e.g. bars 36D and 36C in N4 and N1 and bars 36H and 36G in S2 and S3 in FIG. 2; bars 1 and 1' in N4 and N1 and bars 17 and 17' in S2 and S3 of FIG. 4).
(4) The rotor structure comprises a plurality of conductors in a circumferential array; preferably an arc of a stator pole region encompasses a plurality of rotor bars.
(5) The rotor bars are selectively interconnected at their end regions to form series current paths that pass through a plurality of active zones; the paths of parallel series connected groups of bars successively contact the current collection means.
It will be readily understood that the numbers of poles, conductors, their geometry, and other features of machines in accordance with the invention may be varied from the examples given.
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A dynamoelectric machine, of the direct current type, with a circumferentially segmented stationary magnetic field structure providing magnetic poles including diametrically opposed pairs of north and south poles, with intervening poles of alternating polarity; rotor conductors extending longitudinally and selectively interconnected in sets providing a plurality of series current paths each traversing a plurality of stator active pole regions; and a pair of brushes for current collection at one or both machine ends.
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BACKGROUND OF THE INVENTION
Automobile drive up service points are provided by business and municipalities to make access to services more convenient for the driving public. Banking institutions have a long history of providing a drive up teller windows, and such service points have become very popular at other commercial venues such as fast food restaurants and pharmacies. Highway toll booths and automated banking machines, housed in kiosks, are additional examples of how drive up service points are well known in contemporary society.
Unfortunately, the automobiles which are used to access these drive up service points frequently leak or spill a variety of environmentally hazardous fluids at these locations during the brief time they are located there. These fluids include automobile fuel, lubricants, transmission fluids, and antifreeze, among others. These leaked or spilled fluids accumulate in the traffic lane at the drive up service points. Not only are these accumulations toxic to the environment, they present a safety hazard to pedestrian traffic and are unsightly. Additionally, these fluids have a deleterious effect on the traffic lane surface itself since they are known to attack the chemicals which bind asphalt together. When the surface integrity of asphalt is broken down in this way, rutting and pot holes begin to form and the pavement requires patching or replacement.
To protect themselves from injury liability, their property, and to maintain a pleasing appearance, owners of these facilities attempt to clean the traffic lane adjacent to the drive up service points by a variety of methods, including power washing the traffic lane surface and allowing the waste to flow into nearby storm sewers. These fluids can also migrate into water supplies as a result of storm runoff. However, these leaked or spilled automotive fluids are considered toxic wastes, and such disposals and runoffs are in violation of the Federal Clean Water Act, as well as various state and local laws.
A need exists to safely contain and store leaked or spilled automotive fluids which accumulate in the traffic lane adjacent to a drive up service point until the fluids can be safely and properly disposed of.
SUMMARY OF THE INVENTION
An innovative fluid collection container is provided which is thermally bonded to the surface of the traffic lane. The innovative container is a generally rectangular basin which is sized to be more narrow than an automobile's track, or distance between the centers of parallel wheels, allowing the automobile to pass over the container without contacting it. The fluid collection container is low in profile, and formed of a thermoplastic material which is impervious to automotive fuels and lubricants, resistant to wear, and resistant to degradation by sun, rain, and road salt. Glass beads are embedded within the thermoplastic material to provide a surface which is skid resistant, a safety feature important for pedestrian traffic.
The fluid collection container is installed on the surface of the traffic lane adjacent to the drive up service point at the location at which the vast majority of leaked or spilled automotive fluids accumulate. This location is spaced apart from the service point in the direction normal to the service point so that it resides below the longitudinal centerline of the automobile. This location is also spaced apart from the service point so as to lie ahead of the service point relative to the direction of traffic flow. This placement allows the fluid collection container to reside below the front end of the automobile, approximately between the front wheels of the automobile, when the driver is accessing the service point.
The innovative fluid collection container is formed of multiple thermoplastic components which are assembled during installation on the traffic lane surface. These components include a base sheet which provides the bottom surface of the container, side walls, and end walls. The leading and trailing edges of the end walls may be tapered during installation to remove any abrupt discontinuities in the traffic lane surface. When employed, this feature allows the traffic lane to be cleared by snow plows without damage to the fluid collection container. In areas of especially high traffic volume, the depth of the fluid collection container may be increased to provide additional fluid storage volume.
In traffic lanes where the innovative fluid collection container is fixed to the pavement surface, the leaked or spilled automobile fluids fall directly into the container while the automobile is stopped adjacent to a drive up service point. The fluids are retained within the container without leakage until safely and responsibly removed in compliance with local laws and codes, thus protecting the environment from needless automotive pollution. Use of the fluid collection container prevents degradation of the traffic lane surface by preventing destructive interaction between the leaked or spilled automotive fluids and asphalt, prolonging the functional life of the traffic lane surface. Further, when employed at new construction drive-up service points, use of the fluid collection container allows a choice of using the less expensive asphalt as the lane surface material rather than the more costly but more durable cement, since the innovative fluid collection container greatly increases integrity and useful life span of the asphalt.
Although drive up service points are designed for access by automobile traffic, it is not unknown for pedestrians to use these facilities. Additionally, drive up service points must be monitored and maintained by service personnel who approach them on foot. The innovative fluid collection container is provided with features which improve skid resistance and prevent the pedestrian from becoming soiled in the event that he/she steps into the fluid collection container as they approach a drive up service point.
A method of installing the fluid collection container on a traffic lane surface adjacent to a drive up service point is described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the fluid collection container installed on the traffic lane surface adjacent to a drive up service point, where the container is located on the pavement surface ahead of the service point, the arrow indicating direction of traffic flow.
FIG. 2 is a top view of the traffic lane showing the fluid collection container installed adjacent to a drive up service point, where the longitudinal center line of the container is parallel to the traffic lane, where the transverse center line of the container is lies ahead of the service point, and the automobile (shown in phantom) is in a position to access the service point.
FIG. 3 is a perspective view of the fluid collection container, illustrating how the side walls and end walls over lap the base sheet, and illustrating the tapered outer edges of the end walls.
FIG. 4 is a sectional view of the fluid collection container across line 4 — 4 shown in FIG. 3, illustrating the overlapped relationship of the end walls to the periphery of the base sheet, and the tapered outer edges of the end walls.
FIG. 5 is a sectional view of the fluid collection container across line 5 — 5 shown in FIG. 3, illustrating the overlapped relationship of the side walls to periphery of the base sheet.
FIG. 6 is an alternative embodiment of the sectional view of the fluid collection container across line 5 — 5 shown in FIG. 3, illustrating the stacked relationship of the elongate rectangular riser strips, employed to give the container additional depth, to the base sheet and the side walls.
FIG. 7 is perspective view of an alternative embodiment of the fluid collection container wherein the interior portion of the container is provided with a baffled mat so as to allow pedestrian traffic to step on the fluid collection container without slippage or soiling their shoes.
FIG. 8 is a sectional view of the fluid collection container across line 8 — 8 in FIG. 7, illustrating the relationship of the height of the mat to the height of the container, and showing how the baffling of the interior portion allows fluid to pool between the baffles.
FIG. 9 is a side sectional view of the fluid collection container illustrating the method step of installing the base sheet wherein the base sheet is positioned and heat is applied to the base sheet using a heat source such as a propane torch.
FIG. 10 is a side sectional view of the fluid collection container illustrating the method step of installing the elongate rectangular riser strips used to increase the depth of the container, wherein the elongate rectangular strips are positioned about the peripheral edge of the base sheet and then heat is applied using a heat source such as a propane torch.
FIG. 11 is a side sectional view of the fluid collection container illustrating the method step of installing the end walls (or side walls), wherein the end walls (or side walls) are positioned so that its inside edge overlies the elongate rectangular riser strips and the peripheral edge of the base sheet, and its outside edge overlies the paved surface, and then heat is applied using a heat source such as a propane torch.
FIG. 12 is a side sectional view of the fluid collection container illustrating the method step of installing the end walls , wherein the outside edges of the end walls are tapered using a hand tool such as a putty knife so as to provide a smooth transition in elevation between the paved surface and the fluid collection container.
FIG. 13 is a perspective view of an alternative embodiment of the fluid collection contain illustrating the fluid collection container formed as a single, preformed piece.
DETAILED DESCRIPTION
The inventive fluid collection container will now be described in detail with reference to the figures. As shown in FIGS. 1 and 2, fluid collection container 100 is fixed to the pavement surface 20 of a traffic lane 25 which may or may not be bounded by one or more curbs 30 . In the following description traffic lane surface 20 is formed of asphalt. However, it is well within the scope of this invention to employ fluid collection container 100 on surfaces formed of other materials, such as but not limited to cement.
Preferably rectangular in shape, container 100 is positioned relative to a drive up service point 10 as follows: The longitudinal centerline 110 of container 100 lies parallel to curb 30 . Longitudinal centerline 110 is spaced apart from drive up service point 10 approximately 34 inches along a line which is normal 120 to drive up service point 10 . Note that this spacing does not necessarily center container 100 over the centerline of traffic lane 25 . The transverse centerline 115 of container 100 is spaced apart from drive up service point 10 such that it lies ahead of, or beyond, drive up service point 10 approximately 34 inches with respect to the direction of traffic flow. This location positions container 100 approximately between the front wheels of the automobile, and beneath the engine and transmission of the automobile, when the driver of the automobile is accessing drive up service point 10 .
Drive-up service point 10 may preferably be defined as an access point for receiving goods or services along a traffic lane through a vehicular window. In other words when a vehicular driver brings a driven vehicle to a halt in order to enable the vehicular driver to more readily obtain goods or services from a drive-up window, automated teller machine, or similar other depot for enabling vehicular drivers to obtain good or services via a vehicular window (the access point), the drive-up window, automated teller machine, or similar other depot is located adjacent either the driver-side window of the vehicle or alternatively a passenger's window of the vehicle. The vehicular driver or a vehicular passenger may thus obtain the desired goods or services by extending an arm through the vehicular window to grasp goods or avail oneself of services. A generic drive-up service point 10 is generally illustrated in FIG. No. 1 . Drive-up service point 10 preferably comprises a substantially vertical service point interface 11 as illustrated in FIG. Nos. 1 and 2 . In this regard, it is noted that drive-up windows, automated teller machines. or similar other depots typically comprise a user interface with which the vehicular driver may interact to obtain goods or services. This interface or service point interface 11 typically comprises a substantially vertical window, touch pad, or other interactive means to enable the vehicular driver to more easily obtain the desired goods and services.
Service point interface 11 preferably comprises a fore service point edge 12 as illustrated in FIG. Nos. 1 and 2 ; a rear service point edge 13 as illustrated in FIG. Nos. 1 and 2 ; a superior service point edge 16 as illustrated in FIG. Nos. 1 and 2 ; and an inferior service point edge 17 as illustrated in FIG. No. 1 . A vertically-oriented interface plane referenced at 120 lies intermediate fore service point edge 12 and rear service point edge 13 as illustrated in FIG. No. 2 . It will be seen that interface plane 120 is preferably equidistant from fore service point edge 12 and rear service point edge 13 and thus necessarily is substantially vertically oriented. A spatial-locating plane 14 preferably extends through fore service point edge 12 as illustrated in FIG. No. 2 . Spatial-locating plane 14 is referenced and described so as to enable the reader to more readily ascertain the preferred location or preferred positioned placement of fluid collection container 100 as will be discussed in more detail below.
Service point interface preferably further comprises a substantially planar exterior surface as is generally illustrated in FIG. No. 1 and as is typical of drive-up windows, automated teller machines, or similar other depots. It will be understood that interface plane 120 is perpendicular to the exterior surface at a service point center as is generally illustrated in FIG. No. 2 . The service point center is equidistant from fore service point edge 12 and rear service point edge 13 and is essentially defined by the intersection of interface plane 120 with the planar exterior surface. It will be further understood from an inspection of FIG. No. 2 that spatial-locating plane 14 is preferably parallel with interface plane 120 . For purposes of directing the reader to the preferred positioned placement of fluid collection container 100 , interface plane 120 intersects longitudinal centerline 110 at a spatial-locating point 19 as referenced in FIG. No. 2 .
It is thus contemplated that the present invention essentially comprises fluid collection container 100 for use in combination with drive up service point 10 . Fluid collection container 100 and drive-up service point 10 thus comprise, in combination, a fluid collection container assembly or fluid collection container and a drive-up service point combination as preferably described hereinafter.
Fluid collection container assembly or fluid collection container 100 comprises at least five individual and separate components, which components are bonded together. The bonding process is described in more detail below. The components preferably comprise a rectangular, planar base sheet 138 as illustrated in FIG. Nos. 3 - 6 ; two rectangular, planar side walls as referenced at 134 and 136 in FIG. Nos. 3 , 5 , and 6 ; and two rectangular, planar end walls as referenced at 130 and 132 in FIG. Nos. 3 and 4 . Base sheet 138 , side walls 134 and 136 , and end walls 130 and 132 preferably comprise or are constructed from a thermoplastic material, the thermoplastic material being impervious to vehicular or automotive fluids such as fuels, lubricants, and coolants.
Base sheet 138 preferably comprises a base sheet bottom surface 152 as illustrated in FIG. Nos. 4 and 5 ; a base sheet top surface 150 opposed to base sheet bottom surface 152 as illustrated in FIG. Nos. 4 and 5 ; a base sheet thickness intermediate base sheet top surface 150 and base sheet bottom surface 152 ; a base sheet peripheral edge 154 as illustrated in FIG. No. 4 ; a base sheet center 156 as illustrated in FIG. No. 3 ; a longitudinal axis as referenced at 158 in FIG. Nos. 3 and lies in the plane of base sheet 138 parallel to the length of the base sheet; and a transverse axis as referenced at 160 in FIG. No. 3 and lies in the plane of base sheet 138 parallel to the width of base sheet 138 and perpendicular to longitudinal axis 158 . Longitudinal axis 158 of base sheet 138 coincides with the longitudinal midline of the base sheet and extends from a first end of base sheet 138 to a second end of base sheet 138 . Transverse axis 160 of base sheet 138 coincides with the transverse midline of base sheet 138 and extends from a first side of base sheet 138 to a second side of base sheet 138 .
Base sheet 138 preferably further comprises a geometric center, the geometric center defined by the orthogonal intersection of longitudinal axis 158 and transverse axis 160 as is generally illustrated in FIG. No. 2 . It will be understood that longitudinal axis 158 preferably lies parallel to the traffic lane and thus the geometric center is preferably positioned adjacent the traffic lane surface at a base sheet center location. The base sheet center location is preferably spatially located approximately 34 inches from the exterior surface along interface plane 120 and approximately 54 inches from spatial-locating point 19 along longitudinal axis 158 . Spatial-locating plane 14 is preferably intermediate transverse axis 160 and a rearward end wall of fluid collection container 100 as is illustrated in FIG. No. 2 . In other words, given a right-handed Cartesian coordinate system in which the exterior surface lies in the X-Y plane (the X axis being the horizontal axis and the Y axis being the vertical axis) of the drawing page showing FIG. No. 1 and the origin of the coordinate system placed at the intersection of interface plane 120 and inferior service point edge 17 , interface plane 120 extends in the Z-plane or out of the drawing page showing FIG. No. 1 . The base sheet center location is then preferably located approximately 34 inches from the X-Y plane in the positive Z-direction along interface plane 120 and approximately 54 inches from spatial-locating point 19 in the positive X-direction along longitudinal axis 158 . No specified number of Y-direction inches is provided from inferior service point edge 17 to longitudinal axis 158 as it is noted that the measured dimensions between inferior service point edge 17 and longitudinal axis 158 will differ depending on the drive-up service point scenario with which fluid collection container 100 is utilized. Similarly, it is further recognized that the measured dimension between superior service point edge 16 and inferior service point edge 17 may differ in any given drive-up service point scenario. However, if inferior service point edge 17 were 36 inches from the traffic lane surface, then the base sheet center location may be thought of as being preferably positioned at about (+54i, −35⅞j, +34k) inches from the cited origin, given a base sheet thickness of about ⅛ inch.
Side walls 134 and 136 each preferably comprise a side wall bottom surface 164 as illustrated in FIG. No. 5 ; a side wall top surface 162 opposed to side wall bottom surface 164 as illustrated in FIG. No. 5 ; a side wall thickness; a side wall inside edge 166 as illustrated in FIG. No. 5 and a side wall outside edge 168 as illustrated in FIG. No. 5 . End walls 130 may preferably be defined as a fore end wall or an end wall coinciding with the forward direction of vehicular traffic relative to fluid collection container 100 . End wall 132 may preferably be defined as a rear end wall or an end wall coinciding with the rearward direction of vehicular traffic relative to fluid collection container 100 . End walls 130 and 132 each preferably comprise an end wall bottom surface 174 as illustrated in FIG. No. 4 ; an end wall top surface 172 opposed to end wall bottom surface 174 as illustrated in FIG. No. 4 ; an end wall thickness; an end wall inside edge 176 as illustrated in FIG. No. 4 , and an end wall outside edge 178 as illustrated in FIG. No. 4 . Base sheet 138 , side walls 134 and 136 , and end walls 130 and 132 are bonded together to form fluid collection container 100 , which bonding procedure is described in more detail below.
Fluid collection container 100 is thus positioned in a preferred location as described atop a traffic lane surface adjacent the drive-up service point. In this regard, it is contemplated that fluid collection container 100 is designed to collect vehicular fluids, which emanate from a vehicle temporarily halted adjacent the drive-up service point, which vehicle is temporarily halted in superior relation to the fluid collection container.
“It will be further noted that container 100 is provided in an overall width which is narrower than an automobile's track, or distance between the centers of parallel wheels, allowing the wheels of the automobile to pass on either side of container 100 without contacting it. In the preferred embodiment, the overall width of container 100 is approximately 30 inches. However, it is well within the scope of the invention to provide a container having an overall width which is greater than 30 inches as long as it does not exceed the width of an automobile's track.”
In the preferred embodiment, container 100 is provided in an overall length of approximately 42 inches. This length accommodates variations in automobile size and design. It is, however, well within the scope of the invention to provide a fluid collection container having a slightly smaller or greater length.
Container 100 is preferably formed of a thermoplastic which was developed for use in pavement markings. This highly durable material is composed of an ester modified rosin in conjunction with aggregates, pigments, binders, and glass beads, which is impervious to oil and gasoline, which is resistant to degradation by automotive fluids, the environment, and road salt, and which has a surface which is skid resistant. The material is commercially available under the name Premark 20/20 Flex, and is fully described in U.S. Pat. No. 5,861,206.
Referring now to FIGS. 3-6, container 100 is formed from a plurality of components, all formed from the thermoplastic material described above, which are assembled during installation on traffic lane surface 20 . Application of heat via heat source 50 , where heat source 50 consists of a propane torch or an equivalent localized, manually directable heat source, to the individual components per the method described below bonds the container to traffic lane surface 20 , and bonds the individual components together, resulting in a unified, integrated, leak-proof fluid trap.
It is, however, well within the scope of this invention to provide the inventive fluid collection container as a single, preformed unit 200 as shown in FIG. 13 . This can be accomplished by pre-assembly, including thermally joining individual components, at an alternative location, or by molding container 200 as a single piece of thermoplastic material. If provided as a single, preformed unit, installation of container 200 would be simplified since on-site assembly would not be required.
In the preferred embodiment, container 100 is a shallow, rectangular basin, and consists of a rectangular base sheet, two side walls, and two end walls. However, it is within the scope of this invention to form container 100 in alternative shapes such as circular, oval, or polygonal. A rectangular container is preferred due to the ease of forming and assembling the individual components, but employment of alternative shapes may be considered to suit individual requirements, such as aesthetic considerations.
“Base sheet 138 is preferably formed of a rectangular sheet of thermoplastic material and comprises a bottom surface 152 , a top surface 150 which is opposed to bottom surface 152 and separated from it by the thickness of base sheet 138 , peripheral edge 154 , and center 156 . Base sheet 138 comprises a longitudinal axis 158 which lies in the plane of base sheet 138 on the longitudinal midline, lies parallel to its length, and coincides with longitudinal axis 110 of container 100 , base sheet 138 further comprises transverse axis 160 which lies in the plane of base sheet 138 on its transverse midline, lies parallel to its width and perpendicular to longitudinal axis 158 , and coincides with transverse axis 115 of container 100 .”
In the preferred embodiment, base sheet 138 has the approximate dimensions of 24 inches in width by 36 inches in length with a thickness of ⅛ inch. However, these dimensions can be varied to accommodate larger or smaller fluid collection containers. Size of the fluid collection container can be modified to accommodate locations having greater or smaller traffic volume, and desired frequency of waste removal.
Side walls 134 , 136 are each formed of an elongate rectangular strip of thermoplastic material, each rectangular strip comprising a bottom surface 164 , a top surface 162 which is opposed to side wall bottom surface 164 and separated from it by the thickness of the strip. Side walls 134 , 136 are preferably rectangular in cross section, have an inside edge 166 , and an outside edge 168 which is spaced apart from the inside edge by the width of the strip.
Side walls 134 , 136 are provided in a length which is two inches less than the length of base sheet 138 . Thus, in the preferred embodiment side walls 134 , 136 have an approximate length of 34 inches. The approximate preferred width and depth are 4 inches and ⅛ inch, respectively.
End walls 130 , 132 are each formed of an elongate rectangular strip of thermoplastic material, each rectangular strip comprising a bottom surface 174 , a top surface 172 which is opposed to end wall bottom surface 174 and separated from it by the thickness of the strip. End walls 130 , 132 are preferably rectangular in cross section, have an inside edge 176 , and an outside edge 178 which is spaced apart from the inside edge by the width of the strip.
End walls 130 , 132 are provided in a length which is six inches greater than the width of base sheet 138 . Thus, in the preferred embodiment end walls 130 , 132 have an approximate length of 30 inches. The approximate preferred width and depth are 4 inches and ⅛ inch, respectively.
In colder climates, traffic lane surface 20 may be subjected to clearing of snow using snow plows. To prevent damage to container 100 by a snow plow blade, outside edges 178 of end walls 130 , 132 may be provided with a downward taper, removing any stepwise discontinuity between the pavement and the fluid collection container, and allowing a plow blade to be smoothly lifted onto the top of container 100 . This taper is formed on the outside edges 178 of end wall 130 , 132 by flattening the outside edges 178 toward traffic lane surface 20 with a blunt tool such as a putty knife while the thermoplastic is heated and pliable (FIG. 12 ).
In areas of high traffic volume, or in cases where waste removal from container 100 is infrequent, it may be necessary to provide a fluid collection container having increased depth. Depth of container 100 may be increased from ⅛″ to ¼ inch by insertion of elongate, narrow rectangular strips of thermoplastic material between base sheet 138 and each of the respective side walls 134 , 136 and end wall 130 , 132 (FIG. 6 ). In the preferred embodiment, these risers 140 are provided having a 1 inch width and ⅛ inch thickness, and have lengths which correspond to the respective lengths of the peripheral edges of base sheet 138 . Risers 140 are placed along the peripheral edges 154 of base sheet 138 so that the outer edges of risers 140 are vertically aligned with peripheral edge 154 . However, it is within the scope of the invention to increase the width of risers 140 so that the inner edges of risers 140 overlie the periphery of base sheet 138 and the outer edges of risers 140 extend beyond peripheral edge 154 of base sheet 138 .
Although drive up service points 10 are designed for access by automobile traffic, it is not unknown for pedestrians to use these facilities. Additionally, drive up service points 10 must be monitored and maintained by service persons who approach them on foot. Container 100 is provided with features which improve skid resistance and prevent the pedestrian from becoming soiled in the event that he/she steps into container 100 as they approach a drive up service point 10 .
The first such feature is skid resistance. The thermoplastic material used to form container 100 is embedded with glass beads so as to provide skid resistance. Material specifications require a minimum resistance value of 45 BPN when tested according to ASTM: E 303.
The second such feature is a baffled mat 146 (FIG. 7) which may be provided with container 100 . Mat 146 lies within the basin formed by side walls 134 , 136 and end walls 130 , 132 , and overlies base sheet 138 . Mat 146 is provided with the same thickness as side walls 134 , 136 and end walls 130 , 132 so that upper surface of mat 146 and the respective side and end walls form a level, planar surface for walking on, while the spaces between the baffles form a plurality of small “wells” which receive the leaked or spilled automotive fluids. Although only one baffle pattern is illustrated in the figures, it is understood that the baffles may be provided in a variety of patterns, including, but not limited to, longitudinal parallel baffles, transverse parallel baffles, concentric circular baffles, and intersecting diagonal baffles (diamond baffles). Mat 146 may be formed of thermoplastic material, or materials such as, but not limited to, metal. Alternatively, mat 146 may be formed of a sheet of thermoplastic material which has a pattern impressed upon it while softened by heating.
Fluid collection container 100 , consisting of base sheet 138 , side walls 134 , 136 , and end walls 130 , 132 , is assembled and bonded to traffic lane surface 20 as described in the following method steps:
1. Determine the location on the pavement where the fluid collection container is to be positioned. This location referred to as the application area, and is positioned relative to drive up service point 10 such that longitudinal centerline 110 of container 100 lies parallel to curb 30 and spaced apart from drive up service point 10 approximately 34 inches along a line which is normal 120 to drive up service point 10 . Transverse centerline 115 of container 100 is spaced apart from drive up service point 10 such that it lies ahead of, or beyond, drive up service point 10 approximately 34 inches with respect to the direction of traffic flow. This location positions container 100 approximately between the front wheels of the automobile, and beneath the engine and transmission of the automobile, when the driver of the automobile is accessing drive up service point 10 .
2. Clean and dry the application area. The application area is cleaned to remove all residues, including de-icing compounds such as salt, which could prevent proper adhesion of the oil and gas impervious base sheet to the pavement. Surface moisture is then removed from the application area by heating with a heat source such as a propane torch. This procedure prevents steam from forming between container 100 and traffic lane surface 20 as container 100 is thermally bonded to traffic lane surface 20 (step 4 ).
3. Position base sheet 138 in the application area so that the base sheet center overlies the center of the application area, and longitudinal axis 158 of base sheet 138 is parallel to the direction of traffic flow.
4. Apply heat to base sheet 138 using heat source 50 , such as a propane torch. Heat is applied until base sheet 138 is bonded to traffic lane surface 20 (FIG. 9 ).
5. Check bonding of base sheet 138 to traffic lane surface 20 . This is achieved by attempting to lift container 100 off lane surface 20 by inserting a spatula-type tool between container 100 and lane surface 20 and visually checking the adhesion. After cooling, adhesion integrity is checked by striking base sheet 138 with a chisel. If bonding is imperfect, repeat step 4 .
6. Position one of the side walls 134 , 136 on each of the first and second sides of base sheet 138 such that the respective inside edges 166 of each side wall 134 , 136 overlaps the peripheral side edge of base sheet 138 , and the respective outside edges 168 of each side wall 134 , 136 overlies traffic lane surface 20 adjacent to the peripheral edge of base sheet 138 (FIG. 11 ). Preferably, the respective inside edges 166 of each side wall 134 , 136 overlaps the peripheral side edge of base sheet 138 approximately one inch, so that approximately three inches of the side wall overlies traffic lane surface 20 .
7. Position one of the end walls 130 , 132 on each of said first and second ends of base sheet 138 such that the respective inside edges 176 of each end wall 130 , 132 overlaps the peripheral end edge of base sheet 138 , and the respective outside edges 176 of end walls 130 , 132 overlies traffic lane surface 20 adjacent to the peripheral edge of base sheet 138 . Preferably, the respective inside edges 176 of each end wall 130 , 132 overlaps the peripheral end edge of base sheet 138 approximately one inch, so that approximately three inches of the end wall overlies traffic lane surface 20 .
8. Apply heat to side walls 134 , 136 and end walls 130 , 132 using heat source 50 . Heat is applied until the respective inside edges 166 , 176 of side walls 134 , 136 and end walls 130 , 132 are fused to base sheet 138 and each other to form an integrated, non-leaking, fluid impervious container, and until the respective outside edges 168 , 178 of side walls 134 , 136 and end walls 130 , 132 are bonded to traffic lane surface 20 .
9. Check bonding of side walls 134 , 136 and end walls 130 , 132 to base sheet 138 and to traffic lane surface 20 . If bonding is imperfect, repeat step 8 .
In colder climates, traffic lane surface 20 may be subjected to clearing of snow using snow plows. To prevent damage to container 100 by a snow plow blade, outside edges 178 of end walls 130 , 132 may be provided with a downward taper. In these climates, an additional method step is added immediately following method step 8 as follows:
Method step 8 a : Apply a downward pressure on the respective outside edges 178 of end walls 130 , 132 while the thermoplastic material is hot and pliable so as to remove the upper corner of the outside edge (FIG. 12 ).
In areas of high traffic volume, or in cases where waste removal from container 100 is infrequent, it may be necessary to provide a fluid collection container having increased depth. When risers 140 are employed, the following two method steps are inserted after method step 5 :
Method step 5 a : Position the elongate narrow rectangular strips of thermoplastic material so as to overlie and confront the entire peripheral edge of the base sheet such that the outer edge of the elongate narrow rectangular strip is vertically aligned with the peripheral edge of the base sheet, and the inner edge of the elongate narrow rectangular strip overlies the body of the base sheet adjacent to the peripheral edge of the base sheet.
Method step 5 b : Apply heat to the elongate narrow rectangular strip using heat source 50 . Heat is applied until the elongate narrow rectangular strip is bonded to and integral with base sheet 138 (FIG. 10 ).
In the above description of the method of installing fluid container 100 on traffic lane surface 20 , it is understood that traffic lane surface 20 is formed of asphalt. However, it is well within the scope of this invention to employ fluid collection container 100 on surfaces formed of other materials, such as but not limited to cement. When installing fluid container 100 on cement, a surface sealer designed for sealing cement may be used to improve the adhesion of the thermoplastic material to the cement. Excellent results have been obtained when a commercially available sealant sold under the name “Pliobond” is used. The sealer acts to block moisture from coming up from the cement during the thermal bonding process, thus prevent steam formation between container 100 and traffic lane surface 20 . When installing fluid container 100 on cement, the following method step is inserted after method step 2 :
Method 2 a : Apply a cement sealer to traffic lane surface 20 about the entire application area.
While changes may be made in the detail construction and implementation of method within the skill of those knowlegeable in the art, it shall be understood that such changes shall be within the spirit and scope of the present invention, as defined by the appended claims.
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A combination fluid collection container and drive-up service point in a traffic lane. The fluid collection container for retention of leaked automobile fluids is thermally bonded to the traffic lane surface adjacent to a drive up service point. The shallow, rectangular basin is formed of a thermoplastic material which is impervious to automotive fuels and lubricants, and resistant to wear and degradation by the environment. The container is formed of multiple thermoplastic components which are assembled during installation on the traffic lane surface. These components include a base sheet which provides the bottom surface of the container, side walls, and end walls. The outer edges of the end walls may be tapered during installation to remove any abrupt discontinuities in the traffic lane surface. The leaked fluids are retained within the container until removed in compliance with local laws and codes.
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This application is a continuation of U.S. application Ser. No. 10/009,067, filed Jul. 16, 2002 (now abandoned), which is the National Stage of International Application No. PCT/EP00/05152, filed Jun. 5, 2000, which claims the benefit of U.S. Provisional Application No. 60/180,455, filed Feb. 4, 2000, and which is a continuation-in-part of U.S. application Ser. No. 09/326,501, filed Jun. 4, 1999 (now U.S. Pat. No. 6,388,113).
FIELD OF THE INVENTION
The present invention relates to the use of an oil having a high oleic and high stearic content in various products.
BACKGROUND OF THE INVENTION
The uses of oils are determined by their fatty acid composition. The principal component of oils are the triacylglycerol (TAG) molecules, which constitute normally more than 95% of the oil. Three fatty acids are bound to a molecule of glycerol to make the TAG. If these fatty acids are mainly saturated fatty acids (“saturates”) the product is called fat and it is solid at room temperature. On the other hand if the fatty acids are mainly unsaturated then it is called oil and it is liquid at room temperature.
The oils obtained from seeds cultivated in temperate climate (sunflower, soybean, rapeseed, etc.) have mainly unsaturated fatty acids, like linoleic and oleic acids, so they are liquid and primarily used for cooking, salad dressing, etc. Fats are obtained from animals (margarine, lard, etc.), some tropical trees (cocoa, palm) or chemically modified (hydrogenation and transesterification) liquid vegetable oils. They have mainly saturated (palmitic or stearic acids) or chemically modified fatty acids (trans fatty acids) all with high melting point.
Table 1 shows as an example the fatty acid composition and other properties of some fats and oils. The fats are needed for most of the food industry to make margarine, shortening, bakery, confectionery, snacks, etc. The food industry uses the fat for these purposes because of their plastic properties (they do not melt, can be spread, or do not stick to the hand) and stability (they have a good resistance to oxidation at room or high temperatures).
TABLE 1
Fatty acid composition (%)
Properties
Oil or fat
Others 1
Myristic
Palmitic
Stearic
Oleic
Linoleic
Trans
Saturated
Lard
3
2
25
12
45
10
1
79
Butter
14
10
26
12
28
3
3
84
Margarine
10
7
46
34
23
*
Palm oil
1
45
5
39
9
18
Olive oil
1
14
3
71
10
2
Cocoa butter
26
35
35
3
4
Normal
7
5
30
57
1
sunflower
High
5
4
88
2
1
oleic
sunflower
1 “others” are palmitoleic in the case of lard and olive oil and also fatty acids shorter than 12 carbons in butter
*depends on the level of hydrogenation
The actual available fats are however not a good option because they have negative nutritional properties. The main problem is that they raise the bad form of serum cholesterol (low density lipoprotein, LDL). This is due to several facts, some related to the origin of the fat and others with the manipulation thereof. Animal fats have most of the saturated fatty acids in the position 2 of the TAG molecule. Most vegetable fats and oils, however, have only minor amounts of saturated fatty acids in this position and are therefore more healthy.
During digestion the TAG molecule is hydrolysed by enzymes called lipases ( FIG. 1 ). The fatty acids in positions 1 and 3 are liberated as free fatty acids. If these fatty acids are saturated they form insoluble salts with calcium and magnesium, being mostly excreted. But fatty acids in position 2 form with the glycerol a molecule of monoacylglycerol, which has detergent properties and is easily absorbed into the body. The saturated fatty acids from animal fats are then absorbed, thus raising LDL.
In order to increase the percentage of saturated fatty acids, vegetable oils are hydrogenated and/or transesterified. The hydrogenation process produces trans fatty acids that probably are even worse than saturated fatty acids as illustrated by Willett, W. C. & Ascherio, A. (1994) Trans fatty acids: Are the effects only marginal? American Journal of Public Health 84:722-724. The transesterification process changes randomly the fatty acids within the three positions, converting a healthy vegetable oil with low saturated fatty acid in the 2 position in an oil that has near 30% of saturated fatty acids. So neither of the two chemical modifications leads to a healthy product.
However, not all fats are unhealthy. It has been demonstrated that cocoa butter, which has around 60% of saturated fatty acids, the rest being mainly oleic acid, does not raise serum cholesterol. This is due to two main reasons. One is that only 4% of the saturated fatty acids are in position 2 and the other is that the principal saturated fatty acid is stearic acid. Stearic acid does not have a negative effect on serum cholesterol. Probably the amount of 35% of oleic acid in the cocoa butter also adds to its healthy property.
It is important to note that except in cocoa butter, palmitic acid is the main saturated fatty acid of commodity fats. Palmitic is however not a very healthy fat.
Traditional breeding and mutagenesis has not been the only tool used to form seeds producing oil with different fatty acid profiles. Increases in stearic acid in oil bearing plants have also been addressed by the introduction of transgenes into the germplasm, to alter the fatty acid biosynthesis pathway of the vegetable oil. The fatty acid biosynthesis in vegetable oil, but more particularly sunflower oil, includes the biosynthesis of basically two saturates (palmitate, stearate) and two unsaturates (oleate and linoleate). In oilseeds, the stearoyl-ACP desaturase is the enzyme which introduces the first double bond on stearoyl-ACP to form oleoyl-ACP. Thus, this is an enzyme that assists in the determination of the unsaturation in the C18 length fatty acids.
In U.S. Pat. No. 5,443,974 the inhibition of canola enzyme stearoyl-ACP desaturase was described. The stearate levels were increased but the levels of palmitate were basically unaffected. Inhibition of the plant enzyme stearoyl-ACP desaturase in canola was also reported by Knutzon et al., Proc. Natl. Acad. Sci. USA 89:2624-28 (1992). These results showed an increase in the level of stearate produced in the canola seed. The research also showed that inhibition by antisense in seeds of canola and soybean, respectively, showed increased stearate. When a plasmid containing a gene encoding for stearoyl-ACP desaturase was placed in canola, this inhibition resulted in an increase in stearic acid but unfortunately a reduction in the oleate. However, in the soybean this inhibition of stearate resulted in a less dramatic reduction of the oleate. This slower decrease in oleate however may have been a function of the small initial levels of oleate in the soybean. The fatty acid pathway in most oilseed plants appears to be resistant to maintaining both oleic and stearic at elevated levels.
PCT/US97/01419 describes increased levels of both stearic acid and palmitic acid in sunflowers through the inhibition of the plant enzyme stearoyl-ACP desaturase. As indicated above, palmitic oil is not, however, viewed as being a very healthy oil.
PCT/US96/09486 discloses that sunflower oil levels of both palmitic and oleic acids could be increased, the seeds having increased levels of palmitic acid of 21-23% and of oleic acid of 61%. The sunflower oil is liquid at room temperature. But the increased palmitic fatty acid level is alleged to allow the oil to be used in shortening and in margarine with relatively low level of hydrogenation, which leads to a relatively low level of trans-fatty acids in the resulting product. However, the commercial value may be questioned because of the high level of palmitic acid.
There thus remains a need for a sunflower oil which is both healthy and useful for industrial purposes. Furthermore, it is desirable to have a sunflower oil that has a balance of good saturates and good unsaturates, i.e. that is high in unsaturates but has sufficient saturates to be used for margarines or hardstock without high levels of hydrogenation, thus leading to no trans-fatty acids in the resulting product. Basically, there remains a need for a sunflower plant that can produce seed containing oil which is high in oleic acid and in stearic acid with reduced linoleic levels.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a vegetable oil with high stearic acid (as saturated fatty acid) and high oleic acid (as unsaturated fatty acid) contents that will reduce the above described problems with fat. In this oil the stearic acid should preferably be in positions 1 and 3 of TAG.
The present invention is based on the following considerations. The seed fatty acid biosynthesis occurs inside the plastid ( FIG. 2 ). A series of cycling reactions catalysed by the enzymatic complex FAS I produces the palmitoyl-ACP that has 16 carbons. A second enzymatic complex called FAS II elongates the palmitoyl-ACP to stearoyl-ACP (18 carbons), that is further modified by the stearate desaturase to produce oleoyl-ACP. These are the three main fatty acids synthesised by the plastid, being cleaved off the ACP by the action of the enzyme thioesterase and then exported out of the plastid. Later in the cytoplasm, the oleic acid may be desaturated to linoleic and linolenic acids.
The TAG (storage oil) is produced in the cytoplasm using the pool of fatty acids in the cytoplasm. This fatty acid pool consists of the fatty acids exported from the plastid and the linoleic acid made in the cytoplasm by desaturation. Thus, the fatty acid composition of TAG is determined by the fatty acids exported out of the plastid plus the linoleic acid produced in the cytoplasm.
It was then contemplated that a new plant that is rich in stearic and oleic acids could be selected if a reduced stearate desaturase activity (leading to a decrease in the amount of oleoyl-ACP formed and therefore in an increase in the stearoyl-ACP) was combined with a good thioesterase activity on stearoyl-ACP (which leads to the stearic acid being transported out of the plastid into the cytoplasm). This plant will produce an accumulation of stearoyl-ACP inside the plastid, and the good activity of the thioesterase over stearoyl-ACP should export it very well out of the plastid, having there a high stearic acid content available for TAG biosynthesis.
Out of the plastid, in the cytoplasm the high oleic character is necessary to keep the linoleic acid content low. In high oleic lines, the conversion pathway does not work properly, so there is no conversion of oleic acid to linoleic acid.
The present invention is thus based on the finding that by selection of one parent line that has a high stearic (HS) acid content on the one hand and a second parent line having a high oleic and high thioesterase (HOHT) activity over stearoyl-ACP on the other hand, crosses can be made that result in seeds having a combination of the high stearic and high oleic properties (HSHO). In addition, it was surprisingly found that in said oil a maximum of 10 wt % of the fatty acid groups in the sn-2 position of the TAG molecules are saturated fatty acid groups.
Therefore, the present invention relates to plant seeds that contain an oil comprising an oleic acid content of more than 40 wt % and a stearic acid content of more than 12 wt % based on the total fatty acid content of said oil, and wherein a maximum of 10 wt % of the fatty acid groups in the sn-2 position of the TAG molecules constituting the oil are saturated fatty acid groups. Preferably, the saturated fatty acid groups are stearic acid groups. It is preferred that the oil has in the sn-2 position of the TAG molecules a maximum of 8%, more preferably a maximum of 5 wt % of saturated fatty acid groups, in particular stearic acid groups.
Regarding the other fatty acids, it is preferred that the oleic acid content is from 55 to 75 wt %, the stearic acid content is from 15 to 50 wt %, in particular 20 to 40 wt %, and the linoleic acid content is less than 20 wt %. Preferably the total level of saturated fatty acids is at least 20 wt %.
Selection of the parents can be achieved as follows.
Lines with high stearic acid content are lines having a stearic acid content of more than 12%, preferably more than 20%. One example of such a high stearic (HS) parent line, which was selected after mutagenesis and has a stearic acid content of 26 wt %, is available as “CAS-3” (ATCC deposit no. 75968, deposited on Dec. 14, 1994, with the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md. 20852). Another example is “CAS-4”, having a stearic acid content of 16.1 wt % (ATCC deposit no. 75969, deposited on Dec. 14, 1994, with the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md. 20852). By analysing the fatty acid composition of oil derived from the seeds of other candidate lines, the skilled person will be able to select other suitable parent lines.
It was found that some of the usual high oleic varieties could not be used for the purpose of the invention because they were found to have very low thioesterase activity over the stearoyl-ACP. To overcome this, by measuring the thioesterase activity, lines with good activity over stearoyl-ACP can be selected from the available high oleic lines collections.
In short, one would first analyse the fatty acid composition of the oil of several promising lines. A suitable HOHT parent line would have more than 7-8% stearic acid and either less than 5% linoleic acid or more than 75% oleic acid. Subsequently, the selected lines must be grown and self pollinated. The total thioesterase activity is measured in seeds 15 days after flowering (15DAF) on both oleoyl-ACP and stearoyl-ACP. In suitable lines, the activity over stearoyl-ACP should be more than 10% of the activity over oleoyl-ACP. The ratio between both activities determines whether a line is suitable as a parent line or not.
In Table 2 the fatty acid composition and thioesterase activity of two high oleic sunflower lines are illustrated.
TABLE 2 Stearic acid content and thioesterase Vmax over the stearoyl-ACP of 15 days after flowering seeds from two high oleic sunflower lines. Stearic acid Thioesterase activity Sunflower line (%) Vmax HOHT 17.8 2.03 HOLT 8.0 0.82
The HOHT line is a high oleic line with thioesterase over stearoyl-ACP activity (HOHT) of more than twice the thioesterase Vmax over stearoyl-ACP than an usual high oleic line (HOLT). The relative activity of the enzymes over the stearoyl-ACP standardised with respect to the one over oleoyl-ACP is illustrated in FIG. 3 . This line has as a consequence more stearic acid at 15 days after flowering (Table 2) and also in the oil obtained from the mature seed (Table 3).
TABLE 3 Fatty acid composition (%) of seeds from two high oleic sunflower lines. Fatty acid composition (%) Sunflower line palmitic stearic oleic linoleic araquic behenic HOHT 4.3 9.7 78.5 3.9 1.0 2.6 HOLT 3.8 4.9 84.3 4.8 0.5 1.7
This HOHT parent line was deposited on Sep. 7, 1999 with the American Type Culture Collection (10801 University Boulevard, Manassas, Va. 20110-2209) and was assigned the number PTA-628.
Lines of both types (HOHT and HOLT) have been crossed with the high stearic CAS-3 line. In FIGS. 4 (for HOHT) and 5 (for HOLT), the F2 segregation for both traits (high stearic acid content and high oleic acid content) are shown. The seeds with higher content in stearic and oleic acids are within a circle. From the figures it follows that the HOHT line with high thioesterase activity over stearoyl-ACP has high oleic high stearic seeds and the line without high thioesterase activity has no seeds of this type. Table 4 shows the fatty acid composition of these lines.
TABLE 4
Fatty acid composition of selected high oleic and stearic
lines, with high and low thioesterase activity over
stearoyl-ACP, after crossing with HS line CAS-3
Fatty acid composition (%)
Sunflower line
palmitic
stearic
oleic
linoleic
araquic
behenic
HOHTxCAS-3
5.2
24.6
59.2
6.8
1.8
2.4
HOLTxCAS-3
4.3
17.4
72.1
4.0
1.3
2.8
The selected F2 lines are selfed for 5 to 6 generations in isolated conditions to avoid contamination. The resultant generations are selected, based on high oleic and stearic acid content. Thioesterase activity can be analysed to assist in the selection process. Likewise, marker assisted breeding can be employed to track any or all of the three traits to make the selection process quicker. Various markers such as SSR microsatellite, ASO, RFLP and likewise can be employed. The use of markers is not necessary, as standard tests are known for determining oleic, stearic, and thioesterase activity. However, once identified markers make trait tracking easier and earlier in the plant's life.
The true breeding plants produce an oil having a similar fatty acid composition to the F2 seeds selected with a low content of saturated fatty acid in the 2 position of the TAG molecule (Table 5).
TABLE 5
Fatty acid composition of oil, TAG and sn-positions of
true breeding HSHO plants selected.
Fatty acid composition (mol %)
Palmitic
Stearic
Oleic
Linoleic
Araquic
Behenic
Total oil
5.5
24.9
57.8
8.2
1.7
1.8
TAG
5.6
26.1
57.6
7.4
1.6
1.7
sn-2 position
1.7
1.9
87.4
9.0
n.d.
n.d.
sn-1 and 3
7.2
33.1
46.8
7.3
2.7
2.9
position
n.d. = not detected.
The invention also relates to plants which form seeds which contain the above described oil of the invention and to the oil per se as well as to products derived from the seeds, such as meal and crushed seeds. The plants, seeds, oil, meal and crushed seeds of the invention are for example sunflower plants, seeds, oil, meal and crushed seeds.
The plants and seeds of the invention are obtainable by a method comprising:
a) providing seeds which contain an oil having a stearic acid content of at least 12 wt % based on the total fatty acid content of the oil;
b) providing seeds which contain an oil having an oleic acid content of at least 40 wt % based on the total fatty acid content of the oil, and which have a thioesterase activity over stearoyl-ACP that is at least 10% of the thioesterase activity over oleoyl-ACP;
c) crossing plants grown from the seeds provided in step (a) and (b);
d) harvesting the F1 seed progeny.
Preferably, the method further comprises the steps of:
e) planting the F1 progeny seeds to grow plants;
f) self-pollinating the plants thus grown to produce F2 seed;
g) testing the seed for the presence of a stearic acid content in the oil of at least 12 wt % and an oleic acid content of at least 40 wt % and a thioesterase activity over stearoyl-ACP that is at least 10% of the thioesterase activity over oleoyl-ACP;
h) planting seeds having the desired levels of stearic acid content, oleic acid content and thioesterase activity to grow plants;
i) self-pollinating the plants thus grown to produce F3 seed; and
j) optionally repeating steps g), h) and i) until the desired levels of stearic acid content, oleic acid content and thioesterase activity are fixed.
Preferably, the stearic acid content is at least 15 wt %, preferably at least 20 wt %.
The present invention also covers the method of obtaining an oil, in particular a sunflower oil, having an oleic acid content of more than 40 wt % and a stearic acid content of more than 12 wt % based on the total fatty acid content of the oil by extracting oil from the seeds. The method preferably includes an extraction process which does not involve a substantial modification of the (sunflower) oil.
Additionally, in the process of extraction of the oil from the seeds there is preferably no substantial chemical or physical modification nor enzymatic rearrangement taking place and preferably no substantial hardening of the oil.
The present invention also includes food products comprising oil obtainable from seeds, in particular sunflower seeds, having an oleic acid content of more than 40 wt % and a stearic acid content of more than 12 wt % based on the total fatty acid content of the oil. Food products that are particularly useful for this type of oil include spreads, margarines, shortenings, sauces, ice-cream, soups, bakery products, confectionery products, and the like. In these food products the level of (sunflower) oil is preferably from 3 to 100 wt % relative to the total oil weight in the product. When used to form a spread according to the present invention the (sunflower) oil is preferably used as a hardstock at levels of 5 to 20 wt %.
The sunflower seeds of the present invention are also suitable per se for human and animal consumption.
The present invention also encompasses cosmetic products comprising an oil, in particular a sunflower oil, the oil having an oleic acid content of more than 40 wt % and a stearic acid content of more than 12 wt % based on the total fatty acid content of the oil. These cosmetic products can preferably contain levels of (sunflower) oil from 3 to 100 wt %. Some examples of these cosmetic products would include creams, lotions, lipsticks, soap bars and skin or hair oils.
The present invention also includes a process for selecting Helianthus annuus plants, capable of producing seeds having the desired oil. The steps of the method are a) selecting a number of Helianthus annuus plants, collecting therefrom the seeds, the oil of which has a stearic acid content of at least 12 wt % and preferably 18 wt % based on the total fatty acid content; (b) selecting a number of Helianthus annuus plants, collecting therefrom the seeds, which express an oleic acid content of at least 40 wt % based on the oil present in the seed and a thioesterase activity over stearoyl-ACP that is at least 10% of the thioesterase activity over oleoyl-ACP; (c) crossing the plants grown from the seeds of (a) and (b); and, harvesting the F1 seed progeny.
Additional steps include the steps of: (d) planting of the seeds or embryo rescue of the embryos of the F1 progeny obtained to form F2 segregating seeds; (e) selecting from the F2 seeds which developed plants, those plants which produce seeds having an oleic acid content of more than 40 wt % and a stearic acid content of more than 12 wt % based on the total fatty acid content of the oil, optionally selfing the selected plant to form true breeding inbreds.
The present invention also includes the process for producing F1 hybrid seed. The steps of the method are a) planting seed of two inbreds having high oleic acid content of at least 40 wt % and thioesterase activity over stearoyl-ACP that is at least 10% of the thioesterase activity over oleoyl-ACP, one of which may be male sterile, b) crossing the two inbreds, and c) harvesting the F1 seed capable of producing F2 seed with an at least 40 wt % oleic acid content and an at least 12 wt % stearic acid content.
The present invention encompasses a vegetable oil with a new and unique fatty acid composition produced in easy to grow crops. The preferred crop is sunflower. This plant was used for making this invention. However, the invention is more broadly applicable and selection of suitable parents to produce the derived vegetable oil could likewise modify other crops. These crops would include at least Brassicas , peanuts, palms and other oil producing plants. When mutation is used for making one or both of the parents, the crop should be susceptible to mutagenically induced oil changes. Rape seed meets all these requirements as does sunflower, these crops are presently some of the most useful crops for production of this new and unique fatty acid composition in the oil of their seeds.
BRIEF DESCRIPTION OF THE DRAWINGS
In this application reference is made to the following figures:
FIG. 1 : hydrolysis of triacylgycerols by lipase;
FIG. 2 : plastid showing the fatty acid biosynthesis in oilseeds;
FIG. 3 : elevated thioesterase activity shown as the relative activity of the thioesterase over stearoyl-ACP and oleoyl-ACP of HOHT and HOLT;
FIG. 4 : the F2 segregation for stearic and oleic acids of the cross between high oleic with high thioesterase activity over stearoyl-ACP line (HOHT) and a high stearic acid line (CAS-3);
FIG. 5 : the F2 segregation for stearic and oleic acids of the cross between high oleic with low thioesterase activity over stearoyl-ACP line (HOLT) and a high stearic acid line (CAS-3).
DETAILED DESCRIPTION OF THE INVENTION
Definitions
“SUNFLOWER” shall mean Helianthus annuus.
“PLANT” shall include the complete plant and all plant and cell parts including pollen, kernel, oil, embryo, stalk, head, roots, cells, meristems, ovule, anthers, microspores, embryos, DNA, RNA, petals, seeds, and the like and protoplasts, callus or suspensions of any of the above.
“15DAF” shall mean 15 days after flowering.
“TOTAL FATTY ACID CONTENT” of the sunflower oil refers to the sum of C16:0, 18:0, 18:1, 18:2, 20:0, 22:0 and the traces of other like fatty acids as determined simultaneously in the oil from the seed.
“HOLT” shall mean having high to medium-high (40%-90%) oleic acid levels in the oil when compared to normal, wildtype sunflower seed (oleic acid levels of 17%-20%) wherein there are “LOW LEVELS OF THIOESTERASE ACTIVITY”. A “HOLT LINE” is a line, in particular a sunflower line, having the HOLT trait.
“HOHT” shall mean having high to medium-high (40%-90%) oleic acid levels in the oil when compared to normal, wildtype sunflower seed (oleic acid levels of 17%-20%) wherein there are “HIGH LEVELS OF THIOESTERASE ACTIVITY”. A “HOHT LINE” is a line, in particular a sunflower line, that has the HOHT trait.
“HIGH LEVELS OF THIOESTERASE ACTIVITY” shall mean levels (at 15DAF) of thioesterase activity over stearoyl-ACP which are at least 10% of the thioesterase activity over oleoyl-ACP. Consequently, “LOW LEVELS OF THIOESTERASE ACTIVITY” shall mean levels which are below the “HIGH LEVELS OF THIOESTERASE ACTIVITY”.
“HS” shall mean having stearic acid levels in the oil of at least 12 wt % and preferably at least 15 wt % or more preferably at least 18 wt % or even at least 20 wt % based on the total fatty acid content. “HIGH STEARIC LINE” or “HS LINE” shall mean a line, in particular a sunflower line, having the HS trait.
“HOHS” shall mean having levels of above 40% oleic acid and at least 12 wt % stearic acid in the oil and preferably having levels of at least 15% wt, more preferably at least 18 wt % or even at least 20 wt % stearic acid in the oil. A “HOHS LINE” shall mean a line having the HOHS trait.
EXAMPLES
Introduction
Preparation of HS Parent
In order to obtain the HS parent a method can be used for preparing sunflower seeds having an increased stearic acid and oleic acid content as compared to wild type seeds. This method includes the step of treating parent seeds with a mutagenic agent during a period of time and in a concentration sufficient to induce one or more mutations in the genetic trait involved in stearic acid or oleic acid biosynthesis. This results in an increased production of stearic acid and/or an increased level of oleic acid. These mutagenic agents include agents such as sodium azide or an alkylating agent, like ethyl methane sulfonate, of course any other mutagenic agent having the same or similar effects may also be used. The treated seeds will contain inheritable genetic changes. These mutated seeds are then germinated and progeny plants are developed therefrom. To increase the traits in the lines the progeny can be crossed or selfed. The progeny seeds are collected and analysed.
Sodium azide and ethyl methane sulfonate were used as mutagenic agents in Example 1. Several sunflower lines with a stearic acid content between 12 and 45% have been obtained. In all these cases the original sunflower parent line for the production of the high stearic acid lines used was RDF-1-532 (Sunflower Collection of Instituto de Agricultura Sostenible, CSIC, Cordoba, Spain) that has from 4 to 7% stearic acid content in the seed oil.
Selecting the HOHT Parent
In principle it is sufficient to screen oleic lines for a HOHT phenotype and use this line for either transformation or for crossing to a high stearic line to develop a HOHS line. A suitable line is at least the HOHT parent line that was deposited on Sep. 7, 1999 with the American Type Culture Collection (10801 University Boulevard, Manassas, Va. 20110-2209) and was assigned the number PTA-628.
Making the HOHS Line
Seeds having the HOHT trait or the stearic trait can then be crossed to each other to form the HOHS line. Optionally there can be additional cycles of germination, culturing, and selfing to fix the homozygosity of the traits in the lines and crossing and collection of seeds.
Materials and Methods
Plants Growth Conditions
Sunflower ( Helianthus annuus L.) seeds from high oleic lines with altered seed fatty acid content was used to test for the thioesterase activities over stearoyl-ACP. Plants were cultivated in growth chambers at 25/15° C. (day/night) temperature, 16 hours photoperiod and photon flux density of 300 micromol m −2 s −1 . Seeds for analysis were harvested at 15 days after flowering and kept at −20° C.
Radioactive Reagents and Preparation of Acyl-ACPs
1- 14 C-Oleic with specific radioactivity of 2.1 GBq/mmol and [9,10(n)- 3 H] stearic acid with specific radioactivity of 1.9 GBq/mmol were obtained from American Radiolabeled Chemicals Inc. (St. Louis, Mo., USA). To prepare the fatty acid sodium salt, an appropriate volume of fatty acid solution was transferred to a glass tube, the solvent was removed under a stream of nitrogen, and the residue was dissolved in 10% Triton X-100, 0.6 mM NaOH. This solution was heated at 55° C. for 1 hour to ensure homogeneity.
Acyl-ACPs were prepared using a modification of the enzymatic synthesis procedure of Rock C. O. et al. (1981) Methods Enzymology 72:397-403. Assays contained 0.1 M Tris-HCl (pH 8.0), 0.4 M LiCl, 5 mM ATP, 10 mM MgCl 2 , 2 mM DTT, 130 microM fatty acid sodium salt, 0.27 mM ACP-SH and 1.8 mU of acyl-ACP synthetase (the last two components were purchased from Sigma-Aldrich Quimica S.A. Madrid, Spain) in a final volume of 110 microliter. Reactions were incubated at 37° C. for 3 hours. After this time the pH was acidified to 6.0 by adding 1 microliter of 3.6 M HCl and the mixture was cleaned of free fatty acids using a modification of the method described by Mancha M. et al. ((1975) Anal. Biochem. 68:600-608), which method consists of adding an equal volume of isopropanol and washing three times with hexane saturated in water/isopropanol (1:1; v/v).
Preparation of Crude Extracts for Enzyme Assays and Protein Determination
Frozen seeds were peeled and ground in extract buffer containing 20 mM Tris-HCl (pH 8.5), 2 mM DTT and 5% (v/v) glycerol (Dörmann P. et al. (1994) Biochim. Biophys. Acta 1212:134-136) at 1 g of tissues/10 ml of buffer. Protein concentrations were measured using a Protein Assay Kit (Bio-Rad) according to the manufacturer's recommendations, with BSA as standard.
Enzyme Assays
Acyl-ACP thioesterase activity was assayed in a final volume of 170 microliter using 130 microliter of crude extract. Control assays had crude extract omitted. Reactions mixtures contained 20 mM Tris-HCl (pH 8.5), 5% glycerol and 2 mM dithiothreitol (DTT) and different concentrations of substrates (stearoyl-ACP and oleoyl-ACP). Incubations were carried out for 20 min at 25° C. Reactions were stopped by the addition of 170 microliter of 1 M acetic acid in isopropanol containing 1 mM of oleic acid. Mixtures were then washed three times with hexane saturated in water/isopropanol (1:1, v/v).
Acyl-ACP thioesterase activity was determined by counting the radioactivity of the aqueous phase, which contained the non-hydrolysed substrates. Then, 3 ml of solvent scintillant (purchased from National Diagnostics, Hessle, England) was added and the radioactivity was measured using a scintillation counter (Rackbeta II; LKB, Sweden). Data from acyl-ACP thioesterase assays were fitted to the Michaelis-Menten equation by non-linear least-squares regression analysis using Microcal Origin 4. 1, and correlated to P<0.05, as determined by paired Student's test. Vmax and Km were derived from these curves.
Example 1
Preparation of a HS Line
1. Mutation with EMS
Seeds were mutagenised with a solution of 70 mM of ethyl methane sulfonate (EMS) in water. The treatment was performed at room temperature during 2 hours while shaking (60 rpm). After mutagenesis the EMS solution was discarded and seeds were washed during 16 hours under tap water.
Treated seeds were germinated in the field and plants were self-pollinated. The seeds collected from these plants were used to select new sunflower lines with modifications in the fatty acid composition. By using the method of Garcés, R. and Mancha, M. ((1993) Anal. Biochem. 211, 139-143) the seed fatty acid composition was determined by gas liquid chromatography, after converting the fatty acids into their corresponding methyl esters.
A first plant with 9 to 17% stearic acid content in the oil was selected. The progeny was cultivated for five generations wherein the stearic acid content increased and the new genetic trait became stably fixed in the genetic material of the seed. This line is called CAS-3. The minimum and the maximum stearic acid content of the line were 19 and 35% respectively. The stearic acid content of oil extracted from seeds from this cell line may thus lie between 19 and 35%.
2. Mutation with Sodium Azide
Sunflower seeds were mutagenised with sodium azide, at a concentration of 2 mM in water. The treatment was performed at room temperature during two hours while shaking (60 rpm). Then the mutagenesis solution was discarded and seeds were washed during 16 hours with tap water.
Seeds were planted in the field and plants were self-pollinated. Seeds from these plants were collected, and the fatty acid composition was determined by gas liquid chromatography, after converting the fatty acids into their corresponding methyl esters using the method described in Example 1.
Seeds from a plant having around 10% stearic acid in the oil were selected and cultivated for five generations. During this procedure the stearic acid content was increased and the new genetic trait fixed. This line is called CAS-4. A selected sample of this line was analysed resulting in a stearic acid content of 16.1%. The minimum and the maximum values were 12 and 19%, respectively.
TABLE 6 Percentage fatty acids Line Palmitic Stearic Oleic Linoleic CAS-3 5.1 26.0 13.8 55.1 CAS-4 5.5 16.1 24.3 54.1
CAS-3 and CAS-4 are on deposit with the American Type Culture Collection, having ATCC numbers 75968 and 75969, respectively.
Example 2
Production of a HSHO Line
1. General
Sunflower plants were grown from the sunflower seeds of the HOHT line, seeds of which are on deposited at ATCC (PTA-628). Sunflower plants were also grown from the sunflower seeds of CAS-3. The lines were crossed. The plants were assisted by artificial pollination in order to ensure adequate seed production occurred. The F1 seed was produced on the HOHT line, or vice versa, and harvested. The F2 seeds with more than 20% stearate and more than 40% oleate were selected. Although this produces the oil of the present invention the level of production is limited.
Therefore fixed inbred lines evidencing seeds with these oil profiles are desirable. These homozygous fixed inbred HSHO lines can then be crossed to form hybrid seed, which will produce F2 seed evidencing the desired oil traits of the present invention.
Toward this end the F1 seeds were planted and produced plants were selfed in isolated conditions and F2 seed was produced. The F2 seed was tested for the three traits, high stearic, high oleic and high levels of thioesterase activity. The remaining portion of the seeds evidencing these traits was employed to grow plants to form F3 seed. The selfing and screening and selection process is repeated to develop the fixed homozygous HSHO line, having the following fatty acid profile, C:16 5.4, C:18.0 24.8, C:18.1 58.5, C:18.2 7.2. Once the trait is fixed similar HSHO lines can cross to form hybrid seed having both traits.
According to the invention sunflower plants and seeds from which said oil can be extracted have been obtained by means of a biotechnological process. This high stearic acid content is an inheritable trait and is fairly independent from the growing conditions.
2. First Cross
A sunflower plant was grown from a sunflower seed of an HOHT line having a stearic acid content of 10.7 wt % and an oleic acid content of 74.6 wt %. A sunflower plant was also grown from a CAS-3 sunflower seed. The plants were crossed. The plants were assisted by artificially pollination in order to ensure adequate seed production occurred. The F1 seed was produced on the HOHT line, or vice versa, and harvested.
A F1 seed having a stearic acid content of 9.8 wt % and an oleic acid content of 80.7 wt %, was selected. This F1 seed was planted and produced a plant which was selfed in isolated conditions and F2 seeds were produced. These F2 seeds were tested for oleic and stearic acid contents. A seed containing 23.6 wt % of stearic acid and 65.5 wt % of oleic acid was selected.
This F2 seed was planted and produced a plant which was selfed in isolated conditions and at 15DAF several seeds were collected and analysed for stearoyl-ACP thioesterase activity. Plants with seeds rendering more than 10% stearoyl-ACP thioesterase referred to the oleoyl-ACP thioesterase activity of the same plant were selected.
Mature seeds from the plants selected in the previous step and having stearic acid content higher than 20 wt % and oleic acid content higher than 40 wt % were submitted to the selfing, screening and selection process repeatedly to develop the fixed homozygous high stearic high oleic line having the following fatty acid profile in the oil:
palmitic 7.8 wt %; stearic 24 wt %; oleic 57.7 wt %; linoleic 5.9 wt %; araquic 1.9 wt %; behenic 2.7 wt %.
Once the trait is fixed, similar high stearic high oleic lines can cross to form hybrid seed having the above selected traits.
An analysis of the sn-2 position and sn-1,3 positions of the TAG molecules of this oil indicates the following distribution of fatty acids (in wt %):
sn-2:
palmitic 3.3%; stearic 3.4%; oleic 88.8%; linoleic 4.5%; araquic 0%; behenic 0%
sn-1,3:
palmitic 9%; stearic 29.9%; oleic 51.1%; linoleic 4.7%; araquic 2.3%; behenic 3%
Thus, the total amount of saturated fatty acid groups in the sn-2 position of the TAG molecules of this oil is 6.7 wt %.
3. Second Cross
A sunflower plant was grown from a sunflower seed of an HOHT line having a stearic acid content of 8.4 wt % and an oleic acid content of 78.5 wt %. A sunflower plant was also grown from a CAS-3 sunflower seed. The plants were crossed. The plants were assisted by artificially pollination in order to ensure adequate seed production occurred. The F1 seed was produced on the HOHT line, or vice versa, and harvested. A F1 seed having a stearic acid content of 7.1 wt % and an oleic acid content of 84.6 wt %, was selected. This F1 seed was planted and produced a plant which was selfed in isolated conditions and F2 seeds were produced. These F2 seeds were tested for oleic and stearic acid contents. A seed containing 22.8 wt % of stearic acid and 64.8 wt % of oleic acid was selected.
This F2 seed was planted and produced a plant which was selfed in isolated conditions and at 15 DAF several seeds were collected and analysed for stearoyl-ACP thioesterase activity. Plants with seeds rendering more than 10% stearoyl-ACP thioesterase referred to the oleoyl-ACP thioesterase activity of the same plant were selected. Mature seeds from the plants selected in the previous step and having stearic acid content higher than 20 wt % and oleic acid content higher than 40 wt % were submitted to the selfing, screening and selection process repeatedly to develop the fixed homozygous high stearic high oleic line having the following fatty acid profile in the oil:
palmitic 5.8 wt %; stearic 24.7 wt %; oleic 57.6 wt %; linoleic 8.2 wt %; araquic 1.8 wt %; behenic 1.9 wt %.
Once the trait is fixed, similar high stearic high oleic lines can cross to form hybrid seed having the above selected traits.
An analysis of the sn-2 position and sn-1,3 positions of the TAG molecules of this oil indicates the following distribution of fatty acids (in wt %):
sn-2:
palmitic 1.7%; stearic 1.9%; oleic 87.5%; linoleic 8.9%; araquic 0%; behenic 0%
sn-1,3:
palmitic 7.2%; stearic 33.2%; oleic 46.9%; linoleic 7.3%; araquic 2.6%; behenic 2.8%.
Thus, the total amount of saturated fatty acid groups in the sn-2 position of the TAG molecules of this oil is 3.6 wt %.
4. Third Cross
A sunflower plant was grown from a sunflower seed of an HOHT line having a stearic acid content of 9.9 wt % and an oleic acid content of 81.2 wt %. A sunflower plant was also grown from a CAS-3 sunflower seed. The plants were crossed. The plants were assisted by artificially pollination in order to ensure adequate seed production occurred. The F1 seed was produced on the HOHT line, or vice versa, and harvested.
A F1 seed having a stearic acid content of 8.9 wt % and an oleic acid content of 82.3 wt %, was selected. This F1 seed was planted and produced a plant which was selfed in isolated conditions and F2 seeds were produced. These F2 seeds were tested for oleic and stearic acid contents. A seed containing 23.9 wt % of stearic acid and 64.0 wt % of oleic acid was selected.
This F2 seed was planted and produced a plant which was selfed in isolated conditions and at 15 DAF several seeds were collected and analysed for stearoyl-ACP thioesterase activity. Plants with seeds rendering more than 10% stearoyl-ACP thioesterase referred to the oleoyl-ACP thioesterase activity of the same plant were selected. Mature seeds from the plants selected in the previous step and having stearic acid content higher than 20 wt % and oleic acid content higher than 40 wt % were submitted to the selfing, screening and selection process repeatedly to develop the fixed homozygous high stearic high oleic line having the following fatty acid profile in the oil:
palmitic 5.4 wt %; stearic 24.2 wt %; oleic 62.1 wt %; linoleic 4.7 wt %; araquic 1.6 wt %; behenic 2.0 wt %.
Once the trait is fixed, similar high stearic high oleic lines can cross to form hybrid seed having the above selected traits.
An analysis of the sn-2 position and sn-1,3 positions of the TAG molecules of this oil indicates the following distribution of fatty acids (in wt %):
sn-2:
palmitic 1.8%; stearic 3.3%; oleic 89.6%; linoleic 5.3%; araquic 0%; behenic 0%
sn-1,3:
palmitic 9.5%; stearic 33.5%; oleic 48.2%; linoleic 4.3%; araquic 2.2%; behenic 2.3%
Thus, the total amount of saturated fatty acid groups in the sn-2 position of the TAG molecules of this oil is 5.1 wt %.
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The invention relates to the use in food products, such as spreads, sauces, ice-cream, soups, bakery products, and confectionery products, and cosmetic products, such as creams, lotions, lipsticks, soap bars, and skin or hair oils, of an oil having an oleic acid content of more than 40 wt % and a stearic acid content of more than 12 wt % based on the total fatty acid content of said oil, and wherein a maximum of 10 wt % of the fatty acid groups in the stereospecifically numbered-2 position of the triacylglycerol molecules constituting the oil are saturated fatty acid groups.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 07/332,262, filed Mar. 31, 1989 now U.S. Pat. No. 5,006,582 which is a Continuation-in-Part of copending U.S. patent application Ser. No. 07/226,993, filed Aug. 1, 1988 now abandoned.
BACKGROUND OF THE INVENTION
Acrylic pressure sensitive adhesives (PSAs) have emerged as the product of choice in a variety of end-use applications where color, clarity, permanency, weatherability, versatility of adhesion, or the chemical characteristics of an all acrylic polymer is required. These applications include a variety of consumer, packaging, industrial and health care tapes, paper and film labels, decals, fleet markings/bumper stickers, and the like.
Acrylic PSAs have traditionally been prepared in and subsequently coated from an assortment of hydrocarbon solvents. Aqueous emulsion acrylics have been recognized in recent years as an environmentally safe alternative to solvent-born systems.
Product evolution of acrylic PSA technology has been toward higher solids and a 100% solids hot melt system. Elimination of the carrier has several economic benefits to the adhesive converter including lower energy and conversion costs, increased line speeds and production rates, as well as eliminating any adverse effects of organic solvents.
Given the desirable characteristics of hot melt technology, there has been ongoing interest in developing acrylic hot melt PSAs having the requisite four fold balance of adhesion, cohesion, strechiness and elasticity. The desire to maintain this balance of properties makes it extremely difficult to improve cohesive or internal strength without compromising processability or even the overall pressure sensitivity of the entire system. With acrylic adhesives, long term color stability, weatherability and durability are also important product characteristics.
Early attempts to produce acrylic hot melt pressure sensitive adhesives involved blends of polyacrylates and polymethacrylates having carefully selected compatibility characteristics. These initial blends were found to have a limited service temperature and deficiencies in cohesive strength. Bartman, in U.S. Pat. No. 4,360,638 and U.S. Pat. No. 4,423,182 discloses an ionomeric acrylic hot melt PSA system comprising a polymer containing carboxylic acid, a miscible metal salt, and an o-methoxy-substituted aryl acid. While significant improvements in cohesive properties were reported for the acrylic ionomers two problems existed in controlling the ionomeric interactions at processing temperatures, resulting in unstable melt viscosities and limited commercial utility.
Until recently, prior art relating to acrylic graft or comb polymers was restricted to non-pressure sensitive adhesive end-uses. The preparation of styrenic based macromonomers and their copolymerization with acrylates is described by Milkovich et al. in U.S. Pat. No. 3,786,116. That patent teaches the use of this technology for acrylic thermoplastic rubber applications and not acrylic pressure sensitive adhesives requiring the four fold balance of properties. Schlademan, U.S. Pat. No. 4,551,388, Husman et al, U.S. Pat. No. 4.554,324 and European patent application Ser. No. 104,046 discuss the use of macromonomers with acrylic comonomers in acrylic hot melt pressure sensitive adhesive compositions. While the Schlademen patent focused on the use of styrenic macromonomers, the Husman patent extended the concept to include acrylic PSA compositions based on poly (methyl methacrylate) macromonomers. Schlademan, in U.S. Pat. No. 4,656,213, disclosed that compounding acrylic graft copolymers improves properties but indicated it was essential to have styrenic pendant macromonomer side chains. In addition, only partially hydrogenated rosin ester tackifiers having yellow color were illustrated which would compromise water white color, weatherability and durability features normally associated with high performance acrylic pressure sensitive adhesives.
Finally, since styrenic polymers are known to undergo UV degradation, the macromonomer side chain may also contribute to a deterioration of properties in applications requiring long term outdoor exposure.
Sunagawa et al in Kokai Pat. No. 56[1981]-59882 discloses the preparation and use of acrylic graft copolymers as pressure sensitive adhesives whereas the graft copolymer is synthesized by reacting functional groups along a low Tg main acrylic copolymer with functional groups along a modifying copolymer of higher Tg. However the resulting acrylic graft copolymers were not identified as hot melt candidates nor was it disclosed that compounding improved the balance of pressure sensitive adhesive properties.
SUMMARY OF THE INVENTION
The present application relates to acrylic hot melt pressure sensitive adhesive compositions having a good balance of tack, peel and creep resistance at ambient temperature combined with optical clarity and desirable melt viscosity at elevated temperatures.
Specifically, the present invention provides an acrylic hot melt pressure sensitive adhesive composition comprising
(a) about from 30 to 90% by weight of a thermoplastic comb copolymer of
(i) 2-35% by weight, based on the thermoplastic copolymer, of a macromonomer of the general formula X-(Y)n-Z wherein X is a reactive end group capable of copolymerization under free radical conditions with acrylic comonomers to afford the comb copolymer having pendant macromonomer side chains along an acrylic backbone; Y is a linking group in which n is zero or one; and Z is a poly(methacrylate) based polymeric moiety having a T g greater than 20° C. and a weight average molecular weight of about from 2,000 to 35,000 and being substantially unreactive under copolymerization conditions; and
(ii) 65 to 98% by weight, based on the thermoplastic copolymer, of one or more monomers selected from the group consisting of monomeric acrylic or methacrylic acid ester of a non-tertiary alcohol, the alcohol having from 1 to 18 carbon atoms;
(b) about from 10 to 70% by weight of tackifier; and
(c) up to about 20% by weight of plasticizer.
Optionally, methacrylic acid, acrylic acid, acrylamide, methacrylamide, glycidal methacrylate, hydroxyethyl acrylate can be used in combination with the monomeric acrylic or methacrylic acid esters specified in (ii) above in the preparation of the backbone of the comb polymer.
The present invention further provides sheet materials coated with these adhesive compositions.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a graphical representation of the properties of adhesive compositions of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The hot melt pressure sensitive adhesive compositions of the present invention comprise, as indicated above, an acrylic thermoplastic graft or comb copolymer, a tackifier or modifier resin, and an optional plasticizing component.
The acrylic comb copolymers which can be used in the present invention can be prepared by the general processes shown in Milkovich et al., U.S. Pat. Nos. 3,786,116 and 4,554,324, both hereby incorporated by reference. In the processes there disclosed, a macromonomer is first prepared, and then copolymerized using a free radical process with one or more monomers selected from the group consisting of alkyl acrylates and methacrylates, where the alkyl groups may contain from 1-18 carbon atoms and optionally acrylic acid, acrylamide, and the like.
The macromonomer can be prepared directly from a methacrylate monomer and optionally other, non-styrenic comonomers polymerizable by free-radical initiators in the presence of a cobalt chain transfer agent to immediately afford a vinyl terminal group as taught in U.S. Pat. Nos. 4,694,054 and 4,680,352, hereby incorporated by reference.
Alternatively, the macromonomer can be prepared without the cobalt chain transfer agent and with or without conventional chain transfer agents to obtain a polymer having a functional end-group. This end-group can subsequently be reacted with an appropriate vinyl containing reagent using standard condensation chemistry to afford the required vinyl terminal group.
Preferred monomers for macromonomer synthesis by free-radical polymerization include one of the methacrylate monomers such as methyl methacrylate, ethyl methacrylate, cyclohexyl methacrylate, isobornyl methacrylate, methacrylic acid, glycidal methacrylate. Optional non-styrenic monomers suitable as comonomers include methyl acrylate, ethyl acrylate, acrylic acid, N-phenyl maleimide, acrylonitrile etc.
The macromonomer can be also be prepared from a methacrylate monomers polymerizable by a group transfer process taught in U.S. Pat. Nos. 4,414,372 and 4,417,034, hereby incorporated by reference. In this synthetic procedure, a group transfer initiator containing a blocked functional group can be used to initially prepare the methacrylate polymer. Following polymer synthesis, the protecting group is removed to provide a functional end group capable of further reaction with an appropriate vinyl containing reagent to afford a vinyl terminal group.
Alternatively, the macromonomer can also be prepared by an anionic process involving the initial formation of a living methacrylate polymer having a reactive terminal carbanion. For methacrylate monomers, this is usually carried out using an alkyl lithium initiator at low temperatures, for example, -78° C., to prevent side reactions. The carbanion is usually selectively capped with a reagent such as ethylene oxide prior to final termination or capping. A vinyl containing reagent such as methacryoyl chloride is preferably used to afford a methacrylate terminal group, although other capping reagent can be used. Vinyl lithium initiators can also be used instead of alkyl lithium initiators to provide a vinyl terminal group at the end of a poly methacrylate chain in a single step process.
Preferred monomers for macromonomer synthesis by group transfer or anionic techniques include a methacrylate monomer such as methyl methacrylate cyclohexyl methacrylate, ethyl methacrylate and isobornyl methacrylate. In the event that it is desired to introduce a polar moiety into the macromonomer chain, this can be accomplished by polymerizing a methacrylate monomer having a blocked functional group, and subsequently deblocking to provide the polar moiety along the macromonomer chain.
Regardless of the process, macromonomer should have a Tg of about from 25° to 175° C. and be incompatible with the acrylic backbone of the comb polymer.
Macromonomers which are particularly preferred for use in the present invention are made by polymerizing methyl methacrylate by a group transfer process using a blocked hydroxyl group transfer initiator (1-[2-trimethylsiloxyethoxy]-1-trimethylsiloxy-2-methyl propene) in the presence of tetrabutylammonium m-chlorobenzoate catalyst to a poly methyl methacrylate weight average molecular weight of between 2,000 and 35,000, and preferably between 4,000 and 20,000. Subsequent removal of the hydroxy protecting group followed by the addition of isocyanoethyl methacrylate affords a methacrylate terminal group in excellent yield. It is the methacrylate terminal group which copolymerizes with the alkyl acrylate comonomers. This preparation technique can provide an particularly narrow range of molecular weights, and is often preferred for accurate control of final product characteristics.
Other macromonomers which are often preferred for use in the present compositions are made by polymerizing methyl methacrylate under solution free radical conditions in the presence of bis[boron difloro dimethyl glyoximato] cobaltate [II] to a poly methyl methacrylate weight average molecular weight of between 2,000 and 35,000, and preferably between 4,000 and 20,000. Due to the special chain transfer characteristics of the cobalt additive, the poly methyl methacrylate chains are terminated with a single vinyl end group in excellent yield. Although the resulting vinyl terminal group is different than an acrylate or methacrylate group, it copolymerizes well with acrylate or methacrylate comonomers.
The backbone of the comb polymers used in the present invention can be prepared from alkyl methacrylate and acrylate comonomers in which the alkyl group contains from 1 to 18 carbon atoms. These include methyl acrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate, the four butyl acrylates, amyl acrylates, the hexyl acrylates, the 2-ethylhexyl and other octyl acrylates, the nonyl acrylates and the decyl acrylates, lauryl acrylate, stearyl acrylate. Similar methacrylate analogs as well as lauryl methacrylate, stearyl methacrylate and octadecyl methacrylate may be selectively used at lower concentrations relative to the alkyl acrylate comonomers. Optionally, methacrylic acid, acrylic acid, acrylamide, hydroxyethyl acrylate, and glycidal acrylate can also be used.
Regardless of the comonomer mix, acrylic backbone Tg should be in the range of about from 0° to -80° C., and is incompatible with the macromonomer side chains. Preferred alkyl acrylate and methacrylate comonomers are the octyl acrylates in combination with higher alkyl analogs, which provide improved long term compatibility with the water white poly alicyclic tackifiers derived from completely hydrogenated poly(aromatic) copolymers. Preferred alkyl acrylate and methacrylate comonomers include 2-ethylhexyl acrylate in combination with either isodecyl acrylate, lauryl methacrylate or stearyl methacrylate.
The acrylic comb copolymers can be prepared by copolymerization of the macromonomer with one or more comonomers selected from the group of alkyl acrylates and high alkyl methacrylates and optionally acrylic acid, methacrylic acid, acrylamide by conventional free-radical copolymerization techniques. The preferred copolymers are prepared by copolymerization of about from 5 to 25% by weight, based on acrylic comb copolymer, of the macromonomer with about from 75 to 95% by weight, based on acrylic comb copolymer, of on or more alkyl acrylate comonomers, as taught in U.S. Pat. Nos. 3,786,116 and 4,554,324. As indicated, comonomers including 2-ethylhexyl acrylate and either isodecyl acrylate, lauryl methacrylate or stearyl methacrylate comprise the preferred acrylic backbone composition for compatibility considerations with high performance poly alicyclic tackifiers. A preferred copolymer consists of an acrylic backbone based primarily on 2-ethylhexyl acrylate with poly methyl methacrylate chains attached to the backbone. The copolymerization proceeds according to known relationships based on relative reactivities of the monomers derived from standard copolymerization kinetics. The temperature of copolymerization can vary from 30° to 150° C., depending on initiator type, for periods of about from 1 to 20 hours to achieve comonomer conversion greater than 95%.
Conventional solvents such as ethyl acetate, methyl ethyl ketone, and acetone can be used for the copolymerization step although a solvent is not required.
To achieve adequate adhesive properties, peak comb copolymer molecular weights should be between 70,000 and 600,000, and preferably between 100,000 and 300,000 as measured by Gel Permeation Chromatography using a HP 1090 chromatograph equipped with 4 Waters ultra styrogel columns (10 6 A, 10 5 A, 10 4 A, 10 3 A) calibrated with polystyrene standards.
In the alternate, the graft or comb polymer can be prepared by conventional grafting techniques in which a low Tg acrylic polymer or copolymer is reacted to a higher Tg methacrylic polymer or copolymer using free radicals, or by the use of chemical reactions along the chains of each polymer.
The tackifier and plasticizer resins are added to the acrylic copolymers to improve the balance of hot melt pressure sensitive adhesive properties. Tackifiers for the present invention have ring and ball softening points in the range of about from 25° to 130° C. Plasticizers, by contrast, have ring and ball softening points below about 25° C.
Compounding of the acrylic copolymer is best accomplished by choosing an ingredient having selective compatibility with the acrylic backbone of the comb copolymer. Secondly, and equally as important for an acrylic adhesive, the ingredient should complement the water white color, stability and general durability features normally associated with acrylic polymers. While many classes of tackifiers and plasticizers can be used in this invention to significantly improve the balance of hot melt pressure sensitive properties, the selection of suitable compounding ingredients narrows substantially when also considering color, stability and durability properties. Preferred compounding ingredients include partially hydrogenated rosin esters and completely hydrogenated poly(aromatic) copolymers which can also be referred to as poly alicyclics. The latter poly alicyclic class is preferred because of complete or near complete hydrogenation combined with water white color. This contrasts partial hydrogenation and pale yellow color for current commercial hydrogenated rosin esters compounds.
The amount of tackifier used in the present compositions is about from 10 to 70% by weight based on total adhesive compound. A particularly preferred concentration of tackifier is about from 30 to 50% by weight, based on the total adhesive composition. Within this range, it has been found that a particularly beneficial combination of adhesive properties is realized. Specifically, the combination of tack, shear and viscosity of compositions within this range provides a particularly good balance of adhesive properties and processability. This is a function of unusual trends of properties for the present compositions. Specifically, it has been found that the tack of these compositions decreases while shear increases. In addition, shear increases as viscosity decreases. While it is not unusual for viscosity to decrease with increased concentrations of tackifier, it is unexpected to find increased shear adhesion while tack and viscosity are decreasing.
The overall effect of this preferred tackifier concentration range produces an optimum balance of tack, peel, shear and viscosity for many commercial applications. These trends are summarized in the Figure, which illustrates these characteristics for a typical resin system of the present invention.
Non-Newtonian rheological behavior is also observed for the present compositions, which contributes to the shear characteristics of the system.
Tackifiers which can be used in the present invention include commercially available hydrogenated rosin ester compounds such as those formed with pentaerythritol, glycerin and ethylene glycol. Stabilized rosin ester compounds based on similar alcohols can also be used but are likely to be less effective in maintaining stability and durability. Preferred commercially available poly alicyclic tackifiers include those initially based on aromatic copolymers of styrene, alpha-methyl styrene, and indene, followed by a hydrogenation process. These are characterized by water white color and high stability. Some preferred tackifiers have only short term compatibility with the acrylic backbone based on alkyl acrylate esters comonomers of around 8 carbons in length, and a judicious selection of higher alkyl comonomers is required to ensure long term compatibility and subsequent adhesive properties. For example, acrylic backbones based on 2-ethylhexyl acrylate and a longer chain acrylate or methacrylate including isodecyl acrylate, lauryl methacrylate and stearyl methacrylate have been found to ensure compatibility and prevent a deterioration of adhesive properties and clarity from phasing out of the tackifier.
Specific combinations of tackifiers have been found to provide unusually beneficial adhesive performance in the present invention. For example, adhesive compositions comprising about from 95 to 85%, by weight of the tackifier, of at least one hydrogenated poly(aromatic) copolymer, and, complementally, about from 5 to 15%, by weight of the tackifier, of at least one second tackifier compatible with the acrylic backbone of the comb polymer can result in a substantial improvement of tack, peel and shear, combined with decreased viscosity, compared to the unblended hydrogenated poly(aromatic) copolymer formulation. Such second tackfiers can include, for example, hydrogenated rosin ester compounds, mixed hydrocarbon tackifiers and non-hydrogentated polyaromatic tackifiers.
The plasticizer can be used in amounts of up to about 20% by weight, based on the total adhesive formulation. Preferred plasticizers which are readily available include adipate and glutarate esters, hydrogenated rosin esters and reduced alcohol derivatives. Particularly preferred plasticizers include hydrogenated poly (aromatic) copolymers and mineral or paraffin oils.
The use of tackifiers and plasticizers in the compositions of the present invention, in combination with high molecular weight acrylic comb copolymers allow melt viscosities below 200,000 cps at 177° C. to be obtained. This makes the adhesive compositions suitable for use on conventional hot melt coating equipment. Due to the highly branched nature, acrylic comb copolymers and compounded comb copolymers are non-Newtonian and exhibit shear thinning characteristics. As a result, melt viscosity data is supplied from a Rheometrics Mechanical Spectrometer 800 using parallel plates at 10 sec-1 and 100 sec-1 for both acrylic comb polymers and compounds. The higher shear rate of 100 sec-1 is regarded to be below the operational shear rates typically encountered in high speed hot melt coating.
The acrylic comb copolymer compounds prepared in accordance with the present invention are easily coated upon suitable flexible backing materials by conventional coating techniques to produce coated sheet materials. The adhesive compounds of the present invention can be applied to the flexible backing material as a solution and the solvent subsequently removed to leave a tacky coating on the backing material. However, the preferred adhesives can be applied from the melt directly to the backing allowing a single step coating operation.
Flexible backing material may be any material conventionally used as tape backing or any other flexible backing Flexible backings which can be used for the present adhesive compositions include paper and thermoplastic films of polymers such as polyethylene, polypropylene, polyvinyl chloride, polyesters (i.e. polyethylene terephthalate), cellulose acetate and ethyl cellulose. Backings may also be prepared of silicon release liner, cloth, fabric, metal, metalized polymer films or ceramic sheet materials. The coated sheet materials may take the form of any article conventionally known to be used with pressure sensitive adhesive compositions, such as tapes, labels, decals, protective coverings, trim mountings, medical bandages and the like.
In light of U.S. Pat. No. 4,656,213 it is surprising that an all acrylic comb copolymer will be markedly improved by the addition of tackifier since it was previously believed that it was essential to have poly(vinyl aromatic monomer) macromonomer as the side chain. It is further surprising that an all acrylic comb polymer with very poor initial pressure sensitive adhesive properties can also be markedly improved by the addition of tackifier.
In the following Example, which further illustrates the invention, the following test and evaluation procedures are used.
PRESSURE SENSITIVE ADHESIVE TESTING
The acrylic copolymers obtained were solution coated onto 2 mil Mylar film to give an adhesive dry coating thickness of 1.0 mil. Additionally, the acrylic copolymers were solution compounded with tackifiers and plasticizers as indicated by adding the formulating ingredient to an aliquot of the copolymer syrup and adding sufficient toluene to achieve a final solids content of 40 wt %. The resulting compound solutions were mixed for a period of 18 hours prior to solution coating onto 2.0 mil Mylar film to give an adhesive dry coating thickness of 1.0 mil.
Hot melt compounding was performed using 100% solids acrylic copolymer obtained by devolatilizing the copolymer syrup in a vacuum oven at 40° C. for a period of 48 hours. Compounding was performed as indicated by adding the tackifier to the molten acrylic copolymer at 177° C. in a Brabender mixer over a period of 15 minutes followed by an additional 30 minutes mixing at 177° C. and 100 rpm. The resulting acrylic adhesive compound was hot melt coated at 177° C. onto 2.0 mil oriented polyethylene terephthalate film to a adhesive coating thickness of 1.0 mil using a laboratory Accumeter hot melt coater.
Acrylic adhesive coated flexible sheet materials were cut into smaller strips and tested according to Pressure Sensitive Tape Council and ASTM procedures as follows.
Tack was determined using a Polyken Probe Tack Tester according to ASTM D2979 using a probe speed of 1 cm/sec and a dwell time of 1 second. Tack is reported in grams.
Peel Adhesion was determined according to PSTC No.1 for 180 degree peel. The substrate was stainless steel. Peel is reported in oz/in.
Shear adhesion was measured using a stainless steel substrate according to P STC No.7 utilizing a 1/2"×1/2" contact area and 1 Kg load. Shear adhesion is reported in minutes to failure.
Melt viscosity at 177 C was measured using a Rheometrics Mechanical Spectrometer-800 equipped with parallel plates. Melt viscosity is reported in cps at 10 sec-1 and (100 sec-1) shear rates.
EXAMPLES 1-3 AND CONTROL EXAMPLE A
A. Preparation of a Methacrylate Terminated Poly Methyl Methacrylate Macromonomer via Group Transfer Polymerization and Capping with 2-Isocyanoethyl Methacrylate
A 5 liter flask equipped with thermometer, reflux condenser, N2 inlet, mechanical stirrer, and addition funnels was charged with 895.2 gm of toluene, 49.45 gm of 1-(2-trimethylsiloxyethoxy)-1-trimethylsiloxy-2-methyl propene, .0179 M, and 3.12 ml of a 1.0 M solution of tetrabutylammonium m-chlorobenzoate dissolved in acetonitrile. Feed I, 1796.8 gm of methyl methacrylate, was added over 35 minutes beginning at room temperature. Feed II, 4.5 ml of 1.0 M tetrabutylammonium M-chlorobenzoate and 14.9 gm of glyme, was begun simultaneously with Feed I. Feed II was added over 60 minutes. At 102 minutes, 20 gm of methanol was added to quench the reaction. The polymer formed was at 61.7% solids (99% conversion). To the polymer solution was added 34.0 gm of water and 102.17 gm of iso-propanol. The polymer solution was then refluxed for 5 hours. The IR spectra of some dried polymer showed a band at 3550 cm(-1) that corresponds to an OH band.
Toluene, 300 ml was then added and the polymer solution was then distilled until the vapor temperature reached 105 C. A total of 484.0 gm of material was distilled off. This removed all excess water and alcohols. An Ir spectrum showed the band at 550 cm(-1) still present.
To the polymer solution was added 27.7 gm of a 1% solution of dibutyltin dilaurate in methyl ethyl ketone and 55.54 gm of 2-isocyanoethyl methacrylate, 0.036 M. An IR spectrum showed no OH band at 35550 cm (-1) but a small NCO band at 2265 cm(-1) a small OH band (from the methanol) at 3550 cm(-1), and a carbon-carbon double bond (from the methacrylate functionality) at 1640 cm(-1). GPC analysis of the final product indicated the macromonomer had a Mn=11,000 (theo. Mn=10,000), Mw=14,000, MWD=1.27, based on polystyrene standards.
B. Preparation of Poly Methyl Methacrylate/Acrylic Acid/2-Ethylhexyl Acrylic Comb Copolymer
A 1 liter flask equipped with thermometer, reflux condenser, N2 inlet, mechanical stirrer, and addition funnel was charged with 200.00 gm of ethyl acetate, 65.64 gm of 2-ethylhexyl acrylate, 10.94 gm of the poly methyl methacrylate macromonomer from Section A above, 1.56 gm acrylic acid and .07 gm Vazo 64 initiator. The reaction mixture was heated to 70 C over a period of 30 minutes and held for at 70 C for an additional 15 minutes. Feed II, 100 gm of ethyl acetate, 98.45 gm 2-ethylhexyl acrylate, 16.4 gm of the macromonomer from Section A above, 2.35 gm of acrylic acid, and .11 gm of Vazo 64 initiator was added over a period of 140 minutes. The mixture was allowed to react for an additional 150 minutes at 70 C prior to a 1 hour reflux. The acrylic copolymer solution had a total solids content of 39.0% (theoretical 39.45%). Characterization of the final product indicated that the copolymer had an apparent GPC peak molecular weight of 185,000 and 14% by weight macromonomer, 2% by weight acrylic acid and 84% by weight 2-ethylhexyl acrylate.
This comb copolymer is designated Control Example A, and was tested according to the procedures outlined above. The results are reported in Table I.
C. Solution Compounding of Poly Methyl Methacrylate/Acrylic Comb Copolymers with Tackifiers and Plasticizers
In Examples 1 and 2, the comb copolymer prepared in Section B above was respectively compounded with a rosin ester tackifier (commercially available as Super Ester W-100 tackifier from Arakawa Chemical company) and a hydrogenated rosin ester tackifier (commercially available as Foral 105 tackifier from Hercules), in the amounts indicated in Table I.
The compounded adhesives were tested, and the results are shown in Table I. Both the unmodified and compounded copolymers were tested as 1.0 mil solution cast films on 2.0 mil biaxially oriented polyethylene terephthalate film, and the results are summarized in Table I. The results indicate the significant improvement in the balance of adhesive properties and melt viscosity following compounding with commercially available ingredients.
EXAMPLES 3-7 AND CONTROL EXAMPLE B
A. Preparation of Poly Methyl Methacrylate/ 2-Ethylhexyl Acrylate Comb Copolymer
A 1 liter flask equipped with thermometer, reflux condenser, N2 inlet, mechanical stirrer, and addition funnel was charged with 200.00 gm ethyl acetate, 68.00 gm of 2-ethylhexyl acrylate, 10.94 gm of the poly methyl methacrylate macromonomer prepared in Section A of Examples 1-2 above, together with 0.07 gm of Vazo 64 initiator. The reaction mixture was heated to 70° C. over a period of 30 minutes and held at 70° C. for an additional 15 minutes. Feed II, 100.00 gm of ethyl acetate, 100 gm of 2-ethylhexyl acrylate, 16.41 gm of the same poly methyl methacrylate macromonomer and .11 gm of Vazo 64 initiator was added over a period of 140 minutes. The mixture was allowed to react for an additional 150 minutes at 70 C prior to a 1 hour reflux. The acrylic copolymer solution had a total solids content of 39.1% (theoretical 39.45%). Characterization of the final product indicated that the comb copolymer had an apparent GPC peak molecular weight of 180,000 and 14% by weight macromonomer and 86% by weight 2-ethylhexyl acrylate.
This comb copolymer is designated Control Example B, and was tested according to the procedures outlined above. The results are reported in Table I.
B. Solution Compounding of Acrylic Comb Copolymer with Tackifiers and Plasticizers
In Examples 3-7, the comb copolymer prepared in Section A above was respectively compounded, in the amounts indicated in Table I, with hydrogenated rosin ester tackifier (commercially available as Foral 105 from Hercules, Inc.); with hydrocarbon resin tackifier (commercially available as Super Sta Tac 100 from Reichold); with hydrogenated aromatic copolymer tackifier (commercially available as Regalrez 1078 tackifier from Hercules, Inc.); with a combination of Regalrez 1078 and another hydrogenated aromatic copolymer plasticizer (commercially available as Regalrez 1018 plasticizer from Hercules, Inc.); and with a combination of Super Sta Tac 100 tackifier and a hydrocarbon resin plasticizer (commercially available from Goodyear as Wingtac 10 plasticizer); each in the amounts indicated in Table I.
The compounded adhesives were tested as in Example 1 and 2, and the results are shown in Table I. The results again indicate the significant improvement in the balance of adhesive properties and melt viscosity following compounding with commercially available ingredients.
EXAMPLES 8-11 AND CONTROL EXAMPLE C
A. Preparation of Poly Methyl Methacrylate/Stearyl Methacrylate/2-Ethylhexyl Acrylate Comb Copolymer
A 1 liter flask equipped with thermometer, reflux condenser, N2 inlet, mechanical stirrer, and addition funnel was charged with 200.00 gm ethyl acetate, 54.55 gm of 2-ethylhexyl acrylate, 13.45 gm of stearyl methacrylate, 10.94 gm of the poly methyl methacrylate macromonomer from Section A of Examples 1-2 and .07 gm of Vazo 64 initiator. The reaction mixture was heated to 70 C over a period of 30 minutes and held at 70 C for an additional 15 minutes. Feed II, 100 gm of ethyl acetate, 79.85 gm of 2-ethylhexyl acrylate, 20.15 gm of stearyl methacrylate, 16.41 gm of the same poly methyl methacrylate macromonomer and .11 gm Vazo 64 initiator was added over a period of 140 minutes. The mixture was allowed to react for an additional 150 minutes at 70° C. prior to a 2 hour reflux. The acrylic copolymer solution had a total solids content of 39.2% (theoretical 39.45%). Characterization of the final product indicated that the resulting comb copolymer had an apparent GPC peak molecular weight of 130,000 and 14% by weight macromonomer, 17.2% by weight stearyl methacrylate and 68.8% by weight 2-ethylhexyl acrylate.
The resulting comb polymer was designated Control Example C and tested as before.
B. Compounding of Comb Polymer
In Examples 8-11, the comb polymer prepared in Section A above was compounded with the types and quantities of tackifiers indicated in Table II. The tackifiers used in Examples 10 and 11 were hydrogenated aromatic copolymers commercially available from Arakawa Chemical Company. The adhesive compositions were tested as before, and the results reported in Table II.
EXAMPLES 12-14 AND CONTROL EXAMPLE D
A. Preparation of Poly Methyl Methacrylate/Lauryl Methacrylate/2-Ethylhexyl Acrylate Comb Copolymer
Using the general reaction method of Example 8-11 above, a copolymer was prepared from 14% by weight poly methyl methacrylate macromonomer from Section A of Examples 1-2, 17.2% by weight lauryl methacrylate, and 68.8% 2-ethylhexyl acrylate to afford a final product having an apparent GPC peak molecular weight of 133,000. The resulting comb polymer was designated Control Example D.
B. Compounding of Comb Polymer
In Examples 12-14, the comb polymer prepared in Section A above was compounded with the types and quantities of tackifiers indicated in Table II. The adhesive compositions were tested as before, and the results reported in Table II. The results demonstrate that the acrylic backbone can be tailored by judicious selection of comonomers including methacrylates to afford long term compatibility and allow compounding with a variety of high performance hydrogenated tackifiers. The use of premium tackifiers not only improves the balance of hot melt pressure sensitive adhesive properties but also ensures long term color stability, weatherability and general durability of the formulations.
EXAMPLES 15-16
A. Preparation of a Vinyl Terminated Poly Methyl Methacrylate Macromonomer via Polymerization and Cobalt Chain Transfer Agent
A 5 liter flask equipped with thermometer, reflux condenser, N2 inlet, mechanical stirrer, and addition funnels was charged with 193.5 gm of ethyl acetate, 828.0 gm of methyl methacrylate and .01 gm of bis[boron difloro dimethyl glyoximato] colbaltate [II]. Feed I, 22.5 gm of ethyl acetate and .031 gm of Vazo 67 initiator was added to the reaction flask at reflux temperature over a period of 10 minutes. Feed II, 1242.8 gm of methyl methacrylate was added following completion of feed I at an initial rate of 9.44 gm/min. for 2 hours and a subsequently at a final rate of .92 gm/min. for 2 additional hours. Feed III, 450 gm of ethyl acetate and 2.62 gm of Vazo 67 initiator was begun with feed II and added uniformly over a period of 4 hours. Feed IV, 365.0 gm of ethyl acetate and 2.06 gm of of Vazo 67 was added following completion of feeds II & III over a period of 1.5 hours. Following addition of feed IV, the reaction mixture was refluxed for and additional 2 hours. Feed V, 900.3 gm of ethyl acetate was added over 15 minutes to reduce solution viscosity and solids content. The resulting macromonomer solution had a total solids content of 51.0% (theoretical 51.8). GPC analysis of the final product indicated that the macromonomer had a Mn =7,000, Mw=12,000, MWD=1.71 based on polystyrene standards. Thermal gravimetric analysis (TGA) was used according to the procedures set forth in Cacioli et al., Polymer Bulletin, 11, 325-328 (1984) to determine the percentage of unsaturated or vinyl end groups in the final reaction mixture. The macromonomer was determined to be 95% vinyl terminated or functional by this characterization procedure.
B. Preparation of Poly Methyl Methacrylate/2-Ethylhexyl Acrylate Comb Copolymer for Hot Melt Compounding and Coating
A 5 liter flask equipped with thermometer reflux condenser, N2 inlet, mechanical stirrer, and addition funnels was charged with 1000 gm of ethyl acetate, 339.75 gm of 2-ethylhexyl acrylate, 54.7 gm of the poly methyl methacrylate macromonomer from Section A above, and .35 gm of Vazo 64 initiator. The reaction mixture was heated slowly to 65° C. over a period of 40 minutes and held at 65° C. for an additional 20 minutes. Feed II, 500 gm of ethyl acetate, 500 gm of 2-ethylhexyl acrylate, 82.10 gm of the same poly methyl methacrylate macromonomer and .55 gm of Vazo 64 initiator was added over a period of 210 minutes. The mixture was allowed to react for an additional 120 minutes at 65° C. prior to a 2 hour reflux. The resulting acrylic comb copolymer solution had a total solids content of 39.0% (theoretical 39.45%). Characterization of the final product indicated that the copolymer had an apparent GPC peak molecular weight of 144,000 and 14% by weight macromonomer and 86% by weight 2-ethylhexyl acrylate.
C. Hot Melt Compounding and Coating
The comb copolymer solution prepared in Section B above was stabilized with 1.0 phr Agerite Geltrol antioxidant and vacuum dried for 48 hours at 40° C. In Examples 15 and 16, the resulting 100% solids copolymer was hot melt compounded respectively with the tackifiers and in the quantities specified in Table III. The copolymers were compounded in a Brabender mixer at 177° C. The resulting acrylic adhesive compositions were hot melt applied to biaxially oriented polyethylene terephthalate film at the rate of 10 ft/min. using a laboratory hot melt coater. Adhesive properties obtained on the hot melt coated tapes are shown in Table III. These results show that the two acrylic adhesive compounds have an attractive balance of properties suitable for hot melt pressure sensitive adhesive applications.
EXAMPLES 17-20
The general procedure of Examples 15-16 was repeated, except that the levels of cobalt additive and initiator were initially adjusted to provide a macromonomer having a molecular weight of Mn=5,000, Mw=9,000 and MWD=1.80 based on polystyrene standards. Due to the slightly lower macromonomer molecular weight and higher macromonomer level, the copolymer had an apparent GPC peak molecular weight of 115,000 and 14.5% by weight macromonomer and 85.5% by weight 2-ethyl hexyl acrylate. The resulting comb copolymer was respectively compounded, in the amounts listed in Table IV, with a hydrogenated aromatic copolymer tackifier (Regalrez 1078), a hydrogenated rosin ester (commercially available as KE-311 from Arakawa Chemical Company) and blends of hydrogenated rosin ester and polyaromatic copolymer. The compounded adhesives were tested as 1.0 mil solution cast films on 2.0 mil biaxially oriented polyethylene terephthalate film and the results summarized in Table IV. The resulting adhesive compositions were tested, and those compositions using a blend of tackifiers were found to exhibit markedly improved adhesive properties, also as shown in the Table IV.
TABLE I__________________________________________________________________________ MELT VISCOSITY TACKIFIER TACK PEEL SHEAR @ 177° C.EXAMPLE COPOLYMER (phr) gm oz/in min CPS × 10.sup.-3__________________________________________________________________________Control A PMMA/AA/EHA -- 700 35 57 961 (143)1 " SUPER ESTER 500 91 324 10 (5) W-100 (77)2 " FORAL 105 (77) 550 89 1147 80 (19)Control B PMMA/EHA -- 600 12 7 843 (123)3 " FORAL 105 (80) 700 95 405 56 (16)4 " SUPER STA TAC 650 99 680 170 (30)5 " REGALREZ 1078 (80) 750 87 505 192 (29)6 " REGALREZ 1078 (80) 1250 85 244 174 (26) REGALREZ 1018 (10)7 " SUPER STA TAC 550 90 360 140 (25) 100 (80) WINGTAC 10 (10)__________________________________________________________________________
TABLE II__________________________________________________________________________ MELT VISCOSITY TACKIFIER TACK PEEL SHEAR @ 177° C.EXAMPLE COPOLYMER (phr) gm oz/in min CPS × 10.sup.-3__________________________________________________________________________Control C PMMA/SM/EHA -- 600 6 4 546 (80) 8 " FORAL 105 (80) 1100 92 165 25 (8) 9 " REGALREZ 1078 (80) 1200 81 210 100 (17)10 " ARKON M-100 (73) 550 87 312 117 (21)11 " ARKON P-100 (73) 600 91 410 129 (22)Control D PMMA/LM/EHA -- 650 12 4 425 (67)12 " FORAL 105 (80) 1100 88 154 24 (8)13 " REGALREZ 1078 (80) 1150 90 180 103 (18)14 " ARKON M-100 (73) 700 95 220 100 (20)__________________________________________________________________________
TABLE III__________________________________________________________________________ MELT VISCOSITY TACKIFIER TACK PEEL SHEAR @ 177° C.EXAMPLE COPOLYMER (phr) gm oz/in min CPS × 10.sup.-3__________________________________________________________________________15 PMMA/EHA REGALREZ 1078 (85) 550 94 1187 168 (34)16 PMMA/EHA FORAL 105 (80) 450 95 2040 11 (5)__________________________________________________________________________
TABLE IV__________________________________________________________________________ Melt Viscosity Tackifier Tack Peel Shear @ 177° C.ExampleCopolymer (PhR) gm oz/in. min. CPS × 10.sup.-3__________________________________________________________________________17 PMMA/EHA Regalrez 1078 (85) 650 94 960 90 (24)18 PMMA/EHA Regalrez 1078 (80) 1050 100 1760 65 (19)* KE-311 (5)19 PMMA/EHA Regalrez 1078 (75) 1450 101 3200 41 (15) KE-311 (10)20 PMMA/EHA KE-311 (90) 550 104 820 3 (2)__________________________________________________________________________ *estimated
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Acrylic hot melt pressure sensitive adhesive compositions having a good balance of tack, peel and creep resistance at ambient temperature combined with optical clarity and desirable melt viscosity at elevated temperatures are prepared by copolymerizing acrylic and methacrylic alkyl esters of a non-tertiary alcohol or optionally acids with polymerizable poly methacrylate based macromonomers. The resulting acrylic copolymer has a graft or comb structure in which the acrylic backbone has a low Tg and the pendant macromonomer side chains have a Tg above room temperature. Compounding those acrylic copolymers with tackifiers and plasticizers dramatically improves the balance of pressure sensitive adhesive properties while lowering melt viscosity into a desirable range. The invention provides significant property enhancements even for acrylic copolymers having poor initial peel and shear adhesive properties. Preferably, the acrylic backbone is tailored by judicious selection of acrylic comonomers to allow compounding with several high performance hydrogenated tackifiers and plasticizers that provide water white and clear adhesive formulations while ensuring long term color stability, weatherability and general durability.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 630,483, filed Nov. 10, 1975, now abandoned, which application was a continuation application of Ser. No. 498,796, filed Aug. 19, 1974, now abandoned, which in turn was a continuation application of application Ser. No. 207,623, filed Dec. 13, 1971, now abandoned.
SUMMARY OF THE INVENTION
Inflammation and mucopolysaccharide synthesis are the two important features in the early stage of wound healing. The term "wound" as used in this application means any topical lesion such as a surgical incision, accidental wound or ulcer. Aspirin inhibits both features. The healing inhibitory action of aspirin and other inflammatory agents has been demonstrated. Vitamin A increases mucopolysaccharide synthesis and it also causes inflammation. The ability of vitamin A alone to promote healing and its effectiveness in reversing the healing retardation action of aspirin is known. Retinoic acid (the acid form of vitamin A) and its salts also have been found active compounds in promoting healing. Topical application of retinoic acid or its salts reverses the healing retardation action caused by oral administration of sodium salicylate, prednisone and other inflammatory agents and topical application of salicylic acid or hydrocortisone. Topical application of retinoic acid and its salts promotes skin wound healing in rats and human beings.
It has now been found that 2,6,6,-Trimethyl-1-(10'-carboxy-deca-1', 3', 5', 7', 9'-pentaenyl) cyclohex-1-ene acid and 2,6,6,-Trimethyl-1-(12'-carboxy-dodeca-1',3',5',7',9',11'-hexaenyl) cyclohex-1-ene acid are even more effective than vitamin A or vitamin A acid for wound healing. The corresponding C16, and C18 acids have also been made and tested but they are considerably less effective than the C20 and C22 acids of the present invention. Furthermore, the acids of the present invention have been found to be considerably less toxic, even when used at high concentrations, than retinoic acid.
C20 and C22 acids promote healing. It is very practical to dust these compounds on any surgical wound or to apply either of them as a solution or in an ointment. The C20 acid is preferred.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The local application of C20 or C22 acids has been found to promote wound healing. This is true both of animals which have not been otherwise treated and also true of animals which have been treated with antiinflammatory agents such as a salicylate, hydrocortisone, prednisone, indomethacin, mefenamic acid and the like. These compounds normally retard healing and C20 and C22 acids reverse this action.
The following is one method of preparing the novel C20 and C22 acids of the present invention. In the synthesis selected, beta ionone is first converted to an aldehyde having 16 carbon atoms and this is reacted with triethylphosphonocrotonate to produce the C20 ethyl ester and this is hydrolyzed to the desired C20 acid. It is also possible to go directly from the C12 aldehyde to the C20 ester by employing a phosphono compound having eight carbon atoms with conjugated double bonds. One route for preparing the C22 acid is through the C20 acid.
PREPARATION OF BETA C12 ACID
At 0° pass 84 grams of chlorine gas into 400 ml of 10M sodium hydroxide solution. To which, at room temperature, add 64 grams of beta ionone. Stir for three hours. Add 80 ml of methanol and maintain the temperature below 85° C by adding crushed ice and then bring the pH to about 4 by adding phosphoric acid. Cool to room temperature and the beta C12 acid will rise to the surface and can be filtered with the aid of suction. The crude acid is then dissolved in 20% aqueous sodium hydroxide solution and extracted with ether. The aqueous solution is acidified with phosphoric acid and again extracted with ether. The ether extract is dried with anhydrous magnesium sulfate. The ether is evaporated and the acid is recrystallized from 70% methanol solution to provide the purified C12 acid.
PREPARATION OF C12 ALCOHOL
Ten grams of lithium aluminum hydride is placed in a 3 necked flask under a nitrogen atmosphere and 50 ml of anhydrous ethyl ether is added and stirred with a magnetic stirrer at -15° C. Dissolve 50 grams of the C12 acid previously pepared in anhydrous ether and add slowly into the flask containing the lithium aluminum hydride. The temperature should be maintained below minus 10° C. After all of the acid has been added, the temperature can be allowed to rise to room temperature and kept at this temperature for 1 hour. The mixture is then cooled to 0° and 1N sulphuric acid is added until bubbles cease to form. The temperature should be maintained below 5° C. The reaction mixture is filtered and the precipitate washed with ether. The ether layer is separated and washed with water and is then dried with anhydrous magnesium sulfate and the ether evaporated. The yield is about 93% of theory.
PREPARATION OF C12 ALDEHYDE
In the following reaction, activated manganese dioxide is used which can be prepared either by the method of Attenburrow et al J. Chem. Soc. 1094 (1952) or Carpino, J. Org. Chem. Vol. 35 No. 11 (1970) 3971.
About 50 grams of the C12 alcohol in ether solution is placed in a dropping funnel attached to a two-liter flask. 500 grams of activated manganese dioxide and 1000 ml of anhydrous carbon tetrachloride are placed in the flask and stirred. The C12 alcohol solution is now slowly run into the manganese dioxide suspension and stirring is continued at room temperature for two hours after all of the alcohol has been added. The mixture is filtered and washed with carbon tetrachloride and the extract is then dried and evaporated. The yield is about 95% of theory.
PREPARATION OF C16 ESTER
Weigh 47 grams of a sodium hydride in oil dispersion (57% NaH) and place it in a two liter flask. Wash with anhydrous ether. Add 1000 ml of anhydrous tetrahydrofuran (THF) and cool to zero. One then places 140 grams of triethylphosphonocrotonate in a dropping funnel and adds it dropwise to the sodium hydride suspension with stirring. Stirring is continued at zero degrees for 1/2 hour after all the crotonate has been added. About 50 grams of the C12 aldehyde dissolved in THF is now slowly added and warmed to room temperature and allowed to stand at room temperature over 1/2 hour. The mixture is then cooled to zero and one adds a saturated sodium chloride solution to destroy the excess of sodium hydride. The mixture is now extracted with petroleum ether and the extract dried to evaporate the solvent, yielding the desired ester.
PREPARATION OF C16 ACID
The ester is hydrolyzed by refluxing it in a 10% potassium hydroxide-ethanol solution under nitrogen for 4 hours. The mixture contains 50 grams of the ester, 50 grams of potassium hydroxide, 300 ml of water and 200 ml of ethanol. After the hydrolysis is completed, acidify the mixture. The acid can be extracted with ethyl ether.
PREPARATION OF C20 AND C22 ACIDS
The detailed procedure for obtaining the C20 from the C16 acid is not given since the reactions are substantially the same as outlined above. The C16 acid recovered from the last step is converted to the alcohol, utilizing lithium aluminum hydride and this is converted to the corresponding aldehyde utilizing magnesium dioxide as described above. The aldehyde now is reacted with triethylphosphonocrotonate to produce the C20 ethyl ester and this in turn is hydrolyzed as described above to produce the C20 acid of the present invention. The C22 acid can be prepared from the C20 acid by using the above method and employing triethylphosphonoacetate.
C20 or C22 acids can be applied in the form of an ointment, as a solution in oil or as a powder. In each instance a concentration of about 1% has been found suitable although larger or smaller concentrations may be used. Below about 1/2%, the effectiveness falls off and increasing the concentration from 1 to 2% increases the effectiveness only slightly. Therefore a concentration of about 1%, whether in an ointment, oil solution or powder is about optimum.
Suitable oil carriers include physiologically acceptable oils in which the acid is soluble such as isopropyl myristate, corn oil, cottonseed oil and the like. Powder can be prepared utilizing the C20 or C22 acid crystals by grinding the crystals with a suitable inert carrier such as talc. C20 or C22 acid can be combined with any of the usual ointment bases used in pharmacy. One suitable base is known as NIB (non-ionic base) developed by the University of California School of Pharmacy having the following approximate composition:
______________________________________Cetyl alcohol 6%Stearyl alcohol 6White petrolatum 14Liquid petrolatum 20Methyl paraben 0.15Propyl parben 0.06Polysorbate 80 1.5Polyoxyl 40 stearate 5Propylene glycol 2Purified water q.s. 100%______________________________________
Grindlay and Waugh (Arch. Surg. 63, 288 (1951) used granuloma formation induced by polyvinyl sponge to study tissue regeneration. Since then this method has been used as a standard method to study wound healing. Dunphy and his associates (Ann. N.Y. Acad. Sci. 86, 943 (1960) have pointed out that the repairment of connective tissue is the most basic feature in wound healing, and they used granuloma formation techniques in their many wound healing studies.
This method involves subcutaneous implantation of cotton-pellets and measuring the size of the granuloma induced after a few days. Anti-inflammatory agents reduce the size or weight of granuloma as compared with that of the control. Those compounds which promote healing increase the size or weight of the granuloma.
Growth of granulation tissue into cotton-pellets was induced by subcutaneous implantation at two symmetrical dorsolateral sites of Sprague-Dawley male rats weighing 120 ± 5 g under ether anesthesia.
The cotton-pellet implanted on the right side contains the compound under test and the cotton-pellet implanted on the left side serves as the control. The compound was introduced to the pellet as its ether solution. The ether was completely evaporated before implanation. On the seventh day after implantation, the animals were killed with ether and the body weights were taken. The granulomas were carefully removed and weighed rapidly on a torsion balance. After drying in an oven at 65° C for 48 hours the dried slices were weighed. The following results were obtained.
__________________________________________________________________________EFFECT OF 3',7'-DESMETHYL RETINOIC ACID VINYLOGS ONCOTTON-PELLET INDUCED GRANULOMA IN RATS Granuloma Granuloma Wet. Wt. mg. Dry Wt. mg. No. of Acids Expt. Expt. Expt. Expt.Group Animals Applied Control Control Control Control__________________________________________________________________________I 6 A 238.6±12.1 29.0±2.1 220.5±12.2 1.1 27.2±2.1 1.1II 14 B 331.1±14.8 43.1±2.6 208.8± 5.9 1.5 25.5±1.5 1.7III 43 C 430.2± 8.1 68.9±1.5 205.0± 2.7 2.2 23.9±0.9 2.9IV 30 D 373.9± 8.6 60.5± 1.6 202.9± 4.6 1.8 24.9± 1.2 2.4A Acid: 2, 6, 6, -Trimethyl-1-(6'-carboxy-hexa-1', 3',5'trienyl) cyclohex-1-ene.B Acid: 2, 6, 6, -Trimethyl-1-(8'-carboxy-octa-1',3',5'7'tetraenyl) cyclohex-1-ene or 3',7'-desmethyl retinoic acid.C Acid: 2, 6, 6, -Trimethyl-1-(10'-carboxy-deca-1',3',5',7',9'pentaenyl) cyclohex-1-ene.D Acid: 2, 6, 6, -Trimethyl-1-(12'-carboxy-dodeca-1',3',5',7',9' ,11'hexaenyl) cyclohex-1-ene.__________________________________________________________________________
It is believed apparent from the foregoing that the C20 and C22 acids of the present invention (Acid C and D in the table) are highly effective for wound healing and are much more effective than the homologs having 16 or 18 carbon atoms. The C20 acid is somewhat more effective than the C22 acid.
Further tests established that the C20 and C22 acids are not toxic or at least not as toxic as retinoic acid. Retinoic acid inhibits embryonic chick tibia growth while C20 and C22 do not. Retinoic acid, at higher dosage (4 mg/100g rat) inhibits growth. The C20 at even higher dosages (8 mg/100g rat) does not inhibit growth.
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The C20 and C22 vinylogs of desmethyl retinoic acid has been found highly effective in promoting wound healing. The acid is applied to the wound as a solution, ointment or powder. These acids are the most effective yet found for healing wounds, yet do not have some of the undesirable side effects of retinoic acid.
The compounds of this invention have the following formula: ##STR1## where X is an integer of from 5 to 6.
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This application is a divisional application of and claims priority to U.S. patent application Ser. No. 12/116,380, entitled “STOCHASTIC BIT NOISE CONTROL” (United States Patent Application Publication Number 2009/0044978), which application claimed the benefit of and is a continuation-in-part application of U.S. patent application Ser. No. 11/839,381 filed on Aug. 15, 2007, entitled “SYSTEM AND METHOD FOR CONTROLLING A DRILLING SYSTEM FOR DRILLING A BOREHOLE IN AN EARTH FORMATION.” Both applications (U.S. patent application Ser. Nos. 12/116,380 and 11/839,381) are hereby expressly incorporated by reference in their entirety for all purposes.
BACKGROUND
This disclosure relates in general to drilling a borehole and, but not by way of limitation, to controlling direction of drilling for the borehole.
In many industries, it is often desirable to directionally drill a borehole through an earth formation or core a hole in sub-surface formations in order that the borehole and/or coring may circumvent and/or pass through deposits and/or reservoirs in the formation to reach a predefined objective in the formation and/or the like. When drilling or coring holes in sub-surface formations, it is sometimes desirable to be able to vary and control the direction of drilling, for example to direct the borehole towards a desired target, or control the direction horizontally within an area containing hydrocarbons once the target has been reached. It may also be desirable to correct for deviations from the desired direction when drilling a straight hole, or to control the direction of the hole to avoid obstacles.
In the hydrocarbon industry for example, a borehole may be drilled so as to intercept a particular subterranean-formation at a particular location. In some drilling processes, to drill the desired borehole, a drilling trajectory through the earth formation may be pre-planned and the drilling system may be controlled to conform to the trajectory. In other processes, or in combination with the previous process, an objective for the borehole may be determined and the progress of the borehole being drilled in the earth formation may be monitored during the drilling process and steps may be taken to ensure the borehole attains the target objective. Furthermore, operation of the drill system may be controlled to provide for economic drilling, which may comprise drilling so as to bore through the earth formation as quickly as possible, drilling so as to reduce bit wear, drilling so as to achieve optimal drilling through the earth formation and optimal bit wear and/or the like.
One aspect of drilling is called “directional drilling.” Directional drilling is the intentional deviation of the borehole/wellbore from the path it would naturally take. In other words, directional drilling is the steering of the drill string so that it travels in a desired direction.
Directional drilling is advantageous in offshore drilling because it enables many wells to be drilled from a single platform. Directional drilling also enables horizontal drilling through a reservoir. Horizontal drilling enables a longer length of the wellbore to traverse the reservoir, which increases the production rate from the well.
A directional drilling system may also be used in vertical drilling operation as well. Often the drill bit will veer off of a planned drilling trajectory because of the unpredictable nature of the formations being penetrated or the varying forces that the drill bit experiences. When such a deviation occurs, a directional drilling system may be used to put the drill bit back on course.
The monitoring process for directional drilling of the borehole may include determining the location of the drill bit in the earth formation, determining an orientation of the drill bit in the earth formation, determining a weight-on-bit of the drilling system, determining a speed of drilling through the earth formation, determining properties of the earth formation being drilled, determining properties of a subterranean formation surrounding the drill bit, looking forward to ascertain properties of formations ahead of the drill bit, seismic analysis of the earth formation, determining properties of reservoirs etc. proximal to the drill bit, measuring pressure, temperature and/or the like in the borehole and/or surrounding the borehole and/or the like. In any process for directional drilling of a borehole, whether following a pre-planned trajectory, monitoring the drilling process and/or the drilling conditions and/or the like, it is necessary to be able to steer the drilling system.
Forces which act on the drill bit during a drilling operation include gravity, torque developed by the bit, the end load applied to the bit, and the bending moment from the drill assembly. These forces together with the type of strata being drilled and the inclination of the strata to the bore hole may create a complex interactive system of forces during the drilling process.
The drilling system may comprise a “rotary drilling” system in which a downhole assembly, including a drill bit, is connected to a drill-string that may be driven/rotated from the drilling platform. In a rotary drilling system directional drilling of the borehole may be provided by varying factors such as weight-on-bit, the rotation speed, etc.
With regards to rotary drilling, known methods of directional drilling include the use of a rotary steerable system (RSS). In an RSS, the drill string is rotated from the surface, and downhole devices cause the drill bit to drill in the desired direction. Rotating the drill string greatly reduces the occurrences of the drill string getting hung up or stuck during drilling.
Rotary steerable drilling systems for drilling deviated boreholes into the earth may be generally classified as either “point-the-bit” systems or “push-the-bit” systems. In the point-the-bit system, the axis of rotation of the drill bit is deviated from the local axis of the bottomhole assembly (“BHA”) in the general direction of the new hole. The hole is propagated in accordance with the customary three-point geometry defined by upper and lower stabilizer touch points and the drill bit. The angle of deviation of the drill bit axis coupled with a finite distance between the drill bit and lower stabilizer results in the non-collinear condition required for a curve to be generated. There are many ways in which this may be achieved including a fixed bend at a point in the bottomhole assembly close to the lower stabilizer or a flexure of the drill bit drive shaft distributed between the upper and lower stabilizer.
Pointing the bit may comprise using a downhole motor to rotate the drill bit, the motor and drill bit being mounted upon a drill string that includes an angled bend. In such a system, the drill bit may be coupled to the motor by a hinge-type or tilted mechanism/joint, a bent sub or the like, wherein the drill bit may be inclined relative to the motor. When variation of the direction of drilling is required, the rotation of the drill-string may be stopped and the bit may be positioned in the borehole, using the downhole motor, in the required direction and rotation of the drill bit may start the drilling in the desired direction. In such an arrangement, the direction of drilling is dependent upon the angular position of the drill string.
In its idealized form, in a pointing the bit system, the drill bit is not required to cut sideways because the bit axis is continually rotated in the direction of the curved hole. Examples of point-the-bit type rotary steerable systems, and how they operate are described in U.S. Patent Application Publication Nos. 2002/0011359; 2001/0052428 and U.S. Pat. Nos. 6,394,193; 6,364,034; 6,244,361; 6,158,529; 6,092,610; and 5,113,953 all herein incorporated by reference.
Push the bit systems and methods make use of application of force against the borehole wall to bend the drill-string and/or force the drill bit to drill in a preferred direction. In a push-the-bit rotary steerable system, the requisite non-collinear condition is achieved by causing a mechanism to apply a force or create displacement in a direction that is preferentially orientated with respect to the direction of hole propagation. There are many ways in which this may be achieved, including non-rotating (with respect to the hole), displacement based approaches and eccentric actuators that apply force to the drill bit in the desired steering direction. Again, steering is achieved by creating non co-linearity between the drill bit and at least two other touch points. In its idealized form the drill bit is required to cut side ways in order to generate a curved hole. Examples of push-the-bit type rotary steerable systems, and how they operate are described in U.S. Pat. Nos. 5,265,682; 5,553,678; 5,803,185; 6,089,332; 5,695,015; 5,685,379; 5,706,905; 5,553,679; 5,673,763; 5,520,255; 5,603,385; 5,582,259; 5,778,992; 5,971,085 all herein incorporated by reference.
Known forms of RSS are provided with a “counter rotating” mechanism which rotates in the opposite direction of the drill string rotation. Typically, the counter rotation occurs at the same speed as the drill string rotation so that the counter rotating section maintains the same angular position relative to the inside of the borehole. Because the counter rotating section does not rotate with respect to the borehole, it is often called “geostationary” by those skilled in the art. In this disclosure, no distinction is made between the terms “counter rotating” and “geo-stationary.”
A push-the-bit system typically uses either an internal or an external counter-rotation stabilizer. The counter-rotation stabilizer remains at a fixed angle (or geo-stationary) with respect to the borehole wall. When the borehole is to be deviated, an actuator presses a pad against the borehole wall in the opposite direction from the desired deviation. The result is that the drill bit is pushed in the desired direction.
The force generated by the actuators/pads is balanced by the force to bend the bottomhole assembly, and the force is reacted through the actuators/pads on the opposite side of the bottomhole assembly and the reaction force acts on the cutters of the drill bit, thus steering the hole. In some situations, the force from the pads/actuators may be large enough to erode the formation where the system is applied.
For example, the Schlumberger™ Powerdrive™ system uses three pads arranged around a section of the bottomhole assembly to be synchronously deployed from the bottomhole assembly to push the bit in a direction and steer the borehole being drilled. In the system, the pads are mounted close, in a range of 1-4 ft behind the bit and are powered/actuated by a stream of mud taken from the circulation fluid. In other systems, the weight-on-bit provided by the drilling system or a wedge or the like may be used to orient the drilling system in the borehole.
While system and methods for applying a force against the borehole wall and using reaction forces to push the drill bit in a certain direction or displacement of the bit to drill in a desired direction may be used with drilling systems including a rotary drilling system, the systems and methods may have disadvantages. For example such systems and methods may require application of large forces on the borehole wall to bend the drill-string and/or orient the drill bit in the borehole; such forces may be of the order of 5 kN or more, that may require large/complicated downhole motors or the like to be generated. Additionally, many systems and methods may use repeatedly thrusting of pads/actuator outwards into the borehole wall as the bottomhole assembly rotates to generate the reaction forces to push the drill bit, which may require complex/expensive/high maintenance synchronizing systems, complex control systems and/or the like.
The drill bit is known to “dance” or clatter around in a borehole in an unpredictable or even random manner. This stochastic movement is generally non-deterministic in that a current state does not fully determine its next state. Point-the-bit and push-the-bit techniques are used to force a drill bit into a particular direction and overcome the tendency for the drill bit to clatter. These techniques ignore the stochastic dance a drill bit is likely to make in the absence of directed force.
SUMMARY
In an embodiment, the present disclosure provides for a drill bit direction system that modifies or biases stochastic or natural movement of the drill bit and/or stochastic reaction forces between the drill bit and/or gauge pads and an inner-wall of the borehole being drilled to change a direction of drilling. The change of direction of drilling may in certain aspects be achieved with less effort, less complex surface/downhole machinery and/or more economically than with conventional steering mechanisms. The direction of the drill bit relative to the earth (or some other fixed point) is monitored to determine if the direction happens to align in some way with a preferred direction. If the direction isn't close enough to a preferred direction, a biasing mechanism emphasizes components of radial motion to move the direction closer to the preferred direction. Any of a number of biasing mechanisms can be used. Some embodiments can resort to conventional steering mechanisms to supplement or as an alternative to the biasing mechanism.
In another embodiment, a method for biasing erratic motion of a drill bit to directionally cause the drill bit to drill in a predetermined direction relative to the earth is disclosed. In one step, a direction of the drill bit relative to the earth is determined The direction is compared with the predetermined direction. A biasing mechanism is oriented to emphasize components of radial motion of the drill bit in the predetermined direction. The biasing mechanism is activated when the comparing step determines the direction is not adequately aligned with the predetermined direction.
In yet another embodiment, a drill bit direction system for biasing erratic motion of a drill bit to directionally cause a drill bit to drill in a predetermined direction relative to the earth is disclosed. The drill bit direction system includes a biasing mechanism, a direction sensor and a controller. The biasing mechanism emphasizes components of radial motion of the drill bit in the predetermined direction of the drill bit relative to the earth. The direction sensor determines a direction of the drill bit downhole. The controller compares a predetermined direction with the direction. The biasing mechanism is activated when the direction deviates from the predetermined direction.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating various embodiments, are intended for purposes of illustration only and are not intended to necessarily limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure is described in conjunction with the appended figures:
FIG. 1 depicts a block diagram of an embodiment of a drill bit direction system;
FIGS. 2A through 2C illustrate flowcharts of embodiments of a process for controlling drill bit direction; and
FIGS. 3A through 3C illustrate a state machine for managing the drill bit direction system.
In the appended figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
DETAILED DESCRIPTION
The ensuing description provides preferred exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the preferred exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing a preferred exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set forth in the appended claims.
Referring first to FIG. 1 , a block diagram of an embodiment of a drill bit direction system 100 is shown. An integrated control and information service (ICIS) 104 is located above ground to manage the drillstring rotation control block 112 and the drawworks control block 108 . Additionally, the ICIS 104 generally guides the direction of drilling in the earth formation. Information is communicated downhole to a bottomhole assembly (BHA) 120 such as a desired orientation or direction to achieve for the drill bit and possibly selection of various biasing and steering mechanisms 132 , 136 to use. The direction is defined relative to any fixed point such as the earth. The information may additionally provide control information for the BHA 120 and any biasing and steering mechanisms 132 , 136 .
The ICIS 104 manages the drillstring rotation control block 112 and the drawworks control block 108 . The phase, torque and speed of rotation of the drillstring is monitored and managed by the drillstring control block 112 . Information from the BHA 120 can be analyzed by the ICIS 104 as feedback on how the management is being performed by the drillstring control block 112 . Various operations during drilling use the drawworks control block 108 , for example, removal of the drillstring. The ICIS 104 manages operation of the drawworks control block 108 during these operations.
The BHA 120 includes a downhole controller 124 , an orientation or direction sensor 128 , a bit rotation sensor 140 , one or more biasing mechanism 132 , and one or more steering mechanisms 136 . A typical BHA may have more control systems, which are not shown in FIG. 1 . Information is communicated to the BHA 120 from the surface to indicate a preferred direction of the drill bit. Additionally, use of biasing and steering mechanisms 132 , 136 can be generally controlled by the ICIS 104 , but the downhole controller 124 controls real-time operation of the biasing and steering mechanisms 132 , 136 with information gathered from the direction and bit rotation sensors 128 , 140 .
Information is communicated from the BHA 120 back to the ICIS 104 at the surface. The direction of the drill bit observed may be periodically communicated along with use of various biasing and steering mechanisms 132 , 136 . A borehole path information database 116 stores the information gathered downhole to know how the borehole navigates through the formation. The ICIS 104 can recalculate the best orientation or direction to use for the drill bit and communicate that to the BHA 120 to override the prior instructions. Additionally, the effectiveness of the various biasing and steering mechanisms 132 , 136 can be analyzed with other information gathered on the formation to provide guidance downhole on how to best use the available biasing and steering mechanisms 132 , 136 to achieve the geometry of the borehole desired for a particular drill site.
The direction sensor 128 can determine the current direction of the drill bit with respect to a particular frame of reference in three dimensions (i.e., relative to the earth or some other fixed point). Various techniques can be used to determine the current direction, for example, an inertially or roll-stabilized platform with gyros can be compared to references on the drill bit, accelerometers could be used to track direction and/or magnetometers could measure direction relative to the earth's magnetic field. Measurements could be noisy, but a filter could be used to average out the noise from measurements.
The bit rotation sensor 140 allows monitoring the phase of rotation for the drill bit. The downhole controller 124 takes the sensor information to allow synchronized control of the biasing mechanism(s) 132 . With knowledge of the phase, the biasing can be performed every rotation cycle or any integer fraction of the cycles (e.g., every other rotation, every third rotation, every fourth rotation, every tenth rotation, etc.). Other embodiments do not use a bit rotation sensor 140 or synchronized manipulation of the biasing mechanism(s) 132 .
There are various steering mechanisms 136 that persistently enforce drill bit movement. Steering mechanisms 136 do not intentionally take advantage of the stochastic movement of the drill bit that naturally occurs. A given site may use one or more of these steering mechanisms 136 to create a borehole that changes direction as desired through the formation. Different types of steering mechanisms 136 include bent arms, lever arms synchronized with rotation, universal joints, and geostationary mechanisms that exert force in a particular direction. These steering mechanisms can predictably direct the drill bit, but do not take advantage stochastic movement of the drill bit that could be in the correct direction anyway. Other embodiments may forgo steering mechanisms 136 completely by reliance on biasing mechanisms 132 for directional drilling.
A biasing mechanism 132 can be used before resort to a steering mechanism 136 . The biasing mechanism 132 selects or emphasizes those components of the radial motion of the drill bit in a chosen direction. Directional control is achieved by holding the orientation of the biasing mechanism 132 broadly fixed in the chosen direction. Some embodiments may only have one or more biasing mechanisms 132 downhole without any steering mechanisms 136 . Biasing mechanisms 132 take advantage of the tendency for the drill bit to move around in the bore hole by only activating when the stochastic movement goes in the wrong direction. For example, gage pads or cutters can be moved, a gage ring can exert pressure and/or jetting can be used in various embodiments as the biasing mechanism 132 . Any asymmetry that can be manipulated is usable as a biasing mechanism 132 . In some cases, the drill bit is designed and manufactured so as to exert a side force in a particular azimuthal direction relative to the drill bit. The biasing mechanism 132 is activated to bias the side force. Such a side force rotates with the drill bit to emphasize cutting in the chosen direction. The biasing mechanism 132 can be synchronized to activate and deactivate with rotation of the drill bit.
The downhole controller 124 uses the information sent from the ICIS 104 along with the direction and bit rotation sensors 128 , 140 to actively manage the use of biasing and steering mechanisms 132 , 136 . The desired direction of the drill bit along with guidelines for using various biasing and steering mechanisms 132 , 136 is communicated from the ICIS 104 . The downhole controller 124 can use fuzzy logic, neural algorithms, expert system algorithms to decide how and when to influence the drill bit direction in various embodiments. Generally, the speed of communication between the BHA 120 and the ICIS 104 does not allow real-time control from the surface in this embodiment, but other embodiments could allow for surface control in real-time. The stochastic direction of the drill bit can be adaptively used in a less rigid manner. For example, if a future turn in the borehole is desired and the drill bit is making the turn prematurely, the turn can be accepted and the future plan revised.
With reference to FIG. 2A , a flowchart of an embodiment of a process 200 - 1 for controlling drill bit direction is shown. This embodiment only uses a single biasing mechanism 136 to control the direction of the drill bit. The depicted portion of the process beings in block 204 where an analysis of the formation and end point is performed to plan the borehole geometry. The ICIS 104 manipulates the drillstring, drawworks and other systems in block 208 to create the borehole according to the plan. A desired direction of the drill bit is determined in block 212 and communicated to the downhole controller 124 in block 216 . The desired direction could be a single goal or a range of acceptable directions.
The desired direction along with any biasing selection criteria is received by the downhole controller 124 in block 220 . The current pointing of the drill bit is determined by the direction sensor 128 in block 224 . It is determined in block 228 if the direction is acceptable based upon the instructions from ICIS 104 . This embodiment allows some flexibility in the direction and re-determines the plan based upon the stochastic movement allowed to occur. An acceptable direction is one that allows achieving the end point with the drill bit if the plan were revised. A certain plan may have predetermined deviations or ranges of direction that are acceptable, but still avoid parts of the formation that are not desired to pass through.
Where the direction is not acceptable, processing goes from block 228 to block 236 where the biasing mechanism 132 is activated. The biasing mechanism 132 could be activated once or for a period of time. Alternatively, the biasing mechanism 132 could be activated periodically in synchronization with the rotation of the drill bit. The biasing mechanism 132 selects or emphasizes those components of the radial motion of the drill bit that occur in the desired direction(s).
Where the direction is acceptable as determined in block 228 , processing continues to block 240 . The biasing mechanism 132 achieves directional control by holding the direction in the desired direction(s). Where un-needed because the erratic motion of the drill bit is already in the desired direction(s), the biasing mechanism 132 is not activated. In block 240 , the current direction is communicated by the downhole controller 124 to the ICIS 104 . After reporting, processing loops back to block 212 for further management of the direction based upon any new instruction from the surface.
Referring next to FIG. 2B , a flowchart of another embodiment of the process 200 - 2 for controlling drill bit direction is shown. This embodiment has multiple biasing mechanisms 132 available and can fall back onto a steering mechanism 136 if the biasing mechanism(s) 132 is not effective. The blocks up to block 228 are generally performed the same as the embodiment in FIG. 2A . Where the direction is not acceptable in block 228 , processing continues to block 232 where a selection is made from at least two biasing mechanisms 232 . Guidance from the ICIS 104 may dictate or influence the decision on those biasing mechanisms 132 to select and in what manner they should be controlled. The selected biasing mechanism 132 is used in step 236 .
After using the biasing mechanism 132 , the current direction is reported to the ICIS 104 in block 240 . If the biasing mechanism 132 or some other alternative is still believed to be effective in orienting the drill bit in block 244 , processing loops back to block 212 to continue using that biasing mechanism 132 or some other biasing mechanism 132 that might influence those components of the radial motion of the drill bit to exert a side force in a particular azimuthal direction as desired. Where biasing mechanisms 132 are determined to be no longer effective in block 244 , processing continues to block 248 to activate the steering mechanism 136 , if any.
With reference to FIG. 2C , a flowchart of yet another embodiment of the process 200 - 3 for controlling drill bit direction is shown. This embodiment is similar to that of FIG. 2A except that multiple biasing mechanisms 132 can be chosen from in block 232 . This embodiment only relies upon biasing mechanisms 132 without resort to steering mechanisms 136 .
Referring next to FIG. 3A , an embodiment of a state machine 300 - 1 for managing the drill bit direction system 100 is shown. This control system moves between two states based upon a determination in state 304 if the drill bit is not in alignment with a desired direction or range of directions. This embodiment corresponds to the embodiment of FIG. 2A . Where there is disorientation beyond an acceptable deviation, the drill bit direction system 100 goes from state 304 to state 308 . In state 308 , one or more of the biasing mechanisms are tried 132 . In some cases, the same biasing mechanism 132 is tried with different parameters. For example, a gage pad can be moved at one phase in the bit rotation cycle, but later another phase is tried with the same or a different movement of the gage pad.
With reference to FIG. 3B , another embodiment of the state machine 300 - 2 for managing the drill bit direction system 100 is shown. This embodiment has four states and generally corresponds to the embodiment of FIG. 2B . After attempting a biasing mechanism 132 in state 308 , a determination in state 312 is used to see if the biasing mechanism 132 was effective. Where the biasing mechanism 132 works adequately, the system returns to state 304 . If the biasing mechanism 132 is not effective the drill bit direction system 100 goes from state 312 to state 316 where an active steering mechanism 136 is used before returning to state 304 .
Referring next to FIG. 3C , yet another embodiment of the state machine 300 - 3 for managing the drill bit direction system 100 is shown. This embodiment has a number of biasing techniques and generally corresponds to the process 200 - 3 of FIG. 2C . Where disorientation is found in state 304 , a biasing mechanism or technique is chosen in state 312 . In the alternative, a number of biasing techniques can be chosen from state 312 . The chosen biasing technique is performed in the chosen biasing state 320 before returning to state 304 for further analysis of any disorientation.
A number of variations and modifications of the disclosed embodiments can also be used. For example, the invention can be used on drilling boreholes or cores. The control of the biasing process is split between the ICIS and the BHA in the above embodiments. In other embodiments, all of the control can be in either location.
Specific details are given in the above description to provide a thorough understanding of the embodiments. However, it is understood that the embodiments may be practiced without these specific details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
Implementation of the techniques, blocks, steps and means described above may be done in various ways. For example, these techniques, blocks, steps and means may be implemented in hardware, software, or a combination thereof For a hardware implementation, the processing units may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units designed to perform the functions described above, and/or a combination thereof
Also, it is noted that the embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
Furthermore, embodiments may be implemented by hardware, software, scripting languages, firmware, middleware, microcode, hardware description languages, and/or any combination thereof When implemented in software, firmware, middleware, scripting language, and/or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as a storage medium. A code segment or machine-executable instruction may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a script, a class, or any combination of instructions, data structures, and/or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, and/or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
For a firmware and/or software implementation, the methodologies may be implemented with modules (e.g., procedures, functions, and so on) that perform the functions described herein. Any machine-readable medium tangibly embodying instructions may be used in implementing the methodologies described herein. For example, software codes may be stored in a memory. Memory may be implemented within the processor or external to the processor. As used herein the term “memory” refers to any type of long term, short term, volatile, nonvolatile, or other storage medium and is not to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored.
Moreover, as disclosed herein, the term “storage medium” may represent one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums for storing information. The term “machine-readable medium” includes, but is not limited to portable or fixed storage devices, optical storage devices, wireless channels, and/or various other storage mediums capable of storing that contain or carry instruction(s) and/or data.
While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure.
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A drill bit direction system and method is disclosed that modifies or biases the stochastic movement of the drill bit and/or stochastic interactions between the drill bit and an inner-wall of a borehole being drilled by a drilling system to change the direction of drilling of the drilling system. The direction of the drill bit is monitored to determine if the direction happens to align in some way with a preferred direction. If the direction isn't close enough to a preferred direction, a biasing mechanism modifies the stochastic movement in an attempt to modify the direction closer to the preferred direction. Any of a number of biasing mechanisms can be used. Some embodiments can resort to conventional steering mechanisms to supplement the biasing mechanism.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application contains subject matter that may be related to the subject matter in the following U.S. patent applications, which are all assigned to a common assignee: “Method and System for Reallocating Blocks in a Storage Pool” (application Ser. No. 11/591,422) filed on Oct. 31, 2006; and “Method and Apparatus for Power-Managing Storage Devices in a Storage Pool” (application Ser. No. 11/591,234) filed Oct. 31, 2006.
BACKGROUND
[0002] A typical operating system includes a file system. The file system provides a mechanism for the storage and retrieval of files and a hierarchical directory structure for the naming of multiple files. More specifically, the file system stores information provided by the user (i.e., data) and information describing the characteristics of the data (i.e., metadata). The file system also provides extensive programming interfaces to enable the creation and deletion of files, reading and writing of files, performing seeks within a file, creating and deleting directories, managing directory contents, etc. In addition, the file system also provides management interfaces to create and delete file systems. File systems are typically controlled and restricted by operating system parameters. For example, most operating systems limit the maximum number of file names that can be handled within their file system. Some operating systems also limit the size of files that can be managed under a file system.
[0003] An application, which may reside on the local system (i.e., computer) or may be located on a remote system, uses files as an abstraction to address data. Conventionally, this data is stored on a storage device, such as a disk. To access a file, the operating system (via the file system) typically provides file manipulation interfaces to open, close, read, and write the data within each file. More specifically, the file system stores data on the storage device by managing the allocation of space within the storage device. Typically, the volume manager provides space which is managed by the file system. Two common types of file system space allocation strategies are known as block-based allocation and extent-based allocation. Block-based allocation creates incremental disk space for each file each time the file is extended (i.e., modified via a write request to add information), whereas extent-based allocation creates a large series of contiguous blocks (i.e., extents) each time the file exhausts the space available in the file's last extent.
[0004] When allocating space, both block-based and extent-based allocation use space provided by the volume manager. The volume manager allows multiple physical disks to be used as a single volume (i.e., a virtual disk) to provide larger consolidated storage sizes and simpler management. The volume manager allows users to organize data along volume boundaries (i.e., each volume has physical disk space allocated to the volume such that the volume is tied only to that dedicated physical disk). The volume manager is typically implemented as a separate layer between the physical disks and the file system, and is presented to the user as a virtual disk device. In other words, volume managers organize the collections of physical devices (e.g., disks) into virtual devices. Additionally, the space allocated within the volume manager is handled by the file system. Consequently, the volume manager is not aware of which blocks within the available storage space are in use and which blocks are free for data to be stored.
[0005] Further, file systems may be mounted on the virtual disk devices. Thus, physical disks are partitioned and allocated to multiple virtual disk devices, and each virtual disk device is capable of having a file system that exclusively uses that particular virtual disk device. A request to access a file is typically performed by an application, via the file system, using a file name and logical offset. This file name and logical offset (i.e., the manner in which applications express file operation requests) corresponds to a location within the virtual disk device. Subsequently, the request is translated to physical disk space on the storage device by the volume manager, allowing the user of the application to access the data within a particular file.
[0006] Using the aforementioned infrastructure, when the application wants to perform an Input/Output (I/O) operation (i.e., a request to read data from the file system or a request to write data to the file system), the application issues an 1 / 0 request to the operating system. The operating system forwards the I/O request to the file system. The file system upon receiving the I/O request, forwards the I/O request to the volume manager. The volume manager, in turn, forwards the I/O request to I/O subsystem which places the I/O request in the appropriate device specific I/O queues. The storage devices subsequently perform the I/O request. Typically, once an I/O request is issued to the I/O subsystem, the file system and volume manager is unable to control the scheduling (and subsequent processing) of the I/O request.
SUMMARY
[0007] In general, in one aspect, the invention relates to a method for retrieving a logical block, comprising receiving a request to read the logical block, obtaining metadata associated with the logical block, wherein the metadata comprises a replication type used to store the logical block, and physical block locations in a storage pool for each physical block associated with the logical block, wherein each physical block location specifies one of a plurality storage devices in the storage pool, obtaining power state information comprising a power state for each of the storage devices specified in the physical block locations, selecting a first set of physical block locations using the metadata, the power state information, and a power-usage selection policy, and generating a first set of I/O requests, wherein each I/O request specifies one of the first set of physical block locations, issuing the first set of I/O requests, receiving a first set of physical blocks in response to the first set of I/O requests, and constructing the logical block using the first set of physical blocks.
[0008] In general, in one aspect, the invention relates to a system, comprising a storage pool comprising a plurality of storage devices, a file system comprising an I/O scheduler configured to receive a request to read a logical block, obtaining metadata associated with the logical block, wherein the metadata comprises a replication type used to store the logical block, and physical block locations in the storage pool for each physical block associated with the logical block, wherein each physical block location specifies one of the plurality storage devices in the storage pool, obtain power state information comprising a power state for each of the storage devices specified in the physical block locations, select a first set of physical block locations using the metadata, the power state information, and a power-usage selection policy, generate a first set of I/O requests, wherein each I/O request specifies one of the first set of physical block locations, and issue the first set of I/O requests, and wherein the file system is configured to receive the first set of physical blocks in response to the first set of I/O requests, and constructing the logical block using the first set of physical blocks.
[0009] In general, in one aspect, the invention relates to a computer readable medium comprising computer readable program code embodied therein for causing a computer system to receive a request to read a logical block, obtain metadata associated with the logical block, wherein the metadata comprises a replication type used to store the logical block, and physical block locations in a storage pool for each physical block associated with the logical block, wherein each physical block location specifies one of a plurality storage devices in the storage pool, obtain power state information comprising a power state for each of the storage devices specified in the physical block locations, select a first set of physical block locations using the metadata, the power state information, and a power-usage selection policy, and generate a first set of I/O requests, wherein each I/O request specifies one of the first set of physical block locations, issue the first set of I/O, receive a first set of physical blocks in response to the first set of I/O requests, construct the logical block using the first set of physical blocks.
[0010] Other aspects of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 shows a system diagram in accordance with one or more embodiments of the invention.
[0012] FIG. 2 shows a block diagram of a file system in accordance with one or more embodiments of the invention.
[0013] FIG. 3 shows a diagram of a hierarchical data configuration in accordance with one or more embodiments of the invention.
[0014] FIGS. 4 shows a flow charts in accordance with one or more embodiments of the invention.
[0015] FIGS. 5-7 show diagrams of an example storage pool in accordance with one or more embodiments of the invention.
[0016] FIG. 8 shows a diagram of a computer system in accordance with one or more embodiments of the invention.
DETAILED DESCRIPTION
[0017] Specific embodiments of the invention will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency.
[0018] In the following detailed description of embodiments of the invention, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
[0019] In general, embodiments of the invention provide a method and system for power-aware Input/Output (I/O) scheduling. Specifically, in one or more embodiments of the invention, an I/O scheduler uses a power-use selection policy to determine a subset of physical blocks from which to read data and construct a requested logical block. In one or more embodiments of the invention, the power-use selection policy evaluates the power state of storage devices in a storage pool to determine the most efficient subset of physical blocks (from a power utilization perspective) from which to read and construct a logical block.
[0020] FIG. 1 shows a system architecture in accordance with one or more embodiments of the invention. The system architecture includes an application ( 100 ) interfacing with an operating system ( 102 ). Further, the operating system ( 102 ) includes functionality to interact with a file system ( 104 ), which in turn interfaces with a storage pool ( 112 ). The operating system ( 102 ) typically interfaces with the file system ( 104 ) via a system call interface (not shown). The operating system ( 102 ) provides operations for users to access files within the file system ( 104 ). These operations may include read, write, open, close, etc, In one embodiment of the invention, the file system ( 104 ) is an object-based file system (i.e., both data and metadata are stored as objects). More specifically, the file system ( 104 ) includes functionality to store both data and corresponding metadata in the storage pool ( 112 ). Thus, the aforementioned operations provided by the operating system ( 102 ) correspond to operations on objects.
[0021] More specifically, in one embodiment of the invention, a request to perform a particular operation (i.e., a transaction) is forwarded from the operating system ( 102 ), via the system call interface, to the file system ( 104 ). In one embodiment of the invention, the file system ( 104 ) translates the request to perform an operation on an object directly to a request to perform a read or write operation (i.e., an I/O request) at a physical location within the storage pool ( 112 ). Further, the file system ( 104 ) includes functionality to write the data into the storage pool ( 112 ).
[0022] In accordance with one embodiment of the invention, the file system ( 104 ) may include an I/O scheduler ( 106 ), power distribution I/O queues ( 108 ), a policy store ( 110 ), a compression module (not shown), an encryption module (not shown), a checksum module (not shown), and a metaslab allocator (not shown). Each of these aforementioned modules may be used by the file system ( 104 ) to read data from and/or write data to the storage pool ( 112 ). Each of the aforementioned modules is detailed below.
[0023] In one embodiment of the invention, the I/O scheduler ( 106 ) receives I/O requests and groups the I/O requests into transaction groups. According to one or more embodiments of the invention, the I/O requests are assigned to one of the power distribution I/O queues ( 108 ). The compression module (not shown) provides functionality to compress larger logical blocks into smaller segments, where a segment is a region of physical disk space. Further, the encryption module (not shown) provides various data encryption algorithms. The data encryption algorithms may be used, for example, to prevent unauthorized access. In one or more embodiments of the invention, the checksum module (not shown) includes functionality to calculate a checksum for data and metadata within the storage pool. The checksum may be used, for example, to ensure data has not been corrupted. As discussed above, the file system ( 104 ) provides an interface to the storage pool ( 112 ) and manages allocation of storage space within the storage pool ( 112 ). More specifically, in one or more embodiments of the invention, the file system ( 104 ) uses the metaslab allocator (not shown) to manage the allocation of storage space in the storage pool ( 112 ).
[0024] In one or more embodiments of the invention, the storage pool ( 112 ) includes one or more physical disks. Further, in one or more embodiments of the invention, the storage capacity of the storage pool ( 112 ) may increase and decrease dynamically as physical disks are added and/or removed from the storage pool.
[0025] In one or more embodiments of the invention, the file system ( 104 ) includes one or more power distribution I/O queues ( 108 ). Each power distribution I/O queue ( 108 ) is associated with a physical disk in the storage pool ( 112 ). Each power distribution I/O queue ( 108 ) typically holds the I/O requests for a particular physical disk within the storage pool ( 112 ). Alternatively, there may be one power distribution I/O queue ( 108 ) for the entire storage pool ( 112 ) (or for a portion of the storage pool ( 112 )). In one or more embodiments of the invention, the file system ( 104 ) includes functionality to select which power distribution I/O queue ( 108 ) to send an I/O request. In one or more embodiments of the invention, the file system ( 104 ) includes the functionality to select which power distribution I/O queue ( 108 ) using the I/O scheduler ( 106 ), a policy in the policy store ( 110 ), and metadata regarding the physical disks in the storage pool ( 112 ).
[0026] FIG. 2 shows a block diagram of a file system in accordance with one or more embodiments of the invention. The file system ( 104 ) includes an I/O scheduler ( 106 ) and one or more power distribution I/O queues ( 108 ). The I/O scheduler ( 106 ) includes a power state data structure ( 202 ) and an I/O queue ( 204 ) and is used to manage various I/O requests. In one or more embodiments of the invention, the power state data structure ( 202 ) is configured to store metadata regarding the power states of each of a set of storage devices in a storage pool. The I/O queue ( 204 ) is used to initially store I/O requests sent from applications. In one or more embodiments of the invention, each of the power distribution I/O queues ( 108 ) corresponds to a storage device in a storage pool ( 112 ).
[0027] In addition, the file system ( 104 ) includes a policy store ( 110 ). The policy store (I 10 ) includes a number of policies ( 206 A- 206 N). According to one or more embodiments of the invention, one or more of these policies correlate to a power-use selection policy for selecting a set of physical blocks to read and construct a logical block. For example, a policy ( 206 A) may select blocks based on the amount of power required to obtain the blocks, where the selected blocks minimize the amount of power required to obtain the blocks. Another policy ( 206 N) may select blocks based on the amount of power required to obtain the blocks combined with a minimal performance requirement (e.g., latency between I/O request and response to I/O request).
[0028] The I/O scheduler ( 106 ) receives I/O requests from an application to read a logical block of data, which has been stored as a set of physical blocks. These I/O requests are placed on the I/O queue ( 204 ). The I/O scheduler ( 106 ) may then determine a set of physical blocks to read based on metadata regarding the power state of storage devices ( 208 A- 208 N) in a storage pool ( 112 ) stored in the power state data structure ( 202 ), as well as a power-use selection policy (not shown) stored in the policy store ( 110 ). The I/O requests on the I/O queue ( 204 ) may then be placed on the appropriate power distribution I/O queues ( 108 ), which are associated with storage devices upon which the selected physical blocks are stored.
[0029] FIG. 3 shows a diagram of a hierarchical data configuration (hereinafter referred to as a “tree”) in accordance with one or more embodiments of the invention. As noted above, the storage pool ( 108 ) is divided into metaslabs, which are further divided into segments. Each of the segments within the metaslab may then be used to store a data block (i.e., data) or an indirect block (i.e., metadata). In one embodiment of the invention, the tree includes a root block ( 300 ), one or more levels of indirect blocks ( 302 , 304 , 306 ), and one or more data blocks ( 308 , 310 , 312 , 314 ). In one embodiment of the invention, the location of the root block ( 300 ) is in a particular location within the storage pool. The root block ( 300 ) typically points to subsequent indirect blocks ( 302 , 304 , and 306 ).
[0030] In one embodiment of the invention, indirect blocks ( 302 , 304 , and 306 ) may be arrays of block pointers (e.g., 302 A, 302 B, etc.) that, directly or indirectly, reference to data blocks ( 308 , 310 , 312 , and 314 ). The data blocks ( 308 , 310 , 312 , and 314 ) include actual data of files stored in the storage pool. One skilled in the art will appreciate that several layers of indirect blocks may exist between the root block ( 300 ) and the data blocks ( 308 , 310 , 312 , 314 ).
[0031] In contrast to the root block ( 300 ), indirect blocks and data blocks may be located anywhere in the storage pool ( 108 in FIGS. 1 and 2 ). In one embodiment of the invention, the root block ( 300 ) and each block pointer (e.g., 302 A, 302 B, etc.) includes data as shown in the expanded block pointer ( 302 B). One skilled in the art will appreciate that data blocks do not include this information; rather, data blocks include actual data of files within the file system.
[0032] In one embodiment of the invention, each block pointer includes a metaslab ID ( 318 ), an offset ( 320 ) within the metaslab, a birth value ( 322 ) of the block referenced by the block pointer, a checksum ( 324 ), a logical block size ( 326 ), and a replication type ( 328 ) of the data stored in the block (data block or indirect block) referenced by the block pointer. In one embodiment of the invention, the metaslab ID ( 318 ), offset ( 320 ), logical block size ( 326 ), and replication type ( 328 ) are used to determine the locations of the block (data block or indirect block) in the storage pool. The metaslab ID ( 318 ) identifies a particular metaslab. More specifically, the metaslab ID ( 318 ) may identify the particular disk (within the storage pool) upon which the metaslab resides and where in the disk the metaslab begins. The offset ( 320 ) may then be used to reference a particular segment in the metaslab. In one embodiment of the invention, the data within the segment referenced by the particular metaslab ID ( 318 ) and offset ( 320 ) may correspond to either a data block or an indirect block. If the data corresponds to an indirect block, then the metaslab ID and offset within a block pointer in the indirect block are extracted and used to locate a subsequent data block or indirect block. The tree may be traversed in this manner to eventually retrieve a requested data block.
[0033] In one embodiment of the invention, a given block (e.g., any of the root, indirect blocks, and/or data blocks shown in FIG. 3 ) may be stored as a series of smaller blocks. For example, a 2Kbyte block may be stored as a four 512 byte blocks. In such cases, the 2K block is referred to as a logical block and the four 512 blocks are the physical blocks (i.e., blocks stored in the storage pool). In another example, the 2Kbyte block may be stored using a replication policy such as RAID-5. In such cases, the logical block is the 2Kbyte block and the physical blocks include the four 512 byte blocks along with the requisite parity blocks.
[0034] Returning to the discussion of FIG. 3 , in one or more embodiments of the invention, the logical block may be stored using a replication method (where the replication method may be different for each block). For example, using a mirroring method, there will be several full copies of the logical block located in the file system, stored as several sets of physical blocks. Another example is a RAID-type method, which uses parity blocks along with a set of physical blocks, allowing for the entire logical block to be constructed should one or more of the physical blocks become corrupted. The logical block size and the replication type may be used to determine the location of the corresponding physical blocks in the storage pool. When a replication method is used, there is more than one set of physical blocks that may be used to construct a logical block. In one embodiment of the invention, the I/O scheduler ( 106 of FIGS. 1 and 2 ) is configured to select the set of physical blocks to retrieve in order to construct the requested logical block. As discussed above, the manner in which the set of physical blocks is selected is based on the power-use selection policy.
[0035] FIGS. 4 shows a flow chart in accordance with one or more embodiments of the invention. More specifically, FIG. 4 details a method for reading a logical block in accordance with one or more embodiments of the invention.
[0036] In ST 400 , the I/O scheduler receives a request to read a logical block. In ST 402 , the I/O scheduler obtains metadata regarding the requested logical block. This metadata may include the replication method used to store the logical block, the starting location of the stored physical blocks, the size of the logical block, and the checksum of the logical block. This information allows the I/O scheduler to determine the locations of all the physical block stored in the storage pool that are associated with the requested logical block.
[0037] In one embodiment of the invention, the information obtained in ST 402 may be obtained from the indirect block referencing the logical block (see FIG. 3 ). The logical block size stored in the indirect block referencing the logical block indicates the actual size of the logical block. In other words, because the logical block size of data may be different than the number of blocks placed on store the data (i.e., due to the use of a replication policy to write the data), the logical block size is required to determine how and where the physical data corresponding to the logical block is stored in the storage pool.
[0038] In ST 404 , the I/O scheduler determines the power states of each storage device on which one or more of the physical blocks identified in ST 402 are located. In one embodiment of the invention, power state information for each storage device in the storage pool is stored in a power state data structure. In one embodiment of the invention, the power states may include, but are not limited to, spun-up, spinning-up, spinning-down, spun down, and powered-off.
[0039] In ST 406 , the I/O scheduler determines all subsets of physical blocks from which the complete requested logical block may be constructed. According to one or more embodiments of the invention, there may be several subsets of physical blocks from which the requested logical block may be constructed due to a replication method that was used when the logical block was written to the storage pool.
[0040] In ST 408 , the I/O scheduler selects one of the subsets of physical blocks from which to obtain the data corresponding to the logical block. I/O requests are then placed on the power distribution I/O queues associated with the storage devices on which the selected subset of physical blocks are located.
[0041] In ST 410 , each of the physical blocks in the selected ST 408 are retrieved. In ST 412 , the requested logical block is constructed from the retrieved blocks. In ST 414 , the checksum of the constructed logical block is calculated. In ST 416 , a determination is made about whether the checksum calculated in ST 414 matches the checksum obtained in ST 402 . If the checksums match, then the logical block has been read successfully and the process ends.
[0042] In ST 418 , if the checksums do not match, then another subset of physical blocks is selected, which also allow for the construction of the requested logical block. The process then proceeds to ST 410 .
[0043] While the various steps in this flowchart are presented and described sequentially, one of ordinary skill will appreciate that some or all of the steps may be executed in different orders, may be combined or omitted, and some or all of the steps may be executed in parallel. In addition, steps such as store acknowledgements have been omitted to simplify the presentation.
[0044] FIGS. 5-7 shows examples in accordance with one or more embodiments of the invention. The examples should not be construed as limiting the scope of the invention.
[0045] Turning to FIG. 5 , FIG. 5 shows a diagram of a storage pool in which logical block M has been stored using 3-way mirroring. For the purposes of this example assume that the I/O scheduler has received a request to obtain logical block M and that the current state of the disks in the storage pool is as follows: disks 1 , 3 , and 5 ( 530 A, 530 C, and 530 E) are spun up, while disk 2 and disk 4 ( 530 B and 530 D) are spun down.
[0046] Upon receiving the request to retrieve logical block M, the logical block size is obtained. In this example, the logical block size of logical block M is 1.5Kbytes and each physical block in the storage pool is 512 bytes. Accordingly, each copy of the logical block requires three physical blocks. Thus, the total amount of physical space occupied by logical block M is 4.5 Kbytes (or nine physical blocks) (i.e., M 0 ( 500 ), M 1 ( 502 ), M 2 ( 504 ), M 0 ( 506 ), M 1 ( 508 ), M 2 ( 510 ), M 0 ( 512 ), M 1 ( 514 ), M 2 ( 516 )). In this example, the file system stores logical blocks (including copies) in even numbers of physical blocks, thus, in order to store 1.5Kbytes ten physical blocks are allocated—the nine previously cited physical blocks and M FILL ( 518 ). Based on the replication scheme, there are a number of subsets of physical blocks which may be retrieved in order to construct the logical block.
[0047] More specifically, the logical block M is composed of three physical blocks: M 0 , M 1 , and M 2 , Therefore, in order to be able to construct the full logical block from a set of physical blocks, the I/O scheduler may pull one of several sets of physical blocks. First, the I/O scheduler identifies the physical blocks corresponding to the logical block (i.e., (M 0 ( 500 ), M 1 ( 502 ), M 2 ( 504 ), M 0 ( 506 ), M 1 ( 508 ), M 2 ( 510 ), M 0 ( 512 ), M 1 ( 514 ), M 2 ( 516 )). The I/O scheduler then determines the power state of each disk that includes at least one of the aforementioned physical blocks.
[0048] In this example, Disks 1 through Disk 5 ( 530 A through 530 E) hold the physical blocks that correspond to the logical block M. The power states for each of these disks is as follows:
Disk 1 ( 530 A): Spun Up; Disk 2 ( 530 B): Spun Down; Disk 3 ( 530 C): Spun Up; Disk 4 ( 530 D): Spun Down; and Disk 5 ( 530 E): Spun Up.
[0054] Once the I/O scheduler determines these power states, they are stored in the power state data structure. The I/O scheduler may then determine each subset of physical blocks that may be used to construct the logical block, For this example, in order to construct logical block M, one copy of each of: M 0 , M 1 , and M 2 must be obtained. The following are the potential subsets:
(M 0 ( 500 ), M 1 ( 502 ), M 2 ( 504 )) (M 0 ( 500 ), M 1 ( 502 ), M 2 ( 510 )) (M 0 ( 500 ), M 1 ( 502 ), M 2 ( 516 )) (M 0 ( 500 ), M 1 ( 508 ), M 2 ( 504 )) (M 0 ( 500 ), M 1 ( 508 ), M 2 ( 510 )) (M 0 ( 500 ), M 1 ( 508 ), M 2 ( 516 )) (M 0 ( 500 ), M 1 ( 514 ), M 2 ( 504 )) (M 0 ( 500 ), M 1 ( 514 ), M 2 ( 510 )) (M 0 ( 500 ), M 1 ( 514 ), M 2 ( 516 )) (M 0 ( 506 ), M 1 ( 502 ), M 2 ( 504 )) (M 0 ( 506 ), M 1 ( 502 ), M 2 ( 510 )) (M 0 ( 506 ), M 1 ( 502 ), M 2 ( 516 )) (M 0 ( 506 ), M 1 ( 508 ), M 2 ( 504 )) (M 0 ( 506 ), M 1 ( 508 ), M 2 ( 510 )) (M 0 ( 506 ), M 1 ( 508 ), M 2 ( 516 )) (M 0 ( 506 ), M 1 ( 514 ), M 2 ( 504 )) (M 0 ( 506 ), M 1 ( 514 ), M 2 ( 510 )) (M 0 ( 506 ), M 1 ( 514 ), M 2 ( 516 )) (M 0 ( 512 ), M 1 ( 502 ), M 2 ( 504 )) (M 0 ( 512 ), M 1 ( 502 ), M 2 ( 510 )) (M 0 ( 512 ), M 1 ( 502 ), M 2 ( 516 )) (M 0 ( 512 ), M 1 ( 508 ), M 2 ( 504 )) (M 0 ( 512 ), M 1 ( 508 ), M 2 ( 510 )) (M 0 ( 512 ), M 1 ( 508 ), M 2 ( 516 )) (M 0 ( 512 ), M 1 ( 514 ), M 2 ( 504 )) (M 0 ( 512 ), M 1 ( 514 ), M 2 ( 510 )) (M 0 ( 512 ), M 1 ( 514 ), M 2 ( 516 ))
[0082] Using the power-use selection policy, the aforementioned subsets, and the power states in the power state data structure, the I/O scheduler determines the aggregate power cost for reading logical block M using each of the subsets. According to one or more embodiment of the invention, the power-use selection policy considers reading from disks that are currently spun up as a low power cost, because much less power is needed to read from a disk that is already spun up as compared with spinning up a disk that is currently not spun up. In this example, because Disk 1 ( 530 A), Disk 2 ( 530 C), and Disk 3 ( 530 E) are already spun up, it would require less power to try to read from these disks. In this example, to avoid unnecessarily spinning up any more disks, the following physical blocks could be read to construct logical block M:
(M 0 ( 500 ), M 1 ( 502 ), M 2 ( 510 )) (M 0 ( 500 ), M 1 ( 502 ), M 2 ( 516 )) (M 0 ( 500 ), M 1 ( 508 ), M 2 ( 510 )) (M 0 ( 500 ), M 1 ( 508 ), M 2 ( 516 ))
[0087] In the example shown, the I/O scheduler has chosen to read from Disk 1 ( 530 A) and Disk 3 ( 530 C), which hold the physical block combination: (M 0 ( 500 ), M 1 ( 502 ), M 2 ( 510 )). A person skilled in the art will appreciate that this is a simplified version of how the I/O scheduler would select the subset of physical blocks and disks to read from using the power states. There may be other differences in the characteristics of each disk and how it is running that affect the power cost required to read data located on the disk. The I/O scheduler may have chosen other combinations of physical blocks from the same storage devices. For example, reading from physical blocks (M 0 ( 500 ), M 1 ( 508 ), and M 2 ( 510 )) would again only require reading from Disk 1 ( 530 A) and Disk 3 ( 530 C).
[0088] Further, because the logical block was written using a mirrored replication method in the storage pool, finding a number of subsets of physical blocks from which combine to form the logical block allows for the I/O scheduler to make use of advantages provided by a mirrored replication system. For example, if the I/O scheduler sends requests to the power distribution I/O queues corresponding to Disk 1 ( 530 A) and Disk 3 ( 530 C), but found that Disk 3 ( 530 C) was corrupt, there are alternative subsets of physical blocks located on disks that already spun up. For example, the I/O scheduler may send I/O requests to the power distribution I/O queues corresponding to Disk 1 ( 530 A) and Disk 5 ( 530 E). In doing so, the file system may read the subset of physical blocks (M 0 ( 500 ), M 1 ( 502 ), and M 2 ( 516 )).
[0089] FIG. 6 shows a diagram of an example storage pool in accordance with one embodiment of the invention. More specifically, FIG. 6 shows a storage pool in which logical blocks are written using a RAID-type replication method. As shown in FIG. 6 , the storage pool includes five disks (i.e., Disk 1 ( 640 A), Disk 2 ( 640 B), Disk 3 ( 640 C), Disk 4 ( 640 D), Disk 5 ( 640 E)). Further, two logical blocks, A and B, are stored in the storage pool.
[0090] Logical block A is 1.5Kbytes and is stored across three physical blocks (i.e., A 0 ( 602 ), A 1 ( 604 ), and A 2 ( 606 )). Further, a single parity block (A′ ( 600 )) is generated for logical block A using A 0 ( 602 ), A 1 ( 604 ), and A 2 ( 606 ). As shown in FIG. 6 , the parity block (A′ ( 600 )) is written to the storage pool first followed by the physical blocks that make up logical block A (ie., A 0 ( 602 ), A 1 ( 604 ), and A 2 ( 606 )).
[0091] Logical block B is 3 Kbytes and is stored across six physical blocks (i.e., B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 )). Further, two parity blocks (B′ 0 ( 608 ) and B′ 1 ( 618 )) are generated for the aforementioned physical blocks. Specifically, B′ 0 ( 608 ) is generated using B 0 ( 610 ), B 2 ( 612 ), B 4 ( 614 ), B 5 ( 616 ), while B′ 1 ( 618 ) is generated using B 1 ( 620 ) and B 3 ( 622 ).
[0092] For the purposes of this example, consider the scenario in which a request for logical block B is received. As discussed above, logical block B is stored in the storage pool using eight physical blocks B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 ), and B 1 ′ ( 618 ). In the example given, one or more of the aforementioned blocks is present on each of the disks in the storage pool.
[0093] The I/O scheduler (or a related process) determines the location for each of the aforementioned physical blocks. Using this information, the power state of each of the disks upon which one or more of the physical blocks is located is obtained. In this example, Disk 1 ( 640 A), Disk 3 ( 640 C), and Disk 5 ( 640 E) are spun up, while Disk 2 ( 640 B) and Disk 4 ( 640 D) are spun down.
[0094] The I/O scheduler then determines the possible subsets of the physical blocks that may be used to construct the logical block. Because the logical block has been stored using a RAID-type replication method, there are multiple subsets of physical blocks that allow for the construction of the logical block. These include:
(B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 )) (B 1 ( 620 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 )) (B 0 ( 610 ), B 1 ( 620 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 )) (B 0 ( 610 ), B 1 ( 620 ), B 2 ( 620 ), B 3 ( 622 ), B 5 ( 616 ), B 0 ′ ( 608 )) (B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 0 ′ ( 608 )) (B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 2 ( 620 ), B 3 ( 622 ), B 5 ( 616 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 1 ( 620 ), B 2 ( 612 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 1 ( 620 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 1 ( 620 ), B 2 ( 620 ), B 5 ( 616 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 4 ( 614 ), B 0 ′ ( 608 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 ), B 1 ′ ( 618 )) (B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 4 ( 614 ), B 5 ( 616 ), B 1 ′ ( 618 ))
[0110] Those skilled in the art will appreciate that one or more of the aforementioned subsets includes one or more parity blocks, which may be used to reconstruct one or more of the other physical blocks necessary to obtain logical block B.
[0111] The I/O scheduler may then use a power-use selection policy to determine which subset of physical blocks should be used based on the power cost required to obtain the physical blocks in the subset. For purposes of this example assume that reading from disks that are already spun up requires less power as compared with reading from disks are spun down. Returning to the example, as shown in FIG. 6 , only Disk 1 ( 640 A), Disk 3 ( 640 C), and Disk 5 ( 640 E) are already spun up. Accordingly, it is not possible to read any of the subsets of physical blocks using only the three spun up storage devices. Accordingly, it is necessary to spin up an additional disk in order to read any of the subsets of physical blocks. A person skilled in the art would appreciate that spinning up either Disk 2 ( 640 B) or Disk 4 ( 640 D) would be sufficient to read one of the subsets of physical blocks necessary to reconstruct logical block B. For the purposes of this example, the power-use selection policy selects Disk 1 ( 640 A), Disk 2 ( 640 B), Disk 3 ( 640 C), and Disk 5 ( 640 E). As such, it is necessary to spin up Disk 2 in order to read enough physical blocks to construct logical block B. For purposes of the example, the subset of physical blocks that are used to construct the logical block include: (B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), B 0 ′ ( 608 )). Retrieved physical blocks B 0 ′ ( 608 ), B 0 ( 610 ), B 2 ( 612 ), and B 4 ( 614 ) may be used to reconstruct block B 5 . Subsequently, physical blocks B 0 ( 610 ), B 1 ( 620 ), B 2 ( 612 ), B 3 ( 622 ), B 4 ( 614 ), and constructed physical block B 5 may be combined to form logical block B.
[0112] FIG. 7 illustrates this example by showing the same data pool configuration as the one shown in FIG. 6 and described above. However, in this example, physical block B 2 ( 612 ) is corrupt. Accordingly, when the checksum of constructed logical block B is compared with a stored checksum, the checksums will not match. In such cases, a different subset of physical blocks is selected to construct logical block B.
[0113] As shown above, there are several subsets of physical blocks that may be use to construct logical block B. In this example, because B 2 ( 612 ) is corrupt, there are no subsets of data that may be read using only the original four selected disks discussed above with respect to FIG. 6 . Those skilled in the art will appreciate that because there are four physical blocks associated with each parity block, at least three of the physical blocks are required to reconstruct the remaining physical block. In view of this, the I/O scheduler sends an I/O request to the 110 power distribution 110 queue corresponding to Disk 4 ( 640 D) to read physical block B 5 ( 616 ). As shown in the example, the following physical blocks are read to reconstruct the logical block: (B 0 ( 610 ), B 1 ( 620 ), B 3 ( 622 ), B 4 ( 614 ), B 5 ( 616 ), B 0 ′ ( 608 )). Those skilled in the art will appreciate that this is just one of several subsets of physical blocks that may be read to reconstruct the original logical block. For example, parity block B 1 ′ could be used to reconstruct either B 1 ( 620 ) or B 3 ( 622 ) and thus form a different subset of physical blocks that would still work to combine to form logical block B.
[0114] Embodiments of the invention may be implemented on virtually any type of computer regardless of the platform being used. For example, as shown in FIG. 8 , a computer system ( 800 ) includes one or more processor(s) ( 802 ), associated memory ( 804 ) (e.g., random access memory (RAM), cache memory, flash memory, etc.), a storage device ( 806 ) (e.g., a hard disk, an optical drive such as a compact disk drive or digital video disk (DVD) drive, a flash memory stick, etc.), and numerous other elements and functionalities typical of today's computers (not shown). The computer ( 800 ) may also include input means, such as a keyboard ( 808 ), a mouse ( 810 ), or a microphone (not shown). Further, the computer ( 800 ) may include output means, such as a monitor ( 812 ) (e.g., a liquid crystal display (LCD), a plasma display, or cathode ray tube (CRT) monitor). The computer system ( 800 ) may be connected to a network ( 814 ) (eg., a local area network (LAN), a wide area network (WAN) such as the Internet, or any other similar type of network) via a network interface connection (not shown). Those skilled in the art will appreciate that many different types of computer systems exist, and the aforementioned input and output means may take other forms. Generally speaking, the computer system ( 800 ) includes at least the minimal processing, input, and/or output means necessary to practice embodiments of the invention.
[0115] Further, those skilled in the art will appreciate that one or more elements of the aforementioned computer system ( 800 ) may be located at a remote location and connected to the other elements over a network. Further, embodiments of the invention may be implemented on a distributed system having a plurality of nodes, where each portion of the invention (e.g., operating system, file system, storage pool, disk, I/O scheduler, compression module, encryption module, checksum module, etc.) may be located on a different node within the distributed system. In one embodiment of the invention, the node corresponds to a computer system. Alternatively, the node may correspond to a processor with associated physical memory. The node may alternatively correspond to a processor with shared memory and/or resources. Further, software instructions to perform embodiments of the invention may be stored on a computer readable medium such as a compact disc (CD), a diskette, a tape, a file, or any other computer readable storage device.
[0116] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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A method for retrieving a logical block, including receiving a request to read the logical block, and obtaining metadata associated with the logical block, wherein the metadata includes a replication type used to store the logical block and physical block locations in a storage pool for each physical block associated with the logical block. The method further includes obtaining power state information including a power state for the storage devices specified in the physical block locations, selecting a first set of physical block locations using the metadata, the power state information, and a power-usage selection policy, and generating I/O requests, where each I/O request specifies one of the first set of physical block locations. The method further includes issuing the I/O requests, receiving physical blocks in response to the I/O requests, and constructing the logical block using the physical blocks.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to a dispensing system for use in a heating, ventilating or air conditioning (HVAC) air stream and, in particular, to a central or zoned forced air HVAC media dispensing system for dispensing water vapor and/or other water soluble air-flow borne materials.
More specifically, but without restriction to the particular embodiment and/or use which is shown and described herein for purposes of illustration, this invention relates to a user-programmable central or zoned HVAC dispensing system for introducing various media such as water vapor, fragrances or other air-treating materials to improve living and working environments.
2. Description of Related Technology
The use of a humidification device for a central or zoned forced air HVAC system to improve living and working environments is known to those skilled in this art. Such systems generally comprise either passive evaporation of water from a reservoir adjacent to the HVAC air stream, or a circulating liquid retaining medium which passes in an endless path of movement through a water bath positioned within the HVAC air stream. While such systems are somewhat effective and simple, they are generally activated when an air stream is moving through the HVAC system and do not provide precise user control. If it is desired to dispense an additional medium into the air stream, the additional medium is manually added to the bath for dispensing into the air flow. Such systems consequently have wide variations in the amount of the media dispensed into the air stream which changes as the concentration of the media being dispensed varies, such as by evaporation, as well as the conditions of the ambient air.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to improve central and zoned dispensing systems for dispensing materials into a HVAC air stream.
Another object of this invention is to provide a range of user-programmable operational controls for the dispensing of materials into an HVAC air stream.
A further object of this invention is to provide a user-programmable central dispensing system for dispensing and monitoring the dispensing of one or more water-soluble materials into the air stream of an HVAC system in a predetermined and programmable quantity.
These and other objects are attained in accordance with the present invention wherein there is provided a user-programmable monitoring and dispensing system for controlling the dispensing of water vapor and various other media into an HVAC air stream in residential or commercial structures. The various media to be dispensed are preferably water-soluble, and mixed with the system water supply to be dispensed with the water vapor added to the HVAC air stream. These materials may be fragrances or aromas, intended to produce an aesthetic effect, or they can be agents capable of pesticidal, bacteriacidal, fungicidal or sporacidal effect for use as acute or prophylactic treatment for infestation.
DESCRIPTION OF THE DRAWINGS
Further objects of this invention, together with additional features contributing thereto and advantages accruing therefrom, will be apparent from the following description of a preferred embodiment of the present invention which is shown in the accompanying drawings with like reference numerals indicating corresponding parts throughout and which is to be read in conjunction with the following drawings, wherein:
FIG. 1 is a mechanical schematic of a preferred embodiment of the dispensing system to better illustrate the components thereof and the manner in which such components interrelate in the system operation;
FIG. 2 is a logic block diagram of the system operation;
FIG. 3 is a logic block diagram of the operation of the user interface keypad/display through which the system is programmed; and
FIG. 4 is a logic block diagram of the system controls through which materials are dispensed into the HVAC air stream in response to the user-defined program inputs.
These and additional embodiments of the invention may now be better understood by referring to the following detailed description of the invention wherein the illustrated embodiment is described.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this description, the preferred embodiment and examples shown should be considered as exemplars, rather than limitations on the apparatus and methods of the present invention.
Referring now to the drawings, there is illustrated in FIG. 1 the various air flow components of an HVAC system and the central dispensing system of this invention. The portion of the HVAC system illustrated includes an air movement generating device, such as a blower 10 which generates an air stream which pass through duct work 11 to a desired residential or commercial space. The HVAC system includes a heat exchanger 12 positioned in the air stream path to heat the air moving through the duct 11 in response to the temperature set by a HVAC thermostat controller 20 , the input of which is entered through a user operated keypad/display unit 100 . In addition, an A/C coil 14 is positioned in the air stream to cool the temperature thereof in response to the temperature programmed through the thermostat 20 . The blower 10 , duct work 11 , heat exchanger 12 and A/C coil 14 are standard components utilized in HVAC forced air systems. Positioned down stream from the blower 10 , heat exchanger 12 and A/C coil 14 , in the direction of air movement, is a pressure or flow sensor 21 , such as available from Sensotec Inc., 2080 Arlingate Lane, Columbus, Ohio 43228, a humidity sensor 23 and a temperature sensor 25 , such as a HE-6310 Series Duct-mount humidity/temperature sensor, available from Johnson Controls, Inc., 507 East Michigan Street, Milwaukee, Wis. 53202, all of which are connected to a system central processor 50 , such as an Intel Type 8051 Microcontroller DS89C420-QCS Dallas Semiconductor Ultra High Speed 8051 Based Microcontroller PLCC Package available from Newark Electronics, 3 Marcus Boulevard, Albany, N.Y. 12205-1129, for providing air stream sensor inputs as to the air movement, moisture content of the air stream and the air stream temperature to the system central processor. Further down stream from these sensors, is a dispenser 16 which may be in the form of an ultrasonic transducer, available from Keramos Advanced Piezoelectrics, 5460 W. 84 th Street, Indianapolis, Ind. 46268 and Etalon Innovative Piezo Transducers, P.O. Box 127, Lebanon, Ind. 46052, or vaporizer through which water vapor and/or water-soluble materials, available from Aroma Tech Co., 130 Industrial Parkway, Somerville, N.J. 088076, are dispensed into the HVAC air stream in response to a user-defined program input to the system central processor 50 by means of the keypad/display unit 100 , such as a Type XK-5LC or Type LCD-96M Multi Menu Keypad available from FBII, 149 Eileen Way, Soyosset, N.Y. 11791-5316 or JDS Technologies, 12200 Thatcher Ct., Poway, Calif. 92064-6876. While a single dispenser 16 is illustrated, it is to be understood that a single dispensing head may be utilized as illustrated or multiple dispensing heads may be utilized with each one of the multiple dispensing heads being connected by means of a dilution manifold to each individual media reservoir. The dispensing heads may be piezo-electric ultrasonic transducers, atomizer spray nozzles or a media saturated evaporation wick. The dispenser 16 , as illustrated in FIG. 1, is shown dispensing into the main plenum of an HVAC system for a centralized effect from the medium dispensed. However, it is to be understood that separate dispensers may be utilized in various trunk ducts as well as the central plenum for dispersal of the medium into specific locations serviced by the HVAC system.
The display/HVAC thermostat portion 20 of the keypad/display unit 100 is coupled to the system central processor 50 to provide the inputs illustrated in FIG. 2 to control the heating/cooling operation of the system central processor 50 .
The system central processor 50 is connected to a suitable standard power supply 51 to provide power to the unit upon start up. At this time a thermostat control signal is sent 20 c from the system central processor 50 to actuate one or more of the blower 10 , heat exchanger 12 , or A/C coil 14 , in response to an on/off signal determined from the thermostat setting.
The system central processor 50 is programmed in the manner illustrated in FIG. 3, to control the operation of the media dispensing system on a daily basis, to control the dispensing of a selected medium or media, and to control the intensity thereof during the programmed cycle. The system operation, in response to the user-defined program inputs, and the output from various component sensors used in controlling system operations, are controlled in the manner illustrated in FIG. 4 .
Referring again to FIG. 1, the input from the user-defined program keypad/display unit 100 , including the thermostat signal, is coupled 20 a to the system central processor 50 and appropriate display information is coupled 20 b from the system central processor 50 back to the keypad/display 100 to confirm that the signals input from the keypad/display unit 100 have been received and processed by the system central processor 50 . While in the preferred embodiment disclosed herein as the best mode contemplated by the inventor for practicing the invention the keypad/display unit 100 is utilized, it is to be understood that the input coupled 20 a to the dispenser system central processor 50 could be from a home automation control system commonly used to network and integrate the control and function of several subsystems in the space being controlled, with the feedback 20 b from the system central processor 50 being coupled to such an automation control system instead of a keypad/display unit 100 . A suitable home automation control system, not shown, has been found to be an Omni, Omni LT, and Omni Pro models available from Home Automation, Inc., 5725 Powell Street, Suite A, New Orleans, La. 70123.
When the HVAC system is in operation, an input 21 a will be received from the pressure or flow sensor 21 to the system central processor 50 confirming the movement of the air stream in the duct 11 , and input signals will be received 23 a from the humidity sensor 23 and from the temperature sensor 25 to provide input 25 a to the system central processor 50 as to the moisture content and the temperature of the air stream moving through the duct 11 . This information will be processed through the system central processor 50 and control 30 a the operation of a water intake control valve 30 , available from South Bend Controls, 1237 Northside Boulevard, South Bend, Ind. 46615; HydraForce, Inc., 500 Barclay Boulevard, Lincolnshire, Ill. 60069; and Deltrol Controls, 2740 South 20 th Street, Milwaukee, Wis. 53215, through which water passes from a suitable municipal or domestic supply source 32 into a dilution manifold 34 wherein water soluble media to be dispensed into the air stream are added for dilution prior to dispensing.
The water from water supply 32 is also connected to one or more media reservoir tanks, illustrated in the preferred embodiment as three reservoirs 35 a , 35 b and 35 c . These reservoirs may be either permanent containers which are refillable, or be replaceable as modular units. In addition, each reservoir 35 a , 35 b and 35 c incorporates a recognition media such as a bar code, magnetic strip or holographic symbol so that the system central processor 50 will receive a signal that the reservoir is in proper position and the information contained therein will effect display of the particular medium being dispensed on the keypad/display unit 100 . In addition, it is to be understood that the contour of each of the reservoirs may be such that when the reservoir is properly positioned, such a signal will be provided to the system central processor.
Each of the reservoirs 35 a , 35 b and 35 c preferably contain an inner bladder which effectively creates a second chamber within the media reservoir and the space around the inner bladder is connected in parallel to the water supply 32 such that the water fills the space around the bladder to displace the media contained within the reservoir towards the mixing manifold. Each of the media reservoirs is connected to the dilution manifold 34 by media output valves 36 a , 36 b and 36 c such as inert proportional valves available from the water intake control valve supplier and which are individually activated 37 a , 37 b and 37 c by the system control processor 50 to control the dispensing of water soluble media into the dilution manifold 34 from the respective media reservoirs 35 a , 35 b and 35 c . The water soluble media is mixed with water in the dilution manifold 34 and passes to the ultrasonic transducer or vaporizer 16 in response to the actuation 38 a of a dispensing control valve 38 available from the water intake control valve suppliers previously identified and operated by the system central processor 50 in accordance with the information coupled to the central system processor by the temperature and humidity sensors 25 and 23 , respectively, and the programmed input entered by the user through the keypad/display unit 100 . The intensity of the media contained within the media reservoirs may be achieved by varying the amount of media dispensed during and “on” cycle wherein the media reservoirs contain a constant concentration of the media or the quantity of the medium dispensed may be held constant with the concentration of the media being controlled by controlling the dilution of the medium in the dilution manifold 34 .
The media reservoirs 35 a , 35 b and 35 c are each provided with a sensor 39 a , 39 b and 39 c , respectively, available from Gems Sensors, 1 Cowles Road, Plainville, Conn. 06062, coupled to the system central processor 50 to monitor the level of the medium contained within each reservoir for proper dispensing of the medium contained therein. Alternatively, instead of actively monitoring the level of the medium in the reservoirs 35 a , 35 b and 35 c , the system central processor 50 could calculate the quantity dispensed and thereby derive the amount remaining, assuming that the initial amount supplied to these reservoirs is constant, or otherwise “known” by the system central processor. The system central processor 50 can be programmed, as illustrated in FIG. 3, to dispense one or more of the media from the reservoirs 35 a , 35 b and 35 c into the dilution manifold 34 in increments stepped to vary the intensity or concentration of the media in the dilution manifold in accordance with the input to the system central processor 50 through the keypad/display unit 100 . A water supply pressure feedback input 33 a is connected to the system control processor 50 from a check valve and pressure sensor 33 , available from Sensotec Inc. 2080 Arlingate Lane, Columbus, Ohio 43228, carried in the municipal or domestic water supply line to ensure that an adequate supply of domestic water 32 at a desired pressure is available for use in the dispensing system.
Referring now to FIG. 2, there is illustrated the informational inputs that a user enters into the system through operation of the keypad/display unit 100 to control operation of the system central processor 50 to perform the desired functions. Upon initial system power-up, the user manually enters the time and date through the keypad/display unit 100 which is coupled 102 to the system central processor 50 . This information, once coupled to the system central processor 50 , will be used by the processor to accurately maintain current time in a manner known to those skilled in the art, and displayed on the keypad/display unit 100 .
The user then enters information to place the system central processor in either an “Active” or “Standby” mode. If the “Standby” mode is selected, the system central processor 100 will be idle and the keypad/display unit 100 will display that the system is in the “Standby” mode awaiting further instruction. If the user elects to operate the system, the “Active” mode is selected, displayed, and the user may elect to have the system operated in either a “Manual” or “Program” mode. If the “Manual” mode of operation is selected, the user can either elect to have the system operate in a “Default” sequence or a “Specified” sequence of operation.
In the “Default” sequence of operation, the system central processor 50 will sequentially actuate the first medium dispenser 35 a which will continue to operate to depletion. Upon depletion a signal will be sent by the sensor 39 a to the system central processor 50 which will then actuate the next available medium dispenser, e.g.: 35 b , which will continue to operate to depletion. At that time the sensor 39 b will send a signal to the system central processor 50 which will actuate the next available medium dispenser until all of the medium has been dispensed, at which time the system central processor 50 will cause a message to be displayed on the keypad/display unit 100 that the dispensers are empty and the system has been placed on “Standby”.
If the user elects to choose a “Specified” sequence rather than the “Default” sequence, the user can input a particular order by which the media will be used to depletion, by entering instructions through the keypad/display unit 100 for the system central processor 50 to start with a first programmed medium dispenser and then proceed upon depletion to a second specified medium dispenser and upon the depletion thereof to proceed to another specified medium dispenser. However, regardless of which mode of operation the user selects, in either of these modes the user is required to set the intensity level of each of the media to be discharged from the dispenser 35 a , 35 b , and 35 c into the dilution manifold 34 . The manner in which the intensity parameters are input to the system central processor 50 is illustrated in FIG. 3 .
If the user chooses to operate the system in a “Program” mode, whereby individual medium and intensity parameters can be selected and set for individual days of the week, the user selects the “Program” option when the system “Active” display is presented.
Referring to FIG. 3, upon entering the “Program” mode the user is instructed to either accept or edit a previous program setting. If at this time the user elects not to enter the “Program” mode, an “Escape” instruction is provided which returns the user to the “Active” display whereby the system may be operated in the “Manual” mode or the user may return the system to the “Standby” mode. If, however, the user elects to proceed with the “Program” mode, the user must either “Accept” the previous program settings (or the factory settings if this is an initial installation) or select the “Edit” option if it is desired to make changes in the program previously entered. Throughout the operation in the “Program” mode, an “Escape” option is available to enable the user to return to the “Active” input level thereby cancelling all instructions entered to that point and the system returning to the previous program settings, or a “Menu Step Back” option is also available to permit the user to correct an entry error without losing the settings previously entered.
Upon selecting the “Edit” option, the user sequentially selects each day of the week to define the parameters of operation of the system for that day. These parameters include the time of program operation, identified as “Cycle 1”, “Cycle 2”, “Cycle 3” and “Cycle 4”. These times of operation are set for each day and may be individually accepted as presented previously, or edited. After the program cycle is selected, the particular medium, water vapor only or one of the media 35 a , 35 b , 35 c which is to be dispensed, may be chosen. The intensity level (concentration) of the selected medium which is to be dispensed may be selected as well as the time period selected for operation during the program cycle can be chosen and entered through the keyboard/display unit 100 into the system central processor 50 . This information is sequentially entered into the system central processor 50 through the keypad/display unit 100 for each day of the week.
Functional Description
Referring now to FIG. 4, the user inputs the initial information into the system central processor 50 through the keypad/display unit 100 in the manner previously described, selects the mode of operation and programs the system as desired. The temperature sensor 25 , humidity sensor 23 , flow sensor 21 , media sensors 39 a , 39 b , and 39 c , and water supply sensor 33 a all provide their respective input signals to the system central processor 50 . The keyboard/display 100 shows the status of the informational inputs. If the program cycle inputs, the operational sensor inputs and time of operation call for an activation of a dispensing sequence, dispensing operation is initiated and the keypad/display 100 shows that the system is dispensing as instructed. The selected media dispensing valve 36 a , 36 b or 36 c is opened the prescribed extent and duration. The water intake control valve 30 is opened allowing water and the selected medium to mix in the dilution manifold 34 . The dispensing control valve 38 is opened and the dispenser 16 is actuated for a time period determined by the parameters of the ambient air moving through the air duct 11 . The input from the ambient air flow sensors 21 , 23 and 25 coupled to the system central processor 50 prevent the system from dispensing media at a level beyond the capacity of the air stream flow to move the dispensed medium through the HVAC system.
While this invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, the structure of which has been disclosed herein, it will be understood by those skilled in the art to which this invention pertains that various changes may be made, and equivalents may be substituted for elements of the invention without departing from the scope of the claims. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed in the specification and shown in the drawings as the best mode presently known by the inventors for carrying out this invention, nor confined to the details set forth, but that the invention will include all embodiments, modifications and changes as may come within the scope of the following claims:
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A user-programmable monitoring and dispensing system for controlling the dispensing of water vapor and various other media into an HVAC air stream in residential or commercial structures. The various media to be dispensed are preferably water-soluble, and mixed with the system water supply to be dispensed with the water vapor added to the HVAC air stream. These materials may be fragrances or aromas, intended to produce an aesthetic effect, or they can be agents capable of pesticidal, bacteriacidal, fungicidal or sporacidal effect for use as acute or prophylactic treatment for infestation.
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BACKGROUND OF THE INVENTION
The present invention relates to the opener device of a spinning station of an open-end spinning machine, as well as to a device for the installation of a drive belt. DE-A 22 00 686 discloses an opener device which is assigned to a spinning station of an open-end spinning machine. The opener device has as its essential component an opener roller which is installed in a swivelling cover of the open-end spinning device. During maintenance of the spinning station this cover is opened whereby the opener roller is pressed with its drive wharve against a stationary brake when the swivelling movement is sufficiently wide and is thus braked. It is also provided for the tension roller of the belt drive of the opener roller to be pressed against a fixed component of the opener device by the swivelling motion and for the opener roller to be thus braked. The belt is then clampingly held between the tension roller and a fixed stop. The disadvantage of this device is that in case of wear on the wharve of the drive roller, the braking action is relatively weak, and that in the other case damage and wear on the drive belt and on the tension roller is possible. In both embodiments, it is a further disadvantage that the drive belt remains in the area of the drive disk, so that when the drive belt is replaced great care must be taken. The drive disk which continues to rotate represents a danger to the operating personnel with such a design of the device.
DE-A 21 1 619 discloses an embodiment of an opener device in which the opener roller is also driven by means of a belt drive. To brake the opener roller, the tension roller together with the driving belt is moved away from the drive disk, whereby a trunk of the belt presses against a braking edge which is rigidly attached to the spinning station. The disadvantage of the opener device described here is the fact that the device requires much space. Replacement of the drive belt is difficult because it cannot be relaxed. Furthermore, a tension roller that can be swivelled in this manner is very expensive.
Depending on the wear of the opener roller and of the drive belt and due to the replacement of the opening roller when processing a different output material at the spinning station, it is necessary to stop the opener roller in order to replace the above-mentioned components of the opener device. Furthermore, it is necessary that the opener device may be inspected without danger for maintenance purposes. In the state of the art provisions are made to stop the opener roller automatically through the opening of the cover of the spinning station. It is important here that no danger threaten the operating personnel here, not only during operation, but also during inspection and maintenance of the opener device. In the first place, it is necessary that the opener device be designed so that it can be stopped reliably and quickly. Endangerment by the other components of the opener device should also be kept as low as possible.
OBJECTS AND SUMMARY OF THE INVENTION
It is a principal object of the present invention to propose an opener device for a spinning station of an open-end spinning machine which avoids the disadvantages of the state of the art, by means of which the opener roller can be braked safely and quickly, and which is therefore considerably more maintenance-friendly and maintenance-safe.
Another object of the present invention is to propose a device for the installation of a drive belt of an opening device of an open-end spinning machine by means of which the maintenance of the opener device, in particular also the replacement of the drive belt on the opener device, can be carried out rapidly and above all safely by the operator.
Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the following description, or may be learned through practice of the invention.
The design of the opener device according to the invention makes it possible to stop the opener roller reliably and rapidly. Coasting of the opener roller after actuating the actuating element to stop the opener roller is only so brief that the opener roller has stopped before the operator can reach the opener roller. When the braking bolt intervenes into the running of the drive belt, the belt can be put under further tension so that a better braking action is made possible by avoiding belt slip. Furthermore, it is especially advantageous to push the pulling trunk of the drive belt back against its empty trunk, so that an especially good braking effect is achieved. During braking, the drive belt is lifted from the drive disk and the drive disk is simultaneously advantageously covered in part by the braking bolt so that when a worn drive belt is replaced, the new drive belt can be laid around the tension roller without risk that the operator will come into contact with the drive disk. Braking bolts are understood to be not only a bolt-shaped element within the framework of this invention, but also any suitable element, e.g. also a bent piece of sheet metal, an angular or ball shaped element, or a component of any other shape which can be moved towards the drive belt and is able to influence it in the sense of the invention. It is also possible to use a braking bolt supporting a roller and which presses against the drive belt with this roller. The braking action would thus be produced practically only by the rubbing of the two belt halves against each other. It is especially advantageous if the braking bolt is moved to the drive belt in the area between the drive disk and tension roller, because thereby the drive belt can be lifted quickly from the tension roller and the braking bolt is better able to cover the tension roller to prevent unintentionally touching it.
The further advantageous design of the invention makes it possible to relax the drive belt easily, so that it can be easily lifted from the drive wharve of the opener roller and can be controlled, or can simply be replaced in case of wear. This is possible without danger to the operator. To relax the drive belt, it is not necessary to reach within range of the rotating parts. Furthermore, the intervention to replace the opener roller can be done from the normal operator side of the spinning station, from which the spinning rotor is also accessible, for example. An intervention from the back of the spinning machine or from below the spinning machine is not necessary for this. The danger of over-stretching the drive belt does not exist either, since the tension roller need not be pulled over the belt in the relaxing direction but is controlled by means of the actuating element of the opener device according to the invention. In this process the drive belt is held by braking bolts and tension roller in position at the spinning roller, so that following the replacement of the opener roller, the belt is ready to be applied to the wharve of the new opener roller. When the drive belt is replaced, the newly installed belt is held on the tension roller as soon as it is laid on it, so that the further assembly steps can be carried out without danger that the drive belt may again slide from the drive roller. In this case the drive disk is advantageously covered by the braking bolt, since the braking bolt intervenes into the course of the drive belt between the tension roller and the drive disk.
It is especially advantageous if the braking bolt is installed on a deflection lever, since it can be supported precisely in this manner and the swivelling motion of the braking bolt can be coordinated precisely with the movement of the actuating element. It is advantageous to install the deflection lever on the tension roller support so that it is rotatable, because the movement of the braking bolt and of the tension roll are thereby automatically coordinated with each other. It is especially advantageous for the actuating element to attack at the deflection lever, because the arrangement can thereby be provided with an advantageous lever for the actuation of the braking bolt, whereby the connection is best made rotatable. It is especially advantageous for the opener device to be provided with a cover and for the latter to control the actuating element because this ensures that the opener roller is stopped automatically during maintenance of the opener device. Danger to the operating personnel is thereby totally excluded.
The tension element proposed is advantageously a spring which bears advantageously upon the tension roller support. It is especially advantageous for the tension element to attack at the deflection lever. In this manner the force of the tension element can easily be reduced from the operating position so that a load decrease on the drive belt is possible without great expenditure of force. The design of the actuating element in the form of an actuating lever has the special advantage that, not only traction, but also thrust forces can be transmitted. The rotatability of the deflection lever is advantageously limited by a stop, because thereby a precise geometric attribution of braking bolt, tension roller, and drive disk is ensured, in particular in a braking position. Preferably the opener device is designed so that the pivot point of the actuating element is located on the deflection lever and its center of motion on the tension roll support in braking position so that they are aligned substantially on one line. In this manner the opener device is especially simple in design. The relief of the belt from tension with special economy of force is possible if the tension element attacks at the deflection lever. It is especially advantageous to equip the opener device with a retainer for the positioning of a device for the installation of a drive belt. This makes it possible that auxiliary means can be connected to the opener device for the installation of the drive belt in order to render maintenance of the opener device safer and quicker.
The device according to the invention for the installation of a drive belt has the advantage that the drive belt is received by the device, so that the drive belt can be handled more easily. The drive belt is presented to the operator so that the installation can be carried out quickly, and above all without danger. The drive belt can in this case be removed step by step from the device. The belt is held securely between the different assembly steps. The device is especially advantageous if it has a positioning device. Thereby it can be put in exact position at the opener device so that the belt is presented precisely where it is needed to be installed. It is a further advantage that precise positioning makes it possible to cover up danger spots on the opener device with the device for the installation of the drive belt, so that during maintenance of the opener device there is no danger for the operating personnel. It is thus possible to cover the drive disk for the drive belt of the opener roller in such a manner that contact with the hand is practically impossible. At the same time, the handling of the drive belt is facilitated to such an extent that no special training is required to insert the belt. This means that even an untrained person is able to carry out the maintenance of the opener device without danger. It is especially advantageous to provide the device with an enclosed hollow space since it receives the drive belt securely and grasps the belt securely during the introduction of the device into the opener device. Thanks to the described, advantageous dimensions of the hollow space it is possible for the drive belt to be received securely and to be removed again easily to be installed in the opener device. Making the length of the hollow space of the device advantageously one half of the length of the drive belt makes it possible for the belt to be received over its entire length and for the device to advantageously have a length such that the drive disk can be covered by the device. This advantageous design of the device makes it possible to cover points of the belt drive which may be dangerous to the operating personnel. One half length of the drive belt is to be understood to be the dimension of one half of the circumference of a belt laid out into a circle. The especially advantageous design of the positioning device in the form of a stop makes it possible for the device to bear upon the wharve of the opener roller, so that the device can be introduced into the opener device, with no additional room needed for this, other than the space which must be available for the drive belt itself. The advantageous design of the stop in the form of an elastic clamp makes it possible for the device not only to be positioned but also to be fixed in the opener device during the installation of the belt. A further development of the device, with an opening to take out the drive belt at the end of the device which is turned towards the tension roller during the installation of the drive belt, makes it possible for the drive belt to be taken partially out of the device so that it can be placed next on the tension roller of the opener device. The remaining portion of the drive belt can then be taken out of the device in that the latter is pulled out of the opener device in the direction of the opener roller until the belt has left the device completely. In this state, the drive belt lies directly on the wharve of the drive roller on which it can then be installed by the operator.
The invention is described below through drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of an opener device in operating position, party in a section;
FIG. 2a shows the opener device of FIG. 1 in the braked position;
FIG. 2b shows a similar opener device with a deflection lever of different design;
FIG. 3 shows a device for the installation of a drive belt for an opener deice in a top view;
FIG. 4 shows the device of FIG. 3 in a side view;
FIG. 5 shows a device similar to FIGS. 3 and 4 installed in an opener device; and
FIG. 6 shows a section through a spinning station of an open-end rotor spinning machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. In fact, various modifications and variations can be made in the invention without departing from the scope or spirit of the invention. Additionally, the numbering of components is consistent throughout the application, with the same components having the same number.
The opener device of FIG. 1 is part of a spinning box of an open-end rotor spinning machine. But it could just as well be part of an open-end friction spinning machine. The individual fibers are taken out of the presented sliver by the opener device 1 in a known manner and are conveyed by a pneumatic fiber conveying system to an open-end spinning rotor, for example. The opener roller is covered in a known manner with a clothing consisting of teeth or needles and is rotated rapidly by means of a drive arrangement. The opener device 1 consists essentially of an opener roller 11, a drive disk 2, a drive belt 6 and a tension roller 3. It is installed on the machine frame 9 of a spinning machine. The opener roller 11 is provided with a shaft 14 on which it is mounted and driven. To drive the unit, a wharve 12 is installed on the shaft via which the drive belt 6 drives the opener roller 11. The drive belt 6 is held via a tension roller 3 on the drive disk 2 which is rotated by the drive of the spinning machine. The tension roller 3 is rotatably mounted on a tension roller support 31 and is loaded by means of a tension element 32 in such a manner that it is able to keep the drive belt 6 under tension. The tension element 32 may comprise a torsion spring in the present case, pressing the tension roller 3 in the direction of the frame pipe 91. The tension roller support 31 is mounted on the latter via a support 92. FIG. 1 shows the opener device in operating position in which the drive belt 6 is in contact with the drive disk 2. The rotation of the drive disk 2 is therefore transmitted to the wharve 12 by means of the belt 6 so that the opener roller 11 rotates at several thousand rpm's in its housing 13. The opener device 1 is provided on its left side which is accessible by the machine operator with a cover 7 which can be swivelled around the pivot point 71. This cover 7 can cover not only the opener device 1 in a known manner but, as is normal with rotor spinning machines, also the area of the rotor bearing and of the spinning rotor. To stop the opener roller 11, the opener device 1 is equipped with a brake 40 which is provided with a braking bolt 41. The latter is attached to a deflection lever 4 which is in turn mounted so as to be rotatable around the axis 42 on the tension roller support 31. The swivelling motion of the deflection lever 4 is delimited by the stop 43. In the final position of the swivelling motion of the deflection lever 4, the stop 43 presses against the tension roller support 31. To actuate the braking bolt 41, the deflection lever 4 is connected to an actuating element 5. The latter is made in the form of an actuating lever 51 which is rotatably attached to the deflection lever 4 by its one end. At its other end it is connected to the cover 7. The cover 7 is provided with a lever 72 which has a bolt 73. The bolt 73 enters into an oblong opening 53 of the actuating lever 51. For the manual actuation of the actuating lever 51, the latter is provided with a handle 52 at its end away from the tension roller.
FIG. 2a shows the opener device 1 of FIG. 1 with an open cover 7. Through rotation around the pivot point 71 executed by the cover 7 as it is swivelled, the lever 72 has also been swivelled around pivot point 71. As a result, the position of the bolt 73 has also changed in the direction away from the tension roller. Due to the limited mobility of the bolt 73 in the oblong opening 53 of the actuating lever 51, the latter has also moved to the left, so that the deflection lever 4 has been swivelled around its pivot point, i.e. axis 42. The braking bolt 41 is pressed on the drive belt 6 by this swivelling movement of the deflection lever 4 so that the drive belt 6 was lifted off from the drive disk 2. The latter is therefore no longer in contact with the drive belt 6. The swivelling movement of the deflection lever 4 is limited by the contact of the stop 43 against the tension roller support 31. The braking bolt 41 has come down on the drive belt 6 so that the empty trunk and the pulling trunk of the drive belt 6 touch each other in the area of the braking bolt 41. The braking action is thus not only produced by friction between the braking bolt 41 and the drive belt 6 but also by the friction of the drive belt 6 against itself. In the position shown in FIG. 2 the drive belt 6 continues to be held under tension by the tension roller 3, so that the drive belt 6 cannot slide off of the wharve 12 of the opener roller 11. The opener roller 11 is braked quickly and securely and is brought to a stop. When the cover 7 is being closed, the deflection lever 4 swivels back into the starting position shown in FIG. 1 so that the drive belt 6 is again brought into contact with the drive disk 2. The rotation of the drive disk 2 is transmitted via drive belt 2 to the wharve 12 of the opener roller 11 which is thereby caused to rotate again. The stop 43 ensures that the deflection lever 4 always swivels around axis 42 when the actuating lever 51 moves in the opposite direction arrow A in such manner that the braking bolt 41 is lifted up.
When the machine operator or the maintenance personnel opens the cover 7, the opener roller is stopped automatically so that no danger exists from a still rotating opener roller. After opening of the cover, the opener roller cannot only be inspected but can also be replaced. For this it is necessary to take the drive belt off the wharve of the opener roller. This is done especially easily and safely with the opener device according to FIGS. 1 and 2 because when the cover is open, the drive belt 6 can easily be relaxed by hand by the maintenance person. For this purpose the actuating lever 51 is provided with a handle 52. Upon grasping the handle 52, the maintenance person can pull the actuating lever 51 in the direction of the arrow A until the right end of the oblong opening 53 presses against the bolt 73. This causes the tension roller 3 to be swivelled in the direction of the opener roller, so that the drive belt 6 loses its tension and can easily be pulled from the wharve. The tension element 32, which is a torsion spring in this case, is designed so that it makes the additional movement of the tension roller 3 possible. When the drive belt 6 has been lifted from the wharve 12, the handle 52 of the actuating lever 51 can be released again so that the tension roller 3 swivels back into the position shown in FIG. 2. The bolt 73 is in this position again in contact with the left end of the oblong opening 53. The drive belt 6 remains practically unchanged in the area of the tension roller 3 because it moves down, under the effect of gravity, in the direction of the swivelled cover 7 after being removed from the wharve. At the same time it bears however on the retainer 89 so that the latter, together with the braking bolt 41, holds the drive belt 6 in the opener device 1. When the opener roller 11 has been replaced, the maintenance person can grasp the drive belt hanging below the wharve and, when the actuating lever 51 has again been pulled in the direction of arrow A, can lay the drive belt 6, which is not under tension in this operation, again around the wharve 12 of the opener roller. The actuating lever 51 is then released again so that the tension roller 3 puts the drive belt 6 under tension. During the subsequent closing of the cover 7, the opener roller 11 is again rotated in a known manner. The length of the oblong opening 53 is selected so that the actuating lever 51 can be pulled by the operator only so far in the direction of arrow A that the drive belt 6 is relaxed and can easily be removed from the wharve 12, and on the other hand that the tension roller 3 is not moved too far in the direction of the drive disk 2.
FIG. 2b shows a similar brake 40 as FIG. 2a, and also in braking position. Here however, the tension element 32 is in the form of a tension spring. The latter does not attack at the tension roller support 31 but at the deflection lever 4. The latter is rotatable around axis 42, as in FIG. 2a, and is thus connected to the tension roller support. The braking bolt 41 is made in the form of a hook in this embodiment.
In closing the cover 7, this is not done as in the description of FIG. 2a, with the assistance of the tension element 32, but against the force of the tension spring. As the actuating lever 51 moves in the direction opposite to arrow A, the deflection lever 4 is rotated in a clockwise direction, so that the tension spring is further tensed. During the operation of the opener device 1 the same tension force is exerted on the drive belt as in FIG. 2a. In operation the actuating lever 51 is here however under pressure, since the deflection lever 4 bears on the actuating lever 51. This embodiment of the invention has the advantage that in order to release the drive belt 6 by the operator by using handle 52, less force is needed than in the embodiment of FIG. 2a. since the drive belt of FIG. 2b has a lower tension during braking. This must be compensated for through other measures. In the present case the loop around the braking bolt is larger and furthermore the drive belt bears upon retainer 89.
FIGS. 3 and 4 show a device 8 for the installation of a drive belt in a top view and in a side view. The device 8 consists essentially of a basic body 81 and of the devices 82 for the positioning of device 8. For better handling, a handle 80 is attached to the device 8. The base body 81 consists here of a thin sheet metal, but other materials can also be used. The device has two narrow sides 84 and two wide sides 85, which together enclose a hollow space 83. This hollow space 83 has a height, measured from one of the wide sides 85 to the other wide side 85 which is approximately double the thickness of the drive belt which is to be installed by means of this device in an opener device. The width of the hollow space 83, measured from one narrow side 84 to the other narrow side 84 has approximately the same value as the width of the drive belt to be installed. The length of the device 8, measured between sides A and B has approximately the value of one half length of the drive belt. It is however also possible for this length to be slightly shorter, so that the drive belt peeks out in the form of a loop from opening 87 for taking out the drive belt. The belt is introduced into the hollow space 83 of the device 8 through opening 86 which is produced in that at least part of one of the two narrow sides is missing. For the introduction into the hollow space 83, the drive belt is pressed flat and the two belt segments laying on top of each other are then pushed sideways into the opening. The device 8 can be positioned in the opener device at the proper location by means of at least one device 82 for the positioning of same. The present embodiment shown in FIGS. 3 to 5 is equipped with two positioning devices 82, of which one is a stop 88 which interacts with the wharve of the opener roller on which the belt is to be installed. Both devices 82 are elastic clamps which attach themselves clampingly on a retainer for the positioning of the device 8 on the opener device. This fixes the device 8 and the maintenance personnel has both hands free to handle the drive belt. Device 8 has an opening 87 of the hollow space 83 from which the drive belt located in said hollow space 83 can be taken.
FIG. 5 shows a device 8 for the installation of a drive belt, installed in an opener device 1. The device 82 for the positioning of the device 8 located near the handle 80 engages the wharve 12 of the opener roller 11. The other device 82 for the positioning of the device 8 engages the retainer 89 of the opener device 1. The drive belt extends in the form of a loop 800 from the opening 87 through which it is to be taken out. When the device 8 has been installed in the opener device 1 it remains securely in its position due to the elastic configuration of stop 88 which surrounds the wharve 12 and due to the elastic configuration of the device 82 which surrounds the retainer 89. The operator is therefore able to take the loop 800 of the drive belt 6 out of the opening 87 and to lay it around the tension roller 3. When this has been done, the major portion of the drive belt 6 still remains in the hollow space 83 of the device 8 and is held securely by the latter. The operator is therefore able to grasp the device 8 by its handle 80 without any time pressure and to pull it out of the opener device 1 in the direction of arrow C. Thereby the remainder of the drive belt 6 leaves the hollow space 83 to the extent to which the device 8 is pulled in the direction of arrow C. Shortly before leaving the hollow space 83 the drive belt 6 can be grasped by the operator and applied immediately on the wharve 12, once the tension roller 3 has been swivelled in the direction of the opener roller by pulling on handle 52 of the actuating lever 51. Thereby the drive belt 6 can be applied to the wharve 12 without tension.
As can be clearly seen in FIG. 5, the drive disk 2 is covered towards the bottom by the device 8 so that the operator cannot come into contact with it. The device 8 can thus also serve as a protective cover of dangerous parts of the spinning machine. For this purpose it is then installed in the machine before the beginning of the maintenance tasks. These can then be carried out without danger. The advantageous presentation of the drive belt 6 by the device 8 has the advantage that the operator is able to apply the drive belt 6, without having to hurry, around the tension roller below the braking bolt 41 on tension roller 3. There is no danger that the drive belt 6 may get out of control since it remains for the entire time in the hollow space 83 of the device 8 and is held there. Due to the tension exerted by the loop 801 in proximity of handle 80 upon the inner side of the hollow space 83, the drive belt 6 fixes itself. The force with which the drive belt 6 is held in the device 8 can therefore be set through the height of the hollow space 83. Different heights of the hollow space 83 over the length over which the loop 801 is pulled out can even be adjusted for different take-out positions determining different take-out forces for the drive belt 6. As FIG. 5 clearly shows, the device 8 showed therein has a slight bend near the drive disk 2 so that the opening 87 may be positioned at the optimal location for the operator. In other embodiments of opener devices the device 8, in order to adjust it optimally for the current opener device, may be either completely straight or can be provided with one or several bends. This presents no problem, in particular in the bending direction of the installed drive belt.
FIG. 6 shows a section through a spinning box 100 of an open-end rotor spinning machine. From this drawing the relation of the opener device 1 to the other components clearly appears. The opener device 1 shown here does not have a brake; it is only a schematic drawing to explain the function of cover 7. In addition to the previously mentioned components of the opener device 1, such as opener roller 11, drive disk 2, drive belt 6, tension roller 3 which is attached via tension roller support 31 and support 92 to the frame pipe 91 of the machine frame 9 and cover 7, the spinning box 100 consists of additional known components. These are the rotor housing 101, which is shown here without the rotor cover attached to cover 7, and the rotor bearing 102 with its supporting rings 103. The rotor cover which covers the rotor housing 101 is attached to the inner portion 74 of the cover 7. When the cover 7 is swivelled away, the rotor cover is thus removed from the rotor housing 101, whereby the brake 104 is applied a known manner (not shown here) to the shaft of the spinning rotor. The different brakes (brake 104, brake 40 of the opener device) in the spinning box can be put into operation in this case simultaneously or consecutively and with different opening settings of cover 7.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features described or illustrated as part of one embodiment can be used on another embodiment to yield a still further embodiment. It is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents.
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An opener device in an open-end spinning machine includes an opener roller driven by a drive disk and a drive belt. A tension roller is movable between a first position wherein it exerts a driving tension force on the drive belt, and a second position wherein the tension roller exerts a lesser tension on the drive belt so that the drive belt can be removed from the device. A braking device includes a movable actuating element and a braking belt contacting member, such as a bolt, associated with the actuating element so as to be moved thereby. The actuating element and braking belt contacting member are movable between a first position wherein the braking belt contacting member is at a distance from the drive belt and a second position wherein the braking belt contacting member comes into the contact with the drive belt forcing the belt away from the drive disk.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/964,467, filed Dec. 26, 2007, and entitled “Open Drain Output Buffer for Single-Voltage-Supply CMOS,” which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to electronic circuits, and more particularly to an open-drain output buffer adapted to operate at relatively high voltages.
[0003] To realize manufacturing and economical leverages, topological geometries of semiconductor devices have been continually scaled downward across successive product generations. Supply voltages for semiconductors have correspondingly scaled downward, at least in part, to maintain consistent working voltages across materials, such as gate oxides. Historically a 0.35 micron (μm) technology has incorporated a 3.3 Volt (V) supply voltage and correspondingly, 0.18 μm and 0.13 μm technology generations have used 1.8 V and 1.2 V supplies, respectively. Maintaining consistent maximal operating voltages is necessary to avoid over-voltage conditions across electrical terminals that expose corresponding materials to electric field magnitudes that would cause material breakdown and device failure. The challenge of maintaining operating voltages within electrical limits of material properties comes at the input and output terminals of the semiconductor device. The input and output terminals are where an operating voltage region of a first device interacts with the voltage region of a second device. The device most challenged is the one operating in a lower voltage region. During electrical switching between the two operating voltage regions, the first device, operating at the lower voltage, experiences voltage from the second voltage region that may exceed operational voltage limits of the first device. During voltage excursions to the upper logic levels of the second device, over-voltage conditions in the first device are likely to cause exposed materials to fail.
[0004] Output buffers with open-drain pull-down transistors are typically used for attachment to common buses with other transistors (usually in another package). A single voltage supply point, perhaps with a pull-up resistor to a power source, provides the highest logic level required by any switching transistor on the bus. Output buffers with open-drain pull-down transistors are commonly fabricated in complementary metal oxide semiconductor (CMOS) processes. As an output terminal of an open-drain CMOS buffer turns off, pull-down transistors are switched off and buffer terminals remain in electrical connection with the output pad. An open-drain buffer of the first transistor (as above) experiences a high voltage level corresponding to an upper logic level voltage coming from the second transistor. The magnitude of the high logic-level of the second transistor, when applied to terminals of the first transistor may provide voltages that exceed the operating voltages and maximum sustainable voltages for particular materials in the first transistor. To avoid damage, the pull-down transistors have to be maintained in a semiconductor well provided with a voltage equal to the voltage provided by the second transistor and no gate oxide of a switching transistor may be exposed to a voltage causing failure of the gate. To avoid material breakdown, transistors exposed to elevated external voltages have been placed within a well provided with voltage near the switching voltage levels.
[0005] Typically, designers have found ways of providing a biasing voltage level to a substrate well encompassing a given switching transistor exposed to a relatively higher voltage region. Presuming that no explicit connection to the higher voltage region exists for the first transistor, a designer has been faced with utilizing some means of providing a path from the external voltage source to provide biasing to a well-region isolated from the well-regions operating at the native voltage-region level. Often the isolated or floating well-region is coupled to the output pad by a coupling transistor having a conductance characteristic provided and triggered by the elevated external voltage level. The coupling transistor provides an electrical path to the floating well providing the external voltage level as a well bias. This technique has been limited to a relative voltage level of about two times the operating voltage (VDD) of the first transistor. In order to provide a broader possible range of interface voltage interactions between semiconductor transistors, a means of allowing a greater range of disparity between voltage regions being switched to-and-from would be desirable. It would also be desirable to have a way of incorporating the voltage level of the external region and yet, still incorporate the floating well principle, and at the same time allow continued use of less expensive process technologies for the implementation of the interface transistor.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention is an open-drain output buffer for electrical communication with external voltage regions and associated signaling levels substantially greater than the native supply voltage level of the buffer. The buffer is disposed between a supply voltage terminal and a ground terminal. The output buffer has, in one embodiment, three transistors coupled in series from an output pad to ground. The three transistors may be NMOS transistors configured to electrically couple the output pad to the ground terminal. In order to withstand external voltage levels in excess of the native supply voltage level, output buffer transistors exposed to the elevated voltage levels are situated within the floating wells such that no gate oxide of any transistor, in the present embodiment, is exposed to greater than a predefined value, such as 1.2 V in some embodiment.
[0007] Well-bias selectors couple to an associated one of the floating wells and provide a reverse bias voltage to the associated floating well. For the floating wells including PMOS transistors, the corresponding well-bias selectors select a highest voltage available to provide a correct reverse bias level for the included transistors. Floating wells and well bias selectors may be, as in the present embodiment, cascaded in order that elevated voltage accommodation may be additive. Cascading allows the output buffer to withstand external voltages in excess of 2 times the native supply voltage level. In a similar yet complementary fashion the well-bias selector for the floating well including NMOS transistors is configured to select and provide a reverse bias voltage that is the lesser of two available voltages. Well bias selectors are connected to input terminals that range in voltage according to electrical signaling on the output pad. As a signal level present on the output pad transitions from a low level, such as ground potential, to a high-level voltage the well bias selectors alternate selection of input bias in order to maintain either the highest or lowest available voltage for reverse biasing the floating wells for PMOS or NMOS transistors respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic diagram of an output buffer according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0009] FIG. 1 is a schematic diagram of an open-drain output buffer 100 , in accordance with one exemplary embodiment of the present invention. Open-drain output buffer (hereinafter alternatively referred to as buffer) 100 is shown as including, in part, transistors 105 , 107 , and 109 disposed between output pad OUT and the ground terminal GND. Buffer 100 is also shown as including voltage dividers 130 , 145 , and bias selectors 110 , 112 , and 120 . As described further below, buffer 100 is adapted to receive relatively high voltages, e.g., 3.3 v, at output pad OUT while maintaining proper voltages, e.g., 1.2 v, between the terminals of each of the transistors disposed in buffer 100 . With reference to FIG. 1 , an output terminal of transistor 105 couples to output pad OUT in an exemplary embodiment of buffer 100 . Transistor 105 , transistor 107 , and transistor 109 couple in series between output pad OUT and ground terminal 102 . A gate input terminal of transistor 107 couples to supply-voltage terminal 101 . A gate input terminal of transistor 109 couples to input pad IN.
[0010] Voltage-divider 130 couples between output pad OUT and supply-voltage terminal 101 . Voltage-divider 130 includes transistors 140 a , 140 b , and output terminal 135 . Native transistors are used where a low threshold improves biasing response for voltage dividers or well-bias selectors (further described below). The lower threshold voltage ensures that the voltage divider or well-bias selector is enabled and provides a reverse bias voltage to an associated floating-well as soon as possible. Native transistors are shown including a diagonal pattern in channel regions. A source terminal of transistor 140 a couples to output pad OUT. A gate terminal and a drain terminal of transistor 140 a couple to output terminal 135 . A source terminal of transistor 140 b couples to output terminal 135 . A drain terminal of transistor 140 b couples to supply-voltage terminal 101 . Output terminal 135 couples to a gate terminal of transistor 105 .
[0011] Voltage-divider 145 couples between supply-voltage terminal 101 and ground terminal 102 . Voltage-divider 145 includes transistor 155 a , transistor 155 b , and voltage-divider-output terminal 150 . A drain terminal and a gate terminal of transistor 155 a couple to supply-voltage terminal 101 . A source terminal of transistor 155 a couples to voltage-divider-output terminal 150 . A drain terminal and a gate terminal of transistor 155 b couple to voltage-divider-output terminal 150 . A source terminal of transistor 155 b couples to ground terminal 102 . A bulk terminal of transistor 155 a and a bulk terminal of transistor 155 b couple to ground terminal 102 .
[0012] Well-bias selector 110 is coupled between output pad OUT and output terminal 135 . Well-bias selector 110 includes transistors 115 a , 115 b , and well-bias terminal 190 . A source terminal of transistor 115 a and a gate terminal of transistor 115 b couple to output pad OUT. A drain terminal of transistor 115 a and a source terminal of transistor 115 b couple to well-bias terminal 190 . A drain terminal of transistor 115 b and a gate terminal of transistor 115 a couple to output terminal 135 .
[0013] Well-bias selector 112 is coupled between output terminal 135 and supply-voltage terminal 101 . Well-bias selector 112 includes transistors 117 a , 117 b , and well-bias terminal 192 . A source terminal of transistor 117 a and a gate terminal of transistor 117 b couple to output terminal 135 . A drain terminal of transistor 117 a and a source terminal of transistor 117 b couple to well-bias terminal 192 . A drain terminal of transistor 117 b and a gate terminal of transistor 117 a are coupled to supply-voltage terminal 101 .
[0014] Transistor 160 is coupled between output terminal 135 and supply-voltage terminal 101 . A gate terminal and a source terminal of transistor 160 couple to output terminal 135 . A drain terminal of transistor 160 couples to supply-voltage terminal 101 .
[0015] Well-bias selector 120 couples between an intermediate output terminal 199 and voltage-divider-output terminal 150 . Well-bias selector 120 includes transistors 125 a , 125 b , and well-bias terminal 195 . A source terminal of transistor 125 a and a gate terminal of transistor 125 b are coupled to intermediate output terminal 199 . A drain terminal of transistor 125 a and a source terminal of transistor 125 b are coupled to well-bias terminal 195 . A drain terminal of transistor 125 b and a gate terminal of transistor 125 a are coupled to voltage-divider-output terminal 150 .
[0016] Resistor 170 couples in series with source 165 between output pad OUT and ground terminal 102 . Capacitor 175 is coupled between output pad OUT and ground terminal 102 . Diode 177 couples between well-bias terminal 195 and supply-voltage terminal 101 .
[0017] With continuing reference to FIG. 1 , floating-well 180 includes transistors 140 a , 115 a , and 115 b in the exemplary embodiment of the buffer 100 . Floating-well 182 includes transistors 140 b , 117 a , 117 b , and 160 . Floating-well 185 includes transistors 105 , 125 a , and 125 b . Floating-well 180 , floating-well 182 , and floating-well 185 delineate floating-well regions with corresponding transistors.
[0018] With continuing reference to FIG. 1 , source 165 represents an external voltage region that the buffer 100 may be electrically coupled to. In one embodiment, source 165 may be 3.3 V. The buffer 100 may be coupled to source 165 at a level of 3.3 V and yet ensure that no two terminals sustain more than 1.2 V when the external voltage equals 3.3 V. In particular, buffer 100 ensures that no gate oxide of any transistor is exposed to a voltage equal to or greater than 1.2 V. By maintaining a gate voltages at 1.2 V or less, gate oxide breakdown is avoided. By maintaining no more than 1.2 V across any oxide, stacking of a succession of transistors within floating wells allows the buffer to be attached to external voltage regions more than two times the magnitude of the supply voltage on supply-voltage terminal 101 . The magnitude of voltage on supply-voltage terminal 101 is, for example, 1.2 V.
[0019] Devices of the buffer 100 are, for example, all within a single semiconductor substrate and within a single native voltage region provided by the 1.2 V magnitude on supply-voltage terminal 101 . A plurality of the buffer 100 may be implemented within the same semiconductor and may be used to implement an output bus, for example. Other voltage regions may be available on a substrate where buffer 100 may be implemented. Buffer 100 alleviates the need for an additional voltage reference to be available on the same substrate. Electrical coupling to external voltages between 1.2 V and 3.3 V by buffer 100 are possible. An open-drain-output buffer, such as the buffer 100 , provides an electrical pull-down capability and relies on the voltage level provided by source 165 for logic levels at an elevated voltage.
[0020] As an input voltage, applied to input pad IN, varies from a low-level (i.e., about 0 V) to a high-level (i.e., about 1.2 V), transistor 105 , transistor 107 , and transistor 109 are activated (turned on) and pull output pad OUT to a low-level. On the other hand, as an input voltage to the buffer 100 varies from a high-level to a low-level, transistor 109 is deactivated and allows the voltage provided by source 165 to pull output pad OUT to a high-level. In this way, the buffer 100 is able to provide electronic signaling between to regions operating at different supply voltage levels (i.e., each voltage region with a corresponding supply-voltage VDD).
[0021] In continuing reference to FIG. 1 , when transistors 105 , 107 , and 109 are off, output pad OUT is at the external-voltage of source 165 . The external voltage is provided from output pad OUT to voltage-divider 130 at the source terminal of transistor 140 a . The gate terminal of transistor 140 b is at a second voltage-divider-output voltage level (not shown) provided on voltage-divider-output terminal 150 (discussed in further detail below). The second voltage-divider-output voltage generates an activating gate-source voltage on transistor 140 b . With an activated channel, transistor 140 b conducts current between output terminal 135 and supply-voltage terminal 101 . The gate terminal of transistor 140 a (which is coupled to output terminal 135 ) therefore provides an activating gate-source voltage on transistor 140 a . Transistor 140 a and transistor 140 b are activated and provide a voltage divider effect of external-voltage and supply-voltage VDD and generate a first voltage-divider-output voltage (not shown) on output terminal 135 . For an external-voltage of 3.3 V the first voltage-divider-output voltage may be about 2.1 V.
[0022] External-voltage is provided from output pad OUT to well-bias selector 110 at the source terminal of transistor 115 a . The gate terminal of transistor 115 a is coupled to output terminal 135 . Due to a voltage-divider effect generated by voltage-divider 130 (discussed above) on output terminal 135 , an activating gate-source voltage is provided to transistor 115 a . Transistor 115 a conducts and provides external-voltage to well-bias terminal 190 . By electrical coupling, well-bias terminal 190 provides external-voltage to floating-well 180 . Transistor 140 a receives a bulk terminal voltage from floating-well 180 . With the external voltage level provided to floating-well 180 and with the voltage-divider characteristic of voltage-divider 130 , none of the terminals of transistor 115 a , transistor 115 b , or transistor 140 a experience greater than a 1.2 V difference and thus no over voltage condition occurs.
[0023] With a 1.2 V level on supply-voltage terminal 101 and 3.3 V on output pad OUT, the voltage on output terminal 135 is about 2.1 V. Some variation in the magnitude of the voltage on output terminal 135 from the 2.1 V would occur due to voltage drops through conductive devices and electrical paths involved in the biasing as described.
[0024] With the gate terminal of transistor 115 b coupled to output pad OUT and therefore at the elevated external voltage level and with the source terminal of transistor 115 b coupled to the elevated external voltage level provided on well-bias terminal 190 , a deactivating gate-source voltage exists on transistor 115 b . With transistor 115 a on (conducting) and transistor 115 b off, well-bias selector 110 provides the higher level of the two voltages (i.e., external-voltage and a first voltage-divider-output voltage) to well-bias terminal 190 .
[0025] The first voltage-divider-output voltage is provided from output terminal 135 to well-bias selector 112 at the source terminal of transistor 117 a . The gate terminal of transistor 117 a is coupled to supply-voltage terminal 101 . Due to a voltage-divider effect generated by voltage-divider 130 (discussed above) on output terminal 135 , an activating gate-source voltage is provided to transistor 117 a . Transistor 117 a conducts and provides the first voltage-divider-output voltage level to well-bias terminal 192 . By electrical coupling, well-bias terminal 192 provides the first voltage-divider-output voltage level to floating-well 182 .
[0026] Transistor 140 b receives a bulk terminal voltage from floating-well 182 . With the first voltage-divider-output voltage (2.1 V) provided to floating-well 182 and the voltage-divider characteristic of voltage-divider 130 operative with the first voltage-divider-output voltage and supply-voltage VDD at 1.2 V, none of the terminals of transistor 117 a , transistor 117 b , transistor 140 b , or transistor 160 experience greater than a 1.2 V difference between them and thus no over voltage condition occurs.
[0027] With the gate terminal of transistor 117 b coupled to output terminal 135 and therefore at the first voltage-divider-output voltage level and with the source terminal of transistor 117 b coupled to the first voltage-divider-output voltage provided on well-bias terminal 192 , a deactivating gate-source voltage exists on transistor 117 b and the transistor is off. With transistor 117 a on (conducting) and transistor 117 b off, well-bias selector 112 provides the higher level of the two voltages (i.e., the first voltage-divider-output voltage and supply-voltage VDD) to well-bias terminal 192 .
[0028] Supply-voltage VDD is provided from supply-voltage terminal 101 to voltage-divider 145 at the drain terminal of transistor 155 a . The gate terminal of transistor 155 a is at supply-voltage level VDD. Supply-voltage level VDD generates an activating gate-source voltage on transistor 155 a and allows the channel of transistor to conduct. With an activated channel of transistor 155 a conducting between voltage-divider-output terminal 150 and supply-voltage terminal 101 , the gate terminal of transistor 155 b (which is coupled to voltage-divider-output terminal 150 ) provides an activating gate-source voltage on transistor 155 b . Transistor 155 a and transistor 155 b are therefore activated and provide a voltage divider effect of supply-voltage VDD and Ground GND to generate voltage-divider-output voltage (not shown) on voltage-divider-output terminal 150 . The device-threshold of transistor 155 a and transistor 155 b may be configured such that voltage-divider-output voltage is, for example, about 0.9 V for operation in a voltage region with supply-voltage VDD of 1.2 V and an external-voltage of about 3.3 V.
[0029] The second voltage-divider-output voltage level is provided to well-bias selector 120 at the drain terminal of transistor 125 b . As discussed above, the first voltage-divider-output voltage is about 2.1 V and is provided as the gate terminal voltage on transistor 105 . The intermediate output voltage therefore, may rise to a level about one NMOS device-threshold voltage below the first voltage-divider-output voltage or about 1.8-1.9 V. With the gate terminal of transistor 125 b coupled to the source terminal of transistor 105 and therefore at a voltage level equal to the intermediate output voltage level minus one NMOS device-threshold voltage and with the drain terminal of transistor 125 b at voltage-divider-output voltage, transistor 125 b is on. Transistor 125 b conducts and provides a low-level output voltage on voltage-divider-output terminal 150 to well-bias terminal 195 . By electrical coupling, well-bias terminal 195 provides the low-level voltage from voltage-divider-output terminal 150 to floating-well 185 . Transistor 105 receives a bulk terminal voltage from floating-well 185 .
[0030] With the gate terminal of transistor 125 a coupled to voltage-divider-output terminal 150 and therefore at voltage-divider-output voltage level of 0.9 V and with the source terminal of transistor 125 a coupled to the intermediate output voltage provided on intermediate output terminal 199 at about 1.8-1.9 V, a deactivating gate-source voltage exists on transistor 125 a and the transistor is off. With transistor 125 b on (conducting) and transistor 125 a off, well-bias selector 120 provides the lower level of the two voltages (i.e., voltage-divider-output voltage and the intermediate output voltage) to well-bias terminal 195 .
[0031] With voltage-divider-output voltage level provided to floating-well 185 and with the voltage-divider characteristic of voltage-divider 145 , none of the gate oxide related terminals of transistor 125 a , transistor 125 b , or transistor 105 experience greater than a 1.2 V difference between them and thus no over voltage condition on any of the gate oxides occurs. The drain terminal of transistor 105 is electrically coupled to external-voltage (3.3 V) on output pad OUT but is encompassed by voltage-divider-output voltage (0.9 V) provided to floating-well 185 . In this way, the drain terminal of transistor 105 is provided with a well-bias at the lower bias control voltage available through well-bias selector 120 . It is acceptable to subject a semiconductor junction within a transistor to a voltage difference greater than the magnitude of supply-voltage VDD, which for example is 1.2 V. Yet, the gate oxide of transistors; i.e. any gate-to-source, gate-to-drain, or gate-to-bulk connection; is not to be exposed to a voltage difference greater than 1.2 V, for example.
[0032] In continuing reference to FIG. 1 , with a high-level voltage applied to the gate terminal of transistor 109 and with the source terminal coupled to Ground GND, transistor 109 is on and conducts to a 0 V level on Ground GND. The drain terminal of transistor 109 and therefore the source terminal of transistor 107 are pull-down to 0 V. With the gate terminal of transistor 107 coupled to supply-voltage VDD, transistor 107 receives an activating gate-source voltage and conducts, pulling the drain terminal of transistor 107 to 0 V.
[0033] The gate terminal of transistor 140 b is at a second voltage-divider-output voltage level provided on voltage-divider-output terminal 150 (discussed above). With the source terminal of transistor 140 b at supply-voltage VDD on supply-voltage terminal 101 and the gate terminal of transistor 140 b coupled to voltage-divider-output terminal 150 , voltage-divider-output voltage generates an activating gate-source voltage on transistor 140 b . With an activated channel, transistor 140 b conducts and provides supply-voltage VDD from supply-voltage terminal 101 to output terminal 135 . Output terminal 135 provides supply-voltage VDD to the gate terminal of transistor 105 and transistor 107 conducting, provides 0 V to the source terminal of transistor 105 . Transistor 105 therefore, receives an activating gate-source voltage.
[0034] With a high-level voltage applied to the gate terminals of transistors 105 , 107 , and 109 , a low-level voltage of about 0 V is provided through transistor 105 , transistor 107 , and transistor 109 to output pad OUT. Note that with supply-voltage VDD the highest voltage provided, the source-drain definitions of the PMOS transistors reverse in a complementary biasing context. The low-level voltage is provided from output pad OUT to voltage-divider 130 at the drain terminal of transistor 140 a . The gate terminal of transistor 140 a (which is coupled to output terminal 135 ) therefore receives a deactivating gate-source voltage for transistor 140 a . With transistor 140 a off and transistor 140 b on, supply-voltage VDD is provided on output terminal 135 . Supply-voltage VDD is also provided to the gate terminal of transistor 105 , ensuring the device remains on.
[0035] With the gate terminal of transistor 115 b coupled to output pad OUT and therefore at the low-level voltage and with the source terminal (formerly the drain terminal in the previous complementary biased configuration) of transistor 115 b coupled to supply-voltage VDD on output terminal 135 , an activating gate-source voltage exists on transistor 115 b . Transistor 115 b conducts and provides supply-voltage VDD to well-bias terminal 190 . By electrical coupling, well-bias terminal 190 provides supply-voltage VDD to floating-well 180 . Transistor 140 a receives a bulk terminal voltage (i.e., the native VDD) from floating-well 180 .
[0036] The low-voltage level is provided from output pad OUT to well-bias selector 110 at the drain terminal of transistor 115 a . The gate terminal of transistor 115 a is coupled to output terminal 135 . With supply-voltage VDD on output terminal 135 , a deactivating gate-source voltage is provided to transistor 115 a and the device is off (nonconducting).
[0037] With supply-voltage VDD provided to floating-well 180 , none of the terminals of transistor 115 a , transistor 115 b , or transistor 140 a experience greater than a 1.2 V difference between them and thus no over voltage condition occurs. With transistor 115 b on (conducting) and transistor 115 a off, well-bias selector 110 provides the higher level of the two voltages (i.e., selects the first voltage-divider-output voltage instead of the low-level voltage) to well-bias terminal 190 .
[0038] With the gate terminal of transistor 117 b coupled to output terminal 135 and therefore at supply-voltage VDD and with the source terminal of transistor 117 b coupled to supply-voltage terminal 101 , a deactivating gate-source voltage exists on transistor 117 b and the device is off. With transistor 117 a off (nonconducting) and transistor 117 b off, well-bias selector 112 leaves well-bias terminal 192 floating.
[0039] The first voltage-divider-output voltage is provided from output terminal 135 to well-bias selector 112 at the drain terminal of transistor 117 a . The gate terminal of transistor 117 a is coupled to supply-voltage terminal 101 . With supply-voltage VDD on output terminal 135 , a deactivating gate-source voltage is provided to transistor 117 a , turning the device off.
[0040] With well-bias terminal 192 floating and supply-voltage terminal 101 and output terminal 135 both at supply-voltage VDD, the gate terminals of transistor 105 and transistor 107 are provided with activating gate-source voltages and conduction of both devices is assured.
[0041] Supply-voltage VDD is provided from supply-voltage terminal 101 to voltage-divider 145 at the drain terminal of transistor 155 a as described above. All connections and the operation of voltage-divider 145 remain as described above.
[0042] Well-bias selector 120 , transistor 125 a , and transistor 125 b provide a reverse-bias voltage on well-bias terminal 195 , which comes from either intermediate output terminal 199 or voltage-divider-output terminal 150 , whichever is lower. The well-bias and therefore bulk terminals of transistor 105 , transistor 125 a , and transistor 125 b are provided with the lowest potential these devices are exposed to on conducting channel terminals. When transistor 105 is turned on, intermediate output terminal 199 is close to GND, hence the well of transistor 105 is at GND also. When transistor 105 is turned off, intermediate output terminal 199 goes up to 1.8-1.9, hence the voltage on well-bias terminal 195 is equal to the voltage on voltage-divider-output terminal 150 , which is about 0.9. If transistor 105 is either on or off, all transistors in floating well 185 experience no more than 1.2 v across in the gate oxide.
[0043] An intermediate output voltage level, i.e., the low-level voltage, is provided from intermediate output terminal 199 to well-bias selector 120 at the source terminal of transistor 125 a . The gate terminal of transistor 125 a is coupled to voltage-divider-output terminal 150 . Due to a voltage-divider effect generated by voltage-divider 145 (discussed above) voltage-divider-output voltage generates an activating gate-source voltage on transistor 125 a allowing the device to conduct. Transistor 125 a conducts and provides the intermediate output voltage level (a low-voltage approximately equal to, for example, 0 V) to well-bias terminal 195 . By electrical coupling, well-bias terminal 195 provides the intermediate output voltage level to floating-well 185 . Transistor 105 receives a bulk terminal voltage from floating-well 185 . With the intermediate output voltage level provided to floating-well 185 and with the voltage-divider characteristic of voltage-divider 145 , none of the terminals of transistor 125 a , transistor 125 b , or transistor 105 experience greater than a 1.2 V difference between them and thus no over voltage condition occurs.
[0044] The Diode 177 coupled between well-bias terminal 195 and supply-voltage terminal 101 represents a junction formed by an n-type well that includes floating-well 185 . The n-type well is biased to supply-voltage VDD and isolates floating-well 185 from a common p-type substrate.
[0045] As in the various discussions above and with a 1.2 V level on supply-voltage terminal 101 and 0 V on ground terminal 102 , and the voltage on voltage-divider-output terminal 150 is about 0.9 V. Some variation in the magnitude of the voltage on voltage-divider-output terminal 150 from the 0.9 V would occur due to voltage drops through conductive devices and electrical paths involved in the biasing as described.
[0046] Various exemplary embodiments of switches have been given, where a switch has been presented, alternatively, as an NMOS or a PMOS transistor. As one skilled in the art will readily appreciate, further alternative embodiments of switches exist. For example switches within a semiconductor substrate may be fabricated as JFETs or IGFETs transistors for example. The exemplary embodiments referenced above should be incorporated for alternative means for implementing the embodiments and not seen as a restriction to interpretation of the present invention.
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An open-drain output buffer is operative to sustain relatively high voltages applied to an output pad. The open-drain buffer includes a number of floating wells, output switching devices and corresponding well-bias selectors to ensure that no gate oxide sustains voltages greater than a predefined value. PMOS and NMOS well-bias selectors operate to select and provide an available highest or lowest voltage, respectively, to bias corresponding well-regions and ensure no device switching terminals are electrically over stressed. As output related terminals experience switching related voltage excursions, the well-bias selectors select alternate terminals to continue selection of the respective highest or lowest voltages available and provide correct well-biasing conditions. Voltage dividers are incorporated to generate well-biasing control voltages. By electrical coupling across maximal voltages, the voltage dividers generate reference voltages that induce proper selection of well-bias voltages to the floating wells.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/445,285, filed Feb. 22, 2011, entitled BIKE LOCKING STATION, incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of securing movable goods in a variety of locations in a metropolitan, campus, or other proximal locations. In particular, the invention refers to an automatic parking station for cycles or bicycles, comprising at least one interactive workstation and a plurality of parking slots, in which parking stations are installed in a plurality of sites within a city or a limited geographical area and are electronically tied together through an interactive networked computing system.
BACKGROUND OF THE INVENTION
[0003] Statistics show that in many countries the fleet of cycles and bicycles owned by individual persons are relevant figures. To give some examples, in Italy and France the number of cycles and bicycles that are property of individual citizens amounts to more than 20 million in each country, meaning that there is one cycle or bicycle per 3.5 persons. Similar situations can be found, with some variations, in other countries such as Spain, United Kingdom and Germany. In the Netherlands, there is more than one cycle or bicycle per person.
[0004] According to the United States Census Bureau, there are over 8,000,000 people who call New York City their home. Of these 8,000,000 people, approximately one half of one percent utilize bicycles as a means of commuting around the city on a regular basis. This percentage is even lower if you count the numerous commuters and tourists who travel into New York City from the surrounding suburbs and elsewhere to work and play. Based on these figures, the New York City bicycle commuter market has a vast number of bicyclists. There is an increasingly growing wave of New York City's pro-bicyclist policies, including the enactment of recent laws compelling New York City parking garages, commercial buildings and certain residential buildings to designate spaces exclusively for bicycle parking and the installment of miles of newly created bicycle lanes throughout New York City. This immense fleet of privately-owned cycles and bicycles cannot be ignored when an automatic parking station is built for cycles and bicycles.
[0005] Automatic parking stations for cycles and bicycles installed in diverse sites within a city and connected via a centralized information system are generally known. For instance, U.S. Patent Application Publication Nos. 2007/0220933 (Gagosz) and US 2007/0239465 (Le Gars) disclose apparatuses for automatically renting bicycles. U.S. Patent Application Publication No. 2010/0245128 (Kanof) discloses an apparatus with unique identification tags for each bicycle that use its parking system.
[0006] The above prior art apparatuses suffer from some drawbacks, among which the most relevant one includes the fact that they are either closed systems, which are not suitable to serve a plurality of different users and operators, or provide little or no protection to the bicycle parked at the station in general, and to the wheels in particular.
BRIEF SUMMARY OF THE INVENTION
[0007] In one aspect, the present invention is directed to a system to secure a movable good, comprising: a plurality of securing units, each securing unit comprising: a shroud adapted to obstruct access to some or all of the movable good when the movable good is inserted into the shroud; and a first engaging mechanism within the shroud having a locked state and an unlocked state that, when locked, prevents the movable good from being moved; a server computer connected to a data network, comprising a web site; and a computing device that controls the state of the engaging mechanism and is communicably coupled to the server computer; wherein the server computer loads and runs a computer program into a memory of the server computer that causes the server computer to: receive identifying data from the user; verify the identity of the user based on the identifying data; determine whether the verified user has secured a movable good with the system; send a message to the computing device to unlock the engaging mechanism associated with the secured movable good; send a message to the computing device to indicate which securing unit should be used to secure the movable good; and send a message to the computing device to lock the first engaging mechanism associated with the indicated securing unit.
[0008] In another aspect, the system further comprises a data input interface connected to the server computer that receives identifying data from a user that uniquely identifies the user. In yet another aspect of the present invention, the data input interface comprises a smart phone, a laptop or a tablet computer connected to the server computer through the Internet. In yet another aspect, the server computer is further adapted to indicate a location of a plurality of securing units having at least one securing unit in which a movable good may be secured therewith to the user.
[0009] In another aspect of the present invention, the server computer is further adapted to reserve a securing unit in the plurality in response to a message from the user. In another aspect, the server computer is further adapted to select the location from a database based on least distance to a destination received from the user. In another aspect, the server computer is further adapted to hold the reservation for a limited period of time, based on a current position of the user and the estimated time to travel to the location.
[0010] In another aspect, the system further comprises a track adapted to guide the insertion and removal of the movable good into and out of the shroud.
[0011] In another aspect, the system further comprises a tamper sensor that provides a signal to the computing device indicating attempted movement of the secured movable good. In another aspect of the present invention, the computing device sends a warning message to the server computer in response to receiving the signal from the tamper sensor, and the server computer is further adapted to send a message to the user in response to the warning message from the computing device.
[0012] In another aspect, the present invention further comprises a video camera adapted to transmit an image of the plurality of securing units to the computing device and wherein the server computer is adapted to provide the image to a user having locked a movable good in one of the securing units within said plurality. In another aspect, the present invention further comprises a moving barrier, and wherein the first engaging mechanism engages the moving barrier, and wherein the shroud and the moving barrier, when engaged, together prevents a part of the movable good within the moving barrier and shroud from being removed.
[0013] In an alternative aspect, the present invention further comprises a ring attached to the movable good and wherein the first engaging mechanism engages the ring.
[0014] In another aspect, the present invention further comprises a second engaging mechanism without the shroud having a locked state and an unlocked state that, when locked, comes in contact with the movable good and prevents movement of the movable good and wherein the computing device is further adapted to lock and unlock the second engaging mechanism.
[0015] In another aspect, the present invention further comprises a third engaging mechanism without the shroud having a locked state and an unlocked state that, when locked, comes in contact with another movable good associated with the movable good, wherein the third engaging mechanism prevents movement of the another movable good, and wherein the computing device is further adapted to lock and unlock the third engaging mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a block diagram that illustrates a computer architecture of a preferred embodiment of the present invention;
[0017] FIG. 2 is a flow chart that illustrates steps taken by a control program implementing a reservation system;
[0018] FIG. 3 is a block diagram that illustrates various computer-readable media used to store the control program for a control website;
[0019] FIG. 4 is a top view diagram of an exemplary bike rack;
[0020] FIG. 5 is a perspective view diagram of a parking slot in a bike rack;
[0021] FIGS. 6 and 7 are side view diagrams respectively illustrating a front wheel locking mechanism embodiment of the present invention;
[0022] FIGS. 8 and 9 are top view diagrams illustrating an alternative front wheel locking mechanism embodiment of the present invention;
[0023] FIG. 10 illustrates another exemplary embodiment of a front wheel locking mechanism for the present invention; and
[0024] FIG. 11 illustrates an exemplary embodiment of a rear wheel locking mechanism of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] It is well-known that property, if left unattended, may be subject to vandalism. Especially in New York City, where the sheer number of people provide a challenge to law enforcement to prevent such crimes. While no system is foolproof against the devious nature of the criminal mind, measures can be taken to make such minor and often not prosecuted crimes such as theft and vandalism more difficult to commit. The present invention strives to do just that, in the context of providing a safe, economical and convenient means for bicycle parking.
[0026] The present invention may be described herein in terms of functional block components, code listings, optional selections and various processing steps. It should be appreciated that such functional blocks may be realized by any number of hardware and/or software components configured to perform the specified functions. For example, the present invention may employ various integrated circuit components, e.g., memory elements, processing elements, logic elements, look-up tables, and the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices.
[0027] Similarly, the software elements of the present invention may be implemented with any programming or scripting language such as C, C++, C#, Java, COBOL, assembler, PERL, Visual Basic, Python, CGI, PHP or the like, with the various algorithms being implemented with any combination of data structures, objects, processes, routines or other programming elements. The object code created for the computers can preferably be executed by any general purpose computer such as a personal computer having an appropriate operating system such as Windows™ or MAC™ and an appropriate browser such as Internet Explorer,™ Netscape™ or Safari.™
[0028] Further, it should be noted that the present invention may employ any number of conventional techniques for data transmission, signaling, data processing, network control, and the like.
[0029] It should be appreciated that the particular implementations shown and described herein are illustrative of the invention and its best mode and are not intended to otherwise limit the scope of the present invention in any way. Indeed, for the sake of brevity, conventional data networking, application development and other functional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical or virtual couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical or virtual connections may be present in a practical electronic data communications system.
[0030] As will be appreciated by one of ordinary skill in the art, the present invention may be embodied as a method, a data processing system, a device for data processing, and/or a computer program product. Accordingly, the present invention may take the form of an entirely software embodiment, an entirely hardware embodiment, or an embodiment combining aspects of both software and hardware. Furthermore, the present invention may take the form of a computer program product on a computer-readable storage medium having computer-readable program code means embodied in the storage medium. Any suitable computer-readable storage medium may be utilized, including hard disks, CD-ROM, optical storage devices, magnetic storage devices, and/or the like.
[0031] The present invention is described below with reference to block diagrams and flowchart illustrations of methods, apparatus (e.g., systems), and computer program products according to various aspects of the invention. It will be understood that each functional block of the block diagrams and the flowchart illustrations, and combinations of functional blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by computer program instructions.
[0032] These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means that implement the function specified in the flowchart block or blocks. The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions that execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart block or blocks.
[0033] Accordingly, functional blocks of the block diagrams and flowchart illustrations support combinations of means for performing the specified functions, combinations of steps for performing the specified functions, and program instruction means for performing the specified functions. It will also be understood that each functional block of the block diagrams and flowchart illustrations, and combinations of functional blocks in the block diagrams and flowchart illustrations, can be implemented by either special purpose hardware-based computer systems that perform the specified functions or steps, or suitable combinations of special purpose hardware and computer instructions.
[0034] One skilled in the art will also appreciate that, for security reasons, any databases, systems, or components of the present invention may consist of any combination of databases or components at a single location or at multiple locations, wherein each database or system includes any of various suitable security features, such as firewalls, access codes, encryption, de-encryption, compression, decompression, and/or the like.
[0035] The scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given herein. For example, the steps recited in any method claims may be executed in any order and are not limited to the order presented in the claims. Moreover, no element is essential to the practice of the invention unless specifically described herein as “critical” or “essential.”
[0036] Data Processing Architecture
[0037] FIG. 1 is a block diagram that illustrates a computer architecture of a preferred embodiment of the present invention. In a preferred embodiment, the system and method of the present invention are directed to a computing device at a parking station in communication with a server through the Internet. FIG. 1 discloses a wireless network 130 that provides data communications to mobile devices such as a laptop 115 or handheld cellular device 120 , as well as data connectivity to access points 131 . Bicycle racks 150 and 151 communicate through either wireless network 130 or the Internet 140 to a central server computer 160 . In more detail, with reference to FIG. 1 , because Internet 140 can provide a data communication path between various mobile computing platforms, such as a laptop 115 or a PDA or cellular telephone 120 provided through a wireless network 130 to the Internet 140 , a user is not limited to a desktop 110 with Internet connectivity to make a reservation, check the status of their bike, or receive messages concerning their bike from the central control website 160 . Bike racks 150 , 151 operate under the control of server computer 160 . As wired Internet connectivity may not be available to each bike rack, a rack 151 may be connected through a local area network 132 and a wireless access point 131 .
[0038] The server computer 160 comprises a memory 163 and a processor 165 that receives and processes users' reservation requests and maintains the status of each parking slot on bicycle racks 150 , 151 located throughout the network. In a preferred embodiment, software on desktop computer 110 , laptop 155 or handheld device 120 (collectively, the “client device”) comprises a Web browser, such as Internet Explorer,™ Netscape,™ Firefox,™ Safari™ or other Web browser, or a web-based application program pre-loaded into memory of the client device or is readily-available for download from the Internet into the memory. Such browsers or applications retrieve Web pages or data from a Web server 160 using the hyper-text transfer protocol (HTTP) in response to inputs on a user interface of the client device. Web pages are loaded into memory and then rendered on the display of the client device. In an alternative embodiment, a dedicated, client-based application is installed on client device, wherein such client-based application may use alternate communication protocols from HTTP.
[0039] Software on server computer 160 preferably comprises a Web server application. Web server application listens for TCP/IP (transport control protocol/Internet protocol) connections on a well-known port and receives standard HTTP (hyper-text transfer protocol) requests on that port that identifies particular URL (universal resource locator) that indicates Web pages and other information requested, typically by Web browser on the client device. Preferably, a Web server application comprises Apache and a collection of software modules that generate HTML (hyper-text markup language) Web pages.
[0040] In addition, server computer 160 may include a database stored in memory 163 that includes information related to the physical configuration and status of bicycle parking racks 150 , 151 , users, directions, locations, time and reservations. A database server application is run by processor 165 , is coupled to the database, and provides an interface to the information stored in the database to other application software modules that execute on server computer 160 . In a preferred embodiment, the database is a relational database, which includes a number of interrelated tables. Database server application is preferably an SQL (structured query language) server that accepts queries according to an SQL syntax and provides responses to those queries. Database server application can perform stored database procedures comprising complex queries stored in SQL syntax on server computer 160 . Such queries may involve multiple fetching processes from more than one table in the tables that comprise the database. Stored database procedures are stored in a file system in the memory 163 of server computer 160 .
[0041] Although FIG. 1 illustrates only one server computer 160 and a few client devices 110 , 115 , 120 in communication through networks 130 , 140 , it should be understood that different numbers of computers may be utilized, at the very least, one client device per user. In one example, the networks 130 , 140 may include a plurality of network computers and tens or hundreds of computers, all of which may be interconnected via the networks 130 , 140 . In alternate embodiments, the functions performed by server computer 160 are split among several server computers, for example, having components of Web server application executed on computers different from a database server application. Furthermore, these servers may be geographically separated and, for example, coupled through Internet 140 . In a preferred embodiment, a plurality of client devices are able to simultaneously connect to the server computer 160 . The communication links may be provided as a dedicated hardwired link or a wireless link. Although the communication links are illustrated as a single data link, they may comprise multiple data links.
[0042] The networked computers, client computer 110 and server computer 160 , may be provided in many different geographic locations including a home, different areas of the same city, or they may be located in different states or even countries. Networks 130 , 140 may include a plurality of network computers or server computers (not shown), each of which may be operatively interconnected. Where network 140 comprises the Internet, data communication may take place over communication links via an Internet communication protocol (UDP/IP or TCP/IP). Where the network 130 comprises a wireless network, data communication may take place over communication links via a wireless data protocol such as CDMA2000, W-CDMA or other 3G, 4G cellular or wifi technologies. Similarly, where the network communications comprise data, voice and video, communication may take place via an Internet communication protocol or a wireless protocol.
[0043] System Operation
[0044] The following discussion describes the methods performed by the inventive system. To provide context, the operation of an exemplary, preferred embodiment of a Web-based client/server application and a database server application are described. The description is based on that actions that the computers will perform when the applications are loaded and run.
[0045] Web pages served by server computer 160 may comprise at least two types of pages. One type are static Web pages, that are HTML format pages passed on by client/server application direct to a requesting Web browser without modification. The other type are dynamic or active server pages. An active server page includes a procedure specification that, when requested by a Web browser, is executed under the control of client/server application rather than being directly passed to the Web browser. Execution of the procedure specified by an active server page produces HTML formatted information that is passed by client/server application to a Web browser. In a preferred embodiment, active server pages can be generated by a Visual Basic language procedure, CGI scripts, or a procedure written in some other programming or scripting language such as java, perl, python or php, that are executed under the control of a client/server application running on server computer 160 .
[0046] Active server pages can include references to services provide by a database server application. For instance, a Visual Basic procedure in active server page accesses database server application through an API (application program interface) for the database server application. During execution of the stored procedure, client/server application can access data stored in a database in memory 163 . Active server pages can also include references to database procedures stored in memory 163 . Each stored database procedure includes one or more SQL statements. Client/server application invokes a stored database procedure during execution of an active server page. Database server application controls the execution of stored database procedure to provide data to client/server application. Together, static Web pages, active server pages, and stored database procedures provide the information to generate Web pages through which a user interacts with the system. Alternatively, a dedicated, client-based application can interact with server application directly, without use of a Web browser.
[0047] A database in memory 163 may include a number of separate tables. For example, a rack configuration table includes information related to the geographic location of each rack, the number of slots in each rack, and of those slots, which slots are occupied, which are available, and which are reserved. Like all tables in a database, the rack configuration table is dynamic in that it can be modified, for example, as more racks are added or removed from the system, more slots are added or removed from each rack, or when the status of each slot changes.
[0048] A database in memory 163 may also include a user table that includes information about the user, such as user authentication information, usage information, addresses, destinations, favorites, billing information or the like.
[0049] FIG. 2 is a flow chart that illustrates a preferred method for the various steps taken by a client/server application that is loaded from memory 163 and run by processor 165 in server computer 160 . As shown in FIG. 2 , in step 210 a user makes a reservation by operation of client device 110 , 115 , 120 to send a message to the server computer 160 . Preferably, server computer 160 will reserve an available slot in a bike rack 150 , 151 chosen by the user, and will hold the reservation for a limited period of time. More preferably, the period of time will be based on the location of the user, the location of the rack, and the expected time for the user to ride to the rack. Server computer 160 may reserve an available slot in an alternative bike rack if there are no available slots in the bike rack chosen by the user. In a preferred embodiment, server computer 160 will find an available slot in the nearest bike rack to the user's ultimate destination, to minimize the amount of walking distance that the user may have to traverse. Server computer 160 may even provide directions to the user to the rack in which a slot has been reserved.
[0050] In step 220 , the user arrives with his bicycle at a rack 150 , 151 where a slot has been held for him by the reservation. The user then supplies credentials to authenticate his identity at the rack 150 , 151 . Such authentication can take the form of a credit card swipe, a bar code read, entry of a personal identification number, facial recognition, communication of a unique identifier found in client device, such as MAC address, bluetooth ID, or the like, as is well-known in the art. In an alternative embodiment, the user may arrive at a rack 150 , 151 without a reservation, and then authenticate.
[0051] In step 230 , server computer 160 receives the authentication credentials, verifies the identity of the user, and checks the database stored in memory 163 to see if the user's bike is currently locked in a rack or not. If the bike is locked in a rack, processing proceeds to step 240 , where the server computer sends a message to the rack 150 , 151 , directing the rack to unlock the user's bike.
[0052] If the bike is not locked, then processing proceeds to step 250 , where server computer 160 commands the rack to indicate which slot the user should place his bike. The user then rolls his bike into the rack thereby securely locking the bike in the rack, preferably using one of the mechanisms described below.
[0053] In step 260 , the rack continually monitors a tamper sensor for the bike, and may also stream video back to server computer 160 continuously, or in the event of a tamper sensor activation.
[0054] In step 270 , if a tamper event has occurred, the rack 150 , 151 will notify server computer 160 of the event, which in turn may send a warning message to the corresponding user, as shown in step 280 . The user may then monitor the video feed via the website provided by server computer 160 .
[0055] Software on Media
[0056] In the specification, the term “media” means any computer-readable medium that can record data therein. FIG. 3 illustrates examples of recordable computer-readable media.
[0057] The term “media” includes, for instance, a disk shaped media for 301 such as CD-ROM (compact disc-read only memory), magneto optical disc or MO, digital video disc-read only memory or DVD-ROM, digital video disc-random access memory or DVD-RAM, a floppy disc 302 , a memory chip 304 such as random access memory or RAM, read only memory or ROM, erasable programmable read only memory or E-PROM, electrical erasable programmable read only memory or EE-PROM, a rewriteable card-type read only memory 305 such as a smart card, a magnetic tape, a non-volatile memory, also known as a hard disc 303 , and any other suitable means for storing a program therein.
[0058] A recording media storing a program for accomplishing the above mentioned apparatus may be accomplished by programming functions of the above mentioned apparatuses with a programming language readable by a computer 300 or processor, and recording the program on a media such as mentioned above.
[0059] A server equipped with a hard disk drive may be employed as a recording media. It is also possible to accomplish the present invention by storing the above mentioned computer program on such a hard disk in a server and reading the computer program by other computers through a network.
[0060] As a computer 300 , any suitable device for performing computations in accordance with a computer program may be used. Examples of such devices include a server, a personal computer, a laptop computer, a net-top computer, a microprocessor, a programmable logic device, or an application specific integrated circuit.
[0061] Hardware Architecture
[0062] FIG. 4 is a top view diagram of an exemplary bike rack. With reference to FIG. 4 , a bike rack 400 comprises a plurality of parking slots 410 and a computing device 420 for communicating with server computer 160 , receiving authentication data and supplying signals to lock/unlock each of the parking slots, and to provide indications 430 as to the status of the parking slots. A camera 440 is communicatively coupled to computing device 420 . Bike rack 400 may contain a URL or a bar code providing Web navigation for a user of a handheld client device to interact with the server computer 160 , so that a user interface to computing device 420 will not be required. Computing device 420 may interface with a card reading device for payment by credit card, debit card, smart card or a discount card, bar code reader, or the like well-know in the art to allow the system to provide user access and payment for parking privately owned bicycles, or rent bicycles parked in the slots for that purpose. Discount cards may include cards provided by local merchants as a perk to their customers, similar to validated automobile parking.
[0063] The user will be able to view streaming, up-to-the-second video of their secure bicycle through protected camera 440 that is integrated into the bike rack 400 . Access to such streaming video will only be permitted to users who currently have their bike parked in the corresponding bike rack. In a preferred embodiment, server computer 160 may provide an application for download that will allow users to record and store images of parked bicycles in their client device 110 , 115 , 120 .
[0064] FIG. 5 is a perspective view diagram of a parking slot 500 in a bike rack 400 . Illustrated in FIG. 5 are indicators 510 , helmet lock 520 , shroud 530 , track 540 , and tamper sensor 550 . Indicators 510 may include: (i) a green light indicates that such parking slot is available for parking, (ii) a yellow light that indicates the parking slot is reserved, (iii) a flashing yellow light that indicates that a given reservation is set to expire in a short time period, and (iv) a red light that indicates that a bicycle is currently secured in that slot.
[0065] Helmet lock 520 provides a latching mechanism to secure the user's helmet. Helmet lock 520 provides the user with the ability to slide the “Y” portion of the helmet strap in the slot (which is just wide enough to fit the size of the strap) so that the portion of the Y strap that is attached to the helmet is resting on the base of the slot. Once the bicycle is locked in the parking slot 500 , a retractable pin located in the slot will deploy through the center of the portion of the Y strap that is attached to the helmet, locking the helmet's strap within the slot. The pin will retract, unlocking the Y strap from the slot when the user unlocks their bicycle from parking slot 500 .
[0066] In an alternative embodiment, slot 500 may further comprise a compartment (not illustrated) where the user's helmet may be placed. Helmet lock 520 will provide access to the interior of the compartment, and can be locked and unlocked in the same fashion as described above.
[0067] Shroud 530 protects the front wheel of the bicycle, as described below. Track 540 helps the user guide the bicycle into the proper position to park and secure the bicycle.
[0068] As an additional security measure, each slot is equipped with an anti-theft tamper sensor 550 that provides a signal to the computing device 420 . Tamper sensor 550 may be infrared, ultrasonic, pressure, contact, or any other device or mechanism well-known in the art to detect movement, attempted forced removal or component theft of the bicycle. Computing device 420 may, in turn, (i) instantaneously notify a garage attendant, doorman or passerby located at the site of the triggered anti-theft sensor of any unauthorized movement of a user's bicycle from its parking slot; (ii) send a notification via email to that certain user, notifying him or her that their bicycle has been tampered with; (iii) sound an audible alarm; or (iv) send a message to law enforcement authorities. Tamper sensor 550 may be so displaced as to be sensitive to movements occurring in a volume around a parking slot that is suitable to fully include one bicycle. Computing device may automatically activate or deactivate any notifications based on parking activity in an adjacent slot.
[0069] FIG. 6 is a side view diagram illustrating a front wheel locking mechanism embodiment of the present invention. FIG. 6 discloses a track 610 , a boomerang-shaped lever arm 620 , that pivots on a toggle bolt or shaft 630 , a shroud 640 , and a releasable latching mechanism 650 . As shown in FIG. 4 , the user can push their bicycle along track 610 such that the front wheel comes in contact with the top of boomerang 620 so that boomerang 620 pivots upward around shaft 630 . As the wheel is moved into shroud 640 , the back of boomerang 620 is designed to capture the rear of the front bike tire, thereby preventing the bike from being removed from shroud 640 . When the front wheel is fully inserted, the front of boomerang 620 will engage latching mechanism 650 , thereby preventing boomerang 620 from pivoting, as illustrated in side view diagram, FIG. 7 . Boomerang 620 , in cooperation with shroud 640 , encapsulates the front tire and forks of the user's bike. When the bike is unlocked, latching mechanism 650 releases boomerang 620 to permit the user to withdraw his bike from shroud 640 along track 610 .
[0070] FIGS. 8 and 9 are top view diagrams illustrating another locking mechanism embodiment of the present invention. FIG. 8 illustrates a shroud 810 , blocking plate 820 , pivot 830 , and latch 840 . Blocking plate 820 is attached to pivot 830 , and rotates within shroud 810 about the axis of pivot 830 . Latch 840 comprises a magnetic lock or other electro-mechanically release mechanism that connects to blocking plate 820 , and securely prevents blocking plate from counter-rotation until unlocked.
[0071] In operation, the user pushes their bicycle on a track such as described above, allowing the front wheel to enter shroud 810 . Once the front tire of the bicycle is fully inserted into shroud 810 , the user will turn the wheel of the bicycle, which will rotate blocking plate 820 . Latch 840 latches onto blocking plate 820 , thereby encapsulating front tire within the shroud and preventing rotation of the front wheel from the locked position, as illustrated in FIG. 9 .
[0072] FIG. 10 illustrates another exemplary embodiment of a front wheel locking mechanism for the present invention, comprising a ring 1010 and a latching mechanism 1020 . Ring 1010 is preferably mechanically secured at a predetermined height above the ground to the front fork of a bicycle. Such securing can be accomplished with materials commonly known in the art, such as a pipe clamp and a fastener, welding, or the like. Latching mechanism 1020 , located within shroud 1030 , engages ring 1010 the user guides bicycle along track 1040 , and prevents the removal of the bicycle until latching mechanism 1020 is unlocked, as described above.
[0073] FIG. 11 illustrates an exemplary embodiment of a rear wheel locking mechanism for the present invention. FIG. 11 illustrates a plurality of hydraulic pins 1110 and a track 1120 . Track 1120 is similar to track 610 described above. When the user engages the front wheel locking mechanism of the present invention, hydraulic pins 1110 are advanced to block the rear tire of the bicycle from moving out of the track or passing beyond hydraulic pins 1110 . When the user unlocks the bicycle, hydraulic pins 1110 retract, thereby releasing the rear tire.
[0074] Having thus described at least illustrative embodiments of the invention, various modifications and improvements will readily occur to those skilled in the art and are intended to be within the scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto.
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An automatic parking station for bicycles is disclosed comprising at least one interactive workstation and a plurality of parking slots, in which parking stations are installed in a plurality of sites within a city or a limited geographical area and are electronically tied together through an interactive networked computing system. The station features countermeasures to prevent vandalism of the locked bicycle. The computing system provides the ability for users to reserve spaces and directs users to their reserved space.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to European application No. 12157175.6 filed on Feb. 27, 2012, the whole content of this application being incorporated herein by reference. Should the disclosure of any patents, patent applications, and publications which are incorporated herein by reference conflict with the description of the present application to the extent that it may render a term unclear, the present description shall take precedence.
TECHNICAL FIELD
[0002] The present invention relates generally to the field of nanoparticle-filled polymer composites, more particularly to a process for producing graphene filled polymer nanocomposites.
BACKGROUND ART
[0003] Fillers for polymers may be inert materials that are incorporated to reduce resin cost and improve the processability or other properties of the base polymer. Over the past decade, there has been a growing interest in the development of nanoparticle-filled polymer composites, which were found to have superior mechanical, thermal, and/or conductive properties compared to the base polymer and therefore adapted for a wide range of industrial uses. Moreover, some of these polymer-filler composites were also used for certain sealant parts or fluid lines, due to the good barrier properties imparted by the nanoparticle fillers.
[0004] Different nanoparticle fillers, due to its own particular properties, will affect different properties of the base polymer. For instance, carbon black fillers are widely used in the negative electrode materials to enhance their conductivity property, and nanoclay-filled polymer composites generally provide an improved resistance to flammability.
[0005] In this regard, as reported in documents US 2010/0096595 and US 2010/0096597 (both assigned to The Trustees of Princeton University), graphene sheets (thin layers with a 2-dimensional nanostructure of carbon atoms) can be incorporated into a polymer matrix to form a graphene-filled polymer composite with exceptional gas barrier properties. According to US 2010/0096595 and US 2010/0096597, said graphene-filled polymer composite was prepared by mixing functional graphene sheets (FGS) within the polymer matrix using one of the three methods: a) extrusion process at an elevated temperature; b) solution mixing: separately disperse FGS and polymer in a polar organic solvent (e.g. tetrahydrofuran), combine the two organic solutions, and leave the mixture to the open air for solvent evaporation; and c) solution shear mixing for making FGS/PDMS (polydimethylsiloxane) composites.
[0006] Document US 2011/0114189 (VORBECK MATERIALS CORP.) May 19, 2011 discloses a FGS-polymer composite material which, due to its superior fuel permeation resistance and other mechanical properties, meets the requirements of many fuel system components. According to US 2011/0114189, said FGS-polymer composite is made by any suitable melt-mixing method, such as using a single or twin-screw extrude, a blender, a kneader, or a Banbury mixer.
[0007] Nevertheless, several problems remain in the existing processes for making desired graphene-polymer nanocomposites. In particular, the traditional heat-melt extrusion technique to mix graphene and polymer as suggested in the above-cited documents is inapplicable to heat-sensitive materials, and is known to require a high energy input.
[0008] Moreover, the aforementioned solvent mixing method produces each graphene-polymer nanocomposite using a substantial amount of organic solvent, which is later evaporated to the atmosphere and therefore not environmental friendly. As for the solution shear mixing technique described earlier, although it is generally considered a more suitable approach than extrusion and solution mixing technique for processing highly viscous filler-polymer mixture, it faces a challenge in generating a product with a satisfactory particle-size distribution in a cost-effective manner.
[0009] Another noted limitation of the afore-discussed mixing processes is that, while these processes normally start with a mixture where graphene fillers are sufficiently scattered in the base polymer, graphene coalescence tends to occur in a later processing stage which involves solvent drying or heat melting. Solvent mixing or heat-melt extrusion mixing also do not orient the FGS platelets within the mixture, as noted in documents US 2010/0096595 and US 2010/0096597. Consequently, the products of the afore-discussed processes are not “true” nanocomposites with advantageous properties expected for a nanoscale material, nor materials with exceptional barrier properties—which are characteristic properties of composites having well-dispersed fillers in the base polymer.
[0010] Therefore, there remains a need to develop an environmental friendly technique for producing “true” nanocomposites of various graphene-filled polymers, without using an organic solvent or relying on heat-melt extrusion to mix polymer and graphene.
SUMMARY OF INVENTION
[0011] The Applicant has surprisingly found that, through an aqueous colloidal suspension route, graphene-filled polymer (GFP) nanocomposites can be produced without using an organic solvent or heat-melt extrusion for dispersing graphene into the base polymer.
[0012] Specifically, the present invention resides in a process for producing a composition comprising graphene and at least one polymer, the process comprising the steps of: (i) providing an aqueous suspension of graphene [dispersion (G)]; (ii) mixing the dispersion (G) with an aqueous polymer latex to obtain a liquid mixture [mixture (M)]; and (iii) co-coagulating the mixture (M) to obtain said composition. The expression “aqueous” in the context of the present invention means dispersed or dissolved in water. The “aqueous suspension” in the context of the present invention refers to a suspension in which water is the major liquid component, or a suspension in which water is the only liquid component.
[0013] The Applicant has found that, using the process of the present invention, it is possible to obtain GFP nanocomposites where graphene fillers are advantageously well dispersed in the base polymer. Moreover, films made from the graphene-filled polymer nanocomposite product of the present invention have advantageously shown excellent barrier properties, indicating a nearly homogenous and sufficiently scattered filler distribution in the base polymer.
[0014] This novel process of the present invention for producing GFP nanocomposites is not limited to the application for heat-insensitive polymers, does not require a subsequent grinding step, and is therefore more efficient and energy-saving compared to the traditional heat melt extrusion technique. Moreover, compared to the solvent mixing process, the aqueous mixing process of the present invention does not use toxic or otherwise polluting organic solvent(s) and is therefore more environmental friendly. Additionally, as a further advantage, the process of the present invention noticeably minimizes the coalescence of graphene like fillers in the final composite by avoiding heat melt extrusion and solvent evaporation, and therefore could provide GFP composite materials with superior barrier properties.
[0015] For the purpose of the present invention, the term “graphene” is used to encompass both pristine, non-oxidized graphene and its oxidized form, and the term “graphene oxide” is intended to denote the oxidized graphene of which the oxygen content ranges from 1% to 90% by weight. The graphene used for the present invention can be produced by the reduction of delaminated graphite oxide by chemical methods, thermal methods, and ultraviolet-assisted methods. Graphite oxide is a layered material which can be prepared by oxidizing graphite in the presence of strong acids and oxidants. The graphene derived sheets in graphite oxide thus prepared are largely oxidized and bear a large number of hydroxyl and epoxide functional groups on the basal planes, which are strongly hydrophilic. The level of oxidation in the graphene derived sheets in graphite oxide can be varied based on the reaction condition, the oxidization method, and the precursor graphite used.
[0016] According to a preferred embodiment, the process of the invention comprises a step (i) of providing an aqueous suspension of graphene [dispersion (G)], wherein the graphene is graphene oxide. The graphene oxide used in the present process invention typically has an oxygen content of between 1% and 90% by weight, preferably between 10% and 80% by weight, more preferably between 30% and 60% by weight, and most preferably between 45% to 55% by weight. In a preferred embodiment of the present invention, the graphene oxide used has a hydrogen content of 0.1% to 50% by weight, preferably 1% to 10% by weight, and more preferably 2% to 4% by weight.
[0017] Any method known in the art can be followed in step (i) for providing the aqueous suspension of graphene [dispersion (G)], wherein the graphene is graphene oxide. According to a first embodiment of the present invention, step (i) comprises dispersing a graphene oxide in an aqueous medium. For example, step (i) may be carried out by directly dispersing graphene oxide powder in water by mechanical means, such as under stirring or sonication. The graphene oxide powder can be directly obtained from a commercial source or produced in a laboratory by conventional technologies known in the art.
[0018] According to a second embodiment of the present invention, step (i) comprises subjecting an aqueous suspension of graphite oxide to sonication or, alternatively, stirring the graphite/oxide mixture in the aqueous suspension of graphite oxide, to obtain an aqueous suspension of graphene oxide. The purpose of the sonication or stirring treatment in step (i) of the aforementioned second embodiment is to at least partially exfoliate the graphite oxide in the aqueous medium. Therefore, the sonication or stirring treatment in step (i) of the aforementioned second embodiment can also be conveniently replaced by other exfoliation means known in the art, to obtain the aqueous suspension of graphene oxide.
[0019] For the purpose of the present invention, “exfoliation” of graphite oxide means delaminating graphite oxide into individual graphene oxide sheets. Graphite oxide can be obtained by oxidation of graphite salt, either with strong oxidizing agents or electrochemically, wherein the graphite salt can be nitrate salt or bisulfate salt. Examples of said strong oxidizing agents include potassium chlorate, permanganate, bichromate, chlorine dioxide, and combinations thereof; potassium permanganate is preferred. The graphite oxide used for the present invention typically has an oxygen content of at least 5% by weight, preferably has an oxygen content of at least 20% by weight, and more preferably has an oxygen content of at least 30% by weight. The graphite used for the present invention typically has an oxygen content of less than 2% by weight, preferably less than 1% by weight.
[0020] A preferred method for providing the aqueous suspension of graphene oxide in step (i) includes the following steps:
[0000] (i-a) mixing graphite with a concentrated sulphuric acid;
(i-b) introducing at least one oxidizing agent to the mixture obtained in (i-a) to obtain over-oxygenated graphite salts;
(i-c) adding water to the over-oxygenated graphite salts in step (i-b) to obtain a first graphite oxide suspension [S1];
(i-d) removing metallic and non-metallic ions from the first graphite oxide suspension [S1] to obtain a second graphite oxide suspension [S2]; and
(i-e) subjecting the second graphite oxide suspension [S2] to sonication or, alternatively, stirring the graphite oxide/water mixture in the suspension [S2], to obtain the aqueous suspension of graphene oxide.
[0021] For the purpose of the present invention, the “concentrated sulphuric acid” denotes a water solution of H 2 SO 4 having a concentration of at least 80 wt %, preferably ranging from 85 to 98 wt %, more preferably from 89 to 98 wt %, and most preferably from 95 to 98 wt %. The molar ratio between the sulphuric acid and graphite in step (i-a) typically ranges from 3 to 15, preferably from 4 to 10, and more preferable from 5 to 8. Step (i-a) is carried out either by adding the graphite to the concentrated sulphuric acid or, more preferably, by adding the concentrated sulphuric acid to the graphite. Typically, the mixing of graphite with sulphuric acid in step (i-a) is carried out by stirring or sonication, for a residence time ranging from 10 minutes to 24 hours, preferably from 30 minutes to 18 hours. Moreover, to remove the heat generated by the mixing process, step (i-a) is typically carried out in a reactor equipped with a cooling device, which is typically set to a temperature ranging from −20° C. to 25° C. Preferably, the step (i-a) is carried out in a reactor equipped with at least one baffle, to avoid vortex generation during mixing.
[0022] In step (i-b), the oxidizing agents used can be selected from a group consisting of potassium chlorate, permanganate, bichromate, chlorine dioxide, and combinations thereof. In a preferred embodiment, the oxidizing agents used may be a combination of potassium permanganate and sodium nitrate, with the weight ratio of potassium permanganate to graphite used in step (i-a) typically ranging from 3.0 to 6.0, preferably 4.0 to 5.0, and more preferably 4.2 to 4.6, and the weight ratio of sodium nitrate to graphite used in step (i-a) typically ranging from 0.5 to 1.5, more preferably ranging from 0.6 to 1.2, and most preferably from 0.7 to 0.8. Moreover, the oxidizing agent is preferably introduced to the mixture obtained in (i-a) while maintaining vigorous agitation. The reaction temperature in step (i-b) is preferably controlled with the range of from 10° C. to 50° C., more preferably from 20° C. to 40° C., and most preferably from 20° C. to 35° C., by means of an external cooling device and/or adjusting addition speed of the oxidizing agent. Preferably, the reaction in step (i-b) is carried out while being prevented from visible radiation. The residence time of step (i-b) is typically from 30 minutes to 48 hours, preferably from 7 hours to 24 hours, to obtain over-oxygenated graphite salts.
[0023] In step (i-c), the water added to the over-oxygenated graphite salts obtained in step (i-b) is preferably deionized water. Due to the exothermic nature of the water dilution process for the over-oxygenated graphite salts, the temperature of the reaction medium in step (i-c) is typically controlled under 80° C., preferably from 30° C. to 70° C., more preferably from 40° C. to 60° C., by means of an external cooling device and/or adjusting the water addition rate. Optionally, an amount of hydrogen peroxide is added to the water-diluted graphite oxide suspension [S1], prior to step (i-d), to reduce the residual permanganate and manganese dioxide to manganese sulphate in the suspension [S1], wherein the amount of hydrogen peroxide to the graphite used in step (i-a) typically ranges from 1.5:1 to 10:1 by weight. Also optionally, a neutralizing agent such as anhydrous sodium bicarbonate is added into the water-diluted graphite oxide suspension [S1], prior to step (i-d), to give a pH of 6.0-8.0, preferably 6.5-7.5, and more preferably 6.8-7.2 in the graphite oxide suspension [S1].
[0024] Optionally, steps (i-a) to (i-c) are advantageously carried out under an inert atmosphere, e.g. under a nitrogen atmosphere.
[0025] Step (i-d) can be conveniently carried out by dialysis, preferably dialysis with deionized water, to remove metallic and nonmetallic ions (including acid contaminant) with deionized water, so as to obtain a second graphite oxide suspension [S2].
[0026] The purpose of step (i-e) is to at least partly exfoliate graphite oxide in the suspension [S2]. Therefore, in operation, step (i-e) can be conveniently replaced by other exfoliation means known in the art, to obtain the aqueous suspension of graphene oxide.
[0027] According to another variant of the aforementioned embodiment, the aqueous suspension of graphene oxide provided in step (i) is manufactured via a method comprising the following steps:
[0000] (i-A) dispersing graphite oxide having an oxygen content between 5% and 30% in an aqueous solution of sulphuric acid having a concentration of H 2 SO 4 between 10 wt % and 96 wt %, by sonication, so as to obtain a first graphene oxide dispersion (D1) with a pH in the range of 2 to 5, preferably from 3 to 4.5;
(i-B) adding an amount of hydrogen peroxide to the first graphene oxide dispersion (D1), optionally under sonication, to provide a second dispersion (D2), wherein the weight ratio of graphite oxide dispersed in (i-A) to the amount of hydrogen peroxide is between 1:10 and 1:50;
(i-C) adding to the second dispersion (D2) a soluble Fe (II) salt to give a third dispersion (D3), wherein the weight ratio of the Fe(II) salt added in (i-C) to the hydrogen peroxide added in (i-B) is between 1:10 and 1:100;
(i-D) optionally neutralizing said third dispersion (D3) with a base to reach a pH of 6.0-8.0, preferably 6.5-7.5, more preferably 6.8-7.2; and
(i-E) removing Fe(III) and possibly other impurities to obtain an essentially iron free oxidized suspension of graphene oxide, preferably by dialysis.
[0028] In step (i-A), the graphite is preferably in the form of graphite nanoplatelets, and the graphite is preferably dispersed in the aqueous solution of sulphuric acid by sonication or mechanical stirring. Further, steps (i-A) to (i-D) are typically carried out in a reactor equipped with a cooling device, the cooling device advantageously setting a temperature between −10° C. and 10° C. in step (i-A). Moreover, in step (i-B), the soluble Fe (II) salt is typically added to the acid dispersion under stirring.
[0029] According to the second embodiment of the present invention, the aqueous suspension of graphene oxide obtained in step (i) may be further purified by centrifugation, to remove a small amount of aggregates that precipitate under the centrifugal force, so as to obtain a colloidal suspension of graphene oxide platelets from the remaining supernatant.
[0030] Step (ii) of the present process invention can be conveniently carried out by adding an aqueous polymer latex to the aqueous suspension of graphene [dispersion (G)] provided in step (i), under stirring, sonication, or other mixing means to obtain the liquid mixture [mixture (M)]. Preferably, the aqueous polymer latex is dropwise added to the dispersion (G) under stirring, to obtain the mixture (M). Alternatively, step (ii) may be carried out by adding the dispersion (G) to the aqueous polymer latex under stirring, sonication, or other mixing means to obtain the liquid mixture [mixture (M)]. Optionally, the dispersion (G) may be water diluted before mixing with the aqueous polymer latex, wherein the dilution rate may be 2 times to 100 times, preferably 5 times to 20 times, more preferably from 5 times to 10 times. Likewise, the aqueous polymer latex may be water diluted before mixing with the dispersion (G), wherein the dilution rate may be 2 times to 100 times, preferably 5 times to 20 times, more preferably from 5 times to 10 times.
[0031] The aqueous polymer latex and the dispersion (G) may be mixed in a container by mechanical stirring (e.g. using a magnet stirring bar) or sonication means. Preferably, the aqueous polymer latex and the dispersion (G) is mixed in a container by a magnet stirring bar of which the rotating speed is set between 100 rpm to 500 rpm, more preferably between 200 rpm to 400 rpm, most preferably between 250 rpm to 350 rpm, to produce a mild agitation in the mixture (M).
[0032] The residence time of step (ii) may be between 2 minutes and 60 minutes, preferably between 5 minutes and 30 minutes, more preferably between 10 minutes and 20 minutes.
[0033] In step (iii) of the present process invention, the mixture (M) may be co-coagulated by an addition of electrolyte, by an addition of water miscible solvents, by rapid stirring, or by freezing treatment to the mixture (M). In a preferred embodiment of the present invention, the mixture (M) is co-coagulated by an addition of electrolyte in the mixture (M), e.g., by an addition of a HNO 3 -solution. The concentration of the HNO 3 solution may range from 20% to 65%, preferably from 30% to 65%, more preferably from 50% to 65%. The volume ratio of the HNO 3 solution to the mixture (M) is typically less than 1:200, preferably less than 1:500, more preferably less than 1:1000. In a preferred embodiment of the present invention, the mixture (M) is co-coagulated by dropwise addition of 65% HNO 3 .
[0034] Optionally, the composition obtained in step (iii) is subsequently filtered to remove excess water. The objective of the co-coagulation step (iii) in the present process invention is to assemble graphene particles with polymer latex nanoparticles while achieving a good dispersion of graphene filler in the nanoscale composite.
[0035] The composition obtained in step (iii) of the present process invention may be rinsed by water and subsequently dried, e.g. by vacuum drying. The vacuum drying pressure may be 200 mbar or lower, preferably 150 mbar or lower; and more preferably 10 mbar or lower. The vacuum drying time can range from 30 minutes to 100 hours, preferably from 12 hours to 72 hours, and more preferably from 24 hours to 72 hours. The vacuum drying temperature can be at least 25° C., preferably at least 50° C., and more preferably at least 100° C. In operation, the vacuum drying temperature may be set as high as possible, to reduce the drying time, yet below the polymer melting point to keep the powder morphology of the graphene-polymer composite that is advantageous for the power coating application. The power morphology of the graphene-polymer composite produced from the present process invention is advantageous in that it saves the potentially difficult and expensive grinding treatment of polymer composites, especially in the cases of prefluorinated resin composites.
[0036] According to an exemplary embodiment of the present process invention, the graphene-polymer composition produced in step (iii) is water rinsed on a filter, and subsequently subjected to a first and second vacuum drying treatments each using a different vacuum pressure, drying temperature, and/or duration. The second vacuum drying treatment is intended to partly use graphene oxide in the filled polymer composite and also releases gases from the composite material to avoid foaming or bubble formation during the subsequent processing. In this exemplary embodiment of the present process invention, the composition produced in step (iii) may be water rinsed on a polytetrafluoroethylene (PTFE) filter having a pore size between 2 μm and 10 μm, e.g., a 5 μm PTFE filter.
[0037] According to a preferred embodiment of the present process invention, step (i) comprises providing an aqueous suspension of graphene [dispersion (G)], wherein the graphene is graphene oxide, and the process further comprises a step of heating the composition obtained from step (iii), wherein the heating temperature is preferably above 250° C. The purpose of the heating step is to reduce oxygen content of graphene oxide in the composition, and in this way to restore the desired properties of graphene which are largely lost after oxidation.
[0038] Furthermore, the present process invention optionally comprises a step of melt processing the graphene-polymer composition to obtain a film, a coating, or a lining. The melt processing of the graphene-polymer composition can be performed using any conventional means known in the art, such as by compression moulding, injection moulding, sintering moulding, or by extrusion. In an exemplary embodiment of the present process invention, the composition obtained in step (iii) is subjected to compression moulding to obtain a graphene-polymer composite film with a thickness between 50 and 300 μm, preferably between 100 and 250 μm. Barrier properties of the graphene-polymer composite film can be conveniently evaluated by HCl permeation measurement.
[0039] Illustrated in FIG. 1 is a schematic sketch of the diffusion cell used by the inventor to measure HCl permeability through the graphene-polymer composite film. As shown in FIG. 1 , the diffusion cell used in the inventor's lab includes a membrane holder constructed by the inventor to house a composite film ( 1 ) to be measured. The thickness of the composite film ( 1 ) is pre-measured and is typically between 100 to 200 μm. The composite film ( 1 ) divides the membrane holder into two sections: the first section above the film is used for storing a concentrated HCl (e.g. 30% HCl) and maintains an atmospheric pressure during operation by an air vent (not shown), and the second section below the film has an inlet ( 2 ) and an outlet ( 3 ) for an argon gas flow to pass through. In a permeability measurement, the HCl passing through the composite film is transported by the argon flow and later absorbed in a known volume of water outside the membrane holder, where the conductivity is measured to give the concentration of H + and Cl − in the water, and thus the total amount of HCl permeated through the composite film. The HCl permeation rate, on the other hand, can be calculated from the conductivity evolution with time based on the measured data. As such, the measured quantity or speed of the HCl permeation through the composite film reflects the film's ability to isolate two environments, i.e., the barrier properties of the film.
[0040] By plotting the measured conductivity (σ) against time (t) in the HCl permeation measurement, as shown in FIG. 2 , two permeation phases were revealed. The first phase is the ‘transition phase’ (from time zero to time T1 in FIG. 2 ), when the HCl gas continuously dissolves in the composite film until it reaches HCl saturation. Noticeably, at the beginning of said transition phase, there is an initial period when no HCl gas passes through the test composite film—an indicator that the test film is acting as a qualified HCl barrier. As a result, the measured conductivity (σ) during this initial period in the HCl permeation measurement remains essentially unchanged, and mainly reflects the amount of CO 2 dissolved in the known volume of water. As used in the Examples provided in the present specification and the discussion associated therewith, the length of said initial period in one HCl gas permeation measurement, when the measured conductivity (σ) remains essentially unchanged, is considered as an index of “service life” for the test composite film.
[0041] Specifically, as applied in the Examples provided in the present specification, the service life of a test film in one HCl gas permeation measurement may be obtained by calculating the variation percentage (Δσ) of conductivity (σ) measured at each time point. The formula to calculate said variation percentage of conductivity is as below:
[0000] Δσ=100%*[σ(current time point)−σ(previous time point)]/σ(previous time point)
[0042] If said variation percentage (Δσ) is significant, e.g. 10% or more, it is considered that the service life of the test film has ended.
[0043] Following the first transition phase is the second ‘steady state phase’ for HCl permeation through the composite film, when the HCl passes with a constant flow rate as indicated by the linear correlation observed between the measured conductivity and measuring time, between time T1 and time T2 in FIG. 2 . Accordingly, the conductimeter may be calibrated to give a linear response of conductivity with changing HCl concentration measured in the water.
[0044] Moreover, as the HCl permeability of the composite film is known to be temperature sensitive, the barrier properties of the composites made by the present invention are characterized by HCl permeation measurement conducted under a precisely controlled temperature. For instance, the HCl permeation of one composite film made by the present process invention may be measured in a temperature-controlled oven set at approximately 40° C.
[0045] The graphene-polymer composite films made by the present process invention are found to posses superior barrier properties with a small percentage of graphene fillers in the base polymer. Moreover, the graphene-polymer composition manufactured by the present process invention also has excellent thermal stability and improved electrical conductivity, compared to the unfilled polymer.
[0046] The graphene-polymer composition manufactured by the present process invention can be used to make protective coating against corrosion, gas/liquid diffusion barrier, chemical leakage proof or other industrial products, such as pipes, reactors, valve liners, pumps, sealing products such as O-rings made from fluoroelastomers, and container parts.
[0047] The content of the graphene filler in the composition manufactured by the present process invention may be between 0.1% and 10% by weight, preferably between 0.1% and 5% by weight, more preferably between 0.1% and 3% by weight, and even more preferably between 0.5 and 2% by weight.
[0048] The process of the present invention can be applied to a number of polymers for incorporating the graphene filler—essentially all polymers that can form an aqueous latex thereof.
[0049] The polymer used in the process of the present invention can be an elastomer. To the purpose of the present invention, the term “elastomer” is intended to designate a true elastomer or a polymer resin serving as a base constituent for obtaining a true elastomer. True elastomers as defined by the ASTM, Special Technical Bulletin, No. 184 standard as materials capable of being stretched, at room temperature, to twice their intrinsic length and which, once they have been released after holding them under tension for 5 minutes, return to within 10% of their initial length in the same time. Polymer resins serving as a base constituent for obtaining true elastomers are in general amorphous products having a glass transition temperature (T g ) below room temperature. In most cases, these products correspond to copolymers having a T g below 0° C. and including reactive functional groups (optionally in the presence of additives) allowing the true elastomer to be formed.
[0050] The polymer used in the present invention can also be thermoplastic polymer. For the purpose of the present invention, the term “thermoplastic” is understood to mean, for the purposes of the present invention, polymers existing, at room temperature (25° C.), below their melting point if they are semi-crystalline, or below their T g if amorphous. These polymers have the property of becoming soft when they are heated and of becoming rigid again when hey are cooled, without there being an appreciable chemical change.
[0051] Preferably, the polymer used in the process of the present invention is a fluoropolymer, i.e. a polymer comprising recurring units derived from at least one fluorinated monomer.
[0052] To the purpose of the present invention, the fluoropolymer comprises preferably more than 20% moles, more preferably more than 30% moles of recurring units derived from the fluorinated monomer.
[0053] Non limitative examples of suitable fluorinated monomers are notably:
C 2 -C 8 fluoro- and/or perfluoroolefins, such as tetrafluoroethylene (TFE), hexafluoropropene (HFP), pentafluoropropylene, and hexafluoroisobutylene; C 2 -C 8 hydrogenated monofluoroolefins, such as vinyl fluoride;1,2-difluoroethylene, vinylidene fluoride (VDF) and trifluoroethylene (TrFE); (per)fluoroalkylethylenes complying with formula CH 2 ═CH—R f0 , in which R f0 is a C 1 -C 6 (per)fluoroalkyl or a C 1 -C 6 (per)fluorooxyalkyl having one or more ether groups; chloro- and/or bromo- and/or iodo-C 2 -C 6 fluoroolefins, like chlorotrifluoroethylene (CTFE); fluoroalkylvinylethers complying with formula CF 2 ═CFOR f1 in which R f1 is a C 1 -C 6 fluoro- or perfluoroalkyl, e.g. —CF 3 , —C 2 F 5 , —C 3 F 7 ; hydrofluoroalkylvinylethers complying with formula CH 2 ═CFOR f1 in which R f1 is a C 1 -C 6 fluoro- or perfluoroalkyl, e.g. —CF 3 , —C 2 F 5 , —C 3 F 7 ; fluoro-oxyalkylvinylethers complying with formula CF 2 ═CFOX 0 , in which X 0 is a C 1 -C 12 oxyalkyl, or a C 1 -C 12 (per)fluorooxyalkyl having one or more ether groups, like perfluoro-2-propoxy-propyl; fluoroalkyl-methoxy-vinylethers complying with formula CF 2 ═CFOCF 2 OR f2 in which R f2 is a C 1 -C 6 fluoro- or perfluoroalkyl, e.g. —CF 3 , —C 2 F 5 , —C 3 F 7 or a C 1 -C 6 (per)fluorooxyalkyl having one or more ether groups, like —C 2 F 5 —O—CF 3 ; functional fluoro-alkylvinylethers complying with formula CF 2 ═CFOY 0 , in which Y 0 is a C 1 -C 12 alkyl or (per)fluoroalkyl, or a C 1 -C 12 oxyalkyl or a C 1 -C 12 (per)fluorooxyalkyl, said Y 0 group comprising a carboxylic or sulfonic acid group, in its acid, acid halide or salt form; fluorodioxoles, of formula:
[0000]
[0000] wherein each of R f3 , R f4 , R f5 , R f6 , equal or different each other, is independently a fluorine atom, a C 1 -C 6 fluoro- or per(halo)fluoroalkyl, optionally comprising one or more oxygen atom, e.g. —CF 3 , —C 2 F 5 , —C 3 F 7 , —OCF 3 , —OCF 2 CF 2 OCF 3 .
[0064] Fluoropolymers which have been found particularly suitable for the process of the present invention are per(halo)fluoropolymers and hydrogen-containing fluoropolymer. For the purpose of the invention, the term “per(halo)fluoropolymer” is intended to denote a fluoropolymer substantially free of hydrogen atoms. The per(halo)fluoropolymer can comprise one or more halogen atoms (Cl, Br, I) different from fluorine. The term “substantially free of hydrogen atom” is understood to mean that the per(halo)fluoropolymer consists essentially of recurring units derived from ethylenically unsaturated monomers comprising at least one fluorine atom and free of hydrogen atoms [per(halo)fluoromonomer (PFM)]. The per(halo)fluoropolymer can be a homopolymer of a per(halo)fluoromonomer (PFM) or a copolymer comprising recurring units derived from more than one per(halo)fluoromonomer (PFM).
[0065] Non limitative examples of suitable per(halo)fluoromonomers (PFM) are notably:
C 2 -C 8 perfluoroolefins, such as tetrafluoroethylene (TFE) and hexafluoropropene (HFP); chloro- and/or bromo- and/or iodo-C 2 -C 6 per(halo)fluoroolefins, like chlorotrifluoroethylene; per(halo)fluoroalkylvinylethers complying with general formula CF 2 ═CFOR f1 in which R f1 is a C 1 -C 6 per(halo)fluoroalkyl, such as —CF 3 , —C 2 F 5 , —C 3 F 7 ; per(halo)fluoro-oxyalkylvinylethers complying with general formula CF 2 ═CFOX 01 , in which X 01 is a C 1 -C 12 per(halo)fluorooxyalkyl having one or more ether groups, like perfluoro-2-propoxy-propyl group; per(halo)fluoro-methoxy-alkylvinylethers complying with general formula CF 2 ═CFOCF 2 OR f2 in which R f2 is a C 1 -C 6 per(halo)fluoroalkyl, such as —CF 3 , —C 2 F 5 , —C 3 F 7 or a C 1 -C 6 per(halo)fluorooxyalkyl having one or more ether groups, such as —C 2 F 5 —O—CF 3 ; per(halo)fluorodioxoles of formula:
[0000]
wherein each of R f3 , R f4 , R f5 , R f6 , equal of different each other, is independently a fluorine atom, a C 1 -C 6 perfluoroalkyl group, optionally comprising one or more oxygen atom, e.g. —CF 3 , —C 2 F 5 , —C 3 F 7 , —OCF 3 , —OCF 2 CF 2 OCF 3 ; preferably a per(halo)fluorodioxole complying with formula here above, wherein R f3 and R f4 are fluorine atoms and R f5 and R f6 are perfluoromethyl groups (—CF 3 )
[perfluoro-2,2-dimethyl-1,3-dioxole (PDD)], or a per(halo)fluorodioxole complying with formula here above, wherein R f3 , R f5 and R f6 are fluorine atoms and R f4 is a perfluoromethoxy group (—OCF 3 ) [2,2,4-trifluoro-5-trifluoromethoxy-1,3-dioxole or perfluoromethoxydioxole (MDO)].
[0072] The per(halo)fluoropolymer is advantageously chosen among tetrafluoroethylene (TFE) homopolymers and copolymers of TFE with at least one per(halo)fluoromonomer (PFM) different from TFE.
[0073] Good results have been obtained with TFE copolymers as above detailed comprising at least 1.5% wt and at most 30% wt of recurring units derived from the per(halo)fluoromonomer (PFM) different from TFE.
[0074] Preferred per(halo)fluoropolymers are selected among TFE copolymers comprising recurring units derived from at least one per(halo)fluoromonomer (PFM) chosen among the group consisting of:
1. perfluoroalkylvinylethers complying with formula CF 2 ═CFOR f1′ , in which R f1′ is a C 1 -C 6 perfluoroalkyl, e.g. —CF 3 , —C 2 F 5 , —C 3 F 7 ; and/or 2. perfluoro-oxyalkylvinylethers complying with general formula CF 2 ═CFOX 0 , in which X 0 is a C 1 -C 12 perfluorooxyalkyl having one or more ether groups, like perfluoro-2-propoxy-propyl group; and/or 3. C 3 -C 8 perfluoroolefins, such as hexafluoropropene (HFP); and/or 4. perfluorodioxoles of formula:
[0000]
wherein each of R f3 , R f4 , R f5 , R f6 , equal of different each other, is independently a fluorine atom, a C 1 -C 6 perfluoroalkyl group, optionally comprising one or more oxygen atom, e.g. —CF 3 , —C 2 F 5 , —C 3 F 7 , —OCF 3 , —OCF 2 CF 2 OCF 3 .
[0080] More preferred per(halo)fluoropolymers are selected among TFE copolymers comprising recurring units derived from at least one per(halo)fluoromonomer (PFM) chosen among the group consisting of:
[0000] 1. perfluoroalkylvinylethers complying with general formula CF 2 ═CFOR f1 in which R f1 is a C 1 -C 6 perfluoroalkyl;
2. perfluoro-oxyalkylvinylethers complying with general formula CF 2 ═CFOX 01 , in which X 01 is a C 1 -C 12 perfluorooxyalkyl having one or more ether groups;
3. C 3 -C 8 perfluoroolefins; and
4. mixtures thereof.
[0081] According to one embodiment of the invention, the polymer used for forming the aqueous latex is chosen among TFE copolymers comprising recurring units derived from HFP and optionally from at least one per(halo)fluoroalkylvinylether, as above defined, preferably from at least one perfluoroalkylvinylether complying with general formula CF 2 ═CFOR f1′ in which R f1′ is a C 1 -C 6 perfluoroalkyl.
[0082] Preferred polymers according to this embodiment are selected among TFE copolymers comprising (preferably consisting essentially of) recurring units derived from tetrafluoroethylene (TFE) and hexafluoropropylene (HFP) in an amount ranging from 3 to 15 wt % and, optionally, from 0.5 to 3 wt % of at least one perfluoroalkylvinylether, as above defined. Polymers according to this embodiment are commercially available under the trademark TEFLON® FEP 9494, 6100 and 5100 from E.I. DuPont de Nemours, or from Daikin (e.g. FEP NP-101 material), or from Dyneon LLC (FEP 6322). A description of such polymers can be found notably in U.S. Pat. No. 4,029,868 (DU PONT) Jun. 14, 1977, in U.S. Pat. No. 5,677,404 (DU PONT) Oct. 14, 1997, in U.S. Pat. No. 5,703,185 (DU PONT) Dec. 30, 1997 and in U.S. Pat. No. 5,688,885 (DU PONT) Nov. 18, 1997.
[0083] According to another embodiment of the invention, the polymer used to form the aqueous latex for co-coagulation is chosen among TFE copolymers comprising recurring units derived from at least one per(halo)fluoroalkylvinylether, as above defined, preferably from at least one perfluoroalkylvinylether, as above defined and optionally further comprising recurring units derived from C 3 -C 8 perfluoroolefins. Good results within this embodiment have been obtained with TFE copolymers comprising recurring units derived from one or more than one perfluoroalkylvinylether as above specified; particularly good results have been achieved with TFE copolymers wherein the perfluoroalkylvinylether is perfluoromethylvinylether (of formula CF 2 ═CFOCF 3 ), perfluoroethylvinylether (of formula CF 2 ═CFOC 2 F 5 ), perfluoropropylvinylether (of formula CF 2 ═CFOC 3 F 7 ) and mixtures thereof.
[0084] According to a preferred variant of the aforementioned embodiment of the invention, the polymer used to form the aqueous latex for co-coagulation is advantageously a TFE copolymer consisting essentially of:
[0000] (a) from 3 to 13%, preferably from 5 to 12% by weight of recurring units derived from perfluoromethylvinylether;
(b) from 0 to 6% by weight of recurring units derived from one or more than one fluorinated comonomer different from perfluoromethylvinylether and selected from the group consisting of perfluoroalkylvinylethers complying with general formula CF 2 ═CFOR f1′ in which R f1′ is a C 1 -C 6 perfluoroalkyl and perfluoro-oxyalkylvinylethers complying with general formula CF 2 ═CFOX 01′ , in which X 01′ is a C 1 -C 12 perfluorooxyalkyl having one or more ether groups; preferably derived from perfluoroethylvinylether and/or perfluoropropylvinylether;
(c) recurring units derived from tetrafluoroethylene, in such an amount that the sum of the percentages of the recurring units (a), (b) and (c) is equal to 100% by weight.
[0085] Examples of TFE copolymer suitable to be used for the present invention include MFA and PFA which are commercially available from Solvay Solexis Inc. under the trade name of HYFLON® PFA P and M series and HYFLON® MFA.
[0086] As above mentioned, hydrogen-containing fluoropolymer represents another type of polymers which have been found particularly suitable for the process of the present invention. By “hydrogen-containing fluoropolymer” it is meant a fluoropolymer as above defined comprising recurring units derived from at least one hydrogen-containing monomer. Said hydrogen-containing monomer may be the same monomer as the fluorinated monomer above defined or can be a different monomer. Thus, this definition encompasses notably copolymers of one or more per(halo)fluoromonomer (for instance tetrafluoroethylene, chlorotrifluoroethylene, hexafluoropropylene, perfluoroalkylvinylethers, etc.) with one or more hydrogenated comonomer(s) (for instance ethylene, propylene, vinylethers, acrylic monomers, etc.), and/or homopolymers of hydrogen-containing fluorinated monomers (for instance vinylidene fluoride, trifluoroethylene, vinyl fluoride, etc.) and their copolymers with fluorinated and/or hydrogenated comonomers.
[0087] The hydrogen-containing fluoropolymer is preferably chosen among:
[0000] (A-1) TFE and/or CTFE copolymers with ethylene, propylene or isobutylene (preferably ethylene), with a molar ratio per(halo)fluoromonomer(s)/hydrogenated comonomer(s) of from 30:70 to 70:30, optionally containing one or more comonomers in amounts of from 0.1 to 30% by moles, based on the total amount of TFE and/or CTFE and hydrogenated comonomer(s) (see for instance U.S. Pat. No. 3,624,250 and U.S. Pat. No. 4,513,129);
(A-2) Vinylidene fluoride (VdF) polymers, optionally comprising one or more fluorinated comonomer(s) (see for instance U.S. Pat. No. 4,524,194 and U.S. Pat. No. 4,739,024), and optionally further comprising one or more hydrogenated comonomer(s); and
mixtures thereof.
[0088] The CTFE or TFE copolymers (A-1) preferably comprise:
[0000] (a) from 35 to 65%, preferably from 45 to 55%, more preferably from 48 to 52% by moles of ethylene (E);
(b) from 65 to 35%, preferably from 55 to 45%, more preferably from 52 to 48% by moles of chlorotrifluoroethylene (CTFE) (for the ECTFE polymers, hereinafter) and/or tetrafluoroethylene (TFE) (for the ETFE polymers, herein after); and optionally;
(c) from 0.1 to 30%, by moles, preferably 0.1 to 10% by moles, more preferably 0.1 to 5% by moles, based on the total amount of monomers (a) and (b), of one or more fluorinated comonomer(s) (c1) and/or hydrogenated comonomer(s) (c2).
[0089] Examples of fluorinated comonomers (c1) include (per)fluoroalkylvinylethers, perfluoroalkylethylenes (such as perfluorobutylethylene), (per)fluorodioxoles as described in U.S. Pat. No. 5,597,880, vinylidenefluoride (VdF). Among them, preferred (c1) comonomer is perfluoropropylvinylether of formula CF 2 ═CFO—C 3 F 7 .
[0090] Among comonomers (c), hydrogenated comonomers (c2) are preferred. As non limitative examples of hydrogenated comonomers (c2), mention may be notably made of those having the general formula:
[0000] CH 2 ═CH—(CH 2 ) n R 1 (I)
[0000] wherein R 1 ═OR 2 , or —(O) t CO(O) p R 2 wherein t and p are integers equal to 0, 1 and R 2 is a hydrogenated radical C 1 -C 20 from 1 to 20 carbon atoms, of alkyl type, linear or branched when possible, or cycloalkyl, optionally containing heteroatoms and/or chlorine atoms, the heteroatoms preferably being O or N, R 2 optionally contains one or more functional groups, preferably selected from OH, COOH, epoxide, ester and ether, R 2 optionally contains double bonds, or R 2 is H, n is an integer in the range 0-10. Preferably R 2 is of alkyl type from 1 to 10 carbon atoms containing functional groups of hydroxide type, n is an integer in the range 0-5.
[0091] The preferred hydrogenated comonomers (c2) are selected from the following classes:
[0000] 1. Acrylic monomers having the general formula:
[0000] CH 2 ═CH—CO—O—R 2
wherein R 2 has the above mentioned meaning. As non limitative examples of suitable acrylic monomers, mention can be notably made of ethylacrylate, n-butylacrylate, acrylic acid, hydroxyethylacrylate, hydroxypropylacrylate, (hydroxy) ethylhexylacrylate.
2. Vinylether monomers having the general formula:
[0000] CH 2 ═CH—O—R 2
wherein R 2 has the above mentioned meaning. As non limitative examples of suitable vinylether monomers, mention can be notably made of propylvinylether, cyclohexylvinylether, vinyl-4-hydroxybutylether.
3. Vinyl monomers of the carboxylic acid having the general formula:
[0000] CH 2 ═CH—O—CO—R 2
wherein R 2 has the above mentioned meaning. As non limitative examples of suitable vinyl monomers of the carboxylic acid, mention can be notably made of vinyl-acetate, vinylpropionate, vinyl-2-ethylhexanoate.
4. Unsaturated carboxylic acid monomers having the general formula:
[0000] CH 2 ═CH—(CH 2 ) n —COOH
wherein n has the above mentioned meaning. As non-limitative example of suitable unsaturated carboxylic acid monomer, mention can be notably made of vinylacetic acid.
[0096] More preferred comonomer (c2) is n-butylacrylate.
[0097] Among A-1 polymers, ECTFE polymers are preferred. Particularly adapted to the process of the present invention is ECTFE available from Solvay Solexis Inc., Thorofare, N.J., USA, under the tradename HALAR® and VATAR®
[0098] More preferably, the hydrogen-containing fluoropolymer is a VdF polymer (A-2).
[0099] The VdF polymer (A-2) preferably comprises:
[0000] (a′) at least 60% by moles, preferably at least 75% by moles, more preferably 85% by moles of vinylidene fluoride (VdF);
(b′) optionally from 0.1 to 15%, preferably from 0.1 to 12%, more preferably from 0.1 to 10% by moles of a fluorinated comonomer chosen among vinylfluoride (VF 1 ), chlorotrifluoroethylene (CTFE), hexafluoropropene (HFP), tetrafluoroethylene (TFE), perfluoromethylvinylether (MVE), trifluoroethylene (TrFE) and mixtures therefrom; and
(c′) optionally from 0.1 to 5%, by moles, preferably 0.1 to 3% by moles, more preferably 0.1 to 1% by moles, based on the total amount of monomers (a′) and (b′), of one or more fluorinated or hydrogenated comonomer(s).
[0100] As non limitative examples of the VdF polymers useful in the present invention, mention can be notably made of homopolymer of VdF, VdF/TFE copolymer, VdF/TFE/HFP copolymer, VdF/TFE/CTFE copolymer, VdF/TFE/TrFE copolymer, VdF/CTFE copolymer, VdF/HFP copolymer, VdF/TFE/HFP/CTFE copolymer, VdF/TFE/perfluorobutenoic acid copolymer, VdF/TFE/maleic acid copolymer and the like.
[0101] According to an embodiment of the invention, the polymer used for the process of the present invention is a mixture of at least one VdF homopolymer and at least one VdF copolymer chosen among the group consisting of VdF copolymers comprising from 0.1 to 15%, preferably from 0.1 to 12%, more preferably from 0.1 to 10% by moles of a fluorinated comonomer chosen among vinylfluoride (VF 1 ), chlorotrifluoroethylene (CTFE), hexafluoropropene (HFP), tetrafluoroethylene (TFE), perfluoromethylvinylether (MVE), trifluoroethylene (TrFE) and mixtures therefrom.
[0102] The polymer latex used in the process of the present invention can be prepared by any polymerizing means known in the art, including but not limited to aqueous free-radical emulsion polymerization route. Typically, in said aqueous free-radical emulsion polymerization, a reactor is generally charged with deionized water, water-soluble surfactant capable of emulsifying the reactant mass during polymerization and optional paraffin wax antifoulant. The mixture is generally stirred and deoxygenated. A predetermined amount of chain transfer agent (CTA) can be advantageously introduced into the reactor, the reactor temperature is generally raised to the desired level and the monomer(s) is usually fed into the reactor. Typically, once the initial charge of the monomer(s) is introduced and the pressure in the reactor has reached a desired level, an initiator emulsion or solution is introduced to start the polymerization reaction. The temperature of the reaction can vary depending on the characteristics of the initiator and the monomer selected, and one of skill in the art will know how to select the same. Typically the temperature will be from about 30° to 150° C., preferably from about 60° to 110° C. Generally, once the desired amount of polymer has been reached in the reactor, the monomer feed is stopped, but initiator feed is optionally continued to consume residual monomer. Residual gases (containing unreacted monomers) are typically vented and the latex can be recovered from the reactor.
[0103] The surfactant used in the polymerization can be any surfactant known in the art to be useful in aqueous free-radical emulsion polymerization, including perfluorinated, partially fluorinated, and non-fluorinated surfactants. Nevertheless, the polymerization can be also carried out in the absence of surfactant or in presence of an in situ generated oligomer having stabilizing properties.
[0104] The polymerization generally results in an aqueous latex of polymer generally having a solid level of 10 to 60 percent by weight, preferably 10 to 50 percent, and having a average particle size of less than 500 nm, preferably less than 400 nm, and more preferably less than 300 nm. The average particle size is generally at least 20 nm and preferably at least 50 nm.
[0105] The aqueous latex of polymer can be used as such for co-coagulating with the graphene suspension according to the process of the present invention. This represents a significant advantage of the present process invention over the aforementioned heat-extrusion mixing process, by saving the energy-consuming heat melting treatment of the base polymer before mixing it with graphene fillers.
[0106] The aqueous latex of polymer used in the present invention can comprise at least one surfactant. The surfactant is generally intended to improve shelf-stability and provide additional stabilization of the polymer. Said surfactant can be provided, as a whole or in part, in combination with the polymer in the aqueous polymer latex, as a result of the emulsion polymerization process, and/or can be add, as a whole or in part, after polymerization.
[0107] The surfactant can be selected notably from fluorinated surfactant [surfactant (FS)] and hydrogenated surfactants free from fluorine atoms [surfactant (H)].
[0108] Surfactants (FS), if used, are generally provided in combination with the polymer, in the aqueous latex of polymer (F) comprising said surfactant (FS), as a result of the emulsion polymerization process. The fluorinated surfactant (FS) typically complies with formula (III) here below:
[0000] R f§ (X − ) k (M + ) k (III)
[0000] wherein:
R f§ is selected from a C 5 -C 16 (per)fluoroalkyl chain, optionally comprising one or more catenary or non-catenary oxygen atoms, and a (per)fluoropolyoxyalkyl chain, X − is selected from —COO − , —PO 3 − and —SO 3 − , M + is selected from NH 4 + and an alkaline metal ion, and k is 1 or 2.
[0113] Non-limitative examples of fluorinated surfactants (FS) suitable for the aqueous emulsion polymerization process of the invention include, notably, the followings:
[0000] (a) CF 3 (CF 2 ) n0 COOM′, wherein n 0 is an integer ranging from 4 to 10, preferably from 5 to 7, preferably n 1 being equal to 6, and M′ represents NH 4 , Na, Li or K, preferably NH 4 ;
(b) T-(C 3 F 6 O) n1 (CFXO) m1 CF 2 COOM″, wherein T represents a Cl atom or a perfluoroalkoxyde group of formula C x F 2x+1-x′ Cl x′ O, wherein x is an integer ranging from 1 to 3 and x′ is 0 or 1, n 1 is an integer ranging from 1 to 6, m 1 is an integer ranging from 0 to 6, M″ represents NH 4 , Na, Li or K and X represents F or —CF 3 ;
(c) F—(CF 2 CF 2 ) n2 —CH 2 —CH 2 —RO 3 M′″, in which R is a phosphorus or a sulphur atom, preferably R being a sulphur atom, M′″ represents NH 4 , Na, Li or K and n 2 is an integer ranging from 2 to 5, preferably n 2 being equal to 3;
(d) [R f —O-L-COO − ] i X i+ , wherein L represents a linear partially or fully fluorinated alkylene group or an aliphatic hydrocarbon group, R f represents a linear partially or fully fluorinated aliphatic group or a linear partially or fully fluorinated aliphatic group interrupted with one or more oxygen atoms, X i+ represents a cation having the valence i and i is 1, 2 or 3;
(e) A-R bf —B bifunctional fluorinated surfactants, wherein A and B, equal to or different from each other, have formula —(O) p CFX″—COOM*, wherein M* represents NH 4 , Na, Li or K, preferably M* representing NH 4 , X″ is F or —CF 3 and p is an integer equal to 0 or 1, and R bf is a divalent (per)fluoroalkyl or (per)fluoropolyether chain such that the number average molecular weight of A-R bf —B is in the range of from 300 to 1800; and (f) mixtures thereof.
[0114] Non-limitative examples of suitable hydrogenated surfactants (H) include, notably, ionic and non-ionic hydrogenated surfactants such as 3-allyloxy-2-hydroxy-1-propane sulfonic acid salts, polyvinylphosphonic acid, polyacrylic acids, polyvinyl sulfonic acid, and salts thereof, octylphenol ethoxylates, polyethylene glycol and/or polypropylene glycol and the block copolymers thereof, alkyl phosphonates and siloxane-based surfactants.
[0115] Surfactants (H), if added in the aqueous polymer latex used in the present process invention, are generally added to the aqueous polymer latex after the emulsion polymerization.
[0116] Hydrogenated surfactants (H) which may be preferably added to the aqueous latex are non-ionic surfactants commercially available as TRITON X series and PLURONIC® series.
BRIEF DESCRIPTION OF DRAWINGS
[0117] FIG. 1 illustrates a schematic sketch of the gas diffusion cell used by the inventor to measure the HCl permeability through the graphene-polymer composite film.
[0118] FIG. 2 represents the observed correlation of measured conductivity and measuring time during the HCl permeability measurement of the graphene-polymer composite film.
DESCRIPTION OF EMBODIMENTS
[0119] The invention will be now described in more details with respect to the following examples, whose purpose is merely illustrative and not intended to limit the scope of the invention.
Example 1
a) Preparation of Graphite Oxide
[0120] Preparation of graphite oxide in this example is a process comprising four consecutive steps below.
[0121] Step (A): 1 gram of expanded graphite (TIMREX® Therm 002 from TIMCAL) was poured into a 2-L glass double-wall reactor vessel. The reactor vessel was connected with a PTFE-coated agitator and an external cooling device. The reactor vessel was also equipped with one baffle, to avoid vortex generation when mixing of the reaction medium by the PTFE-coated agitator. The agitator had three blades oriented to produce a pumping effect at the direction of the top of the reactor. A nitrogen atmosphere was maintained in the reactor vessel for the entire reaction duration. 100 ml of 98% Sulphuric acid was subsequently introduced into the reactor vessel, while the associated external cooling device setting its temperature at 25° C. The rotation speed of the agitator in the reactor was adjusted to 300 rpm, and remained unchanged for the entire 1-hour duration of Step (A).
[0122] Step (B): While maintaining cooling and the vigorous agitation in the reaction medium, oxidizing reagents of 0.75 gram sodium nitrate (from Sigma-Aldrich) and 4.5 gram potassium permanganate (from Sigma-Aldrich) were introduced in the reactor vessel, at a speed low enough to avoid a substantive temperature change (±1° C.) in the reaction medium. As soon as all the oxidizing reagents were introduced, the reactor vessel was isolated from sun light by an aluminium foil. In the reaction vessel, the temperature was maintained at 25° C. and the rotation speed of the agitator remained at 300 rpm, for 16 hours.
[0123] Step (C): The reactor vessel was heated up to 35° C. and the rotation speed of the agitator therein maintained at 300 rpm, for a period of 96 hours. The end product of Step (C) was a gray, pasty reaction medium.
[0124] Step (D): The temperature setting point of the cooling device was re-adjusted to 25° C. and, with the reaction medium continuously being stirred by the agitator at 300 rpm, 200 ml of deionized water was added at a speed low enough to keep the temperature in the reaction medium below 80° C. The Applicant noted that this water addition process was notably exothermic in the viscous reaction medium, and therefore needed to be closely watched to keep the medium temperature below 80° C. even with an efficient cooling device. Next, 30 ml of 30% H 2 O 2 (from Merck) was slowly added into the reactor, giving a reaction medium of yellow colour. Some shining particles (graphene platelets) were visible. A neutralizing agent of anhydrous sodium bicarbonate (from Sigma-Aldrich) was then slowly and carefully added to the reactor vessel, until the reaction medium reached a pH of 7. The addition speed of the anhydrous sodium bicarbonate was sufficiently slow to avoid chemical spill or projection accident due to foaming of the reaction medium. The resulting graphite oxide suspension had a high transparency, and restacking was observed upon drying a droplet thereof.
b) Dialysis of Graphite Oxide Suspension
[0125] Approximately 100 ml of the neutral suspension obtained in Example 1a was introduced in a dialysis tube (Spectra/For® 7 cellulose ester membrane from Spectrum Laboratories; molecular cut-off: 1000 kDa; 3.1 or 1.3 ml/cm), filling up to about half of the tube. Up to 5 tubes of ˜100 ml capacity were introduced in a 10-L reactor and deionized water was continuously introduced in the reactor at a flow rate of approximately 5 liter per hour. The entire dialysis duration in Example 1b was 47 hour.
c) Co-Coagulation of the Graphene Oxide Suspension with Polymer Latex
Obtainment of Nanocomposite Sample Nos. 1-4
[0126] 50 ml of the dialysed graphite oxide suspension obtained in Example 1b was sonicated using a Bandelin SONOPULS HD 2200 homogenizer (200 watts; 10 min), and a titanium sonotrode (TT13; diameter: 13 mm) was applied in the sonication. The sonication was delivered by a pulsed mode (50% duty cycle) to avoid excessive heat build-up in the suspension. During the sonication process the temperature in the dialysed graphite oxide suspension was kept below 40° C. with appropriate cooling.
[0127] The suspension was then centrifuged using HERAEUS OMNIFUGE 2.0 RS equipped with 30 ml tubes (4000 rpm; 20 min), to remove a small amount of aggregates that precipitated under the centrifugal force. After that, a colloidal suspension of graphene oxide was obtained from the remaining supernatant (measured pH=7). Hereinafter, this colloidal suspension of graphene oxide will be referred to as the “GO colloidal suspension”.
[0128] Next, 10 ml of the collected GO colloidal suspension was diluted by an appropriate amount of deionised water. An aqueous latex of Hyflon® PFA M620 (from Solvay) was then added dropwise in the diluted graphene oxide suspension and the two were mixed together by a PTFE magnet stirring bar (rotating speed: 300 rpm; duration: 10 min). After mixing, 0.06 ml of 65% HNO3 was added dropwise to the graphene oxide/polymer latex mixture to co-coagulate the mixture, and the reaction medium was continually stirred with a PTFE magnet stirring bar (rotating speed: 200 rpm; duration: 1 minute). The product of the coagulation process was washed with deionised water on a 5 μm PTFE filter, and subsequently subjected to a first vacuum drying treatment (200 mbar, 100° C., 24 hours) and a second vacuum drying treatment (below 10 mbar, 250° C., 48 hours) to obtain a nanocomposite sample in powderous form. The powderous nanocomposite was then compression moulded between two Inox plates (each equipped with a 100 μm aluminium sheet and a 100 μm Kapton sheet; heated at 350° C.) to get a composite film for HCl permeation measurement.
[0129] Following the procedure detailed in the above paragraph and with reference to the parameters recorded in Table 1, four graphene-filled polymer nanocomposite samples (Nos. 1-4) with different filler content were obtained, as listed in Table 1. The filler weight content in each sample was calculated by dividing the solid weight of graphene oxide by the solid weight of the polymer latex used in co-coagulation, wherein the solid weight of graphene oxide was obtained by weighing the solid remained after vacuum drying (200 mbar; 40° C.; 24 h) an equivalent amount (10 ml) of un-diluted GO suspension used for each nanocomposite sample, and the solid weight of polymer latex was obtained by weighing the solid remained after vacuum drying (200 mbar; 40° C.; 24 h) an equivalent volume of Hyflon® PFA M620 latex used for each nanocomposite sample.
d) Barrier Properties Evaluation for Nanocomposite Sample Nos. 1-4
[0130] The rate of HCl permeation through the composite film made from nanocomposite samples 1-4 was measured at 37° C., using the diffusion cell illustrated in FIG. 1 . The HCl permeability of each measured film was expressed in the unit of g·mm·m −2 ·d −1 , the value corresponding to the mass of HCl (gram) that passed through the film over time (days), relative to the film thickness (mm) and the HCl-exposed surface area of the film (m 2 ), as shown in Table 1.
[0131] As shown in FIG. 1 , the diffusion cell used included a 50 mm membrane holder constructed by the inventor to house the composite film ( 1 ) to be measured. The HCl-exposed surface of the composite film was a circular area with a diameter of 33 mm. The composite film ( 1 ) divided the membrane holder into two sections: the first section above the film was filled a 30% HCl and maintained an atmosphere pressure during operation by an air vent (not shown); and the second section below the film has an inlet ( 2 ) and an outlet ( 3 ), through which an argon gas flow was let through during the measurement. In a permeability measurement process, the HCl passing through the composite film was transported by the argon flow and later absorbed in a volume of water outside the membrane holder, where the conductivity was measured to give the concentration of H + and Cl − in the water, and thus the total amount of HCl permeated through the composite film, as well the HCl permeability of each measured film in the steady state phase (i.e. between time T1 and T2 in FIG. 2 as afore-discussed) expressed in the unit of g·mm·m −2 ·d −1 .
[0132] Additionally, the service life of the film Sample No. 3 according to the present invention, namely the initial period in its HCl permeation measurement when the measured conductivity remained essentially unchanged, was calculated using the mathematical approach described in the foregoing text. As used herein, the conductivity in the initial period was measured every 30 minutes and when the variation percentage (Δσ) was calculated to exceed 10%, the service life of the test film was considered to have ended. This calculation gave a service life of 4 hours for the film Sample No. 3.
[0000]
TABLE 1
Process parameters for preparing graphene-filled
nanocomposite sample Nos. 1-4, and the characterization
thereof by filler content and permeability
No. 1
No. 2
No. 3
No. 4
Process parameter
Volume of GO
10
10
10
10
suspension collected
from centrifuge (ml)
Volume of the
100
20
50
50
water-diluted
GO suspension (ml)
Volume of Hyflon ® PFA
19
7.5
3.8
2.5
M620 latex added to the
diluted GO suspension (ml)
filler content
(wt %)
0.2
0.5
1.0
1.5
PERMEABILITY
HCl permeation rate
0.012
0.012
0.007
0.010
(g · mm · m −2 · d −1 )
Film thickness (μm)
149
154
311
147
Example 2
[0133] The process of Example 1 was generally followed to produce a graphene-polymer nanocomposite (sample No. 5), expect that:
[0134] a) For preparation of graphite oxide:
The 2-L reactor vessel was equipped with two baffles; 2 gram of graphite flakes (from Sigma-Aldrich) was used as the precursor graphite; 200 ml of 98% Sulphuric acid was added to the graphite flakes while the cooling device set the temperature at 15° C.; The rotation speed of the PTFE-coated agitator was set at 400 rpm and remained unchanged for the entire 17-hour duration of Step (A); The oxidizing reagents are 1.50 gram of sodium nitrate and 9.0 gram of potassium permanganate, and were added at a speed sufficient low to help maintain the temperature in the reaction medium within −4±1° C.; The rotation speed of the agitator remained at 400 rpm, and the cooling device set at −4° C., while the reaction mixture was isolated from light for 7 hours in Step (B); The reactor vessel was heated up to 35° C. and the rotation speed of the agitator therein maintained at 400 rpm, for the entire 72-hour duration of Step (C); 400 ml of deionized water was added in Step (D), before 35 ml of 30% H 2 O 2 was slowly added into the reactor; and, No neutralizing agent was added to the reactor vessel after the H 2 O 2 addition, making the reaction medium an acidic mixture with a pH of 0.5;
[0144] b) For dialysis of graphite oxide solution, the aforementioned acidic mixture was dialysed with deionized water; and
[0145] c) For co-coagulation: 13 ml of un-diluted Hyflon® PFA M620 latex was added dropwise to a reactor containing 36 ml of the GO colloidal suspension collected from the centrifuge (measured pH=5), and the two were mixed together by a PTFE magnet stirring bar (rotating speed: 75 rpm; duration: 10 min), after which 0.12 ml of 65% HNO3 was added dropwise to co-coagulate the mixture, with the reaction medium continually stirred with a PTFE magnet stirring bar (rotating speed: 100 rpm; duration: 1 min);
[0146] The powderous nanocomposite of Sample No. 5 obtained after vacuum drying was compression moulded to get a 144 μm thick film for HCl permeation measurement, as in Example 1. The rate of HCl permeation through the film was measured to be 0.002 g·mm·m −2 ·d −1 , using the same measurement method as described in Example 1d. The filler weight content of the nanocomposite sample No. 5 was calculated to be 1 wt %, following the same approach described in Example 1c.
Example 3
[0147] The process of Example 1 was generally followed to produce a graphene-polymer nanocomposite (sample No. 6), expect that
[0148] a) For preparation of graphite oxide:
The 2-L reactor vessel was equipped with two baffles; 4.5 gram of graphite flakes (from Sigma-Aldrich) was used as the precursor graphite; 600 ml of 98% Surfuric acid was added to the graphite flakes while the cooling device set the temperature at −10° C.; The rotation speed of the PTFE-coated agitator was set at 200 rpm and remained unchanged for the entire 4-hour duration of Step (A); The oxidizing reagents are 3.40 gram of sodium nitrate and 20.4 gram of potassium permanganate, and were added at a speed sufficient low to help maintain the temperature in the reaction medium within −10±1° C.; The rotation speed of the agitator remained at 200 rpm, and the cooling device set at −10° C., while the reaction mixture was isolated from light for 24 hours in Step (B); The reactor vessel was heated up to 35° C. and the rotation speed of the agitator therein maintained at 200 rpm, for the entire 168-hour duration of Step (C); 750 ml of deionized water was added to dilute the reaction medium in Step (D), after which 30 ml of 30% H 2 O 2 was slowly added into the reactor, resulting in a reaction medium where no shining graphene platelets were visible; and, No neutralizing agent was added to the reactor vessel after the H 2 O 2 addition, making the reaction medium an acidic mixture with a pH of 0.5;
[0158] b) For dialysis of graphite oxide solution, the aforementioned acidic mixture was dialysed with deionized water for 120 hours, using dialysis tubes having a molecular cut-off of 15000 kDa;
[0159] c) For co-coagulation: 1.7 ml of Hyflon® PFA M620 latex was diluted to 5 ml with deionised water, and the 5 ml of diluted Hyflon® PFA M620 latex was then added dropwise to a reactor containing 5 ml of the GO colloidal suspension collected from the centrifuge (measured pH=5), and the two were mixed together by a PTFE magnet stirring bar (rotating speed: 75 rpm; duration: 10 min), after which 1 ml of 65% HNO3 was added dropwise to co-coagulate the mixture, with the reaction medium continually stirred with a PTFE magnet stirring bar (rotating speed: 150 rpm; duration: 10 min).
[0160] The powderous nanocomposite of Sample No. 6 obtained after vacuum drying was compression moulded to get a 141 μm thick film for HCl permeation measurement, as in Example 1. The rate of HCl permeation through the film was measured to be 0.002 g·mm·m −2 ·d −1 , using the same measurement method as described in Example 1d. The filler weight content of the nanocomposite sample No. 6 was calculated to be 1 wt %, following the same approach described in Example 1c
Example 4
[0161] In this example, the dialysed graphene suspension was obtained as described in Example 3, except that the reaction medium used in the step (C) of Example 3a was continually stirred with the agitator for 192 hours, instead of 168 hours.
[0162] The co-coagulation procedure in Example 4 also generally follows the same procedure in Example 3, except that: 0.2 ml of Hyflon® PFA M620 latex was diluted to 5 ml with deionised water, and the 5 ml of diluted Hyflon® PFA M620 latex was then added dropwise to a reactor containing 6.2 ml of the GO colloidal suspension collected from the centrifuge (measured pH=5), and the two were mixed together by a PTFE magnet stirring bar (rotating speed: 75 rpm; duration: 10 min), after which 2 ml of 65% HNO3 was added dropwise to co-coagulate the mixture, with the reaction medium continually stirred with a PTFE magnet stirring bar (rotating speed: 150 rpm; duration: 10 min).
[0163] The powderous nanocomposite of Sample No. 7 obtained after vacuum drying was compression moulded to get a 206 μm thick film for HCl permeation measurement, as in Example 1. The rate of HCl permeation through the film was measured to be 0.028 g·mm·m·m −2 ·d −1 , using the same measurement method as described in Example 1d. The filler weight content of the nanocomposite sample No. 7 was calculated to be 0.2 wt %, following the same approach described in Example 1c.
[0164] For comparison purpose, some key processing parameters for preparing graphene-filled nanocomposite sample Nos. 5-7 were relisted in Table 2 below, together with the samples' properties.
Comparative Example 1
[0165] In order to provide a comparison with films made from un-filled polymer, five 200 μm films were made from Hyflon® PFA M620 by compression moulding using the same condition described in Example 1c. HCl permeation through the film made from Hyflon® PFA M620 latex was measured in the same manner as described in Example 1d, with the average result listed in Table 2.
[0166] Additionally, the service life of the unfilled film used in this comparative Example, via the same calculation approach in Example 1, was estimated to be 1 hour. This value is merely one fourth of the service life for the composite film Sample No. 3 in Example 1.
Comparative Example 2
[0167] Eleven 200 μm films were made from Hyflon® MFA® P6010 powder by compression moulding, using the same condition described in Example 1c. HCl permeation through the film made from Hyflon® MFA® P6010 was measured in the same manner as described in Example 1d.
[0000]
TABLE 2
Process parameters for preparing graphene-filled nanocomposite sample Nos.
5-7, the characterization of the samples and the comparative examples 1-2
Cp Ex. 1
Cp Ex. 2
Ex. 2
Ex. 3
Ex. 4
(Hyflon ®
(Hyflon ®
(No. 5)
(No. 6)
(No. 7)
PFA M620)
MFA P6010)
Process parameter
Volume of undiluted GO
36
5
6.2
—
—
suspension collected
from centrifuge (ml)
Volume of polymer latex
13
1.7
0.2
—
—
added to the undiluted
GO suspension (ml)
filler content
(wt %)
1
1
0.2
0
0
PERMEABILITY
HCl permeation rate
0.002
0.002
0.028
0.037 ± 0.01 1
0.030 ± 0.006 2
(g · mm · m −2 · d −1 )
Film thickness (μm)
144
141
206
170 ± 10 1
150 ± 5 2
1 The average value of permeability/thickness measured from 5 Hyflon ® PFA M620 films,
2 The average value of permeability/thickness measured from 11 Hyflon ® MFA P6010 films
[0168] As seen from the data in Table 1 and Table 2 above, the graphene-filled polymer nanocomposite films obtained from the Examples of the present invention demonstrate superior barrier properties compared to the un-filled polymer films, in that the former greatly reduced the HCl permeation rate for the latter.
[0169] Moreover, the graphene-filled polymer nanocomposite films according to the present invention also noticeably increased its service life as qualified HCl barrier (to as much as 400%), in the extreme test environment.
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The present invention pertains to a process for producing a composition comprising graphene and at least one polymer, and especially for producing a graphene-filled polymer nanocomposite. Specifically, the present invention resides in a process for manufacturing a composition comprising graphene and at least one polymer, the process comprising the steps of: (i) providing an aqueous suspension of graphene [dispersion (G)]; (ii) mixing the dispersion (G) with an aqueous polymer latex to obtain a liquid mixture [mixture (M)]; and (iii) co-coagulating the mixture (M) to obtain said composition. The graphene-filled polymer nanocomposites made by the process of the present invention have advantageously shown excellent barrier properties, indicating a nearly homogenous and sufficiently scattered filler distribution in the base polymer.
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BACKGROUND OF THE INVENTION
Doors comprising a skeleton of wood stiles and rails covered on each side with a metal skin have been widely and successfully used for a substantial period of years. One example of a door of this construction which has had outstanding commercial success is provided by Pease U.S. Pat. No. 3,153,817 of 1964. The metal skins on the door of that patent include flanges along both sides thereof which overlap the edges of the wooden skeleton, and these flanges include additional flanges along their outer edges which are parallel with the skins and fit into a groove in the edge of the wood skeleton but are spaced from each other within that groove to provide an air gap minimizing heat transfer from one skin to the other.
A practical disadvantage of doors constructed in accordance with the Pease patent is that because both side edges of the door are covered with metal flanges, except for the air gap therebetween, the lateral dimensions of the door are fixed, and it is not possible to make any adjustment in those dimensions to accommodate irregularities in the door frame in which it is to be mounted. Also, it is standard manufacturing practice with such doors that the necessary openings in the flanges covering the lock side edge of the door to receive latch and lock hardware are cut at the factory, and the hardware to be installed in such a door is therefore practically limited to such hardware as will accurately fit those openings.
At least in part for each of these reasons, there is a substantial market for metal skin covered doors wherein the flanges on the sides of the skins do not fully cover the edges of the wood skeleton, and some wood projects beyond those flanges so that it can be planed or sanded as may be required to fit within a particular door frame, as well as slotted as needed to receive particular hardware. For example, Seely U.S. Pat. No. 4,152,876 of 1979 shows a metal faced door wherein the retaining flanges on the metal skins are set in slots in the sides of the stiles so that a portion of each of these stiles projects beyond the flanges and can be trimmed as needed to fit within a particular door frame, as well as slotted to receive a latch assembly.
There is a fire resistance limitation with doors constructed as shown in the Seely patent, as well as with similar doors wherein the flanges on the metal skins are retained in rabbets along the edges of the stiles, in that their fire resistance is undesirably low. For example, when subjected to a particular test procedure identified as ASTM E-152-81a, which rates in minutes the ability of each tested door to withstand those conditions, doors constructed in accordance with the Pease patent have a rating of 90 minutes.
In contrast, metal skin covered doors wherein substantial portions of the stiles are exposed have proved to be incapable of a rating higher than 20 minutes. This is an increasingly important consideration for the door making industry, because there is an increasing tendency for building codes to require specific fire resistant rating substantially higher than 20 minutes for door installations such, for example, as entry doors to hotel rooms, and between a residence and its attached garage, for which 45-minute ratings in a steel frame are often required.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a metal skin covered door which has the practical advantages of both varieties of such doors described hereinabove, and which in particular will have a fire rating significantly higher than it has been impossible to attain heretofore with such doors which provide the adjustability feature of a door like those of the Seely patent.
In accordance with the invention, this object is accomplished by the provision of a door comprising a wood skeleton covered with metal skins in such manner that at least one of the hinge side and lock side stiles projects beyond or is exposed between the metal skins for such trimming and/or slotting as may be necessary during installation, and wherein the skins are fastened to each other and to the hinges for the door in such manner as to achieve a fire rating significantly higher than has heretofore been possible with such a skin covered door.
In a preferred example of a door according to the invention which accomplishes this object, inturned flanges on the edges of each skin are set in rabbets extending along both outside corners of the lock side and hinge side stiles in the wood skeleton, and at least on the lock side of the door, a significant portion of the stile projects beyond the skin flanges for such trimming and/or slotting as may be necessary or desirable during installation of the door in a door frame. The hinges by which the door is so mounted are directly connected to the flange along the side of at least one of the skins, to provide a positive connection through the hinges to the door frame.
In addition, the skins are also directly connected to each other adjacent the lock side of the door, preferably by means of a metal strap that extends across the top of the door and is directly connected to the flanges along the tops of both skins. In a preferred embodiment, these direct connections are effected by sheet metal screws which directly connect the hinges to the skin flanges and which also directly connect the flanges along the top of the door to the metal strap that extends therebetween, all as described hereinafter in connection with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation illustrating a door constructed in accordance with the invention and having a hinged mounting in a conventional door frame;
FIG. 2 is a fragmentary perspective view illustrating the upper portion of the door in FIG. 1 as viewed from the hinge side;
FIG. 3 is a perspective view similarly illustrating the door in FIGS. 1 and 2 as viewed from the lock side;
FIG. 4 is a fragmentary section on the line 4--4 in FIG. 3; and
FIG. 5 is a fragmentary section on the line 5--5 in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a door 10 constructed in accordance with the invention and having a conventional handle 11 is mounted by multiple hinges 12 in a door frame which includes a conventional hinge side jamb 15, lock side jamb 16 and top jamb 17. The door 10 comprises metal skins 20 and 22 mounted on a skeleton composed of a lock side stile 25, a hinge side stile 26, a top rail 27 and a bottom rail 28. The interior of this wood skeleton is filled with core material 30, preferably a foamed plastic such as polyurethane or polystyrene, and the skins 20 and 22 are secured to the wood skeleton and the core 30 by conventional adhesive.
Each of the metal skins 20 and 22 is provided with a right angled inturned flange 33 along each of its side edges. Each of these flanges 33 is sufficiently less in width than the stile 25 to expose a substantial area of the stile between the opposed flanges. For example, if the stile is 1.62 inches in width, each of the flanges 33 may be approximately 0.25 inch in width so that the exposed area of stile 25 is approximately 1.12 inches wide.
The lock side stile 25 is provided along each of its outer vertical edges with a rabbet 35 of such dimensions as to receive therein the flange 33 on the adjacent skin 20 or 22 and also to provide a substantial thickness of stile material projecting beyond those flanges as shown at 36 in FIGS. 2 and 3, e.g. a thickness of approximately 0.15 inch.
The hinge side stile 26 is also rabbeted along its outer side edges, but these rabbets 40 are shown as only sufficiently deep to receive the thickness of the flanges 33 so that the hinge side edge of the door is essentially smooth across its width. Alternatively, the rabbets 40 can be made of approximately the same dimensions as the rabbets 35 along the lock side stile 25, but in that case, the resulting projecting portion of the stile 26 should be mortised flush with the flanges 33 to receive one leaf of each of the hinges 12. In another alternative, the flanges 33 may be received in slots cut in the sides of the stiles rather than rabbets in the edges of the stiles.
As shown in FIG. 2, one leaf of each hinge 12 is mounted directly on the exposed edge of the stile 26 by a plurality of conventional wood screws 44. In addition, each of these hinge leaves is mechanically connected with one of the skin flanges 33, by a pair of screws 45 threaded through the flange 33 into the stile 26. As shown, the screws 45 are sheet metal screws, which are self-tapping to provide positive connections between the hinge leaf and the flange 33.
Each of the metal skins 20 and 22 is also provided with a right angled inturned flange 50 along its top and bottom edges. These flanges 50 are preferably somewhat wider than the flanges 33, e.g. a width such that the exposed area of the rails 27 and 28 between opposed flanges 50 is approximately 0.75 inch wide. The stiles 25 and 26 extend to the top of the door substantially flush with the top surface of the top rail 27, and these parts are not rabbeted, so that the flanges 50 overlap the wood surfaces.
A highly fireproof connection is provided between the opposed flanges 50 at a position closely adjacent the front edge of the door, by means of a flat steel strap 52 which spans the top of the stile 25 and the adjacent end of top rail 27 and extends underneath the flanges 50, to which it is positively connected by a pair of self-tapping sheet metal screws 53. It is important that this connection between the skins be located well above the center of gravity of the door, and its location on the top of the door accomplishes this objective as well as being out of sight in the installed position of the door.
At the bottom of the door, inturned flanges 50 overlap the bottom ends of the stiles 25 and 26 and the bottom surface of the rail 28 but are not directly connected thereto or to each other. However, the bottoms of the two stiles and the bottom rail are relieved, to provide tracks in which weather stripping 55 may be slidable mounted as illustrated in FIG. 5.
Tests indicate that the addition of the direct connections of the skins 20 and 22 to the hinges 12 and to each other by means of the strap 52 provide a dramatic increase in the ability of the door to resist destruction by fire. Thus in comparative testing according to ASTM Test E-152, wherein the side of the door exposed to the flame is heated to 1850° F. while the unexposed side reaches 1100° F., a door constructed as shown in the drawings but without the screws 45 and strap 52 could not achieve a rating of 20 minutes before failing.
In contrast, a similar door provided with the screws 45 and connecting strap 52, which are greatly more resistant to both heat and combustion than the wood skeleton of the door, and with the skin on the hinge barrel side of the door, i.e. skin 22, exposed to the higher heat, achieved a rating of 45 minutes and also successfully withstood the subsequent hose stream test, notwithstanding the fact that the wooden components of the door were completely consumed, because the mechanical connections provided by the screws 45, and the strap 52 and screws 53, held the skins 20 and 22 together and in place.
As described above, the use of self-tapping screws 45 and 53 has proved to be highly effective in achieving the results desired for the invention, because they provide direct mechanical and highly heat resistant connections between the metal parts with which they are used without detracting cosmetically from the appearance of the finished door. It is to be understood, however, that mechanically equivalent connecting means could be substituted for these screws, such for example as rivets or welded connections capable of withstanding heat conditions under which the wooden components of the door are consumed.
It should be noted that the fire rating of doors in accordance with the invention has been obtained with doors having hinges which do not span the thickness of the door as shown in FIGS. 2 and 4. If hinges having larger leaves are used, they may be directly connected to both skins by additional screws 45. Also, the hinge leaves can be mounted on and similarly directly connected to the face of skin 22, but this is conventionally less desirable. In every case, the hinges hold the skin 22 securely attached to the hinge jamb part of the door frame, while the other skin is retained against separation from skin 22 by the conventional stop portion of the door frame which establishes the closed position of the door.
It should also be noted that the practice of the invention provides the same advantages with doors which do not include a projecting stile portion 36 on either edge, so that both edges will be of the same configuration as the hinge side edge of door 10, wherein a substantial portion of the stile 26 extends between but does not project beyond the opposed flanges 33.
While the articles herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise articles and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.
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The fire resistance of a metal skin covered door wherein the stile on the lock side projects between the skins for on site trimming purposes is more than doubled by directly connecting one leaf of each hinge to one of the skins and by directly connecting the skins to each other with a metal strap positioned on the top of the door close to the lock side edge thereof.
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This is a divisional of U.S. patent application Ser. No. 13/786,373, filed on Mar. 5, 2013, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
This disclosure relates to a mobile card reader.
BACKGROUND
Generally, a merchant uses a terminal to process a transaction. The terminal is connected, usually with wires, to a cash register and to an Internet connection. Some terminals process chip cards. For such terminals, a card is inserted into the terminal and the user enters a Personal Identification Number (PIN) on a keypad of the terminal. Other terminals process magnetic stripe cards. For such terminals, the card is swiped through a slot.
Mobile card readers are available for magnetic stripe cards. Some mobile card readers, e.g., mobile card readers installed in taxies, use cellular technology to communicate wirelessly with the credit card processor.
Conventional point of sale electronic credit card transactions are authorized and captured. In the authorization stage, a physical credit card with a magnetic stripe is swiped through a merchant's magnetic card reader, e.g., as part of a point of sale device. A payment request is sent electronically from the magnetic card reader to a credit card processor. The credit card processor routes the payment request to a card network, e.g., Visa or Mastercard, which in turn routes the payment request to the card issuer, e.g., a bank. Assuming the card issuer approves the transaction, the approval is then routed back to the merchant. In the capture stage, the approved transaction is again routed from the merchant to the credit card processor, the card network, and the card issuer. The payment request can include the cardholder's signature (if appropriate). The capture state can trigger the financial transaction between the card issuer and the merchant, and optionally create a receipt. There can also be other entities, e.g., the card acquirer, in the route of the transaction. Debit card transactions have a different routing, but also require swiping of the card.
SUMMARY
A wireless card reader can be paired (e.g., configured to communicate wirelessly) with a computing device using various techniques that do not require interaction with a graphical display on the wireless card reader.
In one example, users can pair a wireless card reader with a computing device using a code verification technique that involves inputting a code that is printed on the wireless card reader into a user interface presented on the computing device. In another example, users can pair a wireless card reader with a computing device using a name verification technique that involves inputting a name that is printed on the wireless card reader into a user interface presented on the computing device. Further, in another example, users can pair a wireless card reader with a computing device using a clicker verification technique that instructs a user to click a pairing button located on the wireless card reader in response to certain visual cues. As used in the specification, the pairing button can refer to a button, a switch, or a sensor.
Depending on technique used, the computing device is paired with the wireless card reader when a user has performed the requested actions (e.g., inputting a code or name, or clicking the pairing button as instructed). Once pairing is complete, the wireless card reader can be used to receive card swipes or insertions. The received card swipes or card insertions can be wirelessly communicated to the computing device to perform financial transactions.
In one aspect, a method includes configuring the wireless card reader for pairing mode, wherein the wireless card reader is configured for pairing mode based on an interaction with a pairing button on the wireless card reader; configuring the computing device for pairing mode; accessing, on the computing device, a user interface for pairing the wireless card reader with the computing device, the user interface presenting one or more visual cues for pairing the wireless card reader; in response to the user interface presenting the one or more visual cues for pairing the wireless card reader, engaging a pairing button on the wireless card reader for one or more instances, each respective engagement of the pairing button being synchronized with a respective visual cue being presented on the user interface; determining, on the wireless card reader, whether the pairing button was successfully engaged for the one or more instances; and in response to determining that the pairing button was successfully engaged, pairing the wireless card reader with the computing device. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods. A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions.
Implementations may include one or more of the following. Configuring a wireless card reader for pairing mode comprises: accessing, on a computing device, a user interface for pairing the wireless card reader, the user interface presenting instructions for enabling a pairing mode the wireless card reader; and configuring the wireless card reader for pairing mode based on the presented instructions. Configuring a wireless card reader for pairing mode comprises opening a battery door located on the wireless card reader. The method further includes: receiving, on the computing device and from the wireless card reader, data describing a pairing technique for pairing the wireless card reader; and identifying one or more visual cues based on a pairing technique identified by the data describing the pairing technique.
Engaging the pairing button comprises a combination of pressing and holding the pairing button for one or more instances, each instance being for a specified time duration. Determining, on the wireless card reader, whether the pairing button was successfully engaged for the one or more instances includes: determining, on the wireless card reader, whether an actual timing of each instance the pairing button on the wireless card reader is engaged satisfies a desired timing for the pairing button to be engaged, the desired timing describing a time that corresponds with an occurrence of a visual cue. The one or more visual cues comprise an animated analog clock. The one or more visual cues comprise an animated traffic stoplight. The one or more visual cues comprise an animated game.
In one aspect, a method of pairing a wireless card reader and a computing device, includes: receiving first user input setting the wireless card reader in a pairing mode; sending an indication from the wireless card reader to the computing device that a pairing mode of the wireless card reader is enabled; receiving an indication from the computing device that a pairing mode of the computing device is enabled; receiving, in the wireless card reader, a second user input of a sequence of actuations of a sensor on the wireless card reader; determining, on the wireless card reader, whether the sequence of actuations matches a stored sequence; and in response to determining that the sequence of actuations matches a stored sequence, pairing the wireless card reader with the computing device.
Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods. A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions.
Advantages may include one or more of the following. A computing device can be paired with a wireless card reader by performing various pairing techniques that do not require a graphical display on the wireless card reader. Pairing of a computing device and a wireless card reader can be accomplished without including a graphical display on the wireless card reader using a code or name verification technique. Pairing of a computing device and a wireless card reader can be accomplished without including a graphical display on the wireless card reader using a clicker verification technique.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an example system for conducting a transaction using a wireless card reader.
FIG. 2 is a diagram of an example flow chart for pairing a wireless card reader.
FIGS. 3A-3F illustrate a code verification technique for pairing a wireless card reader.
FIGS. 4A-4F illustrate a reader name verification technique for pairing a wireless card reader.
FIGS. 5A-5F illustrate a clicker verification technique for pairing a wireless card reader.
FIGS. 6A-6B illustrate an example technique for clicker verification.
FIGS. 7A-7B illustrate another example technique for clicker verification.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 is a schematic illustration of an example system 100 for conducting a transaction using a wireless card reader. A transaction can include reading cards such as payment cards (e.g., credit cards), drivers license cards, identification cards, etc. The system 100 is capable of processing a payment transaction between a mobile computing device 102 and a wireless card reader 104 .
The computing device 102 can be a mobile device or a desktop device. Mobile devices include smart phones, tablet computers, laptops, or other mobile data processing apparatus.
The wireless card reader 104 can process magnetic stripe cards or smart chip cards. Smart chip cards can be processed according to the Europay, Mastercard, Visa (EMV) protocol. In some implementations, the wireless card reader 104 processes cards using Near Field Communication (NFC) hardware and the NFC protocol. The wireless card reader 104 is built with one or more mechanisms to capture card data and to communicate wirelessly with the computing device 102 . Thus, the wireless card reader can be smaller, lighter and simpler than card readers with integrated keypads or displays. The wireless card reader 104 need not include a keypad, a display, an interface for receiving signatures, e.g., a touch screen display, or a cellular connection to a payment processing system on an external network, e.g., the Internet.
The computing device 102 can communicate with the wireless card reader 104 wirelessly. Wireless communication can be over a wireless local area network or shorter range wireless network, and can occur in many forms, e.g., Bluetooth, WiFi, or NFC. In some implementations, a Bluetooth Low Energy protocol is used. The wireless card reader 104 can broadcast data to the computing device 102 and vice-versa. In some implementations, the wireless card reader 104 and the computing device 102 undergo a pairing process before establishing communication to verify a source and destination for data transfer, as described below.
For a payment transaction using a magnetic stripe card, a card can be swiped at the wireless card reader 104 . The wireless card reader 104 sends card data of the magnetic stripe card to the computing device 102 using an antenna. The computing device 102 can be waiting to receive card data from the wireless card reader 104 , e.g., by scanning for Bluetooth data broadcasts. The remainder of the transaction can occur between the computing device 102 and other card processing systems.
For a payment transaction using a smart chip card, a card can be inserted into the card reader 104 so that the reader engages electrical contacts for a microchip on the card. The card reader 104 sends a PIN request to the computing device 102 using the antenna. The computing device 102 receives a PIN from the user, e.g., entered through a user interface on or connected to the computing device, and sends the PIN to the card reader 104 for confirmation, e.g., wirelessly. The card reader 104 sends the PIN to the card, which contains a chip with an embedded PIN. The card compares the received PIN to the embedded PIN. If the PINs match, the card sends a confirmation to the card reader 104 , which sends the confirmation to the computing device 102 wirelessly.
After receiving data, e.g., card data or a confirmation, from either the magnetic stripe card or the smart chip card, the computing device 102 can transmit an authorization for transaction to a secure server 108 for payment processing, e.g. by using an external network such as the Internet 106 . The secure server 108 can relay the transaction to the card issuer 104 , which ultimately approves or denies the transaction. The card issuer 104 can communicate the approval or denial to the secure server 108 , which can relay the card issuer's approval or denial to the computing device 102 .
FIG. 2 is a diagram of an example flow chart 200 for pairing a wireless card reader. For convenience, the process 200 will be described as performed using a computing device, e.g., the computing device 102 , and a card reader, e.g., the card reader 104 .
The user accesses a wireless card reader application using a computing device ( 202 ). The card reader application can provide the user with instructions on how to pair a wireless card reader, as described in reference to FIGS. 3A, 4A, and 5A . In some implementations, the computing device determines which pairing technique to use based on data (e.g., a version number) that is received from the wireless card reader during the device discovery phase. For example, when the wireless card reader is in discovery mode, the computing device can search for and locate the wireless card reader. As part of the discovery phase, the computing device can access an identifier associated with the wireless card reader that identifies the model of the wireless card reader and a version number, e.g., a firmware version number, of the wireless card reader.
The user configures a wireless card reader for pairing mode ( 204 ). Depending on the implementation, the wireless card reader can be configured for pairing mode by opening a battery door located on the wireless card reader, as described in reference to FIG. 3B , or by pressing and holding a pairing button located on the wireless card reader, as described in reference to FIGS. 4B and 5B .
The user performs a pairing technique using the computing device ( 206 ). Depending on the implementation, the pairing technique can be a code verification technique, as described in reference to FIGS. 3D-3E , a name verification technique, as described in reference to FIGS. 4 D- 4 E, or a clicker verification technique, as described in reference to FIGS. 5D-5E, 6A-6B , and 7 A- 7 B.
The user pairs the wireless card reader with the computing device once the pairing technique is performed successfully ( 208 ). For example, the pairing technique is performed successfully when the user correctly verifies the code or name printed on the wireless card reader, or when the user successfully clicks the pairing button on the wireless card reader, as instructed.
FIG. 3A illustrates an example user interface 304 for a code verification technique being presented on a computing device 302 . The user interface 304 provides instructions for pairing a wireless card reader using a code verification technique. In some implementations, the code verification technique involves inputting, into the computing device 302 , a code that is printed on the wireless card reader, e.g., on the inside of a battery door of the reader (as shown in FIG. 3B ). The computing device 302 can send the inputted code to the wireless card reader. The wireless card reader can evaluate the code received from the computing device 302 to determine whether the received code matches the code that is printed on the wireless card reader. If the codes match, the computing device 302 is paired with the wireless card reader.
In some implementations, the wireless card reader is configured for pairing mode by opening the wireless card reader's battery door, as described in reference to FIG. 3B . In such implementations, the user interface 304 provides instructions that instruct a user to enable a pairing mode on the wireless card reader by opening the wireless card reader's battery door. The user interface 304 also presents instructions for configuring the computing device 302 to communicate with the wireless card reader. The instructions can vary depending on the type of the computing device 302 . For example, for computing devices that need to be manually configured to communicate with the wireless card reader, the user interface 304 can provide instructions for configuring the computing device 302 to communicate with the wireless card reader, as described in reference to FIG. 3C .
FIG. 3B illustrates an example wireless card reader 306 . In FIG. 3B , the battery door 308 of the wireless card reader 306 is shown as having been opened. Opening the battery door 308 can trigger a switch in the wireless card reader 306 . Triggering of the switch can send a signal that is detected by software or firmware running on the wireless card reader 306 . The wireless card reader 306 is configured to enter a pairing mode with the computing device 302 once the signal is detected by software or firmware running on the wireless card reader 306 .
FIG. 3C illustrates an example user interface 310 , being presented on the computing device 302 , for pairing the computing device 302 with the wireless card reader. The user can interact with the user interface 310 to enable a wireless communication protocol, e.g., Bluetooth, and to select the wireless card reader from a list 311 of detected devices. Once the wireless card reader is selected, the computing device 302 can then communicate with the wireless card reader to receive data (e.g., data indicating that a user has clicked a pairing button located on the wireless card reader).
FIG. 3D illustrates an example user interface 312 , being presented on the computing device 302 , for verifying a code for the wireless card reader. In FIG. 3D , the user interface 312 presents the user with a text box 313 for inputting a code for verifying the wireless card reader. In some implementations, the code is printed inside the battery door of the wireless card reader, as described in reference to FIG. 3E . The user can interact with a virtual keyboard 314 included in the user interface 312 to input the code verifying the wireless card reader. The computing device 302 can send the inputted code to the wireless card reader. The wireless card reader can evaluate the code received from the computing device 302 to determine whether the received code matches the code for the wireless card reader. If the code matches, the computing device 302 is paired with the wireless card reader, as described in reference to FIG. 3F .
FIG. 3E illustrates an example wireless card reader 306 . In FIG. 3E , the battery door of the wireless card reader 308 is shown in an open position. In some implementations, the wireless card reader is configured for pairing mode by opening the wireless card reader's battery door, as described above. A code 309 for verifying the wireless card reader is printed on the inside of the battery door 308 . The code 309 can be used to validate the wireless card reader in a user interface, as described in reference to FIG. 3D .
FIG. 3F illustrates an example user interface 316 , being presented on the computing device 302 , for confirming a pairing of the computing device 302 with the wireless card reader. In FIG. 3F , the user interface 316 presents the user with information confirming the pairing of the computing device 302 with the wireless card reader. Depending on the implementation, the information can include a graphic 317 indicating a successful pairing, an identification number 318 for the wireless card reader, a connection status 319 (e.g., “connected”) of the wireless card reader, and the remaining battery life 320 of the wireless card reader.
FIG. 4A illustrates an example user interface 404 for a name verification technique being presented on a computing device 402 . The user interface 404 provides instructions for pairing a wireless card reader using a name verification technique. In some implementations, the name verification technique involves inputting, into the computing device 402 , a name that is printed on the wireless card reader. The computing device 402 can send the inputted name to the wireless card reader. The wireless card reader can evaluate the name received from the computing device 402 to compare the inputted name with the name that is printed on the wireless card reader. Pairing of the computing device 402 with the wireless card reader is complete if the inputted name matches the name that is printed on the wireless card reader.
In some implementations, the wireless card reader is configured for pairing mode by pressing and holding a pairing button on the wireless card reader for a specified duration of time (e.g., three seconds), as described in reference to FIG. 4B . In such implementations, the user interface 404 provides instructions that instruct a user to pair the wireless card reader by pressing and holding the pairing button on the wireless card reader for a specified duration.
FIG. 4B illustrates an example wireless card reader 406 . In FIG. 4B , a pairing button 408 on the wireless card reader 406 is shown as having been pressed and held for a specified duration of time. The wireless card reader 406 is configured for pairing mode when the pairing button 408 has been held for the specified duration of time.
FIG. 4C illustrates an example user interface 410 , being presented on the computing device 402 , for pairing the computing device 402 with the wireless card reader, as described in reference to FIG. 3C .
FIG. 4D illustrates an example user interface 412 , being presented on the computing device 402 , for verifying a name for the wireless card reader. In FIG. 4D , the user interface 412 presents the user with options 413 for confirming whether the name 414 displayed on the user interface 412 matches the name for the wireless card reader. In some implementations, the name 414 is printed on the wireless card reader, as described in reference to FIG. 4E . The user can select one of the options 413 to confirm whether the name 414 displayed on the user interface 412 matches the name that is printed on the wireless card reader. The computing device 402 can send the selected name 414 to the wireless card reader. The wireless card reader can evaluate the name 414 received from the computing device 402 to determine whether the name 414 matches the name printed on the wireless card reader. If the name 414 matches the name printed on the wireless card reader, the computing device 402 is paired with the wireless card reader, as described in reference to FIG. 4F .
FIG. 4E illustrates an example wireless card reader 406 . FIG. 4E shows the printed name 409 (“Butch”) for the wireless card reader 406 . The name 409 can be used to validate the wireless card reader in a user interface, as described in reference to FIG. 4D .
FIG. 4F illustrates an example user interface 416 , being presented on the computing device 402 , for confirming a pairing of the computing device 402 with the wireless card reader, as described in reference to FIG. 3F . In some implementations, the user interface 416 presents the user with the name 418 of the wireless card reader.
FIG. 5A illustrates an example user interface 504 for a clicker verification technique being presented on a computing device 502 . The user interface 504 provides instructions for pairing a wireless card reader using a clicker verification technique. In some implementations, the clicker verification technique involves pressing and holding a pairing button on the wireless card reader for one or more instances, each instance being for a specified duration of time, as described in reference to FIGS. 5D, 6A-6B, and 7A-7B . As described below, the one or more instances can be a particular pattern of instances (e.g., press and hold the pairing button three separate times, each time for a period of five seconds). In some implementations, the pressing and holding of the pairing button is synchronized with visual cues presented on a user interface.
In some implementations, the wireless card reader is configured for pairing mode by pressing and holding a pairing button on the wireless card reader for a specified duration of time (e.g., three seconds), as described in reference to FIG. 5B . In such implementations, the user interface 504 provides instructions that instruct a user to pair the wireless card reader by pressing and holding the pairing button on the wireless card reader for a specified duration.
FIG. 5B illustrates an example wireless card reader 506 . In FIG. 5B , a pairing button 508 on the wireless card reader 506 is shown as having been pressed and held for a specified duration of time. The wireless card reader 506 is configured for pairing with the computing device once the pairing button has been held for the specified duration of time.
FIG. 5C illustrates an example user interface 510 , being presented on the computing device 502 , for pairing the computing device 502 with the wireless card reader, as described in reference to FIG. 3C .
FIG. 5D illustrates an example user interface 512 , being presented on the computing device 502 , providing a visual cue for performing clicker verification. In FIG. 5D , the user interface 512 displays a virtual analog clock 513 . The user interface 512 also provides the user instructions for performing clicker verification. In some implementations, the user is instructed to click the pairing button on the wireless card reader when a certain event occurs. For example, the user can be instructed to click the pairing button when the clock's 513 large moving hand passes a particular point on the clock (e.g., the 12-hour mark). The number of events for which the user needs to click the pairing button can vary depending on the implementation. For example, the user can be instructed to click the pairing button each time the clock's 513 large moving hand passes the 12-hour mark, for a total of five independent times the clock's 513 large moving hand passes the 12-hour mark.
The computing device 502 can send data describing the timing of when the user should click the pairing button to the wireless card reader. The wireless card reader can compare the actual timing of when the user clicks the pairing button to the data describing the desired timings to determine whether the user has successfully clicked the pairing button on the wireless card reader at a time that is in synch with the occurrence of the certain event. For example, the wireless card reader can determine whether the user has clicked the pairing button on the wireless card reader at or about the same time as the time the clock's 512 large moving hand passes the 12-hour mark by comparing a time when the user clicked the pairing button with a time corresponding to the 12-hour mark. The computing device 502 is paired with the wireless card reader once the wireless card reader determines that the user has successfully clicked the pairing button for a specified number of times, as described in reference to FIG. 5F .
FIG. 5E illustrates an example wireless card reader 506 . The wireless card reader 506 includes a pairing button 509 for use in performing a clicker verification technique. A user can interact with the pairing button to perform a clicker verification technique.
FIG. 5F illustrates an example user interface 516 , being presented on the computing device 502 , for confirming a pairing of the computing device 502 with the wireless card reader, as described in reference to FIG. 3F .
FIG. 6A illustrates an example user interface 602 providing instructions 604 for performing clicker verification. A user can be instructed to perform clicker verification by clicking a pairing button on a wireless card reader when a certain event occurs. In some implementations, the user is instructed to press the pairing button on the wireless card reader when a green light is displayed, as described in reference to FIG. 6B .
FIG. 6B illustrates an example user interface 606 providing visual cues for performing clicker verification. In some implementations, a user is presented with a graphical traffic light 608 that includes a red, yellow, and green light. The user is instructed to press a pairing button on a wireless card reader whenever the green light is displayed as being lit, and to avoid pressing the pairing button when the red or yellow lights are displayed as being lit. The number of green lights for which the user needs to click the pairing button can vary depending on the implementation. For example, the user can be instructed to click the pairing button each time the light is green, for a total of three independent times the light is green.
A computing device on which the user interface 606 is presented can send data describing timings of when the user clicked the pairing button to the wireless card reader. The wireless card reader can determine whether the user has successfully clicked the pairing button on the wireless card reader at a time that is in synch with the occurrence of the green light by comparing timings of when the user clicked the pairing button with timings of when the green light was presented. The computing device is paired with the wireless card reader once the wireless card reader determines that the user has successfully clicked the pairing button in synch with the occurrence with a green light for a specified number of times.
FIG. 7A illustrates an example user interface 702 providing instructions 704 for performing clicker verification. A user can be instructed to perform clicker verification by clicking a pairing button on a wireless card reader when a certain event occurs. In some implementations, the user is instructed to press the pairing button on the wireless card reader while playing a visual game. For example, the user can be instructed to press the pairing button to make a virtual kangaroo leap over obstacles presented in a user interface, as described in reference to FIG. 7B .
FIG. 7B illustrates an example user interface 706 providing visual cues for performing clicker verification. In some implementations, a user is presented with a game 708 in the user interface 706 that displays a kangaroo encountering various obstacles. The user is instructed to press a pairing button on a wireless card reader whenever the kangaroo encounters an obstacle to make the kangaroo jump over the obstacle. The number of obstacles the user needs to make the kangaroo jump over can vary depending on the implementation. For example, the user can be instructed to click the pairing button each time the kangaroo encounters an obstacle, for a total of three independent obstacles.
A computing device on which the user interface 706 is presented can send data describing timings of when the user clicked the pairing button to the wireless card reader. The wireless card reader can determine whether the user has successfully clicked the pairing button on the wireless card reader at a time that is in synch with the kangaroo encountering an obstacle by comparing timings of when the user clicked the pairing button with timings of when the kangaroo encounters and obstacle. The computing device is paired with the wireless card reader once the wireless card reader determines that the user has successfully clicked the pairing button in synch with the kangaroo encountering an obstacle for a specified number of times.
Embodiments of the subject matter and the operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Embodiments of the subject matter described in this specification can be implemented as one or more computer programs, i.e., one or more modules of computer program instructions, encoded on a non-transitory computer storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively or in addition, the program instructions can be encoded on an artificially-generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal, that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. A computer storage medium can be, or be included in, a computer-readable storage device, a computer-readable storage substrate, a random or serial access memory array or device, or a combination of one or more of them. Moreover, while a computer storage medium is not a propagated signal, a computer storage medium can be a source or destination of computer program instructions encoded in an artificially-generated propagated signal. The computer storage medium can also be, or be included in, one or more separate physical components or media (e.g., multiple CDs, disks, or other storage devices).
The operations described in this specification can be implemented as operations performed by a data processing apparatus on data stored on one or more computer-readable storage devices or received from other sources.
The term “data processing apparatus” encompasses all kinds of apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, a system on a chip, or multiple ones, or combinations, of the foregoing. The apparatus can include special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit). The apparatus can also include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, a cross-platform runtime environment, a virtual machine, or a combination of one or more of them. The apparatus and execution environment can realize various different computing model infrastructures, such as web services, distributed computing and grid computing infrastructures.
A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, declarative or procedural languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, object, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language resource), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.
The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform actions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for performing actions in accordance with instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a Global Positioning System (GPS) receiver, or a portable storage device (e.g., a universal serial bus (USB) flash drive), to name just a few. Devices suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
To provide for interaction with a user, embodiments of the subject matter described in this specification can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending resources to and receiving resources from a device that is used by the user; for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.
Embodiments of the subject matter described in this specification can be implemented in a computing system that includes a back-end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front-end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back-end, middleware, or front-end components.
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other. In some embodiments, a server transmits data (e.g., an HTML page) to a client device (e.g., for purposes of displaying data to and receiving user input from a user interacting with the client device). Data generated at the client device (e.g., a result of the user interaction) can be received from the client device at the server.
A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous.
Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. For example, usage of the wireless card reader may not be limited to financial transactions but could also be applied to other environments, such as processing driver's licenses.
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Methods, systems, and apparatus, for pairing a wireless card reader and a computing device, including: receiving first user input setting the wireless card reader in a pairing mode; sending an indication from the wireless card reader to the computing device that a pairing mode of the wireless card reader is enabled; receiving an indication from the computing device that a pairing mode of the computing device is enabled; receiving, in the wireless card reader, a second user input of a sequence of actuations of a sensor on the wireless card reader; determining, on the wireless card reader, whether the sequence of actuations matches a stored sequence; and in response to determining that the sequence of actuations matches a stored sequence, pairing the wireless card reader with the computing device.
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RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 09/750,092, filed Dec. 29, 2000, now U.S. Pat. No. 6,651,546, the full disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a multi-stroke linear actuator capable of achieving a predetermined number of discrete positions, more particularly, it relates to a linear actuator for accurately moving a tooling member a preselected distance.
BACKGROUND OF THE INVENTION
Many conventional devices are known for guiding and positioning a tool or an element, such as a parts gripper, with respect to a work piece. These devices range from simple hand-operated mechanical devices to more accurate and automatic, fluid operated devices in which the tool can be located in numerous positions by controlling the pressure and amount of the fluid. Such devices are commonly used in a variety of environments to perform a multitude of work functions such as the pick-up placement of parts in assembly lines, and the positioning of work pieces or tools for operations such as punching, drilling, printing, clamping and so forth. The devices can also be used to position individual parts for automatic assembly, etc. In each of these jobs, repetitive, precise and accurate movement in the face of undesired external loads is essential.
Pneumatic and hydraulic operated fluid devices accomplish movement of a tool or work piece by a power mechanism acting on a tooling plate. One conventional power mechanism includes a double action piston located within a cylinder and integrally connected to a piston rod. Pneumatic or hydraulic pressure is applied to either side of the piston so that a pressure differential is created across the piston. The differential pressure in the cylinder controls the location of the piston. It causes the piston to displace within the cylinder until the force on both sides of the piston is equal. The displacement, or stroke, of the piston rod is generally limited to the distance the piston can displace within the cylinder. This type of a system can be disadvantageous if the fluid medium is compressed air and the piston is floating in the cylinder and finally positioned by equal fluid forces being established on opposite sides of the piston. In heavy machine tool work, the forces created between the tools and the work can add to the force on one side of the piston within the cylinder, upsetting the equilibrium and throwing the tool out of alignment.
One manner of overcoming this disadvantage has been to utilize a plurality of fluid-actuated cylinders, such as hydraulic cylinders that do not rely on the establishing of equilibrium pressure. These cylinders have piston strokes of varying lengths and are stacked in an end-to-end relationship to provide a more rigid connection between the controlled tool and the positioning device. Such a device is disclosed in U.S. Pat. No. 3,633,465 to Puster. The actuated pistons disclosed in Puster slide the cylinders a distance that is equal to the sum of the stroke lengths of each actuated cylinder. Sizing the cylinders so that each has a different stroke length allows the device to achieve a large number of positions. Conventional multi-stroke, actuated cylinders are not laterally stable and occupy an excessive amount of space during use. In addition, many of these conventional actuators utilize position feedback mechanisms for insuring the accuracy of the positioning of the tooling plate. Typically, these feedback mechanisms include sensitive electrical feedback loops that can cause radio frequency interference with the power and fluid control mechanisms. Also, the use of electrical feedback or position control mechanisms can require shaft encoders that impose a risk of sparks or shorts, thereby creating explosive or otherwise hazardous conditions.
It is an object of the present invention to overcome the disadvantages of the prior art. It is also an object of the present invention to provide a multi-stroke cylinder capable of accurately achieving a large variety of positions without the use of a position feedback mechanism.
SUMMARY OF THE INVENTION
The present invention relates to a multi-stroke air cylinder that provides a precisely directed and controlled stroke in the face of lateral, torsional and tilting loads on a tooling plate. The present invention can use binary techniques or combinations of stroke increments to provide a precise positioner utilizing pneumatic or hydraulic power that provides accurate positioning of a tool without requiring or using position feedback mechanisms. Also, the air cylinder is laterally stable so it can be used in areas such as woodworking, apparel manufacturing, building materials, housing construction and other similar arts.
The present invention utilizes a plurality of mechanically linked pneumatic or hydraulic pistons having different stroke lengths that can be added together in any combination, allowing the user to select any stroke length up to a predetermined, total combined stroke length, in increments equal to the stroke length of the shortest stroke piston. For example, if the invention included four pistons having stroke lengths of one inch, two inches, four inches and eight inches, the user can select any stroke length in increments of one inch up to a total combined stroke length of fifteen inches. A three inch stroke would be obtained by extending the one inch stroke piston and the two inch stroke piston. A seven inch stroke would be obtained by extending the one inch stroke piston, the two inch stroke piston and the four inch stroke piston. The activation and extension of all of the pistons would achieve a fifteen inch stroke. The present invention also includes a plurality of pistons that can move the tooling plate by a fraction of an inch. This fractional movement can be added to the movement of the pistons having full inch increments so that positions in increments of the smallest fraction of an inch can be achieved up to the aggregate stroke length of all of the pistons.
The multi-stroke cylinder according to the present invention includes a head assembly having a fluid inlet for introducing fluid to the cylinder at a first pressure. The cylinder also includes a first positioning system having a plurality of pistons capable of moving the piston rod away from the first positioning system. A second positioning system is located between the head assembly and the first positioning system. The second positioning system comprises a plurality of movable pistons for moving the piston rod a preselected distance and a plurality of fluid supply members which are each secured to a respective one of the pistons of the second positioning system for introducing a fluid between adjacent pistons. The fluid supply members are concentrically arranged and are at least partially coextensive with one another. The disadvantage previously discussed concerning differential pressure pistons does not occur with the present invention because an equilibrium is not established. Instead, low pressure used to maintain the rest position of the pistons is expelled from the cylinder of the second positioning system as the piston is moved by the higher pressure introduced through the fluid supply members.
The first or “fine” positioning system utilizes a plurality of positioning stages having increments of movement in 1/16 of an inch intervals up to a total of 15/16 of an inch. The smallest of the different sized stages is 1/16 of an inch. The second or “coarse” positioning system has increments of movement set in one inch intervals up to a total of fifteen inches. In this system, the pistons would be set to extend at different lengths with the smallest stage length being one inch. By activating the coarse and fine positioning systems, the tooling plate of the present invention can be positively positioned in as many as 256 individual positions. If an additional stage capable of 1/32 of an inch were added, the number of discrete positions that could be achieved would be doubled to 512, thereby increasing the accuracy of the multi-stroke cylinder. Similarly, adding another stage capable of 1/64 of an inch movement could again double the accuracy while quadrupling the original number of discrete positions obtainable to 1024.
The present invention accurately positions the head of a piston rod or other similar devices such as a tooling plate in one, two or three planes by activating one or a plurality of pistons within a cylinder. Valves control the flow of the fluid medium within the cylinder and between the pistons. The head of the tooling piston or plate can securely and accurately carry any number or types of tools for performing an application on a work piece. For instance, by attaching a drill, the user could accurately drill a hole anywhere in an X-Y plane to a depth of Z and repeat the same controlled drilling depth at a second location. Alternatively, the hole could be drilled to a different depth at the second location. By attaching a parts gripper, the operator could retrieve a part from a known inventory position and place it accurately in an assembly a predetermined distance away. The present invention allows these applications to occur without the forces generated at the work piece affecting the position of the head of the piston rod.
Unlike conventional multi-stroke actuators and their related methods for carrying out the above discussed tasks, the embodiments according to the present invention do not require a feedback mechanism to insure the positioning accuracy of the tooling piston or plate. Selecting the proper combination of valves insures that the piston rod moves positively to the selected position. An additional advantage arises from the exclusive use of fluid power to carry out the positioning, thereby eliminating the necessity of employing electrical counters or shaft encoders which impose the risk of sparks or shorts in explosive or otherwise hazardous conditions. Furthermore, the present invention is completely free of radio-frequency interference since no sensitive electrical feedback loops are required. The multi-stroke cylinders according to the present invention are also compact in size and laterally stable so that they are able to be used in a variety of locations for performing many different operations.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic view of a multi-stroke cylinder according to an embodiment of the present invention;
FIG. 2 is a schematic view of the multi-stroke cylinder shown in FIG. 1 with the stages in an extended state;
FIG. 3 illustrates the second positioning system according to the embodiment shown in FIG. 1 at rest, without the cylinder;
FIG. 4 illustrates a cross section of the back plate and pistons of the first positioning system according to the embodiment shown in FIG. 1 ;
FIG. 5 illustrates the back plate and pistons of the first positioning system according to the embodiment shown in FIG. 1 in an extended state;
FIG. 6 is a schematic view of the first positioning system shown in FIG. 5 at rest;
FIG. 7 is a schematic view of a multi-stroke cylinder according to another embodiment of the present invention;
FIG. 8 is a schematic view of the multi-stroke cylinder shown in FIG. 7 with the stages in an extended state;
FIG. 9 is an end view of the multi-stroke cylinder according to FIG. 7 ;
FIG. 10 illustrates the connection between the pistons and fluid supply tubes of the embodiment shown in FIG. 7 ;
FIG. 11 is a schematic view of another embodiment of the multi-stroke binary cylinder according to the present invention;
FIG. 12 is a schematic view of the multi-stroke cylinder shown in FIG. 11 with the stages of the first positioning system in an extended state;
FIG. 13 is a schematic view of the multi-stroke cylinder of FIG. 11 with the stages of the first and second positioning systems in an extended stroke;
FIG. 14 is a schematic view of the tethered pistons of the first positioning system and second positioning system housing;
FIG. 15 shows the pistons of the first positioning system about the second positioning system housing;
FIG. 16 shows a surface of the back plate according to the embodiment shown in FIG. 11 ;
FIG. 17 is a schematic view of another embodiment of the multi-stroke cylinder of FIG. 17 with both positioning stages in their fully retracted states, according to the present invention;
FIG. 18 is a schematic view of the multi-stroke cylinder shown in FIG. 17 with both positioning stages in their fully extended states;
FIGS. 19A-C schematically illustrate a stroke piston as shown in FIG. 17 ;
FIG. 20 illustrates the first stage positioning system with all pistons in their retracted positions as shown in FIG. 17 but with the cylinder wall removed for better clarity;
FIG. 21 illustrates the first stage positioning shown in FIG. 20 but with all pistons in their extended positions;
FIG. 22 is a schematic view of the second stage positioning system with both the 4″ stroke and the 8″ stroke pistons in their retracted positions but with the cylinder wall removed for better clarity;
FIG. 23 illustrates the second stage positioning system shown in FIG. 23 but with the 4″ stroke piston in its extended position;
FIG. 24 illustrates the second stage positioning system shown in FIG. 24 but with both the 4″ stroke and the 8″ stroke pistons in their extended positions;
FIG. 25 schematically illustrates the second stage positioning system shown in FIG. 23 with the enclosing cylinder tube removed;
FIG. 26 schematically illustrates the second stage positioning system shown in FIG. 24 with the enclosing cylinder tube removed and the 4 inch stroke piston extended;
FIG. 27 schematically illustrates the second stage positioning system shown in FIG. 25 with the enclosing cylinder tube removed and with both the 4 inch and 8 inch stroke pistons extended;
FIG. 28 illustrates the multi-stroke cylinder as shown in FIG. 18 but with a color coded Legend which shows the placement of the various seals and bearings;
FIGS. 29A and 29B illustrate the multi-stroke cylinder shown in FIG. 18 but with the input air manifold assembled to the top of the main housing;
FIG. 30 depicts a bottom view of the air input manifold plate showing the grooves which channel compressed air from the plumbing connections to the piston input orifices atop the main housing; and
FIG. 31 is an end view of the air input manifold plate of FIG. 30 .
DETAILED DESCRIPTION OF THE INVENTION
A multi-stroke air or hydraulic cylinder according to the present invention is shown in FIG. 1 . This invention utilizes floating, tethered power pistons interconnected in such a manner as to cause an output piston rod 189 to move a distance equal to the sum of all the distances moved by each of the individual pistons. FIG. 1 schematically illustrates the multi-stroke cylinder 100 in a fully retracted condition. FIG. 2 illustrates the multi-stroke cylinder 100 with its stages, pistons, in a fully extended condition. The first positioning system 110 includes four pistons having fractional stroke lengths (fractions of an inch) located within an annular cylindrical housing 120 . A second positioning system 150 includes four pistons having longer strokes (multiples of one inch) located within a conventional cylinder 160 .
High pressure fluid is introduced between the pistons through a fluid inlet 114 . This introduced fluid causes the pistons to separate to the extent permitted by respective tethering mechanisms in order to move piston rod 189 a predetermined distance. A low pressure fluid, at approximately ¼ to ½ the pressure of the high pressure fluid, is introduced at the end of the second positioning system 150 closest to piston rod 189 to return the pistons of both positioning systems and piston rod 189 to their rest positions. In a preferred embodiment, air or line air is provided at a high pressure of substantially between 80 PSI and 250 PSI with the low pressure being substantially between 20 PSI and 125 PSI. The cross-hatching shown in FIG. 1 between piston 156 and head assembly 190 illustrates the presence of low pressure air. The lack of cross-hatching and the extended condition of the device as shown in FIG. 2 illustrates when high pressure air has been introduced between the pistons.
As shown in FIG. 1 , the first positioning system 110 includes the annular cylindrical housing 120 having an opening 111 through its center section 121 for the passage of tubes 161 - 164 which supply compressed air to the second positioning system 150 . A first stroke piston 115 is positioned against a back plate 112 of housing 120 when it is at rest. The piston 115 is moved a predetermined distance when the introduction of compressed air via a port 113 extending through the rear plate 112 overcomes the low pressure holding the pistons at rest. The remaining pistons 116 - 118 are supplied with high pressure fluid through input ports 114 which enter the annular cylinder wall 125 at right angles to the direction in which pistons 115 - 118 move. Input ports 114 can be positioned at other angles relative to the direction that pistons 115 - 118 move.
In order to facilitate the entry of the compressed air into and out of the spaces between each of the moveable pistons 115 - 118 , a shallow slot 131 is formed in each piston wall 132 on one or both sides of the piston seal slot 133 . Slots 131 extend parallel to the direction of travel of the pistons and are aligned with input port orifices 114 , as shown in FIGS. 1 , 5 and 6 . In FIG. 5 , shallow grooves 135 , cut into the perimeter of each piston, connect each of the slots 131 to three grooves 136 cut radially into the piston faces. Grooves 136 are cut into the pistons 120° apart from each other. Once compressed air is delivered between all or some of the pistons 115 - 118 , the selected pistons are spaced apart a predetermined distance for causing a predetermined amount of movement of positioning rod 189 . The result is a calibrated movement of the piston rod 189 outward as high pressure air fills the precise voids between the pistons and overcomes the force of the low pressure air tending to push them toward the back of the housing 120 . Any number of grooves 136 such as two to six, can be formed on the piston faces so that fluid will flow between adjacent pistons.
For the sake of clarity, FIG. 4 shows a cross section of the first positioning system at full extension but without the confining cylindrical housing 120 or center tube 121 . Sets of locked tethering screws 142 extend between adjacent pistons for limiting their relative and total movement. While tethering screws are discussed with this embodiment, other known tethering members such as those discussed below could also be used. Each set of tethering screws 142 includes at least three screws that limit the travel of their respective piston to a predetermined distance relative to the rear plate 112 or to the piston at its left (as shown in the figures). The tethering screws 142 are secured within the adjacent pistons so that they are slidable relative thereto. Three rigid inter-stage pusher rods 148 extend from positioning system 110 and transmit the cumulative movement of all four pistons 115 - 118 to a fractional stroke piston 152 in the second positioning system 150 . O-rings 141 seal the tethering screw cavities 140 containing tethering screws 142 . A seal 143 such as an O-ring is positioned in each slot 133 for preventing fluid from passing between each piston and the inner surface of the cylinder 120 . Seal 143 is also used between the inner surface of the pistons 115 - 118 and the outer surface of center tube 121 . FIG. 5 shows an outside view of FIG. 4 and illustrates the slots 131 machined axially along the outer, circumferential edge of the annular pistons which connect with the grooves 136 formed across the faces of the pistons in a direction perpendicular to the path of travel of the pistons for the purpose of allowing quick flow of high pressure air from its introduction at ports 114 along the perimeter of the pistons to the working faces thereof. The grooves 136 and slots 131 can be formed by any well known process such as machining, abrading, etc. Additionally tubes or other fluid conduits could be used to present the line air introduced through port 114 to the facial grooves 136 . FIG. 6 shows the annular pistons in the fully retracted condition and illustrates the axial slots 131 and the facial grooves 136 .
An intermediate plate 122 , shown in FIG. 2 , connects the first positioning system 110 to the second positioning system 150 and contains three linear bearings 123 for guidance of the inter-stage pusher rods 148 . Plate 122 provides support for both the inside tube 121 and the cylinder tube 160 which is held in place by four tensioned tie rods (not shown) between the intermediate plate 122 and the head assembly 190 .
FIG. 3 illustrates a sub-assembly of the pistons of the second positioning system without cylindrical housing 120 , the pistons of the first positioning system and cylinder 160 . FIG. 3 shows four power pistons 153 , 154 , 155 and 156 at rest in their fully retracted positions against the fractional piston 152 and four concentric, co-axial conduits or tubes 161 - 164 . The retraction force produced by the low pressure line air works against the reduced effective area of the retract piston 156 which is the result of using an oversized piston rod 189 having one-half or less the surface area of the advancement pistons 152 - 155 . Tubes 161 - 164 tether each of the pistons 153 - 156 to a respective one of the stroke limiting collars 165 - 168 and limit their distances to those discussed herein. Tubes 161 - 164 are formed of rigid material such as aluminum, brass, steel or any high strength plastic such as delrin, nylon, etc. The rigidity of the tubes contributes to the ability of cylinder 100 to resist lateral and torsional forces applied during its operation.
Each concentric tube 161 - 164 is sized so that its outside diameter is sufficiently smaller than the inside diameter of the tube in which it moves to provide an annular cross-sectional area large enough to convey the high pressure fluids, such as air, rapidly to the next succeeding cavity. The wall thickness of each tube is carefully sized to ensure that its strength is sufficient to withstand the tensile and compressive forces it will encounter during the operation of the multi-stroke cylinder 100 . These wall thicknesses can vary depending on the intended use of the cylinder 100 , the materials of the tube and/or the magnitude of the forces that will be applied to the tube. In a preferred embodiment, the wall thickness of each tube 161 - 164 can be substantially 1/32 inch or ⅛ inch. Alternatively, the thickness can be between 1/32 inch and ⅛ inch. The advantages of using coaxial tubes 161 - 164 include less friction, fewer sealing problems, simpler inter-stroke stop mechanisms, reduction in off-center piston loads and increased stability.
High pressure compressed air is introduced through collars 165 - 168 and channeled between pistons 152 - 156 by tubes 161 - 164 . The outside and shortest tube 161 rigidly connects the fractional stroke piston 152 to the collar 165 . Collar 165 channels high pressure air between tubes 161 and 162 . This air travels through the fractional stroke piston 152 to move the piston 153 . Similarly, the tube 162 connects the piston 153 to the collar 166 which channels compressed air between tubes 162 and 163 , which in turn introduce the compressed air between pistons 153 and 154 . The air between pistons 153 and 154 moves piston 154 away from piston 153 . Tube 162 is dimensioned in length to limit movement between the fractional piston 152 and the piston 153 to a precise, predetermined length such as one inch. In this same manner, the stroke limiting collar 167 supplies compressed air between tubes 163 and 164 for contacting and moving piston 155 away from piston 154 . Compressed air is supplied to piston 156 through stroke limiting collar 168 which is tapped, as is piston 155 , to receive the much heavier walled center tube 164 which provides structural support to the entire tethering, co-axial tube sub-assembly. The piston 156 is tethered to the piston 155 through a plurality of the steel shafts 157 which allow precisely eight inches of movement between the two pistons 155 , 156 .
As shown in FIG. 3 , the pistons 152 , 153 and 154 and stroke limiting collars 165 , 166 and 167 which contain tubes 161 - 163 , respectively, each include an assembly 180 having two pieces 181 , 182 formed to complement, capture and retain the flared ends 183 of their respective tubes. Two O-ring static seals 184 within each assembly 180 prevent fluid leakage and each two-part, stroke limiting collar 165 - 167 contains a dynamic seal 185 to prevent leakage between it and the outside wall of the tube on which it slides.
Conventional NPT entry ports 186 located in each of the two-part collars 165 - 167 channel the line air into a connecting radial cavity 187 which distributes it through several holes 188 in its associated fluid supply tube to allow flow into the space between adjacent tubes.
The piston rod 189 is secured to piston 156 and is capable of being rotated within piston 156 so that outside torque forces are not be transmitted to the internal mechanisms which link pistons 155 - 156 to each other.
An alternative form of tethering the pistons is illustrated in FIG. 7 . The same reference numerals are used to indicate common elements between the embodiment shown in FIG. 1 and that shown in FIG. 7 . In FIG. 7 , the inlet tubes 210 are not concentric with one another. Instead, each extends through one of four linear bearings 211 mounted in a square array within rear plate 112 . A stroke limiting collar 212 is rigidly attached to tube 221 about one inch outside rear plate 112 when the pistons are in their retracted position. The spacing between this collar 212 and plate 112 , as well as the length of pusher rods 148 , allows a fractional stroke piston 252 , attached to tube 221 , to move a full 15/16 of an inch. Tube 221 extends into fractional stroke piston 252 but does not pass through it. Instead, tube 221 stops at a face of piston 252 closest to piston 253 .
The three remaining tubes 222 , 223 , 224 , all similar to tube 221 , pass through seals 230 and bearings 231 mounted in a square array within fractional stroke piston 252 . The square array of fractional stroke piston 252 is substantially identical to that of plate 112 so that the tubes remain straight as they extend along the length of the multi-stroke cylinder. Tube 222 is attached to the 1″ stroke piston 253 and the other two tubes 223 , 224 pass through a bearing in piston 253 and are attached to the 2″ stroke piston 254 and the 4″ stroke piston 255 , respectively. Like tube 221 , tubes 222 - 224 have collars 212 rigidly attached at precise positions along their lengths so the collars on adjacent shafts contact one another, as shown in FIG. 8 , and limit the relative movement between the adjoining shafts and adjacent pistons. In this manner, collar 212 is positioned on tube 222 so the movement of the 1″ stroke piston 253 relative to the fractional stroke 252 piston is limited to one inch. Collar 212 is positioned on tube 223 so the movement of the 2″ stroke piston 254 relative to the 1″ stroke piston 253 is limited to two inches. Collar 212 is positioned on tube 224 so stroke piston 255 only moves four inches relative to 2″ stroke piston 254 .
Each of the hollow tubes 221 - 224 are attached to a high pressure fluid source for introducing air between adjacent pistons. Tube 221 , attached to the fractional stroke piston 252 supplies air between stroke pistons 252 and 253 to move stroke piston 253 one inch; tube 222 , attached to the 1″ stroke piston 253 , supplies air between stroke pistons 253 and 254 to move the 2″ stroke piston 254 two inches; and tube 223 , attached to the 2″ stroke piston 254 , supplies air between stroke pistons 254 and 255 to move stroke piston 255 four inches. The 8″ stroke piston 256 is moved by the fluid supplied between stroke pistons 255 and 256 through tube 224 attached to the 4″ stroke piston 255 . As with tube 221 , tubes 222 - 224 terminate at the face of the piston to which they are attached. The relative movement of piston 256 with respect to piston 255 is limited by a pair of stroke limiting shafts 257 which are rigidly attached to the 4″ stroke piston 255 but pass through the 8″ stroke piston 256 via bearings 258 and seals 259 . The piston rod 189 is capable of being rotated within stroke piston 256 so that outside torque forces cannot be transmitted to the internal mechanisms which link the floating pistons to each other. FIG. 10 depicts the stroke limiting action of the collars 212 between the fractional stroke piston 252 and the 1″ stroke piston 253 as they would appear if removed from the confining cylinder. Linear bearings 231 and dynamic tube seals 230 provide low friction, leak proof, relative movement between the air supply tubes and the monolithic pistons. O-rings 265 provide hermetic seals where the tubes are attached to the pistons as shown in FIG. 10 .
When high pressure air is vented from the space between any two of the pistons, the retraction force of the low pressure air (shown by hatching in FIG. 7 ) in cylinder 160 between head assembly 190 and piston 156 causes piston 156 to move toward the rear plate 112 . The force of the low pressure air expels the residual air between the two adjacent pistons and moves the pistons and the piston rod 189 inward from their extended positions as shown in FIG. 8 . The pistons and piston rod 189 move an amount equal to the length of the distance between them. The air is vented to the atmosphere through the exhaust port in the three-way valve which supplies high pressure air to the various pistons. Low pressure air returns between piston 256 and head assembly 190 through fluid port 191 . A self compensating type of pressure reducer is used to return the lower pressure fluid between piston 256 and the head assembly 190 .
A co-axial multi-stroke cylinder 100 ′ according to another embodiment of the present invention is illustrated in FIGS. 11-16 . This embodiment utilizes coaxial cylinders for housing its piston rod positioning systems. Elements of this embodiment that are similar to those previously described will be identified using the same numerals. The embodiment shown in FIG. 11 eliminates the need for low pressure air to retract a piston rod 189 ′. Instead, this embodiment takes advantage of line air for cylindrical and piston rod retraction.
With all of the embodiments discussed herein, the use of line air operating against smaller piston areas has the advantage of not requiring a self-relieving pressure reducing valve which increases system costs and plumbing complexity. Also, the prior art systems which use air must vent their air to the atmosphere when any of the pistons advance. Line air is not vented from the system but is pumped back into the supply line by the advancing pistons, thus saving the costs of producing compressed air—a fairly expensive commodity in an industrial plant. By including a three-way valve to handle the line air used for retraction, one could remotely vent this air and thereby effectively double the push power of the cylinder should the occasion arise.
As illustrated in FIG. 11 , cylinder 100 ′ includes first positioning system 110 ′ and second positioning system 150 ′. As with the multi-stroke cylinders discussed above, common elements have the same reference numerals as used with the description of the previous embodiments. The total stroke length of cylinder 100 ′ is 15 and 15/16 inches. However, the individual stroke lengths of each positioning system 110 ′ and 150 ′ are different from those discussed above. Contrary to the multi-stroke cylinders discussed above, first positioning system 110 ′ is capable of moving piston rod 189 ′ a total of 1 and 15/16 inches. Second positioning system 150 ′ is only capable of moving piston rod 189 ′ a total of 14 inches. Nevertheless, the combined total possible stroke length of cylinder 100 ′ is 15 and 15/16 inches when the cylinder has been fully extended as shown in FIG. 13 .
First positioning system 110 ′ operates in a similar manner to that discussed above with respect to positioning system 110 . First positioning system 110 ′ includes annular cylindrical housing 120 surrounding a plurality of pistons 115 - 119 . Housing 120 includes an outer surface 124 and an inner surface 126 . Input port orifices 114 extend between surfaces 124 and 126 for introducing compressed air from a conventional source into housing 120 and between pistons 115 - 119 . As discussed above, conventional three-way solenoid or pilot operated valves can be used with the embodiments of the present invention. Such valves which are able to be used with each embodiment described herein are produced by companies such as MAC valves, ASCO, Humphrey and Parker Hannifin. As shown in FIGS. 14 and 15 , pistons 115 - 119 each include a seal 143 , positioned in slot 133 , that engages with inner surface 126 to prevent the introduced air from passing between each piston 115 - 119 and inner surface 126 . Pistons 115 - 119 also include an inner seal 143 for engaging the outer surface of a housing 151 ′ of second positioning system 150 ′. Tethering members 142 are used to limit the travel of pistons 115 - 119 relative to each other and back plate 112 , as discussed above. Like piston 153 of second positioning system 150 , piston 119 has a total stroke length of one inch. This one inch, when added to the combined 15/16 of an inch stroke of pistons 115 - 118 , provides positioning system 110 ′ with its total stroke length of 1 and 15/16 inches.
Second positioning system 150 ′ operates in a similar manner to that discussed above with respect to positioning system 150 . Second positioning system 150 ′ includes housing 151 ′, a rear plate 152 ′ and a plurality of power, stroke pistons 154 - 156 for imparting movement to piston rod 189 ′. As seen in FIGS. 11-13 , housing 151 ′ has an elongated, generally tubular shape that extends within and through housing 120 such that they are coaxially aligned and mutually supported. This overlapping, coaxial positioning of housings 120 and 151 ′ forms a more stable multi-stroke cylinder when compared to those of the prior art. The overlapping, coaxial positioning of the housings also creates a compact, multi-stroke cylinder 100 ′ that does not occupy as much space, when activated and when at rest, as prior art multi-stroke cylinders. The multi-stroke cylinder 100 ′ is more compact and better able to resist the forces created when piston rod 189 ′ moves. The present invention eliminates the conventional back to back piston relationship used in the prior art. The coaxial positioning also makes the cylinder easier and less costly to manufacture when compared to conventional multi-stroke cylinders.
Housing 151 ′ includes a raised, first positioning system engaging portion 148 ′ that transfers the cumulative stroke of pistons 115 - 119 from first positioning system 110 ′ to second positioning system 150 ′ and to piston rod 189 ′. As shown in FIG. 14 , piston 119 is secured to the engaging portion 148 ′ by a plurality of fastening screws 149 ′. The engaging portion 148 ′ passes through a guide bushing and kinetic seal 123 ′ in plate 122 ′ and reduces the effective area of the return side of piston 119 to provide the force differential needed to extend and retract housing 151 ′ relative to housing 120 . The engaging portion 148 ′ can be varied in diameter from model to model to provide modest variations in the ratio between the forces needed to extend and retract the cylinder. Piston 154 is moved by introducing a high pressure fluid through input port 161 ′ and between back plate 152 ′ and piston 154 . Pistons 155 and 156 are moved by the introduction of fluid via tubes 163 and 164 , as discussed above. Tube 164 passes through a guide bushing/seal arrangement in stroke limiting collar 167 . As with those discussed above, this seal arrangement, shown in FIG. 13 , prevents the escape of fluid within tube 163 from between collar 167 and the outer wall of tube 164 .
After the pressurized fluid exits tube 164 through openings 169 ′, it forces hollow piston rod 189 ′ and rod cap 200 ′ a distance of eight inches away from piston 155 . Piston rod 189 ′ is secured to piston 156 so that no relative movement exists therebetween. As shown in FIG. 13 , an eight inch tethering rod 157 ′ extends through a guide bushing and a kinetic seal contained within an insert 166 ′ at the end of hollow piston rod 189 ′ where it is secured to piston 156 . Tethering rod 157 ′ includes a tethering head 158 ′ for contacting the insert 166 ′ in order to limit the movement of the piston rod 189 ′. Piston rod 189 ′ includes a hollow center for receiving tethering rod 157 ′ when piston 156 is in contact with piston 155 , such as when the cylinder 100 ′ is at rest, as shown in FIG. 11 . Cylinder 100 ′ is compact and space efficient, in part, due to the piston rod 189 ′ receiving tethering rod 157 while the cylinder 100 ′ is at rest. Low pressure air is introduced into ports 165 ′ and 191 for returning the advanced pistons to their rest positions.
FIG. 15 shows an external view of the same pistons in the extended mode. These pistons are slightly reduced in diameter on one or both sides of the full diameter section 144 which contains the seal slots 133 and kinetic seals 143 . This arrangement allows full flow of air in and out of the cavities between the pistons 115 - 119 to the various ports 114 as the pistons 115 - 119 move relative to these ports 114 within the cylinder walls. The reduced diameter sections 135 provide the same function as the parallel slots 131 shown in FIGS. 5 and 6 but allow the input ports 114 to be placed at any convenient position around the circumference of the piston. As discussed above, shallow lateral slots 131 machined at multiple places across the face of each piston allow quicker movement of compressed air between adjoining pistons as they separate or come together.
FIG. 16 shows an end view of the top of the cylinder with the 1/16 inch stroke port 113 at top. Also shown are the 2 inch stroke stop 168 , the 4 inch stroke stop 167 and the 2 inch stroke port 161 ′. Four screws 158 ′ attach the rear end plate 112 to the housing 110 . Up to eight tapped input ports 201 conduct compressed air axially through the solid portions of the housing to connect with radial ports 114 located between adjacent pistons or to other ports machined into the forward plate 122 . This approach simplifies the complicated plumbing of conventional cylinders and is made possible by the reduced diameters 135 on the outside of the annular pistons as described heretofore.
FIG. 17 illustrates another embodiment of a multi-stroke cylinder 100 ″ that is similar and operates in essentially the same manner as the multi-stroke cylinder 100 ′ shown in FIG. 11 . As a result, a discussion of its components that are also included in cylinder 100 ′ and its operation will not be repeated. Contrary to the embodiment of FIG. 11 , the two inch stroke piston 154 ′, according to this embodiment, is housed in the first positioning system 110 ″. As a result, the second positioning system 150 ″ only includes two pistons 155 , 156 and one fluid introduction tube 164 . First positioning system 110 ″ has a total stroke length of 3 and 15/16 inches. Second positioning system 150 ″ has a total stroke length of only twelve inches. FIG. 17 schematically illustrates the multi-stroke cylinder 100 ″ in a fully retracted condition. This embodiment is easier, more compact, more stable and more economical to manufacture when compared to conventional cylinders. Also, as with the embodiment shown in FIGS. 1 and 11 , this embodiment is more accurate and better able to resist the forces created during its operation.
The multi-stroke, hydraulic cylinder 100 ″ is shown in FIG. 18 with all of its stages extended. This invention utilizes floating, tethered pistons, interconnected in such a manner as to cause an output piston rod 189 to move a distance equal to the sum of all the distances moved by each of the individual, activated pistons. The first positioning system 110 ″ includes six annular pistons 115 , 116 , 117 , 118 , 119 and 154 ′ having respective stroke lengths of 1/16″, 1/18″, ¼″, ½″, 1″ and 2″ which operate within annular cylindrical housing 120 . The first positioning system is thus capable of stroking 3 15/16″ in increments of 1/16″. The second positioning system 150 ″, extending within the first positioning system, includes two conventional pistons 155 and 156 having respective stroke lengths of 4″ and 8″ and is thus capable of stroking 12 ″ in increments of 4″. The 2″ stroke piston 154 ′ is rigidly attached to the second stage cylinder tube 151 ′ and to the steel extension tube 148 ″ which acts to guide it through the head plate 122 ′ of the first positioning system as its pistons 115 - 119 , 154 ′ advance and retract. The piston 154 ′ can be integrally formed with the extension tube 148 ″ as a single unit. The outside diameter of the extension tube 148 ″ is sized so that the area left between it and the inside diameter of the annular cylinder 121 approximately one-half the face area of the other annular pistons 115 - 119 , 154 ′. As a result of this size relationship, compressed air at line pressure acting against this area creates a retraction force against the extended 2″ stroke piston 154 ′ which forces all the first stage pistons 115 - 119 , 154 ′ to the rear of plate 112 of the annular cylinder 121 . The piston tube 189 of the second stage is sized in a similar manner with respect to piston 156 so that line pressure acting on the retraction face of the 8″ stroke piston 156 forces it against the 4″ piston 155 and pushes both to the rear of the second stage cylinder tube 151 ′. Air orifices 191 placed near the left end of the extension tube 148 ″ and the right end of the second stage cylinder tube 151 ′ allow compressed air to flow in and out of the retraction sides of both cylinders, thus maintaining constant retraction forces regardless of the positions of the pistons within the two cylinders.
The introduction of line air through a port 113 or a port 114 between any two pistons will create extension forces that are approximately twice those of the retraction forces needed to return the extended pistons to rest as discussed above. The extension forces cause the affected piston to move toward the head of its respective cylinder (rightward as shown in FIG. 18 ) the precise distance allowed by the inter-piston tethering mechanisms.
FIGS. 19A-C illustrate the construction details of the 1″ stroke piston 119 which is typical of the fractional movement annular pistons 115 - 119 , 154 ′. The piston body 132 would typically be fashioned of an easily machined metal, such as aluminum, or a plastic, such as delrin. The piston 119 includes three or more slotted wells 136 ′ machined into each piston face at regular intervals and of sufficient depth to accommodate approximately one half the length of I-shaped metal tethers 142 ′ which link it to the pistons on either side 118 , 154 ′. Flat steel rings 134 , fastened to both faces of the piston body by multiple through-bolts 180 ′ as shown in FIGS. 19A-C , contain three or more matching rectangular slots 131 ′ which are aligned with the piston body wells and capture the T-shaped ends of the metal tethers 142 ′, which precisely limit the movements of the various pistons relative to one another and ensure that the piston faces are maintained parallel to each other in the tethered positions. These flat steel rings 134 also prevent the end faces of their respective pistons from being damaged (scratched, broken, nicked, etc.) by an adjacent piston. They also prevent the forces applied by the tethers 142 ′ from damaging the end faces of their respective pistons. The tethers 142 ′ are formed from relatively thin, heavy, high strength, heat treated sheet metal stampings with a slight curvature about their long axes for extra rigidity. The thin cross section of these tethers 142 ′ allow a thinner walled, annular piston and, therefore, greater compactness in overall design. Additionally, the tethers are contained in wells 136 ′ when the pistons are in a retracted position for additional compactness of the air or hydraulic cylinder 100 ″. A plurality of bolt holes 280 extends through each piston and its rings 134 for securing the portions of the piston together. O-rings 141 are installed beneath a bolt head 281 to prevent the passage of air through the bolt holes 280 and preserve the pneumatic integrity of each piston. The outer cylindrical surface 135 ′ of each piston body, on one or both sides 137 of the outer sealing slot lands carrying dynamic seal 133 ′, is stepped down in diameter in order to provide a passageway 135 for compressed air to move into and out of the piston actuating area regardless of the respective piston's movement or position. As discussed above, dynamic seals 133 ′ on both the inner and outer diameters of each piston 115 - 119 , 154 ′ prevent passage of compressed air past the piston as it moves back and forth within the containing cylinder 121 .
FIG. 20 depicts the first stage positioning system 110 ″ without the enclosing cylinder tube 121 and with all pistons fully retracted against the rear housing plate 112 . The tip ends of the 1/16 stroke piston tethers 142 ′ appear to the left of the 1/16″ piston 115 . Compressed air entry ports 113 and 114 for actuation of the six annular pistons 115 - 119 , 154 ′ are represented by arrows and are positioned just to the rear (left as shown in FIG. 20 ) of the dynamic seal lands 137 for each piston.
FIG. 21 illustrates the first stage positioning system shown in FIG. 20 with all six pistons extended to the limits allowed by their tethers 142 ′. The overall piston length is designed to provide adequate depth for containing the associated tethers 142 ′ within their slotted wells 136 ′. The width and placement of the lands 137 and seal grooves 133 ′ are designed to provide adequate lengths for the reduced diameter sections 135 so that compressed air can flow unimpeded through the side input orifices 113 , 114 and 165 to and from the piston cavities 138 regardless of the position of the pistons within the confining cylinder.
FIGS. 22 and 25 schematically illustrate the second stage positioning system 150 ″ without the confining cylinder tube 151 ′ and with both the 4″ stroke piston 155 and the 8″ stroke piston 156 forced into their fully retracted positions by line air pressure 124 ″ working against the right hand face (as seen in FIG. 22 ) of the 8″ stroke piston. FIG. 22 illustrates the second stage positioning system 150 ″ in cross section and the direction of the effective air pressure.
FIGS. 23 and 26 depict the second stage positioning system shown in FIG. 22 as it would appear with line air pressure 124 ″ entering through orifice 161 ′ and working against the left hand face of the 4″ stroke piston 155 thus forcing both 4″ stroke piston 155 and 8″ stroke piston 156 outward (rightward as seen in FIG. 23 ) the precise 4″ allowed by the adjustable tethering stop nuts 168 . FIG. 23 illustrates the second stage positioning system 150 ″ in cross section and the direction of the effective air pressures.
FIGS. 24 and 27 depict the second stage positioning system shown in FIGS. 22 and 23 with line air pressure flowing through the air supply tube 164 and orifices 169 into the cavity between the 4″ stroke piston 155 and the 8″ stroke piston 156 . This cavity or space is eventually vacated by the 8″ stroke piston 156 as the pistons 155 , 156 separate. The tethering stop nuts 158 provide a lockable adjustment for precisely setting the 8″ tethered travel between the 4″ stroke piston 155 and the 8″ stroke piston 156 . Other well known adjustable locking members could also be used. FIG. 24 illustrates the second stage positioning system 150 ″ in cross section and the direction of the effective air pressures.
FIGS. 28 illustrate the multi-stroke cylinder of FIG. 18 but with a color-coded Legend which shows position of the various static O-ring seals, linear motion bearings, U-cup type dynamic seals and Quad Ring type dynamic seals.
FIG. 29A illustrates the multi-stroke cylinder of FIG. 17 with the air distribution manifold assembly 170 mounted in position atop the annular cylinder 121 housing. FIG. 29B depicts an end view of the cylinder in FIG. 29A with the nine air input connections 172 which channel compressed air between the eight individual pistons and the back plate 112 , and to the return air chambers in the front of the two cylinders (right side as shown in FIG. 29 A).
FIG. 30 depicts a bottom view of air input manifold plate 171 showing the grooves 173 which channel compressed air from the plumbing connections 172 to the orifices 113 , 114 atop the annular cylinder housing 121 . These air flow grooves can be formed by any well known procedure such as machining.
The following description applies to the operation of the above discussed embodiments. By limiting the stroke of the first piston 115 to 1/16 of an inch and allowing each succeeding power piston to move a distance precisely double that of the preceding piston, a total stroke length of 15 15/16 can be achieved in discrete intervals of 1/16 inch. The eight individual power pistons 115 - 118 and 153 - 156 or 115 - 119 and 153 - 156 (depending on the described embodiment) thus have stroke lengths of 1/16, ⅛, ¼, ½, 1, 2, 4, and 8 inches, as discussed above.
For example, in the embodiment shown in FIG. 1 , if the required stroke were 11 11/16 inches, valves (not shown) would be opened and high pressure air would be introduced for powering the ½″ stroke piston 118 , the ⅛″ stroke piston 116 and the 1/16″ stroke piston 115 . The introduction of air between these pistons causes the inter-stage pusher rods 148 to advance and move the fractional stroke piston 152 a total of 11/16 of an inch. Simultaneously, valves would also open to power the 8″ stroke piston 156 , the 2″ stroke piston 154 and the 1″ stroke piston 153 , thus moving the piston rod 189 the required total of 11 11/16 inches.
While the operation is similar in the embodiment shown in FIG. 11 , the opening of the valves and introduction of pressurized fluid between the pistons results in the first system engaging portion 148 ′ advancing housing 151 ′ a distance of 1 and 11/16inches. As a result, only the 2″ stroke piston 154 and 8″ stroke piston 156 are moved in system 150 ′. Moreover, by balancing the number of pistons used in the first and second positioning systems against the combined strokes of the various systems, a maximum output stroke can be achieved by a device having a relatively small retracted length. Moreover, in the embodiment shown in FIG. 17 , the movement of piston rod 189 is effected by the first positioning system 110 ″ moving the extension tube 148 ″ a distance of 3 and 11/16 inches. Air introduced between plate 112 and stroke piston 115 , between stroke pistons 115 and 116 , between stroke pistons 117 and 118 , between stroke pistons 118 and 119 , and between stroke pistons 119 and 154 cause engaging portion 148 ′ to move the predetermined distance. Air introduced between stroke pistons 155 and 156 cause piston rod 189 to move the remaining 8 inches to achieve the total 11 and 11/16 inches. Moving all the valves to an exhaust position would cause the piston rod 189 to retract to its original position. Exhausting through only the 1/16″ stroke valve and the 2″ stroke valve would cause the piston rod to retract to the 9 and ⅝ inches stroke position, etc. Opening or exhausting any other combination of valves would move the piston rod 189 to whatever other position was desired among the 256 discrete positions it would be capable of assuming. The movements would be quick and positive and there would be no doubt about the extended position of the piston rod in the properly sized and powered system.
Although the present invention includes a 256 position mechanism, the addition of another fractional piston having a 1/32″ stroke could easily double the obtainable positions to 512. Similarly, further adding a 1/64″ stroke piston could increase the useful strokes to 1024.
In practice, a user of the invention would either manually or automatically, possibly using a programmable logic controller, select the stroke length desired in inches and fractions of an inch. One such programmable logic controller is a MITSUBISHI F1-ZONER. However, other well known controllers such as those produced by G.E. or ALLEN BRADLEY may also be used.
Any suitable 3-way valve can be used with the embodiments of the present invention. Well known valves which may be used are produced by ASCO, MAC valves, Parker Hannifin or Humphrey.
The kinetic seals used in the embodiments of this application are formed elastomeric rings which fit into grooves machined into pistons for the purposes of preventing air or liquid flow past the piston as it moves back and forth within a cylinder. The shapes of these rings are designed to exploit the differential fluid pressures existing on either side of the rings so that the surfaces of the seals are pressed against the groove walls and the moving surfaces of the cylinder in such a manner that no fluid can escape past the seal. Additionally, these seals provide little friction force against the movement of their piston. These seals take on many shapes and forms and are produced and sold by companies such as Parker Hannifin and Minnesota Rubber.
Numerous characteristics, advantages and embodiments of the invention have been described in detail in the foregoing description with reference to the accompanying drawings. However, the disclosure is illustrative only and the invention is not limited to the illustrated embodiments. Various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention. For example, although the movement of the stroke pistons is described with respect to 1/16 inch increments, the stroke of each piston can be any increment including 1/10 of an inch. Also, the total stroke length is not limited to 15 and 15/16 inches. The cylinder according to the present invention could have a total stroke length that is greater or less than 15 and 15/16 inches. The embodiments including a shorter stroke length will be more compact and easier to manufacture than the 15 and 15/16 inch version. As is common, the symbol ″ has been used in this application as an abbreviation for the term “inch”.
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A multi-stroke air cylinder providing a precisely directed and controlled stroke in the face of lateral, torsional and tilting loads on a tooling plate. The multi-stroke cylinder utilizes a plurality of mechanically linked pneumatic or hydraulic pistons having different stroke lengths that can be added together in any combination, allowing the user to select any stroke length up to a predetermined, total combined stroke length, in increments equal to the stroke length of the smallest cylinder. The multi-stroke cylinder includes a head assembly having a fluid inlet for introducing fluid to the cylinder at a first pressure. The cylinder also includes a first positioning system having a plurality of pistons capable of moving a piston rod away from the first positioning system, and a second positioning system located between the head assembly and the first positioning system. The second positioning system comprises a plurality of movable pistons for displacing the piston rod a preselected distance and at least one elongated fluid supply member secured to a respective one of the pistons of the second positioning system for introducing a fluid between adjacent pistons. When a plurality of fluid supply members are used in the second positioning system, they are concentrically arranged and are at least partially coextensive with one another.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/706,935 filed Aug. 10, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a centrifuge rotor and tube holder design, and more particularly, to a rotor assembly for producing a relatively low power, low audible level, cool running centrifuge.
[0004] 2. Background Art
[0005] Centrifuges are commonly used in medical and biological research for separating and purifying materials of differing densities such as viruses, bacteria, cells, proteins, and other compositions. A centrifuge normally includes a motor, a rotor, and specimen holders capable of spinning up to tens of thousands of revolutions per minute. Specimen holders include, for example, test tubes, test tube holders, or any other means that is suitable for retaining a specimen.
[0006] A preparative centrifuge rotor has some means for accepting specimen holders or “buckets” containing the samples to be centrifuged. Preparative rotors are commonly classified according to the orientation of the sample tubes or buckets. Vertical tube rotors carry the sample tubes or buckets in a vertical orientation, parallel to the vertical rotor axis. Fixed-angle rotors carry the sample tubes or buckets at an angle inclined with respect to the rotor axis, with the bottoms of the sample tubes being inclined away from the rotor axis so that centrifugal force during centrifugation forces the sample toward the bottom of the sample tube or buckets. Swinging bucket rotors have pivoting tube carriers that are not horizontal when the rotor is stopped and that pivot the bottoms of the tubes outward under centrifugal force.
[0007] With current swinging bucket rotor designs, the centrifuge buckets are primarily left uncovered by the rotor and generate considerable aerodynamic drag. This drag increases as the non-aerodynamic features move further away from the axis of rotation. Although these aerodynamic features significantly impact upon rotor operations at speeds lower than 3,000 RPM, they can be an even more significant factor at higher RPMs. Because many newer laboratory and forensic protocols require much higher rotational speed during centrifugation, including up to, and well exceeding, 4,000 RPM, identifying efficient and cost effective means of reducing aerodynamic drag is desirable. With current rotor technology, the curved shape of the centrifuge buckets prevents the buckets from retracting into the rotor housing to completely seal the voids therein. Thus, significant aerodynamic drag is generated during centrifugation due to air entering the rotor through these voids.
[0008] Centrifugation generally involves rotating a sample solution at high speed about an axis to create a high centrifugal force to separate the sample into its components based upon their relative specific gravity. The sample is carried in a rotor which is placed in a centrifuge chamber in a centrifuge instrument. The rotor is driven to rotate at high speed by a motor beneath the centrifuge chamber. At high speed operations, aerodynamic drag on the rotor becomes increasingly significant. Significantly more power is required to overcome the aerodynamic drag at high speed. In addition, cooling means must be provided to offset the heat generated by aerodynamic friction. Some centrifuges are provided with means for drawing a vacuum or partial vacuum in the centrifuge chamber in an effort to reduce the aerodynamic drag; however, cooling can still be necessary.
[0009] In the past, cooling of the centrifuge chamber has been accomplished by attaching refrigerant coils to the outside of the centrifuge chamber (see, e.g., U.S. Pat. No. 5,477,704 to Wright). In such a configuration, a space must be provided between adjacent passages to allow for welding (e.g. at 19 and 20), which reduces the available surface area for efficient heat transfer from the chamber. Significant drawbacks of this design are that cooling or refrigerating the chamber is expensive and prone to malfunction. Accordingly, there is a need for a simple, cost effective means of reducing aerodynamic drag and resulting friction heat with certain swinging bucket rotor designs.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to overcome the shortcomings of the prior art by providing a rotor and specimen holder assembly comprised of a centrifuge rotor assembly and a plurality of specimen holders. The rotor assembly is specifically designed to enable the specimen holders to retract into the body of the rotor during centrifugation to produce aerodynamic features. Slotted openings along the periphery of the rotor house the specimen holders. The specimen holders are designed to fill or plug these peripheral voids in the rotor as the rotor begins to rotate and the holders move into the retracted position.
[0011] Once the specimen holders are in the retracted position, the subjacent surface of each holder forms an uninterrupted interface about its slot which prevents circulating air from entering the rotor and tube holder assembly. This produces a continuous surface and an aerodynamic assembly that approaches the drag characteristics of a spinning disk. This interface also protects samples from the warmer circulating air and aids in keeping the samples at or near ambient temperatures. Voids near the center of the rotor may optionally be left open, as these locations' overall effect on drag is minimal.
[0012] The above and still further features and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof, particularly when taken in conjunction with the accompanying drawings, wherein like reference numerals in the various figures are utilized to designate like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a rotor and specimen holder assembly shown in the rotational position according to the present invention.
[0014] FIG. 2 is a cross-sectional view of a rotor and tube holder assembly shown in the rotational position according to the present invention.
[0015] FIG. 3 is a bottom perspective view of a rotor and tube holder assembly shown at rest according to the present invention.
[0016] FIG. 4 is a cross-sectional view of a rotor and tube holder assembly shown at rest according to the present invention.
[0017] FIG. 5 is a cross-sectional view of a centrifuge assembly with the rotor shown at rest according to the present invention.
[0018] FIG. 6 is a perspective view of a specimen holder according to the present invention.
[0019] FIG. 7 is a cross-sectional view of a rotor featuring a specimen holder interface according to the present invention. Subsequent airflow about the rotor is also depicted.
[0020] FIG. 8 is a cross-sectional view of a rotor shown without a specimen holder interface. Circulating air flows into the rotor through openings positioned along the rotor periphery.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring now to FIGS. 1-8 , the present invention comprises a novel design for a fully retractable specimen holder and rotor assembly for use in existing and new centrifuges 14 that are employed, for example, in medical, industrial, and laboratory settings.
[0022] The specimen holder 10 can either hold a specimen or some type of container, such as a test tube, test tube holder, or “bucket” containing a sample to be centrifuged. The rotor 12 and specimen holder assembly of the present invention may incorporate the use of specimen holders 10 having an extended collar 16 , rotation pins, or other pivot mechanisms that enable the specimen holder 10 to swing from a resting position to a rotational position. Pivot mechanisms may include, for example, mounting holes, rivets, bolts, trunnions, springs, hinges, and the like.
[0023] The rotor 12 allows for the vertical or near vertical insertion of the specimen holder 10 and its contents. The extended collar 16 , rotation pins, or other pivot mechanisms on the specimen holder prevent the specimen holder from falling through the rotor 12 . In a preferred embodiment, the specimen holder 10 is primarily rectilinear in its cross-sectional geometry or includes at least one lower flat surface that forms a continuous, uninterrupted planar surface with the rotor bottom 18 to produce a more perfect aerodynamic feature. The present invention also enables the full retraction, inside the lower planar surface of the rotor, of round or multifaceted specimen holder configurations, significantly improving aerodynamic performance of the rotor assembly.
[0024] The rotor comprises a ribbed disc that supports and protects the specimen holders 10 . The lower planar surface of the disc forms the rotor bottom 18 to which the ribs are attached. As an option, an outer rib 20 may extend about the outside circumference of the rotor bottom 18 . The outer rib extends upward from the rotor bottom to form an exterior wall of the rotor 12 about the area containing the specimen holder. The outer rib 20 provides an aerodynamic shape to reduce air drag, protects the distal tip of the specimen holder 10 , and provides radial support to the rotor 12 . At the center of the rotor bottom 18 is a rotor hub 22 that extends upward from the rotor bottom. The rotor hub 22 has an open center to fit over a drive shaft of a centrifuge motor, which rotates the rotor. The rotor hub 22 acts as a bearing surface for the rotor 12 .
[0025] As shown in FIGS. 3 and 4 , a series of elongated support channels 24 extend upward from the lower surface 18 of the rotor. The rotor 12 of the present invention may also employ fewer or more support channels 24 , as appropriate for a particular application. Each channel 24 includes a pair of side ribs 26 , 28 that support the specimen holder 10 and its contents during centrifugation. The bottom of the side rib 26 abuts the rotor bottom 18 , and the top of the side rib 26 is parallel thereto. The interior or proximal section of the side rib 26 is positioned towards the rotor hub 22 . The distal section of the side rib 26 extends towards the outer rib 20 . The proximal section forms a ninety degree (90°) angle with, abuts against and supports the collar 16 , rotation pins, and/or other pivot mechanisms of the specimen holder 10 . The side ribs 26 , 28 prevent movement of the specimen holder 10 beyond the horizontal position during rotation and also provide radial strength to the rotor 12 .
[0026] In a preferred embodiment of the invention, the specimen holder 10 is ensconced within the support channel 24 so that, in the rotational position, no more than the outer tip (distant from the rotor hub 22 ) of the specimen holder extends beyond the distal edge of the side ribs 26 , 28 . In use, there is minimal to no protrusion of the specimen holder 10 into the centrifugal air stream about the rotor 12 . In a preferred embodiment, the dimensions of the side ribs 26 , 28 are commensurate to the proportions of the specimen holder 10 so that there is no protrusion of the specimen holder 10 beyond the support channel 24 (and into the centrifugal air stream).
[0027] Because the geometry and dimensions of the specimen holder 10 generally correspond to those of the support channel 24 , the specimen holder 10 is able to nest or retract upward into, and horizontally align with, the support channel 24 during rotation of the rotor 12 . Once the specimen holder 10 is in the retracted position, the subjacent surface of the holder is flush with the bottom 18 of the rotor so as to form a continuous planar surface. This uniform surface or interface 34 forms a barrier that severs access from the support channel 24 to a clearance slot 30 in the bottom surface 18 of the rotor. As a result, circulating air is prevented from entering the rotor and tube holder assembly, significantly decreasing aerodynamic drag on the rotor 12 .
[0028] As depicted in FIGS. 1 and 4 , each support channel 24 also includes a clearance slot 30 about the bottom 18 of the rotor to receive the specimen holder 10 . Each clearance slot 30 has an interior end near the rotor hub 22 . As shown, a side rib 26 extends upward from the rotor bottom 18 on each side of the clearance slot. The clearance slot 30 , which may be predominantly square in its cross section geometry, allows the specimen holder 10 to swing from a generally vertical, resting position into a horizontal position during rotation of the rotor 12 . During centrifugation, the specimen holder 10 remains recessed within the channel 24 and supported by the side ribs 26 , 28 . The clearance slot 30 is preferably wider than the main body of the specimen holder 10 , but smaller than the diameter of the collar 16 of the specimen holder. Each side rib 26 , 28 is shown flush with the clearance slot 30 ; however this arrangement is merely illustrative. The dimensions of the rotor 12 , and clearance slot 30 may be configured to accommodate various specimen holder and pivot designs.
[0029] As shown in FIGS. 1 and 2 , the specimen holders 10 are designed to be contiguous with the clearance slots 30 as the rotor 12 begins to rotate and the holders move into the retracted position. Once the specimen holders 10 are in the retracted position within the body of the rotor 12 , the lower or subjacent surface of each holder forms a substantially continuous and uninterrupted surface with the rotor bottom 18 , which is preferably planar. As a result of this relative seal or interface 34 about the clearance slot 30 , circulating air is prevented from entering the rotor and tube holder assembly. There is, therefore, no interruption in the flow of air (drag) about the rotor 12 , and the specimen holder 10 itself is not subjected to the friction of air resistance during centrifugation. This produces an aerodynamic assembly that approaches the drag characteristics of a spinning disk. The continuous interface 34 also protects samples from the warmer circulating air and aids in keeping the samples at or near ambient temperatures. Voids near the center of the rotor 12 may optionally be left open, as these locations' overall effect on drag is minimal.
[0030] Extending from the side ribs 26 , 28 of each channel 24 and towards the rotor hub 22 is an inner rib 32 that extends upward from the rotor bottom 18 . The inner rib provides radial strength to the rotor 12 . The distance between the inner ribs 32 on each side of the clearance slot 30 is preferably slightly wider than the width of the clearance slot, but smaller than the diameter of the extended collar 16 or other pivot mechanism of the specimen holder 10 . A top surface of the inner ribs 32 is shown parallel to the rotor bottom 18 and intersects the proximal surface of the side ribs 26 , 28 at a ninety degree (90°) angle.
[0031] FIGS. 4-5 show the specimen holder 10 positioned in a near vertical position due to the design of the rotor 12 . As shown, the distance between the proximal surface of the side rib 26 and the interior end of the clearance slot 30 is less than the diameter of the main body of the specimen holder. The specimen holder 10 pivot mechanism rests against the proximal surface of both side ribs 26 , 28 and the top surface of the inner rib 32 on each side of the clearance slot 30 .
[0032] In one embodiment of the invention, a flat cover (not shown) may be fitted over the top of the rotor 12 to protect the insides of the rotor. The cover can also be used to provide a more aerodynamic air flow over the rotor. The cover includes a center hole to allow insertion of one or more specimen holders 10 when the rotor is at rest.
[0033] The rotor 12 is utilized by being mounted to a drive system of the motor of the centrifuge 14 . The specimen holder 10 can either hold a specimen or some type of container, such as a test tube or bucket containing a sample to be centrifuged. In a preferred embodiment, the specimen holder 10 is primarily square in its cross section geometry and/or includes at least one substantially planar or flat side. As such, the specimen holder 10 can be placed into a clearance slot 30 of the centrifuge 12 in any orientation. It will be appreciated that the geometry of the specimen holders 10 may be varied in accordance with the needs of a particular application or user preference. Similarly, any number and size of specimen holders 10 can be accommodated, dependent only on the size of the rotor 12 .
[0034] When in place, the extended collar 16 or other pivot mechanism of the specimen holder rests against the inner ribs 32 associated with each clearance slot 30 , whereby the collar supports the specimen holder 10 in a vertical or near vertical position in the rotor 12 . The optional cover may already be in place during insertion of the specimen holder 10 . Any additional components of the centrifuge 14 are properly positioned. The rotor 12 is rotated by the motor. The centrifugal force of rotation causes the specimen holder 10 to rotate upward from a rest or a near vertical position to a retracted position, as shown in FIGS. 1 and 2 . When the specimen holder 10 is in the retracted position, the lower surface of the collar 16 of the specimen holder rests against the proximal surface of the side ribs 26 , 28 , and the support channel 24 protects the specimen holder within the rotor 12 . While the specimen holder 10 is retracted within the rotor body during centrifugation, the inferior or subjacent surface of the specimen holder 10 is generally flush with the lower plane or bottom 18 of the centrifuge rotor.
[0035] As depicted in FIG. 2 , during rotation of the rotor 12 , the specimen holder 10 is retracts upward and nests within the support channel 24 . In the retracted position, the specimen holder 10 is horizontally aligned with the support channel 24 . Also, because the preferably planar subjacent surface of the holder is flush with the bottom surface 18 of the rotor, the holder surface and rotor bottom 18 comprise a single and uninterrupted interface. This continuous interface 34 traverses the clearance slot 30 in the bottom surface 18 of the rotor and serves as a barrier that severs access from the support channel 24 to the clearance slot 30 . By substantially sealing the clearance slot 30 of the rotor 12 , circulating air generated during rotation of the rotor 12 is prevented from entering the rotor body and tube holder assembly by way of the clearance slot 30 . Moreover, the specimen holder 10 is not entirely subjected to the friction of air resistance during rotation and does not heat up due to the friction.
[0036] In the present invention, the specimen holder 10 fully, or at least substantially, occupies the support channel 24 , and simultaneously overlays the clearance slot 30 such that there is generally no exposed area within the channel 24 and no protrusion of the specimen holder 10 into the centrifugal air stream about the rotor 12 . As a result of this continuous interface 34 , the clearance slot 30 is impervious to centrifugal air flow. Moreover, because there is no protrusion of the specimen holder 10 beyond the support channel 24 (and into the centrifugal air stream), the specimen holder contents are able to achieve a fully retracted position during rotation. This, in turn, allows for high-quality straight-line separation of fluids of varying densities, or fluids and suspended solids within the specimen holder 10 .
[0037] When rotation of the rotor 12 is terminated, that is, when the centrifuge 14 stops spinning, the specimen holder 10 returns to its original, at rest position, due to gravity.
[0038] There are several advantages provided by the novel specimen holder design of the present invention. Because the specimen holder 10 will retract into a vertical position at relatively low RPM (less than 250 or 500 RPM), the specimen holder design impacts upon the aerodynamics of the rotor 12 operation even at relatively low RPM. At higher RPM, the design significantly impacts upon power consumption of the centrifuge 14 , and substantially decreases the noise generated by aerodynamic drag. Moreover, the decrease in aerodynamic resistance results in less heat from friction.
[0039] Because the relationship between increased RPM and necessary horsepower is logarithmic, decreasing aerodynamic drag of the rotor 12 can have a considerable impact on the horsepower requirements for high speed operations. Moreover, since many modern centrifuges 14 use low temperature samples, this reduction in heat from friction is a tremendous benefit of the rotor specimen holder design of the present invention. Although the geometry of the specimen holder 10 (round, cylindrical, rectangular, etc.) may be varied in accordance with the needs of a particular application or user preference, it is preferable for the specimen holder 10 to be designed with at least one substantially planar surface, such as the design depicted in FIGS. 1 and 2 . It is advantageous, in a preferred embodiment of the invention, that the cross section of the specimen holder be rectilinear and, preferably, square. The increased aerodynamic performance of the present rotor 12 and specimen holder 10 assembly decreases load on the centrifuge motor, and permits motors of smaller horsepower to be used to achieve a desired separation speed.
[0040] It will be appreciated that a representative use of the present invention involves the separation of platelets from plasma. Because this is more easily accomplished at RPMs in excess of 4,000, use of the present invention with the general rotor 12 design depicted in FIG. 5 allows the centrifuge 14 to achieve the required RPM with up to fifty percent (50%) less power than conventional means.
TABLE 1 Rotor/Specimen Holder Seal vs. Conventional Centrifuge Rotors ROTOR/ CONVENTIONAL CONVENTIONAL SPECIMEN SPECIFICATIONS ROTOR A ROTOR B HOLDER SEAL Maximum RPM 1700 2400 3300 Time to Maximum RPM (sec) 120 90 60 Sample Degradation Above Ambient 11 9 7 After 5 Minutes (F) Sample Degradation Above Ambient 26 17 9 After 10 minutes (F) Sample Degradation Above Ambient 53 20 10 After 60 minutes (F) Sample Processing Time for 15 12 7 Chemistries (min) Sample Processing Time for 25 20 15 Coagulation Studies (min) Operating Power Consumption 231 120 92 (Watts)
[0041] Referring now to Table 1, there is shown a comparison of the improved operating speeds, sample quality and integrity, sample processing times, and power consumption of the rotor and specimen holder seal of the present invention versus conventional rotors. The data was collected at 115 VAC using a 1/30 th horsepower permanent split capacitor motor. Results were reproduced to ensure accuracy. Testing was conducted at QBC Diagnostics, Inc., State College, Pa. and at The Drucker Company, Inc., Philipsburg, Pa.
[0042] The foregoing data demonstrate that as compared to conventional centrifuge rotors, the specimen holder seal and rotor assembly of the present invention is able to: (a) reach desirable operating speeds in less time, (b) reach higher operating speeds without increasing power consumption, (c) reduce sample processing time, (d) improve sample quality due to the higher G forces, and (e) maintain sample integrity by minimizing the sample temperature rise above ambient.
[0043] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various alterations in form and detail may be made therein without departing from the spirit and scope of the invention.
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A rotor and specimen holder assembly for producing a relatively low power, low audible level, cool running centrifuge. The centrifuge rotor assembly is designed to enable a specimen holder to retract into the body of the rotor during centrifugation to produce aerodynamic features.
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FIELD OF THE INVENTION
This invention relates to gas control apparatus, particularly those used with ventilators for therapeutic treatment of patients with respiratory problems, and more particularly relates to a medical gas mixer for selecting gases to be mixed while maintaining the accuracy of the resulting mixture over a specified range, independent of inlet pressure fluctuation.
BACKGROUND OF THE INVENTION
For various medical reasons, patients are often put on mechanical or electronic ventilators which provide air, oxygen, or a mixture of air and oxygen to the patient. The gas mixture concentration is usually expressed as a percentage of oxygen. In surgery or for pain control, sometimes a mixture of oxygen and nitrous oxide is provided to the patient. Sometimes, gases other than nitrous oxide will be used, such as anesthetics. If an anesthetic or nitrous oxide is provided, it is important to accurately know the concentration of the gas provided to safeguard the health of the patient.
Thus, for example, U.S. Pat. No. 3,351,057 to Goodyear discloses an anesthesia apparatus which supplies oxygen, anesthesia or a combination of both, with a toggle mechanism which shuts off one gas supply and connects the device to ambient air in the event the oxygen supply is inadvertently shut off. The mechanism described, however, is complex and it requires the patient to draw the ambient air into the system.
Another patent, U.S. Pat. No. 3,896,837 to Rohling, discloses a gas mixing apparatus for respirators and medical devices with a gas bypass arranged such that when the pressure in a mixed gas delivery line drops below a predetermined pressure, a bypass valve opens to permit direct passage of an inlet gas, or to permit passage of a third gas from a gas tank. In Rohling, however, there is no regulation control on the added gas which can lead to an unknown mixture of gasses being delivered to the patient.
Continuous flow gas metering devices are known in the art For example, U.S. Pat. No. 4,266,573 to Braatz discloses an anesthesia machine for providing a mixture of oxygen and a second gas, such as nitrous oxide, in selected proportions. Each of the two gasses pass through separate needle valve metering assemblies which are interconnected so that when a predetermined ratio of nitrous oxide and oxygen is achieved, the percentage of oxygen may not be further diminished, thereby safeguarding the health of the patient. However, the needle valve assemblies are complex, and pressure variations can affect the relative flow rates.
Another gas metering device uses pulsed solenoid control valves, as described in U.S. Pat. No. 4,576,159 to Hahn. However, the pulsed valve actuation causes pressure surges which are so severe that specially designed mixing chambers must be used which dampen the pressure fluctuations of the mixed gases. The pressure fluctuation and pulsed gas disbursement can also lead to inaccuracies in the relative gas concentrations in the mixed gas.
SUMMARY OF THE INVENTION
The present invention relates to an improved gas mixing device which provides an accurate mixture of several gases. This invention allows the operator to select one of two gases for mixing with a third gas. Advantageously, the third gas is a sustaining gas such as oxygen, and one of the first two gases which, while potentially hazardous, has beneficial properties in controlled mixtures with other gases, such as nitrous oxide would when mixed with oxygen.
An important feature of this invention is that its design is intended to prevent a hazardous gas from being inadvertently supplied to the patient if the source of a sustaining gas, which is being mixed with the hazardous gas, inadvertently fails.
Another advantage of this invention is that it is constructed so that if two non-hazardous gases are being mixed and supplied to the patient, such as air and oxygen, then the bypass feature allows provision of either mixed gas in the event one of the supplies for the non-hazardous mixed gases inadvertently fails.
Another significant feature of this invention is an inter-locking feature to further prevent the inadvertent passage of a predetermined one of the first two selected gases, such as a hazardous gas, from being bypassed directly to the patient in the event of a supply failure of the mixed gas.
A further feature of this invention is the positive positioning of a selector knob coaxially with a mixing knob. The selector knob allows the operating personnel to select the desired gases for mixing, while the mixing knob controls the mixture of the selected gases. To prevent inadvertent passage of a hazardous gas to the patient when the selection knob is inadvertently set in a position which could select either of two gases, one of which is hazardous, a return device urges the selector knob to select the non-hazardous gas and to lock out the hazardous gas from being bypassed directly to the patient.
A further advantage of the coaxial knob is that it is configured to enable the mixtures of the selected gases to be read off the knob no matter which of the first two gases are selected for mixing with the third gas. The selector knob is configured so that it switches scales depending upon which of the two gases are selected, with the selected scale moving with the mixing knob. The scales are advantageously calibrated in terms of percentage concentration relative to the third gas, which gas is usually oxygen.
This invention allows easy selection of two of three gases for mixing, by use of two coaxial knobs, with one knob selecting the gases for mixing, and a second knob selecting the mixture of the gases. The gas selector knob also advantageously actuates the safety inter-lock to prevent passage of a hazardous gas directly to a gas outlet going to a patient.
DESCRIPTION OF THE DRAWINGS
The above, and other, objects and advantages of the present invention will be better understood from the description of the preferred embodiment as given below, taken in conjunction with the drawings in which like reference characters or numbers refer to like parts throughout the description, and in which:
FIG. 1 is a schematic illustration of this invention;
FIG. 2 is a perspective view of an embodiment of the invention;
FIG. 3 is a sectional view taken along A--A of FIG. 2;
FIG. 4 is a sectional view taken along B--B of FIG. 2;
FIG. 5 is an exploded perspective view of a control knob of this invention; and
FIG. 6 is a perspective view of a control knob showing a cammed surface.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment is best understood by referring to the schematic of FIG. 1. FIGS. 2-4 show a physical embodiment of the invention. Given the following disclosure and the drawings, one skilled in the art could determine various ways to configure the fluid passages to provide the required fluid communication. Thus, to make the figures easier to understand, many of the fluid communication pathways are not shown in FIGS. 2-4.
Referring to FIGS. 1 through 4, but primarily to FIGS. 1 and 2, a plurality of gas sources are illustrated as comprising a first gas source 10, a second gas source 12 and a third gas source 14. Preferably, the first gas source 10 comprises a source of pressurized air, while the second gas source 12 comprises a source of pressurized nitrous oxide, and the third gas source 14 comprises a source of pressurized oxygen. These preferred gas sources 10, 12, 14 are commonly available sources of pressurized gas in hospitals.
The gas sources 10, 12, 14 are in fluid communication with means for providing one-directional flow from the respective gas sources such as check valves, or preferably, duckbill, c.v. 30 micron filters, 16, 18 and 20, respectively. The fluid connections between the gas sources 10, 12 and 14, and the duckbills 16, 18 and 20 are of conventional types known in the art, and preferably comprise male and female DISS fittings, NIST fittings, or other gas fittings.
A housing 21 (FIG. 2) contains a selector valve assembly 22 (FIG. 1), to which the duckbills 16, 18 respectively are fluidly connected. The valve assembly 22 comprises a selector valve control knob 24, a safety inter-lock 26 (FIGS. 1 and 4) and a gas selector piston assembly 28 (FIGS. 1 and 3). Duckbill 20 (FIG. 1) connected to the third gas source 14, is in fluid communication with a bypass valve assembly 30 (FIGS. 1 and 4) also contained in housing 21 (FIG. 2).
Referring primarily to FIGS. 1 and 3, the gas selector piston assembly 28 will be referred to as a gas selector or gas selector assembly, and comprises a cylindrical member such as a plunger or piston 32 having a first contoured end 36 and opposite thereto a second, substantially flat end 38 which is oriented perpendicular to the longitudinal axis of the piston 32. Advantageously, the end 36 is spherical, and preferably comprises a rotating ball. A recessed area 40 is located intermediate the ends 36, 38, with the recessed area 40 having a smaller diameter than the cylindrical plunger or piston 32, and extending substantially around the circumference of piston 32. A first aperture 42 extends radially inward from the outer surface of the recessed area 40, towards the longitudinal axis of the cylindrical piston 32. A second aperture 44 extends along the longitudinal axis of the piston 32, between the first aperture 42 and the flat end 38. The apertures 42, 44 form a gas passage from the recess 40 to the end 38 of piston 32.
The piston 32 is mounted in a generally cylindrical chamber 46 so that the plunger can reciprocate along the longitudinal axis of the piston 32. Inlet ports 48, 50 open into the chamber 46, and are in fluid communication with the first and second gas supplies 10, 12, respectively, through duckbills 16, 18, respectively. An outlet port 52, opens into chamber 46, with the outlet port 52 being in fluid communication with the recess 40 through the first aperture 42 and the second aperture 44. A resilient member, such as coil spring 54, is located between an end of the chamber 46 and the flat end 38 so as to resiliently urge the spherical end 36 of the piston 32 against a contoured or cammed surface 56 on the gas selector control knob 24. Sealing means, such as O-rings 58, are located on opposite sides of the recess 40 to seal the piston 32 against the walls of the chamber 46.
The piston 32 is slidably positioned in chamber 46 by the contoured surface 56 to define alternate fluid communication passages with the gas sources 10, 12 through inlet ports 48, 50, respectively. For example, when the piston 32 is positioned with the recessed area 40 adjacent the inlet port 48, then a fluid passage is formed from the first gas source 10, through the check valve 16, through the inlet port 48, to the recessed area 40, through the first and second apertures 42, 44, and out the outlet 52. Similarly, when the piston 32 is positioned with the recessed area 40 adjacent the inlet port 50, then a fluid passageway is formed from gas source 12, through check valve 18, inlet port 50, recess 40, apertures 42 and 44, and outlet port 52. The piston 32 may be positioned so that either the first gas source 10 or the second gas source 12 is directed to the exit port 52, but does not permit both the first and second gas sources 10 and 12 to be simultaneously in fluid communication with the exit port 52. There is thus provided means for selectively communicating gases to an outlet from one of two gas sources.
The piston 32 is spring-loaded by coil spring 54 so as to urge the piston 32 into a position which delivers the first gas (air) instead of the second gas (nitrous oxide). Thus, in the event the knob 24 is only partially rotated so as to not definitively select the second gas, the piston 32 will be urged into the position to select only the first gas (air).
Referring to FIGS. 1 and 4, the safety inter-lock 26 comprises a generally cylindrically-shaped member such as push rod 60, having a first contoured end 62, and opposite thereto a substantially flat end 64 oriented substantially perpendicular to the longitudinal axis of the push rod 60. Advantageously, the end 62 is spherical, and preferably comprises a rotating ball. A smaller diameter cylindrical member such as stop pin 66 extends along the longitudinal axis of the push rod 60 from the flat end 64. Resilient means, such as coil spring 68 surrounds the stop pin 66 and urge the end 62 of push rod 60 against the contoured surface 56 of the knob 24.
Still referring to FIGS. 1 and 4, the bypass valve assembly 30 comprises a chamber 70 and a first inlet port 72, which is in fluid communication with the third gas source 14 through the check valve 20. A second inlet port 74 is located at the end of the chamber 70, opposite the inlet port 72. The inlet port 74 is in fluid communication with the outlet port 52 of gas selector 28. Located intermediate the inlets 72, 74 is an outlet 76, which also communicates with the inside of the chamber 70. Located intermediate the inlets 72, 74 is an aperture 78 into the chamber 70, which is positioned closer to the inlet 72 than to the inlet 74, and is further positioned so that stop pin 66 may extend through the aperture 78.
A piston 80 is slidably mounted inside the chamber 70, with resilient means, such as coil springs 82, 84, being located on opposite ends of the piston 80 to urge the piston 80 towards a neutral position. Sealing means, such as O-rings 87, are located on opposite ends of the piston 80 so as to provide a substantially gas-tight fit between the piston 80 and the adjacent walls of the chamber 70. In the neutral position, piston 80 and sealing means 87 cooperate to block the exit port 76 so as to prevent the flow of the third gas through the outlet port 76, and also prevent the flow of either the first or second gases from the outlet port 52 through the inlet port 74 and outlet port 76.
Referring to FIGS. 1 and 3, but primarily to FIG. 1, a first balancing regulator 86 is in fluid communication with the third gas source 14 and with the outlet port 52 of the selector valve 22. The balancing regulator 86 substantially equalizes the pressures of the gases flowing through the regulators. The balancing regulator 86 is described in more detail in U.S. Pat. No. 3,895,642, and comprises a first chamber 88 having an inlet port 90 which is in fluid communication with the outlet port 52 of selector valve assembly 22. The balancing regulator 86 has a second chamber 92, having an inlet port 94 which is in fluid communication with the third gas source 14. First and second chambers 88, 92 contain valve seats 96, 98, respectively. A two-seated valve 100 is located intermediate the first second and second chambers 88, 90, and is mounted such that in a neutral position, it is located equidistant from, but not seated against, valve seats 96, 98 to define a substantially equal fluid flow path from both the first and second chambers 88, 92, respectively. The two seated valve 100 may advantageously comprise two separate balls seating against two separate valve seats. Resilient means, such as coil springs 102, 104, located in chambers 88, 92, respectively, communicate with opposite ends of valve 100 and urge the valve 100 to maintain this neutral position.
The valve 100 has sufficient area in each of the first and second chambers 88, 92 such that a pressure differential in one of the chambers will exert sufficient force on the valve 100 and cause it to open one of the valve seats 96, 98, and close the other of the valve seats. Thus, a higher pressure in one of the chambers 88, 92 will cause a reduced flow area between the respective valve seat 94 or 96 and the valve 100 to cause a reduction in the volume of gas passing through the higher pressure chamber, while simultaneously causing an increase in the amount of gas flowing between the valve 100 and the adjacent valve seat 96 or 98 in the opposite, lower pressure chamber. The result is that an increase in pressure causes a reduction in the exit area while causing an increase in the exit area of the opposite chamber so that the volume of gas exiting both of the chambers tends to approach one another.
The balancing regulator 86 can equalize the pressures of the gases exiting from chambers 88, 92, to within about 1%, and can accommodate about 20 pounds per square inch (psi) of pressure differential. A pressure differential greater than 20 psi, will cause the valve 100 to completely seat and prevent all flow of gas from the high pressure chamber. Similarly, if no gas enters one of the chambers 88, 92, the valve 100 will seat completely in the chamber containing gas so as to effectively prevent any gas flow through the regulator 88.
Preferably, a second balancing regulator 106 is placed in fluid communication with the first balancing regulator 86. Thus, the second balancing regulator 106 has a first chamber 108 containing an inlet port 110 which is in fluid communication with the first chamber 88 of the first balancing regulator 86, through the space between the valve seat 96 and the valve 100 of the first balancing regulator 86. The first chamber 108 contains a valve seat 112 into which a mating valve 114 extends, with resilient means such as coil spring 116, urging the valve 114 toward the valve seat 112. The space between the valve seat 112 and valve seat 114 defines an exit port from the first chamber of the second balancing regulator 86.
Similarly, a second balancing regulator 106 contains a second chamber 118 containing an inlet port 120 in fluid communication with the second chamber 92 of the first balancing regulator 86 through the space between the valve 100 and the valve seat 98. The chamber 118 has a valve seat 122 surrounding a portion of the dual-sided valve 114, and with resilient means such as coil spring 124, urging the valve 114 toward the valve seat 122. The springs 116, 124 are balanced so that in a neutral position, a space is defined between valve seats 112, 122 and the adjacent portions of the valve 114 so as to define equally sized exit flow paths from the chambers 108 and 118. As with the valve 100 in the first balancing regulator 86, the two seated valve 114 may comprise two separate balls seating against two separate valve seats. The use of two balancing regulators 86, 106, equalizes the pressure of the gases flowing through them to about 0.1%.
Referring to FIGS. 1 and 3, a mixing valve 126 is in fluid communication with the gases exiting from the second balancing regulator 106, or if the second balancing regulator is not used, with the first balancing regulator 86. The mixing valve 126 comprises a chamber 128 having a first inlet port 130, a second inlet port 132, and an outlet port 134. The first inlet port 130 is in fluid communication with the gases exiting from the first chamber 108 of the second balancing regulator 106. The second inlet port 132 is in fluid communication with the gases exiting from the second chamber 118 of the second balancing regulator 106. A flow varying member such as mixing valve poppet 136 extends through the mixing chamber 128 and has a portion extending through the first and second inlets 130, 132. One end of the mixing valve poppet 136 is connected to a knob or dial 138. The dial 138 contains scales allowing operating personnel to read the oxygen concentration, as described in more detail later. As described later in FIG. 5, the dial 138 is coaxial with knob 24.
The mixing valve 126 is assembled such that rotation of the mixing knob, or dial 138 causes the amount of gases passing through the first and second inlets to vary in a predetermined manner such that rotation of the dial 138 allows a predetermined mixture of gases to be selected The poppet 136 translates between two valve seats to vary the areas of inlets 130, 132 so as to increase the flow area of inlet 130 while decreasing the flow area of inlet 132, and vice versa. Advantageously the two metered gases may be mixed within the mixing valve 126 and then exit through outlet port 134 to a gas outlet 139 (see FIG. 2).
The gases exiting from outlet port 134 are in fluid communication with the patient (not shown) by means known in the art such as ventilators, respirators, etc., none of which are described or illustrated herein.
In an alternate embodiment of this invention, the outlet 76 of the bypass valve assembly 30 is in fluid communication with a unidirectional flow means such as a duckbill, or a bypass check valve 140 as shown in FIG. 1, which in turn is in fluid communication with gas outlet 139.
A first normal operational flow path is thus defined from the gas sources 10, 12, through the selector valve assembly 22, through balance regulators 86, 106, through mixing valve 126, to the gas outlet 139. A second normal operational flow path is defined from the third gas source 14, through balance regulators 86, 106, through mixing valve 126, to the gas outlet 139. A first, failsafe bypass flow path is defined for the gas source 10, through the bypass valve assembly 30, through outlet 76, and through the bypass check valve 140, to the gas outlet 139. Gas source 12, the hazardous gas in the illustrated embodiment, has no bypass system. A second, failsafe bypass flow path is defined for the gas source 14, through the bypass valve assembly 30, through outlet 76, and through the bypass check valve 140, to the gas outlet 139. The first and second, failsafe bypass flow paths become functional only when a predetermined pressure differential is applied to gas bypass valve 30, with the bypass flow paths being operational in only one direction via the duckbills 16, 18, 20, or if present, the check valve 140.
Referring to FIGS. 1 and 2, but primarily to FIG. 1, a metering/bypass valve assembly 146 has an inlet port 148 which is in fluid communication with the third gas inlet 20. The bypass valve 146 comprises a tapered or converging cavity 150 which contains a visible ball to movably obstruct the cavity and form a flow meter 152. The position of the visible ball 152 indicates the flow rate. The flow meter 152 is known in the art and is thus not described in detail herein.
A valve 154, and valve seat 156 are located intermediate the flow meter 152, and a second gas outlet 158. The valve 154 has one end connected to a valve knob 160, with the valve 154 being mounted in the bypass valve 146 such that rotation of the valve knob 160 causes the valve 154 to move relative to the valve seat 156 in order to vary the amount of gas passing from the inlet 148, to the second outlet 158.
Referring primarily to FIG. 1, the operation of the gas mixer will now be described The disclosed apparatus provides for one of two predetermined gases may be mixed with a third gas. Alternately phrased, the apparatus provides for the successive mixing of two gases from three separate pressurized gas supplies 10, 12, and 14, with one of the gases being selected from a predetermined combination of two of the three gases. The operation will be described with respect to the preferred gases which are air, nitrous oxide, and oxygen. A person rotates knob 24 to select a gas from one of gas supplies 10 or 12 (air or nitrous oxide), with the selected gas being mixed with the third gas 14 (oxygen). A scale on knob or dial 138 is calibrated so that the relative concentrations are illustrated, thus allowing operational personnel to readily select the desired mixture of gases by rotation of knob 138.
Rotation of the control knob 24 of the selector valve assembly 22 causes the cammed surface 56 to position both the cylindrical push rod 60, and the piston 32. Positioning the piston 32 will cause one of the first or second gases, either air or nitrous oxide, but not both, to pass through the gas selector 28 and exit through the exit port 52.
Alternately phrased, as the first and second gases from sources 10, 12, respectively, are exposed to the selector valve assembly 22, rotation of the control knob 24 causes the cammed surface 54 to contact the piston 32, thereby disposing the piston 32 relative to the first and second inlet ports 48, 50, of the selector valve assembly 22 so as to permit passage of either the first or second gas to the outlet 52 of the selector valve assembly 22.
The selected gas, illustrated in FIG. 1 as being air, is fluidly communicated to the bypass valve assembly 30, and also fluidly communicated to the first balancing regulator 86. The select gas passes through the first balancing regulator 86, through the second balancing regulator 106, and then into the first inlet 130 of mixing valve 126. The third gas source 14, which in this case is oxygen, provides the third gas to both the bypass valve assembly 30, and also to the inlet 94 of the first balancing regulator 86. The third gas passes through the first chamber 92 of the first balancing regulator 86, through the second chamber 118 of the second balancing chamber 108, and then into the inlet 132 of mixing valve 126. The balancing regulators 86, 106, equalize the pressure between the two gases passing through those regulators. The mixing valve 126 controls the mixtures of the two gases by varying the aperture area through which the two gases flow at substantially the same pressure. The metered gases then pass to the gas outlet 139 and to the patient through a respirator, etc.
The third gas 14 may be controllably provided directly to the patient through outlet 158, with the flow rate of the third gas being determined by the flowmeter 146, to which the third gas is also connected.
When the knob 24 is positioned so that piston 32 selects the second gas, nitrous oxide, then the cammed surface 56 simultaneously causes the push rod 60 to move downward against resilient member 68 such that stop pin 66 extends through the aperture 78 and prevents the piston 80 from moving into a position which would allow nitrous oxide to pass through the bypass valve 30 via second inlet 74 and outlet 76. As the gas passing from the bypass valve 30 through outlet port 76 goes to the gas outlet 139, the safety inter-lock 26 prevents the second gas, such as nitrous oxide, from being delivered to the patient through the bypass valve 38 in the event there is a failure of the third gas supply 14. There is thus provided a means for preventing a predetermined gas (second gas) of the first and second gas from being bypassed directly to the gas outlet 139, and thus passed directly to the patient.
The third gas source 14 which supplies oxygen is in fluid communication with the bypass valve assembly 30, with the first balancing regulator 86, and with the bypass valve assembly 30. In the event the selected gas passing through the exit port 52 of the gas selector 28 fails, then the gas pressure at the inlet 72 will exert a sufficient force on the slidable piston 80 so as to overcome the resistance of spring 84 thereby causing the piston 80 to uncover the exit port 76 and allow the third gas (oxygen) to pass through the bypass valve 30, through bypass check valve 140, and to the gas outlet 139. Thus, the bypass valve assembly 30 ensures a supply of the third gas to the gas outlet 139 in the event the gas supply selected by the selector valve assembly 22 is terminated or exhausted.
In a similar manner, if the gas selected by the selector valve assembly 22 is the first gas, namely air, then the safety inter-lock device 26 does not inhibit movement of the piston 80, and if the third gas supply 14 fails, then the first gas is bypassed directly to the outlet 139 via bypass valve 30.
On the other hand, if the gas selected by the selector valve assembly 22 is the second gas, the predetermined hazardous gas (nitrous oxide), then the safety inter-lock device 26 is activated by cam surface 56 so as to inhibit movement of piston 80, and thus prevents the bypass valve 30 from directly bypassing the second gas directly to the patient in the event of a failure of the third gas 14. Further, in the event the selected mixture of gases is the second gas (nitrous oxide) and the third gas (oxygen), then the balance regulators 80, 106, would shut down the flow of the second gas (nitrous oxide) to the patient in the event the third gas source 14 fails.
Referring to FIGS. 2, 3, and 5, but primarily to FIGS. 3 and 5, an interconnection between the knobs 24 and 138 will be described. The knob 24 comprises a circular disk having a central hole through which the mixing member 136 extends. The line L--L in FIG. 5 is along the longitudinal axis of mixing member 136. The knob 24 rotates about line L--L, and abuts against the housing 21.
A stop pin 168 extends from the knob 24, along an axis substantially aligned with the longitudinal axis of mixing member 136. A threaded recess 169 (FIG. 5) is formed in the radial periphery of the knob 24. A tube 170 surrounds the mixing member 136, and has a first, exterior threaded end 172 (FIG. 3) extending through the hole in the knob 24. The mixing member 136 is sealed inside the tube 170 by an O-ring 175.
Referring to FIG. 6, the bottom of knob 24 contains the cammed surface 56, which is illustrated as comprising a slot having a curved, semicircular axis. The cammed surface 56 advantageously comprises a first slot 171 extending into the knob 24 at a first slope at a fixed radius from the center of the knob 24. The first slot 171 ends at a detente, such as a raised portion or ridge 173. The ridge is below the surrounding surface of the knob 24.
A second slot 174 begins at the ridge 173 and extends further into the knob 24 at a second slope along the same radius as that of the first slot 171. The slope of the second slot 174 is greater than the slope of the first slot 171. It is believed advantageous to have the slopes of the slots 171, 174 be non-linear, and increase as the depth of the slot increases.
Also as illustrated in FIGS. 3 and 6, the bottom surface of the knob 24 contains a recessed area around the periphery, forming a recessed lip which fits into a recessed area in the housing 21 (FIG. 3) to help hold the knob 24.
Referring to FIGS. 3 and 5, a flanged tube 176 surrounds a portion of the threaded end 172, with the tube 176 fitting inside the hole in the knob 24 so the knob 24 may rotate relative to the tube 176. One end of the flanged tube 176 removably engages the housing 21 in such a manner that the tube 176 is restrained from rotation Such engagement could comprise projections on the tube 176 fitting into slots in the housing 21, but such connecting means are known and not illustrated.
A flange 178 is located intermediate the ends of the tube 176, and extends radially outward. The flange 178 abuts the surface of the knob 24. A segment of the radial periphery of the flange 178 has a reduced radius to form a recessed area 180 in the outer periphery of the flange 178, with first and second shoulders 182, 184 at opposite ends of the recessed area 180. The recessed area subtends an arc of about 120 degrees.
The pin 168 is placed radially outward from the center of the knob 24 such that when the flange 178 abuts knob 24, the pin 168 can fit within the recessed area 180 and move between the first and second shoulders 182, 184, respectively, as knob 24 rotates relative to the flange 178.
A second pin 186 is placed on the flange 178, slightly to one side of the center of the recessed area 180, and just radially inward from the recessed area. The pin 186 is substantially aligned with the longitudinal axis of mixing member 136. A third pin 188 is placed on the flange 178, at the same radial distance as second pin 186, and aligned with the second pin 186. The third pin 188 is located about 30 degrees counterclockwise from the first shoulder 182. As the pins 184, 186 are connected to the non-rotating flanged tube 176, neither the second pin 184 nor the third pin 186 rotate.
When the flange 178 is assembled to abut knob 24, the pins 168, 186, and 188 are aligned along the same longitudinal axis. The lengths of the pins 168, 186, 188 are such that all of the pins end at about the same distance from the surface of the knob 24.
A semi-circular shield 190 abuts against the end of the flanged tube 176. The shield is best seen in FIG. 5 as comprising a radially extending arm 192, an axial offset arm 194, and a semicircular shield portion 196 substantially parallel to the arm 192. The shield portion 196 is color coded, having a yellow portion (for air) and a blue portion (for nitrous oxide) for the illustrated embodiment. The pin 168 does not contact the shield 190, as the flanged tube 176 holds the shield sufficiently away from the end of the pin 168 (FIG. 3).
A threaded fastener such as nut 198 threadably engages the threaded first end 172 of tube 170, and fastens the shield 190 between the nut 198 and the flanged tube 176. The nut 198 has a hole through which one end of the mixing member 136 extends, with the nut containing an O-ring seal to provide friction with the knob 138.
The knob 138 is fastened to the end of the mixing member 136. The knob 138 has an axial portion 199, and a radial flange 200 on which visible indicia, such as numbers, are placed. The numbers are advantageously calibrated relative to the device of this invention to reflect the percentage concentration of a selected gas being mixed.
In the illustrated embodiment, the numbers are calibrated relative to the third gas, oxygen, and thus visually display the percentage of oxygen. Advantageously, there are two sets 202, 204, of such calibrated numbers on the flange 200. The first set of numbers 202 is located radially inward on the flange 200, and reflects the percentage of the third gas (oxygen) when mixed with the second gas (nitrous oxide in the illustrated embodiment). The second set of numbers 204 reflects the percentage of the third gas (oxygen) when mixed with the first gas (air in the illustrated embodiment).
Depending from the flange 200 is a projection 207. The projection is illustrated as a screw, although it may be more economical to mold a ridge-like projection 207 integrally with the flange 200. The projection 207 is dimensioned and radially positioned on the flange 200, so that projection 207 can contact the ends of pins 168, 186, and 188 (FIG. 3).
A cap or cover 206 fits over the knob 138, and is connected by diverse means, such as set screw 208 (FIG. 5), so as to move with the knob 24. The cover 206 has a radially extending portion 209 containing a central aperture through which the axial portion of knob 138 extends. A first window 210 is formed in the radial portion 209 of cover 206 at a first radial distance. A second window 212 is also formed at a second radial distance in the radial portion 209. The first set of numbers 202 may be viewed through the first window 210. The second set of numbers 204 may be viewed through the second window 212.
When assembled, the shield portion 196 is located between the radial portion 209 of cover 206 and the radial flange 200 of the knob 138. The shield 190 is preferably made out of flexible plastic, which facilitates the assembly.
As previously described, rotation of the knob 24 selects one of the first or second gases 10, 12, to be mixed with the third gas 14, and in some circumstances engages safety lock 26 (FIG. 1). FIG. 5 illustrates a configuration in which the second gas 12 (nitrous oxide) is selected for mixing with the third gas 14 (oxygen). In this configuration, the cammed surface 56 on the bottom of knob 24 (FIG. 1) engages the safety lock 24 while simultaneously selecting the second gas 12 by gas selector assembly 28 (FIG. 1). The cammed surface 56 (FIG. 1) has detentes which inhibit movement of the ends 36 and 62 (FIG. 1) out of the selected position, and which urge the knob 24 to remain in this position until knob 24 this physically rotated.
As the cover 206 rotates with the knob 24, the rotation simultaneously selects which set of calibrated data is to be viewed through the windows 210, 212. As cover 206 rotates, the windows 210, 212 rotate relative to shield portion 196, so that one of the windows 210, 212 is always covered. For example, the first window 210 may be covered by shield portion 196, but the second set of numbers 204 may be read through the second window 212. Conversely, when the second window 212 is blocked by shield portion 196, the first set of numbers 202 may be read through the first window 210. There is thus provided means for changing calibrated scales to correspond to the selection of the gases being mixed with the same operation that selects the gases to be mixed or blended.
Once a particular gas is selected for mixing via the knob 24, then the knob 138 determines the particular blend of gases. The knob 138 is directly connected to the mixing member 136, so that rotation of knob 138 directly affects the mixture of the gases as described previously. However, a specified rotation of the knob 138 may cause different concentrations of the third gas (oxygen in the illustrated embodiment) which is being displayed. Thus one scale may need to rotate further than another scale. To accommodate this difference, variable rotational stop means are provided.
In the illustrated embodiment, the variable stop means comprise the pins 186 and 188, and the projection 207 on knob 138, although pin 168 may be used to inhibit motion. Referring to FIGS. 1, 5, and 6, FIG. 5 illustrates a configuration in which the second gas 12 (nitrous oxide) is selected for mixing with the third gas 14 (oxygen). In this configuration, the cammed surface 56 on the bottom of knob 24 (FIG. 1) engages the safety lock 24 while simultaneously selecting the second gas 12 by gas selector assembly 28 (FIG. 1). Also in this configuration, the end 36 of selector valve assembly 28 (FIG. 1) rests in the end of the first slot 171 adjacent the detente ridge 173 (FIG. 6). The end 62 of safety lock 26 (FIG. 1) is out of the slots 171, 174 (FIG. 6), and thus forced into a locking position to inhibit movement of piston 80 (FIG. 1).
The detente ridge 173 cammed surface 56 (FIG. 1) has detentes which inhibit movement of the ends 36 and 62 (FIG. 1) out of the selected position, and which urge the knob 24 to remain in this position until knob 24 this physically rotated.
Referring to FIGS. 3 and 5, the first pin 168 is forced against the shoulder 184 of recess 180 as the knob 24 is rotated so as to select the second gas 12 and third gas 14 (FIG. 1) for mixing. The first pin 168 and the third pin 188 limit rotation of the knob 138 as the depending projection 207 will hit the pins 168, 188 and be inhibited from further rotation. The knob 138 is allowed to rotate about 150 degrees between pins 168, 188 when in the position illustrated in FIG. 5.
While the pin 168 cannot rotate past shoulder 184, the pin 168 is restrained from rotation in the opposite direction only by the force of end 36 of the gas selector valve 28 (FIG. 1) being urged into the detente at the end of slot first slot 171 in knob 24 (FIG. 6) by the spring 54 and by the pressure of the gas on the cylindrical member 32 (FIG. 1). This force, in addition to the force to urge the end 36 (FIG. 1) over the ridge 173 inhibits movement of the pin 168 by the projection 207.
This increased resistance to further rotation can be perceived by an operator turning knob 138. This increased resistance also occurs as the oxygen concentration starts going below about 21% oxygen, the amount found in normal air. The increased resistance serves to notify the personnel operating the gas blender that little oxygen is being directly passed to the patient.
When the cover 206 and knob 24 are rotated so the pin 168 is against the first shoulder 182, then the end 36 (FIG. 1) is in the end of the second slot 174 (FIG. 6) and the end 62 (FIG. 1) is in the end of the first slot 171 (FIG. 6). In this position, the first gas 10 (air) has been selected for mixing with the third gas 14 (oxygen). Movement of knob 24 rotates the pin 168 between the two stationary pins 16, 188, which stop the rotation of knob 138 when projection 207 hits the pins 186, 188.
As the cover 206 and knob 24 are rotated to place the pin 168 against the shoulder 182, the second window is moved from above the shield portion 196 so the second set of numbers 204 may be read through the second window 212. Simultaneously, the first window 210 is moved over the shield portion 196 to prevent the first set of numbers 202 from being read through the first window 210.
The shield portion 196 may be color coded to further indicate which gas is being transmitted. For example, if the gas selected is nitrous oxide, the second gas 12, then the portion of the shield 196 displayed through the second window 212 may be blue to indicate nitrous oxide is being mixed. Conversely, if air is selected, the color yellow may be displayed through the first window 210.
There is thus advantageously provided means for changing calibrated scales to correspond to the selection of the gases being mixed while simultaneously selecting the gas to be mixed. There is further provided means for shutting off the passage of a selected (hazardous) gas if an operator attempts to select a gas mixture providing an undesirable concentration of a specified gas.
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A mixing device for respiratory, therapeutic, or anesthetic uses provides two of three gases to a mixed gas outlet. A gas selecting means fluidly connected with a first and second gas supplies selectively provides fluid passage of only one of the first or second gases to the outlet. A gas bypass selectively bypasses two of the three gases to the gas outlet. A locking device activated by the selecting means prevents a predetermined one of the first or second gases from being bypassed to the gas outlet. A first and second pressure balancing regulator equalizing the pressures of the selected gas and the third gas before passing those gases to a controllable mixing device which meters the gases into a mixing chamber, after which the gases are passed to the gas outlet. Advantageously, a gas selector knob is positioned coaxially with a mixing valve such that rotation of the selector valve causes correctly calibrated scales to become visible to reflect the mixture of the selected gases as they are mixed.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This document is a continuation application which claims the benefit of, and priority to, U.S. patent application Ser. No. 11/626,796, filed on Jan. 24, 2007, incorporated herein by reference in its entirety for all purposes.
TECHNICAL FIELD
[0002] The present disclosure relates generally to the field of women's undergarments. More specifically, the present disclosure relates to an apparatus for women with surgically altered breasts for support and cosmetic purposes.
BACKGROUND
[0003] The brassiere or “bra” has been around for centuries in different forms. The brassiere is commonly referred to as a bra. A bra is a piece of clothing that typically supports, covers, and may elevate the breasts of the user wearing the piece of clothing. The brassiere is typically an undergarment. The bra may also be utilized as a fashion statement as well as a support structure for enhancement, support, and/or alteration of a body profile.
[0004] The bra was originally developed about two centuries ago and has evolved from the corset. Bras are different than their predecessor garments in that they contain cups to support and cover the breast and also typically have shoulder straps to elevate and lift the breast to a desire height. Additionally, bras may have a variety of different colors, designs, fabrics, and cup sizes to fit users with larger and/or smaller breast sizes.
[0005] The evolution of the bra is typically tied to the socio-economic status of women throughout history. For instance, as women achieved higher and higher status in society, both in new occupations and activities, the outwear and the underwear evolved with these new social status and activities. At various points, women have used these garments and devices to cover, restrain or elevate their breasts.
[0006] Early in the development of the modem bra, the most common type of undergarment for the breast was the corset, which was used predominately by wealthier women and women of status. The corset pushed the breast upwards which gave the impression of larger, fuller, breasts and helped support larger breasts. Later, many clothing designers that worked on women's clothes experimented with corset design by splitting the corset into multiple parts, including support structures where the corset included shoulder straps or neck straps.
[0007] Soon thereafter, the modern bra became a reality, although the modern bra was not common place for the common woman until almost the first half of the 20 th century. Since that time, the bra has become a very common garment used my most post-puberty women. The bra serves multiple purposes, including the functionalities of support, lift, and body sculpting. Additionally, the bra also serves to provide a fashion statement, e.g., via visual enhancement and, sometimes, as a stand-alone fashion characteristic.
[0008] The common bra typically consists of cups for the breasts, a center panel, a band running around the torso under the breast, and a shoulder strap for each side. Bras typically are made of some fabric, usually cotton or polyester. However, bras can be constructed from spandex, lace, and a plurality of different materials, depending on the taste and feel of the user. The cups of the bra are usually reinforced by underwire made of metal and/or plastic. Additionally, the bra is usually fastened with a hook fastener on the band, typically at the back. However, sometimes the fastener may be located on the front portion or even side portion of the bra, depending on style, taste, and fashion.
[0009] Many bras are fashioned with significant padding that functions to increase comfort and to make the breasts look bigger. Other types of bras, such as the push-up bras, are fashioned to enhance the cleavage, and use padding to achieve this effect. However, in the early 1960's a new problem came into play with the advent of breast augmentation. With breast augmentation, round or shaped breast implants are inserted either on top of or below the pectoral muscle, which is the large chest muscle on which the breast lies. The implants can be inserted through the armpits, via the nipples, from below the breast, or even from the umbilicus through very small incisions, which leave minimal scarring of the breast tissue. An advantage of the procedure of having breast augmentation is the breasts' ability to be supported by the implant. Women having received breast augmentations typically do not need as much support and/or lift that a bra provides; therefore, many women with breast augmentation do not wear bras.
[0010] However, many users with breast augmentations may want to wear a bra for support, fashion, and style. But these users do not need the formal structure of the bra, including the straps, underwire, and other support means, because, typically, the after-effects of breast augmentation allows for a woman to function without the need for a bra. Another potential problem for women that have undergone breast augmentation is the sensitivity of the breast nipples. Changes in sensitivity of the breast nipple may occur after breast augmentation, whereby some users suffer from a loss of sensitivity. However, a large number of women suffer from the opposite problem. Many women, after breast augmentation, are prone to breast nipple sensitivity, wherein the breast nipple remains in a prolonged erect state. While a woman with breast augmentation may not need a bra to support or lift her breasts, she may prefer to wear a bra to conceal the erect nipple from showing through the clothing.
[0011] Accordingly, a need still exists for an apparatus that may be utilized by women with breast augmentation that is aesthetically pleasing, yet functional. Moreover, a need exists for an improved bra for women with breast augmentations, wherein the bra provides very little support for the surgically enhanced breast, but allows for concealment of erect nipples in an aesthetically pleasing fashion.
SUMMARY
[0012] The present disclosure relates to an apparatus that may be used as an undergarment, e.g., a woman's undergarment. Additionally, the present disclosure may be utilized in other women's garments, including dresses and swim wear. The apparatus may be a bra having a strap that fastens to each of the cups of the bra to protect and hold the breast of the user. The apparatus has a cup having a first layer which contacts the user's skin. The apparatus further has a second layer which is directly opposed to the first layer and may contact the outer clothing of the user. Moreover, the apparatus has a third layer and/or insert which is positioned between the first layer and the second layer, wherein the third layer may provide an extra zone of thickness for the breast nipple, and thereby enable concealment of an erect breast nipple.
[0013] In an exemplary embodiment the present disclosure, a women's undergarment is provided. The undergarment has a first and second shoulder strap having a front end and a back end adapted to extend over the shoulder of an user. Additionally, the undergarment has a back strap whereby the first and second shoulder strap extend over the shoulder and are connected to the back strap by a fastening means. Moreover, the undergarment has a first cup and second cup attached to the first and second shoulder straps, the first and second cup adapted to support the breast and at least one insert whereby the insert is positioned directly in front of the nipple of an user to conceal the nipple from showing through clothing.
[0014] In an exemplary embodiment, the undergarment comprises a first cup and second cup having a plurality of layers.
[0015] In an exemplary embodiment, the undergarment comprises a first cup and second cup having a first layer and a second layer, whereby the first layer and second layer are separated from each other, wherein the first layer is adapted to be in contact with the breast of the user, and wherein the second layer is adapted to be in proximity to the outer garment of the user.
[0016] In an exemplary embodiment, the undergarment comprises a first cup and second cup having a first layer and a second layer, wherein the insert fits between the first layer and the second layer.
[0017] In an exemplary embodiment, the undergarment comprises a first cup and second cup that has a first layer and second layer wherein the insert is affixed to the first layer.
[0018] In an exemplary embodiment, the undergarment comprises a first cup and second cup having a first layer and a second layer, wherein the insert is placed between the first and second layer, wherein the insert is proportioned smaller than the total space utilized by the first and second layers, and wherein the insert is removably affixed to either of the first and second layers by an attachment means.
[0019] In an exemplary embodiment, the undergarment comprises an insert that is of greater thickness than either of the first and second layers of the undergarment.
[0020] In an exemplary embodiment, the undergarment comprises a first cup and second cup having a first layer and second layer, wherein the first and second layer are constructed of a similar material.
[0021] In an exemplary embodiment, the undergarment comprises a first cup and the second cup having a first layer and a second layer, wherein the first and second layers are constructed of different materials.
[0022] In an exemplary embodiment, the undergarment comprises an insert dimensioned for coverage of the nipple of the user, wherein the insert is thickest at a position where the nipple contacts the insert.
[0023] In an exemplary embodiment, the undergarment comprises a first and second cup having a first layer and a second layer which are removably attached from one another by a fastener, whereby the fastener allows for an opening between the first layer and the second layer.
[0024] In an exemplary embodiment, the undergarment comprises a fastener which is a hook and loop system.
[0025] In an exemplary embodiment, the undergarment comprises an insert which is constructed into a cosmetic and aesthetic fashion and placed within the first cup and second cup of the undergarment.
[0026] To this end, in an exemplary embodiment of the present disclosure, a method for using a women's undergarment is provided. The method comprises: providing a first and second shoulder strap having a front end and a back end adapted to extend over the shoulder of an user; providing a back strap whereby the first and second shoulder strap extend over the shoulder and are connected to the back strap by a fastener; providing a first cup and second cup attached to the first and second shoulder straps, the first and second cup adapted to support the breast; and inserting an insert into the first and second cup, whereby the insert is positioned directly in front of the nipple of an user to conceal the nipple from showing through clothing.
[0027] In an exemplary embodiment, the method further comprises positioning the insert between a first layer and a second layer of the first cup and the second cup of the undergarment.
[0028] In an exemplary embodiment, the method further comprises removably affixing the insert to the first and second cups of the undergarment utilizing an attachment means whereby the attachment means is a hook and loop system.
[0029] In an exemplary embodiment, the method comprises providing a first cup and a second cup having a first layer and a second layer, wherein the insert is placed between the first layer and second layer at a position corresponding to the nipple of the breast of the user.
[0030] In an exemplary embodiment, the method comprises providing a first cup and a second cup having a first layer and second layer, wherein the insert is placed between the first layer and the second layer, and whereby the insert has a thickness greater than the first layer and second layer.
[0031] In an exemplary embodiment, the method further comprises allowing an user to separate a first layer and a second layer of a first and second cup, whereby the user may introduce, adjust, or remove the insert from between the first layer and second layer of the first cup and second cup of the undergarment.
[0032] In an exemplary embodiment, the method comprises allowing an user to separate a first layer and a second layer of a first and second cup by the use of a fastener, whereby the fastener may allow for manual manipulation of the first and second layers, whereby the user may insert, adjust, or remove the insert from between the first layer and second layer of the first cup and second cup of the undergarment. To this end, in an exemplary embodiment of the present disclosure, a convenient apparatus relating to a women's undergarment is provided.
[0033] In another exemplary embodiment, a women's undergarment is provided. The undergarment may be constructed for women who do not need as much structured support for the breasts.
[0034] Another exemplary embodiment is a women's undergarment that may have a plurality of layers therein, wherein the plurality of layers may increase the comfort of the undergarment.
[0035] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed for users that do not need the extra support of a conventional related art bra.
[0036] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed for users having surgically enhanced breasts.
[0037] An exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed for users having just reached puberty, and wherein the user does not need extra support to lift and support the breast.
[0038] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed for users having surgically augmented breasts.
[0039] Another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed for users having surgically lifted breasts and/or breasts that are not prone to normal gravitational pulls.
[0040] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed with a shoulder strap for comfort.
[0041] An exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a cup to hold and/or support the breast of the user utilizing the undergarment.
[0042] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a support structure such as an underwire if desired, but would preferably not have said support structure.
[0043] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, including a first layer, a second layer and a third layer.
[0044] Another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, wherein the plurality may include at least two layers.
[0045] An exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein the plurality of layers may be constructed of different materials.
[0046] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein the plurality of layers may be constructed of the same materials.
[0047] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein the plurality of layers may be constructed of the same materials.
[0048] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed with a plurality of layers, and wherein some of the layers may have similar materials while other layers have different materials.
[0049] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed with a plurality of layers, wherein some of the layers may have similar materials while other layers have different materials, and wherein the differing materials may have different functions such as support, comfort, and/or concealment.
[0050] Another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers where at least one layer may be thicker at its midpoint.
[0051] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers where at least one layer may be thicker than other layers, and wherein the thicker layer may be thicker only a certain specified points such as the point that contacts the nipple of the breast of an user.
[0052] Another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers including a first layer, a second layer and a third layer, wherein the first layer and third layer may be of a uniform thickness, and wherein the second layer may be of a thickness greater than both the first and third layers.
[0053] Yet another exemplary embodiment of the present disclosure is to provide a women's garment for concealment of the erect nipple of an user, wherein the present disclosure may be utilized in a dress and additionally may be utilized in women's swim wear,
[0054] Additionally, in an exemplary embodiment, the device maybe utilized in women's dresses, tank tops, blouses, and/or any other garment that may conceal the erect nipple of the user.
[0055] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed with a plurality of colors.
[0056] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers including a first layer, a second layer, and a third layer, wherein the first layer and third layer may completely surround and enclose the second layer.
[0057] In yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein the at least one layer may be thicker than the other of the plurality of layers.
[0058] Another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein one layer may not take up the entire volume of the other of the plurality of layers.
[0059] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, wherein a first layer and second layer may be adjacent, and a third layer may be in contact with the breast of the user, and wherein the third layer is of differing thickness to the first and second layer.
[0060] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be machine and/or hand washable.
[0061] Another exemplary embodiment of the present disclosure is to provide a women's undergarment wherein the undergarment may have a plurality of layers, wherein a first layer and second layer may be adjacent, and a third layer may be in contact with the breast of the user, and wherein the third layer is of differing material than the first and second layers.
[0062] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein at least one layer may be removed from the undergarment if desired.
[0063] Another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein at least one layer may be removed from the undergarment and replaced with another layer having either an increased or decreased thickness.
[0064] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed of cotton.
[0065] Still a further exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed of polyester.
[0066] Another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed of lace.
[0067] In another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed of nylon.
[0068] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may be constructed of any suitable material.
[0069] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein the layers may be constructed of different materials including cotton, polyester, lace, nylon, and/or any other suitable material.
[0070] Still another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment may have a plurality of layers, and wherein at least one layer provides the advantage of concealing the erect nipple of the breast of the user wearing the undergarment.
[0071] Yet another exemplary embodiment of the present disclosure is to provide a women's undergarment, wherein the undergarment allows for concealment of the erect nipple of the breast of the wearer.
[0072] Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments of the disclosure, along with the accompanying drawings in which like numerals represent like components.
[0073] Additional features and advantages of the present disclosure are described herein, and will be apparent from the detailed description of the presently preferred embodiments and from the drawings.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0074] FIG. 1 is a diagram illustrating a front perspective view of a brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0075] FIG. 2 is a diagram illustrating another front perspective view of the brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0076] FIG. 3 is a diagram illustrating a rear view of the brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0077] FIG. 4 is a diagram illustrating a cross-sectional side view of the brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0078] FIG. 5 is a diagram illustrating a front view of the brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0079] FIG. 6A is a diagram illustrating a cross-sectional side view of a brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0080] FIG. 6B is a diagram illustrating another cross-sectional side view of a brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0081] FIG. 6C is another cross-sectional side view of a brassiere, in accordance with an exemplary embodiment of the present disclosure.
[0082] FIG. 7 is a diagram illustrating a front view of the brassiere, in accordance with an exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION
[0083] Turning now to the drawings, wherein elements are identified by numbers and like elements are identified by like numbers throughout the several figures of the Drawing, the brassiere 1 is generally depicted in FIG. 1 ; and the brassiere or bra 1 may be utilized by an user 31 that may not need underwire support (not shown).
[0084] Referring to FIG. 1 , this diagram illustrates, in a front perspective view, a brassiere 1 , in accordance with an embodiment of the present disclosure. The brassiere 1 (hereinafter referred to as a “bra”) may have a plurality of different configurations, but for illustrative purposes is shown in conventional common use form. The bra 1 may have shoulder straps 5 , 17 and first and second cups 13 , 15 that may be used to hold and/or support the breast 9 of an user 31 . The bra 1 may have a clasp 11 between the first cup 13 and a second cup 15 of the bra 1 . The bra 1 may have a contoured shape in an exemplary embodiment, whereby the cups 13 , 37 are shaped to hold and/or support the breast 9 of the user. In an exemplary embodiment, the bra 1 is produced for those users who do not require the structural element of an underwire (not shown) and/or push up facilities.
[0085] Still referring to FIG. 1 , the bra 1 comprises a first cup 13 and a second cup 15 and may be generally contoured to fit the breast 9 of an user 31 . A first shoulder strap 5 and a second shoulder strap 17 may be respectively attached to the first cup 13 and the second cup 15 for securing the bra 1 around the chest cavity 18 the user 31 (also FIG. 2 ). Understood is that the bra 1 may be constructed in a plurality of differing shapes and forms for cosmetic and aesthetic bras and still fall within the scope of the present disclosure.
[0086] Still referring to FIG. 1 , each of the first cup 13 and the second cup 15 respectively accommodate interchangeable inserts, such as a first insert 21 and a second insert 23 . The first insert 21 and the second insert 23 may be placed within the first cup 13 and the second cup 15 respectively. The inserts 21 , 23 are comprise a thickness greater than a thickness of any other portion of the bra 1 . Further the inserts 21 , 23 are configured to be positioned at the contact point of the nipple of the breast 9 and would thereby conceal the erect nipple of the user utilizing the bra 1 . The inserts 21 , 23 may be either permanently affixed to the bra 1 and/or, in an exemplary embodiment, may be insertable and/or removed from the bra 1 if desired. Additionally, the ability to insert and/or remove the inserts 21 , 23 may also give the user the ability to manipulate and move the inserts 21 , 23 into the desire position within the bra 1 . For example, many women have nipples that may not be at the midpoint of the breast 9 . This is sometimes the result of augmented breasts and/or other breast surgeries. Often times, the nipple is not centralized on the breast tissue. The present disclosure may allow for manipulation of the inserts 21 , 23 into a position that results in correct alignment of the inserts 21 , 23 about the nipple of the user 31 .
[0087] Referring to FIGS. 2 and 3 , these diagrams respectively illustrate, in a front perspective view and a rear view, a bra 1 comprising shoulder straps 5 , 17 attached to the first and second cups 13 , 15 , in accordance with an embodiment of the present disclosure. Also illustrated, within the cups 13 , 15 are the removable inserts 21 , 23 disposable at different positions within the bra 1 as needed to conceal the erect nipple of the user 31 . In an exemplary embodiment, the inserts 21 , 23 may have an adhesive 35 to attach to the outside layer 37 of the bra 1 (shown in FIG. 4 ). In another exemplary embodiment, the inserts 21 , 23 may utilize a hook and fastener 25 to facilitate attachment to the outside layer 37 of the bra 1 , whereby the user 31 may detach the inserts 21 , 23 from the bra 1 completely when desired, or, in the alternative, may utilize the fastener 39 to alter the position of the inserts 21 , 23 to properly conceal the erect nipple of the user 31 . In another exemplary embodiment, the inserts 21 , 23 may have an adhesive 35 to facilitate attachment to the outside layer 37 of the bra 1 (shown in FIG. 4 ). In another exemplary embodiment, the inserts 21 , 23 may utilize a hook and fastener 39 to facilitate attachment to the outside layer 37 of the bra 1 , whereby the user 31 may detach the inserts 21 , 23 from the bra 1 completely when desired, or in the alternative, may utilize the fastener 39 to alter the position of the inserts 21 , 23 to properly conceal the erect nipple of the user 31 . In another exemplary embodiment, a shelf or pocket (not shown) may be utilized to allow for positioning of the inserts 21 , 23 in the cup 13 , 15 of the bra 1 . The shelf and/or pocket maybe constructed into the bra 1 and may allow for proper placement of the inserts 21 , 23 and allow for easy removal and placement within the cups 13 , 15 .
[0088] Referring to FIG. 3 , this diagram illustrates, in a rear view, the back portion 37 of the bra 1 . In an exemplary embodiment, the shoulder straps 5 , 17 may be connected at the back portion 37 by a locking member 41 . The locking member 41 may be a latch 45 whereby the latch 45 may be a clasp 47 for attaching the shoulder straps 5 , 17 to a first back strap 49 and a second back strap 51 .
[0089] Referring to FIG. 4 , this diagram illustrates, in a cross-sectional view, a bra 1 being utilized by a user 31 , in accordance with an embodiment of the present disclosure. The breast 55 having a nipple 57 is shown, wherein the breast 55 may be covered by a cup, such as the first cup 13 , of the bra 1 . In an exemplary embodiment, the bra 1 may have a first layer 61 and a second layer 63 . The first layer 61 may contact the breast 55 of the user 31 and may be constructed of any suitable material such as cotton, polyester, lace, nylon, and the like. In an exemplary embodiment, the first layer 61 is constructed of cotton for comfort. The second layer 63 is the outer most layer and may contact the clothes (not shown) of the user 31 . The second layer 63 may be constructed of any suitable material such as cotton, polyester, lace, nylon, and the like. In an exemplary embodiment, the second layer 63 may be constructed of cotton for comfort. However, understood is that the first layer 61 and the second layer 63 may be constructed of different materials depending on comfort, aesthetic preferences and the like. The first layer 61 and the second layer 63 are preferably of equal thickness and attached to each other at a portion of the shoulder straps 5 , 17 of the bra 1 .
[0090] Still referring to FIG. 4 , this diagram further illustrates a third layer 71 . The third layer 71 may be the inserts 21 , 23 mentioned above. The third layer 71 is of greater thickness than either of the first and second layers 61 , 63 . Additionally, the third layer 71 may not utilize the entire space from the top portion 75 of the cup 12 to the bottom portion 77 of the cup 13 , whereby the third layer 71 may only occupy a smaller portion of the space between the first layer 61 and the second layer 63 . The third layer inserts 21 , 23 may have a tapered shape, wherein the midpoint 81 of the insert 21 is thicker than the top portion 83 and/or bottom portion 85 of the insert 21 . The midpoint 81 has a thickness that helps to greatly reduce or completely eliminate the display of an erect nipple through the fabric of the bra 1 . Additionally, the localized positioning of the insert 21 within the first and second layers 61 , 63 may eliminate unwanted bulk and weight of the bra 1 for the user 31 . The insert 21 is placed between the first layer 61 and the second layer 63 .
[0091] Referring to FIG. 5 , this diagram illustrates a front view of the brassiere 1 , comprising an insert 21 being placed within a first cup 13 , in accordance with an exemplary embodiment of the present disclosure. In an exemplary embodiment, the first layer 61 and the second layer 63 may be separated by an opening 95 , whereby the opening 95 may be positioned on an outside portion 97 of the first layer 61 and an outside portion 99 of the second layer 63 . The first layer 61 and second layer 63 may have an opening 95 , whereby the opening 95 allows for insertion of the insert 21 into a position 25 between the first layer 61 and the second layer 63 . The opening 95 may have an attachment feature 103 for facilitating separating the first layer 61 from the second layer 63 as well as insertion and removal of the insert 21 from therebetween. The attachment means 103 , in an exemplary embodiment, is a hook and fastener, whereby the first layer 61 and the second layer 63 may be easily separated from each other and reattached with little effort by the user 31 utilizing the bra 1 . In an additional exemplary embodiment, the inserts 21 , 23 maybe attached to the first and/or second layers 61 , 63 by a pocket or shelf system (not shown), whereby a small pocket or shelf (not shown) is built into either of the first layer 61 and/or second layer 63 , whereby the inserts 21 , 23 may be inserted into the shelf or pocket thereby removing the need for an attachment feature 103 . However, understood is that the attachment feature 103 may be any method or apparatus for attaching the first layer 61 to the second layer 63 , such as a snap-on, clasp, zipper, button, shelf system, pocket, or the like.
[0092] Referring to FIG. 6A , this diagram illustrates, in a cross-sectional side view, of a brassiere 1 , wherein the insert 21 may be placed in different positions within the layers 61 , 63 and may be of varying sizes depending on the need of the user 31 , in accordance with an exemplary embodiment of the present disclosure. Contemplated is that the bra 1 of the present disclosure is utilized by women having breast augmentation and/or surgically enhanced breasts, but the bra 1 may be also utilized by teens or users that do not need additional lift and support for their breasts. The insert 21 is placed between the first layer 61 and the second layer 63 .
[0093] Referring to FIG. 6B , this diagram illustrates, in another cross-sectional side view, a brassiere 1 , wherein the insert 21 is positioned on the inside of the first layer 61 , whereby the insert 21 may be attached to the first layer 61 and may directly contact the nipple 57 of the user 31 , in accordance with an exemplary embodiment of the present disclosure. The insert 21 may be fastened to the first layer 61 by a fastener 39 , whereby the user 31 may shift or move the insert 21 as desired to place the insert 21 over the nipple 57 . Additionally, if desired, the user 31 may completely remove the insert 21 from the bra 1 .
[0094] Referring to FIG. 6C , this diagram illustrates, in another cross-sectional side view, a brassiere 1 , wherein an insert 21 with a much thicker top portion 83 and bottom portion 85 . whereby users 31 that wish for a more uniform breast look, or for the perception of larger breasts 55 may have the added padding of the insert 21 give that perception, in accordance with an exemplary embodiment of the present disclosure.
[0095] Referring to FIG. 7 , this diagram illustrates, in a front view, the brassiere 1 , wherein the inserts 21 , 23 may be attached to the second layer 63 and/or may be seen through the second layer 63 , whereby the inserts 21 , 23 may depict a variety of different characters, emblems, or fashion features, in accordance with an exemplary embodiment of the present disclosure. In the illustrated embodiment, the bra 1 has an insert 21 , whereby the insert 21 is fashioned in the form of a cherry 91 ; and the second insert 23 is fashioned in the form of a leaf 93 , by example only.
[0096] Thus, specific embodiments and applications of the apparatus have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. The terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.
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An apparatus to be used as a woman's undergarment is provided. The apparatus is a bra having a strap that fastens to the cups of the bra that protect and hold the breast of the user. The apparatus has a cup having at least a first layer which contacts the individual's skin. The apparatus further has a second layer which is directly opposed to the first layer and may contact the outer clothing of the individual. Moreover, the device has a third layer which is positioned between the first layer and the second layer and further wherein the third layer may provide an extra zone of thickness for the breast nipple and thereby may enable concealment of an erect breast nipple. The third layer may be of varying thickness and in an embodiment may be thicker than the first and second layer and may be removable from the undergarment if desired.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to the method and system of testing the electronic circuits including the integrated circuits (ICs). More particularly, this invention relates to an improved system configuration and method for simplifying and expediting the testing processes for electronic circuits including integrated circuits (ICs) by applying an improved algorithm by taking into account the defect probability as a key factor for generating the testing vector.
[0003] 2. Description of the Prior Art
[0004] As the integrated circuits (ICs) and other form of electronic circuits become more complicate with higher level of integration and increasingly faster operational speed, the traditional techniques of the circuit testing configurations and methods are challenged by many technical difficulties. One of the major difficulties is the concept of “fault-coverage” in an attempt to more thoroughly and completely test the electronic circuits supported on either a semiconductor wafer or on other circuit support platforms applying various fabrication processes. Since the integrated circuit (IC) chip(s) is generally the most critical and expensive part of an electronic system, it is highly desirable to more thoroughly test the IC chip(s) to assure that functionalities as designed onto each IC chip can function properly. In order to achieve this goal, a high percentage of fault coverage is desirable. However, as the IC chips and electronic device becomes miniaturized to include large number of different transistors and accompanied circuits, high percentage fault coverage becomes an extreme heavy burden on the manufacturing and testing of the IC chips. As will be discussed further below, an IC chip designer is now required to design into the IC chips testing circuits for relieving this heavy burdens placed on testers of the IC chips to allow for more conveniently achieving a higher percentages of fault coverage in the testing processes and this is called DFT.
[0005] The development of the fault coverage concept in testing the electrical circuits started in an era before the IC fabrication and other similar techniques were developed. Prior to integrated circuit (IC) and other similar fabrication technologies, manual point-to-point crossed wiring with insulated copper wire and manual cabling are major tasks of the electric and electronic system manufacturing processing. In this type of process, the probability of any node being shorted or mis-wired to any other node is unpredictable or at the least very hard to characterize. However in that time, all the system complexity is very low in terms of test equipment capability. An one-hundred percents (100%) fault coverage can be easily achieved. There are no practical needs to spend effort in reducing test vectors. However, in the meantime, the theory of fault coverage is formulated and firmly planted in the mind of the testing industries as an important index of merit in carrying out circuit tests.
[0006] Due to the rapid development of very large-scale integrated circuit (VLSI) and system on chip (S.O.C) technology, the extreme circuit complexity of state of art VLSI and S.O.C. has made testability becoming a major issue in the production process. The conventional pattern generation algorithm guided by fault coverage theory has come to a point that an astronomical number of test patterns are required to produce sufficient test coverage and that leads to the use of complex device to carry out very costly tests. In increasing numbers of cases, the test requirement becomes too complicate and not practical or economically not viable even by using those most advance test equipments.
[0007] One specific example is U.S. Pat. No. 6,385,750 issued to Kapur et al. They disclose a method and system for increase the fault coverage of test vectors for testing integrated circuits. The Kapur et al. provide a method and system for reducing the number of deterministic test vectors required for testing integrated circuits by inserting test points. A fault list having all the potential faults of an integrated circuit design is initialized and all the potential faults are marked as untestable. A set of test patterns, T, for testing several of the potential faults is generated. A fault simulation process is then performed on the integrated circuit design with the test patterns, T, to mark off untested faults. During fault simulation, fault propagation is monitored to determine the nets in the design to which faults were propagated. The nets at which fault propagation discontinues (e.g., de-sensitized) are also monitored. This information is collected over the set of test patterns, T. Based on the fault propagation information; test points are selectively inserted to maximize the fault coverage of the set of test patterns, T. In one embodiment, Kapur et al. also select nets to which most untested faults propagate for test point insertion and applying user-defined parameter to determine the selected number of test points. These steps are then repeated for another set of set patterns until the desired fault coverage is achieved. By adding test points, Kapur et al. intend to improve the fault coverage of the test patterns to reduce the test data volume. However, even with the benefits of reduced volume of testing data, as more testing points are added for the purpose of reducing the volume of test data, additional costs and time are required for carrying out the tests to include those inserted testing points.
[0008] To overcome this manufacturing bottle neck, a variety of testing techniques have been adapted such as BIST which needs additional circuitry to be incorporated into the device during early design stage thus costing not only silicon real state and design engineering time but also affecting device performance and capacity. Some other techniques such as IDDQ can only provide limited improvement but are not effective enough to remedy the problem significantly. All prior art have fault coverage as the goal and measurement of effectiveness, but in current production environment, different sets of test pattern with same fault coverage may have different numbers of malfunction device undetected in the same lot of devices.
[0009] Therefore, there is still a demand in the art of IC and electron circuit testing for a new technique and system configuration which can simplify the IC and electron circuit testing processes thus significantly reducing the requirements for expensive testing equipments, the long-hours of engineers' efforts for testing pattern generating and output signal simulation, the memory required for the storage of the testing input and output data. ( )
SUMMARY OF THE PRESENT INVENTION
[0010] It is therefore an object of the present invention to provide a new IC and electron circuit testing technique and system configuration to overcome the aforementioned difficulties encountered in the prior art.
[0011] Specifically, it is an object of the present invention to provide a new IC and electron circuit testing technique for generating testing pattern signals weighted by the fault probability to greatly simplify and reduce the number of testing vectors required for conducting the IC and electron circuit functionality tests.
[0012] Another object of the present invention is to provide a new IC and electron circuit testing technique by taking into consideration that the electrical short conditions occur mostly between nodes which are physically next to each other and designated as adjacent nodes in this Patent Application. The “fault coverage” concept is revised to test faults occurred between adjacent nodes and the test vectors are generated based a fault-probability weighted algorithm.
[0013] In a preferred embodiment, this invention discloses a method for generating a set of test patterns for testing an electronic circuit having a plurality of circuit nodes. The method includes a step of generating the set of test patterns by applying a weighting factor based on the probability of an unintended shorted circuit connection between two of the plurality of circuit nodes due to defects during manufacturing process.
[0014] These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment which is illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a flowchart for showing the processing steps carried out by a test system of this invention to provide simplified, effective tests for electronic devices taking into consideration of defect probability.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The present novel invention is different and totally non-obvious when compared to the conventional wisdom of fault coverage theory. Instead of focusing on detection of all faults or maximum number of faults, it takes into the account of the characteristics of modern day technologies of manufacturing processes for the integrated circuit and other electron circuit. A new approach is implemented to detect potential defects of circuits or circuit connectivity by taking into account the defect probability and defect density. Typically there are three types of failures that commonly cause circuit faults. The first two types, the internal circuit continuity, i.e., broken traces, within a node and excessive leakage between nodes are much less of a problem for testing. An internal circuit continuity test can be simply carried out by driving the respective nodes to two different states, i.e., 1 and 0's in binary logic system until an output change occurs and measuring the output for correct responses. Simply driving the respective nodes to different states and measuring the supply current can detect the excessive leakage between nodes. In actual practice, measuring the ICC or IDD while exercising all circuit functions is often performed to detect excessive current.
[0017] The major problem is in the testing of the third type fault, i.e., the short between nodes. In order to detect shorts between every two nodes, the required test patterns would be astronomical under the assumption that the probabilities of a short between any nodes are equal. While all of the prior art test technologies are generating test patterns to achieve maximum fault coverage under this assumption, this assumption has long been outdated when applied to the configurations of connections between different nodes for the modern IC and circuits fabricated by other techniques.
[0018] The essence of this invention is to take into account that the probability of short between any two nodes depends on their respective physical locations and type of process and technology. For most cases, the highest probability of short is between adjacent nodes, i.e., nodes physically located adjacent to each other. The circumstances where short occurs for a connection between an node to other nodes without shorting to adjacent node would be almost impossible. In most electronic circuits including the integrated circuits (IC) connections are constructed by stack of layers of circuitry separated by insulation material and connected by feed through holes. In this case, adjacent nodes would be nodes with conducting traces or areas next to each other horizontally on the same layer and/or having vertical overlap area between respective adjacent layers. Short over adjacent node in those cases have to be either shorten through more than one layer without shortening to the middle layer or shorten across more than one trace without shortening to the middle trace in between. Since in today's process, shorts through layer will be highly unlikely and will almost always accompany with shorts between adjacent traces in the same layer, it will be practical to concentrate the test effort in testing shorts between adjacent traces in each layer. Of course in other hand if extremely low defect-miss requirement is necessary, an adjacent node category can include a test between layers and include nodes separated by one or more traces or layers. Even with the expanded category of adjacent nodes under such low defect-miss requirement, compared to the prior art technologies, the test vectors will still be significantly less.
[0019] Once the adjacent node category is defined, the internal circuit continuity test which has test pattern exercising all nods is to be run and at the same time, all traces having its adjacent nodes being at least once in the opposite states is to be marked out as fully test nodes. The following step is to generate test vectors to make those unmark adjacent nodes to be in different stats at least once.
[0020] To achieve above operation in actual practice, the first step is to merge the CAD circuit layout data base with the logic simulation database such that each layout trace on each layer can be identified by the corresponding physical CAD layout dimension and CAD layout coordinate, simulation node name and simulation logic level at each basic simulation timing slot. There are many ways to merge these two databases. One of the ways is to attach each node name in the net-list for the logic simulation database with the physical dimension and coordination data from the layout database. The second step is to run the internal circuit continuity test vector, which is normally the functional test generated by design engineer to check out the logic function of the chip and some times it can be a self-diagnostic program of the chip, through the system logic simulator and at each system clock cycle, scan through each circuit layer to mark out all traces with it's adjacent node being in a different state. When the test finished, those nodes with all it's adjacent nodes having at least once been in a different state. These nodes are registered as tested nodes and marked out differently, e.g., setting up a data file table that includes the net-list of all node names of the tested nodes. Also, all the partially tested nodes which have part of it's adjacent nodes being at least once in a different state are marked as partially tested nodes. There are varieties of different ways to accomplish the marking out those tested nodes and partial tested nodes. One of which is to setup a table for storing the tested node names and another table for storing the partial tested node names attached with node names of the logic states of which have been differ from the partial tested node. The third step is to generate test vectors to make nodes of those untested and partially tested nodes in a different state and check for correct output responses. These test vectors can be generated by back tracking through the logic simulation or by means of self-diagnostic program. The last step is to merge common parts of those newly generated test vectors sets to minimize the number of test vector.
[0021] FIG. 1 is a flowchart showing the steps for carrying out a simplified and effective process of this invention. The test process starts (step 100 ) by checking if it is the end of stimulus (step 105 ) and end the test process if it is the end of the stimulus (step 110 ). The test processes continues with reading in the next stimulus (step 115 ) and carry out a logic simulation using the stimulus received (step 120 ). After the logic simulation is completed, the test process continues by setting pointer to the first node in the net-list in the logic simulation database (step 125 ). A check is carried out by checking if the current node is stored in the tested node table, if it is, then a check is carried out to determine if the current node is the end of the net list (step 175 ). If the current node is not stored in the tested node table, the process continues by getting the current logic state from the logic simulation database and also the layout data from the layout database for current node (step 135 ). Then a search is carried out in the layout database for node name of all nodes disposed physically adjacent to the current node. The node names of these adjacent nodes are used to obtain the logic state of these adjacent nodes from the logic simulation database (step 140 ). Then it is checked if the current node is in the partial tested table (step 145 ) and the logic state of the current node is compared with that of the adjacent nodes if the current node is not listed in the partially tested table (step 155 ). The logic state of the current node is compared to the adjacent nodes except the attached nodes of the current node if the current node is listed on the partially tested table (step 150 ). After comparing the logic state of the current node with the adjacent nodes (step 160 ), a comparison is made to determine if the logic state of the current node is different from the logic state of all the adjacent nodes. When all adjacent node logic state differs from current node logic state, then the name of the current node is placed into the tested node table. The name of the adjacent nodes are placed into the partially tested table with the name of the current node attached to each of those partially tested node names (step 170 ) followed by a check to determine if the current node is the end of the net-list. Under the condition that not all adjacent node logic state is different from the current node logic state, then the test process is followed by a check to determine if some adjacent node logic state differs from the current node logic state (step 180 ), if it is, then current node name is placed into the partially tested table attached with those node names with the state opposite to current node logic state. The node names with the state opposite to current node logic state is placed into the partially tested table with the current node name attached to these partially tested adjacent nodes (step 185 ). The process is followed by a check to determine if the current node is the end of net-list (step 175 ) followed by a check to determine if there is further stimulus as input to continue the test process (step 105 ) and end the process when there is no more stimulus to proceed with the test process (step 110 ).
[0022] According to above descriptions, this invention discloses a method for generating a set of test patterns for testing an electronic circuit having a plurality of circuit nodes. The method includes a step of generating the set of test patterns by applying a weighting factor based on a defect probability of a circuit connection between two of said plurality of circuit nodes. In a preferred embodiment, the step of generating the set of test patterns further comprising a step of applying a weighting factor based on a defect probability of a circuit connection between two of said plurality of nodes physically adjacent to each other.
[0023] Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is not to be interpreted as limiting. Various alternations and modifications will no doubt become apparent to those skilled in the art after reading the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alternations and modifications as fall within the true spirit and scope of the invention.
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A method for generating test pattern signals weighted by the fault probability to greatly simplify the test process and to reduce the number of test vectors required for conducting the integrated circuit functionality tests. The method takes into consideration that the electrical short conditions occur mostly between adjacent nodes. The “fault coverage” concept is revised to test faults occurred between adjacent nodes and the test vectors are generated based a fault-probability weighted algorithm such that tests are conducted mostly on connections between adjacent nodes either on a same horizontal layer or on adjacent vertical layer having vertical overlapping areas.
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RELATED APPLICATION
This is a division of application Ser. No. 327,730, filed Jan. 29, 1973, now U.S. Pat. No. 3,894,314, entitled TREATMENT OF SPINNING FIBERS IN A TEXTILE MILL.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to apparatus in a textile mill for treating fibrous material, prior to handling by mill equipment preparatory to and in connection with the converting of fibers to yarn or thread.
In the processing of fibrous material, such as cotton fibers, from the point of entry into a mill to the formation of a yarn or thread suitable for weaving, the fibers pass through a sequence of equipment performing the functions of opening up of the fibers from the compressed state in the incoming bales, separating dirt and other foreign matter from the fibers, parallelizing and drawing out the fibers to convert the individual fibers from a tangled mass into generally parallel alignment suitable for the formation of continuous slivers, and further drawing out of the slivers, and twisting and spinning the slivers, to ultimately produce the yarn or thread suitable for the subsequent weaving processes. During these several processes, the fibers are subjected to much mechanical handling by the components of the equipment which inherently produce much friction between the machine parts and the fiber material. Conditions of high friction and sticking of the fiber material are aggravated where the material has a high sugar content and where there is a higher than normal dirt or contamination contained in the fiber.
Another undesirable condition, in this machinery is the inherent build up of static electricity due to friction which causes further tendency of the fibers to stick together to resist separation of foreign matter, to resist the desired actions of the processing equipment resulting in increased fiber breakage which reduces the quality of the yarns. Because of these inherent conditions and problems with the fiber processing equipment, there is ultimately an end loss of spinnable fibers and a reduction in yarn strength due to the higher percentage of short fibers.
An inherent result from excessive friction in equipment of this type is that the wear of the equipment is increased resulting in the frequent necessity for replacement of parts and also resulting in overall reduced life.
A principal object of this invention therefore is to provide apparatus for the treating of fibers in a textile mill which, improves the subsequent processing of the fibers through the various equipment of the mill by improving the conditions which result in the above outlined disadvantages.
Another principal object is to provide apparatus which may be used in conjunction with the conventional mill equipment for treating the fibers to eliminate or improve on these problems.
A further object of this invention is to provide spray apparatus for applying a fine mist spray of a selected solution to the surface of the fibrous material at an early stage in mill processing, so that the subsequent processing operations may be carried out in an improved and efficient manner.
Still another object of this invention is to provide a system whereby the application of a spray solution to the material is automatically controlled by bale opening equipment which distributes the incoming fiber material onto a conveyor for the spray treatment and for delivery to subsequent processing equipment.
Apparatus for the treatment of fibrous material includes a powered conveyor; powered apparatus for distributing the fibrous material uniformly onto the conveyor; spray apparatus including at least one nozzle for spraying a finely diffused liquid on the fibrous material carried on such conveyor, said spray apparatus being disposed adjacent to the conveyor at a point spaced from said powered distributing apparatus; and control means responsive to the operation of the distributing or conveying apparatus for effecting the operation of the spray apparatus.
A principal feature of the apparatus of the invention is that the fibrous material is treated with a treatment composition, at a stage in its processing prior to handling by various stages of equipment, which better conditions the fibers for the subsequent processing by the equipment and has the side effect of being deposited on the equipment to further reduce problems which inherently result from the processing. The treatment compound is added to the material in such quantities as to provide a synthetic shield or coating on the fibers to preserve the inherent quality of the fibers which is often dissipated through the friction generated as the fibers are carried through and acted on by the processing equipment. The treatment composition provides lubricity of the fibers and functions to greatly minimize the build up of static electricity which is generated by the movement of the fibers through the processing equipment. The treatment composition is of a nature that a portion will be deposited from the fibrous material to the parts of the equipment which act on the fibers, thereby coating such parts to further minimize the friction between the fibers and equipment parts and to inherently then reduce the wear of such equipment parts.
The novel features and the advantages of the invention, as well as additional objects thereof, will be understood more fully from the following description when read in connection with the accompanying drawings.
DRAWINGS
FIG. 1 is a diagrammatic illustration of apparatus used in a textile mill, with which the invention is practiced;
FIG. 2 is a diagrammatic illustration of the spray station identified in FIG. 1; and
FIG. 3 is a schematic diagram of the control circuit embodied in the console control unit at the spray station.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 of the drawing is a diagrammatic illustration, somewhat in the form of a flow diagram, illustrating typical processing equipment in a textile mill concerned with the spinning of cotton fibers for example.
The four units 11 identified as bale breakers act on hard compressed slabs of fibers from the bale to reduce these fibers to a fairly fluffy state, and then distribute the fibers at a controlled rate to a belt conveyor 12. During this process some of the dirt and trash contained in the cotton lint or fibers may be removed. The individual bale breakers may be used to process cotton or other materials of different quality so that a desired blend is discharged to the conveyor belt 12. It is also possible at this point of entry to a textile mill, that other fibrous material, such as synthetic fibers, may be blended with cotton at this stage.
The fibers are deposited relatively uniformly onto the open conveyor belt 12, and are conveyed through a spray station 13. A liquid solution is deposited on the surfaces of the fibers by means of one or more spray nozzles, in the form of a finely diffused spray. The conveyor 12 may be of some length such as 20 or 30 feet for example in order to convey the material from the atmosphere of the bale breaking room to an atmosphere more suitable for the spraying operation. Following the spraying, the fiber material is discharged into the entry hopper of a pneumatic conveyor duct 15.
The equipment to which the fibers are conveyed will vary from plant to plant, and, as indicated by the dotted lines 15a, 15b and 15c c the material may alternatively be conveyed to opening equipment 16, picker equipment 17 or carding equipment 18. If opening equipment is provided the fibers will first be processed with this equipment which functions to further open up the fluffed cotton and to permit additional cleaning of the cotton fibers. The fibers may then be processed by picker equipment 17 which further cleans the cotton fibers and forms the cotton into a substantially uniform and fairly dense batt or lap suitable for handling by carding equipment 18. In some plants, the cotton fibers are fed directly from a pneumatic conveyor 15 to suitable chute feed devices for the carding equipment 18.
The fibrous material which is received at the inlet of the carding equipment in the form of a relatively thick batt or lap has a uniform density. The carding equipment receives these batts at a relatively slow rate and combs or aligns the individual fibers to form a fine delicate web at the output end. This fine web is funneled into one or more so-called trumpets which shape the web into a round sliver having a diameter of approximately 1/2 inch for example. The slivers are coiled into cans for transport to the next processing equipment.
The slivers may be processed through several stages of drawing equipment 19 wherein the sliver is reduced in diameter and density and where the fibers are further parallelized and the regularity of the weight per unit length of the material is increased. Roving equipment 20 also reduces the sliver to smaller and smaller diameters and twists it slightly to maintain a continuous strand. The last indicated equipment in the flow cycle is the spinning equipment 21 which further draws the fibers and twists the fibers to produce yarn or thread.
In all of the stages of processing of the fibers there is inherent friction between the fibers and the elements of the equipment which act on the fibers. This friction inherently produces wear on the equipment parts which come in contact with the fibers. This friction causes a build up of static electricity which acts between the fibers being processed to resist separation of the fibers and to resist removal of seed fragments and other contamination during the cleaning processes, and which acts between the fibers and the machine parts to increase drag of the material or sticking of the material to the several parts. Sticking is further caused by high sugar content and other contamination within the fibrous material with this problem being aggravated by the static electricity which resists the removal of these contaminants.
According to applicant's invention, a solution of a treatment composition is introduced to the surface of the fibers at a point in the processing prior to the handling by much of the equipment. The treatment composition serves to give the fibers a certain lubricity, and has anti-static properties to reduce to a large extent the build up of static electricity.
A preferred solution for this purpose is an aqueous solution consisting of about 75% water for example and further consisting of animal or vegetable fats as an active compound which is converted to ionic salt by reaction of the organic acids contained in the animal and vegetable fats with an amine and subsequently with an alkyl sulfate.
A preferred formulation for the solution is as follows, with the percentage of ingredients by weight being indicated:
______________________________________Tallow imidazolinium methosulfate 121/2%Ethyl sulfate C.sub.2 H.sub.5 SO.sub.4 7%Dimethyl distearyl ammonium chloride 51/2%[(CH.sub.3) .sub.2 (C.sub.18 H.sub.37).sub.2 N.sup.+] Cl--Water 75% 100%______________________________________
In this formulation the basic formula for tallow imidazolinium methosulfate is as follows: ##STR1## wherein R1 is an aliphatic hydrocarbon radical (C 10- 20), wherein R2 is a saturated aliphatic hydrocarbon radical (C 2-6), wherein R3 is a aliphatic alcohol (C 1-5), and wherein R' 2 is an alkyl sulfate (C 2-5).
The dimethyl distearyl ammonium chloride functions as a lubricating constituent of the composition.
The spray station 13 is illustrated diagrammatically in FIG. 2 wherein there is shown a spray nozzle 25 positioned above the belt conveyor 12 to spray treating solution onto fibrous material 26. FIG. 2 is essentially a schematic diagram of the hydraulic circuit for supplying the treating solution and air to the nozzle 25 and indicates, in broken lines, a spray control unit 30 which controls the spray station and houses certain components.
The treatment solution may be supplied to the mill in a 55 gallon drum 31, for example. A conduit 32 associated with the control unit 30 is the suction line to a pump 33, which may be an electric motor driven, positive displacement fluid pump. Pump outlet conduit 34 directs the solution through solenoid controlled shut off valve 35 to the nozzle 25. Adjacent to the nozzle 25 the fluid is directed through a pressure responsive cut off valve 37 which functions to open in response to a supply pressure of about 9 psi for example and to close when the pressure drops below that value. This valve maintains solution in the discharge conduit and prevents leakage of the liquid from the nozzle.
To effect the dispensing of the liquid from the nozzle in the desired fine mist spray, pressurized air is supplied to the nozzle at a pressure of 16 to 30 psi for example, This air is preferably supplied from plant air if available; or a supplementary air compressor may be associated with the spray station. In the diagrammatic illustration of FIG. 2, air is supplied from either plant air or a compressor through inlet conduit 41, to solenoid actuated on-off valve 42 within the control unit 30, then through supply conduit 43 to the nozzle 25.
FIG. 3 of the drawing is a schematic diagram of the electric control circuit for the control unit 30, and associated circuitry. The spray control unit 30 may be a housing containing the circuit components to be described as well as other components such as the liquid pump 33 and solenoid valves.
For internal wiring of the components within the control unit, a terminal panel includes four terminal blocks designated 1, 2, 3 and 4 and each having a pair of interconnected terminal posts a and b. Power for the control unit is supplied through terminal blocks 1 and 4 by means of conductors 51a and 51b which are connected to a conventional 110 volt AC power supply for example.
The several components which are to be energized to dispense treatment solution are the electric motor driven pump 33, the solenoid controlled liquid valve 35, solenoid controlled air valve 42, and a pilot light 52. All of these components are connected across the terminal blocks 3 and 4, the pump and the pilot light being connected by means of conductors 53a and 53b, and solenoid valves 35 and 42 being connected by means of conductors 54a and 54b. The terminal block 4 and connected conductors 51b, 53b and 54b will be referred to for convenience as the "ground circuit"; while conductor 51a and terminal blocks 1, 2 and 3 are associated with the "power circuit".
A selector control switch 55 has its common terminal C connected to block 1 through conductor 56, has a terminal M connected to block 3 through conductor 57, and has a terminal A connected to block 2 through conductor 58. For manually operating the spray station, the selector switch connects its terminals C and M thereby connecting block 3 in the power circuit to energize the spray station components. For automatic operation, the selector switch 55 connects its terminals C and A thereby connecting block 2 in the power circuit and disconnecting block 3.
Automatic operation is controlled through start controller 60 having input terminals 6a and 6b and a stop controller 61 having input terminals 7a and 7b. Start controller 60 includes a solenoid operated switch arm which is normally positioned to couple its common terminal C and its contact NC; and which, when the controller is energized, couples the terminals C and contact NO. The controller includes an adjustable timer to select a delay interval prior to movement of the switch arm from the NC to the NO contact.
Similarly the stop controller 61 includes a solenoid operated switch arm normally coupling its common terminal C and its contact NC, and which shifts to make its contact NO when the controller is energized and after a preselected delay interval through an associated adjustable timer.
These controllers are connected into the circuit in the following manner. The common terminal C of both the start controller and the stop controller are connected to the block 2 through conductors 62, 63 and 64. The start controller NC contact is connected to the input terminal 7a of the stop controller through conductor 65; and the other input terminal 7b is connected into the ground circuit through conductor 66 and terminal block 4. The start controller NO contact is connected to block 3 through conductors 67 and 68; stop controller NC contact is also connected to block 3 through conductors 67 and 69.
The input terminals 6a and 6b for the start controller are connected in the power circuit for either the bale breakers 11 or the conveyor 12, so that when power is supplied to this equipment power is simultaneously supplied to energize the start controller. By the same token when the power to this equipment is shut off, the start controller is deenergized.
Operation
The start controller 60 and the stop controller 61 function together to couple terminal blocks 2 and 3 at the desired time, to switch terminal block 3 into and out of the power circuit for energizing the operating components of the spray control unit. This portion of the circuit operates in the following manner. When the selector switch 55 is placed in the automatic position, the power circuit is extended through terminal conductors 62 and 63, the start controller NC contact, and conductor 65 to energize the stop controller 61. After the preselected delay interval, the stop controller switch arm breaks from its NC contact; and at this point block 3 is not connected in the power circuit. This is the "ready" condition of the control circuit.
Now when power is supplied to the bale breakers 11 or conveyor 12, power is also supplied to terminals 6a and 6b to energize the start controller. After the preselected delay interval, allowing time for fibers to move along the conveyor from the bale breakers 11 to the spray station 13, the switch arm swings over to make the NO contact. This couples blocks 2 and 3 in the power circuit through conductors 62, 63, 68 and 67; and the spray control unit components are energized to dispense the treatment solution. With the breaking of the start controller NC contact, power to the stop controller 61 through the input terminal 7a is removed, and its switch arm immediately makes its NC contact. This completes a parallel power circuit coupling blocks 2 and 3 consisting of conductors 62, 64, 69, and 67. This condition of the spray control circuit will be maintained until such time as the power supply to the bale breakers 11 and conveyor 12 is removed.
When this occurs, the start controller is deenergized resulting to an immediate breaking of its NO contact and an immediate making of its NC contact, the latter of which again completes the power circuit for energizing the stop controller. With the breaking of the start controller NO contact, one of the parallel power circuits coupling terminal blocks 2 and 3 is broken; however the second power circuit through the stop controller is maintained for the preselected delay interval following energization of the stop controller. This interval allows time for the last fibers placed on the conveyor belt by the bale breakers to reach the spray station 13, at which time the stop controller NC contact breaks to open the power circuit to the terminal block 3 thereby shutting down the spray unit. This operating cycle repeats itself each time power is supplied to the bale breakers 11 or conveyor 12.
The use of the above described apparatus and method of the invention has produced a number of advantages as established by reliable mill and laboratory tests. These include: (1) the control of lint fly throughout the mill; (2) the elimination of sticking caused by high-sugar content, seed fragments and other contamination; (3) an increase in the removal of dirt and other foreign matter in the preparatory stages, without increasing the loss of spinnable fibers; (4) the elimination of static electricity; (5) a reduction in fiber breakage; (6) the production of a more compact and smoother picker lap with no change in the logger-head pressure; and (7) the production of yarn having a significant increase in yarn strength, and a reduction in the yarn strength range. Other advantages realized from the use of the invention are: (8) a reduction of down-time caused by ends-down in processing; (9) an increase in the apparent fiber tenacity of the yarns produced; (10) extended life of mill machinery resulting from reducing the fiber-to-metal friction; (11) better preparation of laps and slivers; and (12) the reduction of comber-noil with no loss in yarn quality.
A particular feature of the above described apparatus is the positive control of the spray station through the distributing equipment which eliminates waste of the treatment composition and which assures positive control of the spray of the treatment composition to the fibers when the fibers are passing the spray station. The spray station then operates in response to the presence of fiber material, but the control is a positive control acting directly in response to the feeding of material onto the conveyor at point spaced from the spray station.
While the preferred embodiments of the invention have been illustrated and described, it will be understood by those skilled in the art that changes and modifications may be resorted to without departing from the spirit and the scope of the invention.
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Fibers enter a textile mill at bale breaking equipment where fibers are distributed onto an open conveyor, and possibly blended, for transmittal to processing machinery such as opening and cleaning equipment, picker equipment for forming a lap, carding equipment, and drawing, roving and spinning equipment. The fibers are carried on the open conveyor past a spray station including at least one nozzle for spraying a finely diffused liquid onto the surface of the fiber material carried on the conveyor. The liquid is an aqueous solution which consists of about 75% water and about 121/2% of animal or vegetable fats as an active compound which is converted ionic salt by reaction of the organic acids contained in the animal and vegetable fats with an amine and subsequently with an alkyl sulfate. After passing the spray station, the fiber material may be transmitted through pneumatic conveyor systems to the additional processing equipment which ultimately converts the fibers into yarn or thread. An automatic control system for the spray station is energized by activation of either the bale breaking machinery or the open conveyor, and provides a delay control allowing the fibers on the open conveyor to move from the opening machinery station to the spray station.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending application Ser. No. 11/424,184, filed Jun. 14, 2006, which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to an apparatus for lifting and moving pressurized tanks and more particularly relates to a compact apparatus for lifting and moving heavy pressurized oxygen tanks to assist in their installation in and removal from EMS response vehicles.
[0004] 2. Description of Related Art
[0005] Pressurized oxygen cylinders are standard equipment onboard most ambulances and other EMS response vehicles. Most of the pressurized cylinders used are made from either aluminum or steel. Though a lightweight material, an empty aluminum pressurized oxygen cylinder can weigh over one hundred pounds. Steel cylinders are heavier yet.
[0006] The Occupational Safety and Health Administration (OSHA) does not have a standard which sets limits on how much a person may lift or carry. However, a sister agency, the National Institute for Occupational Safety and Health (NIOSH), has developed a mathematical model which helps predict the risk of injury based on the weight being lifted and accounts for many confounding factors. The model is based on previous medical research into the compressive forces needed to cause damage to bones and ligaments of the back.
[0007] NIOSH has shown through research that a lifting index greater than 3.0 can clearly be linked to an increased risk of back and other injuries. In applying the NIOSH equation for calculating a lifting index, an EMS worker lifting a one hundred pound pressurized oxygen tank from the floor and stowing it in a compartment of an ambulance would likely encounter a lifting index of 3.9 or higher. A heavier tank would increase this number even more. Because of this, a single EMS worker attempting to lift and move such a cylinder faces a significant risk of back injury.
[0008] Cylinder storage compartments onboard EMS vehicles tend to be quite small, some barely larger than the cylinders themselves. These cramped spaces further compound the dangers faced by an EMS worker faced with the task of changing out cylinders. Because the spaces are so small, only one worker can realistically fit within the compartment to manipulate the cylinders.
[0009] Potential back injury is not the only possible hazard associated with pressurized tanks. The cylindrical shape makes them difficult to grasp and awkward to handle by a single person. However, due to the cramped compartment in which they are stored, only one person can realistically be expected to handle the cylinders. Thus, a real danger exists that a pressurized cylinder being handled could fall from a vehicle unexpectedly. If the cylinder were to strike an object with the exposed valve, the cylinder might rupture. A ruptured cylinder can explode with tremendous force or even become a missile that can cause significant damage to anything it impacts.
BRIEF SUMMARY OF THE INVENTION
[0010] In light of the difficulties faced with lifting and moving pressurized tanks, it is one object of the present invention to provide an apparatus that can safely and efficiently lift, support, and control a pressurized tank during transport.
[0011] It is yet another objective of the present invention to provide an apparatus that can be easily maneuvered by a single operator under all load conditions.
[0012] It is yet another objective of the present invention to provide an apparatus that is simple to operate.
[0013] It is yet another objective of the present invention to provide an apparatus that is compact in size to allow easy manipulation of tanks within the confines of ambulance stowage compartments.
[0014] In accordance with a preferred embodiment of the present invention, a battery-powered electric hoist is, provided that incorporates a tank cradle for firmly and safely restraining a pressurized tank for transport. The hoist incorporates an electric linear actuator that can raise the tank to the desired height of an ambulance stowage compartment. Large swivel casters are also provided to allow for easy movement of the hoist and attached tank by a single operator. In addition, the tank cradle and base are compact in size to allow for easy maneuverability. This affords greater ease in inserting and removing a pressurized tank from the cramped stowage compartments of an ambulance.
[0015] The invention accordingly comprises the features described more fully below, and the scope of the invention will be indicated in the claims. Further objects of the present invention will become apparent in the following detailed description read in light of the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0016] The present invention will be more fully understood by reference to the following detailed description of the preferred embodiments of the present invention when read in conjunction with the accompanying drawings, in which like reference numerals refer to like parts throughout the views, wherein:
[0017] FIG. 1 is a perspective view of an embodiment of the present invention;
[0018] FIG. 2 is a perspective view of an embodiment of the present invention with a pressurized tank attached to the cradle for transport; and
[0019] FIG. 3 is a side-facing illustration of an embodiment of the present invention with a pressurized tank in position for transport.
[0020] Where used in the various figures of the drawing, the same reference numbers designate the same or similar parts. Furthermore, when the terms “top,” “bottom,” “first,” “second,” “upper,” “lower,” “height,” “width,” “length,” “end,” “side,” “horizontal,” “vertical,” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the invention.
[0021] All figures are drawn for ease of explanation of the basic teachings of the present invention only; the extensions of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements will likewise be within the skill of the art after the following teachings of the present invention have been read and understood.
REFERENCE NUMERALS
[0000]
100 hoist
102 cradle
104 safety ring
106 strap
108 lip
110 linear actuator assembly
112 height switch
114 battery charger
116 battery
118 handle
120 base
122 swivel caster
124 fixed caster
DETAILED DESCRIPTION OF THE INVENTION
[0035] FIG. 1 and FIG. 2 illustrate a hoist 100 according to one embodiment of the present invention. FIG. 1 shows the hoist 100 without a pressurized tank attached to its cradle 102 . FIG. 2 shows the hoist 100 with a pressurized tank attached to its cradle 102 and lifted for transport. The hoist 100 features a tank cradle 102 for securely attaching a pressurized cylindrical tank and supporting it during transport. The cradle 102 is attached to a linear actuator assembly 110 that provides vertical lifting motion to the cradle 102 . The electrical power for the linear actuator comes from a 24V battery 116 that features its own trickle battery charger 114 . The linear actuator assembly 110 is attached to a narrow base 120 that features heavy duty casters on its four corners. The front of the base 120 features fixed casters 124 while the rear features swivel casters 122 to allow for easy steering and maneuverability.
[0036] The major structural components of the hoist 100 are constructed from steel. Steel was chosen because it is inexpensive, easy to fabricate, structurally stable, and readily available. However, a person having ordinary skill in the art of fabrication would realize that other metals such as aluminum or even materials such as polymer composites may be used depending upon the structural load requirements. Lighter materials may make the hoist 100 easier to maneuver due to the lighter weight. However, the tradeoff may be in increased cost and reduced stability of a fully-loaded device. Steel provides a good balance of cost, stability, and maneuverability.
[0037] With reference to FIG. 1 and FIG. 2 , the hoist 100 according to the present embodiment features a narrow base 120 with swivel casters 122 for increased maneuverability. The base 120 is fabricated such that there is a center opening between two outer rails. The center opening is just wide enough to allow for a pressurized cylinder to fit between the rails for attachment to the tank cradle 102 . The base 120 also features an attached handle 118 . The handle 118 allows an operator to maintain a comfortable grip on the hoist 100 while maintaining proper control under a full load. The forward edge of the outer rails of the base 120 feature fixed casters 124 while the rearward edge of the rails feature swivel casters 122 . The swivel casters 122 are located essentially beneath the operator's handle 118 to allow the hoist 100 to be easily steered into position even with a load attached. In addition, the swivel casters 122 also feature locking mechanisms to allow a fully-loaded hoist 100 to be safely parked.
[0038] While the current embodiment provides four casters for maximum stability, other configurations are possible and are within the scope of the present invention. For example, in another embodiment all four of the casters could swivel. In yet another embodiment, the base 120 could utilize only three casters; two on the forward ends of the outer rails of the base 120 nearest the tank opening and one swivel caster on the opposite end of the base 120 , located in the center approximately beneath the linear actuator 110 . Utilizing only three casters would improve the maneuverability of the hoist 100 but at the same time would sacrifice some of the vertical stability.
[0039] With reference to FIG. 1 and FIG. 2 , the hoist 100 according to the present embodiment features a tank cradle 102 that is shaped to wrap partially around a pressurized tank for support. The radius of the curve of the cradle 102 approximates the radius of the body section of the pressurized tank. The cradle 102 also extends vertically to the approximate height of the body portion of a full-sized pressurized tank. Thus, because its height is suitable for the tallest tank, the cradle 102 can support essentially any sized pressurized tank.
[0040] With reference to FIG. 1 and FIG. 2 , the cradle 102 features a lip 108 near the bottom that engages the base of a pressurized tank that is to be attached to the cradle 102 . To attach a tank, the lip 108 is brought into contact with the base of the tank. The tank is then tipped slightly away from the lip 108 so that the lip 108 can slide beneath the tank. Once the tank rests on the lip 108 , the primary and backup attachment means can be utilized to restrain the tank within the confines of the cradle 102 .
[0041] With reference to FIG. 1 and FIG. 2 , the primary attachment means provided in the present embodiment is a strap 106 with an adjustable side release buckle. The strap 106 is wrapped around the body of the tank and the side release buckle is engaged and adjusted to put tension on the strap 106 to restrain the tank within the cradle 102 . While the present embodiment utilizes a strap 106 for the primary attachment means, other embodiments could utilize chain, rope, or cable. Also, a strap with a ratchet tightening mechanism, a belt-type buckle, or a hook and loop fastener could be used in place of the adjustable side release buckle for maintaining proper tension on the strap 106 .
[0042] With reference to FIG. 1 and FIG. 2 , the backup attachment means provided in the present embodiment is a safety ring 104 . The safety ring 104 is designed to provide backup retention of the tank in the cradle 102 should the strap 106 inadvertently release. In the present embodiment, the safety ring 104 is constructed of plastic coated steel cable. The steel cable provides tensile strength while the plastic coating prevents the cable from scratching or marring the finish of a tank. While the present embodiment utilizes plastic coated steel cable for the safety ring 104 , other embodiments could utilize uncoated steel cable, chain, rope, or even strap.
[0043] The safety ring 104 is threaded through a piece of tubular steel that fits within the center piece of slightly larger diameter tubular steel that makes up the framework of the cradle 102 . Thus, the safety ring 104 can be lifted by raising the attached piece of tubular steel to a height that allows the safety ring 104 to slip easily over the tank's valve portion. When released, the tubular steel attached to the safety ring 104 slips down within the larger center piece of tubular steel that makes up the framework of the cradle 102 . This allows the safety ring 104 to be rapidly installed and removed.
[0044] The hoist 100 according to the present embodiment features a linear actuator assembly 110 that is attached to both the cradle 102 and base 120 . The linear actuator 110 uses electrical power from the 24V battery 116 to operate. The height switch 112 allows the linear actuator to extend and raise the tank cradle 102 with attached tank up to 27 inches above the floor surface. This height is sufficient for insertion of a tank into typical ambulance stowage compartments. A second position of the height switch 112 allows the linear actuator 110 to retract and thus return the cradle 102 to the floor level.
[0045] Power for the linear actuator 110 comes from a rechargeable 24V battery 116 . The hoist 100 also features a built-in trickle charger 114 to allow the hoist 100 to be plugged into a standard wall socket and recharged when not in use. Battery power is utilized to prevent the need for an electrical cord to provide power to operate the hoist 100 . This increases the devices portability and maneuverability. While the present embodiment utilizes a 24V power source, other voltages may be substituted as determined by the voltage requirements of the linear actuator 110 mechanism.
[0046] FIG. 3 shows a hoist 100 being used by an operator 300 to transport a pressurized tank 302 . The operator 300 maneuvers the hoist 100 by utilizing the handle 118 . Once in position, the hoist 100 can be parked by locking the swivel casters 122 . The cradle 102 can then be raised or lowered by operation of the height switch 112 .
[0047] In view of the foregoing, the hoist 100 serves special needs required by the EMS community. In particular, the hoist 100 allows a single operator to safely and efficiently lift and transport a pressurized tank without the risk of back injury. The compact features of the hoist 100 lend to the device's maneuverability and ease of operation. Thus, a single operator can effectively remove a pressurized tank from an ambulance compartment and install a new one without assistance.
[0048] Although the invention hereof has been described by way of a preferred embodiment, it will be evident that other adaptations and modifications can be employed without departing from the spirit and scope thereof. The terms and expressions employed herein have been used as terms of description and not of limitation; and thus, there is no intent of excluding equivalents, but on the contrary it is intended to cover any and all equivalents that may be employed without departing from the spirit and scope of the invention.
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A hoist with a cradle for coupling with a pressurized tank. A primary means of restraining the tank on the cradle is provided along with a backup means should the primary means fail for any reason. A linear actuator assembly raises the cradle up to 27 inches from the floor surface. An onboard battery with an integrated battery charger provides power to the linear actuator. A compact base with swivel casters allows a raised tank to be safely lifted and transported by a single operator. The compact size of the hoist allows it to operate in confined spaces.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/972,064 filed on Sep. 13, 2007, entitled “Pants With Leg Lifting Straps”, which is incorporated fully herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to work, industrial and specialty pants and more particularly, relates to a device and method of using the device for supporting the lower leg of the pants below the knee.
BACKGROUND INFORMATION
[0003] For years, workers, sports participants, soldiers and first responders such as police and fire fighting personnel have struggled with the restriction long pants inflict on natural range of motion of the naked human leg. In all cases, because the pant is suspended from the waist, the fabric in each leg of the pants drapes over the thigh, crosses over the knee and hangs more or less loosely covering the calf. When physical protection is mandated by the potential danger of hostile exposure, there is a requirement that the pant be configured to cover the entire leg, and when that danger of hostile conditions becomes aggressive, multiple layers and more bulky, less compliant and “heavier” or thicker fabrics are used to protect, which effects a compounding of the restriction of leg motion.
[0004] It has been estimated that this weight and restriction on the leg of the wearer effectively reduces the wearer's physical endurance by as much as 15%. That translates into physical exhaustion and lower levels of safe operations for any human who requires the pant leg to extend to the lower calf.
[0005] The problem is one of “bio-geometrics”, where the cloth in the pant, because of its inherent characteristics, cannot move with anywhere near the elasticity of human skin, thereby setting up a conflict in range of flexibility and motion between the human wearer and the worn pant. The fact that the fabric(s) in the pant cause constriction of motion in the leg is well established. Particularly when the leg is lifted, but also in almost every other ranging motion where the leg is taken out of straight line shape (walking, running, crawling, kneeling, squatting), the fabric in the pant leg will catch on the knee and thigh, causing binding, wrinkling, bunching and constrictions.
[0006] When the leg is lifted, for example, the pant leg catches at the top of the thigh at the knee, basically impairing or severely limiting the human wearer's range of motion. To compensate for this, the wearer will “fight” the pant, using muscular strength to overcome the restriction(s). When this occurs, the wearer becomes exhausted much more rapidly, and can become emotionally stressed and compound the physical constraint with a bad decision about condition, thereby increasing the danger of injury.
[0007] To compensate for this restrictive element, pants have been built with lower waists, with special knee and crotch patterns, and with cloth that does a better job flexing. But nevertheless, the restriction persists, primarily because none of these design features have addressed the root cause of the restriction, the convergence of the upper leg, knee and lower leg at the knee, where the pant fabric(s) are forced to pivot around the knee. Patterns for cutting the pieces in a pant have changed. Stitching has changed. Even cloth has changed, but still the problem persists, because none of the solutions to date have eliminated the primary point of constriction, the bending knee and raised thigh.
[0008] Accordingly, the present invention provides a device and method of using the device which secures the leg of a pant or trouser below the knee to the human leg, allowing the pant or trouser fabric to be raised or collected above the knee, forming a pocket of loose pant legs, allowing the leg to move and flex freely without restriction or constriction of the pant leg binding up at the knee and lower thigh.
SUMMARY
[0009] The present invention features a device and method of using same wherein the placement of a restricting/retaining device, such as an adjustable strap, in or on the pant in such a way that it is retained at a specific circumference in the mid-calf area of the pant leg. A take-up mechanism, such as but not limited to a buckle, allows for quick, sure, one or two handed tightening of this restricting device, or strap. The restricting device or strap will hold the upper pant in a lifted or bloused position around and above the knee and lower thigh when tightened around the smaller circumference immediately below the knee and immediately above the calf muscles. This accomplishes two complementary things: a) the upper pant legs form a pocket that removes the pant leg from contact with the thigh and knee, and b) by constricting just below the knee, the smaller circumference prevents the pocket formed from relaxing and disappearing as the wearer walks, runs or otherwise exercises the protected leg. This will eliminate the majority of pant leg contact with the knee and lower thigh, rendering the user more mobile and free to move.
[0010] To activate the mechanism and use the present method, the leg (with the pant already on), is raised to a position such that the thigh is slightly higher than parallel with the ground. The pant leg is raised, with manual lifting or hiking-up as required, to a relaxed position on the still-raised leg. Once the wearer has lifted his leg and adjusted the pants to fit loosely and with relaxation over the raised and bent leg, the strap is tightened, retaining the pant leg it captures by tightening the strap closed around the narrowest circumference of the human calf just below the knee. When the wearer lowers his leg, the pant will remain in the raised position, forming a pocket in the pant around the knee, relieving that point of constriction. The wearer will immediately notice the freedom from restrictions usually caused by the pant leg cloth binding up around the knee flexing normal to the user's trade. With this point of resistance eliminated, the pant no longer conflicts with the bending knee, and the wearer regains full freedom, almost as though the pant were not there.
[0011] There are a number of different ways in which this invention might take form. Straps, adjustable clamps, elastic members, and other means may be utilized to accomplish the same effect, which is to capture the pant leg in a raised or bloused and relaxed position at the point of smallest circumference of the upper calf of the wearer's leg just below the knee. The simplicity, economy of weight and cost, and retrofit-ability to pants already in service may be factors used to select the configuration.
[0012] It is important to note that the present invention is not intended to be limited to a device or method which must satisfy one or more of any stated or implied objects or features of the invention. It is also important to note that the present invention is not limited to the preferred, exemplary, or primary embodiment(s) described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] 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:
[0014] FIG. 1 is perspective, schematic view of the pant leg retaining device according to the present invention;
[0015] FIG. 2 is a perspective view of the pant leg retaining device in place on a pant leg;
[0016] FIG. 3 is a schematic perspective view of a pant leg retaining device partially incorporated into a pant knee pant;
[0017] FIG. 4 is a schematic view of a pant leg retaining device shown positioned below the wearer's knee;
[0018] FIG. 5 is a schematic view of a wearer adjusting a pant leg prior to installing the pant leg retaining device; and
[0019] FIG. 6 is a schematic view of the gather or pocket of pant material at or above the wearer's knee caused by the pant leg retaining device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention features a pant leg retaining device 10 , FIG. 1 . The pant leg retaining device 10 has a fastener such as a buckle receiver 10 proximate to one end, and corresponding fastener mating device such as a buckle bayonet device 11 threaded to the other end, where a take up tab 8 makes it easy to grasp and operate the pant leg retaining device 10 with a bulky glove covering the hand. The location of the strap is set according to the fit rule cited herein. The loose strap end is fastened or retained by means appropriate to the application, for example, but not limited to hook-and pile, snaps or belt-loops. The receiving portion of the fastener is located on or near the rear side of the take up tab.
[0021] When the wearer becomes aware of the possibility that significant leg work is imminent, he/she may raise each leg, to a position where the thigh is parallel with or higher angled than the ground on which the wearer is standing. The pant leg is lifted manually to allow for its most relaxed position on the raised leg.
[0022] Once the pant has been lifted in this manner, the strap is tightened, thoroughly, at a point just above the large calf muscle group immediately below the knee. The wearer may then lower the effected leg. This process is then repeated on the other leg. Once this is done on both legs, the worker is free of upper pant leg restriction and the resultant exhaustion.
[0023] The pant leg retaining device 10 has a width suitable for the application and length to match the relaxed circumference of the pant leg immediately adjacent to the location of the strap with enough length to allow for a take-up tab 8 configured with a take-up buckle 11 , such as a quick release parachute buckle or other similar means.
[0024] Proper location of the pant leg-retaining device on existing pants dictates that pants of the type to be outfitted with the invention are donned by the wearer, and the leg is lifted to a level where the thigh is slightly above parallel to the level floor. The pants are marked to identify, when the pant has been lifted to remove as much restriction as possible, where the narrowest circumference of the wearer's calf, immediately below the knee and immediately above the wearer's calf's large muscle group.
[0025] A typical attachment will be under knee pad 13 or a patch of pant outer shell material or other protective material to protect the strap and prevent it from catching on foreign objects and distracting the wearer. A patch of pant shell material 14 is configured to provide a sliding space wider than the width of the strap, and length to cover the circumference of the strap not covered by the knee pad, with a 2-3 inch allowance for the take up buckle assembly.
[0026] One variant of this method is to take advantage of the presence of a knee pad on the garment which is intended to protect and provide comfort to the wearer's knee when crawling or kneeling. The location of this pad is already graded and the invention may be located at the base seam of this pad.
[0027] The pant leg retaining device 10 is located according to the fit rules under the knee pad 13 with the take up buckle receiver facing to the wearer's back knee region, on the outside of the pant leg. The patch of shell material 14 is sewn to the pant leg adjacent to the knee pad's lower seam such that the strap will slide through it easily when threaded. The strap is threaded through the patch and the take up bayonet 11 is installed such that the strap will lock when tightened against the leg as described above.
[0028] The pant leg retaining device assembly 10 may be of any suitable width and thickness to suit the application, and of a length that, when fully loosened, roughly matches the circumference of the pant leg onto which it is assembled. In one embodiment, one end of the strap may be attached to a receiving buckle while the other end is threaded through an adjustable bayonet mating buckle, with a terminus of a doubling or tripling of the strap to provide the wearer with a stout, easily grasped take-up end which can easily be found and operated even with a gloved hand.
[0029] In the preferred embodiment the pant leg-retaining device is configured from a 1″ wide strap that may be looped through a receiver buckle and stitched with a closing loop of approximately ½ inch to prevent fraying. The strap's other end is closed into a take up tab with a double fold which provides a gripping loop that is approximately 2½″ long, and a double back that is approximately ½ inch long to prevent the strap end from sliding out of the bayonet mating buckle. The strap end is looped through the bayonet buckle so as to allow for tension adjustment by pulling on the take up tab. The entire assembly, with the mating buckles closed, conforms generally in length to the outer circumference of the pant onto which they are mounted.
[0030] The pant leg retaining device assembly 10 , FIG. 3 , may be installed on a pant leg 6 at a point where, when the wearer's leg is lifted so that the thigh is at or higher than parallel with the ground, the strap will, when tightened, constrict around the narrowest circumference at the top of the wearer's calf immediately below the knee.
[0031] The strap may be added to or hidden by a knee pad 5 which has already been located to match this alignment. The take up buckle and strap end are on the outside of the wearer's pant legs 6 for easy and consistent access. The buckle assembly 11 , 12 is displaced to the side so that whether in use or relaxed, the buckle will never interfere with knee contact with the deck when the wearer is kneeling or crawling.
[0032] Pant leg retaining device assembly 10 , FIG. 4 is shown tightened onto the smallest circumference of the calf portion 16 of the leg. The pant leg is outlined 17 with a pant liner 18 showing compression under the pant leg retaining device when tightened.
[0033] To install the pant leg retaining device, the wearer raises each pant leg FIG. 5 to a point where the thigh is level or higher than level with the ground, and settles the pants across the thigh and knee, pulling the pant leg up away from the foot region as needed until the pant leg is relaxed and at ease across the thigh and knee. This will usually raise the pant leg several inches.
[0034] With the pant leg in this position and the knee and leg still raised, the wearer grasps the take-up end of the adjustment strap and tugs the strap tight around the smallest circumference at the top of the calf, just below the knee. Then the take-up adjustment strap is stowed on the opposite side.
[0035] With the strap tightened, the pant remains in its raised position, FIG. 6 , allowing a blousing effect 22 when the leg is lowered. The upper pant does not conflict with the thigh or knee. In this position, the wearer may raise his leg parallel to the ground and feel no pant leg restriction. In the raised position the pant leg tightens across the thigh and knee at the same point it was set when the strap was tightened.
[0036] In contrast, the leg that does not have the invention, begins to restrict the leg when it is raised barely off the ground, and the restriction increases as the leg is lifted higher, aggravating the condition.
[0037] In another embodiment, the pant leg retaining device according to the present invention may have a double pull and be installed directly in the pant leg. Two straps of suitable width for this application may be cut to a length to fit as follows: Step 1: a static strap to be embedded in the knee pad may be cut to accept a take-up buckle on each end, and accommodate the width of the knee pad under which it will be installed. Step 2: The take-up strap is cut to a length to provide the construction of pull tabs on each end, and of sufficient length to rest relaxed across the remaining circumference of the pant leg not taken up by the knee pad and static strap. Step 3: The pant is usually configured with a knee pad, but where there is none, a knee pad of appropriate dimensions may be added to. Step 4: A patch of the material of the outer layer of the pant (the shell material) may be pre-cut to a width that is approximately 3 times the width of the strap, and to a length that will allow 2 to 3 inches of space not covered by it and the knee pad when installed on the pant leg. The patch may match the color and physical characteristics of the pant outer shell. The components then are the straps and the buckles, the knee pad where needed and the shell material patch.
[0038] The static strap may be installed just above the lower line of stitching of the knee pad, perpendicular to the leg (parallel with the ground when the wearer is standing), by stitching or other means. It may be fastened so that the buckles will not slide out from under the knee pad. The take up strap may be prepared by stitching tabs on each end of uniform length and which incorporate fly-ends to prevent accidental release from the buckles.
[0039] The patch of shell material may be stitched on the back side of the pant leg adjacent to the knee pad and such that the take up strap will slide freely when installed on the take-up buckles, under the patch. The take up strap is threaded through the patch such that each end is available to the take up buckles. The take up strap is threaded though the buckles such that the take up straps may be tightened and locked and release when the take up buckles are released.
[0040] Another embodiment envisions a loose, independent strap assembly that dons on the pant leg quickly and easily, and accomplishes the same result. While this strap assembly may be less convenient to locate and activate than a built-in system such as those described above, it is possible that some wearers may prefer its economy and absence from the pants when not in use.
[0041] In this configuration, the strap may have either one take-up or quick release buckle attachment feature or a double take up feature with a quick release introduced so that the wearer does not have to thread his leg through the strap to install it.
[0042] In a one-buckle system, the take-up may be accomplished at the quick release buckle on the one-piece strap. The buckle may have a take-up ladder feature to adjust the tightness of the strap, and a quick-release feature to open the strap's loop to make donning and doffing quick and easy. A static strap may have two take-up buckles, one on either side of the knee, and a low-profile quick release buckle, hook, or hook and pile closure on the back side of the knee, rendering the take-up strap a two-part strap. In either case, attachment of the strap to the pant leg may be accomplished by releasing the quick release means, wrapping the strap around the raised calf as described above, and then using the adjustment means to tighten the strap around the small circumference of the knee as described above.
[0043] Other configurations that are obvious to one schooled in the art may be self-fabric straps or tabs attached by stitching to the pant outer shell, shock cord, or elastic members used to retain the strap and the pant leg in the raised, bloused position, snaps or take-up means attached or made a part of the pant leg, such that the pant leg is closed around the calf at the point of constriction just below the knee and self-fastened by means of snaps, hook and pile or other means. Latches, buckles and other means of closing this critical circumference and holding the pant leg in a raised, bloused position freeing the wearer's knee and thigh by holding the pant in the raised position at the narrow point immediately below the knee and immediately above the large muscle group at the top of the calf are considered within the scope of the present invention.
[0044] The present invention also contemplates the use of a boot-mounted means of closing the pant leg at the point immediately below the knee and immediately above the wearer's calf muscles. In this configuration, the boot is sized to allow the pant leg to fir “inside” the boot and may have a top-mounted chap that is cut to allow variability in wearer's leg length, so that the point of constriction mentioned above is accessible to the wearer. The means of tightening the pant around the point of constriction described above may be a strap, a self-closing shell that would extend around and trap the pant under itself, or other means.
[0045] Yet another configuration contemplates the installation of the strap or other means of closure disposed inside the shell or even the liner of the pant, if multiple layers are present. In this configuration, the strap would be retained on the inverse side of the pant leg, (or pant leg liner or barrier layer). Once installed, the strap and take-up system may be relatively low-profile, and may be used or released depending on circumstances.
[0046] In applications where the pant is of multiple layers, the invention includes the use of fasteners to attach the layers together so that the layers do not slide out independently from the point of restriction under the retention strap or other means.
[0047] It is important to note that as stated above, the present invention is not intended to be limited to a device or method which must satisfy one or more of any stated or implied objects or features of the invention. It is also important to note that the present invention is not limited to the preferred, exemplary, or primary embodiment(s) 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 allowed claims and any legal equivalents thereof.
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A pant leg retaining device for or in a pair of pants is provided to support the weight and bulk of pants in such a way as to allow a blousing effect at the knee such that the pant fabrics do not compress on the thigh/knee area and restrict leg motion. The use of a strap or retaining/restricting assembly mounted at mid-calf in or on the pant which when tightened gathers the pant leg mass just below the knee creating a blousing or pocket at and above the knee, and holds it in place. By constricting the pant at this point, the pant leg will not fall back down, rendering the pant leg bloused until the restricting/retaining means or strap is released, which is easily accomplished by means of a quick release buckle on the strap or elastic band type restraining device.
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BACKGROUND OF THE INVENTION
This invention relates to method and apparatus for cutting multiple threads in a single, controlled step on a work product being sewn by a multi-needle sewing machine.
The use of multi-needle sewing machines for simultaneously forming a plurality of rows of stitches in a work piece materially reduces the amount of time involved in completing various work products. Such multi-needle operation does create problems, however. For example, when the work piece having several rows of stitches is completed, the operator is required to delay commencing a new sewing operation while the multiple threads extending from both the needles and the loopers of the machines are cut, usually by hand. It is also difficult for the operator to cut the threads expeditiously by hand, since it is generally necessary to pull the work product out of the machine and to cut the threads with scissors. Such manual operation wastes time and thread, since the operator usually must pull the work product too far out of the machine in order to see and reach the threads, resulting in either the lengths of thread at the needles and loopers being too long, or the threads of thread hanging from the finished work product being too long.
Heretofore, various types of automated thread cutters for mechanically cutting the threads extending from the needles and loopers have been developed. Prior art multiple thread cutters often require individual cutting members for each thread, as shown in U.S. Pat. No. 3,139,849 of Cohen et al, which are integral with the sewing machine itself, thus requiring machines especially built for specific applications. Still others, as exemplified in U.S. Pat. No. 3,532,065 of Marforio, act to pull the threads to be cut out of the sewing area, thus creating, at least in some cases, unnecessarily long lengths of thread.
Many prior art arrangements are limited with respect to the number of threads that can be cut; some require that the needles be staggered so that separate cutting elements can be applied to individual threads, and, as in the case of the Cohen et al arrangement, many are not adapted for use on a variety of machine configurations. Another characteristic of many prior art devices is the use of two cutters, one for cutting the needle threads, the other for cutting the looper threads, which at least in some arrangements, can only be done at the end of the work piece, and not at some intermediate point.
SUMMARY OF THE INVENTION
The present invention is an improved method and apparatus for cutting multiple threads extending from the work piece to both the needle and the loopers and employs a single cutting member for cutting both sets of threads. When the machine operator finishes sewing a work piece, or when for any reason it is desired to cut the threads, the foot operated control pedal, which in addition to its normal operating positions has a cut position is moved to the cut position by the operator. As a result, a motion control stops the needles in their raised position and the presser foot of the machine is raised.
At the same time, thread slack units are activated to create slack in the threads extending to the needles and to the loopers, and then to hold the threads from the spools firmly. The operator pulls the work piece backwards away from the stitching area until the slack in the threads is removed and the threads are taut. When the threads are taut, a cutting member located beneath the work piece and above the loopers is driven forward, cutting the threads from both the needles and the loopers.
It is, therefore, an object of the present invention to provide an improved method and apparatus for cutting multiple threads extending from a work piece to the needles and loopers of a multi-needle sewing machine with a cutting blade by moving the cutting blade forward beneath the work piece to cut all of the threads at the same time.
It is another object of this invention to provide an improved method and apparatus for controlling the length of the threads being cut in a multiple needle sewing machine by activating thread puller feet to create slack in the threads extending to the needles and the loopers and then engaging and holding the threads with thread brakes to hold the threads taut when the operator pulls back on the work product, enabling a cutter to cut all of the threads in a single stroke.
Still another object of the invention is to provide an improved method and apparatus for cutting with a thread cutter multiple threads from a work piece being sewn by a multi-needle sewing machine leaving enough thread extending from the needles and loopers of the sewing machine so that the needles and loopers remain threaded for the next sewing operation.
It is still another object of the present invention to provide an attachment for a multi-needle sewing machine, with the attachment enabling the operator to cut the threads extending from the needles and loopers to the work piece by pulling the work piece rearwardly while actuating a cutting means which simultaneously cuts all the threads in one cutting operation.
Other objects, features, and advantages of the present invention will become apparent from the following detailed description read in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a multi-needle sewing machine equipped with a thread cutter attachment;
FIG. 2 is a side elevation view showing the action of the cutter blade in the needle area; and
FIG. 3 is a perspective view of the cutting blade and the actuating mechanism therefor.
DETAILED DESCRIPTION
Turning to FIG. 1, there is shown a sewing machine 11 having a head portion 12 from which extends a plurality of aligned sewing needles 13 mounted to needle drive plate 14 and shaft 16 (FIG. 2). A plurality of spools 17 of thread 18 are located adjacent the machine 11 and supply thread 18 to a plurality of creels or tensioning devices 19. From the creels 19 the threads pass through a first thread guide 21, a second thread guide 22, through a thread braking and pulling assembly 23, which will be discussed more fully hereinafter, a third guide 24, a tensioning guide 26, and through fourth and fifth thread guides 27 and 28 to needles 13.
The looper thread supply is basically similar to the needle thread supply, and comprises a plurality of spools 29 of thread 31 located adjacent the machine. From the spools the treads 31 pass through creels 32, and first and second thread guides 33. From guide 34 the threads 31 pass through a thread braking and pulling assembly 36, thread guide 37, thread tensioning member 38, and thread guide 39 to loopers 41 (FIG. 2). As thus far described, the arrangement of FIG. 1 is a standard multi-needle type sewing machine except for thread braking and pulling assemblies 23 and 36, and guides 22, 24 and 34, 37, which will be explained more fully hereinafter.
Control of the machine 11 is through an operator actuated control pedal 42 which is connected by a crank assembly 43 to a control box 44. Control box 44 controls drive motor 46 and also the various elements of the thread cutting components of the present invention. The entire mechanism is turned on and off by a suitable switch 47.
Mounted on the bed 48 of the machine 11 is the cutting mechanism 49 of the present invention.
As illustrated in FIG. 3, cutting mechanism 49 (FIG. 1) comprises a cylinder and piston assembly 51 which can be either hydraulically or pneumatically operated through fluid or air supply conduits 52, 53. Piston rod 50 reciprocates slide plate 54 which carries laterally extending blade support arm 55, blade support block 56 and thread cutting blade 57. Pilot valve 60 is actuated by the extension 54a of slide plate 54 during the reciprocation of the cutting blade 57. It can be seen in FIG. 2 that blade 57 is located above bed 48 and throat plate 58 but below the work piece 59 and presser foot 61. Also shown in FIG. 2 are feed rollers 62 and 63 which function to pull the work piece 59 through the sewing area and keep it aligned properly. Feed dogs 64 (FIG. 3), also function to feed the work piece 59 through the sewing area. Feed dogs are standard equipment on most sewing machines.
In FIG. 2, thread cutting blade 57 is shown in dashed outline in its normal position in front of the needles where it stays during the sewing operation and is also shown in solid line in its cutting position. In FIG. 3, the blade 57 is shown in its normal position.
Returning to FIG. 1, upper thread braking and pulling assembly 23 comprises a first brake or nipper cylinder and piston 66 which may be either pneumatically or hydraulically actuated. A piston rod extension 67 has a foot 68 mounted on its free end adapted to fit within a U-shaped plate 69. As can be seen in FIG. 1, threads 18 pass over the upturned ends of plate 69 and beneath shoe 68. When the piston and cylinder unit 66 is actuated, shoe 68 is driven down against threads 18, pressing them firmly against plate 69, thereby effectively braking the threads. Assembly 23 also includes a second brake or nipper cylinder and piston 71, extended piston rod 72, foot 73, and plate 74, which function in the same manner as the elements of the first brake. Situated between brake elements 66 and 71 is a thread puller cylinder and piston 76, having an extended piston rod 77 with a foot 78 mounted on the free end thereof. When cylinder and piston unit 76 is actuated, foot 78 presses down against thread 18 to create slack in the threads extending between brake foot 73 and creels 19.
Lower thread braking and pulling assembly 36 is virtually identical to upper assembly 23, operating on the looper threads 31 in the same manner as assembly 23 operates on needle threads 18. Assembly 36 comprises a first brake unit having a cylinder and piston unit 81, extended piston rod 82, foot 83, and plate 84. A second brake unit comprises cylinder and piston unit 86, extended piston rod 87, foot 88, and plate 89. Between units 81 and 86 is located puller cylinder and piston unit 91 having extended rod 92 and foot 93. Fluid conduits 94, 96, and 97 supply actuating fluid to units 81, 86, and 91, respectively. While both assemblies 23 and 36 have been shown and discussed as either pneumatically or hydraulically actuated, it is also possible that they be solenoid operated. In addition, no fluid supply, either hydraulic or air, has been shown, inasmuch as such elements are of standard design and their operation is well known.
It can readily be seen that the thread cutting unit 49 and brake and pulling units 23 and 36 are not integral parts of the sewing machine 11 but are readily attachable thereto. Together these elements constitute a thread cutting assembly readily attachable to a variety of sewing machines.
OPERATION
During normal sewing operation, none of the piston units of assemblies 23, 36 and 49 is actuated, the cutting blade 57 is in its normal position as shown in FIG. 3, and feet 68, 73, 78, 83, 88, and 93 are in the raised position, out of contact with threads 18 and 31. When the sewing operation is completed, or when, for any reason the operator wishes to cut the threads, the operator moves the foot pedal 42 (FIG. 1) to the cutting position. A motion control means in the control box 44 connected to the control pedal 42 by a control rod 43 and linkage, engages upon movement of the control pedal 42 and elevates the needles 13, 15 and the presser foot 61 away from the workpiece 59. Such a control means is standard equipment on most machines, and examples are described in U.S. Pat. Nos. 3,590,969 and 3,804,043. Immediately thereafter piston units 71 and 86 are actuated, braking the thread to the needles and loopers. While the threads are thus braked, thread puller units 76 and 91 are actuated, pushing down on the threads and creating slack in the threads between the actuated brakes 71 and 86 and the creels. As soon as the threads are depressed to from slack in the treads, as shown in FIG. 1, brake units 66 and 81 are actuated, braking the threads, and brake units 71 and 86 are released, leaving a loop of slack in the thread extending from the actuated brake to the needles and to the loopers.
When the slack has been formed in both needle and looper threads, the operator pulls back on the work piece, pulling the slack from the threads to both the needles and loopers, and the cutter piston unit is actuated, causing the cutter blade 57 to pass through the sewing area and cut the threads coming from both the needles and the loopers, leaving both needles and loopers still threaded. One of the purposes for creating slack in the threads just prior to cutting is to insure that there will be sufficient thread to avoid unthreading either the needles or the loopers and to insure that a sufficient length of threads remains on the work product.
The timing of the various steps is controlled by the control box, and can be varied to suit the operator. However, the sequence remains the same.
Although a single, straight edge cutting blade 57 has been illustrated and described for the purpose of cutting the threads extending from the work product, other thread cutters can be substituted for the blade, if desired. For example, a serrated blade or a pair of reciprocatable serrated blades can be used, or other cutters of relatively flat configuration can be used with can pass beneath the work product.
The foregoing has been a description of the invention in a preferred embodiment thereof. Numerous modifications, additions, or deletions may readily occur to workers in the art without departure from the spirit and scope of the invention.
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A thread undercut attachment for use on multi-needle sewing machines uses a single piston actuated cutting blade which passes through the sewing area beneath the workpiece and above the loopers. To prevent the needles and loopers from becoming unthreaded or to prevent undue lengths of thread after cutting, apparatus is provided for creating a measured amount of slack in the threads leading to the needles and loopers, and then holding the threads firmly to prevent further payout of thread when the workpiece is pulled toward the operator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/428,043 filed Mar. 13, 2015, which is a National Phase of PCT/EP2013/068317 filed Sep. 4, 2013 which claims priority to EP 12184500.2 filed Sep. 14, 2012, the disclosures of which are hereby incorporated by reference in their entirety.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)
[0002] Incorporated by reference in its entirety is a sequence listing in computer-readable form submitted concurrently herewith and identified as follows: ASCII (text) file named “49433A_SeqListing.txt,” 59,514 bytes, created on Oct. 9, 2017.
BACKGROUND OF THE INVENTION
[0003] The invention relates to a method and a kit for diagnosing a molecular phenotype of a patient suffering from an illness accompanied by chronic inflammation as well as a medicament for treating such a patient.
[0004] Chronic inflammations constitute an increasing medical problem area of high socioeconomic significance. This includes in particular the following groups of illnesses: autoimmune diseases and diseases from the area of rheumatic diseases (manifestations among others on the skin, lungs, kidneys, vascular system, nervous system, connective tissue, locomotor system, endocrine system), immediate-type allergic reactions and asthma, chronic obstructive lung diseases (COPD), arteriosclerosis, psoriasis and contact eczema and chronic rejection reactions after organ and bone marrow transplants. Many of these diseases are showing a rising prevalence in the last decades not only in industrial nations, but sometimes around the world. For example, in Europe, North America, Japan and Australia more than 20% of the population suffers from allergic diseases and asthma. Chronic obstructive lung diseases are currently the fifth most frequent cause of death throughout the world and according to calculations of the WHO they will represent the third most frequent cause of death in the year 2020. Arteriosclerosis with the secondary diseases of cardiac infarction, stroke and peripheral arterial disease leads the world in morbidity and mortality statistics. Together with neurodermatitis, psoriasis and contact eczema are in general the most frequent chronic inflammatory diseases of the skin.
[0005] Due to the interactions between environmental factors and a genetic disposition, which are to date only poorly understood, there are sustained dysregulations of the immune system. In this connection the following common principles can be established for these different diseases:
[0006] (A) An excessive immune response to what are ordinarily harmless antigens for human beings. These antigens can be components of the environment (e.g. allergens such as pollen, animal hairs, food, mites, chemical substances such as preservatives, dyestuffs, detergents). In these cases patients develop an allergic reaction. In the case of e.g. active and passive smokers, chronic pulmonary lung diseases (COPD) develop. On the other hand, the immune system can also react against components of its own organism, recognize them as foreign and initiate an inappropriate inflammatory response. In these cases an autoimmune illness develops. In any case, harmless, non-toxic antigens are erroneously as foreign or dangerous and an inappropriate inflammatory response is set in motion.
[0007] (B) The diseases run in phases, including initiation, progression of the inflammatory response and the associated destruction and reconstruction with loss of organ functionality (so-called remodeling).
[0008] (C) The diseases show patient-specific sub-phenotypic manifestations.
[0009] (D) Components of the innate and acquired immunity have a sustained involvement in the initiation, maintenance and destructive and remodeling processes. Under the influence of the innate immunity (important components: antigen-presenting cells with their diverse populations and the complement system) there is an activation and differentiation of the cells of the adaptive immune system (important components: T and B lymphocytes)>The T cells take over central functions in the further course by differentiating in highly specialized effectors.
[0010] In this connection they activate and acquire certain effector mechanisms, including, in particular the following functions: antibody production: control of the functionality of effector cells of the immune system (e.g. such as neutrophilic, basophilic, eosinophilic granulocytes), feedback to functions of the innate immune system, influencing of the functionality of non-hematopoietic cells such as e.g. epithelial, endothelial, connective tissue, bones and cartilage and above all neuronal cells. Here there is a special interaction between immune and nervous systems, from which the concept of neuro-immunological interaction in the case of chronic inflammations developed.
[0011] Since the T cells, which have already been mentioned, take over central functions in the course of the disease, an understanding of their specialization is critical. A complex signal transduction cascade is involved in the differentiation of naïve CD4 + cells to Th1 or Th2 cells.
[0012] The stimulation via the T cell receptor through the corresponding peptide MHC complex induces clonal expansion and programmed differentiation of CD4 + T lymphocytes to T helpers (Th) 1 or Th2 cells. The differentiation of these two sub-types occurs on the basis of their cytokine profiles. Th1 cells produce interferon- γ (INF γ ), interleukin 2 (IL-2) and tumor-necrosis-factor-α, while Th2 cells secrete IL-4, IL-5, IL-9 and IL-13. Bacterial and viral infections induce an immune response which is dominated by Th1 cells. On the other hand Th2 cells regulate igE production against parasites. In the process there is a balance between Th1 and Th2 cells. The destruction of this balance causes diseases, so an excessive Th1 cell response is associated with autoimmunity diseases, while allergic diseases are at the basis of a reinforced Th2 cell response.
[0013] It is known that Th1 cytokines are involved in the pathogenesis of autoimmune diseases such as e.g. autoimmune uveitis, experimental allergic encephalomyelitis, type 1 diabetes mellitus or Crohn's disease, while Th12 cytokines (IL-4, IL-5, IL-13 or IL-9) are involved in the development of chronic inflammatory respiratory ailments, such as e.g. airway eosinophilia, asthma, mucus hypersecretion and airway hyperresponsiveness. These diseases are brought about by pathophysiological changes during the production of characteristic cytokines by antigen-specific Th cells. Th2 cell sub-populations in the lungs and the airways cause the characteristic symptoms of bronchial asthma in the animal model
[0014] Among other things, two transcription factors are involved in the development of autoimmune diseases and chronic inflammatory reactions: the Th1 cell-specific transcription factor Tbet and the Th2 cell-specific transcription factor GATA-3.
[0015] The Th1 cell-specific transcription factor Tbet is primarily responsible for the differentiation of naïve CD4 + T cells to Th1 cells. Its expression is controlled via the signal transduction pathways of the T cell receptor (TZR) and via INF γ receptor/STAT1. Tbet transactivates the endogenous INF γ gene and induces INF γ production. The in vivo function of Tbet is confirmed in knock-out mice (Tbet-/-). The quantity of Th2 cytokines is increased in mice that are deficient in Tbet.
[0016] The function of Tbet in mucosal T cells is known in the development of inflammatory bowel diseases. The transcription factor Tbet specifically induces the development of Th1 cells and controls the INF γ production in these cells. Through the inhibition of Tbet the balance between Th1 and Th2 cells is shifted in favor of the Th2 cells.
[0017] Many inflammatory diseases on the other hand, such as allergic asthma for example, are associated with an activation of Th2 cells. Th2 cells have an essential function in the development of allergic diseases, in particular various asthma ailments. The differentiation of Th0 cells to Th2cells necessary for this is dependent on the transcription factor GATA-3. GATA-3 is a member of the GATA family of transcription factors.
[0018] The Th2 cell-specific transcription factor GATA-3 is primarily responsible for the differentiation of naïve CD4 + T cells to Th2 cells. In the process, the Th2 cell differentiation is primarily controlled by two signal transmission pathways, the T cell receptor (TZR) and the IL-4 receptor pathway: Signals forwarded from TZR activate the Th2 cell-specific transcription factors cMaf and GATA-3 as well as also the transcription factors NFAT and AP-1. The activation of the IL-4 receptor results in the binding of STAT6 on the cytoplasmic domain of the IL-4 receptor, where it is phosphorylated by Jak1 and Jak3 kinases. The phosphorylation for its part results in the dimerization and translocation of STAT6 to the nucleus, where STAT6 activates the transcription of GATA-3 and other genes. GATA-3 is a zinc finger transcription factor which is expressed exclusively in mature Th2 cells, not in Th1 cells.
[0019] Th2 cells produce cytokines such as for example IL-4, IL-5, IL-6, IL-13 and GM-CSF. The polarization to Th2 inhibits a Th1 differentiation through suppression of Tbet and vice versa. However, the expression of GATA-3 is not restricted to T cells. An expression of GATA-3 was also able to be confirmed in eosinophilic and basophilic granulocytes, mast cells and epithelial cells. GATA-3 plays a central role in the immunopathogenesis of chronic inflammatory diseases, in particular of allergic asthma.
[0020] Established preparations for the treatment of chronic inflammatory diseases are among others Corticosteroids, anti-leukotrienes, immunosuppressives and Anti-IgE monoclonal antibodies. Asthma patients however respond with varying degrees of success to these therapeutic agents. For a long time the question of what these differences in effectiveness were to be attributed to has remained unresolved. As a consequence, the appropriate therapy had to be fine-tuned on the patient more or less in accordance with the principle of “trial and error”.
[0021] However, only recently was it determined that patients suffering from asthma, for example, could be further divided into subgroups (Woodruff et al., 2009, T-helper Type 2-driven inflammation Defines Major Subphenotypes of Asthma, Am J RespiCrit Care Med, Vol 180, 388-395). Thus, it was shown that there are at least two sub-groups of asthma patients, which were designated as “Th2 high” and “Th2 low”. The subgroup “Th2 high” in the process has an increased expression of the POSTN gene, which codes for the protein periostin, as well as the genes for IL-3 and IL-5. The group “Th2 low” of tested asthma patients shows a low POSTN gene expression, comparable to a control group of healthy persons. These differing molecular phenotypes could be one cause for the different effectiveness of common therapeutic agents. Thus for the subgroup “Th2 high” an improved treatment response to treatment with corticosteroids was determined.
[0022] It was also found that two groups of asthma patients, namely “Th2 high” and “Th2 low”, respond with varying degrees of success differently to a therapy with a humanized monoclonal antibody to IL-13 (Corren et al., 2011, Lebrikizumab Treatment in Adults with Asthma, The New England Journal of Medicine, 10.1056/NEJMoa 1106469). In the process, an empirical classification of asthma patients in the group “Th2 high” occurred first, when the values for serum-IgE were higher than 100 IU/ml and the number of eosinophilic granulocytes was at 0.14×10 9 cells per liter or greater. With corresponding values below these patients were placed in the group “Th2 low”. Alternatively, there was a classification by the serum periostin level, which serves as a surrogate marker for Th2 cytokine IL-13, which is difficult to establish in blood or airway samples. In the process, the fact that IL-13 among others induces in vitro the expression of the periostin coding gene POSTN in epithelial cells (Woodruff et al., 2007, Proc Natl Acad Sci USA,104(40):15858-63. Genome-wide profiling identifies epithelial cell genes associated with asthma and with treatment response to corticosteroids). In accordance with Corren et al., 2011, patients with a serum periostin level above the average were placed in a “periostin high” group. For the mentioned sub-groups “Th2 high” and “Periostin high” a better treatment response to treatment with Anti-IL-13 antibodies by tendency was described.
[0023] According to WO 2009/124090 A1, a certain classification of asthma patients is likewise proposed, wherein the gene expression of a plurality of candidate genes, such as for example POSTN, CLCA1 and SERPINB2 is employed. Since it is known that this gene is highly regulated by the Th2 cytokine IL4 or IL-13, the cluster is also referred to as “IL-4/IL-13 signature”. Along with the measurement of the serum periostin level as well as the corresponding mRNA quantity, in the process a determination of the values for serum IgE and the number of eosinophilic granulocytes were also described.
[0024] One disadvantage of patient stratification on the basis of this gene expression, above all of POSTN, is the fact that along with an “IL-4/IL-13 signature”, the cytokine IL-5 also plays a significant role in the genesis of asthma. In addition, the role of the protein periostin in the immune cascade and thus the pathogenesis is unknown.
[0025] Thus the problem arises of finding a biomarker that is suitable for reliable and simultaneously clinically practicable molecular phenotyping of a human patient who is suffering from a disease that is accompanied by chronic inflammations in the groups “Th2 high” or “Th2 low” or “Th1 high” or “Th1 low”. In addition, the patient classified in this manner should be able to be treated with a therapeutic agent that is especially effective specifically for this subgroup. The biomarker should make possible/facilitate an individual prediction about the effectiveness of a therapeutic agent with respect to a patient, in particular an asthma patient.
BRIEF SUMMARY OF THE INVENTION
[0026] In accordance with the invention, the problem is solved by a method for diagnosing a molecular phenotype of a human patient suffering from an illness accompanied by chronic inflammation, wherein the molecular phenotype is selected from the group consisting of the subgroups “Th2 high”, “Th2 low”, “Th1 high” and “Th1 low” and the gene expression of GATA-3 and/or Tbet is measured in a biological isolate of the patient and used for the assignment to a molecular phenotype of the illness. The more detailed classification of a human patient suffering from an illness accompanied by chronic inflammation occurs in the process by measurement of the gene expression of the transcription factor GATA-3 and/or of the transcription factor Tbet. As explained initially, the Th1 cell-specific transcription factor Tbet and the Th2 cell-specific transcription factor GATA-3 are involved in the development of autoimmune illnesses and chronic inflammation reactions. The polarization to Th2 inhibits a Th1 differentiation through suppression of Tbet and vice versa. Depending on the expression level of GATA-3 and/or Tbet an assignment to a molecular phenotype, that is, to a subgroup of the illness accompanied by chronic inflammation, can take place. With the inventive diagnostic method the mentioned molecular phenotyping can be performed without difficulties in a routine clinical setting with a high degree of predictability.
[0027] The transcription factors GATA-3 and Tbet are the central key molecules in the development of Th1 or Th2 dependent chronic inflammatory diseases. Therefore, the direct measurement of the protein or mRNA expression represents best possible patient stratification approach since no interconnected mechanisms can possible falsify the results.
[0028] In accordance with one preferred embodiment of the method, the expression level of GATA-3 and/or Tbet is determined via the protein or mRNA quantity. In the process, the protein quantity can be quantitatively determined with the help of an immunoassay. The immunoassay is preferably an enzyme-linked immunosorbent assay (ELISA) test, a radioimmunoassay (RIA), an electrochemiluminescence (ECL) immunoassay, a CLIA (chemoluminescence-linked immunosorbent assay), an FLIA (fluorescence-linked immunosorbent assay) or a multiplex-assay.
[0029] Along with high sensitivity and specificity, the mentioned assays offer the advantage of a potential automation and are thus particularly well suited for daily clinical practice. Of course, if necessary any other suitable test for quantitative determination of the protein quantity of GATA-3 and/or Tbet can be selected within the scope of the present invention. Furthermore, the expression level of GATA-3 and/or Tbet can occur via mass spectrometric methods, chromatographic methods such as gas chromatography, fluid-based methods with solid phase separation, such as HPLC, or microfluidic and nanofluidic methods.
[0030] The method for determining the expression of GATA-3 or Tbet with the help of an ELISA test can if necessary comprise the following:
Production of a lysate through cell disruption; Addition of the lysate to a recess of a microwell plate which is coated with a first GATA-3 or Tbet specific antibody Washing the microwell plate; Addition of a second GATA-3 or Tbet specific antibody to the recess of the microwell Washing the microwell plate Detection and quantification of the GATA-3 or Tbet protein.
[0037] For the purpose of detection, the second specific antibody can for example be marked with biotin and a separate addition of an enzyme coupled to streptavidin can take place. However, the second specific antibody can also be directly coupled to an enzyme. If appropriate, a third antibody directed toward the second specific antibody can be used that is coupled to an enzyme.
[0038] The enzyme is preferably a peroxidase or alkaline phosphatase and is implemented with a suitable substrate that is suitable for colorimetry or chemiluminescence and the like.
[0039] In accordance with a further aspect of the present invention, the mRNA quantity of GATA-3 and/or Tbet can be determined additionally or as an alternative to the mentioned determination of the protein quantity. Preferably a PCR, particularly preferably a qPCR or a micro-array chip is suitable for this purpose. A person skilled in the art is aware of how to select GATA-3 and Tbet specific probes or primers for the mentioned detection methods.
[0040] In accordance with a preferred design of the method, the biological isolate was obtained whole blood, urine, sputum, a bronchial alveolar lavage (BAL), a biopsy, a brush biopsy, liquor, tracheal secretion, seminal fluid, ascitic fluid, saliva, punctate or lymph fluid. A person skilled in the art is familiar with the routine methods for obtaining suitable biological isolate.
[0041] GATA-3 and Tbet are proteins which, as transcription factors, have their effect in the cell core of T helper cells of the subtype Th1 and Tlh2. In order to determine the concentration of these two nuclear proteins in a specified volume of a biological isolate, as in a specified volume of whole blood or the like, cells which form GATA-3 and Tbet must first be isolated and subsequently lyzed. A direct confirmation of these proteins from human serum or plasma is hardly possible, since they are not available there in detectable concentration. An analysis of GATA-3 and Tbet therefore takes place if necessary in four stages:
Partitioning and isolation of the GATA-3/Tbet expressing cells from the other cellular components of the whole blood Disruption of the cells and release of the intracellular/nuclear proteins Measurement of the concentration of GATA-3 and Tbet and Standardization of the found concentrations of GATA-3 and Tbet.
[0046] According to an advantageous development, regardless of whether the expression level of GATA-3 and/or Tbet is determined via the protein or mRNA quantity, the inventive method comprises also one or more of the following steps:
(i) Isolation of leukocytes, preferably by means of Ficoll gradient centrifugation; (ii) Enrichment of leukocytes, preferably by means of size exclusion filtration or (iii) Enrichment of Th1/Th2 cells in particular CD4 + T cells with the help of cell-specific antibodies which are preferably coupled to magnetic beads.
[0050] The mentioned steps (i)-(iii) are performed prior to the cell disruption and in each case facilitate an increase in the sensitivity as well as predictability of the diagnostic method, since, in particular in the leukocytes the genes GATA-3 and Tbet are differentially expressed.
[0051] According to a further aspect of the present invention an assignment of the patient to a molecular phenotype of the subgroup “Th2 high” occurs when at least one of the following conditions is fulfilled:
a) The GATA-3 gene expression in the biological isolate is higher than a defined reference value b) The ratio of GATA-3: Tbet gene expression in the biological isolate is higher than a defined reference value.
[0054] The subgroup “Th2 high” is thus characterized either by a high absolute GATA-3 gene expression in comparison to a defined reference value. In the process,—in the case of the measurement of the protein quantity—a corresponding value of the GATA-3 protein content in the isolate of a healthy person can be used as a reference value. However, absolute reference values can also be used. In the case of the measurement of the mRNA quantity a corresponding value of the GATA-3 mRNA quantity in the isolate of a healthy person can be used as a reference value. However, on the other hand, absolute reference values such as for example copies/ml can also be used.
[0055] An assignment of the patient to the mentioned molecular phenotype of the subgroup “Th2 high” takes place according to an advantageous embodiment of the inventive method when as an alternative to or in addition to the increased GATA-3 gene expression the ratio of GATA-3: Tbet gene expression in the biological isolate is higher than a defined reference value. In the process a corresponding value of the ratio of GATA-3: Tbet gene expression in the isolate of a healthy person is used. The determination of the ratio of GATA-3: Tbet gene expression increases the certainty of the statement, since in the process along with the GATA-3 gene expression the Tbet gene expression is established as an additional parameter. Since the two transcription factors mutually regulate one another in their expression, as initially described, the inclusion of Tbet constitutes an internal control for the measurement of the GATA-3 gene expression.
[0056] According to one advantageous development, the inventive method for assigning the patient to the molecular phenotype of the subgroup “Th2 high” comprises the steps:
Release of proteins or RNA from cells of a biological isolate of the patient; Determination of the expression level of the proteins or of the mRNA for GATA-3 and/or Tbet; Placement of the patient in the subgroup “Th2 high” when at least one of the foregoing conditions mentioned under a) or b) apply.
[0060] As an alternative, in addition to the mentioned determination of the GATA-3 and/or Tbet gene expression, a determination of further parameters for certain placement/classification in the subgroup “Th2 high” can take place. Thus, for example the serum IgE level and the number of eosinophilic granulocytes can be measured. An assignment to the subgroup “Th2 high” takes place additionally whenever the serum IgE level is higher than 100 IU/ml and/or the number of the eosinophilic granulocytes is 0.14×10 9 cells per liter or higher. As an alternative, if required, the concentration in nitric oxide in the exhaled air, thus a determination of the FeNO value can be performed.
[0061] Another advantageous embodiment of the inventive method relates to an assignment of the patient to a molecular phenotype of the subgroup “Th2 low” when at least one of the following conditions is fulfilled:
a) The GATA-3 gene expression in the biological isolate is lower than a defined reference value, b) The ratio of GATA-3: Tbet gene expression in the biological isolate is lower than a defined reference value.
[0064] The subgroup “Th2 low” is thus characterized either by a low absolute GATA-3 gene expression in comparison to a defined reference value. In the case of the measurement of the protein quantity, in the process, a corresponding value of the GATA-3 protein content in the isolate of a healthy person can be used as a reference value. Here it should be noted that in the case of a patient of the subgroup “Th2 low” with an illness accompanied by chronic inflammations the absolute GATA-3 gene expression will regularly be higher than in an isolate of a healthy patient. However, the absolute GATA-3 gene expression can also be lower than in the case of a healthy person. In any case, the GATA-3 gene expression is also not as high as described for the subgroup “Th2 high”. Consequently, an assignment of the patient to the subgroup “Th2 low” occurs when said patient's GATA-3 protein content in comparison to an isolate of a healthy person, if at all, is only moderately increased. However, fixed reference values can also be used. In the case of the measurement of the mRNA quantity, a corresponding value of the GATA-3 mRNA quantity in the isolate of a healthy person can be used as a reference value, wherein an assignment of the patient to the subgroup “Th2 low” takes place when said patient's GATA-3 mRNA quantity is lower than in a corresponding sample of a healthy person or in any event is not significantly increased. However, on the other hand fixed reference values can be used.
[0065] An assignment of the patient to the mentioned molecular phenotype of the subgroup “Th2 low” takes place according to one advantageous embodiment of the inventive method, when as an alternative to or in addition to the decreased lower GATA-3 gene expression, the ratio of GATA-3: Tbet gene expression in the biological isolate is lower than a defined reference value. In the process a corresponding value of the ratio of GATA-3: Tbet gene expression in the isolate of a healthy person can be used as a reference value. The determination of the ratio of GATA-3: Tbet gene expression also increases the certainty of the statement in this case, since in the process along with GATA-3 gene expression as an additional parameter the Tbet gene expression is determined. Since the two transcription factors mutually regulate one another in their expression, as initially described, the inclusion of Tbet constitutes an internal control for the measurement of the GATA-3 gene expression.
[0066] According to one advantageous further development the inventive method for assigning the patient to the molecular phenotype of the subgroup “Th2 low” comprises the steps:
Release of proteins or RNA from cells of a biological isolate of the patient; Determination of the expression level of the proteins or of the mRNA for GATA-3 and/or Tbet; Placement of the patient in the subgroup “Th2 low” when at least one of the foregoing conditions mentioned under a) or b) apply.
[0070] As an alternative, in addition to the mentioned determination of the GATA-3 and/or Tbet gene expression, in turn a determination of further parameters for certain placement in the subgroup “Th2 low” can take place. Thus, for example the serum IgE level and the number of eosinophilic granulocytes can be measured. An assignment to the subgroup “Th2 low” takes place additionally whenever the serum IgE level is lower than 100 IU/ml and/or the number of the eosinophilic granulocytes is below 0.14×10 9 cells per liter. As an alternative, if required, the concentration in nitric oxide in the exhaled air, thus a determination of the FeNO value can be performed.
[0071] According to another advantageous embodiment, an assignment of the patient to a molecular phenotype of the subgroup “Th1 high” occurs when at least one of the following conditions is fulfilled:
a) The Tbet gene expression in the biological isolate is higher than a defined reference value, b) The ratio of Tbet: GATA-3 gene expression in the biological isolate is higher than a defined reference value.
[0074] The subgroup “Th1 high” is thus characterized either by a high absolute Tbet gene expression in comparison to a defined reference value. In the case of the measurement of the protein quantity, in the process, a corresponding value of the Tbet protein content in the isolate of a healthy person can be used as a reference value, wherein an assignment of the patient to the subgroup “Th1 high” takes place when said patient's Tbet protein content is increased. However, fixed reference values can also be used. In the case of the measurement of the mRNA quantity, a corresponding value of the Tbet mRNA quantity in the isolate of a healthy person can be used as a reference value, wherein an assignment of the patient to the subgroup “Th1 high” takes place when said patient's Tbet mRNA quantity is increased. However, on the other hand, fixed reference values can also be used.
[0075] An assignment of the patient to the mentioned molecular phenotype of the subgroup “Th1 high” takes place according to one advantageous embodiment of the inventive method, when as an alternative to or in addition to the decreased Tbet gene expression, the ratio of Tbet : GATA-3 gene expression in the biological isolate is higher than a defined reference value. In the process a corresponding value of the ratio of Tbet: GATA-3 gene expression in the isolate of a healthy person can be used as a reference value. The determination of the ratio of Tbet: GATA-3 gene expression also increases the certainty of the statement in this case, since in the process along with the Tbet gene expression as an additional parameter the GATA-3 gene expression is determined and the inclusion of GATA-3 constitutes an internal control for the measurement of the Tbet gene expression.
[0076] According to one advantageous development, the inventive method for assigning the patient to the molecular phenotype of the subgroup “Th1 high” comprises the steps:
Release of proteins or RNA from cells of a biological isolate of the patient; Determination of the expression level of the proteins or of the mRNA for Tbet and/or GATA-3; Placement of the patient in the subgroup “Th1 high” when at least one of the foregoing conditions mentioned under a) or b) apply.
[0080] A further aspect of the present invention relates to a method that facilitates an assignment of the patient to a molecular phenotype of a subgroup “Th1 low” when at least one of the following conditions is fulfilled:
a) The Tbet gene expression in the biological isolate is lower than a defined reference value, b) The ratio of Tbet: GATA-3 gene expression in the biological isolate is lower than a defined reference value.
[0083] The subgroup “Th1 low” is thus characterized either by a low absolute Tbet gene expression in comparison to a defined reference value. In the case of the measurement of the protein quantity, in the process, a corresponding value of the Tbet protein content in the isolate of a healthy person can be used as a reference value. Here it should be noted that in the case of a patient of the subgroup “Th1 low” with an illness accompanied by chronic inflammations the absolute Tbet gene expression can however be higher than in an isolate of a healthy person. However, the absolute Tbet gene expression can also be lower than in the case of a healthy person. In any event, the Tbet gene expression is not as high as described for the subgroup “Th1 high”. Hence, an assignment of the patient to the subgroup “Th1 low” takes place when said patient's Tbet protein content in comparison to an isolate of a healthy person, if at all, is increased, however not significantly. However, fixed reference values can also be used. In the case of the measurement of the mRNA quantity, a corresponding value of the Tbet mRNA quantity in the isolate of a healthy person can be used as a reference value, wherein an assignment of the patient to the subgroup “Th1 low” takes place when said patient's Tbet mRNA quantity is lower than in the corresponding sample of a healthy patient or in any event is not significantly increased. However, on the other hand, fixed reference values can also be used.
[0084] An assignment of the patient to the mentioned molecular phenotype of the subgroup “Th1 low” takes place according to one advantageous embodiment of the inventive method, when as an alternative to or in addition to the decreased Tbet gene expression, the ratio of Tbet: GATA-3 gene expression in the biological isolate is lower than a defined reference value. In the process a corresponding value of the ratio of Tbet: GATA-3 gene expression in the isolate of a healthy person can be used as a reference value. The determination of the ratio of Tbet: GATA-3 gene expression also increases the certainty of the statement in this case, since in the process along with the Tbet gene expression as an additional parameter the GATA-3 gene expression is determined and the inclusion of GATA-3 constitutes in a certain sense an internal control for the measurement of the Tbet gene expression.
[0085] According to one advantageous development, the inventive method for assigning the patient to the molecular phenotype of the subgroup “Th1 low” comprises the steps:
Release of proteins or RNA from cells of a biological isolate of the patient; Determination of the expression level of the proteins or of the mRNA for Tbet and/or GATA-3; Placement of the patient in the subgroup “Th1 low” when at least one of the foregoing conditions mentioned under a) or b) apply.
[0089] As an alternative, in addition to the mentioned determination of the GATA-3 and/or Tbet gene expression, in turn a determination of further parameters for certain placement in the subgroup “Th1 high” and “Th1 low” can take place. Thus, for example the number of eosinophilic granulocytes or the serum IgE level can be measured. An assignment to the subgroup “Th1 high” takes place when the serum IgE level is lower than 100 IU/ml and/or the number of the eosinophilic granulocytes is below 0.14×10 9 cells per liter. Otherwise, an assignment to the subgroup “Th1 low” takes place. As an alternative, if required, the concentration in nitric oxide in the exhaled air, thus a determination of the FeNO value can be performed.
[0090] In order to consider differences in sample preparation, a standardization of the concentrations of GATA-3 and Tbet can be performed. Differences in the sample preparation can for example come about through differing cell numbers that are lyzed, through differing lysis efficiencies of the individual samples or through differing content in the various cell types within the cell preparations. In accordance with the invention, possibilities for standardization include the following: Standardization to the total protein content of the cell lysate, standardization to the cell number that has been lyzed or standardization to the concentration of specific marker proteins that are specifically found in specified cell types.
[0091] The patients with the diagnosed molecular phenotype of the subgroup “Th2 high” can under circumstances simultaneously be placed in the subgroup “Th1 low”. Also, patients with the diagnosed molecular phenotype of the subgroup “Th1 high” can under circumstances simultaneously be placed in the subgroup “Th2 low”. This is to be attributed to the fact represented above that the polarization to Th2 inhibits a Th1 differentiation through suppression of Tbet and vice versa.
[0092] Within the scope of the present invention, illnesses are diagnosed or treated that are accompanied by chronic inflammations, such as autoimmune diseases and diseases from the area of rheumatic diseases (manifestations among others on the skin, lungs, kidneys, vascular system, nervous system, connective tissue, locomotor system, endocrine system), immediate-type allergic reactions and asthma, chronic obstructive lung diseases (COPD), arteriosclerosis, psoriasis and contact eczema as well as chronic rejection reactions after organ and bone marrow transplants. Also tumor diseases can be diagnosed and treated in accordance with the invention, provided GATA-3 or Tbet are involved in the development and/or deregulated as after-effects.
[0093] Within the scope of the present invention, the chronic inflammatory disease is either Th2-induced, such as for example allergic bronchial asthma, rhinoconjunctivitis, allergic sinusitis, atopical dermatitis, food allergies, pemphigus, ulcerative colitis, parasitic illnesses, or Th1-induced, such as for example psoriasis, allergic contact eczema, Crohn's disease, COPD, rheumatoid arthritis, autoimmune diseases, type 1 diabetes mellitus or MS.
[0094] The aforementioned problem is additionally solved in accordance with the invention through a medicament for the treatment of illnesses of a human patient with a molecular phenotype that are accompanied by chronic inflammations, wherein the molecular phenotype has been determined in accordance with one or more embodiments of the mentioned inventive diagnostic method. The identified molecular phenotype comprises in the process in particular the groups “Th1 low, “Th1 high”, “Th2 low” or “Th2 high”.
[0095] According to one preferred embodiment the mentioned medicament contains a specific ribonucleic acid or deoxyribonucleic acid specific for GATA-3 or Tbet, in particular a DNAzyme specific for GATA-3 or Tbet.
[0096] The “10-23” model represents a general DNAzyme model (Sontoro et al., 1997). DNAzymes of the10-23 model—also referred to as “10-23 DNAzymes” have a catalytic domain of 15 nucleotides, which are flanked by two substrate binding domains. The catalytic domain in the process preferably has the sequence ggctagctacaacga (SEQ ID No. 154). The length of the substrate binding domains is variable: they are either of equal length or variable in length. In one preferred design, the length of the substrate binding domains ranges between 6 and 14 nucleotides, very especially preferably in each case at least nine nucleotides. Such DNAzymes comprise the general sequence nnnnnnnnnggctagctacaacgannnnnnnnn (SEQ ID NO 155). Especially preferable in the process are substrate binding domains that bind the mRNA, coding for the proteins GATA-3 and Tbet.
[0097] The specified catalytic central domain ggctagctacaacga is only one preferred embodiment. A person skilled in the art is aware of the fact that “10-23 DNAzymes” can be obtained with comparable biological activity with a modified catalytic domain.
[0098] In one especially preferred embodiment, the substrate binding domains are completely complementary to the region that flanks the cleaving site. However, in order to bind the target RNA and cleave it, the DNAzyme does not necessarily have to be completely complementary. DNAzymes of the 10-23 type cleave the target mRNA on purine-pyrimidine sequences. Within the scope of the present invention the DNAzymes preferably comprise the in vivo active DNAzymes against GATA-3 and Tbet in accordance with WO 2005/033314 A2, whose content is incorporated as disclosure content of the present invention.
[0099] A medicament for specific inhibition of the GATA-3 expression in vivo contains in particular at least one DNAzyme selected from the group consisting of DNAzymes with a sequence in accordance with one of the sequences SEQ ID NO 1 through SEQ ID NO 70. Such a DNAzyme binds preferably on an mRNA which codes for a human GATA-3 gene with a gene sequence selected from the sequences SEQ ID NO 151 (human GATA-3 from database no.: XM_043124), SEQ ID NO 152 (human GATA-3 from Database No.: X58072) and SEQ ID NO 153 (human GATA-3, sequenced from plasmid pCR2.1).
[0100] A medicament for specific inhibition of the GATA-3 expression in vivo preferably contains the DNAzyme hgd40 with the sequence 5′-GTGGATGGAggctagctacaacgaGTCTTGGAG (SEQ ID NO 40).
[0101] A medicament for specific inhibition of the Tbet expression in vivo contains in particular at least one DNAzyme selected from the group consisting of DNAzymes with a sequence according to one of the sequences SEQ ID NO 71 through SEQ ID NO 148. Such a DNAzyme preferably binds on an mRNA which codes for a human Tbet gene with a gene sequence selected from the sequences SEQ ID NO 149 (human Tbet from the Database No.: NM_013351) and SEQ ID NO 150 (human Tbet sequenced from pBluescript-SK).
[0102] A medicament for specific inhibition of the Tbet expression in vivo contains preferably the DNAzyme td69 with the sequence 5′-GGCAATGAAggctagctaccaacgaTGGGTTTCT (SEQ ID NO 139) or td70 with the sequence 5′-TCACGGCAAggctagctacaacgaGAACTGGGT (SEQ ID No 140).
[0103] As an alternative to the DNAzymes the medicament for specific inhibition of the GATA-3 or Tbet expression can contain a suitable siRNA.
[0104] The medicament preferably has a formulation with which the mentioned specific ribonucleic acid or deoxyribonucleic acid molecules can be administered to the patient in the form of a pharmaceutically acceptable composition either orally, rectally, parenterally, intravenously, intramuscularly or subcutaneously, intracisternally, intravaginally, intraperitoneally, intrathecally, intravascularly, locally (powder, ointment or drops) or in the form of a spray. For the local administration of the medicament of this invention include ointments, powders, sprays or inhalants. The active component is mixed under sterile conditions with a physiologically acceptable excipient and possible preservatives, buffers or propellants, depending on requirements.
[0105] The medicament can be used for therapy for all diseases that are accompanied by chronic inflammations.
[0106] According to an especially preferred design of the present invention, the treatment of the patients takes place with a molecular phenotype of the subgroup “Th2 high” with a GATA-3 specific DNAzyme. The therapy of a patient with a molecular phenotype of the subgroup “Th1 high” takes place with a Tbet specific DNAzyme. In addition, the treatment of a patient with the molecular phenotype of the subgroup “Th2 low” can take place with a Tbet specific DNAzyme and the treatment of a patient with the molecular phenotype of the subgroup “Th1 low” can occur with a GATA-3 DNAzyme.
[0107] An inventive medicament with a GATA-3 specific DNAzyme is thus provided preferably for the treatment of a patient with the molecular phenotype of the subgroup “Th2 high” and a medicament with a Tbet specific DNAzyme is preferably provided for the treatment of a patient with the molecular phenotype of the subgroup “Th1 high”.
[0108] In accordance with the invention, one special advantage of the medicament according to an embodiment mentioned above for the specific therapy of an inventively diagnosed subgroup of patients—namely “Th2 high”, “Th2 low”, “Th1 high” or “Th1 low” lies in the fact that with the help of the specific medicament, in particular of a DNAzyme and/or an siRNA, a functional inactivation of the coding ribonucleic acid molecules of transcription factors takes place, whose differential expression was determined beforehand and which is involved in the development of the chronic inflammatory reactions and autoimmune diseases. This strategy differs distinctly from conventional approaches and also differs from the approach according to Corren et al., 2011, since there, one the one hand for example the quantity of periostin (surrogate marker) is measured, but then a therapy aimed at another target, such as for example IL-13 with the help of an anti-IL13 antibody was proposed. The inventive medicament on the other hand has a high specificity. It causes a cell-specific intervention and is specific for compartments and organs.
[0109] Dosage forms of the inventive medicament comprise pharmaceutically acceptable compositions which contain modifications and “prodrugs”, provided they do not trigger excessive toxicity, irritations or allergic reactions in patients according to reliable medical assessment. The term “prodrug” relates to compounds that are transformed for improvement of the absorption, such as for example through hydrolysis in the blood.
[0110] The inventive medicament can also be used in the form of a multiple emulsion for application of the mentioned specific nucleic acid molecules. A suitable multiple emulsion to this end comprises an exterior water phase W1, an oil phase O dispersed in the exterior water phase W1 and an interior water phase W2 dispersed in the oil phase O, wherein in the interior water phase W2 at least one electrolyte selected from the group of alkali metal halides and earth alkali metal halides and sulfates and at least one specific ribonucleic acid or deoxyribonucleic acid molecule, preferably a DNAzyme specific for GATA-3 or Tbet is provided, wherein the exterior water phase W1 contains a hydrophilic emulsifier which is a polymer of ethylene oxide and propylene oxide, and the oil phase O is formed by triacylglycerides and has a lipophilic emulsifier from the group of dimethicones. With the help of such multiple emulsion in particular nucleic acid molecules can be especially effectively protected from undesirable decomposition.
[0111] The type of dosage will be determined by the attending physician in accordance with the clinical factors. A person skilled in the art is aware of the fact that the type of dosage is dependent on different factors such as e.g. body size, weight, body surface, age, sex or the general health of the patient, but also depends on the agent to be administered, the duration and type of administration and on other medicaments that may be administered in parallel. In the process, according to an especially advantageous embodiment, the quantity of the active ingredient of the medicament can be adapted to the measured expression level. Thus, in the case of placement in the subgroup “Th2 high” and an established very high GATA-3 gene expression an increase dose of the active ingredient, in particular a DNAzyme specific for GATA-3 specific can be administered. Correspondingly, in the case of placement in the subgroup “Th1 high” and an established very high Tbet gene expression an increased dose of the active ingredient, in particular of a DNAzyme specific for Tbet can be administered.
[0112] A further aspect of the present invention relates to a kit for diagnosing a molecular phenotype of a human patient suffering from an illness accompanied by chronic inflammation, wherein the kit contains at least one specific component for quantitative determination of the protein or mRNA quantity of GATA-3 and/or Tbet in a biological isolate of the patient.
[0113] The inventive kit for diagnosis can be easily offered in the form of a ready to use “kit” which comprises antibodies or antigens that are adsorbed on a surface of a carrier and a preparation of human IgG antibodies which e.g. in the case of a human, a preparation of anti-human IgG antibodies that are marked such that they are proved by a cascade of reactions of the type biotin-streptavidin peroxidase or alkaline phosphatase.
[0114] As an alternative, the kit for diagnosis also comprises, in addition to a carrier, buffers and reagents, e.g. reagents which are necessary for proof of the reaction such as e.g. streptavidin that is coupled to a marker that gives a color reaction.
[0115] As an alternative, the kit additionally comprises a standard sample of GATA-3 and/or Tbet for calibration of the kit, wherein for proof of the protein or mRNA of GATA-3 and/or Tbet, a standard sample is used.
[0116] In the case of one preferred embodiment, a specific antibody against GATA-3 and/or Tbet is included for the quantitative determination of the protein quantity. If necessary, in accordance with a modification, further components for execution of an immunoassay, in particular an ELISA, can be included.
[0117] The further component for carrying out the ELISA is selected from the group consisting of lysis buffers for cell disruption, a microwell plate, protein quantity standards for GATA-3 and/or Tbet, secondary antibodies and a coupled enzyme for implementation of a substrate for detection. Preferably, in addition to a first specific antibody against GATA-3 and/or Tbet the kit comprises a further specific antibody against GATA-3 or Tbet.
[0118] The kit can contain a sequence specific probe and/or primer for the GATA-3 and/or Tbet genes for quantitative determination of the mRNA quantity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0119] Further features, details and advantages of the invention arise from the wording of the claims as well as from the following description of exemplary embodiments with the assistance of the drawings. The figures show the following:
[0120] FIG. 1 shows the influence of various detergents on the release of GATA-3 from stimulated Jurkat cells,
[0121] FIGS. 2 a,b show results of a quantification of Tbet and GATA-3 by means of chromogenic sandwich ELISA,
[0122] FIG. 3 shows a standard curve of a GATA-3 ELISA for quantification of samples
[0123] FIG. 4 shows a standard curve of a Tbet ELISA for quantification of samples
[0124] FIG. 5 shows a standardized determination of Tbet in lysates of human peripheral mononuclear cells (PBMC)
[0125] FIG. 6 shows a significant improvement of allergic airway inflammation after four-day treatment with the GATA-3 specific DNAzyme hgd40 (SEQ ID NO 40) compared to untreated mice,
[0126] FIG. 7 shows the influence of the GATA-3 specific DNAzyme hgd40 (SEQ ID NO 40) on the number of neutrophils occurring in the chronic inflammation, the number of eosinophils in the BAL and the release of IL-5 after an eight-week treatment and
[0127] FIG. 8 shows the influence of the GATA-3 specific DNAzyme hgd40 (SEQ ID NO 40) on the peribronchial/perivascular inflammation and goblet cell hyperplasia in the lung tissue.
DETAILED DESCRIPTION OF THE INVENTION
Material and Methods:
[0128] Cells can be isolated, for example, by means of technologies based on the binding of specific antibodies. Magnetic beads, which can be obtained from the firms Miltenyi (Macs-System), Dynal (DynaBeads) or BD-Bioscience (iMAG), are used. As an alternative this happens via a cell purification by means of fluorescent marked antibodies on cell sorters for example from the firm Cytomation (MOFLO) or BD-Bioscience (FACS-Vantage). The purity of the target cells is preferably at least 80%, more strongly preferred at least 95% and most preferred at least 99%.
[0129] Methods for the isolation of RNA are e.g. described in Sambrook and Russell, Molecular Cloning, A Laboratory Manual, 3 rd Edition, Cold Spring Harbor Laboratory (2001), New York and Ausubel et al., Current Protocols in Molecular Biology, John Wiley & Sons (1998), New York. In addition it is possible for the average person skilled in the art to use commercially available kits (Silika-Technologie) e.g. the RNeasy Kit from the firm Qiagen, for RNA isolation. In addition it is preferable to purify mRNA directly from the target cells by using commercial kits for example from the firm Qiagen (Oligotex mRNA Kit), Promega (PolyATract mRNA Isolation System) or Miltenyi (mRNAdirect).
EXEMPLARY EMBODIMENTS
Exemplary Embodiment 1
[0130] GATA-3 and Tbet are proteins that, as transcription factors, have their effect in the cell core of T helper cells of the subtype Th1 and Th2. In order to determine the concentration of these two nuclear proteins in a specified volume of a biological isolate in particular in a specified volume of whole blood, cells which form GATA-3 and Tbet must first be isolated and subsequently lyzed. A direct proof of these proteins from human serum or plasma is not possible, since they are not present there in detectable concentration. An analysis of GATA-3 and Tbet therefore takes place in 4 stages:
Partitioning and isolation of the GATA-3/Tbet expressing cells from the other cellular components of the whole blood Disruption of the cells and release of the intracellular/nuclear proteins Measurement of the concentration of GATA-3 and Tbet and Standardization of the found concentrations of GATA-3 and Tbet.
Partitioning and Isolation of the GATA-3/Tbet Expressing Cells from the other Cellular Components of the Whole Blood
[0135] This can be performed by different methods of variable complexity, in particular the following steps for partitioning and isolation within the scope of the present invention:
An isolation of leukocytes from whole blood by means of Ficcoll density gradient centrifugation with subsequent affinity purification of the Th1/Th2 cell types by antibodies against specific surface markers, If necessary, the affinity purification of the Th1/Th2 cell types by antibodies against specific surface markers can also be performed as a 1-stage method without prior enrichment of the leukocytes, If necessary, the isolation of leukocytes through Ficoll density gradient centrifugation from whole blood suffices in order to perform a quantification of the proteins GATA-3 and Tbet, If necessary, in place of the Ficoll density gradient centrifugation a bead-based affinity purification of the Th1/Th2 cell types through antibodies against specific surface markers in a deep-well plate in the 96 well format can be employed, If required, in place of the Ficoll density gradient centrifugation a bead-based affinity purification of the leukocytes through antibodies against specific surface markers in a deep-well plate in the 96 well format can be employed, If necessary, a hypoosmolar lysis of the erythrocytes can take place to obtain a leukocyte preparation or If necessary the protein disruption can occur directly from the whole blood
Disruption of the Cells and Release of the Intracellular/Nuclear Proteins
[0143] This can be achieved through various methods and principles, in particular within the scope of the present invention the following procedural steps:
Destruction of cellular membranes through lysis buffers with different principles of operation:
a) Hypotonic buffers which induce a bursting of the cells b) Buffers containing detergents, which destroy the cell membrane and as a result, release intracellular proteins c) Buffers of high ionic strength or osmotically active buffers which remove water from the cells and as a result destroy the cell integrity
Physical methods such as heating up, shock freezing or ultrasound Mechanical methods such as homogenizing or grinding.
[0150] Examples of buffers containing detergents could be:
Buffer systems with a high concentration of ionic (e.g. SDS or cholate and its derivatives) or non-ionic (e.g. triton or Tween-20) detergents Mixtures of ionic and non-ionic detergents (e.g. Ripa buffers with 50 mM Tris·HCI (pH 7.5), 150 mM NaCl, 1% NP40, 0.5% sodium deoxycholate and 0.1% SDS) Commercially available lysis buffers with unknown composition (e.g. M-PER)
The influence of different detergents on the release of GATA-3 from stimulated Jurkat cells is illustrated in FIG. 1 . The lysis of Jurkat cells (human T cell line) through various lysis buffers and quantification of GATA-3 by means of ELISA resulted in an especially high release of GATA-3 protein in the case of the use of the RIPA buffer (1% RIPA). About 50 ng/ml of GATA-3 were verified.
Measurement of the Concentration of GATA-3 and Tbet
[0154] In principle, the concentration of the two transcription factors GATA-3 and Tbet can be determined with different methods. Within the scope of the present invention, among others there are:
ELISA (enzyme linked immunosorbent assay) CLIA (chemoluminescence linked immunosorbent assay) FLIA (fluorescence linked immunosorbent assay) Mass spectrometric methods Chromatographic methods (e.g. gas chromatography) Fluid-based methods with solid phase separation, (e.g. HPLC) Microfluidic and nanofluidic methods
[0162] FIGS. 2 a and FIG. 2 b show the results of a quantification of Tbet and GATA-3 by means of chromogenic sandwich ELISA. The cells were obtained from whole blood through Ficoll density gradient centrifugation. The cells (stimulated human mononuclear cells) were lyzed with a Ripa buffer. The lysate was examined with two ELISA prototype methods with respect to the concentration of GATA-3 and Tbet. The concentration of the two proteins was depicted with respect to the total protein concentration of the cell lysates (standardization to protein content).
[0163] The results in accordance with FIG. 2 a show that Th1 cells have a higher content of Tbet (circa 160 ng/ml analyte/mg protein) than Th2 cells (circa 56 ng/ml analyte/mg protein) and this fact can be clearly confirmed from the results of the ELISA test:
[0000]
Ng/ml Tbet/mg
Cells
Protein
Th2 B11-14
51.01
Th2 B11-15
58.40
Th2 B11-16
50.24
Th2 B11-17
68.79
Th2 B11-19
49.63
Th2 B11-20
55.85
Mean
55.65
STABW
7.31
VK(%)
13.14
Th1 B11-14
202.24
Th1 B11-19
106.34
Th1 B11-20
167.46
Mean
158.68
STABW
48.55
VK(%)
30.59
[0164] The Tbet content in the Th1 cells is thus more than two times greater, namely by a factor of about three, than in the Th2 cells.
[0165] According to FIG. 2 b the content in GATA-3 in the Th2 cells (circa 10 ng/ml analyte/mg protein) is higher than in Th1 cells (circa 6 ng/ml analyte/mg protein) The GATA-3 content is more than 1.5 times higher in the Th2 cells here—namely by a factor of about 1.7—than in Th1 cells.
[0166] In addition, one can see from FIGS. 2 a and 2 b that in the case of standardization to the protein content the quantity ratio of Tbet: GATA-3 in Th1 cells differs significantly form the corresponding ratio in Th2 cells. Thus the quantity ratio of Tbet: GATA-3 here in Th1 cells is about 27, thus more than 20, while the corresponding quantity ratio in Th2 cells is circa 6, thus less than 10.
[0167] The quantitative determination of GATA-3 and Tbet occurs in each case by means of a sandwich ELISA (Enzyme linked immune sorbent assay).
Exemplary Embodiment 2—GATA-3 ELISA:
[0168] To this end, the wells of a 96 well microwell plate are coated with specific antibodies against GATA-3. After addition of the sample or of a standard, GATA-3 binds on the antibodies on the 96 well plate. After a wash step to remove the non-bound substances a second, specific biotinylated antibody against GATA-3 is added. After an additional wash step to remove the non-bound substances peroxidase marked streptavidin is added. After a last wash step to remove the non-bound substances substrate is added. The color development is terminated after a defined time by adding a stop solution. The intensity of the color development is quantified by a microwell plate reader. The quantification of the samples occurs by a comparison to the included standards of known protein concentration. FIG. 3 shows a corresponding standard curve of a GATA-3 ELISA.
[0169] According to the exemplary embodiment for the performance of the GATA-3 ELISA, the steps relate to the following in detail:
Insert number of required wells into a frame of the 96 well plate Addition of 50 μl/well assay buffer Addition of 100 μl/well standard/control/sample Incubation for 60 minutes on the shaker Wash all wells 4× with 400 μl/well of wash buffer Addition of 100 μl/well biotinylated anti-GATA-3 antibodies Incubation for 60 minutes on the shaker Wash all wells 4× with 400 μl/well of wash buffer Addition of 100 μl/well peroxidase marked streptavidin Incubation for 30 minutes on the shaker Wash all wells 4× with 400 μl/well of wash buffer Addition of 100 μl/well substrate Incubation for 30 minutes Stop reaction by addition of 100 μl stop solution Measurement of optical density at 450 nm with a microwell plate reader
Exemplary Embodiment 3—Tbet ELISA:
[0185] The verification of the Tbet protein is executed in accordance with the following test principle: The quantitative determination of Tbet occurs by means of a sandwich ELISA (Enzyme linked immuno sorbent assay). To this end the wells of a 96 well microwell plate are coated with specific antibodies against Tbet. After addition of the sample or of a standard, Tbet binds on the antibodies on the 96 well plate. After a wash step to remove the non-bound substances a second, specific antibody against Tbet is added. After an additional wash step to remove the non-bound substances a peroxidase marked antibody against the Tbet specific antibody is added. After a last wash step to remove the non-bound substances substrate is added. The color development is terminated after a defined time by adding a stop solution. The intensity of the color development is quantified by a microwell plate reader. The quantification of the samples occurs by a comparison to the included standards of known protein concentration. FIG. 4 shows a corresponding standard curve of a Tbet ELISA.
[0186] According to the exemplary embodiment for the performance of the Tbet ELISA the steps relate to the following in detail:
Insert number of required wells into a frame of the 96 well plate Addition of 50 μl/well assay buffer Addition of 100 μl/well standard/control/sample Incubation for 60 minutes on the shaker Wash all wells 4× with 400 μl/well of wash buffer Addition of 100 μl/well anti-Tbet antibodies Incubation for 60 minutes on the shaker Wash all wells 4× with 400 μl/well of wash buffer Addition of 100 μl/well peroxidase marked anti-Tbet specific antibodies Incubation for 30 minutes on the shaker Wash all wells 4× with 400 μl/well of wash buffer Addition of 100 μl/well substrate Incubation for 30 minutes Stop reaction by addition of 100 μl stop solution Measurement of optical density at 450 nm with a microwell plate reader
Standardization of the Concentrations of GATA-3 and Tbet
[0202] In order to consider differences in the sample preparation, a standardization of the concentrations of GATA-3 and Tbet can be performed. Differences in the sample preparation can arise e.g. due to the following:
Differing cell numbers to be lyzed Differing lysis efficiencies of the individual samples or Differing content in the different cell types within the cell preparations.
[0206] Possibilities for standardization include the following:
Standardization to the total protein content of the cell lysate (see under “Measurement of the Concentrations of GATA-3 and Tbet”) Standardization to the cell number being lyzed (see FIG. 5 ) or Standardization to the concentration of specific marker proteins that are specifically found in specified cell types.
[0210] FIG. 5 shows a standardized determination of Tbet in lysates of human peripheral mononuclear cells (PBMC). In the process a lysis of PBMCs of healthy subjects and patients suffering from allergic illnesses, such as e.g. allergic bronchial asthma, rhinoconjunctivitis, allergic sinusitis, atopical dermatitis, food allergies takes place. The concentration of Tbet was standardized to the cell number in the lysates. The illness is Th2 dependent and consistently a slight concentration in Tbet (circa 12 ng/ml/1 million cells) for allergy sufferers was determined compared to healthy subjects (circa 27 ng/ml/1 million cells). The Tbet concentration was thus reduced in the case of allergy sufferers by more than a factor of 2 compared to healthy subjects. Consequently, an assignment of the patients to the molecular phenotype “Th1 low” is easily possible here, since the Tbet gene expression in the biological isolate is lower than a defined reference value, here the Tbet gene expression of healthy subjects.
Exemplary Embodiment 4
[0211] In modification of Examples 2 and 3, in accordance with Example 4 Th1/Th2 cells are enriched by means of magnetic beads coated with cell specific antibodies for the sample preparation. Subsequently the verification of GATA-3 occurred in accordance with the provision according to Example 2.
Exemplary Embodiment 5
[0212] In modification of Examples 2 and 3, in accordance with Example 4 leukocytes are enriched by means of size exclusion filtration for the sample preparation. Subsequently the verification of GATA-3 occurred in accordance with the provision according to Example 2.
Exemplary Embodiment 6
[0213] A GATA-3 specific DNAzyme shows therapeutic effects in the mouse model of the OVA induced allergic airway inflammation of the “Th2 high” phenotype.
[0214] In order to provide the best possible illustration of the clinical phenotype “Th2 high” in the mouse model BALB/c mice were sensitized with the model allergen ovalbumin (OVA) in the presence of the adjuvant AI(OH) 3 on days 0, 14 and 21 through intraperitoneal injection. On days 24-26 the mice inhaled a 1% OVA aerosol in order to cause a Th2 dominated allergic inflammatory reaction in the lungs. On days 23-26 the GATA-3 specific DNAzyme hgd40 (SEQ ID NO 40), dissolved in PBS, was intranasally administered. In the process the Balb/c-mouse strain is characterized in that it generates preferentially strong Th2 responses. This is reinforced by the use of AL(OH) 3 as an adjuvant, which distinctly supports the formation of Th2 dominated immune responses. The described mouse model is correspondingly characterized by a massive infiltration of eosinophils an Th2 cells in the airways accompanied by a hyperplasia of the mucus forming goblet cells with increased mucus production as well as the formation of an airway hyperresponsiveness. Immunologically, along with allergen specific Th2 cells, characterized by the production of the typical cytokines IL-4, IL-5 and IL-13, also OVA specific antibodies of the immune globulin classes IgE and IgG1 (in the mouse both Th2 dependent) were detectable. All these parameters are typical clinical features of a “Th2 high” phenotype (Wenzel et al., Am J Respir Crit Care Med. 199 Sep; 160(3):1001-8; Woodruff et al., 2009). In the process the reaction strength with respect to some parameters in the animal model were even more distinctly pronounced than in the clinical situation with human patients, e.g. eosinophilic granulocytes constitute circa 60-70% of all leukocytes in the bronchial alveolar lavage (BAL) in the mouse model, while already 3-5% of these cells in the sputum of patients indicates a Th2 dominated phenotype.
[0215] According to FIG. 6 , after four-day treatment with the GATA-3 specific DNYzyme hgd40 (SEQ ID NO 40) compared to untreated mice, a significant improvement of the allergic airway inflammation was ascertained. Above all the number of eosinophils in the BAL was significantly reduced. In addition, the BAL concentrations of the characteristic cytokines for the phenotype “Th2 high”, IL-5 and IL-13, were able to be significantly reduced.
Exemplary Embodiment 7
[0216] A GATA-3 specific DNAzyme shows significant therapeutic effects in the chronic mouse model of a Th2 dominated allergic airway inflammation.
[0217] In order to provide the best possible illustration of the clinical phenotype “Th2 high” in the mouse model, BALB/c mice were sensitized with the model allergen ovalbumin (OVA) in the presence of the adjuvant AI(OH) 3 on days 0, 14 and 21 through intraperitoneal injection. By means of twice weekly OVA aerosol provocations over a time period of 14 weeks a chronic inflammation of the airways was caused in the mice. During the last eight weeks therapy was provided three times a week (until day 121) either with budesonide or the GATA-3 specific DNAzyme hdg40 through intranasal application.
[0218] According to FIGS. 7 and 8 after eight weeks of treatment with GATA-3 specific DNAzyme hdg40 (SEQ ID NO 40) the number of eosinophils in the BAL was able to be significantly reduced and in addition a reduction of the number of neutrophils occurring in the chronic inflammation was also observed. This was accompanied by a lowered peribronchial/perivascular inflammation and reduced goblet cell hyperplasia. Simultaneously, in re-stimulated lymphocytes of those treated with hgd40 a reduced release of IL-5 was observed. In the budesonide group, on the other hand no significant improvement of the parameters cold be observed.
[0219] The invention is not restricted to one of the previously described embodiments, but rather can be modified in many respects.
[0220] All features and advantages arising from the claims, the description and the drawings, including design details, spatial arrangements and procedural steps can be essential to the invention both individually as well as in a variety of combinations.
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Chronic inflammation is an increasing medical problem area of high socioeconomic significance. The invention relates to a method and a kit for diagnosing a molecular phenotype of a patient suffering from an illness accompanied by chronic inflammation, and to a medicament for treating such a patient. To that end, the gene expression of GATA-3 and/or Tbet in a biological isolate of the patient is measured and used for association with a molecular phenotype of the illness.
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FIELD OF THE INVENTION
[0001] This invention is related generally to prevention of erosion and promotion of seed germination in soil, and more particularly, to installation of erosion blankets to prevent erosion and promote seed germination.
BACKGROUND OF THE INVENTION
[0002] Erosion blankets are used throughout the world to stabilize soil before seed germinates and/or small plant plugs cover the ground. Erosion blankets are used for a variety of reasons, such as stabilizing large areas along highways, stabilizing areas around detention/retention ponds, establishing fine quality lawns for commercial and residential properties and restoring prairies. Erosion blankets are typically provided in rolls of 65 to 100 yard rolls, depending upon the type of blanket. The most widely used blankets are made of straw and wood fiber. Typically, erosion blankets of every type are installed by hand.
[0003] Erosion blankets are typically utilized to keep the soil and seed from eroding away during and after precipitation. In addition to preventing erosion, such blankets retain moisture in the soil under the blanket for a much longer period of time. The extended presence of moisture enables the seed to germinate much more quickly than without blanket cover.
[0004] In addition, erosion blankets retard weed growth when grass seed is planted in the late spring and early summer months. Due to the consistent shade that is provided by the erosion blanket the vast majority of noxious weed seed will not germinate.
[0005] In the landscaping industry, two alternative products are often used to encourage seed germination. These products are straw mulch and hydro mulch, both of which are typically mechanically blown or dropped onto the soil. However, bales of straw which are broken apart and spread on the soil as straw mulch can blow away which leads to mixed results. Hydro mulch, a paper component with seed and fertilizer mixed in slurry of water, helps the seed germinate but does not control erosion. Furthermore, hydro mulch is a poor medium to keep moisture in the soil during critical dry times of the growing season. While straw mulch and hydro mulch are less effective than erosion blankets, their use is popular due to their lower associated costs, especially the labor costs involved in installing the mulch on the soil.
[0006] Erosion blankets are typically installed after a site has been fine graded (soil prepared for seed) and seeded. The seed may be broadcast or installed using a mechanical seeder. For use with small plant plugs, the erosion blanket is installed and the plant plugs are manually planted into the blanket. In either use, after the erosion blanket has been laid on the ground, stakes must be manually driven through the blanket into the ground to keep the blanket in correct position. The stakes are typically six inches long and must be driven deep enough such that they are flush with the erosion blanket so that mowers do not strike them. The manual operations dealing with the installation of stakes significantly increase the cost of installing an erosion blanket and often lead landscapers to use the less labor-intensive products mentioned above for reasons involving both time and costs.
[0007] Therefore, there is a continuing significant need in the field of erosion prevention and seed germination promotion for improvements related to the installation of erosion blankets and for more efficient installation thereof. An improved device and method achieving these goals would lead to better erosion protection and, therefore, higher quality lawns and prairies, as well as cleaner lakes, creeks, streams, rivers and oceans.
OBJECTS OF THE INVENTION
[0008] It is an object of the invention to provide an improved device which efficiently installs erosion blankets.
[0009] Another object of the invention is to provide an erosion blanket installation device which is simple in structure and operation in order to facilitate effective installation.
[0010] Another object of the invention is to provide an erosion blanket installation device which mechanically drives stakes into the ground to hold the blanket in position.
[0011] Another object of the invention is to provide an erosion blanket installation device which mechanically drives staples into the ground to hold the blanket in position.
[0012] Another object of the invention is to provide an erosion blanket installation device which simultaneously unrolls and pins to the ground the erosion blanket.
[0013] Another object of the invention is to provide a method of mechanically installing an erosion blanket on the ground.
[0014] Still another object of the invention is to provide a method of installing an erosion blanket on the ground which minimizes the need for manual operations during installation.
[0015] Still another object of the invention is to provide an easy penetration point in the ground for the insertion of a stake which automatically pins an erosion blanket to the ground.
[0016] Yet another object of the invention is to provide a method of automatically pinning an erosion blanket to the ground during installation.
[0017] These and other objects of the invention will be apparent from the following descriptions and from the drawings.
SUMMARY OF THE INVENTION
[0018] This invention is an improved method and device for efficiently and effectively installing erosion blankets on ground surfaces. The invention represents a significant advance over the state of the art by providing a novel device, which allows for an automatic method of installation which is heretofore unknown in the art.
[0019] The erosion blanket installation device is able to install a 500 yard roll of a straw erosion blanket on the ground while securing the blanket in place until the turf or vegetation naturally stabilizes the ground soil via a staple or a pneumatically driven stake which enters a 5″-6″ furrow.
[0020] The device for installing an erosion blanket, i.e., laying and securing the blanket along a pathway on the ground, is comprised of a vehicle frame, an axle arm connected with respect to the vehicle frame and engaging an axle around which the blanket roll is sleeved, at least one staple or stake gun connected with respect to the frame and at least one staple or stake cartridge connected with respect to the gun for supplying staples or stakes to pin the blanket to the ground.
[0021] The erosion blanket is rolled so that it may be sleeved around the blanket axle before use of the device. The blanket is positioned in the vehicle frame by sliding the roll around the blanket axle. As the device is propelled along the pathway the blanket is unwound from the roll and is placed on the ground. The device preferably includes a blanket guide roller for which directs the blanket to the ground upon unwinding. The gun pins the blanket in position by driving a staple or stake through it into the ground.
[0022] For use with a stake gun, rather than a staple gun, the device also preferably includes at least one furrow blade connected with respect to the frame. Preferably three furrow blades are supported by a furrow bar which is connected to a hydraulic cylinder which urges the blades into the ground. The blades furrow the ground during movement of the device and are urged to stay in position by their arcuate shape.
[0023] The preferable device includes at least one hitch connection point connected with respect to the frame. The hitch connection points are designed to connect to a hitch of a tractor or other vehicle which is able to tow the device. There are preferably three hitch connection points to provide sufficient connection to the towing vehicle.
[0024] The preferable device further includes an air compressor which is connected to each gun for forcing staples or stakes through the blanket into the ground. An air compressor is connected to each gun via a compressor hose and allows for pneumatic pinning of the blanket.
[0025] It is also preferred that the device include a retractable arm which is connected with respect to the frame. The retractable arm is movable between an open position which allows the roll to be loaded by sliding over the blanket axle and a closed position in which the retractable arm engages the free end of the blanket axle to hold the roll in place. A spring-loaded retractable-arm pin is connected with respect to the frame and pivotably supports the retractable arm with respect to the frame. A retractable-arm brace connects the retractable-arm pin to the frame. In use, the retractable arm is pivoted so that the erosion blanket may be positioned within the vehicle. After the blanket roll is in position within the device, the retractable arm is pivoted so that the second end of the blanket axle may engage the retractable arm to hold the roll in place.
[0026] In another preferred embodiment the device includes at least one compression wheel for pressing the blanket against the ground as the blanket unwinds. The compression wheel is supported by a compression-wheel frame. The compression-wheel frame preferably supports each gun and staple or stake cartridge as well.
[0027] The novel method of installing erosion blankets on ground surfaces comprises (a) propelling a blanket-laying device along a pathway, (b) rotating the roll of the erosion blanket supported in the device such that the blanket unwinds and is positioned on the surface along the pathway; and (c) in conjunction with the rotating step, mechanically pinning the blanket to the ground.
[0028] It is preferred that the rotating and pinning steps are performed simultaneously. The rotating and pinning steps are also preferably performed continuously until the roll expires. Furthermore, the rotating step is preferably performed in conjunction with, and as a result of, the propelling step. That is, the propelling of the device causes the roll to rotate and unwind. In the novel method, the blanket is preferably initially anchored to the ground surface by manually driving staples or stakes through the blanket into the yard. However, alternate embodiments of the invention allow for the blanket to be anchored to the ground without any manual manipulation.
[0029] The preferred method includes the step of pressing the blanket to the surface as it unwinds from the roll to allow for effective surface coverage. Such step is preferably performed by compression wheels, and more preferably by at least 3 axially-spaced compression wheels, e.g, one wheel pressing the left side of the blanket, one wheel pressing the middle of the blanket, and one wheel pressing the right side of the blanket.
[0030] The preferred method also includes the step of furrowing the surface before the pinning step. Such a step is preferably performed by at least 3 blades which are aligned with the means for mechanically pinning the blanket to the ground.
[0031] The device is preferably propelled along the pathway at at least about 3 miles per hour (mph). A tractor or similar vehicle can be connected to the device via a hitch in order to tow the device at the proper velocity. It is preferred that the erosion blanket is installed on the surface at a rate of at least about 400 yards every 3 minutes, or 400 feet/minute. Even more preferably, the erosion blanket is installed on the surface at a rate of at least about 500 yards every 3 minutes, or 500 feet/minute.
[0032] The pinning step is preferably performed using staples or stakes. Such staples or stakes are preferably biodegradable. The staples or stakes are preferably forced through the blanket into the ground by an air compressor included in the vehicle. As discussed above, the air compressor is connected to a gun which fires the staples or stakes into the ground. The gun is connected to a staple or stake cartridge which supplies the staples or stakes.
[0033] It is preferable that the number of staples or stakes held by the device be proportional to the length of the roll. Upon expiration of the roll positioned in the device, the preferred method includes the steps of loading staples or stakes and another roll of the blanket with respect to the device; propelling the device along a pathway; rotating the roll such that the blanket unwinds and is positioned on the surface along the pathway; and in conjunction with the rotating step, mechanically pinning the blanket to the ground.
[0034] The step of loading staples or stakes and another roll is preferably accomplished in less than about 15 minutes. The preferred method uses blanket rolls which are 500 yards long and at least 15,000 yards of blanket are installed in 8 hours.
[0035] An alternate method of installing an erosion blanket along a pathway on a ground surface comprises providing a roll of an erosion blanket; supporting the roll in a device; propelling the device in a direction along a pathway; and unwinding the roll so that the blanket covers the pathway, the device automatically pinning the blanket to the ground surface as it unrolls.
[0036] The preferred alternate method further comprises the step of pressing the blanket to the surface as it unwinds to allow for effective surface coverage. Such a step is preferably performed by compression wheels, and more preferably by at least 3 axially-spaced compression wheels.
[0037] The preferred alternate embodiment also comprises the step of furrowing the surface simultaneous with the propelling step. The furrowing step is preferably performed by at least 3 blades The pinning step is preferably performed using staples or stakes. The staples and stakes are preferably biodegradable and are forced through the blanket into the ground by an air compressor included in, or connected to, the device.
[0038] In the preferred alternate method, the erosion blanket is installed on the surface at a rate of at least about 400 feet/minute. More preferably, the erosion blanket is installed on the surface at a rate of about 500 feet/minute.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] [0039]FIG. 1 is a front view of the erosion-blanket-laying device in accordance with the invention.
[0040] [0040]FIG. 2 is a rear view of the erosion-blanket-laying device in accordance with the invention.
[0041] [0041]FIG. 3 is a view from the right side of the erosion-blanket-laying device in accordance with the invention.
[0042] [0042]FIG. 4 is a view from the left side of the erosion-blanket-laying device in accordance with the invention.
[0043] [0043]FIG. 5 is a overhead plan view of the erosion-blanket-laying device in accordance with the invention.
[0044] [0044]FIG. 6 is a detailed view of the compression wheel, gun and cartridge in accordance with the invention.
[0045] [0045]FIG. 7 is a detailed view of the compression wheel in accordance with the invention.
[0046] [0046]FIG. 8 is a detailed view of typical stakes for use with the erosion-blanket-laying device in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0047] [0047]FIG. 1 is a front view of the erosion-blanket-laying device 10 in accordance with the invention. Device 10 includes a frame 20 which comprises five frame supports (two external frame supports 20 a , 20 e and three internal frame supports 20 b , 20 c , 20 d ) which, as seen in FIGS. 3 and 4, extend horizontally from the front before arcing downwardly toward the rear of device 10 . Frame supports 20 a , 20 b , 20 c , 20 d , 20 e are connected by front frame crossbars 30 a , 30 b and rear crossbars 30 c , 30 d . Each frame support and crossbar is preferably 2″ by 2″ steel framing (hollow square framing with a thickness of ¼″). Alternatively, each frame support and crossbar is 90-degree angle bar. Preferably, the frame supports and crossbars are 1018 Cold Roll steel.
[0048] Connected to front frame crossbars 30 a , 30 b is a vertical stabilizer frame 24 comprising five vertical stabilizer bars 24 a , 24 b , 24 c , 24 d , 24 e . Vertical stabilizer bars 24 are preferably flat pieces which are 4″ wide, ½″ thick and 1′11″ to 2′ long. Lower end 25 b of vertical stabilizer bar 24 b is connected to hitch-connection point 35 b . Upper portion 23 c of vertical stabilizer bar 24 c is connected to hitch-connection point 35 c . Lower end 25 d of vertical stabilizer bar 24 d is connected to hitch-connection point 35 d . The three hitch connection points 35 provide for connection of device 10 to a tractor or other towing vehicle. Such a vehicle preferably has a category 2 , three-point hitch and at least a 100 hp engine. All connections between frame supports 20 , cross bars 30 and hitch-connection points 35 are weldings.
[0049] As seen in FIG. 3, fixed axle arm 26 is welded to a rear portion of external frame support 20 a and extends forward. Axle arm is preferably 2″ by 2″ steel framing. Axle arm 26 includes a connection point for erosion blanket axle 92 . Preferably, blanket axle 92 is welded to axle arm 26 at distal end 92 a of blanket axle. Erosion blanket 90 (shown in FIGS. 3 and 4) is wound into a roll so it can be slipped onto blanket axle 92 when being positioned in device 10 . Blanket axle 92 is preferably made of lightweight polished steel with ⅜″ thick wall. Blanket axle preferably has a diameter of 3½″ and a length of about 6′7″. Blanket axle 92 must have sufficient strength to hold a 500 yard blanket roll which has an approximate mass of 150 lbs.
[0050] As seen in FIG. 4, retractable arm 27 is connected to external frame support 20 e through retractable-arm pivot 28 so that retractable arm 27 may swing about pivot 28 . Retractable arm 27 is preferably constructed from flat bar steel. The lower end of retractable arm 27 has an opening provide for connection to the proximal end 92 b of blanket axle 92 . Pressure clips (not shown) are provided at the opening to hold the connection to blanket axle 92 in place. Such pressure clips can be opened manually in order to disconnect blanket axle 92 from retractable arm 27 .
[0051] Retractable-arm brace 29 is connected to frame support 20 e . Provided on retractable-arm brace 29 is a connection point for spring-loaded retractable-arm lock 31 . Retractable-arm lock 31 is preferably a spring-loaded pin which passes through retractable arm 27 and retractable-arm brace 29 to prevent retractable arm 27 from pivoting about retractable-arm pivot 28 . In order to load a roll of erosion blanket 90 , retractable-arm lock 31 is removed from retractable arm 27 and retractable arm 27 is pivoted about retractable-arm pivot 28 so that the lower end of retractable arm 27 is moved toward frame support 20 e . Retractable arm 27 may be suspended in the blanket loading position by connection to pin hole 32 . Erosion blanket 90 is positioned within the opening created by slipping blanket 90 over blanket axle 92 after retractable arm is pivoted out of the way. Then retractable arm 27 is pivoted back to its original locked position and proximal end 92 b of blanket axle 92 is connected to the lower end of retractable arm 27 . Retractable-arm lock 31 is reconnected to retractable arm 27 and retractable-arm brace 29 to lock blanket 90 in position.
[0052] Compression wheels 70 are connected with respect to the lower end of interior frame supports 20 b , 20 c , 20 d . Such connection is preferably through a spring-mounted piston-like arrangement (shown in FIG. 6) for reasons discussed below. Compression wheels 70 are preferably composite cement rollers epoxied with a textured rubber coating and have lengths of 9″ and diameters of 6″. The composite cement is preferably formed from poured concrete and fiberglass fibers which add strength and durability. The rubber surface is preferably ½″ thick. Wheels 70 preferably weigh about 18.5 lbs each. Compression wheels 70 rotate about compression-wheel axles 71 which pass through forked wheel brackets 72 . Compression-wheel axles are preferably of the ball bearing type.
[0053] As shown in FIG. 7, wheel brackets 72 upwardly terminate in hollow bracket shafts 73 which house springs 74 with lengths of 12″ and diameters of ¾″. Bracket shafts 73 are preferably 1⅜″ by 1⅜″ and are received within the interior frame supports 20 b , 20 c , 20 d . Springs 74 extend out of bracket shafts 73 and engage spring stops 21 which are positioned within interior frame supports 20 b , 20 c , 20 d . Thus compression wheels 70 are urged downward from frame supports 20 b , 20 c , 20 d . This configuration allows wheels 70 to support the weight of the device (approximately 1200 lbs.) while absorbing the vibrations encountered when the device is propelled along a pathway on the ground.
[0054] Mounted to the rear side 72 a of each wheel bracket 72 is a gun 60 . The mounting arrangement is preferably designed to allow for gun 60 to be easily removed from and reattached to wheel brackets 72 . Preferably, each gun 60 is connected to each wheel bracket 72 with self-locking nuts. Each gun 60 has an outer hard metal casing with an airtight finish to prevent dust and water from entering the internal motor.
[0055] Each gun 60 is powered by air compressor 40 which is secured to the top of center frame support 20 c (as seen in FIG. 5). Air compressor 40 is preferably comprised of a 2½ gallon steel tank with various air valves. The tank is pressurized by a compressor motor which is powered by a power take-off 45 from the tractor or other towing vehicle. Device 10 preferably includes a female power take-off fitting for connection to a male power take-off at the rear of the towing vehicle. Air-compressor hoses 41 extend from air compressor 40 and lead to guns 60 . Air compressor 40 has a preferred operating pressure of between about 75 and 115 psi. Such pressure is sufficient to force staples or stakes 61 through blanket 90 and into the ground.
[0056] Before use, the air compressor is turned on and each pneumatic gun 60 is calibrated for a predetermined tractor speed and the number of staples or stakes to be installed per yard.
[0057] Cartridge 62 is connected to gun 60 to provide staples or stakes 61 for pinning blanket 90 to the ground. For use with stakes, each cartridge 62 holds approximately 170 stakes. By firing a stake every 3 feet, 170 stakes are used for 510 feet of erosion blanket. Therefore, three cartridges 62 are loaded into each gun 60 to provide enough stakes for a 500 yard roll of erosion blanket. Stakes 60 are preferably biodegradable and breakdown in the environment after about 6 months. Each stake 60 is preferably 6 inches long.
[0058] Guide chamber 63 (best shown in FIG. 5) allows stakes 61 to be forwarded to gun 60 and set into position for “hammer,” one at a time, from the roll of stakes in cylindrical cartridge 62 . Hammer mechanism 64 shoots stakes 61 into the ground one at a time when triggered by trigger wire 65 .
[0059] Trigger wire 65 extends from hammer mechanism 64 to a position 2.87″ from each wheel axle 71 . Trigger wire 65 monitors each wheel 70 and triggers each hammer mechanism 64 every two revolutions of each wheel 70 (approximately every 3′ the device travels). The middle trigger wire (connected to middle gun 60 c ) is preferably offset from the outer trigger wires (connected to outer guns 60 b , 60 d ) by 1½′ so that staples or stakes 60 are fired into blanket 90 in a pattern which more strongly secures blanket 90 to the ground.
[0060] Blanket guide roller 80 (FIGS. 3 and 4) is connected with respect to axle arm 26 and exterior frame support 20 e . Guide roller 80 rotates about roller axle 81 which connects to roller bracket 82 and axle arm 26 through greased ball bearing fittings. Guide roller 80 preferably is lightweight steel with a ⅜″ thick steel wall cylinder with a ¼″ thick textured rubber surface covering. Roller axle 81 is preferably a 1″ ball bearing axle. Roller bracket 82 is connected to exterior frame support 20 e . When blanket 90 unwinds, it is directed between guide roller 80 and frame supports 20 b , 20 c , 20 d . Blanket 90 is then directed downward to compression wheels 70 where blanket 90 is positioned on the ground surface.
[0061] Furrow bar 50 is pivotally mounted with respect to exterior frame supports 20 a , 20 e (shown in FIGS. 3 and 4) and supports three furrow blades 55 (shown in FIGS. 1 and 2). Each furrow blade 55 is aligned with a compression wheel 70 and gun 60 . Each furrow blade 55 is preferably formed from A-36 Steel or a chromium based hardened steel. The blades 55 must be durable and replaceable in case of breakage. Each blade 55 is preferably 9″ long and curved forward so that it digs into the ground during the forward motion of device 10 .
[0062] Furrow bar 50 is preferably primarily 1″ by 1″ steel with ends which are ¾″ diameter cylindrical steel to allow for pivoting with respect to device 10 . Furrow bar 50 is pivotally attached to exterior frame supports 20 a , 20 e (shown in FIG. 5). Furrow bar 50 is not attached to wheel bracket 72 . A 1″ by 1″ by 4″ piece of steel is welded at the end of furrow bar 50 to attach to a commercially available hydraulic cylinder 58 with a steel eye bracket. The upper end of hydraulic cylinder 58 is connected to axle arm 26 with another steel eye bracket. Hydraulic hose 59 extends from the upper end of cylinder 58 and leads to a hitch connection point. A hydraulic control lever is positioned near the driver's seat in the tractor (not shown) so that the driver may activate the cylinder to raise or lower furrow bar 50 and, thus, furrow blades 55 .
[0063] The total weight of the preferred device (including a 500 yard blanket roll) is approximately 1250 lbs. The total weight of the alternative device which uses 90 degree angle steel is approximately 975 lbs.
[0064] In order to begin use of the erosion blanket installation device, an erosion blanket roll must first be loaded into the device. The end of the blanket roll is threaded over the guide roller and under the compression wheels and is then manually stapled or staked into place by hand. This is done to ensure that the end of the roll stays in place and the roll unwinds properly as the device is towed forward. The tractor driver will lower the furrow blades via the hydraulic control lever mounted near the driver's seat. The blades cause the device to rise about 6″ from the ground. Then the driver will engage the power take-off which powers the air compressor.
[0065] For use with stakes, a furrow blade preferably readies the ground for penetration. Once the tractor begins towing the device at the predetermined speed, the furrow blades will immediately dig into the ground to a depth of 5″ to 6″ and the device will be lowered onto the spring-loaded compression wheels. Because blanket 90 is positioned between wheels 70 and the ground, blanket 90 will unroll. At the same time, three guns 60 will fire stakes 62 through blanket 90 into the furrows in the ground. Stakes 62 lock in the ground and anchor the blanket in place until turf or vegetation grows through blanket 90 and naturally stabilizes the ground.
[0066] When the roll expires, another blanket roll is installed in the device and the cartridges are refilled. The end of the new roll is again manually stapled or staked and the process is repeated.
[0067] Use of the novel device with a tractor connected via a three-point hitch allows an erosion blanket to be installed and stapled or staked in place with 3 rows of staples or stakes. A 500 yard erosion blanket roll can be installed and sufficient staples or stakes can be reloaded in the device in 15 minutes. Such a device allows two people to install a 500 yard roll in the device. For use with stakes, the device preferably creates 3 rows of 6″ deep furrows into which the 6″ biodegradable stakes are driven by a pneumatic gun. Such furrows are created by 9″ curved blades connected to the bottom of the device. Furrows are not necessary for use with staples.
[0068] Thus, it should be apparent that there has been provided, in accordance with the present invention, a novel device for efficiently and effectively installing erosion blankets on ground surfaces that fully satisfies the objectives and advantages set forth above.
[0069] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
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An improved device and method for mechanically installing erosion blankets on a ground surface. The device holds a roll of an erosion blanket and provides that the blanket unwind when the device is propelled forward. Upon unwinding, the device positions the blanket on the ground and pins the blanket in position using staples, stakes or the like. Preferred embodiments of the device provide for furrowing of the ground before installation of the blanket.
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FIELD OF THE INVENTION
[0001] The present disclosure relates to aircraft propulsion systems, and more specifically, to integrated engine exhaust systems and methods for providing reduced drag and/or thermal stress reduction for an aircraft.
BACKGROUND OF THE INVENTION
[0002] Many types of aircraft, including transport aircraft, are equipped with wing-mounted turbofan engines. In this configuration, the exhaust flow from the wing-mounted engines may impinge upon the wing surfaces. Some conventional aircraft may utilize the exhaust flow to augment wing lift during low-speed operations, enabling short field take off and landing capabilities for such aircraft.
[0003] Although desirable results have been achieved using existing wing-mounted turbofan engines, there is room for improvement. For example, reduced drag will enable aircraft operation from even shorter airfields. In addition, due to the impingement of the high temperature exhaust on the flap and wing surfaces of some aircraft configurations, these surfaces must be designed to withstand extreme thermal loads. Titanium flaps may be required rather than aluminum flaps to withstand the harsh thermal environment. Generally, these design considerations add weight to the aircraft and increase manufacturing costs. Novel systems that mitigate the weight and cost penalties associated with wing-mounted engines would therefore have utility.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to integrated engine exhaust systems and methods for providing lower drag and thermal stress reduction for an aircraft. Embodiments of the present invention may advantageously provide reduced take off and landing distances, reduced aircraft weight, reduced fuel consumption, reduced production and maintenance costs, and reduced noise levels in comparison with the prior art.
[0005] In one embodiment, a propulsion system for an aircraft includes an engine installation configured to be mounted on a wing assembly of the aircraft. The engine installation includes an engine, and an exhaust system operatively coupled to the engine. The exhaust system includes at least one nozzle configured to exhaust an exhaust flow from the engine. The nozzle includes a variable portion configured to vary an exit aperture of the nozzle from a first shape to a second shape to change the flowfield shape of at least a portion of the exhaust flowfield proximate the wing assembly to reduce at least one of drag and thermal loading on the wing assembly. In a further embodiment, the exhaust system includes an inner nozzle that exhausts a core exhaust flow, and an outer nozzle that exhausts a secondary exhaust flow, the outer nozzle having the variable portion configured to vary the exit aperture of the outer nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Embodiments of the present invention are described in detail below with reference to the following drawings.
[0007] FIG. 1 is a partial isometric view of an aircraft in accordance with an embodiment of the invention;
[0008] FIG. 2 is an enlarged isometric view of an exhaust system of the aircraft of FIG. 1 operating in a conventional mode of operation;
[0009] FIG. 3 is an enlarged isometric view of an exhaust system of the aircraft of FIG. 1 operating in a representative non-conventional mode of operation in accordance with an embodiment of the invention;
[0010] FIG. 4 is an isometric view of the exhaust system operating in the conventional mode of operation as shown in FIG. 2 including a cutaway view of an exhaust flowfield;
[0011] FIG. 5 is an isometric view of the exhaust system operating in the non-conventional mode of operation as shown in FIG. 3 including a cutaway view of the exhaust flowfield;
[0012] FIG. 6 is an isometric view of the exhaust flowfield of FIG. 4 and an impingement pattern on a wing assembly for the exhaust system operating in the conventional mode of operation;
[0013] FIG. 7 is an isometric view of the exhaust flowfield of FIG. 5 and an impingement pattern on the wing assembly for the exhaust system operating in the representative non-conventional mode of operation;
[0014] FIG. 8 shows the effect of engine exhaust on span load distribution in accordance with an embodiment of the invention;
[0015] FIG. 9 is a lower elevational view of a wing temperature distribution of the exhaust system operating in the conventional mode of operation as shown in FIG. 2 ;
[0016] FIG. 10 is a lower elevational view of a wing temperature distribution of the exhaust system operating in the non-conventional mode of operation as shown in FIG. 3 ; and
[0017] FIGS. 11 and 12 are isometric views of aircraft exhaust systems in accordance with alternate embodiments of the invention.
DETAILED DESCRIPTION
[0018] The present invention relates to integrated engine exhaust systems and methods for providing lower drag and thermal stress reduction for an aircraft. Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 1-12 to provide a thorough understanding of such embodiments. The present invention, however, may have additional embodiments, or may be practiced without one or more of the details described below.
[0019] Integrated engine exhaust systems and methods in accordance with the invention may reduce the aerodynamic drag, weight, and production and maintenance costs of aircraft having coupled propulsion and high-lift (or powered-lift) systems. In general, embodiments of the present invention use a variable shape fan exhaust nozzle to control exhaust flow field shape during operation. The resulting exhaust flowfield (including one or both of an outer flowfield and an inner flowfield) affects the wing spanload, resulting in less induced drag and reduced thermal stresses on the wing assembly in comparison with prior art systems.
[0020] FIG. 1 is a partial isometric view of an aircraft 100 in accordance with an embodiment of the invention. The aircraft 100 includes a fuselage 102 and a wing assembly 104 that includes a main wing portion 106 . A slat portion 108 extends along a leading edge of the main wing portion 106 , and a flap portion 110 extends along a trailing edge of the main wing portion 106 .
[0021] The aircraft 100 further includes an engine installation 120 coupled to the wing assembly 104 by a pylon 112 . The engine installation 120 includes an engine nacelle 122 , and an exhaust system 124 situated at a downstream (or aft) end portion of the engine installation 120 . Any suitable turbofan engines may be employed, including, for example, those engines manufactured by General Electric of Fairfield, Conn., Pratt & Whitney of East Hartford, Conn., and Rolls-Royce of London, U.K.
[0022] FIG. 2 is an enlarged isometric view of the exhaust system 124 of FIG. 1 . The exhaust system 124 includes an elongated inner nozzle 126 configured to exhaust a core exhaust flow from a combustor portion of the engine installation 120 , and a relatively-shorter outer nozzle 128 disposed about the inner nozzle 126 and located proximate a trailing edge portion of the engine nacelle 122 . The outer nozzle 128 is configured to exhaust a relatively-cooler fan flow passing through the engine installation 120 . This type of nozzle is referred to as a separate flow nozzle. A mixed flow nozzle (not shown) is configured opposite, the inner core nozzle is short, and the fan nozzle is long. The core nozzle is buried inside of the outer fan nozzle. The embodiment of this invention would also be applicable to a mixed flow nozzle.
[0023] The outer nozzle 128 is further configured to be controllably adjusted to provide changes in the shape of its exit aperture. For example, as shown in FIG. 2 , in a conventional mode of operation 130 , the outer nozzle 128 has a circular-shaped exit aperture. In cooperation with the outer surface of the inner nozzle 126 , the outer nozzle 128 forms an annular-shaped nozzle exit 132 for exhausting the fan flow in the conventional mode of operation 130 .
[0024] In accordance with embodiments of the present invention, the shape of the exit aperture of the outer nozzle 128 may be adjusted to a non-circular shape. FIG. 3 shows the exhaust system 120 in a non-conventional mode of operation 134 . In this embodiment, the exit aperture of the outer nozzle 128 includes a flattened upper portion 136 , while the remainder of the exit aperture is modified such that the exit area is the same as the exit area of the conventional nozzle. Keeping the area of the exit aperture of the non-conventional nozzle the same as that of the conventional engine ensures similar engine thrust levels and maintain engine cycle compatability. Thus, the inner and outer nozzles 126 , 128 cooperatively form a non-annular nozzle exit 138 for exhausting the fan flow in the non-conventional mode of operation 134 . In one particular embodiment, for example, in the non-conventional mode of operation 134 , a separation distance between the inner nozzle 126 and the flattened upper portion 136 of the outer nozzle 128 is reduced to one-half (50%) of the corresponding separation distance between the inner and outer nozzles 126 , 128 in the conventional mode of operation 130 .
[0025] The outer nozzle 128 may employ a variety of mechanisms to achieve the desired variation in shape of the exit aperture. For example, in one embodiment, the outer nozzle 128 includes a plurality of flaps which collectively form the exit aperture. The flaps may be controllably adjusted by a set of actuators that enable the exit aperture of the outer nozzle 128 to be adjusted to a non-circular shape. The plurality of flaps may be controllably actuated by any known means, including hydraulic, electric, or shape-memory-alloy (SMA) actuation. More specifically, the plurality of flaps and associated actuation systems of the outer nozzle 128 may include, for example, any of those systems and methods generally disclosed in U.S. Pat. No. 7,004,047 B2 issued to Rey et al., U.S. Pat. No. 5,893,518 issued to Bruchez et al., U.S. Pat. No. 5,245,823 issued to Barcza, U.S. Pat. No. 4,994,660 issued to Hauer, U.S. Pat. No. 4,245,787 issued to Freid, U.S. Pat. No. 4,000,610 issued to Nash et al., and in published U.S. patent application Ser. No. 11/014,232 by Webster, and U.S. patent application Ser. No. 11/049,920 by Rey et al.
[0026] FIG. 4 is an isometric view of the exhaust system 124 operating in the conventional mode of operation 130 ( FIG. 2 ), including a cutaway view of an exhaust flowfield 400 . In the conventional mode of operation 130 , the exit aperture of the outer nozzle 128 is circular, and the exhaust flowfield 400 is generally axisymmetric. An annularly-shaped fan flow 402 emanates from the outer nozzle 128 and is disposed about a central, approximately axisymmetric core flow 404 that emanates from the inner nozzle 126 .
[0027] For comparison, FIG. 5 is an isometric view of the exhaust system 124 operating in the non-conventional mode of operation 134 ( FIG. 3 ), including a cutaway view of an exhaust flowfield 500 . In the non-conventional mode of operation 134 , the exit aperture of the outer nozzle 128 is non-circular and includes the flattened upper portion 136 . Consequently, the exhaust flowfield 500 is non-axisymmetric with a non-annular fan flow 502 emanating from the outer nozzle 128 and disposed about an approximately axisymmetric core flow 504 emanating from the inner nozzle 126 . As shown in FIG. 5 , an upper portion 506 of the non-conventional exhaust flowfield 500 is varied in shape and less concentrated than a comparable upper portion 406 of the axisymmetric, conventional exhaust flowfield 400 shown in FIG. 4 .
[0028] FIG. 6 is an isometric view of the exhaust flowfield (shown by Mach number) 400 of FIG. 4 , and a pressure distribution 600 on the wing assembly 104 , for the exhaust system 124 operating in the conventional mode of operation 130 ( FIG. 2 ). Similarly, FIG. 7 is an isometric view of the exhaust flowfield (shown by Mach number) 500 ( FIG. 5 ) and pressure distribution 700 for the exhaust system 124 operating in the non-conventional mode of operation 134 ( FIG. 3 ). Comparison of the pressure distributions 600 , 700 shown in FIGS. 6 and 7 shows that in the non-conventional mode of operation 134 , the exhaust flowfield 500 results in a more uniform pressure distribution on the wing flap 110 of the wing assembly 104 in comparison with the conventional exhaust flowfield 400 . More specifically, in this embodiment, the pressure distribution 600 for the conventional mode of operation 130 ( FIG. 6 ) is marked by a relatively concentrated pressure pattern having a central, relatively-higher peak pressure value (shown as a central dark region). On the other hand, the pressure distribution 700 for the non-conventional mode of operation 134 exhibits a relatively less-concentrated pressure pattern with a relatively-lower peak pressure value (shown as a central, relatively-lighter region). Consequently, there is a smoother spanload distribution and a reduction in induced drag on the wing assembly 104 in the non-conventional mode of operation 134 .
[0029] FIG. 8 shows the effect of variation of the shape of the engine exhaust on span load distribution in accordance with an embodiment of the invention. More specifically, FIG. 8 shows a graph 1200 of sectional lift versus spanwise position along the wing. A first lift distribution 1202 shows predicted drag data (in terms of the Oswald efficiency factor “e”) for the exhaust system 124 operating in the conventional mode of operation 130 ( FIG. 2 ), and a second load distribution 1204 shows predicted drag data for the exhaust system 124 operating in the non-conventional mode of operation 134 ( FIG. 3 ). As shown in FIG. 8 , the non-conventional mode of operation 134 provides a more favorable load distribution than the conventional mode of operation 130 due to its relatively less-concentrated pressure pattern with a relatively-lower peak pressure value. For a twin engine aircraft, the predicted aerodynamic efficiency due to the variable fan exhaust increases by about 10% relative to the conventional axisymmetric configuration. This efficiency is proportionately related to the induced component of the drag. Thus, a significant reduction in total drag may be realized since the induced drag is the largest component of airplane drag, including during high lift conditions. Proportionately larger gains in aerodynamic efficiency may be realized from a four-engine aircraft. Reduced total drag translates to reduced required engine power, and hence, it leads to shorter take off distance.
[0030] FIGS. 9 and 10 show wing temperature distributions 800 , 900 for the exhaust system 124 operating in conventional and non-conventional modes of operation 130 , 134 , respectively. Comparison of the wing temperature distributions 800 , 900 shown in FIGS. 9 and 10 shows that in the non-conventional mode of operation 134 , the exhaust flowfield 500 results in lower temperatures on the wing flap 110 in comparison with the conventional exhaust flowfield 400 . More specifically, in this embodiment, the temperature distribution 800 for the conventional mode of operation 130 ( FIG. 9 ) exhibits a relatively concentrated temperature pattern having a central, relatively-higher peak temperature value (shown as a central dark region). On the other hand, the temperature distribution 900 for the non-conventional mode of operation 134 exhibits a relatively less-concentrated temperature pattern with a relatively-lower peak temperature value (shown as a central, relatively-lighter region). Consequently, there is less thermal load on the wing assembly 104 in the non-conventional mode of operation 134 .
[0031] Embodiments of the invention may provide significant advantages over the prior art. By exploiting the interaction of the non-circular fan exhaust with the surrounding flow passing over the engine nacelle and with the engine core exhaust, embodiments of the invention alter the turbulent mixing of the exhaust flow such that the nozzle flowfield interaction with the wing and flap surfaces results in smoother pressure increment and reduced temperature in comparison with the conventional flowfield impingement. Thus, embodiments of the invention may be used to tune wingspan load distributions, reduce induced drag, enhance jet mixing, and accelerate temperature decay.
[0032] The economical and operational impacts of the drag reduction afforded by the present invention may be substantial, and may allow the use of smaller engines or shorter runways. Reduced engine size may, in turn, lead to reduced aircraft weight, reduced fuel consumption, reduced maintenance costs and reduced noise levels. Similarly, the reduction in structural temperature limits may allow the use of aluminum flaps rather than titanium flaps, which leads to reduced production costs and reduced aircraft weight.
[0033] It will be appreciated that a variety of alternate embodiments of the invention may be conceived, and that the invention is not limited to the particular embodiments described above. In the following discussion of alternate embodiments, components which remain unchanged from the previously described embodiments are designated with like reference numerals. For the sake of brevity, only substantial structural and operational differences from the previously-discussed embodiments will be described.
[0034] FIG. 11 shows an isometric view of an aircraft exhaust system 1024 in accordance with an alternate embodiment of the invention. In this embodiment, in a non-conventional operating mode 1034 , an outer nozzle 1028 of the exhaust system 1024 includes both a flattened upper portion 1036 and a flattened lower portion 1038 . The resulting exit aperture of the outer nozzle 1028 is a non-circular shape disposed about the axisymmetric inner nozzle 126 . Consequently, the resulting non-conventional exhaust flowfield (not shown) is varied in shape proximate to the wing assembly, and less concentrated (e.g. having relatively-lower peak pressure and temperature values at the surfaces of the wing assembly 104 ) than the comparable upper portion 406 of the axisymmetric, conventional exhaust flowfield 400 shown in FIG. 4 .
[0035] Similarly, FIG. 12 shows an isometric view of an aircraft exhaust system 1124 in accordance with another alternate embodiment of the invention. In a non-conventional operating mode 1134 , an outer nozzle 1128 of the exhaust system 1124 is controllably positioned into an approximately elliptical shape with a vertical minor axis. Again, the resulting non-conventional exhaust flowfield (not shown) is varied in shape and less concentrated (e.g. having relatively-lower peak pressure and temperature values at the surfaces of the wing assembly 104 ) than the comparable upper portion 406 of the axisymmetric, conventional exhaust flowfield 400 shown in FIG. 4 . Thus, the advantages of reduced drag and reduced thermal loads, as described more fully above, may be achieved using a variety of alternate exhaust system embodiments.
[0036] While preferred and alternate embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
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Integrated engine exhaust systems and methods for reducing drag and thermal loads are disclosed. In one embodiment, a propulsion system includes an engine installation configured to be mounted on a wing assembly of an aircraft. The engine installation includes an engine, and an exhaust system operatively coupled to the engine. The exhaust system includes at least one nozzle configured to exhaust an exhaust flow from the engine. The nozzle includes a variable portion configured to vary an exit aperture of the nozzle from a first shape to a second shape to change a flowfield shape of at least a portion of the nozzle flowfield proximate the wing assembly, thereby reducing at least one of drag and thermal loading on the wing assembly. In a further embodiment, the exhaust system includes an inner nozzle that exhausts a core exhaust flow, and an outer nozzle that exhausts a secondary exhaust flow, the outer nozzle having the variable portion configured to vary the exit aperture of the outer nozzle.
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BACKGROUND OF INVENTION
[0001] The present disclosure relates generally to a method for predicting headlamp reflector temperature and in particular, to a method for predicting the maximum temperature on automotive headlamp reflectors.
[0002] A variety of thermoplastic materials are available in the marketplace for use in automotive lighting systems. A basic criterion for material selection in lighting systems is heat resistance and in general, the higher the heat resistance, the higher the cost of the thermoplastic. Heat resistance is the maximum temperature the components can sustain indefinitely without degradation of function. If the component is a headlamp reflector, the maximum temperature of the reflector can be affected by design considerations such as reflector diameter, bulb diameter, bulb depth, lens depth, spacer depth and reflector depth. Predicting the maximum temperature for use in the selection of materials in lighting applications, such as the headlamp reflector material, can involve detailed fluid dynamics and heat transfer analysis for a particular configuration. The process of performing detailed fluid analysis and heat transfer analysis for each configuration in order to determine the maximum temperature on the reflector (hot spot) can be cumbersome and time consuming. Estimating the maximum temperature accurately is important in order to avoid the expense and time associated with re-creating thermoplastic molding tools and processes.
SUMMARY OF INVENTION
[0003] One aspect of the invention is a method for predicting headlamp reflector temperature. The method comprises receiving a headlamp type and transmitting a request for an input parameter value responsive to the headlamp type. The input parameter value is received in response to transmitting the request. A transfer function is executed in response to the input parameter and the headlamp type and the execution results in a predicted maximum reflector temperature. The predicted maximum reflector temperature is then output.
[0004] Another aspect of the invention is a method of creating a transfer function for calculating a predicted maximum reflector temperature. The method comprises receiving a headlamp application group including a member. The member is classified based on geometric primitives and the classification results in a headlamp type. Key material and geometric parameters that affect a predicted maximum reflector temperature for the headlamp type are identified. A simple parametric geometric model is created responsive to the key material and geometric parameters. A design space is set for the key material and geometric parameters. The method further comprises creating a set of design of experiments in response to the design space and the model. The set of design of experiments is carried out and results in output. A transfer function is derived to calculate the predicted maximum reflector temperature for the headlamp type responsive to the output. The predicted maximum reflector temperature varies in response to an input parameter.
[0005] Another aspect of the invention is a system for predicting headlamp reflector temperature. The system comprises a network, a user system in communication with the network, a storage device and a host system. The host system is in communication with the network and the storage device and the host system includes application software to implement a method comprising receiving a headlamp type from the user system via the network. The method further comprises transmitting a request across the network for an input parameter value responsive to the headlamp type. The input parameter value is received from the user system via the network in response to transmitting the request. A transfer function stored on the storage device is executed in response to the input parameter and the headlamp type and the execution results in a predicted maximum reflector temperature. The predicted maximum reflector temperature is then output to the user system via the network.
[0006] A further aspect of the invention is a computer program product for predicting headlamp reflector temperature. The computer program product comprises a storage medium readable by a processing circuit and storing instructions for execution by the processing circuit for performing a method. The method comprises receiving a headlamp type and transmitting a request for an input parameter value responsive to the headlamp type. The input parameter value is received in response to transmitting the request. A transfer function is executed in response to the input parameter and the headlamp type and the execution results in a predicted maximum reflector temperature. The predicted maximum reflector temperature is then output.
[0007] Further aspects of the invention are disclosed herein. The above discussed and other features and advantages of the invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0008] Referring to the exemplary drawings wherein like elements are numbered alike in the several FIGURES:
[0009] [0009]FIG. 1 is a block diagram of an exemplary process to create a calculator for predicting headlamp reflector temperature;
[0010] [0010]FIG. 2 is an example of the geometry that could be associated with a fog lamp;
[0011] [0011]FIG. 3 is an example of a simplified parametric model for the fog lamp depicted in FIG. 2;
[0012] [0012]FIG. 4 is a block diagram of an exemplary process for utilizing a calculator to predict headlamp reflector temperature; and
[0013] [0013]FIG. 5 is a block diagram of an exemplary system for predicting headlamp reflector temperature.
DETAILED DESCRIPTION
[0014] An embodiment of the present invention includes several complimentary components that can be utilized to rapidly provide a prediction of hot-spot temperatures for headlamps, bypassing the need for many man days of finite element modeling and many hours of computer processing unit time. Various lamps are characterized into general classes according to their basic shape. For example, fog lamps can be characterized into teardrop, round, square and oval. Each class is then parameterized by assigning suitable geometric primitives that both approximate the basic shape and which can be varied more or less independently. An experimental design is created for each class that outlines what range of parameters and bulb wattages should be fully explored to adequately describe each class. Next, the experiments specified in the experimental design are carried out by calculating, via three-dimensional fluid dynamics, the hot-spot temperature of each parameterized design/wattage combination indicated by the design experiment. The results of the experiments are fed back through a statistical experimental analysis, and the significant parameters are culled and the transfer functions that relate the hot-spot temperature to those significant parameters are derived. A user can access the hot-spot calculator through a graphical user interface that is customized to accept the headlamp class and the significant parameters. The class and parameters are fed as inputs to the previously derived transfer functions and the resulting output is a predicted hot-spot temperature, or maximum temperature. The calculator can be deployed in a variety of manners including: web deployed, personal digital assistant deployed, and personal computer deployed.
[0015] [0015]FIG. 1 is a block diagram of an exemplary process to create a calculator for predicting headlamp reflector temperature. At step 102 , the headlamps within an application group are classified based on geometric primitives, resulting in headlamp types. For example, in the case of automotive lighting applications, there are several application groups such as fog lamps and motorcycle lamps that can be further broken down and classified based on their geometric primitives into headlamp types (e.g., round, square, oval). A variety of thermoplastic materials are available from resin manufacturers for use in automotive lamps. A key criteria for selecting a particular thermoplastic material from the group of available thermoplastic materials includes the heat resistance required by the automotive lamp and the heat resistance provided by the particular thermoplastic material. The effect of varying geometric and material parameters on the required heat resistance (also referred to as the hot-spot temperature) in automotive lamps can be categorized based on geometric primitives. Geometric primitives dictate the shape of the automotive lamp (e.g., round, teardrop, square).
[0016] Next, at step 104 , the key material and geometric parameters affecting the temperature on the reflector surface are identified for a particular class of headlamps within an application group. For example, a lamp in the fog lamp application group with a round classification may include geometric parameters such as reflector diameter, reflector depth and wattage of the bulb. Material parameters may include thermal conductivity of material and emissivity of reflective coating. At step 106 , a simple parametric geometric model is created utilizing the parameters. This simple parametric geometric model covers almost all headlamps in the classification group by varying the key parameters. See FIG. 3, below, for an example of a parametric model for a round fog lamp. The intended design space, or parameter range, is set at step 108 . At step 110 , a design of experiments (DOE) is created for the parametric geometric model. The DOE includes a number of experiments based on possible combinations of geometric, material and process parameters. The DOE can be created using an automated tool (e.g., Design for Six Sigma from Minitab, Inc., Regression, Response Surface Methodology from Minitab, Inc.). Inputs to the DOE tool include the simple parametric geometric model, the intended design space and the parameters. The output from the DOE tool includes a set of experiments that will cover the design space and that should be performed in order to determine an associated transfer function that correlates the parameters to the temperature on the reflector surface.
[0017] At step 112 , the set of experiments described by the output of the DOE tool is performed. In an exemplary embodiment, the experiments are carried out utilizing heat transfer and flow analysis simulation tools (i.e., computational fluid dynamics) to determine the temperature distribution on the reflector surface. Thermal prediction software (e.g., FLUENT from Fluent, Inc.) is utilized to conduct these experiments in a virtual environment. When all of the experiments have been completed, or simulated, a transfer function is derived at step 114 using the results of the experiments. The resulting transfer function relates input parameters (all or a subset of the key parameters in the simple parametric geometric model) to the temperature on the reflector surface. The transfer function is created using a separate regression analysis tool (e.g., Minitab from Minitab, Inc.). Alternatively, the transfer function is created using the DOE tool. The transfer function relates the response variable (the maximum temperature) to the key parameters considered for the DOE. The derived transfer function is then utilized for calculating the maximum temperature on the reflector surface. Geometric and material parameter values for specific customer applications within the design space are input to the transfer function via the calculator. A different transfer function is derived for each class of headlamp, or for each parametric geometric model created in step 106 . In an exemplary embodiment, the transfer function is stored in a database of transfer functions that are indexed by headlamp classification within an application group. The processing described in FIG. 1 is repeated for each headlamp classification defined in step 102 and for headlamps in the other application groups based on implementation requirements.
[0018] [0018]FIG. 2 is an example of the geometry that is associated with a fog lamp, one of the application groups for automotive headlamps. The headlamp includes a bulb, a reflector, a lens, a decorative bezel and a housing unit. As shown in FIG. 2, the fog lamp is four and a half inches high, four inches wide, and two and seven sixteenths inches deep. Additionally, the fog lamp depicted in FIG. 2 is classified as a round fog lamp. FIG. 3 is a simplified parametric model associated with the fog lamp depicted in FIG. 2. The parameters depicted in FIG. 3 can be utilized to create the hot-spot calculator. In addition, several of the parameters depicted in FIG. 3 may be input to the hot-spot calculator in order to predict a maximum reflector temperature. The basic geometric primitives for this parametric model include: circular arc 314 , parabolic curve 316 (note that the reflector is generally, but not necessarily parabolic, and that other shapes, for example a polyelipsoid can also be employed in an alternate embodiment) and right angle cylinder 320 . The fog lamp application group can be broken down into classes based on these basic geometric primitives and can result in classes such as teardrop shaped, round and square depending on the values of the geometric primitives. Also shown in FIG. 3 are parameters that may affect the temperature of the reflector in a fog lamp including reflector diameter 302 , lens depth 304 , spacer depth 306 , reflector depth 308 , bulb diameter 310 , bulb depth 312 . In addition, the wattage of the bulb 318 will also have an effect on the temperature of the reflector. These are the variables that will be tested through the DOE process and may be reflected in the resulting transfer function depending on the results of the DOE. For other application groups (e.g., high beam lamps) other geometric primitives and parameters may be utilized to describe the application group and the associated classes.
[0019] [0019]FIG. 4 is a block diagram of an exemplary process for utilizing a calculator to predict headlamp reflector temperature. The process depicted in FIG. 4 includes a user accessing the hot-spot calculator from a user system or from a hand held device. At step 402 , the user selects a type of headlamp which includes selecting an application group (e.g., fog lamps, motorcycle lamps) and within the application group a particular classification (e.g., round, square, teardrop shape). At step 404 , the user enters input parameter data values in response to a prompt from the calculator. Parameter values include values for the key parameters that were determined to have an impact on the reflector temperature during the DOE process. Next, step 406 is performed and the hot-spot calculator calculates the maximum heat on the reflector using the transfer function developed as described in reference to FIG. 1. Based on the results of the transfer function, the calculator, at step 408 , selects, or recommends, a thermoplastic material with an adequate heat resistance rating. The calculator can be vendor specific and recommend a thermoplastic material that the vendor produces or it could be vendor independent and include thermoplastic materials from several vendors. For example, the result of step 406 may be that the maximum heat on the reflector is one hundred and ninety degrees Celsius. Then, at step 408 , the calculator would suggest a thermoplastic material with a maximum heat capacity that exceeds one hundred and ninety degrees Celsius. At step 410 , the calculator displays the suggested material and results of the transfer function. The user can perform this process, from step 402 through 410 , any number of times and can use this data as input to the design process.
[0020] [0020]FIG. 5 is a block diagram of an exemplary system for predicting headlamp reflector temperature. The system of FIG. 5 depicts how a user (e.g., a designer, a field engineer, an external customer) can make a request, through a user system 502 (e.g., a personal computer, a host attached terminal) or a hand held device 510 (e.g., a personal digital assistant) to an application program on the host system 504 to access the calculator for predicting headlamp reflector temperature. The users can be physically located in one or more geographic locations and can be directly connected to the host system 504 or coupled to the host system via the network 506 . In an exemplary embodiment, the host system 504 executes programs that provide access to the calculator for predicting headlamp reflector temperature and data relating to the temperature prediction (e.g., transfer functions) are stored on the storage device 508 attached to the host system. Each user system 502 and hand held device 510 may be implemented using a general-purpose computer executing a computer program for carrying out the processes described herein. If the user system 502 or hand held device 510 includes a personal computer, the processing described herein may be shared by a user system 502 or hand held device 510 and the host system 504 by providing an applet to the user system 502 .
[0021] The network 506 may be any type of known network including a local area network (LAN), a wide area network (WAN), an intranet, or a global network (e.g., Internet). A user system 502 or hand held device 510 may be coupled to the host system 504 through multiple networks (e.g., intranet and Internet) so that not all user systems 502 and hand held devices 510 are required to be coupled to the host system 504 through the same network. One or more of the user systems 502 , hand held device 510 and host system 504 may be connected to the network 506 in a wireless fashion and the network 506 may be a wireless network.
[0022] The host system 504 may be implemented using a server operating in response to a computer program stored in a storage medium accessible by the server. The host system 504 may operate as a network server (often referred to as a web server) to communicate with the user systems 502 and hand held device 510 . The host system 504 handles sending and receiving information to and from user systems 502 and hand held devices 510 , and can perform associated tasks. The host system 504 may also include a firewall to prevent unauthorized access to the host system 504 and enforce any limitations on authorized access.
[0023] The host system 504 also operates as an application server. The host system 504 executes one or more application programs to create and implement the calculator for predicting headlamp reflector temperature. In an alternate embodiment, the host system 504 includes application programs to implement the calculator for predicting headlamp reflector temperature and the application programs to create the calculator reside remotely from the host system 504 . Processing may be shared by the user system 502 and/or hand held device 510 and the host system 504 . Alternatively, the user systems 502 and hand held device 510 may include stand-alone software applications for performing all or a portion of the processing described herein. It is understood that separate servers may be used to implement the network server functions and the application server functions.
[0024] The storage device 508 may be implemented using a variety of devices for storing electronic information such as a file transfer protocol (FTP) server. It is understood that the storage device 508 may be implemented using memory contained in the host system 504 or it may be a separate physical device. The storage device 508 contains a variety of information relating to predicting headlamp reflector temperature including a database of transfer functions and associated parameters for various classes of headlamps within application groups. The host system 504 may also operate as a database server and coordinate access to application data including data stored on the storage device 508 . The data stored in the storage device 508 can be physically stored as a single database with access restricted based on user characteristics or it can be physically stored in a variety of databases including portions of the database on the user systems 502 , hand held device 510 and host system 504 .
[0025] An embodiment of the present invention can be utilized for determining the maximum temperature of a component in a variety of lighting applications and is not limited to automotive lighting nor to reflector components of lamps. Types of lighting applications that may utilize an embodiment of the present invention include, but are not limited to: fog lamps, car head lights, motorcycle lights, projector lamps, industrial lighting and commercial lighting. In addition, an embodiment of the present invention can be expanded to other design spaces and is not limited to lamps. For example, embodiments of the present invention may be utilized: to perform thermal evaluation of electrical enclosures, for structural evaluation of energy absorbing applications, for evaluation of a simplified part manufacturing process, and to perform a quick evaluation of the desired functionality of an application or product with fair accuracy before selecting an application or product from a range available in the market.
[0026] The methodology for developing the calculator is based on generating transfer functions that are derived from three-dimensional thermal analysis of generic parametric models representing configurations currently utilized in lighting design. The simulation tools and statistical tools used for the analysis that are utilized to build the hot-spot calculator are commercially available. Design of experiment (DOEs) techniques are utilized in order to derive the transfer functions. The use of the resulting hot-spot calculator can reduce the time required for the material selection process, which in turn can reduce product design cycle time. Design trade-off studies can be carried out for various lighting system shapes and parameters by utilizing the hot-spot calculator.
[0027] An embodiment of the present invention provides for a method to estimate the temperature of headlamp reflectors that is completely based on transfer functions. This can result in a quick estimate that can be utilized at the conceptual level of design and can allow a designer to obtain several estimates and use the results in creating the design of the headlamp. An embodiment of the present invention is web enabled and can be utilized by field engineers, or authorized customers, to assist customers in making immediate material selection decisions for specific applications. Also, the ability to estimate the maximum temperature of a headlamp reflector can result in choosing the most economic thermoplastic material that meets the design requirements. This can also result in eliminating costly rework to thermoplastic molding tools or processes.
[0028] As described above, the embodiments of the invention may be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. Embodiments of the invention may also be embodied in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. An embodiment of the invention can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
[0029] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 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.
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A method for predicting headlamp reflector temperature comprising receiving a headlamp type and transmitting a request for an input parameter value responsive to the headlamp type. The input parameter value is received in response to transmitting the request. A transfer function is executed in response to the input parameter and the headlamp type and the execution results in a predicted maximum reflector temperature. The predicted maximum reflector temperature is then output.
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This application is a Continuation of application Ser. No. 08/183,120, filed Jan. 18, 1994, now abandoned.
BACKGROUND TO THE INVENTION
The present invention relates to novel alkoxyalkylene glycol esters of substituted phenylpropionic acids and to their use as antioxidant stabilizers for organic materials subject to oxidative deterioration, such as synthetic polymers and resins.
It is generally necessary to incorporate antioxidants into materials made from organic polymers and resins, in order to arrest the effects of oxidative deterioration. Various hindered phenolic esters are known to be useful for this purpose, including some alkylene glycol esters of substituted phenylalkanoic acids. For example, British Patent No. 1,376,482 discloses 3,5-dialkyl-4-hydroxyphenylalkanoic acid esters with mono- or polyalkylene glycol alkyl monoethers and their use as antioxidants. However, the alkyl ether moiety in these compounds contains only 1 or 2 carbon atoms.
Most previously known antioxidants of this type are solids with relatively high melting points, which causes several problems in polymer processing plants. Such antioxidants are used in small quantities, and it is difficult to ensure their homogeneous distribution throughout a bulk polymeric material, with which they may have poor compatibility. Such miscibility problems are particularly great when adding a solid antioxidant to a liquid polymeric material, such as liquid polyols for polyurethanes or paints, and a readily miscible liquid stabilizer is desirable for this. Stabilizers which are liquids or low melting point solids are also much better suited for use with automatic metering equipment in modern synthetic resin manufacturing plants.
A further problem with solid stablizers arises in modern polyolefin manufacturing plants, where it is preferred to do away with melt mixing of the bulk polymer and stabilizer, and instead to treat large diameter polymer particles with stabilizer in the liquid phase, followed by drying.
Accordingly, there is a need for effective new antioxidants, which are liquids or low melting point solids, and consequently do not suffer from such problems.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide new substituted phenylpropionic acid esters of polyalkylene glycols which are effective as antioxidants for polymeric organic materials. It is another object of the invention to provide such esters which are liquids or low melting point solids, and which have good polymer compatibility, so that they may be readily incorporated into bulk polymeric materials. It is a further object of the invention to provide such novel esters with superior activity as antioxidant stabilizers for polymeric materials.
We have now surprisingly found that certain substituted phenylpropionic acid esters of mono- or polyalkylene glycol alkyl monoethers, wherein the alkyl ether moiety has 8 or more carbon atoms, overcome the above-described problems. These esters are liquids or low melting point solids, which exhibit good polymer compatibility, and also excellent antioxidant activity, heat stabilization and resistance to nitrogen oxides, in conjunction with low volatility and a reduced tendency to surface migration.
Thus, in a first aspect, the invention provides a compound of formula (I): ##STR2## wherein: R 1 represents an alkyl group having from 1 to 6 carbon atoms;
R 2 represents an alkyl group having from 8 to 24 carbon atoms;
EO represents an ethyleneoxy group;
PO represents a propyleneoxy group;
k is 0 or an integer from 1 to 10; and
m is 0 or an integer from 1 to 5;
provided that the total of (k+m) is greater than 0 and not greater than 10.
The present invention further provides an antioxidant for organic polymeric materials, comprising at least one compound of the above formula (I) as an active ingredient.
DETAILED DESCRIPTION OF THE INVENTION
In the above formula (I), R 1 may be a straight or branched alkyl group having from 1 to 6 carbon atoms such as, for example, a methyl, ethyl, propyl, isopropyl, butyl, s-butyl, t-butyl, pentyl, isopentyl, t-pentyl, hexyl or isohexyl group. More preferably, R 1 represents an alkyl group having from 1 to 4 carbon atoms; and most preferably R 1 is a methyl or t-butyl group.
R 2 in the above formula (I) may be a straight or branched alkyl group having from 8 to 24 carbon atoms such as, for example, an octyl, 2-ethylhexyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, icosyl, henicosyl, docosyl, tricosyl or tetracosyl group. Preferably, R 2 represents a straight or branched alkyl group having from 8 to 18 carbon atoms, more preferably one with 12 to 18 carbon atoms, and most preferably one having from 16 to 18 carbon atoms.
The portion {(EO) k +(PO) m } in formula (I) represents an ethylene oxide, polyethylene oxide, propylene oxide or polypropylene oxide group, or a mixed adduct formed from one or more ethylene oxide groups with one or more propylene oxide groups. In the case of such a mixed ethylene oxide/propylene oxide adduct, there is no restriction on the order of addition of the ethylene oxide and propylene oxide groups; and the indices k and m represent the average molar numbers for the ethylene oxide and propylene oxide units in the adduct.
The total of (k+m) in formula (I) is preferably from 1 to 8, more preferably from 1 to 6, and most preferably from 1 to 3.
A preferred sub-group of compounds within formula (I) are those wherein:
R 1 represents a straight or branched alkyl group having from 1 to 4 carbon atoms;
R 2 represents a straight or branched alkyl group having from 8 to 18 carbon atoms; and
the total of (k+m) is from 1 to 8.
A more highly preferred sub-group of compounds within formula (I) are those wherein:
R 1 represents a methyl or t-butyl group;
R 2 represents a straight or branched alkyl group having from 12 to 18 carbon atoms; and
the total of (k+m) is from 1 to 6.
The most highly preferred compounds of formula (I) are those wherein:
R 1 represents a t-butyl group;
R 2 represents a straight or branched alkyl group having from 16 to 18 carbon atoms; and
the total of (k+m) is from 1 to 3.
Some typical examples of the compounds of formula (I) are shown in Table 1. The abbreviations used in this Table have the following meanings:
______________________________________Bu butyl Me methylt-Bu t-butyl Oc octylDcs docosyl Ocdc octadecylDdc dodecyl PO propyleneoxyEO ethyleneoxy Pr propylEt ethyl i-Pr isopropylHx hexyl Trdc tridecylHxdc hexadecyl Ttcs tetracosylIcs icosyl______________________________________
TABLE 1______________________________________Compd. No. R.sup.1 (EO).sub.k + (PO).sub.m ! R.sup.2______________________________________1 Me (EO).sub.1 ! 2-Et-Hx2 Me (EO).sub.2 ! 2-Et-Hx3 Et (EO).sub.2 ! 2-Et-Hx4 Pr (EO).sub.2 ! 2-Et-Hx5 t-Bu (EO).sub.1 ! 2-Et-Hx6 t-Bu (EO).sub.2 ! 2-Et-Hx7 t-Bu (EO).sub.4 ! 2-Et-Hx8 t-Bu (EO).sub.8 ! 2-Et-Hx9 t-Bu (PO).sub.1 ! 2-Et-Hx10 t-Bu (PO).sub.2 ! 2-Et-Hx11 t-Bu (EO).sub.2 + (PO).sub.1 ! 2-Et-Hx12 t-Bu (EO).sub.2 + (PO).sub.2 ! 2-Et-Hx13 Me (EO).sub.1 ! Oc14 Me (EO).sub.2 ! Oc15 t-Bu (EO).sub.1 ! Oc16 t-Bu (EO).sub.2 ! Oc17 t-Bu (EO).sub.2 ! 3,5,5-Me.sub.3 -Hx18 Me (EO).sub.1 ! Ddc19 Me (EO).sub.2 ! Ddc20 t-Bu (EO).sub.1 ! Ddc21 t-Bu (EO).sub.2 ! Ddc22 t-Bu (EO).sub.4 ! Ddc23 t-Bu (EO).sub.8 ! Ddc24 t-Bu (PO).sub.2 ! Ddc25 t-Bu (EO).sub.2 ! Trdc26 t-Bu (PO).sub.2 ! Trdc27 Me (EO).sub.1 ! Hxdc28 Me (EO).sub.2 ! Hxdc29 Me (EO).sub.3 ! Hxdc30 Me (EO).sub.4 ! Hxdc31 Me (PO).sub.1 ! Hxdc32 Me (EO).sub.2 + (PO).sub.1 ! Hxdc33 Et (EO).sub.2 ! Hxdc34 i-Pr (EO).sub.2 ! Hxdc35 t-Bu (EO).sub.1 ! Hxdc36 t-Bu (EO).sub.2 ! Hxdc37 t-Bu (EO).sub.3 ! Hxdc38 t-Bu (EO).sub.4 ! Hxdc39 t-Bu (EO).sub.6 ! Hxdc40 t-Bu (EO).sub.8 ! Hxdc41 t-Bu (PO).sub.1 ! Hxdc42 t-Bu (PO).sub.2 ! Hxdc43 t-Bu (PO).sub.3 ! Hxdc44 t-Bu (EO).sub.2 + (PO).sub.1 ! Hxdc45 t-Bu (EO).sub.3 + (PO).sub.1 ! Hxdc46 t-Bu (EO).sub.6 + (PO).sub.4 ! Hxdc47 Me (EO).sub.1 ! Ocdc48 Me (EO).sub.2 ! Ocdc49 Me (EO).sub.4 ! Ocdc50 Me (PO).sub.2 ! Ocdc51 Me (EO).sub.2 + (PO).sub.1 ! Ocdc52 t-Bu (EO).sub.1 ! Ocdc53 t-Bu (EO).sub.2 ! Ocdc54 t-Bu (PO).sub.3 ! Ocdc55 t-Bu (PO).sub.7 ! Ocdc56 t-Bu (EO).sub.8 ! Ocdc57 t-Bu (EO).sub.10 ! Ocdc58 t-Bu (PO).sub.2 ! Ocdc59 t-Bu (PO).sub.3 ! Ocdc60 t-Bu (EO).sub.2 + (PO).sub.1 ! Ocdc61 t-Bu (EO).sub.10 + (PO).sub.2 ! Ocdc62 t-Bu (EO).sub.2 + (PO).sub.2 ! Ocdc63 t-Bu (EO).sub.1 ! Ics64 t-Bu (EO).sub.2 ! Ics65 t-Bu (EO).sub.4 ! Ics66 t-Bu (PO).sub.2 ! Ics67 t-Bu (PO).sub.4 ! Ics68 t-Bu (EO).sub.2 + (PO).sub.1 ! Ics69 t-Bu (EO).sub.2 ! Dcs70 t-Bu (PO).sub.2 ! Ttcs______________________________________
Among the compounds listed in Table 1, the following are preferred, namely Compounds Nos. 7, 8, 11, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 31, 32, 35, 36, 37, 38; 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 62 and 64, of which Compounds Nos. 8, 11, 21, 22, 23, 24, 28, 35, 36, 37, 41, 42, 43, 52, 53, 54, 58 and 59 are more preferred.
The compounds of the present invention can be prepared by any suitable method generally known in the art for the preparation of compounds of this type, including various esterification methods. Three examples of such methods are illustrated in the following reaction schemes, respectively labelled Method A, Method B and Method C. ##STR3## In the above reaction schemes: R 1 , R 2 , k and m have the meanings previously defined for formula (I);
R 3 represents a straight or branched alkyl group having from 1 to 4 carbon atoms such as, for example, a methyl, ethyl, propyl, isopropyl, butyl or isobutyl group, and preferably represents a methyl group; and
X represents a halogen atom such as chlorine or bromine.
The starting materials of formula (II) are adducts of alkylene oxides with various alcohols, which may be described as alkylene glycol alkyl monoethers or as O-alkylated alkylene glycols. It will be appreciated that, in the case of polyalkylene oxide adducts, the commercially available products are often mixtures of several individual compounds with varying numbers of ethylene oxide and/or propylene oxide units; and, if such a mixture is used as the starting material, the end product of formula (I) will be constituted of a corresponding mixture. Accordingly, it should be understood that, in such mixtures, the indices k and m may represent the average number of ethylene oxide and propylene oxide units, respectively, and may therefore be fractional numbers for the overall mixture.
Method A involves a transesterification between the alkylene glycol monoether of formula (II) and the substituted phenylpropionic acid ester of formula (IIIa). This reaction may be performed in the presence or absence of a solvent, as desired, and in the presence of a transesterification catalyst.
If a solvent is used for this reaction, suitable inert solvents include, for example, ethers such as diisopropyl ether, dioxane and tetrahydrofuran, halogenated hydrocarbons such as carbon tetrachloride and dichloroethane, linear or cyclic aliphatic hydrocarbons such as hexane, heptane, octane, isooctane, cyclohexane, methylcyclohexane, ethylcyclohexane and kerosine, and aromatic hydrocarbons such as benzene, toluene and xylene. Aromatic hydrocarbons are preferred.
Suitable transesterification catalysts include, for example, alkali metals such as lithium, sodium and potassium, alkali metal amides such as lithium amide, sodium amide, and lithium N,N,-diisopropylamide, alkali metal alkoxides such as sodium methoxide, sodium ethoxide and potassium t-butoxide, alkali metal hydroxides such as lithium hydroxide, sodium hydroxide and potassium hydroxide, alkali metal carbonates such as lithium carbonate, sodium carbonate and potassium carbonate, alkali metal bicarbonates such as lithium bicarbonate, sodium bicarbonate and potassium bicarbonate, titanium (IV) alkoxides such as titanium (IV) tetraisopropoxide and titanium (IV) tetrabutoxide, and metal oxide salts such as tin oxide. Alkali metal alkoxides are preferred.
The reaction temperature and time can vary, depending upon the starting materials, catalyst and solvent (if any) employed. However, a temperature from 50° C. to 200° C. will generally be used, more preferably from 80° C. to 140° C.; and the reaction time is usually from 2 to 24 hours, more preferably from 4 to 12 hours.
After completion of the transesterification reaction, the desired product of formula (I) can be isolated by means of conventional techniques. For example, the reaction mixture is washed and neutralised with a dilute mineral acid (e.g. dilute hydrochloric or sulfuric acid), insolubles are removed (e.g. by filtration), the resulting liquid is dried over a dehydrating agent (e.g. anhydrous magnesium sulfate), and the solvent is evaporated off. If desired, the resulting product can be purified, for example by distillation under reduced pressure or column chromatography.
Method B involves the esterification of the alkylene glycol monoether of formula (II) with the substituted phenylpropionic acid of formula (IIIb). This reaction is generally carried out in an inert solvent and in the presence of an acid catalyst.
Suitable inert solvents whicn may be used for this reaction include, for example, ethers such as diisopropyl ether, dioxane and tetrahydrofuran, halogenated hydrocarbons such as methylene chloride, carbon tetrachloride and dichloroethane, aliphatic hydrocarbons such as hexane, heptane, octane, ethylcyclohexane and kerosine, and aromatic hydrocarbons such as benzene, toluene and xylene. Aromatic hydrocarbons are preferred.
The acid catalysts which may be used for this reaction include, for example, sulfonic acids such as benzenesulfonic acid, p-toluenesulfonic acid, trifluoromethanesulfonic acid and methanesulfonic acid, and mineral acids such as hydrochloric acid and sulfuric acid, Mineral acids and sulfonic acids are preferred, more particularly sulfuric acid as the mineral acid and p-toluenesulfonic acid as the sulfonic acid.
The reaction temperature and time can vary, depending upon the starting materials, solvent and catalyst; but the temperature will generally be from 60° C. to 200° C., more preferably from 100° C. to 150° C., and the reaction time will generally be from 3 hours to 24 hours, more preferably from 4 hours to 12 hours.
After completion of the esterification reaction, the desired product of formula (I) can be isolated by conventional techniques. For example, the reaction mixture is washed and neutralised with an aqueous alkali solution (e.g. aqueous sodium bicarbonate), insolubles are removed (e.g. by filtration), the resulting liquid ms dried over a dehydrating agent (e.g. anhydrous magnesium sulfate), and the solvent is evaporated off to give the product of formula (I). If desired, the product can be purified, for example by distillation under reduced pressure or by column chromatography.
Method C involves the esterification of the alkylene glycol monoether of formula (II) with the substituted phenylpropionic acid halide of formula (IIIc). This reaction is generally carried out in an inert solvent, and in the presence of a hydrogen halide scavenger.
Examples of suitable solvents for this reaction include those already listed above for the reaction of Method A.
Examples of suitable hydrogen halide scavengers include alkali metal hydroxides such as lithium hydroxide, sodium hydroxide and potassium hydroxide, alkali metal carbonates such as lithium carbonate, sodium carbonate and potassium carbonate, alkali metal bicarbonates such as lithium bicarbonate, sodium bicarbonate and potassium bicarbonate, aliphatic tertiary amines such as triethylamine, trioctylamine, N-methylmorpholine and N,N-dimethylpiperazine, and pyridines such as pyridine and N,N-dimethylaminopyridine. Triethylamine and pyridines are preferred.
The reaction temperature and time can vary, depending upon the starting materials, solvent and hydrogen halide scavenger employed. However, the reaction temperature will usually be from 0° C. to 120° C., more preferably from 10° C. to 60° C., and the reaction time will usually be from 1 hour to 12 hours, more preferably from 4 hours to 8 hours.
After completion of the reaction, the desired product of formula (I) can be isolated by means of conventional techniques. For example, the reaction mixture is washed with a dilute mineral acid (e.g. dilute hydrochloric or sulfuric acid), insolubles are removed (e.g. by filtration), the resulting liquid is dried over a dehydrating agent (e.g. anhydrous magnesium sulfate), and the solvent is evaporated off to give the desired product. If desired, the product can be purified for example by distillation under reduced pressure or by column chromatography.
We have discovered that the compounds of formula (I) exhibit excellent polymer compatibility, heat stabilization and resistance to nitrogen oxides, in conjunction with low volatility and a reduced tendency to surface migration. This combination of properties renders them valuable as novel antioxidant stabilizers for organic materials such as fats, lubricants and polymeric materials.
The antioxidant compounds of the invention can be incorporated with the organic material to be stabilized by means of per se known techniques, at any suitable stage. For example, they can be added before or after polymerization, or during a processing step such as injection molding. For example, the antioxidant may be mixed with a granular or powdery polymeric material; or a solution or suspension of the antioxidant may be mixed with the polymeric material, and the mixture dried; or the antioxidant may be mixed with a liquid monomer, polyol, isocyanate, plasticizer or prepolymer, and the resulting pre-mix then mixed with the polymeric material. The antioxidants of the invention may also be used in conjunction with other additives which are conventionally used in the field of polymer technology.
Suitable synthetic resins and polymeric materials for use with the antioxidant stabilizers of the present invention include the following:
Olefins and diene polymers
Homopolymers of olefins and dienes (e.g. low density, linear low density, high density and cross-linked polyethylenes, polypropylene, polyisobutene, polymethylbutene-1, polymethylpentene-1, polyisoprene and polybutadiene); mixtures of such homopolymers (e.g. mixtures of polypropylene and polyethylene, of polypropylene and polybutene-1 and of polypropylene and polyisobutylene); copolymers of olefins (e.g. ethylene-propylene copolymer, propylene-butene-1 copolymer and ethylene-butene-1 copolymer); copolymers of olefins and dienes (e.g. terpolymers of ethylene, propylene and dienes, such as butadiene, hexadiene, dicyclopentadiene and ethylidene norbornene); and natural rubbers;
Styrene polymers
Polystyrene, poly-α-methylstyrene, and copolymers of styrene or α-methylstyrene (e.g. styrene-maleic anhydride copolymer, styrene-butadiene copolymer, styrene-acrylonitrile-methyl methacrylate copolymer, styrene-acrylonitrile-acrylate copolymer, styrene-acrylonitrile copolymer modified with an acrylate for impact strength, and styrene polymer modified with an ethylene propylene diene monomer, also for impact strength); and graft copolymers of styrene e.g. a graft copolymer of styrene and polybutadiene, graft copolymers of styrene and acrylonitrile to polybutadiene (generally referred to as acrylonitrile-butadiene-styrene polymers), mixtures of such graft copolymers with the styrene copolymers given above! and heat-resistant acrylonitrile-butadiene-styrene polymers copolymerised with maleimide derivatives;
Vinyl halide, vinylidene halide and halogeneted olefin polymers
Polyvinyl chloride, polyvinylidene chloride, polyvinyl fluoride, polyvinylidene fluoride, polychloroprene, vinyl chloride-vinylidene chloride copolymer, vinyl chloride-vinyl acetate copolymer, vinyl chloride-ethylene copolymer, vinylidene chloride-vinyl acetate copolymer chlorinated polyethylene, chlorinated polypropylene, polychlorotrifluoroethylene and polytetrafluoroethylene;
Polymers of α,β-unsaturated acids and their derivatives
Polyacrylic acid esters, polymethacrylic acid esters, polyacrylamides and polyacrylonitriles;
Polymers of unsaturated alcohols and unsaturated amines or their acyl derivatives or acetals
Polyvinyl alcohols, polyvinyl acetate, polyvinyl stearate, polyvinyl benzoate, polyvinyl maleate, polyvinyl butyral, polyallyl phthalate or polyallyl melamine, and copolymers of such monomers with other vinyl compounds (e.g. ethylene-vinyl acetate copolymer);
Polyalkylene oxides and polyphenylene oxides
Polyoxymethylene, oxymethylene-ethylene oxide copolymer, polyoxyethylene, polypropylene oxide, polyisobutylene oxide and polyphenylene oxide;
Modified celluloses
Cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cellulose propionate, nitrocellulose and ethyl cellulose;
Polyamides and copolyamides
Polyamides and copolyamides derived from diamines and aliphatic acids or aromatic dicarboxylic acids and/or from aminocarboxylic acids or corresponding lactams (e.g. Nylon 6, Nylon 6/6, Nylon 6/10, Nylon 11 and Nylon 12);
Polyesters
Polyesters derived from dicarboxylic acids and dialcobols and/or from oxyacids or corresponding lactones (e.g. polyethylene terephthalate, polybutylene terephthalate, polycyclohexane-1,4-dimethylene terephthalate);
Polycarbonates, polyester carbonates, polyether imides, polyether ketones, polyether sulfones, polyphenylene sulfides, polysulfones and silicone resins
Polyurethanes and polyureas
Cross-linked polymers
Cross-linked polymers consisting of a moiety derived from aldehydes and another moiety derived from phenol, urea or melamine (e.g. phenol formaldehyde resins, urea-formaldehyde resins, melamine-formaldehyde resins and diaryl phthalate resins);
Epoxy polymers
Homopolymers and copolymers of epoxy compounds (e.g. polyethylene oxide); and polymers of bisglycidyl ether compounds;
Alkyd resins
Glycerol-phthalic acid resins and mixtures thereof with melamine-formaldehyde resins;
Unsaturated polyester resins
Unsaturated polyester resins derived from copolyesters of saturated and unsaturated dicarboxylic acids and polyhydric alcohols and prepared using vinyl compounds as cross-linking agents; and unsaturated polyester resins modified by chlorination for enhanced flame retardancy.
The quantity of stabilizer of the present invention necessary to achieve the desired stabilization effect will vary depending on a number of factors which will be clear to those skilled in the art. However, typical factors which need to be taken into account include the type of polymer to be stabilized, its properties and its intended use, and especially whether other additives are to be used. In general, though, we prefer to use from about 0.01 to about 5% by weight of the stabilizer of the present invention based on the weight of the polymer.
The preferred amount used, as stated above, will vary depending on the kind of polymer. For example, for olefin, diene and styrene polymers, suitable amounts of stabilizer are from about 0.01 to about 2.0% by weight, preferably from about 0.05 to about 2.0% by weight; for vinyl chloride and vinylidene chloride polymers suitable amounts are from about 0.01 to about 5.0% by weight, preferably from about 0.05 to about 2.0% by weight; and for polyurethane and polyamide polymers, suitable amounts are from about 0.01 to about 5.0% by weight, preferably from about 0.05 to about 2.0% by weight.
It will be appreciated that two or more stabilizers of the present invention may be used in combination or with any other additives, as desired.
Various kinds of additives customarily used in the field of polymer technology can suitably be added separately or together with the stabilizers of the present invention. Suitable such additives include, for example:
Phenol antioxidants 2,6-di-t-Butyl-p-cresol; stearyl-β-(4-hydroxy-3,5-di-t-butylphenyl) propionate; distearyl (4-hydroxy-3-methyl-5-t-butylbenzyl) malonate; 2,2'-methylenebis-(4-methyl-6-t-butylphenol); 4,4 -methylenebis (2,6-di-t-butylphenol); 2,2'-methylenebis 6-(1-methylcyclohexyl)-p-cresol!; bis 3,3-bis (4-hydroxy-3-t-butylphenyl) butyric acid! glycol ester; 4,4'-butylidenebis (6-t-butyl-m-cresol); 1,1,3-tris(2-methyl-4-hydroxy-5-t-butyl-phenyl)butane; 1,3,5 - tris(3,5-di-t-butyl-4- hydroxy benzyl)-2,4,6-trimethylbenzene; 3,9-bis 1,1-dimethyl-2-(3,5-di-t-butyl-4-hydroxyphenyl) ethyl!-2,4,8,10-tetraoxaspiro 5.5!undecane; pentaerythrityl tetrakis- 3-(3,5-di-t-butyl-4-hydroxyphenyl) propionate!; 1,3,5-tris (3,5-di-t-butyl-4-hydroxybenzyl) isocyanurate; 1,3,5-tris (3,5-di-t-butyl-4-hydroxyphenyl) propionyl-oxyethyl!isocyanurate; and bis 3-(3,5-di-t-butyl-4 -hydroxyphenyl)propionyl!oxamide.
Thioester Stabilizers
Dilauryl thiodipropionate, dimyristyl thiodipropionate, distearyl thiodipropionate, and pentaerythrityl tetrakis(dodecylthiopropionate).
Phosphite stabilizers
Tris(2,4-di-t-butylphenyl) phosphite; triphenyl phosphite; tris(nonylphenyl) phosphite; distearyl pentaerythritol diphosphite; 4,4-butylidenebis-(3-methyl-6-t-butylphenyl-di-tridecyl) phosphite; bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite; and tetrakis(2,4-di-t-butylphenyl) 4,4-biphenylene phosphonite.
Hindered amine photostabilizers
4-Benzoyloxy-2,2,6,6-tetramethylpiperidine;
4-stearoyloxy-2,2,6,6-tetramethylpiperidine;
4-methacryloyloxy-2,2,6,6-tetramethylpiperidine;
4-methacryloyloxy-1,2,2,6,6-pentamethylpiperidine;
bis(2,2,6,6-tetramethyl-4-piperidinyl) sebacate;
bis(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate;
bis(2,2,6,6-tetramethyl-1-octoxy-4-piperidinyl) sebacate;
2-methyl-2-(2,2,6,6-tetramethyl-4-piperidinyl)imino-N-(2,2,6,6-tetramethyl-4-piperidinyl)propionarnide;
2-methyl-2-(1,2,2,6,6-pentamethyl-4-piperidinyl)imino-N-(1,2,2,6,6-pentamethyl-4-piperidinyl)propionamide;
1-acryloyl-4-benzyloxy-2,2,6,6-tetramethylpiperidine;
bis(1,2,2,6,6-pentamethyl-4-piperidinyl)-2-butyl-
2-(3,5-di-t-butyl-4-hydroxybenzyl)butyl malonate;
8-acetyl-3-dodecyl-7,7,9,9-tetramethyl-1,3,8-triazaspiro 4,5!decane-2,4-dione;
tetrakis(2,2,6,6-tetramethyl-4-piperidinyl)-1,2,3,4-butanetetracarboxylate;
tetrakis(1,2,2,6,6-pentamethyl-4-piperidinyl)-1,2,3,4-butanetetracarboxylate;
tridecyl-tris(2,2,6,6-tetramethyl-4-piperidyl)-1,2,3,4-butanetetracarboxylate;
tridecyl.tris(1,2,2,6,6-pentamethyl-4-piperidyl)-1,2,3,4-butanetatracarboxylate;
4-{3-(3,5-di-t-butyl-4-hydroxyphenyl)propionyloxy}-1- 2-{3-(3,5-di-t-butyl-4-hydroxyphenyl)propionyloxy-}ethyl!2,2,6,6-tetramethylpiperidine;
ditridecyl.bis(2,2,6,6-tetramethyl-4-piperidinyl)-1,2,3,4-butanetetracarboxylate;
ditridecyl -bis(1,2,2,6,6-pentamethyl-4-piperidinyl)-1,2,3,4-butanetetracarboxylate;
3,9 -bis 1,1-dimethyl-2-{tris (2,2,6,6-tetramethyl-4-piperidinyloxycarbonyl)butylcarbonyloxy-}ethyl!-2,4,8,10- tetraoxaspiro 5,5!undecane;
3,9-bis 1,1-dimethyl-2-(tris{1,2,2,6,6-pentamethyl -4-piperidyloxycarbonyl)butylcarbonyloxy}ethyl!-2,4,8,10-tetraoxaspiro 5,5!undecane;
dimethyl succinate 4 - hydroxy-1-(2-hydroxyethyl)-2,2,6,6-tetramethylpiperidine polycondensation product;
poly ethylene{(2,2,6,6-tetramethyl-4-piperidinyl)-imino}hexamethylene{(2,2,6,6-tetramethyl-4-piperidinyl)-imino}!;
poly {6-(1,1,3,3-tetramethylbutyl)amino-1,3,5-triazine-2,4-diyl}{(2,2,6,6-tetramethyl-4-piperidyl)-imino}-hexamethylene {(2,2,6,6-tetramethyl-4-piperidinyl)-imino}!;
poly {6-(cyclohexylamino)-1,3,5-triazine -2,4-diyl}-{(2,2,6,6,-tetramethyl-4-piperidinyl)imino}hexa-methylene{(2,2,6,6-tetramethyl-4-piperidinyl) imino}!;
poly {6-(morpholino)-1,3,5-triazine-2,4-diyl}-{(2,2,6,6-tetramethyl-4-piperidinyl) imino}hexa-methylene- {(2,2,6,6-tetramethyl-4-piperidinyl) imino}!;
1,6,11-tris {4,6 -bis (N-butyl-N-(2,2,6,6-tetramethyl-4-piperidyl)amino)-1,3,5-triazin-2-yl}amino!azaundecane;
1,6,11-tris {4,6-bis (N-butyl-N-(1,2,2,6,6-pentamethyl-4-piperidyl) amino) -1,3,5-triazin-2-yl}amino!azaundecane;
1,5,8,12-tetrakis 4,6-bis{N-butyl-N-(1,2,2,6,6-pentamethyl-4-piperidinyl) amino)-1,3,5-triazin-2-yl!-1,5,8,12-tetraazadodecane; and
polymethylpropyl-3 -oxy 4-(2,2,6,6-tetramethyl)-piperidinyl!siloxane. Particularly preferred are bis (2,2,6,6-tetramethyl-4-piperidinyl) sebacate; bis (1,2,2,6,6-pentamethyl -4-piperidinyl) sebacate; tetrakis (2,2,6,6-tetramethyl-4-piperidinyl) 1,2,3,4 -butanetetracarboxylate; tetrakis (1,2,2,6,6-pentamethyl-4-piperidinyl) 1,2,3,4-butanetetracarboxylate; dimethyl succinate 4 -hydroxy- 1-(2-hydroxyethyl)-2,2,6,6-tetramethyl-piperidine polycondensation product; poly {6-(1,1,3,3-tetramethyl-butyl)amino-1,3,5 -triazine -2,4-diyl}{(2,2,6,6-tetramethyl 4-piperidinyl)imino}-hexamethylene {(2,2,6,6-tetramethyl-4-piperidyl) imino}!; poly {6-morpholino-1,3,5-triazine-2,4-diyl}{(2,2,6,6-tetramethyl-4-piperidyl)imino}-hexamethylene{(2,2,6,6 -tetramethyl-4-piperidyl) imino}!; and 1,5,8,12-tetrakis{4,6-bis-(N-1,2,2,6,6,-pentamethyl-4-piperidyl)-butylamino}-1,3,5-triazin-2-yl!-1,5,8,12-tetraazadodecane.
Ultraviolet absorbers
2,4-Dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone; 2-hydroxy-4-methoxybenzophenone-5-sulfonic acid; 2-hydroxy-4-octoxybenzophenone; 2-hydroxy-4-dodecyloxybenzophenone; 2-hydroxy-4-benzyloxybenzophenone; bis(5-benzoyl-4-hydroxy-2-methoxyphenyl)methane; 2,2'-dihydroxy-4-methoxybenzophenone; 2,2'-dihydroxy-4,4'-dimethoxybenzophenone; 2,2',4,4'-tetrahydroxybenzophenone; 2,hydroxy-4-methoxy-2'-carboxybenzophenone; 2-(2'-hydroxy-5'-methylphenyl)benzotriazole; 2- 2'-hydroxy-3',5'-bis(α,α-dimethylbenzyl)-phenyl!benzotriazole; 2-(2'-hydroxy-3',5'-di-t-butyl-phenyl)benzotriazole; 2-(2'-hydroxy-3'-t-butyl-5'-methylphenyl)-5-chlorobenzotriazole; 2-(2'-hydroxy-3',5'-di-t-butyl-phenyl)-5-chlorobenzotriazole; 2-(2'-hydroxy-3',5'-di-t-amylphenyl)-benzotriazole; 2-(2'-hydroxy-5'-t-octylphenyl)-benzotriazole; 2,2'-methylene-bis 4-(1,1,3,3-tetramethylbutyl)-6-(2N-benzotriazol-2-yl)phenol!; a condensation product of methyl-3- 3-t-butyl-5-(2H-benzotriazol-2-yl)-4-hydroxyphenyl! propionate and polyethylene glycol; and 2-(2-hydroxyphenyl)benzotriazole copolymer.
Hydroxybenzoate photostabilizers
2,4-di-t-butylphenyl 3,5-di-t-butyl-4-hydroxybenzoate, 2,6-di-t-butylphenyl 3,5-di-t-butyl-4-hydroxybenzoate, and hexadecyl 3,5-di-t-butyl-4-hydroxybenzoate.
Nickel-containing stabilizers
Nickel monoethyl-3,5-di-t-butyl-4-hydroxybenzyl-phosphonate; butylamine-nickel-2,2'-thiobis-(4-t-octylphenolate) complex; nickel dibutyl-dithiocarbamate; and nickel 3,5-di-t-butyl-4-hydroxybenzoate.
Metal salts of higher fatty acids
Calcium, magnesium, barium, zinc, cadmium, lead or nickel stearate, and calcium, magnesium, cadmium, barium or zinc laurate.
The various additives of the types listed above may, of course, be used singly or in combinations of two or more, as appropiate to the intended purpose.
The stabilizers of the present invention may also be used in combination with such other agents as heavy metal deactivators, nucleating agents, organic tin compounds, plasticizers, epoxy compounds, pigments, paints, fluorescent brighteners, fillers, boosters, foaming agents, antistatic agents, mildew-proofing or bactericidal agents, lubricants and processing aids.
Polymers incorporating the stabilizers of the present invention can be used as desired, such as in the form of films, sheets, fibers, tapes, compression molding materials, injection molding materials, coating compositions, sealing materials or adhesives.
Embodiments of the present invention will now be described more fully by way of the accompanying Examples and Reference Examples, which are non-limiting on the scope of the invention. In the accompanying Examples and Reference Examples, "parts" and "%", where used, mean parts by weight and % by weight, respectively, unless otherwise specified.
Starting materials used in the Examples are adducts of alkylene oxides with various alcohols, which may be described as alkylene glycol monoethers or as O-alkylated alkylene glycols. These are commercially available or can be prepared by known methods, e.g. as described at pages 141-142 in "Synthesis and Applications of Surface Active Agents" by Ryohei Oda and Kazuhiro Teramura 13th edition (1972) published Maki Publishing Co. Ltd., Japan. As previously explained, the commercially available adducts may be mixtures of several individual compounds with varying numbers of ethylene oxide and/or propylene oxide units, so that the number of units indicated in the name of the compound may therefore represent the average number in such a mixture.
EXAMPLE 1
2-{2- 2-(2-ethylhexyloxy) ethoxy!ethoxy}propyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate
A mixture consisting of 50 ml of toluene, 12.51 g of 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid, 8.29 g of an adduct of O-(2-ethylhexyl)diethylene glycol with 1 mol of propylene oxide, and 0.16 g of p-toluenesulfonic acid was heated under reflux for 6 hours with stirring, then the water which formed was distilled off. The reaction mixture was left to cool and then washed with 5% aqueous sodium bicarbonate solution and water. The toluene was stripped off under reduced pressure, giving 13.6 g of the title compound as a pale yellow oil with n D 20 1.4885.
EXAMPLE 2
Condensation product of O-(2-ethylhexyl)octaethylene glycol and methyl-3-(3,5-di-t-butyl-4-hydroxypheny1)-propionate
A mixture of 370 ml of xylene, 92.1 g of methyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 145.6 g of an adduct of 2-ethylhexyl alcohol with ethylene oxide (1:8 molar ratio) and 0.5 g of tetraisopropyl orthotitanate was heated under reflux for 3.5 hours with stirring, then the mixture of toluene and methanol which formed was distilled off. The reaction mixture was left to cool and then washed with 30 ml of water. The xylene was stripped off under the reduced pressure, giving 215.5 g of the title compound as a pale yellow oil with n D 20 1.4845.
EXAMPLE 3
Condensation product of O-dodecyldiethylene glycol and 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid
The title compound was prepared from an adduct of dodecyl alcohol with ethylene oxide (1:2 molar ratio), by a procedure analogous to that of Example 1, as a pale yellow oil with n D 20 1.4877.
EXAMPLE 4
Condensation product of O-dodecyldipropylene glycol and 3-(3,5-di-t-buty1-4-hydroxyphenyl)propionic acid
The title compound was prepared from an adduct of dodecyl alcohol with propylene oxide (1:2 molar ratio), by a procedure analogous to that of Example 1, as an oil with n D 20 1.4831.
EXAMPLE 5
O-dodecyloctaethylene glycol 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate
A mixture consisting of 40 ml of toluene, 1.08 g of methyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 2.0 g of O-dodecyloctaethylene glycol (specific gravity 0.889 20/4° C., available from Wako Pure Chemical Industries, Ltd.) and 0.1 g of tetraisopropyl orthotitanate was heated under reflux with stirring for 7 hours, then the mixture of toluene and methanol which formed was distilled off. The reaction mixture was left to cool and then filtered. Water was added to the flitrate, and the reaction product was extracted three times with 20 ml of ethyl acetate. The extract was dried over anhydrous magnesium sulfate and concentrated. The residue was purified by column chromatography (eluted with ethyl acetate/n-hexane=1/3) giving 2.15 g of the title compound as an oil with n D 20 1.4823.
Elemental Analysis: Calculated for C 45 H 82 O 11 : C: 67.63%; H: 10.34%; Found: C: 67.35%; H: 10.36%.
EXAMPLE 6
Condensation product of O-hexadecylethylene glycol and 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid
The title compound was prepared from an adduct of hexadecyl alcohol with ethylene oxide (1:1 molar ratio), by a procedure analogous to that of Example 1, as an oil with n D 20 1.4868.
EXAMPLE 7
Condensation product of O-hexadecyldiethylene glycol and methyl-3-(3,5-di-t-buty1-4-hydroxyphenyl)propionate
A mixture consisting of 150 ml of toluene, 53.5 g of methyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 60.0 g of an adduct of hexadecyl alcohol with ethylene oxide (1:2 molar ratio, n D 45 1.4428) and 0.9 g of tetraisopropyl orthotitanate was heated under reflux for 10 hours with stirring, then the mixture of toluene and methanol which formed was evaporated off. Water (8.3 ml) was added to the reaction mixture, the resulting mixture was stirred under reflux for 1 hour, and then the water and toluene were evaporated off. The reaction mixture was filtered, and the filtrate was concentrated under reduced pressure giving 101.6 g of the title compound as a slightly yellowish oil with n D 20 1.4867.
EXAMPLE 8
Condensation product of O-hexadecyltriethylene glycol and methyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate
The title compound was prepared from an adduct of hexadecyl alcohol with ethylene oxide (1:3 molar ratio), by a procedure analogous to that of Example 7, as an oil with n D 20 1.4850.
EXAMPLE 9
Condensation product of O-hexadecyldipropylene glycol and 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid
The title compound was prepared from an adduct of hexadecyl alcohol with propylene oxide (1:2 molar ratio), by a procedure analogous to that of Example 1, as a slightly yellowish oil with n D 20 1.4800.
EXAMPLE 10
Condensation product of O-Hexadecyldiethylene glycol and and methyl-3-(3-t-butyl-4-hydoxy-5-methylpheny1)propionate
A mixture consisting of 30 ml of toluene, 7.5 g of methyl 3-(3-t-butyl-4-hydoxy-5-methylphenyl)propionate, 10 g of an adduct of hexadecyl alcohol with ethylene oxide (1:2 molar ratio, n D 45 1.4428) and 0.02 g of sodium methoxide was heated under reflux with stirring for 6 hours, then the mixture of toluene and methanol which formed was distilled off. The reaction mixture was left to cool, then neutralised with 5% aqueous sulfuric acid, washed twice with water, dried over anhydrous sodium sulfate and concentrated, giving 15.7 g of the title compound as an oil with n D 20 1.4887.
EXAMPLE 11
Condensation product of O-octadecyldiethylene glycol and 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid
The title compound was prepared from an adduct of octadecyl alcohol with ethylene oxide (1:2 molar ratio), by a procedure analogous to that of Example 1, as an oil with n D 20 1.4855.
EXAMPLE 12
Condensation product of O-octadecyldipropylene glycol and methyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate
The title compound was prepared from an adduct of octadecyl alcohol with propylene oxide (1:2 molar ratio), by a procedure analogous to that of Example 10, as a pale yellow oil with n D 20 1.4805.
EXAMPLE 13
Condensation product of O-octadecyltripropylene glycol and 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionic acid
The title compound was prepared from an adduct of octadecyl alcohol with propylene oxide (1:3 molar ratio), by a procedure analogous to that of Example 1, as a pale yellow oil with n D 20 1.4783.
EXAMPLE 14
Heat Stability Test
Unstabilized polypropylene powder having a melt flow rate of about 4.0 was kneaded with 0.1% of antioxidant (specified in Table 2) in a mixer (Laboplasto™ mill, manufactured by Toyo Seiki Seisakusho) at 200° C. for 10 minutes, to homogeneity. The resulting homogeneous preparation was immediately rolled into a sheet of about 2-3 mm thickness, using a water-cooled hydraulic press.
A portion of this sheet was cut out and was pressed at 240° C. for 4 minutes in the press to obtain a 0.5 mm thick sheet. Test strips cut from this 0.5 mm sheet, measuring 10×100 mm, were placed in an oven at 130° C. and the number of days recorded until oxidative degradation (whitening) occurred. The results are shown in Table 2.
In Table 2, the compounds of the invention are identified by reference to the numbers in the compound list of Table 1, and also by reference to the above Examples illustrating their preparation. The Comparative Compounds 1 and 2 are the compounds prepared in Reference Examples 1 and 2 below, respectively, and form part of the prior art disclosed in GB Patent 1,376,482.
TABLE 2______________________________________Test Compound Heat resistanceExample Compound List at 130° C. (days)______________________________________Example 1 No. 11 11Example 2 No. 8 13Example 3 No. 21 16Example 4 No. 24 12Example 5 No. 23 10Example 6 No. 35 18Example 7 No. 36 26Example 8 No. 37 22Example 9 No. 42 25Example 10 No. 28 21Example 11 No. 53 29Example 12 No. 58 26Example 13 No. 59 16Comparative Compound 1 5Comparative Compound 2 4______________________________________
Comparative Example 1
2-Methoxyethyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate
The title compound was prepared from 90 g of toluene, 102.4 g of methyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)-propionate, 18.2 g of ethylene glycol monomethyl ether and 0.35 g of sodium methoxide, by a procedure analogous to that of Example 10. Yield 42.2 g. Melting point 62°-64° C.
Reference Example 2
2-Methoxypropyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate
The title compound was prepared from methyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate and propylene glycol monomethyl ether, by a procedure analogous to that of Reference Example 10. White powder with mellting point 73°-74° C.
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Compounds of formula (I): ##STR1## wherein: R 1 represents an alkyl group having from 1 to 6 carbon atoms;
R 2 represents an alkyl group having from 8 to 24 carbon atoms;
EO represents an ethyleneoxy group;
PO represents a propyleneoxy group;
k is 0 or an integer from 1 to 10; and
m is an integer from 1 to 4;
provided that the total of (k+m) is greater than 1 and not greater than 10;
are useful as antioxidant stabilizers for polymeric materials.
| 2
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TECHNICAL FIELD
[0001] The present disclosure relates generally to a hydrogen generator, and more particularly, to a hydrogen generator located on-board a mobile vehicle.
BACKGROUND
[0002] Various technologies have been implemented by engine manufacturers to meet diesel engine emission requirements mandated by the Environmental Protection Agency (EPA). Selective Catalytic Reduction (SCR) is one common technology used to control emission of NO x from diesel engines. The basic principle of SCR is the reduction of NO x to N 2 and H 2 O by a reductant in the presence of a catalyst. In typical automotive SCR systems, a gaseous or liquid reductant (most commonly ammonia or urea) is added to the exhaust gas stream of the engine. The reductant reduces the NO x from the exhaust in a catalytic converter at high temperatures. The catalytic converter typically contains a catalyst that will trigger the reducing reaction at the desired temperature. Various catalyst media, such as metal containing zeolite or metal containing catalyst coated on an alumina porous carrier media, have been used with automotive SCRs. The particular metal catalyst and the carrier media are typically selected based on the exhaust gas temperature.
[0003] There is considerable discussion among engine manufacturers about the relative merits of different reductants used to reduce NO x . Specifically, while ammonia generally offers good NO x reduction, it is toxic and difficult to handle safely. Urea, on the other hand, is safer to handle but not quite as effective. In both cases, the reductant must be pure, to prevent impurities from clogging an inlet surface of the catalyst. A major issue with urea reductants is the lack of distribution infrastructure available to support this technology for automotive uses. For this reason, the EPA has been reluctant to certify diesel engines fitted with an SCR system employing ammonia or urea catalyst.
[0004] To alleviate the necessity of supplying the reductant from external sources, NO x reduction technologies employing in-situ reductant production have been proposed. These technologies use various combinations of fuel (or other hydrocarbon additives), air and water to produce an H 2 /CO reductant mixture on-board the vehicle for NO x removal. One such exhaust NO x reduction technique using a reductant produced on-board a vehicle is described in U.S. Pat. No. 7,163,668 B2 (the '668 patent) issued to Bartley et al. on Jan. 16, 2007. In the NO x reduction approach described in the '668 patent, diesel fuel is partially oxidized to produce a reductant mixture of hydrogen (H 2 ) and carbon monoxide (CO) with traces of carbon dioxide (CO 2 ) and water (H 2 O). The mixture is then passed into the exhaust gas stream of an engine. The exhaust, along with the reductant mixture, is then passed through a hydrogen SCR(H—SCR), where the H 2 in the mixture reduces the NO x to nitrogen and water.
[0005] Although the NO x reduction technique of the '668 patent may alleviate the need to supply the reductant from external sources, the described approach may have some drawbacks. A common problem with such reductant systems is CO and hydrocarbon “slip.” Slip describes exhaust pipe emissions of CO and hydrocarbon that occur when exhaust gas temperature is too cold for the SCR reaction to occur, and/or when the injection device feeds too much reductant into the exhaust gas stream for the amount of NO x present. In the NO x reduction technique of the '668 patent, in addition to the CO tail pipe emissions that result from diesel fuel oxidation, incomplete oxidation of the diesel fuel may also cause hydrocarbon tail pipe emissions to increase. Using diesel fuel to generate the hydrogen gas may also increase the fuel consumption, and, thus the operating costs, of the engine.
[0006] The present disclosure is directed at overcoming one or more of the shortcomings set forth above.
SUMMARY OF THE INVENTION
[0007] In one aspect, a hydrogen generator for use with an engine is disclosed. The hydrogen generator includes an exhaust duct situated to receive exhaust from the engine, and an SCR device located within the exhaust duct. The hydrogen generator also includes a housing in fluid communication with the exhaust duct upstream of the SCR device, an electrolyte solution disposed within the housing, and a plurality of electrodes at least partially submerged in the electrolyte solution. The electrodes are electrically powered to produce hydrogen gas, and the hydrogen gas is directed to mix with the exhaust.
[0008] In another aspect, a method of reducing NO x contained in exhaust gas of an engine is disclosed. The method includes passing electric current through electrodes immersed in an electrolyte to produce hydrogen gas, and mixing the hydrogen gas with an exhaust flow from the engine. The method further includes catalyzing the hydrogen/exhaust gas mixture to reduce the NO x in the exhaust gas.
[0009] In yet another aspect, a machine is disclosed. The machine includes an engine configured to combust fuel/air mixture to produce exhaust gas containing NO x , a fuel delivery system configured to direct fuel into the engine, and a battery configured to crank engine. The machine also includes a housing containing a supply of electrolyte, and a plurality of electrodes at least partially submerged in the electrolyte. The electrodes are powered by the battery to produce hydrogen gas. The machine also includes an SCR device, which receives a mixture of the hydrogen gas and the exhaust gas, and reduces at least a portion of the NO x to nitrogen and water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic illustration of an exemplary disclosed engine system;
[0011] FIG. 2 is a diagrammatic illustration of an exemplary disclosed hydrogen generator for use with the engine of FIG. 1 ; and
[0012] FIG. 3A and FIG. 3B are exemplary embodiments of an exemplary disclosed electrode for use with the hydrogen generator of FIG. 2 .
DETAILED DESCRIPTION
[0013] FIG. 1 illustrates a machine 500 having an engine system 400 . The machine 500 may be a mobile or stationary machine. Non-limiting examples of the machine 500 include automobiles, trains, generators, construction equipment, etc. The engine system 400 may include various systems and components that cooperate to convert chemical energy contained in a fuel to mechanical work. Engine system 400 may include, among others, a power source 10 , a fuel/air input system 20 , an exhaust system 30 , and a hydrogen generator 100 . Power source 10 may be coupled between fuel/air input system 20 and exhaust system 30 . Fuel/air input system 20 may input a fuel 5 and air into the power source 10 for combustion. Exhaust system 30 may remove exhaust gases 25 produced by the combustion process from power source 10 .
[0014] Power source 10 may include an internal combustion engine such as, for example, a diesel engine, a gasoline engine, a natural gas engine, or any other engine apparent to one skilled in the art. During operation, power source 10 may convert heat energy released by the combustion of fuel 5 (a hydrocarbon based fuel) to mechanical energy. The combustion process may also release byproducts, such as exhaust gas 25 .
[0015] Fuel/air input system 20 may be configured to introduce fuel 5 for combustion into the power source 10 . Fuel 5 may be input into power source 10 in a form suitable for efficient combustion. Depending upon the type of power source 10 , this suitable form may include a mixture of fuel 5 and air. In some applications, fuel 5 and air may be input separately into power source 10 . Fuel/air input system 20 may include valves, compressors, carburetors, injectors, pumps, ducting and other components known in the art.
[0016] Exhaust system 30 may direct exhaust gas 25 out of power source 10 . Exhaust gas 25 may comprise many chemical species including, among others, NO x , which may be regulated by government agencies. NO x in exhaust gas 25 includes a mixture of nitrogen dioxide (NO 2 ) and nitrogen oxide (NO). Exhaust system 30 may include components and systems designed to reduce the amount of adverse chemical species in the exhaust gas 25 prior to being released to the environment. These components and systems may include, among others, a particulate filter 32 and an SCR system 34 . Particulate filter 32 may extract solid particulate matter from the exhaust gas 25 , and SCR system 34 may reduce or eliminate the NO x present in the exhaust gas 25 . Exhaust system 30 may also include additional filtration and catalytic conversion devices designed to further reduce the amount of chemical species in exhaust gas 25 .
[0017] Particulate filter 32 may include any filter used in the art to remove particulate matter from the exhaust stream of an engine. In some embodiments, particulate filter 32 may include a flow-through or a wall-flow filter media made of ceramic honeycomb or metal fiber material. Particulate matter contained in exhaust gas 25 may be collected on the filter media while the exhaust gas 25 flows through particulate filter 32 . Particulate filter 32 may require periodic regeneration. Regeneration is the process of removing the accumulated particulate matter from the filter media by burning it off. The particulate filter 32 may be regenerated when a temperature of the particulate matter trapped in the particulate filter 32 reaches an ignition temperature. Regeneration of the particulate filter 32 may be carried out passively or actively. In embodiments where passive regeneration is employed, the filter media may include catalysts to lower an oxidation temperature of the trapped particulate matter. In embodiments where active regeneration is employed, the particulate filter 32 may be associated with heaters to heat the filter media to the oxidation temperature of the trapped particulate matter.
[0018] SCR system 34 may include any catalytic converter known in the art to reduce NO x to nitrogen and water. SCR system 34 may include a porous substrate with a washcoat to support a catalyst. In some applications, this porous substrate may include a ceramic honeycomb or various metal type substrates. The washcoat may form a rough irregular surface on the porous substrate and may increase the surface area of the substrate. The catalyst may be coated on the surface of the substrate. In some embodiments, the catalyst may be added as a suspension in the washcoat before application to the substrate. The catalyst may include a metal or a metal oxide. In some embodiments, the catalyst may include a precious metal, such as platinum, palladium or rhodium. Exhaust gas 25 may be mixed with a reductant, such as, for example, H 2 75 and then passed through the SCR system 34 . While in the SCR system 34 , chemical reactions may reduce some or all of the NO x present in exhaust gas 25 to N 2 and H 2 O. The catalyst of the SCR system 34 may affect the rate of these reactions. The current disclosure can be used with any known SCR substrate and catalyst.
[0019] Hydrogen generator 100 may produce the reductant H 2 75 , which is mixed with the exhaust. In some embodiments, hydrogen generator 100 may produce a mixture of H 2 75 in combination with other liquids or gases. In these embodiments, a gas separator 110 may separate the H 2 75 from the mixture. H 2 75 produced by hydrogen generator 100 may be input to engine system 400 at multiple locations. In some embodiments, H 2 75 may be input to both fuel/air input system 20 and exhaust system 30 . It is contemplated that, in some embodiments, H 2 75 may be input into only one of these systems. In embodiments where H 2 75 is directed into fuel/air input system 20 , an inlet duct 120 may direct the H 2 75 into the fuel 5 upstream of engine 10 . It is contemplated that, in some embodiments, the H 2 75 may alternatively or additionally be directed into an air supply prior to mixing with fuel 5 . It is also contemplated that, in some embodiments, H 2 75 may be input directly into a combustion chamber of power source 10 . In embodiments where H 2 75 is directed into exhaust system 30 , an inlet duct 130 may direct the H 2 75 into exhaust gas 25 at a location downstream of engine 10 . In some embodiments, H 2 75 may be input into the exhaust downstream of particulate filter 32 .
[0020] Hydrogen generator 100 may produce H 2 75 on-board machine 500 . For instance, hydrogen generator 100 may be configured to produce H 2 75 by electrolysis of an electrolyte. Electrolysis is a method of separating bonded elements and/or compounds in an electrolyte by passing an electric current through the electrolyte. In some embodiments, water may be used as the electrolyte. In these embodiments, electrolysis of water decomposes water into oxygen and hydrogen gas with the aid of an electric current. It is also contemplated that an acid or a base material mixed with water may serve as the electrolyte. In some embodiments, hydrogen generator 100 may produce a mixture of H 2 75 and other gases. In these embodiments, gas separator 110 may separate H 2 75 from the mixture of gases.
[0021] FIG. 2 illustrates an exemplary hydrogen generator 100 that may be located on-board machine 500 and used in conjunction with engine system 400 . Hydrogen generator 100 may be disposed at any location relative to engine system 400 . In some applications, hydrogen generator 100 may be mounted on engine system 400 . It is also contemplated that in some applications, hydrogen generator 100 may be formed integral with engine system 400 . Hydrogen generator 100 may include a housing 112 . Housing 112 may be made of any material that can safely contain an electrolyte 128 , and can withstand temperatures produced during electrolysis of electrolyte 128 . Although housing 112 of a rectangular shape is depicted in FIG. 2 , housing 112 may be of any shape. Housing 112 may be of unitary construction, or may include multiple parts (for instance, a body and a lid) attached together.
[0022] Housing 112 may also include ports that provide access to the inside thereof. These access ports may include, among others, a gas port 114 and an electrolyte port 118 . Gas port 114 may serve as an outlet for the gas produced within hydrogen generator 100 . Electrolyte port 118 may serve as a conduit for replenishment of electrolyte 128 . Although only one gas port 114 and one electrolyte port 118 are depicted in FIG. 2 , it is contemplated that other embodiments may include multiple gas ports 114 and/or multiple electrolyte ports 118 . Multiple electrodes 126 may also be included within housing 112 . A portion of these electrodes 126 may be at least partially immersed in electrolyte 128 .
[0023] Electrodes 126 may include an anode electrode 28 , and a cathode electrode 26 . The electrodes 126 may also include one or more secondary electrodes 24 interposed between anode electrode 28 and cathode electrode 26 . In some embodiments, some or all of the secondary electrodes 24 may be electrically connected to each other. Different connection schemes may be used to connect the electrodes. For example, in some embodiments, half of all the secondary electrodes 24 may be connected to the cathode electrode 26 , while the other half of secondary electrodes 24 may be connected to the anode electrode 28 . In some embodiments, the electrodes 126 may have a fixed spatial relationship to each other. In these embodiments, it is contemplated that housing 112 may include some mechanism to maintain the fixed spatial relationship between electrodes 126 . In some embodiments, spacing between adjacent electrodes 126 may be substantially constant. Electrical cables may connect anode and cathode electrodes 28 , 26 to poles of a power source (not shown). In some embodiments, an anode cable 122 may electrically connect anode electrode 28 to the negative pole of the power source, and a cathode cable 124 may electrically connect cathode electrode 124 to the positive pole of the power source. In some embodiments, electrical cables 122 and 124 may connect anode electrode 28 and cathode electrode 26 to different connection points on the external surface of housing 112 . In these embodiments, additional electrical cables may connect these connection points to appropriate poles of the power source. The power source may be a battery of machine 500 used to crank engine 400 and power other components of machine 500 .
[0024] Electrodes 126 may be made of any electrically conductive material. In some embodiments, electrodes 126 may be made of a base metal. Non-limiting examples of materials that may be used as electrodes 126 include iron, aluminum, chromium, nickel, tin, and lead. In general, electrodes 126 may have a solid or a porous structure. FIGS. 3A and 3B show two embodiments of an electrode having a porous structure. The electrode surface area in contact with the electrolyte 128 may be higher for electrodes 126 having a porous structure. Consequently, gas production with electrodes 126 having a porous structure may also be higher. Electrodes 126 having a porous structure may include open cell foams, high porosity sintered metal fibers, metal mesh and the like.
[0025] Any electrolyte 128 may be used with hydrogen generator 100 . In some embodiments, electrolyte 128 may include water. However, other electrolytes such as acidic solutions, aqueous bicarbonate solutions, hydroxide solutions, or mixtures thereof are also contemplated. As mentioned earlier, when a voltage is applied to anode electrode 28 and cathode electrode 26 , electrolyte 128 may decompose to produce H 2 . In embodiments where electrolyte 128 is water (pure or mixed with other electrolytes), the electrolyte 128 may decompose according to Eq. 1 below:
[0000] 2H 2 O→2H 2 +O 2 Eq. 1
[0026] The resulting H 2 and O 2 mixture may exit the hydrogen generator 100 through gas port 114 , and H 2 may be separated from the mixture by gas separator 110 . Energy may also be released during the decomposition process. The released energy may increase the temperature of hydrogen generator 100 .
[0027] Electrolyte 128 may be consumed during operation of hydrogen generator 100 . The consumed electrolyte 128 may be replenished through the electrolyte port 118 . Although not shown in FIG. 2 , hydrogen generator 100 may include sensors and alarms to detect a low amount of electrolyte 128 , and warn an operator when the electrolyte level drops below a preset value. Hydrogen generator 100 may also include valves and other safety features for the safe operation of hydrogen generator 100 . These safety features may include gas release valves and pressure indicators that maintain the pressure within housing 112 within acceptable limits.
[0028] As described above, decomposition of electrolyte 128 by electrolysis may produce hydrogen gas as a mixture of gases. H 2 75 may then be separated from this gaseous mixture in gas separator 110 prior to mixing with fuel 5 or exhaust gas 25 . In some applications, it may be desirable to eliminate gas separator 110 and produce substantially only hydrogen gas in hydrogen generator 100 . In these embodiments, an electrochemical reaction may be used to produce H 2 75 as substantially the only reaction product, and the H 2 75 may be directly mixed with fuel 5 and/or exhaust gases 25 . An electrochemical reaction is a chemical reaction between the electrodes and the electrolyte when an electric current passes through them. The electrochemical reaction in such an embodiment may proceed as indicated in Eq. 2 below:
[0000] 2M+2H 2 O+2OH − →2M(OH) 2 +H 2 +2 e − Eq. 2
[0029] Any metal (M) can be used as electrodes 126 . However, since electrodes 126 may be consumed in the electrochemical reaction, they may need more frequent replacement, as compared to a hydrogen generator 100 producing H 2 75 by electrolysis of electrolyte 128 . Therefore, in the electrochemical embodiments, low cost and easy availability of the electrode material may be important factors in the selection of electrodes 126 .
[0030] An elevated temperature may increase the rate of the electrolysis reaction. Therefore, a heater 116 may be provided in hydrogen generator 100 to vary the rate of H 2 75 production. In some embodiments, heater 116 may be an external heater. In some embodiments, operation of heater 116 may be controlled to vary the rate of H 2 75 production depending upon the need for NO x reduction by machine 500 .
[0031] An electronic control module (ECM) 50 (shown in FIG. 1 ) may be used to control the rate of H 2 75 production based on the needs of machine 500 . In some embodiments, ECM 50 may be part of a larger control system of machine 500 . ECM 50 may be any control device that affects the operation of exhaust system 30 based on inputs from multiple sensors. These sensors may include, among others, an upstream NO x sensor 54 , a downstream NO x sensor 56 , a hydrogen sensor 58 , and a temperature sensor 52 .
[0032] Upstream NO x sensor 54 may be connected on the upstream side of SCR system 34 , and may measure the quantity of NO x present in exhaust gases 25 upstream of SCR system 34 . Downstream NO x sensor 56 may be connected on the downstream side of SCR system 34 , and may measure the quantity of NO x present in exhaust gases 25 downstream of SCR system 34 . Using measurements from upstream NO x sensor 54 and downstream NO x sensor 56 , ECM 50 may determine the NO x conversion efficiency of SCR system 34 .
[0033] Hydrogen sensor 58 may measure H 2 75 flow from hydrogen generator 100 into the exhaust stream. Hydrogen sensor 58 may be a flow meter or other kind of measurement device that is capable of measuring the quantity of H 2 75 flowing through inlet duct 130 . Some embodiments may also include measurement devices that measure the concentration of hydrogen gas emanating from hydrogen generator 100 and gas separator 110 .
[0034] Temperature sensor 52 may include any type of sensor that measures a temperature of hydrogen generator 100 . Although FIG. 2 depicts the temperature sensor 52 as being positioned to measure a temperature of electrolyte 128 , temperature sensor 52 can alternatively be positioned to measure a temperature anywhere within hydrogen generator 100 .
[0035] ECM 50 may perform numerous control functions to increase the efficiency and promote safe operation of the hydrogen generator 100 and exhaust system 400 . Non-limiting examples of some of the control tasks that may be performed by ECM 50 include: decreasing H 2 production in hydrogen generator 100 when NO x content in exhaust gas 25 is low, shutting down hydrogen generator 100 when temperature sensor 52 indicates an excessive temperature or when other sensors in hydrogen generator 100 indicate an abnormal condition, warning a machine operator at the occurrence of an event, etc.
[0036] In some embodiments, ECM 50 may control the electric current to heater 116 ( FIG. 2 ) or electric current to cathode electrode 26 and anode electrode 28 to regulate the amount of H 2 75 produced based on the NO x conversion efficiency. For instance, if NO x sensor 56 indicates an excessive concentration of NO x , H 2 75 production in hydrogen generator 100 may be increased. ECM 50 may also control H 2 production based on a desired ratio of H 2 :NO x . The rate of NO x reduction in SCR system 34 may be affected by the relative concentrations of NO x and H 2 . Typically, a 1:1 molar ratio of NO to H 2 will enable efficient reduction of NO, and a 1:2 molar ratio of NO 2 to H 2 will enable efficient reduction of NO 2 . Typically, a H 2 :NO x ratio between about 1 and about 3 may enable efficient NO x removal from exhaust gas 25 .
[0037] In some embodiments, a portion of the H 2 75 produced by hydrogen generator 100 may be input into fuel/air input system 20 . The hydrogen enhanced fuel 5 may result in increased engine efficiency and/or less NO x in exhaust gas 25 . In some cases, H 2 75 produced in excess of what is needed to reduce NO x in SCR system 34 may be diverted to the fuel/air system 20 . In some embodiments, excess H 2 75 may be stored in a hydrogen storage vessel 115 . This stored H 2 75 may then be used to respond to rapid increases in H 2 demand and/or extended or excessive H 2 demands.
INDUSTRIAL APPLICABILITY
[0038] The disclosed hydrogen generator may be applicable to any engine system where NO x reduction is desired. The hydrogen gas chemically reduces NO x to nitrogen and water. To illustrate the operation of the hydrogen generator, an exemplary application will now be described.
[0039] During operation of machine 500 , exhaust gas 25 containing NO x may be released into exhaust system 30 by engine system 400 . In exhaust system 30 , exhaust gas 25 may flow sequentially through particulate filter 32 and SCR system 34 . Particulate matter contained in exhaust gas 25 may be filtered out by particulate filter 32 , so that exhaust gas 25 down stream of particulate filter 32 may contain less particulate matter than exhaust gas 25 upstream of particulate filter 32 . NO x sensor 54 may measure the NO x content in exhaust gas 25 upstream of SCR system 34 . In response to the measured amount of NO x in exhaust gas 25 , ECM 50 may instruct hydrogen generator 100 to produce a corresponding amount of H 2 . Instructing hydrogen generator 100 may include passing electric current from a battery through cathode electrode 26 and anode electrode 28 , and/or by controlling heater 116 to increase the temperature of electrolyte 128 .
[0040] Hydrogen generator 100 may produce H 2 75 by an electrochemical reaction. Iron (Fe) electrodes 126 may be partially immersed in electrolyte 128 made of potassium hydroxide solution (KOH+H 2 O) contained within the hydrogen generator 100 . ECM 50 may control hydrogen generator 100 to produce H 2 75 to achieve a H 2 :NO x ratio in exhaust gas 25 of about 2. Hydrogen generator 100 may produce H 2 75 according to the electrochemical reaction of Eq. 3 below:
[0000] Fe 0 +KOH+2H 2 O→Fe(OH) 3 +K + +H 2 +e − Eq. 3
[0041] H 2 75 produced by the electrochemical reaction may be input into exhaust system 30 through inlet duct 130 . H 2 75 may mix with exhaust gas 25 before entering the SCR system 34 . The NO x components of exhaust gas 25 may react with the mixed H 2 75 in the presence of the catalyst of SCR system 34 in accordance with the chemical reactions of Eq. 4 and Eq. 5 below. These reactions may substantially reduce the NO x content in the exhaust gas 25 released into the atmosphere.
[0000] 2NO+2H 2 →N 2 +2H 2 O Eq. 4
[0000] 2NO 2 +4H 2 →N 2 +4H 2 O Eq. 5
[0042] In the hydrogen generator 100 of the current disclosure, H 2 75 , which is used as the reductant in SCR system 34 , may be produced on-board machine 500 . On-board production of the reductant may eliminate the need for a distribution network to support the use of the technology. In embodiments of hydrogen generator 100 , where H 2 75 is produced by an electrochemical reaction, the consumable electrodes 126 may need to be supplied to hydrogen generator 100 periodically. However, in these embodiments, selection of a commonly available material as electrodes 126 may minimize the need for a dedicated distribution network.
[0043] Since the reactions within hydrogen generator 100 of the current disclosure produce only non-toxic gases, dangers associated with the release of these gases to the atmosphere may be minimized. In embodiments of the hydrogen generator 100 producing H 2 75 by an electrochemical reaction, gas separation systems may also be unnecessary, thereby decreasing the cost of the hydrogen generator 100 . In addition, since water or another non-fuel electrolyte is used to produce H 2 75 , the fuel efficiency (and thus the operating cost) of machine 500 may be minimally affected.
[0044] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed on-board hydrogen generator. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed hydrogen generator. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.
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A hydrogen generator for use with an engine is disclosed. The hydrogen generator has an exhaust duct situated to receive exhaust from the engine, and an SCR device located within the exhaust duct. The hydrogen generator also has a housing in fluid communication with the exhaust duct upstream of the SCR device, an electrolyte solution disposed within the housing, and a plurality of electrodes at least partially submerged in the electrolyte solution. The electrodes are electrically powered to produce hydrogen gas, and the hydrogen gas is directed to mix with the exhaust.
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This is a Continuation In Part of Co-pending application U.S. Ser. No. 10/401,644 filed Mar. 27, 2003.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates generally to water sports to such as wakeboarding. More particularly, the invention concerns a wake tower of novel construction for use with powerboats for towing a performer behind the boat using a towrope that is connected to the wake tower.
In recent years the sport of wakeboarding has become very popular. As the name implies, the wake boarder intentionally rides the wake of the boat and prefers to have as large wake as possible generated behind the boat. Experience has shown that to take full advantage of the wake generated by the boat, it is preferable to anchor the towline used to tow the wake boarder at a relatively high elevation above the deck of the boat. Accordingly, a large number of elevated wake towers of various constructions have been suggested in the past.
Typically, the prior art wake towers comprise a rather large and somewhat elaborate framework that is affixed to the boat deck. Such prior art wake towers are heavy and generally quite cumbersome to install and remove from the boat. Further, such towers may interfere with the boat's passage beneath bridges and other types of overpasses. Additionally, because of the complexity of the framework of several of the prior art wake towers, visibility of the operator of the boat can be impaired. Exemplary of prior art wake towers are those illustrated and described in U.S. Pat. No. 5,979,350 issued to Larson et al. and U.S. Pat. No. 6,193,819 issued to Larson et al.
To accommodate the overhead clearance problem, certain of the prior art wake tower structures can be dismantled if necessary. However, such prior art structures often have questionable structural stability when erected and can present substantial safety hazards after being disassembled. For example, after the wake tower structures have been disassembled they can present a substantial tripping hazard to passengers on the boat especially when the boat is being rocked by waves. Further, in their dismantled configuration, the wake tower structures typically undesirably reduce the usable space on the boat deck.
Another approach to accommodating overhead clearance problems has been to construct a wake tower assembly that is pivotally interconnected with the boat so that the wake tower can be moved from an elevated position to a lowered position. Exemplary of this prior art approach, it is a wake tower assembly sold by the Titan Company of Rancho Cordova, Calif.
SUMMARY OF THE INVENTION
By way of summary, one form of the wake tower assembly of the present invention comprises a first base member that can be connected to the gunwale on one side of a power boat; a second base member that can be connected to the gunwale on the opposite side to of a power boat; a generally U-shaped, structural member having a first curved side connected to the first base member and a second curved side connected to the second base member, each of the sides having an upper portion and a lower portion each of which is generally oval in cross-section, the lower portion of each of the sides having a first width and the upper portion of each of the sides having a second width less than the first width; and a bight portion interconnecting the upper portions of the sides, the bight portion being generally circular in cross-section. In one form of the invention, the U-shaped structural member can be pivoted downwardly toward the bow of the powerboat and in another form of the invention the U-shaped structural member can be pivoted downwardly toward the stern of the boat.
With the foregoing summary in mind, it is an object of the present invention to provide a highly attractive wake tower assembly of a unique, generally U-shaped configuration that can be readily mounted on powerboats of various constructions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally perspective view of one form of the wake tower of The present invention shown affixed to the gunwales of a powerboat.
FIG. 2 is a top view, partly in cross-section, illustrating one form of the method of the invention for making the wake tower.
FIG. 3 is a side elevational view, partly in cross-section further illustrating the method of the invention for making the wake tower.
FIG. 4 is a side elevational view, partly broken away to show internal construction, of the form of the wake tower shown in FIG. 1 .
FIG. 5 is a view taken along lines 5 — 5 of FIG. 4 .
FIG. 6 is a greatly enlarged, cross-sectional view taken along lines 6 — 6 of FIG. 5 .
FIG. 7 is an enlarged, cross-sectional view taken along lines 7 — 7 of FIG. 6 .
FIG. 8 is in enlarged, cross-sectional view taken along lines 8 — 8 of FIG. 6 .
FIG. 9 is in enlarged, cross-sectional view taken along lines 9 — 9 of FIG. 6 .
FIG. 10 is a generally perspective, exploded view of one of the base members and one of the connecting segments of the wake tower of the invention.
FIG. 11 is a fragmentary cross-sectional view of the lower portion of one side of the wake tower of the invention illustrating the manner in which the wake tower pivots relative to the base member.
FIG. 12 is a generally perspective view of an alternate form of wake tower of the present invention shown mounted on the gunwales of a powerboat.
FIG. 13 is a side elevational view illustrating the manner of making one of the side members of the wake tower shown in FIG. 12 .
FIG. 14 is a side elevational view of the wake tower of the alternate form of the invention shown in FIG. 12 .
FIG. 15 is an enlarged, cross-sectional view taken along lines 15 — 15 of FIG. 14 .
FIG. 16 is a view taken along lines 16 — 16 of FIG. 14 .
FIG. 17 is a greatly enlarged, cross-sectional view taken along lines 17 — 17 of FIG. 16 .
FIG. 18 is a cross-sectional view taken along lines 18 — 18 of FIG. 17 .
FIG. 19 is a cross-sectional view taken along lines 19 — 19 of FIG. 17 .
FIG. 20 is a cross-sectional view taken along lines 20 — 20 of FIG. 17 .
FIG. 21 is a fragmentary cross-sectional view similar to FIG. 17 , but illustrating the rearward pivotal moment of the wake tower of the alternate form of the invention.
FIG. 22 is a side elevational view of still another form of the wake tower of the invention that is cast from a metal such as aluminum.
FIG. 23 is an enlarged, cross-sectional view taken along lines 23 — 23 of FIG. 22 .
FIG. 24 is a cross-sectional view taken along lines 24 — 24 of FIG. 23 .
FIG. 25 is a greatly enlarged cross-sectional view of the area designated as “ 25 ” in FIG. 22 .
FIG. 26 is a cross-sectional view taken along lines 26 — 26 of FIG. 25 .
FIG. 27 is a cross-sectional view taken along lines 27 — 27 of FIG. 25 .
FIG. 28 is a generally perspective view of still another form of the wake tower of the present invention shown affixed to the gunwales of a powerboat.
FIG. 29 is a side elevational view, of the form of the wake tower shown in FIG. 28 .
FIG. 30 is a view taken along lines 30 — 30 of FIG. 29 .
FIG. 31 is an enlarged, cross-sectional view taken along lines 31 — 31 of FIG. 29 .
FIG. 32 is an enlarged, cross-sectional view taken along lines 32 — 32 of FIG. 29 .
FIG. 33 is an enlarged, cross-sectional view taken along lines 33 — 33 of FIG. 29 .
FIG. 34 is an enlarged, cross-sectional view taken along lines 34 — 34 of FIG. 30 .
FIG. 35 is an enlarged, cross-sectional view taken along lines 35 — 35 of FIG. 30 .
FIG. 36 is an enlarged, cross-sectional view taken along lines 36 — 36 of FIG. 35 .
FIG. 37 is an enlarged, cross-sectional view taken along lines 37 — 37 of FIG. 35 .
FIG. 38 is a cross-sectional view taken along lines 38 — 38 of FIG. 35 .
FIG. 39 is a cross-sectional view taken along lines 39 — 39 of FIG. 35 .
FIG. 40 is a generally perspective, exploded view of the base assembly shown in FIGS. 35 through 39 .
FIG. 41 is a fragmentary, cross-sectional view similar to FIG. 35 showing the generally U-shaped, upwardly extending assembly pivoted into a stowed position.
FIG. 42 is a fragmentary, cross-sectional view similar to FIG. 41 further, illustrating the downward and rearward pivotal movement of the U-shaped assembly.
DESCRIPTION OF THE INVENTION
Referring to the drawings and particularly to FIGS. 1 , 4 and 5 , one form of the wake tower of the invention is shown interconnected with a powerboat 30 of conventional construction having a bow portion 30 a and a stem portion 30 b . As best seen in FIG. 5 , the powerboat also has first and second spaced apart gunwales 32 and 34 respectively to which the wake tower is connected. In the present form of the invention the wake tower includes an upwardly extending first base member 36 connected to the first gunwale 32 and an upwardly extending second base member 38 connected to said second gunwale 34 . The base members 36 and 38 are of a curved configuration and are preferably cast from a lightweight metal such as aluminum.
Interconnected with the base members is a generally U-shaped, upwardly extending structural assembly generally designated by the numeral 40 . The structural assembly 40 includes a generally “L” shaped structural member 42 having a first curved side 42 a and a cast aluminum first connector segment 44 . Structural member 42 a is connected to aluminum first connector segment 44 by any suitable means such as welding. In a manner presently to be described, connector segment 44 is, in turn, pivotally connected to first base member 36 . Structural assembly 40 also includes a second generally “L” shaped structural member 46 having a curved side 46 a and a second, cast aluminum connector segment 48 that is connected to second curved side 46 a by any suitable means such as welding. Connector segment 48 is, in turn, pivotally connected second base member 38 .
As will be discussed in greater detail hereinafter, each of the sides of structural assembly 40 is first swaged into the desired configuration and then is strategically formed to create a curved, tapered portion having an oval shape. More particularly, as best seen in FIGS. 1 and 4 , each of the sides of the structural assembly 40 includes a lower portion 51 having a first width W and an upper portion 53 having a second width W- 1 that is substantially less than said first width W. structural assembly 40 further includes a bight portion 54 interconnecting upper portions 53 of the sides. As indicated in FIG. 4 , bight portion 54 is generally circular in cross-section.
In the form of the invention shown in FIGS. 1 through 11 , the wake tower further includes a tow rope connector member 56 that is connected to and spans upper portion 53 of the sides 42 and 46 . Connected to the connector member 56 is a conventional type of connector 58 to which the towrope “TR” can be connected.
Turning next to FIGS. 6 , 7 and 8 , a portion of one side of the wake tower of the invention is there shown. It is to be understood that the other side of the wake tower is of a similar construction, but is not shown in the drawings in order to simplify the description. Each of the base members is provided with a cavity 60 and each of the connector segments is provided with a pair of spaced apart, downwardly extending ears 62 and 64 that are receivable within the base member cavities. As shown in FIG. 6 , downwardly extending ear 62 has a bore 62 a formed therein and, similarly, downwardly extending ear 64 has a bore 64 a formed therein. Receivable within bore 62 a is a pivot pin 66 about which side 46 and connector segment 48 can pivot in the manner shown in FIG. 11 .
As illustrated in FIGS. 9 and 10 , pivot pin 66 extends through aligned bores 69 formed in base member 38 . Similarly, a locking pin 72 is receivable within bore 64 a formed in ear 64 . Locking pin 72 extends through aligned bores 73 formed in base member 38 and, when in position within these openings in the manner shown in FIGS. 6 to 9 , prevents pivotal movement of side 46 and connector segment 48 about pivot pin 66 . As indicated by the phantom lines in FIG. 7 , when the locking pin 72 is removed from the base member, the combination of side 46 and connector segment 48 is free to pivot about pivot pin 66 in the manner shown in FIG. 11 .
In accordance with one form of the method of making the wake tower illustrated in FIGS. 1 through 11 , the first and second base members 36 and 38 are cast in a conventional manner from a suitable lightweight castable material such as aluminum and are appropriately finished. This done, the base members are interconnected with the powerboat by a plurality of threaded connectors 76 in the manner shown in FIG. 6 .
The side members 42 a and 46 a are each formed individually by first heating a first length of tubing to an elevated, annealing temperature. This first length of tubing, which by way of example can be 6061-T6 aluminum tubing that has a diameter of approximately 5 inches, a first end 80 a and a second end 80 b . In the manner illustrated in FIG. 2 , the heated length of tubing is swaged in a conventional manner well known to those skilled in the art to form a first swaged tube 80 having a tapered swaged portion 82 having a first end 84 of first diameter D- 1 and a second end 86 of a second lesser diameter D- 2 and a uniform diameter portion 86 a having a diameter D- 3 substantially equal to said second lesser diameter D- 2 .
Using an appropriate forming die, the tapered swaged portion 82 of the swaged tube 82 is strategically formed to produce a tapered swaged portion 82 a and an elongated uniform diameter portion 86 a (FIG. 3 ). As illustrated in FIG. 3 , swaged portion 82 a is generally oval shaped in cross-section and has a thickness “E”. Swaged portion 82 a has a width W- 1 , while uniform diameter portion 86 a has a lesser width W- 2 . This swaging step is done in a conventional manner using conventional tooling that is of the character well understood by those skilled in the art.
Following the swaging step, the swaged to first tube 80 is strategically bent into the desired shape to form a first bent tube that is generally “L” shaped in configuration and generally corresponds to the shape of member 42 a.
Next, first connector segment 44 is cast in a conventional manner from a light weight castable material such aluminum and is connected by any suitable means such as welding to the bent tube formed by the swaging step to form a first wake tower subassembly 42 , which generally corresponds to one-half of the structural assembly 40 .
Following the forming of the first wake tower subassembly, a second length of aluminum tubing is swaged and formed in the identical manner described in the preceding paragraphs to produce a second side 46 a . This done, second connector segment 48 is suitably cast from a light weight metal such as aluminum and is interconnected as by welding to form assembly 46 that generally corresponds to the second half of the structural assembly 40 .
Next, the elongated, uniform diameter portions of the first and second wake tower subassemblies 42 and 46 are interconnected at their ends as by a welding to form the structural member 40 .
After completion of the construction of the structural member 40 in the manner described in the preceding paragraphs, the structural member is pivotally interconnected with the base members 36 and 38 in the manner depicted in FIGS. 6 through 10 of the drawings to form the construction shown in FIGS. 1 and 3 . More particularly, the ears formed on each of the connector segments are inserted into the base cavities, the pivot pins 66 are inserted into bores 69 and 62 a and the locking pins are inserted into bores 73 and 64 a . With this construction, when it is desired to pivot the structural member into the forwardly stowed position in the manner illustrated in FIG. 11 , locking pin 72 are removed from bores 73 and 64 a to permit the structural member to pivot about pivot pin 66 .
Turning next to FIGS. 12 through 21 an alternate form of the wake tower of the invention is shown and generally designated by the numeral 90 . This embodiment is similar in many respects to the embodiment shown in FIGS. 1 through 11 and like numerals are used in FIGS. 12 through 21 to identify like components. One of the main differences between this latest form of the invention and the earlier described form resides in the fact that the wake tower slopes rearwardly instead of forwardly and instead of being pivotally movable toward the bow of the boat is pivotally movable toward the stern of the boat as shown in FIG. 14 of the drawings.
Referring to FIG. 12 of the drawings, wake tower 90 is shown interconnected with a powerboat 30 of conventional construction having a bow portion 30 a , a stern portion 30 b and first and second spaced apart gunwales 32 and 34 respectively. In this latest form of the invention, the wake tower includes an upwardly extending first base member 96 that is connected to the first gunwale 32 and an upwardly extending second base member 98 that is connected to said second gunwale 34 . The base members 96 and 98 are of a curved configuration and are preferably cast from a lightweight metal such as aluminum.
Interconnected with the base members is a generally U-shaped, upwardly extending structural assembly generally designated by the numeral 100 . The structural assembly 100 includes a generally “L” shaped structural member 102 having a first curved side 102 a and a cast aluminum first connector segment 104 . Structural member 102 is connected to aluminum first connector segment 104 by any suitable means such as welding. In a manner presently to be described, connector segment 104 is, in turn, pivotally connected to first base member 96 . Structural assembly 100 also includes a second generally “L” shaped structural member 106 having a curved side 106 a and a second, cast aluminum connector segment 108 that is connected to second curved side 106 a by any suitable means such as welding. Connector segment 108 is, in turn, pivotally connected to second base member 98 .
As in the earlier described embodiment of the invention, each of the sides of structural assembly 100 is first swaged into the desired configuration and then is strategically formed to create an elongated swaged portion having an oval shape (see FIGS. 13 and 15 ). As indicated in FIG. 14 , in this latest form of the invention, the bight portion 110 of the structural assembly 100 is also generally oval shaped in cross-section. Unlike the earlier described embodiment of the invention, the tow rope TR is directly connected to a connector 112 that is connected to bight portion 110 proximate the center thereof.
Turning next to FIGS. 17 through 21 , a portion of one side of the wake tower of this latest form of the invention is there shown. It is to be understood that the other side of the wake tower is of a similar construction, but is not shown in the drawings in order to simplify the description. As best seen in FIGS. 17 and 21 , each of the base members is provided with a cavity 114 and each of the connector segments is provided with a pair of spaced apart, downwardly extending ears 116 and 118 that are receivable within the base member cavities. As shown in FIG. 17 , downwardly extending ear 116 has a bore 116 a formed therein and, similarly, downwardly extending ear 118 , which has a length greater than the length of the ear 116 , has a bore 118 a formed therein. Receivable within bore 118 a is a pivot pin 120 about which side 106 and connector segment 108 can pivot in the manner shown in FIG. 21 . As illustrated in FIGS. 19 and 20 , pivot pin 120 extends through aligned bores 125 formed in base member 98 . Similarly, a locking pin 124 is receivable within bore 116 a formed in ear 116 . Locking pin 124 extends through aligned bores 123 formed in base member 98 and, when in position within these openings in the manner shown in FIGS. 17 and 20 , prevents pivotal movement of side 106 and connector segment 108 about pivot pin 120 . As indicated by the phantom lines in FIG. 20 , when the locking pin 124 is removed from the base member, the combination of side 106 and connector segment 108 is free to pivot about pivot pin 120 in the manner shown in FIG. 21 .
In accordance with an alternate form of the method of making the wake tower illustrated in FIGS. 12 through 21 , the first and second base members 96 and 98 are cast in a conventional manner from a suitable lightweight castable material such as aluminum and are appropriately finished. This done, the base members can be interconnected with the powerboat by a plurality of threaded connectors 129 in the manner shown in FIG. 17 .
The side members 102 a and 106 a are each formed individually by first heating to an elevated, annealing temperature a first length of tubing, such as 6061-T6 aluminum tubing that has a diameter of approximately 5 inches. The heated length of tubing is swaged in a conventional manner well known to those skilled in the art to form a first swaged tube 130 of the general configuration shown in FIG. 12 .
Using an appropriate forming die, the swaged tube 130 is strategically formed so that it is generally oval shaped in cross-section. This swaging step is done in a conventional manner using conventional tooling that is of the character well understood by those skilled in the art. Following the swaging step, the swaged to first tube 130 is strategically bent into the desired shape to form a first bent tube that is generally “L” shaped in configuration and generally corresponds to the shape of member 102 a.
Next, first connector segment 104 is cast in a conventional manner from a light weight castable material such aluminum and is connected by any suitable means such as welding to the bent tube formed by the swaging step to form a first wake tower subassembly 102 , which generally corresponds to one-half of the structural assembly 100 .
Following the forming of the first wake tower subassembly, a second length of aluminum tubing is swaged and formed in the identical manner described in the preceding paragraphs to produce a second side 106 a . This done, second connector segment 108 is suitably cast from a light weight metal such as aluminum and is interconnected as by welding was second side 106 a to form assembly 106 that generally corresponds to the second half of the structural assembly 100 .
Next, the first and second wake tower subassemblies 102 and 106 are interconnected at their ends as by a welding to form the structural member 100 . After completion of the construction of the structural member 100 in the manner described in the preceding paragraphs, the structural member is pivotally interconnected with the base members 96 and 98 in the manner depicted in FIGS. 6 through 10 of the drawings to form the construction shown in FIGS. 12 and 16 . More particularly, the ears formed on each of the connector segments are inserted into the base cavities, the pivot pins 120 are inserted into bores 123 and 118 a and the locking pins are inserted into bores 125 and 116 a . With this construction, when it is desired to pivot the structural member rearwardly into the stowed position in the manner illustrated by the phantom lines in FIG. 14 , locking pin 124 is removed from bores 125 and 116 a to permit the structural member to pivot about pivot pin 120 .
Referring to FIGS. 22 through 27 , still another form of the wake tower of the invention is there shown and generally designated by the numeral 140 . This embodiment is also similar in many respects to the embodiment shown in FIGS. 1 through 11 and like numerals are used as in in FIGS. 12 through 21 to identify like components. The main differences between this latest form of the invention and that earlier described resides in the fact that the wake tower is cast by conventional casting techniques from a lightweight metal such as aluminum or from other suitable castable materials such as plastic.
Referring to FIG. 22 of the drawings, wake tower 140 is interconnected with a powerboat 30 of the previously described, conventional construction having a bow portion, a stern portion and first and second spaced apart gunwales. As before, the wake tower includes an upwardly extending first base member 36 that is connected to the first gunwale and an upwardly extending second base member 38 that is connected to said second gunwale. The base members are of a curved configuration and are also preferably cast from a lightweight material such as aluminum or the like.
Interconnected with the base members is a generally U-shaped, upwardly extending structural assembly generally designated by the numeral 142 . The structural assembly 142 includes a pair of generally “L” shaped structural members each having a curved side 142 a and a connector segment 142 b that includes a basewall 142 c that closes the lower extremity of the curved sides 142 a . The connector segments 142 b are pivotally connected to the first and second base members in the manner previously described to enable the structural assembly to be pivoted into the stowed position as illustrated in FIG. 29 . More particularly, as earlier discussed herein, the ears 62 and 64 , which form a part of the connector segments, are inserted into the base cavities 60 , the pivot pins 66 are inserted into bores 62 a and the locking pins are inserted into bores 64 a . With this construction, when it is desired to pivot the structural member into the stowed position in the manner previously described, locking pins 72 are removed from bores 73 to permit the structural member to pivot about pivot pins 66 .
As best seen in FIGS. 22 and 25 , each of the sides of the structural assembly 140 includes a lower portion having a first width W and an upper portion having a second width W- 1 that is substantially less than said first width W. Structural assembly 140 further includes a bight portion 144 that interconnects the upper portions of the sides (FIG. 22 ). As indicated in FIGS. 22 , 23 and 24 , bight portion 144 is generally circular in cross-section. At the time of assembly of the structural assembly 142 , the bight portions are interconnected together by any suitable means such as welding (see FIG. 23 ). As illustrated in FIG. 26 , the sides of the structural assembly are generally oval in cross-section. It is to be understood that the two sides of the wake tower 140 are of a similar construction, but only one side a shown in the drawings in order to simplify the specification.
In this latest form of the invention, like the form of the invention shown in FIGS. 1 through 11 , the wake tower 140 further includes a tow rope connector member 146 that is connected to and spans upper portion of the sides 142 a . Connected to the connector member 146 is a conventional type of connector 58 to which the towrope “TR” can be connected.
Referring to FIGS. 28 through 42 still another form of the wake tower of the invention is there shown and generally designated by the numeral 150 . This embodiment is also similar in some respects to the embodiment shown in FIGS. 1 through 11 and like numerals are used in FIGS. 28 through 42 to identify like components. One of the main differences between this latest form of the invention and the earlier described form resides in the fact that the side portions of the wake tower are of a different shape and of a different cross-sectional configuration.
Referring particularly to FIGS. 28 , 29 and 30 , wake tower 150 is shown interconnected with a powerboat 30 of conventional construction having a bow portion, a stem portion and first and second spaced apart gunwales 32 and 34 respectively. In this latest form of the invention, the wake tower includes a pair of upwardly extending base assemblies 152 that are connected to the first and second gunwales 32 and 34 . Base assemblies 152 , which are of identical construction, each comprise a base connector 154 and a side connector 156 which forms a part of a generally U-shaped, upwardly extending structural assembly generally designated by the numeral 160 . In the manner shown in FIG. 41 , generally U-shaped, upwardly extending structural assembly 160 is pivotally connected to the base connector (FIG. 35 ). The base connectors and side connectors are preferably cast from a lightweight metal such as aluminum.
Generally U-shaped structural assembly 160 includes a first side assembly 162 , a second side assembly 164 and a bight portion 166 . Each of the side assemblies 162 and 164 , which are of substantially identical construction, is attached as by welding to one of the side connectors 156 in the manner best seen in FIG. 35 . As shown in FIG. 29 , a towrope TR is directly connected to a connector 112 that is connected to bight portion 166 proximate the center thereof.
Referring particularly to FIGS. 31 , 32 and 35 it can be seen that each of the side assemblies 162 and 164 comprises a pair of spaced apart, generally tubular members 168 and 170 which curve upwardly and inwardly. Intermediate their lengths, the tubular members are interconnected by a generally tubular shaped cross member 172 . At their lower extremities, the tubular members are connected to side connectors 156 as by welding and proximate their upper extremities are connected as by welding to bight member 166 which is oval in cross-section (FIGS. 28 and 34 ). Tubular members 168 and 170 cooperate with side connectors 156 to define a generally triangularly shaped opening “O”.
Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims.
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An attractive wake tower assembly of a unique, generally U-Shaped configuration that can be readily pivotally mounted on powerboats of various constructions to enable the wake tower assembly to be pivoted from an upstanding to a lowered position. The wake tower assembly is of a high-strength, simple construction that does not interfere with the visibility of the boat operator. Each of the side members of the assembly has an upper portion and a lower portion, each of which is generally oval in cross section. The lower portion of each of the side members have a first width and the upper portion of each of the side members have a first width; and a bight portion interconnecting the upper portions of the sides, the bight portion being generally circular in cross section.
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FIELD OF THE INVENTION
The present invention relates to a method for producing a highly concentrated lactic-acid product fermented from rice, tasting sweet and sour, and having excellent flavor and texture.
In particular, the present invention relates to a method for producing the product comprising the steps of gelatinizing grainy rice which has not been ground, treating the gelatinized rice with α-amylase and glucoamylase thereby to producing glucose from rice-starch, which is a substrate for lactic acid fermentation, and producing lactic acid continuously by lactic acid fermentation.
SUMMARY OF THE INVENTION
The present invention is directed to a method for producing a highly concentrated, rice-derived lactic acid fermented product which tastes sweet and sour comprising the steps of immersing unground, grainy rice in water to gelatinize it, treating the gelatinized rice with an amylolytic enzyme containing α-amylase and glucoamylase to liquefy and saccharify it, heating the saccharified solution to inactivate the amylolytic enzyme and to sterilize the solution at the same time, inoculating the sterilized solution with a starter containing Streptococcus and Lactobacillus, fermenting the solution at high concentration, and homogenizing the fermented solution.
The present invention is also directed to a method for improving the qualities of a rice-derived, lactic acid fermented product which tastes highly sweet and sour, and of which the flavor and texture are excellent, comprising the steps of immersing unground, grainy rice in water to gelatinize, treating the gelatinized rice with amylolytic enzyme including α-amylase and glucoamylase to liquefy and saccharify it, heating the saccharified solution to inactivate the amylolytic enzyme and to sterilize the solution at the same time, inoculating the sterilized solution with a starter containing Streptococcus and Lactobacillus, fermenting the solution at high concentration, simultaneously with the secondary addition of amylolytic enzyme including α-amylase and glucoamylase in a bacteria-free state to produce glucose, which is a substrate for lactic acid fermentation, and homogenizing the fermented solution, whereby the glucose produced by the secondary enzymatic treatment is continuously fermented into lactic acid providing the final product with plenty of oligoosaccharides, monosaccharides, and lactic acid.
The Streptococcus of both processes discussed above may be Streptococcus thermophilus. The Lactobacillus of both processes discussed above may be Lactobacillus acidophilus, Lactobacillus bulgaricus, or Lactobacillus plantarum.
The mixing ration of Streptobacillus and Lactobacillus is 1 to 1.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the effect of acid-production in rice-derived, lactic acid fermented product by the secondary enzymatic treatment according to the present invention;
FIG. 2 is a graph showing the effect of overall preference in rice-derived, lactic-acid fermented product by the secondary enzymatic treatment according to the present invention; and
FIG. 3 is a photomicrograph showing micro-structure of rice-derived, lactic acid fermented product which has been treated secondarily with the enzyme according to the present invention.
Hereunder, the present invention is described in detail. In the specification, all % is by weight unless specified otherwise.
DETAILED DESCRIPTION OF THE INVENTION
(1) Gelatinization of rice
Rice used in the invention was "Sunchang, Junrabuk-Do" in Korea in 1989. When ground rice suspended in water is gelatinized, the viscosity of the suspension increases greatly and therefore, it is hard to stir the suspension. Accordingly, it is almost impossible to stir the suspension uniformly at a solution concentration of 10-15%. Furthermore, the heat transfer rate of the solution becomes decreased due to its high viscosity, thereby increasing energy consumption.
In the present invention unground, grainy rice is immersed in water at 40°-50° C. for 30 minutes (rice=1:1.25 part by weight), followed by heating the same at 100° C. for 30 minutes to gelatinize the starch thereof.
(2) Primary liquefaction, saccharification and sterilization
Enzymes used in the invention were α-amylase (90 units/mg, manufactured by Sigma Chemical Co., St. Louis, MO., U.S.A.) and glucoamylase (8400 units/g, Sigma Chemical Co., St. Louis, MO., U.S.A.)
A 50-75% enzyme solution containing 0.1% of amylase and 0.1% of glucoamylase is added to the gelatined rice at 55° C. for 1-2 hours, to simultaneously liquefy and saccharify the same simultaneously. Optimum sweetness after saccharification is determined as about 15°-20° Brix. If too much saccharification is conducted, the too much, sweetness of the solution increases too much, inhibiting the growth of lactic acid bacteria due to its high osmotic pressure. The inventors have tried to provide sweetness of the solution suitable for the growth of lactic acid bacteria, employing the enzymes for liquefaction and saccharification which are inactivated by heating at 95° C. for 30 minutes, which also results in sterilization of the solution.
(3) Fermentation with secondary enzymatic treatment
Lactic acid bacteria used in the invention are three species of lactobacillus and one species of Streptococcus. The lactic acid bacteria which can be used in the invention are selected from one or more species from the group consisting Strephococcus thermophilus, Lactoba cillus, acidophilus and L. bulgaricus. L. plantarum bacteria can also be used only if they conduct a lactic acid fermentation from rice. Lactic acid bacteria used in the invention were Lactobacillus acidophilus ATCC 11506, L. bulgaricus KCTC 2179 and L. Plantarum ATCC 8014, and Streptococcus thermophilus KCTC 2185.
The lactic acid bacteria can be used alone or a mixture of one of those three Lactobacillus and Streptococcus thermophilus KCTC 2185,a mixing ratio being 1:1, can be used, also. The lactic acid bacteria are added thereto in an amount of 2%, which have been activated in a rice-saccharified solution.
A starter of lactic-acid bacteria is inoculated therewith and the saccharified solution is treated with sterilized, bacteria-free enzym atic solution in which α-amylase alone or α-amylase mixed with gluco-amylase is contained.
By the treatment with the enzymatic solution, rice-starch is hydrolyzed into glucose, which is a substrate for lactic-acid fermentation, so that glucose is continuously fermented into lactic acid to obtain a fermented product tasting highly sweet and sour. The fermentation is conducted at 37° C. and completed after 15-30 hours. After the (fer) mentation the fermented solution is homogenized by a homogenizer (Nissei AM-8, manufactured by Nihonseiki Kaisha Ltd, Japan) to obtain the final product.
After fermentation for 18 hours, acid-production has been increased greatly due to the secondary enzymatic treatment, compared with a control plot. Also, acid-production with Lactobacillus plantarum appears small but production with the mixed culture (with Streptococcus thermophilus) improves greatly. Generally, acid-production appears larger when fermented by a mixture of Lactobacillus and Streptococcus thermophilus however, acid-production appears small when fermented by Lactobacillus alone.
The results of the organoleptic test for the product fermented for 18 hours are shown in FIG. 2. The organoleptic test (sensory evaluation) which was repeated three times, was conducted by six trained panel members and was evaluated by a 5-point method.
______________________________________ Very good 5 scores Good 4 scores Fair 3 scores Bad 2 scores Very bad 1 scords______________________________________
In consideration of the effects of the secondary enzymatic treatment, the treatment plot with 0.02% of α-amylase reveals no significant difference compared with the control plot; however the treatment with each 0.02% of α-amylase and glucomylase brings about significant improvement in the overall preference (overall eating quality score). Furthermore, examining the overall preference according to the species of lactic acid bacteria, we have found out that the best preference is obtained when the fermentation is conducted by the mixed Lactobacillus bulgaricus and Streptococcus thermophilus, the mixing ratio being 1:1, and each 0.02% of each of α-amylase and glucoamylase are used.
The micro-structure of the product treated with the secondary enzymes, as shown in FIG. 3, brings about a conspicuous reduction in the size of insoluble solid particles, so that the texture in the mouth increases greatly. While not wishing to be bound by any theory, it is believed that insoluble solid portions are caused by the retrogradation of starch, and that the secondary enzymatic treatment prevents starch from retrogradation thereby reducing the size of the solid portion.
It is generally accepted that the critical particle size to be sensed extraneous in the mouth is about 20 μm. The insoluble solids which have been treated with the fermenting strain and the secondary enzymes according to the present invention were measured by a microscope equipped with a micrometer, and the results are shown in Table 1.
TABLE 1______________________________________The effects of the particle size in insoluble solid portionsof rice-derived, lactic acid fermented product by the secondaryenzymatic treatment at fermentation. particle size (μm)lactic acid 0.02% 0.02% α amylase +amylasea control α 0.02% glucoamylase______________________________________L. acidophilus (L.a.) 27.0 11.8 8.2L. bulgaricus (L.b.) 17.4 14.5 8.9L. plantarum (L.p.) 23.0 21.0 12.8S. thermophilus (S.t.) 20.6 8.8 6.9L.a. + S.t. 22.7 10.5 12.5L.b. + S.t. 24.2 13.5 9.3L.p. + S.t. 19.8 10.3 8.1______________________________________
The control, which has not been treated with the secondary enzymes, reveals 17-27 μm in average particle size, whereas the product which has been treated with 0.02% of α-amylase caused reduction of particle size to reach 9-21 μm. The product which has been treated with 0.02% of each of α-amylase and glucoamylase brings about a remarkable reduction of particle size to reach 7-13 μm thereby great contributing toward the improvement in texture.
Lactobacillus bulgaricus and Streptococcus thermophilus selected as improved strains, were used to ferment rice for 18 hours, and the effects of the secondary enzymatic treatment on organoleptic elements are shown in Table 2 with respect to the fermented product thereby obtained.
TABLE 2__________________________________________________________________________The effects to organoleptic elements of rice-derived, lacticacid fermented product with the secondary enzymatic treatmentat fermentationCondition forsecondary Organoleptic elementsenzymatic overalltreatment flavor taste smoothness consistency preference__________________________________________________________________________Control 3.2A 3.8BC 3.7A 3.3A 2.8Camylasealpha. 3.4A 2.9C 2.7B 3.0A 3.8BCamylase +pha. 3.6A 4.0AB 3.7A 2.8A 3.8AB0.02% glucoamylaseamylase +pha. 3.5A 4.3A 4.0A 2.7A 4.3A0.06% glucoamylase__________________________________________________________________________ *There is no significant difference at 5% level with respect to the score marked by the same character in each organoleptic element.
The effects of the secondary enzymatic treatment with respect to preference of flavor, smoothness and consistency reveals no significant difference but remarkable improvements were observed in taste and overall preference.
Significant difference was not recognized between the case treated with 0.02% of each of α-amylase and glucoamylase and the other case treated with 0.06% of each of the same; therefore, the proper level in which α-amylase and glucoamylase are added thereto is determined as 0.02% each of both enzymes.
The properties of the product treated with each of 0.02% of α-amylase and glucoamylase at fermentation using Lactobacillus bulgaricus and Streptococcus thermophilus according to said procedures are shown in Table 3.
TABLE 3______________________________________Properties of rice-derived lactic acid fermented productItem______________________________________pH 2.95acidity (%) 0.53moisture content (%) 76.10solid (%) 23.90protein (%) 2.00sweetness (° Brix) 24.00number of viable 1.54 × 10.sup.8bacteria per mlapparent viscosity (mPa s) 35 (shear rate 100s.sup.-1)______________________________________
EXAMPLE
Rice immersed in water or crushed rice obtained during milling (rice: water=4:5 parts by weight) was heated for 30 minutes to gelatinize, followed by the addition of 75% of amylase-solution containing 0.1% of α-amylase and 0.1% of glucoamylase to the gelatinized rice, thereby to saccharifying the same for 1-2 hours. Thereafter, a starter containing 1% of each of Lactobacillus bulgaricus and Streptococcus thermophilus which have been activated in a rice-saccharified solution was added and 0.02% of each enzyme (α-amylase and glucoamylase) sterilized by passing through a bacteria-free filter was added thereto at 37° C. to ferment for 15-30 hours. After homogenization, the highly concentrated, rice-derived lactic acid fermented product without any additives such as sugar and acid was obtained, which tasted sweet and sour, and of which the flavor and texture were excellent.
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Disclosed is a method for producing a highly concentrated, rice-derived lactic acid fermented product which tastes highly sweet and sour, and of which the flavor and texture are excellent. In this method, unground, grainy rice is gelatinized and then it is liquefied and saccharified by the primary treatment with α-amylase and glucoamylase. After sterilization, it is inoculated with lactic acid bacteria and undergoes a secondary treatment with α-amylase and glucoamylase. The glucose produced thereby continuously ferments to lactic acid. Finally, high concentrated lactic fermented product, tasting sweet and sour, and having excellent flavor and texture, is produced.
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FIELD OF THE INVENTION
[0001] The invention relates to a roller drawing apparatus for spinning machines in which the covering for the pressure roller at the output of a drafting field consists of an outer layer and of an inner layer fastened on the core of the pressure roller. The outer layer is thinner and harder than the inner layer, which outer layer loosely surrounds the inner layer so that the outer layer can move relative to the inner layer.
BACKGROUND
[0002] A roller drawing apparatus is described in DE 102 60 025.2. Since the apron covering on the withdrawal cylinder has a running speed approximately 40 times greater than is the case in customary drafting aprons, it is very important that the apron covering is well guided and causes as little friction as possible on the deflection rail. The tensioning force required for the guidance of the apron covering is therefore very low and is advantageously only produced in that the apron covering tends to assume an approximately circular form in the circumferential direction in the unloaded state (DE 103 48 452 A1). Conditioned by this low tension with which the apron covering glides over the deflection roller, fibers collect on the deflection roller during a rather long operation of this apparatus. As a consequence, laps form around the deflection rail that hinder the easy gliding over the deflection rail and generate a higher and higher tension that finally leads to breaking of the deflection rail.
[0003] Furthermore, the running properties of the apron covering over the deflection rail are adversely affected in that the yarn insert applied to hinder longitudinal expansion is customarily produced by winding a yarn onto the first inner layer, that is then covered with another layer. As a result, it occurs again and again that, at the high running speed, the apron covering behaves asymmetrically corresponding to the winding and has the tendency to run off to one side. This can be counteracted by positioning edges on the deflection rail. However, the borders of the apron covering are stressed and worn down by running against the edge.
SUMMARY
[0004] The present invention addresses the problem of avoiding the described disadvantages and of avoiding adverse effects during the gliding of the very rapidly running apron covering over the deflection rail. Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[0005] It surprisingly turned out that given sufficiently large dimensioning of the circumference of the cross section of the deflection rail, the lap problems of prior art systems can be avoided. The circumference of the cross section of the deflection rail is preferably greater than the length of the longest fiber of the fiber material processed on the drafting apparatus. A running of the rapidly running apron covering against limiting edges is avoided by the curvature of the apron gliding surface of the deflection rail transversely to the running direction of the apron. The limitation by edges can even be entirely eliminated, especially if the covering constructed as an endless apron is provided with a double yarn insert, which yarn inserts are wound in opposing directions. The opposing winding of the yarn inserts eliminates the asymmetric behavior of the apron covering at high running speeds. In addition, the advantage results that when using a rigid holder, the apron covering can still be readily replaced. The rigid holder for the apron covering is preferably mounted on the pressure roller shaft in a freely rotatable manner and is supported via stops on the upper roller carrying arm of the drafting apparatus. In this manner, an especially simple and operationally reliable guidance of the apron covering is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Further details of the invention are described using the drawings.
[0007] FIG. 1 shows a cross section through the drafting apparatus.
[0008] FIGS. 2 to 4 show different cross-sectional profiles of the deflection rail.
[0009] FIG. 5 shows a one-piece design of the deflection rail with the holder.
[0010] FIG. 6 shows a replaceable deflection rail with holder.
[0011] FIG. 7 shows the apron covering with opposingly wound yarn inserts.
[0012] FIG. 8 shows another embodiment of the apron covering holder in a top view.
[0013] FIG. 9 shows the apron covering holder of FIG. 8 in the insertion state and in section.
DETAILED DESCRIPTION
[0014] Reference will now be made to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each embodiment is presented by way of explanation of the invention, and not as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a further embodiment. It is intended that the invention include these and other modifications and variations of the embodiments described herein.
[0015] The drafting apparatus in FIG. 1 shows the customary construction of a double apron drafting system with lower cylinders 31 , 61 and 71 by means of which apparatus fiber structure F is drawn to a yarn F′. The middle pressure roller 6 is looped around by a drafting apron 60 that is guided and tensioned by apron cage 63 . Lower cylinder 61 is looped around by a drafting apron 62 that runs over the deflection rail 64 and is pressed against upper apron 60 . Compressors 8 and 9 are provided in front of and in the drafting field for the compression of the fiber structure.
[0016] The delivery cylinder pair consists of the lower cylinder 31 and the pressure roller 3 , that is looped around by an apron covering 1 that runs over deflection rail 2 . Since pressure roller 3 has a speed approximately 40 or 60 times greater than pressure rollers 6 and 7 , cover apron 1 must run very rapidly. The deflection rail 2 is therefore provided with a smooth, low-fiction apron sliding surface 27 and covering 1 , designed as an apron, of pressure roller 3 is tensioned only slightly. The intrinsic tension of apron covering 1 that would result in a circular form of the apron 1 in the free non-tension state, is sufficient for this. Apron covering 1 is stretched by the arrangement of deflection rail 2 . The tension produced as a result is already sufficient for the unobjectionable running of apron covering 1 .
[0017] A clearer (i.e. cleaning) roller 5 is arranged in a customary manner above pressure roller 3 and of apron covering 1 in order to keep apron covering 1 free of fibers. However, during rather long running times of the drafting device, fibers accumulate on the inside of apron covering 1 between apron covering 1 and apron sliding surface 27 of deflection rail 2 , which fibers are not eliminated by or cannot be prevented by the clearer roller. These fibers become firmly fixed so that a greater and greater accumulation of fibers develops on gliding surface 27 of deflection rail 2 , and the tension of apron covering 1 increases in an inadmissible manner. The tension can even become so great that not only is apron covering 1 considerably braked and the course is thus adversely affected, but also deflection rail 2 breaks.
[0018] The accumulation of fibers between apron covering 1 and apron sliding surface 27 of deflection rail 2 is counteracted by the shaping of deflection rail 2 , especially of the cross-sectional circumference U. It turned out here that the size of the circumference U is important, and in any case should be greater than the average staple length of the fiber material drawn on the drafting apparatus. Good results were achieved, for example, with a cross-sectional circumference U of deflection rail 2 of at least 1.5 times the average fiber length. Since it is obviously important that the start and the end of a fiber can not close themselves to a ring around circumference U of deflection rail 2 , the cross-sectional circumference U of deflection rail 2 should preferably be slightly longer than the longest fiber of the fiber material drawn on the roller drafting apparatus.
[0019] Even the cross-sectional form plays a certain part here. It can be circular in accordance with FIG. 2 . However, it turned out that cross-sectional forms like the ones shown in FIG. 1 or in FIGS. 3 and 4 avoid the accumulation of fibers under apron covering 1 the best. However, it is still important that the cross-sectional circumference U is sufficiently large that the fibers cannot form a ring around deflection rail 2 . FIG. 3 shows, for example, a cross section in which apron sliding surface 27 has the form of a circular arc whereas the flanks are flattened. In deflection rail 2 according to FIG. 1 , the cross section of deflection rail 2 is rectangular; however, the small sides are rounded off in an arched form so that apron sliding surface 27 is rounded off. In the embodiment according to FIG. 4 , apron sliding surface 27 of deflection rail 22 is also rounded off; however, the sides are maintained straight. This cross-sectional form is particularly resistant to pressure loads and offers a smaller apron sliding surface 27 so that less friction is exerted on apron covering 1 . As can be gathered from FIG. 1 , a clearer roller 5 is advantageously arranged above pressure cylinder 3 in order to keep apron covering 1 free of fibers on its outside.
[0020] FIG. 5 shows the holder 4 with two deflection rails 23 arranged as a pair. Holder 4 has cheeks 41 with which it rests on shaft 65 of pressure roller 3 . Cheeks 41 are designed in one piece with the two deflection rails 23 . Deflection rails 23 comprise cylindrical apron sliding surfaces 27 with lateral edges 24 that prevent a running off of apron covering 1 . As a result of the one-piece design of holder 4 with deflection rails 23 , this part can be especially advantageously produced and mounted as only one part.
[0021] FIG. 6 shows an embodiment similar to that of FIG. 5 but here the deflection rails 200 are screwed into the cheeks 41 of holder by a threading and can be replaced without replacing holder 4 . In this manner, an adaptation to different spindle pitches is readily possible. Furthermore, deflection rails 200 are provided with a slightly curved apron sliding surface 203 . Apron covering 1 is held in the middle of sliding surface 203 by this curvature transversely to the direction of travel of the apron, which prevents it from running against sleeve 204 . An edge can be eliminated on the free side of deflection rail 200 , which simplifies the removal of apron covering 1 .
[0022] FIG. 8 shows another embodiment of a holder 40 for apron covering 1 . In accordance with the customary design of pressure roller 3 , deflection rails 25 are formed in pairs on cheeks 42 of holder 40 so that they form one part with holder 40 . Cheeks 42 comprise recesses 44 with which holder 40 rests and is supported on shaft 65 of pressure roller 3 . A side edge 26 is formed on each free end of deflection rails 25 which edge extends only over apron sliding surface 203 of deflection rail 25 .
[0023] FIG. 9 shows holder 40 in insertion position with the view onto holder 40 corresponding to section AA of FIG. 8 . The shaft 65 of pressure roller 3 is held in a customary manner in a spring clamp (not shown in more detail) in the upper roller carrying arm 51 . Holder 40 grips with cheeks 42 by means of recesses 44 over pressure roller axis 65 , around which it can freely pivot. Holder 40 is pivoted counterclockwise during operation in accordance with the torque exerted via pressure roller 3 and apron covering 1 so that it is supported via stops 43 onto upper roller carrier arm 51 and is fixed in this position. This should advantageously take place at an angle α of approximately 30°. This fastening is extremely simple and ensures an assembly and disassembly of the entire holder 40 together with apron 1 without special fastening means. Coating aprons 1 can be easily stripped off pressure roller 3 laterally off deflection rail 25 via the edge 26 . Nevertheless, a reliable holding and guidance of apron covering 1 is ensured even at high turning speeds of pressure roller 3 .
[0024] As is described in DE 102 60 025.2, apron covering 1 is stiffened by a yarn insert in the direction of travel of apron covering 1 and is therefore largely non-elastic in this direction. The yarn insert is wound in a spiral during the production of apron covering 1 onto the running layer of apron coating 1 . During the cutting of apron covering 1 projecting fringes are produced by the yarn insert on the edges. This is disadvantageous because these fringes result in accumulations of fibers. Apron borders 13 ( FIG. 7 ) should be completely smooth so that no fibers are caught on them and entrained. Such a fringe-free cutting is achieved by cutting with a laser.
[0025] As a result of the yarn insert applied in spiral form, apron covering 1 exhibits an asymmetric behavior and runs on the one side against edge 24 . As a consequence, the smoothly cut borders 13 are roughened and a fringe formation with the above-described negative effects reoccur. The application of a yarn insert 11 in Z form and a yarn insert 12 in S form results in a crossing of the yarns in the spiral winding. Moreover, this counteracts the asymmetric behavior. Apron covering 10 runs uniformly, so that no damage occurs due to running on borders 13 . Edges 24 can even be omitted if apron sliding surface 203 of deflection rail 200 has a slight curvature transversely to the direction of travel of the apron. Apron covering 10 is constantly held and guided as a result in the middle of sliding surface 203 . The omission of outer edges 24 also has the advantage that apron covering 10 can be more readily replaced, even if deflection rail 200 is rigidly arranged. In the embodiment according to FIG. 6 apron covering 10 can simply be pushed off the deflection rail 200 laterally. A raising over an edge is not required.
[0026] All these described measures bring about an easy and trouble-free course of apron covering 1 or 10 . Since this apron covering 1 or 10 runs at a very high speed, slight disturbances work themselves out to a large extent. The described measures can avoid disturbances in a simple manner and achieve an unobjectionable course of covering 1 even at high turning speeds of pressure roller 3 .
[0027] It should be appreciated by those skilled in the art that modifications and variations can be made to the embodiments described herein without departing from the scope of the appended claims.
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The coating of the pressure roller ( 3 ) of a drawing roller frame for spinning frames comprises an outer layer and an inner layer fixed to the core of the pressure roller. The outer layer is thinner and harder than the inner layer and is embodied as an endless belt ( 1 ) which loosely surrounds the inner layer such that the belt can be displaced in relation to the inner layer. In order to improve the running of the belt, the belt is guided over a deflector rail ( 2 ), the cross-sectional area (u) of the rail being wider than the average staple length of the fibre material (F) drawn on the drawing roller frame. Furthermore, the belt is designed in such a way that it comprises a double thread interlining, one thread interlining being wound counter to the second thread interlining such that the threads of one thread interlining cross the threads of the second thread interlining.
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BACKGROUND OF THE INVENTION
This invention pertains to a security lock as usable with horizontal slider windows for retaining the window in a closed, locked position.
It is generally known in the art to lock a closure, such as a door or window, by means of a bolt which can be moved between extended and retracted positions. Such structure includes a case which movably mounts the bolt and which has structure internally of the case responsive to manual operation, as by rotation of a shaft, for controlling the position of the bolt. In the prior art, the case has had a top wall and side walls and also a bottom wall as provided by a plate secured to the case to retain the bolt and operating parts within the case primarily during shipment and installation of the structure. The use of a bottom plate to completely enclose the case results in additional structure and cost for the unit and can also result in increased height of the case unless special provision is made for mounting the bottom plate in recessed relation with respect to the side walls of the case.
SUMMARY OF THE INVENTION
A primary feature of the invention disclosed herein is to provide a security lock wherein the case has an open bottom and the bolt and operating structure therefor are constructed and assembled in a manner to provide for retention of the parts within the case without the necessity for a bottom plate to enclose the case.
More particularly, the security lock embodies a case with a top wall and side walls with an internal channel opening toward the open bottom of the case and which movably receives a bolt which is movable between extended and retracted positions. Manually-operable structure is associated with the case for positioning of the bolt and includes a shaft rotatably mounted in the case and means including a member fixed to the shaft for transmitting shaft movement to the bolt and said member being fixed to the shaft in a position whereby said means engages the bolt and prevents fall-out of the bolt from the open bottom of the case.
In one embodiment of the invention having the structure as set forth in the preceding paragraph, the bolt has a recess opening toward the bottom of the case and a driver in the form of a generally planar member is fixed to the lower end of the shaft and has an arm which fits into said recess to prevent fall-out of the bolt and also convert shaft rotation into linear movement of the bolt.
Another embodiment of the invention is constructed with an over-center feature to prevent retraction of the bolt by force applied directly to the bolt. A slide member is interposed between the driver which is affixed to the shaft and the bolt with the slide member having an arm engageable within the recess of the bolt and the driver and slide member having a pin and slot connection, with the parts related whereby a force applied to the bolt when the bolt is in extended position prevents retraction of the bolt because of the parts being in an over-center condition.
As an additional feature of this embodiment, the pin of the pin and slot connection is defined by a headed member, such as a rivet, which holds the slide member in assembled relation with the driver and as a result causes the slide member to hold the bolt within the case.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the security lock shown mounted in association with fragmentarily represented components of a window;
FIG. 2 is a sectional view, taken generally along the line 2--2 in FIG. 1;
FIG. 3 is a sectional view, taken generally along the line 3--3 in FIG. 2;
FIG. 4 is a view, similar to FIG. 3, with the bolt shown in retracted position;
FIG. 5 is a view, similar to FIG. 1, of another embodiment of the invention;
FIG. 6 is a sectional view, taken generally along the line 6--6 in FIG. 5;
FIG. 7 is a sectional view, taken generally along the line 7--7 in FIG. 6, with the bolt extended; and
FIG. 8 is a view, similar to FIG. 7, showing the bolt in retracted position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the invention is shown in FIGS. 1 to 4. The security lock indicated generally at 10 is shown mounted in position for locking of a window 11. With the window 11 being mounted for movement in a plane which is perpendicular to the drawing, the security lock 10 can be mounted on adjacent structure 12 in proper position for causing the bolt thereof to engage a keeper on the frame of the slider window when closed.
The security lock has a case defined by a top wall 15 and two pairs of side walls 16 and 17 and 18 and 19, respectively, with the side wall 19 being of a substantial thickness. The top wall and side wall define a generally hollow interior for the case which opens to the bottom thereof and toward the right, as viewed in FIG. 2.
A bolt-receiving channel is formed within the case and opens toward the bottom thereof. This channel includes walls formed by a part of the top wall 15, an internal surface 25 of the side wall 19, and an internal wall 26. The case of the security lock can be formed of molded plastic material and, as shown in FIG. 2, the channel has a gradually increasing dimension as it approaches the open bottom of the case as a result of the molding operation. The channel receives a bolt 30 which is movable linearly within the channel between the extended position shown in FIG. 3 and the retracted position shown in FIG. 4. The bolt 30, intermediate its ends, has a recess 31 for association with the structure to be described.
The lock has manually-operable structure for positioning of the bolt including, a shaft 40 rotatably mounted within an opening 41 formed integrally in a part integral with the top wall 15 and with an exposed end of the shaft having an operating knob 42. An end 45 of the shaft 40 is positioned within the case and generally co-planar with the recess 31 of the bolt. A driver 50, in the form of a planar member, has an opening 51 of a generally square shape to fit on the square shaft end 45 and with the shaft end being swaged, as shown at 52, to capture the driver. The driver 50 has an arm 55 which extends into the recess 31 of the bolt.
The periphery of the driver 50 has a pair of detent surfaces in the form of notches 60 and 61 which co-act with a V-shaped end 62 of a spring member 63 to yieldably hold the driver and, therefore, the bolt 30 in either the extended position, shown in FIG. 3, or the retracted position, shown in FIG. 4. The spring member 63 is suitably captured within the case by surfaces 64 formed within the case and by a spring end 65 engaging the side wall 18 of the case.
The security lock 10 is mounted to a supporting structure 12 by means of a pair of screws 70 and 71 which pass through openings formed in the case.
With the security lock mounted for use, as shown in FIG. 2, it will be seen that the interior of the case opens to the mounting structure 12 and without the presence of any bottom plate for the case. The disclosed structure avoids the need for a bottom plate since, during assembly, the bolt 30 can be positioned in its guide channel and the driver 50 is then moved into position with the arm 55 engaged in the recess 31 and the opening 51 of the driver fitted on the shaft end 45 and, thereafter, the end of the shaft is swaged to retain the driver fixed to the shaft. This assembly method results in the driver capturing the bolt and then the driver being secured to the shaft whereby the parts are retained in position without any bottom plate.
The security lock is shown in an operative position in FIG. 4 wherein the driver is releasably retained in position by the spring member 63 and the bolt 30 is retracted. Manual rotation of the knob 42 causes rotation of the driver 50 and the driver arm 55 engages a wall of the recess 31 formed in the bolt 30 to move the bolt from the position shown in FIG. 4 to the extended position shown in FIG. 3. The parts are yieldably retained in this position by the spring 63. When the bolt is to be retracted, the knob is rotated to return the parts to the position shown in FIG. 4, with the driver arm 55 acting on an opposite wall of the recess 31.
In the embodiment of FIGS. 5 to 8, the security lock has modified structure to provide an over-center action whereby the bolt cannot be forced to a retracted position by force applied by direct engagement with the bolt. In this embodiment, the parts which are the same as those shown in the embodiments of FIGS. 1 to 4 are given the same reference numeral with a prime affixed thereto. The bolt 30' is the same as the bolt 30, but having a lesser width.
A slide member 100 is mounted within the case and has an arm 101 which is positioned within the recess 31' of the bolt and transmits linear movement of the slide member to the bolt. The slide member 100 is guided for linear movement by the wall 26' of the case and a wall 110 thereof which coact with a pair of flanges 111 and 112, respectively, which are formed at opposite ends of the slide member. To retain a spring 135 within the case, there is an additional flange 115 extending outwardly from the flange 112 which engages against the outer edge of the spring.
A driver member 120 is secured to the shaft 40' by swaging in the same manner as in the embodiment of FIGS. 1 to 4; however, the driver does not directly engage the bolt 30'. The driver transmits rotation of the shaft to the slider member 100 through a pin and slot connection, with there being a slot 125 formed in the slider member 100 and extending in a direction transverse to the path of linear movement of the slider member. The pin of the connection is defined by a rivet 126 having a head 127 which captures and holds the slider member in association with the driver and with the rivet secured to the inner face of the driver, as indicated at 130.
With this construction, rotation of the driver 120 causes movement of the pin in a counterclockwise direction, as viewed in FIG. 8, to cause movement of the slider member to the position shown in FIG. 7 and resulting in movement of the bolt 30' to lock position. Movement of the pin in a clockwise direction from the position shown in FIG. 7 to the position shown in FIG. 8 causes retraction of the bolt.
The spring 135, which is held in captured position within the case between the flange 115 and a surface 116 of the wall 110, has a V-shaped end 136 for coacting with a pair of detent surfaces formed by notches 137 and 138 in the periphery of the driver 120 to yieldably hold the bolt in either extended or retracted position.
The operating structure for the bolt is constructed to prevent retraction of the bolt by force applied directly thereto by having the pin carried by the driver moved to an over-center position when the bolt is in extended position. More particularly, the pin 126, when positioned as shown in FIG. 7, is in engagement with an end of the slot 125 and, if a force is applied to the bolt tending to retract the bolt, this force is transmitted to the slider member 100 and acts on the pin to urge the pin to rotate in a counterclockwise direction, as viewed in FIG. 7; however, the pin cannot rotate in this direction since it is in engagement with the end of the slot 125.
In assembly, the driver is swaged to the shaft 45 and the rivet captures the slide member 100 to the driver and the arm 101 of the slide member holds the bolt 30' in its channel. With this construction, there is no need for a bottom plate to hold the parts.
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A security lock for movable closure and, more particularly, for horizontal slider windows in which a case for the lock has a top wall and side walls defining a generally hollow interior opening to the bottom of the case, a bolt is movably mounted in a channel formed within the case with the channel opening toward the bottom of the case. The bolt is movable between extended and retracted positions. Structure for positioning of the bolt includes a driver associated with a manually-rotatable shaft and a connection between the driven and the bolt which functions to retain the bolt from falling out of the guide channel through the open bottom of the case during handling and shipping and to also transmit movement of the shaft to the bolt.
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FIELD OF THE INVENTION
The invention relates to a press line or multi-stage press for large components, having a transporting apparatus for transporting workpieces.
BACKGROUND OF THE INVENTION
In a press, press line or multi-stage press for large components, transfer apparatuses are provided for transporting workpieces into the processing stages. In recent systems according to EP 0 672 480 B1 or EP 0 693 334 A1, the transporting operation between individual processing stations takes place individually by individual transporting apparatuses, which allow, in particular, a high flexibility of the capacity for movement of the workpiece transportation between individual processing stages. By means of such a drive, which is fully independent of the central drive of the press, it is possible to optimize the transportation of the workpiece in a number of degrees of freedom, in particular in relatively large press installations. For this purpose, you are referred to EP 0 672 480 or EP 0 693 334. By way of example, carrying rails, on which carriages with dedicated drive travel, are provided over the entire press length. For accommodating the workpieces, use is made of crossmembers which are provided with retaining means and are each fastened on 2 opposite carriages. In the most straightforward embodiment, 2 transporting movements are provided for transferring the workpieces, to be precise a vertical movement and a horizontal movement. The vertical movement serves for removing the workpiece from the bottom die part or depositing the workpiece in the same, while the horizontal movement provides the actual transporting step. This transporting step can take place from one press into the following press or, in the case of a multi-stage press for large components, from one forming station into the next.
However, it is usually the case that the workpieces and/or dies are not of such straightforward configuration as to allow transportation in biaxial operation. By way of example, in the case of passenger-vehicle doors, the latter, in the first forming stage, are drawn from a common blank in order then, following a cutting operation, to run, each as separate workpieces, through the processing stages together. In order to avoid more expensive and complicated dies, it is necessary for the workpiece to be brought into an optimum processing position during the transfer operation. This change in position is usually carried out by way of intermediate set-down locations or orienting stations.
Such an intermediate set-down location, both for single and for double components, is disclosed by EP 0 383 168 B1 or DE 196 51 934 A1. Of particular note are the 5 degrees of freedom which can be used for changing the position of workpieces of complex configuration. It is thus possible, if required, for the position of the workpiece to be manipulated in 5 axes.
Essential disadvantages of this functionally satisfactory intermediate set-down location are as follows:
the press installation or multi-stage press for large components requires a long overall length since the intermediate set-down locations are arranged between the processing stages and the appropriate amount of space thus has to be provided. The number of workpiece-specific changeover parts is high. The parked position of the crossmembers during the forming operation is restricted. The cycle speed and functional reliability of the press may be adversely affected by the relatively large number of transporting steps.
This resulted in considerations to dispense with the intermediate set-down location and to integrate the necessary degrees of freedom in the transporting systems. It is thus proposed, [lacuna] DE 44 08 449 A1, to configure the transporting system such that the crossmember can be brought into a sloping position in the vertical direction. It is additionally possible to pivot an axis in the direction transverse to the transporting direction.
Some of the possible movements of the intermediate set-down location have thus been integrated in the transporting system, but the full functionality of this intermediate set-down location has not.
SUMMARY OF THE INVENTION
Taking the prior art as the departure point, the object of the invention is to propose a transporting system for forming machines which has the highest possible number of degrees of freedom or movement axes.
This object is achieved, taking as the departure point a transporting system in accordance with the invention as described below. Adantages of the invention as described in the description below and in view of the claims.
The invention is based on the idea of configuring a separately driven transfer for each die stage such that workpieces can undergo an optimum change in position adapted to the forming process in each case.
By way of example, the change in position may include the following movement axes:
horizontal displacement in and counter to the transporting direction sloping position in the transporting direction displacement in the direction transverse to the transporting direction pivoting in and counter to the transporting direction pivoting in the direction transverse to the transporting direction vertical change in height
By a different combination of the movements, the change in position is made possible during introduction of the workpieces into the die and removal of the workpieces from the die.
Provision is made here to ensure the functionality both for individual large-surface-area workpieces and for 2 workpieces, that is to say so-called double components.
In the case of the design, taking as departure point the known individually driven, crossmember-bearing transporting systems, such as carriages, slides, pivoting arm, telescopic arm, etc., the number of movement axes is increased by additional drives and movement-transmissions. By using spherical mountings, such as ball and socket joints or universal joints, a sloping position of the crossmember is also made possible.
Further details and advantages of the invention can be gathered from the following description of an exemplary embodiment.
The higher-outlay solution of transporting double components has been selected for the exemplary embodiment. If, however, the task is to transport just one large-surface-area workpiece rather than a double component, the crossmember is replaced by the sucker crossmember. This function is achieved by the attachment of die-specific transporting and retaining means to the crossmember.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows part of a multi-stage press for large components,
FIGS. 2 a , 2 b show a view of a transporting unit in the direction transverse to the transporting direction,
FIGS. 3 a , 3 b show a detail from FIG. 2 , and
FIGS. 4 a , 4 b show a plan view of the transporting unit.
DETAILED DESCRIPTION OF THE INVENTION
Processing stations or forming stages 8 , 9 of a multi-stage press for large components 1 are illustrated in FIG. 1 . Arrow 30 shows the transporting direction of the workpieces. The transporting apparatus 2 is arranged on the press upright 3 and also mirror-invertedly on the opposite upright. The transporting apparatus 2 is driven by pivot drive 6 , which is in operative connection with pivoting arm 4 . The crossmember, which is provided for workpiece-transporting purposes, is designated 5 and is mounted on the pivoting arm 4 . This figure shows, in particular, the following degrees of freedom
vertical movement horizontal movement crossmember 5 pivot [sic] in and counter to the transporting direction
Via the pivoting drive 6 , in operative connection with a lifting drive 7 , by virtue of a combination of movements, a transporting curve or a transporting step comprising vertical and horizontal movements is executed. The transporting step serves for transferring the workpiece from, for example, forming stage 8 to forming stage 9 . If a change in position of the workpieces, on account of different removal and feeding positions, and thus better introduction and delivery is necessary, the crossmember 5 can be pivoted about the axis of rotation 12 . A drive 10 causes the crossmember 5 to pivot via a toothed-belt drive 11 . Different positions of the crossmember 5 can clearly be seen in FIG. 1 .
The illustration in FIGS. 2 a+b shows crossmember 5 in a horizontal position and in a vertically sloping position. The figures show the mutually opposite arrangement of the transporting apparatuses 2 . 1 and 2 . 2 with fastening on the left-hand and right-hand uprights 3 . 1 and 3 . 2 . Movably arranged workpiece-specific sucker crossmembers 13 for transporting double components are provided on the crossmember 5 by way of example in FIGS. 2 a+b . It is also possible, without any restrictions, to use just one centrally arranged sucker crossmember 13 , as is necessary, for example, for transporting a large, not yet divided blank or a large workpiece. In this case, the suckers are connected directly, as changeover parts, to crossmember 5 . A transverse-displacement movement may be provided.
The following degrees of freedom are illustrated in FIGS. 2 a+b:
pivoting the sucker crossmember 13 in the direction transverse to the transporting direction in the case of double components horizontal and sloping position in the vertical direction of the crossmember 5 .
The pivoting of the sucker crossmember 13 is described in more detail in FIGS. 3 a+b.
The vertically sloping position of the crossmember 5 is achieved by different movement sequences of transporting apparatus 2 . 1 and 2 . 2 . For the compensation in length which is required by the sloping position according to FIG. 2 b , a spline shaft 14 is provided. The universal joint 15 allows the angled position of the crossmember 5 . Instead of a universal joint 15 , an axis of rotation is also initially sufficient for this sloping position.
FIGS. 3 a+b show design details for pivoting the sucker crossmember 13 . The following is also illustrated as a further degree of freedom:
transverse displacement of the sucker crossmember 13
FIGS. 3 a+b show the end of the pivoting arm 4 of the transporting apparatus 2 with the mount for the crossmember 5 . The toothed-belt drive 11 is integrated in the transporting apparatus 2 in order to pivot the crossmember 5 about the axis of rotation 12 . The spline shaft 14 , on the one hand, transmits the rotational movement and, in addition, allows the compensation in length for the sloping position of the crossmember 5 . The spline shaft 14 is fastened to the universal joint 15 . The pivotable bearing block 17 bears drives 18 , 19 , which drive spindle/nut system 20 and 21 via shafts and angular gear mechanisms. Rods 23 arranged on both sides are in operative connection with spindle/nut system 20 and are connected to circle segment 24 and pivot the latter at the point of rotation 25 . The maximum size of the pivoting angle is W 1 and W 2 . The circle segment 24 is guided and supported by segment guides or guide rollers 26 , which are fastened on horizontal slide 27 . The workpiece-retaining sucker crossmember 13 is connected to the circle segment 24 . Guides 28 serve for guiding the horizontal slide 27 . Said horizontal slide 27 can be displaced by the distance M 1 and M 2 in relation to its central position. Horizontal slide 27 is driven, via rod 29 and spindle/nut system 21 , by drive 19 . This apparatus described may be fitted on the crossmember 5 on its own or as one of two. The combination of movements is possible by simultaneous actuation of the drives 18 , 19 . The rotational-speed regulation may result in the same or different rotational speeds, as a result of which optimum conditions for handling the workpieces are achieved. This high flexibility may also be advantageous during die changeover, where, if appropriate, it is possible to dispense with the exchange of the component-specific sucker crossmember 13 and to execute just a horizontal movement. If, however, an exchange of the sucker crossmembers 13 is necessary, then all the movement elements on crossmember 5 remain.
The crossmember 5 can be disengaged at the separating location 22 , as may be necessary, for example, during a conversion from a double component to a large-surface-area single component. Advantageously, in the arrangement proposed, there is no need to exchange the drives 18 , 19 , and these remain in the press 1 .
A combination of pivoting and horizontal displacement of the sucker crossmember 13 is not absolutely necessary in every case. Alternatively, the attachment may be such that only one movement is possible in each case, i.e. the slide 27 or the circle segment 24 may then be dispensed with.
FIGS. 4 a+b show a plan view of crossmember 5 in a horizontal position and a horizontally sloping position in the component-transporting direction in accordance with arrow 30 . The double-sided arrangement of the actuating rods 23 , 29 and, in extension thereof, the pivoting and transverse-displacement apparatus are illustrated. Two sucker crossmembers 13 are likewise attached.
Pairs of the actuating rods 23 , 29 are fitted in each case on the spindle/nut systems 20 , 21 , which are provided as a single unit. FIG. 4 b shows the following further degree of freedom:
horizontally sloping positioning about the vertical axis in or counter to the transporting direction
If it is only this sloping position which is required, the function can be performed with an axis of rotation and the compensation in length by spline shaft 14 . If, however, the vertically sloping position described in FIG. 2 is likewise envisaged, then the use of a universal joint 15 is necessary. By virtue of this design solution, any desired combination of vertically and horizontally sloping positions is also possible, and thus an
sloping positioning in space is provided as the further degree of freedom.
In its maximum inventive configuration, the transporting system proposed may thus carry out workpiece manipulation in the following degrees of freedom.
Vertical movement upward and downward horizontal movement in and counter to the transporting direction pivoting of the crossmember and sucker crossmember in and counter to the transporting direction vertically sloping positioning of the crossmember and sucker crossmember pivoting of the sucker crossmember in the direction transverse to the transporting direction transverse displacement of the sucker crossmember horizontally sloping positioning of the crossmember and sucker crossmember in and counter to the transporting direction sloping positioning of the crossmember and sucker crossmember in space
The invention is not restricted to the exemplary embodiment which has been described and illustrated. It also covers all expert configuration within the scope of this disclosure. Thus, a universal joint is only to be understood by way of example as a movable mounting, and it is possible to use all spherical joints which satisfy the requirements of the inventive idea.
As has been explained, it is possible, during the transportation of single components, to dispense with a separate pivotable sucker crossmember 13 and to use crossmember 5 directly as sucker crossmember.
LIST OF DESIGNATIONS
1 Multi-stage press for large components
2 Transporting apparatus
3 Press upright
4 Pivoting arm
5 Crossmember
6 Pivoting drive
7 Lifting drive
8 Forming stage
9 Forming stage
10 Drive
11 Toothed-belt drive
12 Axis of rotation
13 Sucker crossmember
14 Spline shaft
15 Universal joint
17 Bearing block
18 Drive
19 Drive
20 Spindle and nut
21 Spindle and nut
22 Separating location
23 Rod
24 Circle segment
25 Point of rotation
26 Guide
27 Horizontal slide
28 Guide
29 Rod
30 Component-transporting apparatus
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The invention proposes a transporting apparatus for transporting single or double workpieces through processing stations of presses, in which apparatus up to 9 degrees of freedom are integrated in the transporting system. Necessary changes in position for, for example, feeding into dies can take place directly by way of the transporting apparatus. It is possible to dispense with intermediate set-down locations or orienting stations.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation application of U.S. application Ser. No. 11/494,279, filed on Jul. 27, 2006 (now U.S. Pat. No. 7,592,435), which claims priority from Great Britain Application Serial No. 0517097.2, filed on Aug. 19, 2005. Applicants claim priority under 35 U.S.C. §120 as to the said United States application and claim priority under 35 U.S.C. §119 as to the said Great Britain application. The entire disclosures of both applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The invention relates to modified guanine-containing nucleosides and nucleotides and more specifically to modified fluorescently labelled guanine-containing nucleosides and nucleotides which exhibit reduced quenching effects, and hence enhanced brightness of the fluorophore.
BACKGROUND TO THE INVENTION
Advances in the study of biological molecules have been led, in part, by improvement in technologies used to characterise the molecules or their biological reactions. In particular, the study of the nucleic acids DNA and RNA has benefited from developing technologies used for sequence analysis.
Nucleic acid sequencing methods have been known in the art for many years. One of the best-known methods is the Sanger “dideoxy” method which relies upon the use of dideoxyribonucleoside triphosphates as chain terminators. The Sanger method has been adapted for use in automated sequencing with the use of chain terminators incorporating fluorescent labels.
There are also known in the art methods of nucleic acid sequencing based on successive cycles of incorporation of fluorescently labelled nucleic acid analogues. In such “sequencing by synthesis” or “cycle sequencing” methods the identity of the added base is determined after each nucleotide addition by detecting the fluorescent label.
In particular, U.S. Pat. No. 5,302,509 describes a method for sequencing a polynucleotide template which involves performing multiple extension reactions using a DNA polymerase to successively incorporate labelled polynucleotides complementary to a template strand. In such a “sequencing by synthesis” reaction a new polynucleotide strand based-paired to the template strand is built up in the 5′ to 3′ direction by successive incorporation of individual nucleotides complementary to the template strand. The substrate nucleoside triphosphates used in the sequencing reaction are labelled at the 3′ position with different 3′ labels, permitting determination of the identity of the incorporated nucleotide as successive nucleotides are added.
The guanine base of DNA is known to act as a quencher of some fluorophores, meaning that a fluorophore attached to G is harder to detect than the equivalent fluorophore attached to C, A or T (Torimura et al., Analytical Sciences, 17: 155-160 (2001); Kurata et al., Nucleic Acids Res., 29(6) e34 (2001)). In the context of a sequencing reaction based on detection of fluorescent labelled nucleotides, this in turn means that the fluorescent signal detected from labelled guanine nucleotides incorporated during the sequencing reaction will be of lower intensity than that detected from labelled nucleotides bearing the same fluorophore attached to adenine, thymine or cytosine containing nucleotides. Thus, in certain circumstances the presence of a “G” nucleotide may be harder to call with certainty than the presence of A, T or C under the same reaction and detection conditions.
Accordingly, in the context of nucleic acid sequencing reactions it would be desirable to be able to increase the intensity of the fluorescent signal from fluorescently labelled G nucleotides so that the intensity of the signal compares more favourably with that which can be obtained from fluorescently labelled A, T or C nucleotides under the same reaction and detection conditions.
SUMMARY OF THE INVENTION
The inventors have now determined that by altering, and in particular increasing, the length of the linker between the fluorophore and the guanine base, so as to introduce a polyethylene glycol spacer group, it is possible to increase the fluorescence intensity compared to the same fluorophore attached to the guanine base through prior art linkages. The design of the linkers, and especially their increased length, also allows improvements in the brightness of fluorophores attached to the guanine bases of guanosine nucleotides when incorporated into polynucleotides such as DNA. The nucleotides of the invention are thus of use in any method of analysis which requires detection of a fluorescent label attached to a guanine-containing nucleotide, including but not limited to nucleic acid sequencing and nucleic acid labelling.
Therefore, in a first aspect the invention provides a modified nucleotide or nucleoside comprising a guanine base or a derivative thereof attached to a fluorophore through a linking group, characterised in that said linking group comprises a spacer group of formula —((CH 2 ) 2 O) n — wherein n is an integer between 2 and 50.
In a second aspect the invention provides a polynucleotide comprising at least one modified nucleotide according to the first aspect of the invention.
In a third aspect the invention provides use of a modified nucleotide or nucleoside according to the first aspect of the invention or a polynucleotide according to the second aspect of the invention in any method of analysis which requires detection of a fluorescent signal from the modified nucleotide or nucleoside.
In particular embodiments the invention provides use of a modified nucleotide or nucleoside according to the first aspect of the invention or a polynucleotide according to the second aspect of the invention in a method of nucleic acid sequencing, re-sequencing, whole genome sequencing, single nucleotide polymorphism scoring, or any other application involving the detection of the modified nucleotide or nucleoside when incorporated into a polynucleotide.
In a further aspect the invention provides a method of detecting a modified guanosine nucleotide incorporated into a polynucleotide which comprises:
(a) incorporating at least one modified nucleotide according to the first aspect of the invention into a polynucleotide and
(b) detecting the modified nucleotide(s) incorporated into the polynucleotide by detecting the fluorescent signal from said modified nucleotide(s).
In a preferred embodiment the at least one modified nucleotide is incorporated into a polynucleotide by the action of a polymerase enzyme.
In a particular embodiment step (a) may comprise incubating a template polynucleotide strand with a reaction mixture comprising fluorescently labelled modified nucleotides according to the first aspect of the invention and a polymerase under conditions which permit formation of a phosphodiester linkage between a free 3′ hydroxyl group on a polynucleotide strand annealed to said template polynucleotide strand and a 5′ phosphate group on said modified nucleotide.
Specific but non-limiting embodiments of this method comprise incorporation of modified nucleotides according to the invention by inter alia polymerase chain reaction (PCR), primer extension, nick translation or strand displacement polymerisation.
In a still further aspect, the invention provides a method of sequencing a template nucleic acid molecule comprising:
incorporating one or more nucleotides into a strand of nucleic acid complementary to the template nucleic acid and determining the identity of the base present in one or more incorporated nucleotide(s) in order to determine the sequence of the template nucleic acid molecule;
wherein the identity of the base present in said nucleotide(s) is determined by detecting a fluorescent signal produced by said nucleotide(s);
characterised in that at least one incorporated nucleotide is a modified nucleotide according to the first aspect of the invention.
In a still further aspect, the invention provides a kit comprising a plurality of different nucleotides including a modified nucleotide according to the first aspect of this invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a graph evidencing the improved brightness of the Alexa 488 fluorophore in modified nucleotides of the invention having —((CH 2 ) 2 O) 11 — (denoted G-PEG12-A488) and —((CH 2 ) 2 O) 23 — (denoted G-PEG24-A488) spacing groups over a modified nucleotide not of this invention with no such spacer (denoted G-N 3 -A488, and improved brightness of the fluorophore having the —((CH 2 ) 2 O) 23 —, as opposed to the —((CH 2 ) 2 O) 11 —, spacing group. Fluorescence intensity was measured for each labelled nucleotide in 100 mM Tris, 30 mM NaCl pH7 when incorporated into polynucleotide both before and after treatment with TCEP to cleave the linking group. Cleavage of the linkers with TCEP shows that the free fluorophore is not quenched in solution, thus the enhanced signal is not simply caused by the PEG moiety attached to the fluorophore.
DETAILED DESCRIPTION
The present invention will now be further described. In the following passages, different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.
When describing the invention, certain terms used have particular meanings to those skilled in the art some of which are as set forth below. These definitions are to be used in construing the terms unless the context dictates otherwise.
The invention, as described and claimed herein, provides improved modified guanosine nucleosides and nucleotides, methods of using these, particularly methods of using guanosine nucleotides in molecular biological applications where it is desired to monitor incorporation of the modified nucleotides into polynucleotides, including but not limited to sequencing by synthesis applications and other applications involving labelling of nucleic acids, and kits comprising such nucleosides or nucleotides.
As is known in the art, a “nucleotide” consists of a nitrogenous base, a sugar, and one or more phosphate groups. “Nucleosides” consist of the nitrogenous base and sugar only. In naturally occurring or native nucleotides the sugar component is usually either ribose, as in ribonucleotides and the corresponding polynucleotide RNA, or deoxyribose, i.e., a sugar lacking the 2′ hydroxyl group that is present in ribose, as in deoxyribonucleotides and the corresponding polynucleotide DNA. The naturally occurring sugars may be modified, for example by removal or substitution of the 3′ hydroxyl group. The nitrogenous base is a derivative of purine or pyrimidine. The purines are adenine (A) and guanine (G), and the pyrimidines are cytosine (C) and thymine (T) (or in the context of RNA, uracil (U)). The equivalent nucleosides incorporating these bases are respectively denoted adenosine, guanosine, cytidine and thymidine. The C-1 atom of deoxyribose is bonded to N-1 of a pyrimidine or N-9 of a purine. A nucleotide is also a phosphate ester of a nucleoside, with esterification occurring on the hydroxyl group attached to C-5 of the sugar. Nucleotides may be mono, di, tri or cyclic phosphates.
The modified nucleotides or nucleosides of the invention comprise the guanine base, sugar (and one or more phosphate groups, if appropriate) and a detectable label comprising a fluorophore. The detectable label is attached to the guanine base through a linking group.
In the modified nucleosides and nucleotides of the invention the linking group comprises a polyethylene glycol spacer, although other suitably hydrophilic groups of similar length to the polyethylene glycol spacers of the invention (approximately 5 to 150 atoms) may be used as an alternative to polyethylene glycol spacers. Preferably the spacer comprises between 5 and 30 ethylene oxide groups —((CH 2 ) 2 O)—, still more preferably between 10 and 25 ethylene oxide groups. Exemplified herein, and thus particularly preferred ethylene oxide spacer groups are —((CH 2 ) 2 O) 11 — and —((CH 2 ) 2 O) 23 — preferably —((CH 2 ) 2 O) 23 —.
The linking groups used in the present invention serve to space the fluorescent label away from the guanine base such that the amount of quenching of the fluorescent signal from the fluorophore by the guanine base is reduced or substantially eliminated, as compared to a nucleotide or nucleoside of analogous structure but lacking the linking group. At the same time, the fluorophore is maintained in indirect covalent attachment with the remainder of the nucleotide/nucleoside.
The nature of the fluorophore present in the fluorescent label is generally not limited. It may be any fluorophore compatible with labelling of nucleosides/nucleotides and, depending on the intended use of the modified nucleotides, also with subsequent incorporation of the modified nucleotides into a polynucleotide. The invention is particularly applicable to modified nucleotides labelled with any fluorophore that shows a decrease in the fluorescence emission intensity when covalently attached to a guanosine nucleotide. Appropriate fluorophores are well known to those skilled in the art and may be obtained from a number of commercial manufacturers, such as Molecular Probes Inc.
For example, Welch et al. ( Chem. Eur. J. 5(3):951-960, 1999) discloses dansyl-functionalised fluorescent moieties that can be used in the present invention. Zhu et al. ( Cytometry 28:206-211, 1997) describes the use of the fluorescent labels Cy3 and Cy5, which can also be used in the present invention. Labels suitable for use are also disclosed in Prober et al. ( Science 238:336-341, 1987); Connell et al. ( BioTechniques 5(4):342-384, 1987), Ansorge et al. ( Nucl. Acids Res. 15(11):4593-4602, 1987) and Smith et al. ( Nature 321:674, 1986). Other commercially available fluorescent labels include, but are not limited to, fluorescein, rhodamine (including TMR, Texas red and Rox), alexa, bodipy, acridine, coumarin, pyrene, benzanthracene and the cyanins.
For example, two classes of particularly preferred fluorophores which may be used according to this invention are the Alexa series available from Molecular Probes, (sometimes referred to as Alexa Fluor dyes) and fluorescent labels in the Atto series available from Atto-tec (sometimes referred to as Atto fluorescent labels) of Atto-tec. An example of a preferred Alexa dye is Alexa 488, and an example of a particular Atto dye is Atto 532.
Other than the ethylene oxide spacer moiety, the linkage between the base and detectable label may comprise other chemical functionality. This may serve to afford cleavable or non-cleavable linkers. Examples of cleavable linkers are known to those skilled in the art (see for example Applicant's published International patent applications WO03/048387 and WO2004/018493).
As aforesaid, the sugar components of the nucleosides and nucleotides according to the invention may be further modified (from the native ribose or deoxyribose) in order to confer some useful property without affecting the function of the fluorescent label component. A particularly preferred embodiment of the invention is the provision of modified guanosine nucleosides and nucleotides having a cleavable 3′ blocking group, and most preferably deoxyribonucleosides and deoxyribonucleotides including such a 3′ blocking group. Exemplary, and preferred, blocking groups are described in our co-pending application WO 2004/018497. Preferably the nucleoside and nucleotides of the invention contain a 3′ blocking group and a cleavable linker to the detectable label, more preferably still wherein the block and linker may both be cleaved under the same conditions so as to reveal the 3′-OH group in the resultant product upon a single chemical reaction. Examples of such functionalities are described fully in WO2004/018497.
Linkage of the fluorescent label to the guanine base via the linking group may be to any suitable position of the base, provided that it does not interfere with the intended function/use of the modified nucleotide or nucleoside. For example, if a modified nucleotide according to the invention is to be enzymatically incorporated into a polynucleotide by the action of a polymerase then the position of linkage of the fluorescent label via the linking group should not prevent such enzymatic incorporation. Typically linkage will be via the 7 position of the “guanine” base. It will be appreciated that in order to provide the necessary valency for covalent linkage at the 7 position a 7-deaza guanine derivative may be used in preference to the native guanine base. Accordingly, references herein to modified “guanine-containing” nucleosides or nucleotides or to modified “guanosine” nucleosides or nucleotides should be interpreted as encompassing analogous structures which contain a guanine derivative, and in particular 7-deaza guanine, rather than the native guanine base, unless the context implies otherwise. In other embodiments the linking group may be attached to the 8 position of the guanine ring system. Further modifications or substitutions may be included elsewhere in the guanine ring system, in addition to the position at which the linking group is attached, as in for example 7-deaza-8-aza guanine. Again references herein to modified “guanine-containing” nucleosides or nucleotides or to modified “guanosine” nucleosides or nucleotides should be interpreted as encompassing such further modified forms of the guanine base unless the context implies otherwise.
In specific, but non-limiting, embodiments described herein with reference to the accompanying examples the invention provides:
7-[3-(-Alexa488-PEG 12 -LN 3 -linker acetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP, and 7-[3-(-Alexa488-PEG 24 -LN 3 -linkeracetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP
The invention also encompasses polynucleotides incorporating one or more modified guanosine nucleotides according to the invention. Preferably such polynucleotides will be DNA or RNA, comprised respectively of deoxyribonucleotides or ribonucleotides joined in phosphodiester linkage. Polynucleotides according to the invention may comprise naturally occurring nucleotides, non-natural (or modified) nucleotides other than the modified nucleotides of the invention or any combination thereof, provided that at least one modified nucleotide according to the invention is present. Polynucleotides according to the invention may also include non-natural backbone linkages and/or non-nucleotide chemical modifications. Chimeric structures comprised of mixtures of ribonucleotides and deoxyribonucleotides are also contemplated.
Preferred Uses of the Nucleotides of the Invention
The modified nucleotides (or nucleosides) of the invention may be used in any method of analysis which requires detection of a fluorescent label attached to a guanine-containing nucleotide or nucleoside, whether on its own or incorporated into or associated with a larger molecular structure or conjugate. In all such methods of analysis the use of the modified guanosine nucleotides or nucleosides of the invention provides an advantage in that the brightness of the fluorescent signal is increased compared to that which would be obtained using guanosine nucleotides or nucleosides of analogous structure but lacking the longer linking group present in the modified nucleotides or nucleosides of the invention.
In particular embodiments of the invention, modified nucleotides of the invention may be used in any method of analysis which requires detection of a fluorescent label attached to a modified guanine nucleotide incorporated into a polynucleotide. In this context the term “incorporated into a polynucleotide” requires that the 5′ phosphate is joined in phosphodiester linkage to the 3′ hydroxyl group of a second (modified or unmodified) nucleotide, which may itself form part of a longer polynucleotide chain. The 3′ end of the modified nucleotide of the invention may or may not be joined in phosphodiester linkage to the 5′ phosphate of a further (modified or unmodified) nucleotide.
Thus, in one non-limiting embodiment the invention provides a method of detecting a modified guanosine nucleotide incorporated into a polynucleotide which comprises:
(a) incorporating at least one modified nucleotide according to the first aspect of the invention into a polynucleotide and
(b) detecting the modified nucleotide(s) incorporated into the polynucleotide by detecting the fluorescent signal from said modified nucleotide(s).
This method requires two essential steps: a synthetic step (a) in which one or more modified nucleotides according to the invention are incorporated into a polynucleotide and a detection step (b) in which one or more modified nucleotide(s) incorporated into the polynucleotide are detected by detecting or quantitatively measuring their fluorescence.
In a preferred embodiment the at least one modified nucleotide is incorporated into a polynucleotide in the synthetic step by the action of a polymerase enzyme. However, other methods of joining modified nucleotides to polynucleotides, such as for example chemical oligonucleotide synthesis, are not excluded. Therefore, in the specific context of this method of the invention, the term “incorporating” a nucleotide into a polynucleotide encompasses polynucleotide synthesis by chemical methods as well as enzymatic methods.
In a specific embodiment the synthetic step may comprise incubating a template polynucleotide strand with a reaction mixture comprising fluorescently labelled modified guanosine nucleotides of the invention and a polymerase under conditions which permit formation of a phosphodiester linkage between a free 3′ hydroxyl group on a polynucleotide strand annealed to said template polynucleotide strand and a 5′ phosphate group on said modified nucleotide.
This embodiment comprises a synthetic step in which formation of a polynucleotide strand is directed by complementary base-pairing of nucleotides to a template strand.
In all embodiments of the method, the detection step may be carried out whilst the polynucleotide strand into which the modified guanosine nucleotides are incorporated is annealed to a template strand, or after a denaturation step in which the two strands are separated. Further steps, for example chemical or enzymatic reaction steps or purification steps, may be included between the synthetic step and the detection step. In particular, the target strand incorporating the modified nucleotide(s) may be isolated or purified and then processed further or used in a subsequent analysis. By way of example, target polynucleotides labelled with modified nucleotide(s) according to the invention in a synthetic step may be subsequently used as labelled probes or primers. In other embodiments the product of the synthetic step (a) may be subject to further reaction steps and, if desired, the product of these subsequent steps purified or isolated.
Suitable conditions for the synthetic step will be well known to those familiar with standard molecular biology techniques. In one embodiment the synthetic step may be analogous to a standard primer extension reaction using nucleotide precursors, including modified guanosine nucleotides according to the invention, to form an extended target strand complementary to the template strand in the presence of a suitable polymerase enzyme. In other embodiments the synthetic step may itself form part of a polymerase chain reaction producing a labelled double-stranded PCR product comprised of annealed complementary strands derived from copying of the target and template polynucleotide strands. Other exemplary “synthetic” steps include nick translation, strand displacement polymerisation, random primed DNA labelling etc.
The polymerase enzyme used in the synthetic step must be capable of catalysing the incorporation of modified guanosine nucleotides according to the invention. Otherwise, the precise nature of the polymerase is not particularly limited but may depend upon the conditions of the synthetic reaction. For example, if the synthetic reaction is a PCR reaction then a thermostable polymerase is required, whereas this is not essential for standard primer extension. Suitable thermostable polymerases which are capable of incorporating the modified nucleotides according to the invention include those described in WO 2005/024010.
In specific non-limiting embodiments the invention encompasses use of the modified nucleotides or nucleosides according to the invention in a method of nucleic acid sequencing, re-sequencing, whole genome sequencing, single nucleotide polymorphism scoring, any other application involving the detection of the modified nucleotide or nucleoside when incorporated into a polynucleotide, or any other application requiring the use of polynucleotides labelled with the fluorescent modified nucleotides according to the invention.
In a particularly preferred embodiment the invention provides use of modified nucleotides according to the invention in a polynucleotide “sequencing-by-synthesis” reaction. Sequencing-by-synthesis generally involves sequential addition of one or more nucleotides to a growing polynucleotide chain in the 5′ to 3′ direction using a polymerase in order to form an extended polynucleotide chain complementary to the template nucleic acid to be sequenced. The identity of the base present in one or more of the added nucleotide(s) is determined in a detection or “imaging” step. The identity of the added base is preferably determined after each nucleotide incorporation step. The sequence of the template may then be inferred using conventional Watson-Crick base-pairing rules. For the avoidance of doubt “sequencing” can also encompass incorporation and identification of a single nucleotide. Determination of the identity of a single base may be useful, for example, in the scoring of single nucleotide polymorphisms.
In nucleic acid sequencing protocols, because the brightness of the fluorescent signal obtained from the modified nucleotides of the invention is increased compared to that which would be obtained using guanosine nucleotides of analogous structure but lacking the longer linking group present in the modified nucleotides or nucleosides of the invention, it is possible to “call” the presence of G nucleotides accurately at much lower template concentrations. With prior art guanosine nucleotides the brightness of the fluorescence from G may be a limiting factor on the performance of any given sequencing reaction, particularly affecting the lower limit on the amount of template which must be added to the reaction. With the use of the modified nucleotides of the invention the amount of fluorescence from each individual incorporated guanosine nucleotide is increased, hence it may be possible to accurately sequence reduced amounts of template.
In an embodiment of the invention, the sequence of a template polynucleotide is determined in a similar manner to that described in U.S. Pat. No. 5,654,413, by detecting the incorporation of one or more nucleotides into a nascent strand complementary to the template polynucleotide to be sequenced through the detection of fluorescent label(s) attached to the incorporated nucleotide(s). Sequencing of the template polynucleotide is primed with a suitable primer (or prepared as a hairpin construct which will contain the primer as part of the hairpin), and the nascent chain is extended in a stepwise manner by addition of nucleotides to the 3′ end of the primer in a polymerase-catalysed reaction.
In preferred embodiments each of the different nucleotides (A, T, G and C) is labelled with a unique fluorophore which acts as a blocking group at the 3′ position to prevent uncontrolled polymerisation. The polymerase enzyme incorporates a nucleotide into the nascent chain complementary to the template polynucleotide, and the blocking group prevents further incorporation of nucleotides. Any unincorporated nucleotides are removed and each incorporated nucleotide is “read” optically by suitable means, such as a charge-coupled device using laser excitation and filters. The 3′-blocking group is then removed (deprotected), to expose the nascent chain for further nucleotide incorporation. Typically the identity of the incorporated nucleotide will be determined after each incorporation step but this is not strictly essential.
Similarly, U.S. Pat. No. 5,302,509 discloses a method to sequence polynucleotides immobilised on a solid support. The method relies on the incorporation of fluorescently-labelled, 3′-blocked nucleotides A, G, C and T into a growing strand complementary to the immobilised polynucleotide, in the presence of DNA polymerase. The polymerase incorporates a base complementary to the target polynucleotide, but is prevented from further addition by the 3′-blocking group. The label of the incorporated base can then be determined and the blocking group removed by chemical cleavage to allow further polymerisation to occur.
The nucleic acid template to be sequenced in a sequencing-by-synthesis reaction may be any polynucleotide that it is desired to sequence. The nucleic acid template for a sequencing reaction will typically comprise a double-stranded region having a free 3′ hydroxyl group which serves as a primer or initiation point for the addition of further nucleotides in the sequencing reaction. The region of the template to be sequenced will overhang this free 3′ hydroxyl group on the complementary strand. The overhanging region of the template to be sequenced may be single stranded but can be double-stranded, provided that a “nick is present” on the strand complementary to the template strand to be sequenced to provide a free 3′ OH group for initiation of the sequencing reaction. In such embodiments sequencing may proceed by strand displacement. In certain embodiments a primer bearing the free 3′ hydroxyl group may be added as a separate component (e.g. a short oligonucleotide) which hybridises to a single-stranded region of the template to be sequenced. Alternatively, the primer and the template strand to be sequenced may each form part of a partially self-complementary nucleic acid strand capable of forming an intramolecular duplex, such as for example a hairpin loop structure. Preferred hairpin polynucleotides and methods by which they may be attached to solid supports are disclosed in our co-pending International application publication no. WO 2005/047301.
Nucleotides are added successively to the free 3′ hydroxyl group, resulting in synthesis of a polynucleotide chain in the 5′ to 3′ direction. The nature of the base which has been added may be determined, preferably but not necessarily after each nucleotide addition, thus providing sequence information for the nucleic acid template.
The term “incorporation” of a nucleotide into a nucleic acid strand (or polynucleotide) refers to joining of the nucleotide to the free 3′ hydroxyl group of the nucleic acid strand via formation of a phosphodiester linkage with the 5′ phosphate group of the nucleotide.
The nucleic acid template to be sequenced may be DNA or RNA, or even a hybrid molecule comprised of deoxynucleotides and ribonucleotides. The nucleic acid template may comprise naturally occurring and/or non-naturally occurring nucleotides and natural or non-natural backbone linkages, provided that these do not prevent copying of the template in the sequencing reaction.
In certain embodiments the nucleic acid template to be sequenced may be attached to a solid support via any suitable linkage method known in the art. Preferably linkage will be via covalent attachment.
In certain embodiments template polynucleotides may be attached directly to a solid support (e.g. a silica-based support). However, in other embodiments of the invention the surface of the solid support may be modified in some way so as to allow either direct covalent attachment of template polynucleotides, or to immobilise the template polynucleotides through a hydrogel or polyelectrolyte multilayer, which may itself be non-covalently attached to the solid support.
Arrays in which polynucleotides have been directly attached to silica-based supports are those for example disclosed in WO 97/04131, wherein polynucleotides are immobilised on a glass support by reaction between a pendant epoxide group on the glass with an internal amino group on the polynucleotide. In addition, we disclose in our co-pending International patent application publication number WO2005/047301 arrays of polynucleotides attached to a solid support, e.g. for use in the preparation of SMAs, or clustered microarrays, by reaction of a sulfur-based nucleophile with the solid support.
A still further example of solid-supported template polynucleotides is where the template polynucleotides are attached a to hydrogel supported upon silica-based or other solid supports. Silica-based supports are typically used to support hydrogels and hydrogel arrays as described in WO00/31148, WO01/01143, WO02/12566, WO03/014392, U.S. Pat. No. 6,465,178 and WO00/53812.
A particularly preferred surface to which template polynucleotides may be immobilised is a polyacrylamide hydrogel. Polyacrylamide hydrogels are described in the prior art, some of which is discussed above. However, a particularly preferred hydrogel is described in WO 2005/065814.
Preferably, where the template polynucleotide is immobilized on or to a solid support, this comprises a planar wave guide as is described in our co-pending British patent application no. 0507835.7.
The use of a planar wave guide serves to enhance the sensitivity of detection of a nucleotide incorporated into a polynucleotide molecule, wherein the incorporated nucleotide is detected by detecting a signal produced by said nucleotide when exposed to an evanescent field generated by coupling of light into said planar waveguide.
The template(s) to be sequenced may form part of an “array” on a solid support, in which case the array may take any convenient form. Thus, the method of the invention is applicable to all types of “high density” arrays, including single-molecule arrays and clustered arrays.
The method of the invention may be used for sequencing templates on essentially any type of array formed by immobilisation of nucleic acid molecules on a solid support, and more particularly any type of high-density array. However, the method of the invention is particularly advantageous in the context of sequencing of clustered arrays.
In multi-polynucleotide or clustered arrays distinct regions on the array comprise multiple polynucleotide template molecules. The term “clustered array” refers to an array wherein distinct regions or sites on the array comprise multiple polynucleotide molecules that are not individually resolvable by optical means. Depending on how the array is formed each site on the array may comprise multiple copies of one individual polynucleotide molecule or even multiple copies of a small number of different polynucleotide molecules (e.g. multiple copies of two complementary nucleic acid strands).
Multi-polynucleotide or clustered arrays of nucleic acid molecules may be produced using techniques generally known in the art. By way of example, WO 98/44151 and WO 00/18957 both describe methods of nucleic acid amplification which allow amplification products to be immobilised on a solid support in order to form arrays comprised of clusters or “colonies” of immobilised nucleic acid molecules. The nucleic acid molecules present on the clustered arrays prepared according to these methods are suitable templates for sequencing using the method of the invention.
The sequencing method of the invention is also applicable to sequencing of templates on single molecule arrays. The term “single molecule array” or “SMA” as used herein refers to a population of polynucleotide molecules, distributed (or arrayed) over a solid support, wherein the spacing of any individual polynucleotide from all others of the population is such that it is possible to effect individual resolution of the polynucleotides. The target nucleic acid molecules immobilised onto the surface of the solid support should thus be capable of being resolved by optical means. This means that, within the resolvable area of the particular imaging device used, there must be one or more distinct signals, each representing one polynucleotide. This may be achieved, preferably wherein the spacing between adjacent polynucleotide molecules on the array is at least 100 nm, more preferably at least 250 nm, still more preferably at least 300 nm, even more preferably at least 350 nm. Thus, each molecule is individually resolvable and detectable as a single molecule fluorescent point, and fluorescence from said single molecule fluorescent point also exhibits single step photobleaching. The terms “individually resolved” and “individual resolution” are used herein to specify that, when visualised, it is possible to distinguish one molecule on the array from its neighbouring molecules. Separation between individual molecules on the array will be determined, in part, by the particular technique used to resolve the individual molecules. The general features of single molecule arrays will be understood by reference to published applications WO 00/60770 and WO 01/57248.
Although a preferred use of the modified nucleotides of the invention is in sequencing-by-synthesis reactions the utility of the modified nucleotides is not limited to such methods. In fact, the nucleotides may be used advantageously in any sequencing methodology which requires detection of fluorescent labels attached to guanosine nucleotides incorporated into a polynucleotide.
In particular, the modified nucleotides of the invention may be used an automated fluorescent sequencing protocols, particularly fluorescent dye-terminator cycle sequencing based on the chain termination sequencing method of Sanger and co-workers. Such methods generally use PCR to incorporate fluorescently labelled dideoxynucleotides in a primer extension sequencing reaction.
So-called Sanger sequencing methods, and related protocols (Sanger-type), rely upon randomised chain-termination at labeled dideoxynucleotides including a known base. An example of a Sanger-type sequencing protocol is the BASS method described by Metzker ( Nucleic Acids Research, 22(2)):4259-4267, 1994). Other Sanger-type sequencing methods will be known to those skilled in the art.
Thus, the invention also encompasses modified guanosine nucleotides according to the invention which are dideoxynucleotides lacking hydroxyl groups at both the 3′ and 2′ positions, such modified dideoxynucleotides being suitable for use in Sanger type sequencing methods. Modified guanosine nucleotides of the present invention incorporating 3′ blocking groups, it will be recognized, may also be of utility in Sanger methods and related protocols since the same effect achieved by using modified dideoxyguanosine nucleotides may be achieved by using guanosine nucleotides having 3′-OH blocking groups: both prevent incorporation of subsequent nucleotides.
Where nucleotides according to the present invention, and having a 3′ blocking group are to be used in Sanger or a Sanger-type sequencing methods it will be appreciated that the detectable labels attached to the nucleotides need not be connected via cleavable linkers, since in each instance where a labeled nucleotide of the invention is incorporated, no nucleotides need to be subsequently incorporated and thus the label need not be removed from the nucleotide.
The invention also provides kits including modified guanosine nucleosides and/or nucleotides according to the invention. Such kits will generally include a supply of at least one modified nucleotide or nucleoside according to the invention together with at least one further component. The further component(s) may be further modified or unmodified nucleotides or nucleosides. For example, modified guanosine nucleotides according to the invention may be supplied in combination with unlabelled or native guanosine nucleotides, and/or with unlabelled or native adenosine, cytidine or thymidine nucleotides and/or with fluorescently labeled adenosine, cytidine or thymidine nucleotides or any combination thereof. Combinations of nucleotides may be provided as separate individual components or as nucleotide mixtures In other embodiments the kits may include a supply of a polymerase enzyme capable of catalyzing incorporation of the modified guanosine nucleotides into a polynucleotide. The polymerase component may be included in addition to or instead of further nucleotide components. Other components to be included in such kits may include buffers etc.
The modified nucleotides according to the invention, and other any nucleotide components including mixtures of different nucleotides, may be provided in the kit in a concentrated form to be diluted prior to use. In such embodiments a supply of a suitable dilution buffer may be included.
The invention will be further understood with reference to the following experimental examples.
EXAMPLES
Example 1
Synthesis of 7-[3-(-Alexa488-PEG 12 -LN 3 -linker acetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP (3)
Alexa488-PEG 12 carboxylic acid (1)
Alexa fluor 488 carboxylic acid succinimidyl ester (mixed isomers, 20 mg, 31 μmoles) was dissolved in dry DMF (1 ml). A solution of amino dPEG 12 acid (55.5 mg, 90 μmoles) and DIPEA (31.3 μl, 180 μmoles) in 0.1 M triethyl ammonium bicarbonate buffer (TEAB, 0.5 ml, pH 7.5) was added. The reaction was then stirred at RT for 3 hrs. All the reaction mixture was diluted with 0.1 M TEAB (5 ml) and loaded onto a column of DEAE-A25 Sephadex (1×12 cm). The column was eluted with 0.1 M (60 ml), 0.3 M (80 ml) (product fractions) and 0.6 M (80 ml) (fraction of free carboxylic acid form of Alexa fluor 488) TEAB. 0.1 M eluent was discarded. 0.3 M eluent was collected and evaporated under reduced pressure. The residue was co-evaporated with water (2×10 ml) and then further purified by semi-preparative reverse phase HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 2% B (flow 2-5 ml/min); 2-20 min, 2-20% B (flow 5 ml/min); 20-22 min, 20-95% B (flow 5 ml/min); 22-25 min, 95% B (flow 5 ml/min); 25-27 min, 95-2% B (flow 5 ml/min); 27-30 min, 2% B (flow 5-2 ml/min)]. The first isomer product with retention time of 19.11 min was collected and evaporated under reduced pressure and the residue was co-evaporated with water (2×5 ml) to give the title compound as triethyl ammonium salt (5.22 μmol, quantification at λ max(493) in 0.1 M TEAB buffer, 16.8%). This isomer was used to forward synthesis. The second isomer product with retention time 19.73 min was kept aside. 1 HNMR of product with Rt 19.11 min in D 2 O indicated approximately two triethylammonium count ions. 1 H NMR (400 MHz, D 2 O), δ 1.11 (t, J=7.3 Hz, 18H, CH 3 , triethylammonium count ion), 2.37 (t, J=6.4 Hz, 2H, CH 2 ), 3.03 (q, J=7.3 Hz, 12H, CH 2 , triethylammonium count ion), 3.30-3.70 (m, 50H), 6.80 (d, J=9.3 Hz, 2H, Ar—H), 7.08 (d, J=9.3 Hz, 2H, Ar—H), 7.53 (s, 1H, Ar—H) and 7.80-7.95 (m, 2H, Ar—H). LC-MS (electrospray negative): 565.85 [(M/2e)−1].
Alexa488-PEG 12 -LN 3 linker carboxylic acid (2)
Alexa488-PEG 12 carboxylic acid (1) (5 μmol) was co-evaporated with dry DMF (5 ml) and the residue was then dissolved in dry DMF (1.5 ml). A solution of TSTU (10 μmol, 100 μl, concentration: 30 mg TSTU in 1 ml dry DMF) in dry DMF was added. The reaction was stirred at room temperature for 10 minutes. LN 3 linker ((2-{2-[3-(2-amino-ethylcarbamoyl)-phenoxy]-1-azido-ethoxy}-ethoxy)-acetic acid) (15 μmol, 5.51 mg) was added followed by DIPEA (50 μmol, 8.7 μl). The reaction was stirred at room temperature overnight. The reaction was then diluted with 0.1 M TEAB buffer (10 ml) and then loaded onto a DEAE-A25 Sephadex column (1×10 cm). The column was eluted with 0.1 M TEAB (60 ml, this fraction was discarded) and 0.35 M TEAB (80 ml). The product-containing fraction (0.35 M eluent) was evaporated under reduced pressure. The residue was co-evaporated with water (2×10 ml). The residue was further purified by semi-preparative reverse phase HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 5% B (flow 2-5 ml/min); 2-15 min, 5-22% B (flow 5 ml/min); 15-21 min, 22-45% B (flow 5 ml/min); 21-22 min, 45-95% B (flow 5 ml/min); 22-25 min, 95% B (flow 5 ml/min); 25-27 min, 95-5% B (flow 5 ml/min); 27-30 min, 5% B (flow 5-2 ml/min)]. The product with retention time of 19.26 min was collected and evaporated under reduced pressure and the residue was co-evaporated with water (2×5 ml) to give the title compound (2) as triethyl ammonium salt (2.29 μmol, quantification at λ max(494) in 0.1 M TEAB buffer, 45.8%). 1 HNMR of product with Rt 19.26 min in D 2 O indicated approximately average 5.6 triethylammonium count ions. 1 H NMR (400 MHz, D 2 O), δ 1.00 (t, J=7.3 Hz, 51H, CH 3 , triethylammonium count ion), 2.35 (t, J=5.6 Hz, 2H, CH 2 ), 2.75 (q, J=7.3 Hz, 34H, CH 2 , triethylammonium count ion), 3.22-3.62 (m, 56H), 3.70-3.78 (m, 1H), 3.79 (s, 2H, OCH 2 CO 2 H), 3.87-3.95 (m, 1H), 4.02-4.12 (m, 2H, ArOCH 2 ), 4.90-4.98 (m, 1H, CHN 3 ), 6.78 (d, J=9.3 Hz, 2H, Ar—H), 6.98-7.08 (m, 3H, Ar—H), 7.14-7.22 (m, 2H, Ar—H), 7.28 (t, J=7.9 Hz, 1H, Ar—H), 7.51 (s, 1H, Ar—H), 7.86 (d, J=8.0 Hz, 1H, Ar—H) and 7.91 (d, J=8.0 Hz, 1H, Ar—H). LC-MS (electrospray negative): 740.35 [(M/2e)−1], 493.50 [(M/3e)−1] as mono-potassium adduct salt.
7-[3-(-Alexa488-PEG 12 -LN 3 -linkeracetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP (3)
Alexa488-PEG 12 -LN 3 linker carboxylic acid (2) (2 μmol) was co-evaporated under reduced pressure with anhydrous DMF (2 ml) and the re-dissolved in anhydrous DMF (0.8 ml). A solution of TSTU (6 μmol, 100 μl, concentration: 18 mg TSTU in 1 ml dry DMF) in dry DMF was added. The reaction was stirred at room temperature for 10 minutes. [7-(3-amino-prop-1-ynyl)]-3′-azidomethyl-dGTP (6 μmol, prepared by evaporating an aqueous solution of [7-(3-amino-prop-1-ynyl)]-3′-azidomethyl-dGTP in 0.1 M TEAB buffer (1.82 ml) and with tri-n-butyl amine (14.3 μl, 60 μmol) in DMF (200 μl)) in 0.1 M TEAB buffer (0.2 ml) was then added. The reaction was stirred at room temperature for 4 hrs, and then diluted with chilled 0.1 M TEAB (4 ml). The whole reaction mixture was then loaded onto a DEAE-A25 Sephadex column (1×10 cm). The column was then eluted with 0.1M (60 ml), 0.3 M (60 ml) and 0.7 M (80 ml) TEAB buffer. The 0.7 M eluent was collected and evaporated under reduced pressure and the residue was co-evaporated with water (2×5 ml). The residue was dissolved in 0.1 M TEAB (5 ml), then further purified by semi-preparative reverse phase HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 5% B (flow 2-5 ml/min); 2-15 min, 5-22% B (flow 5 ml/min); 15-21 min, 22-25% B (flow 5 ml/min); 21-22 min, 25-95% B (flow 5 ml/min); 22-25 min, 95% B (flow 5 ml/min); 25-27 min, 95-5% B (flow 5 ml/min); 27-30 min, 5% B (flow 5-2 ml/min)]. The product with retention time of 18.49 min was collected and evaporated under reduced pressure to give the title compound (3) as triethyl ammonium salt (1.27 μmol, quantification at λ max(494) in 0.1 M TEAB buffer, 63.5%). 1 HNMR of product with Rt 18.49 min in D 2 O indicated approximately average 71 triethylammonium count ions. 1 H NMR (400 MHz, D 2 O), δ 1.09 (t, J=7.3 Hz, 639H, CH 3 , triethylammonium count ion), 2.20-2.31 (m, 1H, H a -2′), 2.32 (t, J=5.9 Hz, 2H, CH 2 ), 2.36-2.52 (m, 1H, H b -2′), 3.01 (q, J=7.3 Hz, 426H, CH 2 , triethylammonium count ion), 3.23-3.59 (m, 54H), 3.61-3.82 (m, 3H), 3.87-4.12 (m, 9H), 4.13-4.18 (m, 1H, H-4′), 4.44-4.50 (m, 1H, H-3′), 4.74-4.80 (m, 2H, OCH 2 N 3 ), 4.89-4.97 (m, 1H, CHN 3 ), 5.96-6.08 (m, 1H, H-1′), 6.73-6.81 (m, 3H), 6.95 (s, 1H), 7.00-7.15 (m, 5H), 7.49 (s, 1H, Ar—H), and 7.80-7.92 (m, 2H, Ar—H). 31 P NMR (D 2 O), δ−20.94 (m, β P), −10.08 (d, J=18.6 Hz, α P) and −5.00 (d, J=21.1 Hz, γ P). LC-MS (electrospray negative): 1038.2 [(M/2e)−1].
Example 2
Preparation of 7-[3-(-Alexa488-PEG 24 -LN 3 -linkeracetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP (6)
Alexa488-PEG 24 carboxylic acid (4)
Alexa fluor 488 carboxylic acid succinimidyl ester (mixed isomers, 10 mg, 15.5 μmoles) was dissolved in dry DMF (2 ml). Amino dPEG 24 t-butyl ester (41.5 mg, 34.5 μmoles) and DIPEA (69.6 μl, 400 μmoles) were added. The reaction was then stirred at RT for 3 hrs. All the solvents were evaporated under reduced pressure and the residue was then dissolved in a mixture solvent of TFA (2 ml) and DCM (8 ml). The reaction was stirred at room temperature. After 30 minutes, all the solvents were evaporated under reduce pressure. The residue was then diluted with chilled TEAB buffer (0.1 M, 100 ml). The solution was then loaded onto a column of DEAE-A25 Sephadex (2×15 cm). The column was eluted with 0.1 M (50 ml) and 0.3 M (50 ml) TEAB buffer. 0.1 M eluent was discarded. 0.3 M eluent was collected and evaporated under reduced pressure. The residue was co-evaporated with water (2×10 ml) and then further purified by semi-preparative reverse phase HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 5% B (flow 2-5 ml/min); 2-20 min, 5-25% B (flow 5 ml/min); 20-22 min, 25-95% B (flow 5 ml/min); 22-25 min, 95% B (flow 5 ml/min); 25-27 min, 95-5% B (flow 5 ml/min); 27-30 min, 5% B (flow 5-2 ml/min)]. The first isomer product with retention time of 20.25 min was collected and evaporated under reduced pressure and the residue was co-evaporated with water (2×5 ml) to give the title compound as triethyl ammonium salt (5.5 μmol, quantification at λ max(494) in 0.1 M TEAB buffer, 35.4%). This isomer was used to forward synthesis. The second isomer product with retention time 20.62 min was kept aside. 1 HNMR of product with Rt 20.25 min in D 2 O indicated approximately 1.5 triethylammonium count ions. 1 H NMR (400 MHz, D 2 O), δ 1.12 (t, J=7.3 Hz, 13.5H, CH 3 , triethylammonium count ion), 2.46 (t, J=6.2 Hz, 2H, CH 2 ), 3.04 (q, J=7.3 Hz, 9H, CH 2 , triethylammonium count ion), 3.34-3.66 (m, 98H), 6.81 (d, J=9.3 Hz, 2H, Ar—H), 7.08 (d, J=9.3 Hz, 2H, Ar—H), 7.55 (s, 1H, Ar—H) and 7.93 (s, 2H, Ar—H). LC-MS (electrospray negative): 829.75 [(M/2e)−1], 553.25 [(M/3e)−1].
Alexa488-PEG 24 -LN 3 linker carboxylic acid (5)
Alexa488-PEG 24 carboxylic acid (4) (0.6 μmol) was co-evaporated with dry DMF (2 ml) and the residue was then dissolved in dry DMF (1 ml). A solution of TSTU (2.4 μmol, 100 μl, concentration: 7.23 mg TSTU in 1 ml dry DMF) in dry DMF was added. The reaction was stirred at room temperature for 10 minutes. LN 3 linker ((2-{2-[3-(2-amino-ethylcarbamoyl)-phenoxy]-1-azido-ethoxy}-ethoxy)-acetic acid) (6 μmol, 2.2 mg) was added followed by DIPEA (30 μmol, 5.2 μl). The reaction was stirred at room temperature. After overnight (18 hrs), the reaction was diluted with chilled 0.1 M TEAB buffer (10 ml) and then loaded onto a DEAE-A25 Sephadex column (1×10 cm). The column was eluted with 0.1 M TEAB (30 ml, this fraction was discarded) and 0.30 M TEAB (50 ml). The product-containing fraction (0.30 M eluent) was evaporated under reduced pressure. The residue was co-evaporated with water (2×5 ml). The residue was further purified by semi-preparative reverse phase HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 5% B (flow 2-5 ml/min); 2-15 min, 5-22% B (flow 5 ml/min); 15-21 min, 22-50% B (flow 5 ml/min); 21-22 min, 50-95% B (flow 5 ml/min); 22-25 min, 95% B (flow 5 ml/min); 25-27 min, 95-5% B (flow 5 ml/min); 27-30 min, 5% B (flow 5-2 ml/min)]. The product with retention time of 19.46 min was collected and evaporated under reduced pressure and the residue was co-evaporated with water (2×2 ml) to give the title compound (5) as triethyl ammonium salt (0.224 μmol, quantification at λ max(494) in 0.1 M TEAB buffer, 37.3%). 1 HNMR of product with Rt 19.46 min in D 2 O indicated approximately average one triethylammonium count ions. 1 H NMR (400 MHz, D 2 O), δ 1.11 (t, J=7.3 Hz, 9H, CH 3 , triethylammonium count ion), 2.35 (t, J=5.9 Hz, 2H, CH 2 ), 3.04 (q, J=7.3 Hz, 6H, CH 2 , triethylammonium count ion), 3.20-3.70 (m, 104H), 3.65-3.78 (m, 1H), 3.80 (s, 2H, OCH 2 CO 2 H), 3.85-4.05 (m, 1H), 4.13 (d, J=4.2 Hz, 2H, ArOCH 2 ), 4.96 (t, J=4.3 Hz, 1H, CHN 3 ), 6.80 (d, J=9.4 Hz, 2H, Ar—H), 7.06 (s, 1H, Ar—H), 7.08 (d, J=9.4 Hz, 2H, Ar—H), 7.15-7.25 (m, 2H, Ar—H), 7.32 (t, J=7.8 Hz, 1H, Ar—H), 7.53 (s, 1H, Ar—H), 7.87 (d, J=8.2 Hz, 1H, Ar—H) and 7.91 (d, J=8.2 Hz, 1H, Ar—H). LC-MS (electrospray negative): 669.30 [(M/3e)−1], 501.90 [(M/4e)−1].
7-[3-(-Alexa488-PEG 24 -LN 3 -linkeracetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP (6)
Alexa488-PEG 24 -LN 3 linker carboxylic acid (5) (0.5 μmol) was co-evaporated under reduced pressure with anhydrous DMF (1 ml) and then re-dissolved in anhydrous DMF (0.5 ml). A solution of TSTU (2 μmol, 50 concentration: 12 mg TSTU in 1 ml dry DMF) in dry DMF was added. The reaction was stirred at room temperature for 10 minutes. [7-(3-amino-prop-1-ynyl)]-3′-azidomethyl-dGTP (2.5 μmol) in 0.1 M TEAB buffer (0.2 ml) was then added. The reaction was stirred at room temperature for 3 hrs and stored in fridge overnight (18 hrs). It was then diluted with chilled 0.1 M TEAB (10 ml). The whole reaction mixture was then loaded onto a DEAE-A25 Sephadex column (1×10 cm). The column was then eluted with 0.1M (30 ml), 0.3 M (30 ml) and 0.6 M (50 ml) TEAB buffer. The 0.6 M eluent was collected and evaporated under reduced pressure and the residue was co-evaporated with water (10 ml). The residue was dissolved in 0.1 M TEAB (5 ml), then further purified by semi-preparative reverse phase HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 5% B (flow 2-5 ml/min); 2-15 min, 5-25% B (flow 5 ml/min); 15-21 min, 25-30% B (flow 5 ml/min); 21-22 min, 30-95% B (flow 0.5 ml/min); 22-25 min, 95% B (flow 5 ml/min); 25-27 min, 95-5% B (flow 5 ml/min); 27-30 min, 5% B (flow 5-2 ml/min)]. The product with retention time of 19.57 min was collected and evaporated under reduced pressure to give the title compound (6) as triethyl ammonium salt (0.231 μmol, quantification at λ max(494) in 0.1 M TEAB buffer, 46.2%). 1 HNMR of product with Rt 19.57 min in D 2 O indicated approximately average one triethylammonium count ions. 1 H NMR (400 MHz, D 2 O), δ 1.11 (t, J=7.3 Hz, 9H, CH 3 , triethylammonium count ion), 2.20-2.24 (m, 1H, H a -2), 2.35 (t, J=5.8 Hz, 2H, CH 2 ), 2.38-2.48 (m, 1H, H b -2′), 3.03 (q, J=7.3 Hz, 6H, CH 2 , triethylammonium count ion), 3.40-3.60 (m, 102H), 3.65-3.85 (m, 3H), 3.87-4.11 (m, 9H), 4.12-4.20 (m, 1H, H-4′), 4.49-4.51 (m, 1H, H-3′), 4.77-4.82 (m, 2H, OCH 2 N 3 ), 4.85-5.00 (m, 1H, CHN 3 ), 6.00-6.20 (m, 1H, H-1′), 6.73-6.85 (m, 3H), 6.96 (s, 1H), 7.05-7.18 (m, 5H), 7.52 (d, J=1.4 Hz 1H, Ar—H), 7.80 (d, J=8.1 Hz, 1H, Ar—H) and 7.90 (dd, J=1.5 and 8.1 Hz, 1H, Ar—H). LC-MS (electrospray negative): 1302.9 [(M/2e)−1].
Comparative Example
Synthesis of 7-[3-(-Alexa488-LN 3 -linker acetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP (8)
Alexa488-LN 3 linker carboxylic acid (7)
Alexa flour 488 6-carboxylic acid (9 μmol) was stirred with N,N′-di-succinimidyl carbonate (19.8 μmol, 5.07 mg), DMAP (19.8 μmol, 2.42 mg) and DIPEA (30 μmol, 5.23 μl) in dry DMF (1 ml). After 15 minutes at room temperature, LN 3 linker ((2-{2-[3-(2-amino-ethylcarbamoyl)-phenoxy]-1-azido-ethoxy}-ethoxy)-acetic acid) (30 μmol, 11.0 mg) was added followed by DIPEA (60 μmol, 10.45 μl). The reaction was stirred at room temperature overnight (18 hrs). The reaction was then diluted with chilled water (15 ml) and then loaded onto a DEAE-A25 Sephadex column (1×10 cm). The column was eluted with 0.1 M TEAB (50 ml, this fraction was discarded) and 1.0 M TEAB (50 ml). The product-containing fraction (1.0 M eluent) was evaporated under reduced pressure. The residue was co-evaporated with water (2×10 ml). The residue was further purified by preparative HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 5% B (flow 2-10 ml/min); 2-19 min, 5-25% B (flow 10 ml/min); 19-21 min, 25-95% B (flow 10 ml/min); 21-24 min, 95% B (flow 10 ml/min); 24-26 min, 95-5% B (flow 10 ml/min); 26-30 min, 5% B (flow 10-2 ml/min)]. The product with retention time of 20.06 min was collected and evaporated under reduced pressure and the residue was co-evaporated with water (2×5 ml) to give the title compound (7) as triethyl ammonium salt (3.69 μmol, quantification at λ max(495) in 0.1 M TEAB buffer, 51%; also recovered 1.76 μmole Alexa flour 488 6-carboxylic acid). 1 HNMR of product in D 2 O indicated approximately average 3.7 triethylammonium count ions. 1 H NMR (400 MHz, D 2 O), δ 1.08 (t, J=7.3 Hz, 33H, CH 3 , triethylammonium count ion), 2.94 (q, J=7.3 Hz, 22H, CH 2 , triethylammonium count ion), 3.45-3.65 (m, 6H), 3.68-3.78 (m, 1H), 3.79 (s, 2H, OCH 2 CO 2 H), 3.87-3.93 (m, 2H), 3.95-4.05 (m, 1H), 4.84 (t, J=4.0 Hz, 1H, CHN 3 ), 6.69 (d, J=9.3 Hz, 1H, Ar—H), 6.72 (d, J=9.3 Hz, 1H, Ar—H), 6.84 (d, J=9.3 Hz, 1H, Ar—H), 6.85-6.94 (m, 2H, Ar—H), 6.95-7.04 (m, 2H, Ar—H), 7.07 (t, J=7.9 Hz, 1H, Ar—H), 7.13 (s, 1H, Ar—H), 7.81 (d, J=8.1 Hz, 1H, Ar—H) and 7.84 (d, J=8.1 Hz, 1H, Ar—H). LC-MS (electrospray negative): 882.80 [M−1].
7-[3-(-Alexa488-LN 3 -linkeracetylamino)-prop-1-ynyl]-3′-azidomethyl-dGTP (8)
Alexa flour 488 LN 3 linker carboxylic acid (7) (1.65 μmol) was dissolved in dry DMF (0.5 ml). N,N′-di-succinimidyl carbonate (5.4 μmol, 1.38 mg) and DMAP (3.6 μmol, 0.44 mg) were added. After 15 minutes at room temperature, all the above reaction mixture was added to [7-(3-amino-prop-1-ynyl)]-3′-azidomethyl-dGTP (5.8 μmol, prepared by evaporating an aqueous solution of [7-(3-amino-prop-1-ynyl)]-3′-azidomethyl-dGTP in 0.1 M TEAB buffer (1.45 ml) and with tri-n-butyl amine (144 μl)). The reaction was stirred at room temperature 3 hrs. The reaction was then diluted with chilled 0.1 M TEAB (10 ml) and then loaded onto a DEAE-A25 Sephadex column (1×8 cm). The column was eluted with 0.1 M (50 ml, this fraction was discarded) and 2.0 M TEAB (50 ml). The product-containing fraction (2.0 M eluent) was evaporated under reduced pressure. The residue was co-evaporated with water (2×5 ml). The residue was further purified by semi-preparative reverse phase HPLC [HPLC gradient: A, 100% 0.1 M TEAB; B 100% MeCN; 0-2 min, 5% B (flow 2-5 ml/min); 2-14 min, 5-20% B (flow 5 ml/min); 14-20 min, 20-23% B (flow 5 ml/min); 20-22 min, 23-95% B (flow 5 ml/min); 22-25 min, 95% B (flow 5 ml/min); 25-26 min, 95-5% B (flow 5 ml/min); 26-30 min, 5% B (flow 5-2 ml/min)]. The product with retention time of 16.63 min was collected and evaporated under reduced pressure and the residue was co-evaporated with water (5 ml) to give the title compound (8) as triethyl ammonium salt (0.257 μmol, quantification at λ max(495) in 0.1 M TEAB buffer, 15.6%). 1 H NMR (400 MHz, D 2 O), 2.14-2.30 (m, 1H, H a -2′), 2.38-2.52 (m, 1H, H b -2′), 3.49-4.02 (m, 16H), 4.15-4.25 (m, 1H), 4.45-4.55 (m, 1H), 4.80 (d, J=6.9 Hz, 1H, Ar—OCH a H b ), 4.84 (d, J=6.9 Hz, 1H, Ar—OCH a H b ), 4.87-4.92 (m, 1H, CHN 3 ), 5.86-5.95 (m, 1H), 6.54 (t, J=9.1 Hz, 1H, Ar—H), 6.62-6.67 (m, 1H, Ar—H), 6.70 (d, J=8.0 Hz, 1H, Ar—H), 6.78-6.83 (m, 2H, Ar—H), 6.87-7.04 (m, 4H, Ar—H), 7.39 (s, 1H, Ar—H) and 7.81-7.90 (m, 2H, Ar—H). MS (electrospray negative): 757.40 [(M/2e)−1], 505.00 [(M/3e)−1] (as mono potassium adduct salt).
Example 3
Preparation of Atto532-Peg12-LN3-dGTP
Step 1
Synthesis of Atto532-Peg12
Atto532NHS ester (20 mg, 26.9 μmol) (Atto-tec AD532-3) was dissolved in DMF (1.5 ml). A solution of H2N-PEG12-COOH (49.8 mg, 80.7 μmol) in 0.1 M TEAB (0.5 ml) was added to the reaction. The reaction was monitored by TLC (eluting system ACN: H 2 O 4:1) and reached completion in 90 min. It was quenched with 2 ml of 0.1 M TEAB and concentrated to dryness. The crude was purified by doing a Sephadex column (1×10 cm). We eluted three fractions, first with 40 ml of 0.1 M TEAB, second with 100 ml of 0.3 M TEAB and finally with 100 ml of 0.5 M TEAB. The product of the reaction was contained in fraction 2. This was submitted to HPLC purification (5-50 method in 20 min in the semiprep Zorbax column), retention time 13.7 min. The product was obtained in 64% yield.
MS (es−, m/z): 1243, 622
1H NMR (400 MHz; D 2 O) 7.65-7.56 (2H, m, CHar, CHar), 7.52-7.45 (1H, m, CHar), 7.40-7.36 (1H, m, CHar), 7.23-7.18 (2H, m which includes doublet, J 9.6, CHar, CHar), 6.92 (1H, d, J 9.6 CHar), 6.91 (1H, d, J 9.6, CHar), 3.58 (2H, t, J 6.8, CH 2 ), 3.55-3.45 [44H, m, 11×(O—CH 2 )+11×(CH 2 —O)], 3.40 (2H, t, J 5.6, CH 2 ), 3.33 (4H, q, J 7.2, 2×CH 2 ), 3.19 (1H, t, J 5.6, CH), 3.14 (1H, t, J 5.6, CH), 3.09 (1H, br.t, CH), 2.78 (3H, s, CH 3 ), 2.31 (2H, t, J 6.8, CH 2 ), 1.60-1.52 (2H, m, CH 2 ), 1.32-1.24 (2H, m, CH 2 ), 1.17 (6H, t, J 7.2, 2×CH 3 ).
Step 2
Preparation of Atto532-PEG12-LN 3
Atto532PEG (21.6 mg, 17.4 μmol) was dissolved in DMF (1.8 ml). A solution of TSTU (7.8 mg, 26.1 μmol) in DMF was added to the reaction. Since not much progress was observed after 30 min by TLC (eluting system ACN: H 2 O 4:1), DIPEA (15 μl, 87 μmol) was added. The activation was completed in 30 min and LN3 (15.9 mg, 43.5 μmol) dissolved in DMF was added. The reaction was left stirring for 16 h, after which it was quenched with 10 ml of 0.1 M TEAB and vacuumed off. The reaction crude was purified by HPLC (5-50 method in 20 min in the semiprep Zorbax column), retention time 14.9 min. The product was obtained in 66% yield.
MS (es−, m/z): 796
1H NMR (400 MHz; D 2 O) 7.66-7.56 (2H, m, CHar, CHar), 7.54-7.45 (1H, m, CHar), 7.38-7.34 (1H, m, CHar), 7.28 (1H, q, J 8.0, CHar), 7.23-7.15 (4H, m, CHar), 7.08-7.01 (1H, br.d, J 8.0, CHar), 6.90 (1H, d, J 5.2, CHar), 6.88 (1H, d, J 5.2, CHar), 4.94 (1H, t, J 4.4, CHN 3 ), 4.12 (2H, br.d, J 4.0, CH 2 ), 4.00-3.86 (2H, double m, CHH), 3.81 (2H, s, O—CH 2 ), 3.81-3.72 (1H, m, CHH), 3.63-3.55 (5H, m, 2×CH 2 +CH), 3.54-3.26 [53H, triple m, 4×CH 2 +CH+11×(O—CH 2 )+11×(CH 2 —O)], 3.22-3.12 (2H, m, CH 2 ), 2.76 (3H, s, CH 3 ), 2.35 (2H, t, J 5.6, CH 2 ), 1.96-1.90 (1H, m, CH), 1.60-1.49 (1H, m, CH), 1.31-1.22 (1H, m, CH 2 ), 1.17 (6H, t, J 7.2, 2×CH 3 ).
Step 3
Synthesis of G-Atto532-PEG12-LN3
Atto532PEGLN3 (18 mg, 11.3 μmol) was dissolved in DMF (3 ml). A solution of TSTU (5.1 mg, 17 μmol) in DMF (200 μl) was added. The progress of the reaction was monitored by TLC (eluting system ACN: H2O 4:1). No activation is observed after 30 min, so DIPEA (10 μl) was added. After 30 min, the TLC shows that the activation was completed. PPPG (34 μmol, 2.25 mM) was co-evaporated with tributylamine (81 μl) and redissolved in 0.1 M TEAB (0.5 ml). After 30 min, TLC showed that the reaction had gone to completion (eluting system ACN: H2O 4:1). The reaction was quenched with 10 ml of 0.1 M TEAB at 0° C. and vacuumed off. The reaction crude was purified by HPLC (5-50 method in 20 min in the semiprep Zorbax column), retention time 14.8 min. The product was obtained in 57% yield.
MS (es−, m/z): 1095, 729, 546
1H NMR (400 MHz; D 2 O) 7.64-7.60 (2H, m, CHar), 7.51-7.44 (1H, m, CHar), 7.35-7.31 (1H, m, CHar), 7.16-7.12 (4H, m, CHar), 7.09 (1H, s, CHbase), 6.99-6.96 (1H, br.s, CHar), 6.88 (1H, d, J 4.0, CHar), 6.86 (1H, d, J 4.0, CHar), 6.83-6.77 (1H, m, CHar), 6.06-5.96 (1H, m, H-1′), 4.96 (1H, br.s, CHHN 3 ), 4.82 (1H, br.s, CHHN 3 ), 4.54-4.46 (1H, m, H-3′), 4.20-4.14 (1H, m, H-4′), 4.12-3.89 (8H, double m, 3×CH 2 +2H-5′), 3.86-3.60 (4H, m, CH 2 +CH 2 —N), 3.56 (2H, t, J 6.0, CH 2 ), 3.54-3.28 [56H, set m, 11×(O—CH 2 )+11×(CH 2 —O)+6CH 2 ], 3.18 (2H, t, J 5.6, CH 2 ), 2.74 (3H, s, CH 3 ), 2.46-2.23 (4H, m+t+m, J 6.0, 2H-2′+CH 2 ), 1.61-1.34 (3H, m, CH 2 +CH), 1.29-1.14 (8H, m+t, J 7.2, CH 2 +2×CH 3 ).
Example 4
Demonstration of Reduced Quenching of Fluorophores in Modified Nucleotides of the Invention
The modified nucleotides of Examples 1 and 2 ((3) and (6)) and the compound of the Comparative Example (8) described above were each incorporated into a polynucleotide by phosphodiester linkage of the modified nucleotide to the 3′ end of a DNA strand, the precise sequence of which is not of relevance. The fluorescent intensity of the Alexa 488 dye in the modified nucleotides was then measured, both before and after treatment with Tris-(2-carboxyethyl) phosphine (TCEP). FIG. 1 shows the intensity measured of the Alexa 488 dye, for all three modified nucleotides, both before and after cleavage of the linkers with TCEP. The modified nucleotide of the comparative example (i.e. G-N3-A488 with no PEG in the linker) clearly shows the highest level of quenching (i.e. lowest fluorescence intensity) before TCEP cleavage. However, the similarity in fluorescence intensity measured after cleavage of all three linkers is striking. Since the point of cleavage in the chain leaves the PEG moieties still attached to the Alexa 488 fluorophore, this experiment demonstrates that because the “free” fluorophore (i.e. without the guanine base) is not quenched in solution, the enhanced signal in the fully functionalised nucleotides (ff's) of the invention is not simply an artefact of the PEG moiety being attached to the fluorophore. The FIGURE also illustrates that compound (6) demonstrates a greater reduction in quenching (i.e. higher fluorescence intensity before TCEP treatment) over not only the modified nucleotides of the comparative example, but also over compound (3).
All patents, patent applications, and published references cited herein are hereby incorporated by reference in their entirety. While this invention has been particularly shown and described with references to preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the scope of the invention encompassed by the claims.
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The invention is directed to modified guanine-containing nucleosides and nucleotides and uses thereof. More specifically, the invention relates to modified fluorescently labelled guanine-containing nucleosides and nucleotides which exhibit enhanced fluorophore intensity by virtue of reduced quenching effects.
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BACKGROUND OF THE INVENTION 1. Field of the Invention
This invention relates to a solid state image sensing device for image sensing.
2. Description of the Prior Art
In a frame transfer type area (two-dimensional) sensor, the number of cells in the longitudinal direction of the image sensing portion has been 245, namely, about one-half of the number of scanning lines, in the case of NTSC system, and the number of picture elements which can be stored in each cell at a time has been 245 which corresponds to one field because each cell has been provided with the functions of photosensing and transfer, and images corresponding to one field have been obtained by effecting an interlace operation which comprises reading out a signal charge corresponding to the one field, thereafter effecting image sensing by moving the effective photosensitive area of each cell, and subsequently reading out the amount corresponding to the one field.
Such a system matches the NTSC television system very well and is characterized by its ability to provide an image of excellent resolution in spite of the small number of cells.
On the other hand, in recent years, studies and developments have been carried out for sensing images by using an image sensing device such as CCD instead of the conventional silver salt film known as the video still camera or the video photography and magnetically recording the sensed images. Where the conventional frame transfer type area sensor is used in such a system, there is the disadvantage that if an attempt is made to record one frame to obtain a high quality of image, the resultant image comprises two fields deviated a little from each other in time, or deviated from each other by 1/60 sec. in terms of TV signal rate and when the image of a moving object is sensed, there is only obtained an unsightly image and if one-field recording is adopted to avoid such a phenomenon, the resolution in vertical direction is reduced to about one-half.
SUMMARY OF THE INVENTION
In view of the above-noted disadvantage peculiar to the prior art, it is an object of the present invention to provide a solid state image sensing device suitable for a video still camera.
It is another object of the present invention to provide a solid state image sensing device which can provide a frame signal comprising a plurality of field signals from images sensed at the same point of time.
It is still another object of the present invention to provide a solid state image sensing device which can be used for both photographing stationary images and photographing moving images.
It is yet another object of the present invention to provide a solid state image sensing device suitable for photographing moving images and which can provide a field signal of high resolution.
Other objects of the present invention will become apparent from the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows the construction of a frame transfer type CCD according to a first embodiment of the present invention.
FIG. 2 is a schematic view of a portion of the CCD according to the first embodiment.
FIG. 3 shows the condition of the interior potential of the CCD according to the first embodiment.
FIG. 4 shows the sequence when the first embodiment is used to photograph a stationary image and the sequence when the first embodiment is used to photograph a moving image.
FIG. 5 diagrammatically shows the driving circuit of the CCD according to the first embodiment.
FIG. 6A is a timing chart of the various portions of FIG. 5 during the photographing of a stationary image.
FIG. 6B is a timing chart of the various portions of FIG. 5 during the photographing of a moving image.
FIG. 7 schematically shows the construction of a frame transfer type CCD according to a second embodiment of the present invention.
FIG. 8 is a schematic view of a portion of the CCD according to the second embodiment.
FIG. 9 shows the condition of the interior potential of the CCD according to the second embodiment.
FIG. 10 shows the sequence when the second embodiment is used to photograph a stationary image and the sequence when the second embodiment is used to photograph a moving image.
FIG. 11 diagrammatically shows the driving circuit in the second embodiment.
FIG. 12A is a timing chart of the various portions of FIG. 11 during the photographing of a stationary image.
FIG. 12B is a timing chart of the various portions of FIG. 11 during the photographing of a moving image.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will hereinafter be described with respect to some embodiments thereof by reference to the drawings. FIG. 1 shows the construction of a frame transfer type CCD according to a first embodiment of the present invention. In FIG. 1, reference numeral 1 designates the image sensing portion of the frame transfer type CCD. In this image sensing portion, for example, in the case of the NTSC system, the number of cells in the vertical direction is set to a number substantially equal to the number of scanning lines, namely, on the order of 490. That is, this CCD has a number of cells about twice that in the conventional frame transfer type CCD. As the number of cells in horizontal direction, a number on the order of 390, 570 or 780 which corresponds to the color sub-carrier frequency is usually adopted. Of these cells, none elements in the vertical direction and four elements in the horizontal direction are shown in FIG. 1. Reference numeral 2 designates an electrode for applying to this image sensing portion a voltage for effecting light reception and transfer. Reference numeral 3 denotes a storing portion, in which the number of cells in the vertical direction is about 1/2 of that in the image sensing portion and the number of cells in the horizontal direction is equal to that in the image sensing portion. Accordingly, this storing portion comprises a number of cells substantially equal to that in the conventional frame transfer type CCD. Reference numeral 4 designates an electrode to which a voltage for transferring a charge is applied. Reference numeral 5 denotes a horizontal transfer register which is constructed as a row of charge transfer portion comprising a number of cells substantially equal to the number of cells in the horizontal direction of the image sensing portion or the storing portion. Designated by 6 is an electrode for applying a voltage for transferring the charge of the horizontal transfer register 5. Denoted by 7 is an amplifier for converting the charge transferred from the horizontal register 5 into a voltage output.
There are several charge transfer methods such as single phase drive, two-phase drive, three-phase drive, four-phase drive, etc., and any of these methods may be adopted in the construction of the CCD of the present invention, and the single phase drive method may be that described, for example, in U.S. Pat. No. 4,229,752.
FIG. 2 is a schematic plan view of the image sensing device according to the present invention. In FIG. 2, reference numeral 20 designates channel stoppers for preventing leakage of charge between the cells in the horizontal direction, and hatched portion 21 designated the poly-silicon electrode of the image sensing portion, this electrode comprising a first area (I) and a second area (II) which differ from each other in the potential condition in the silicon. Reference numeral 22 denotes a virtual electrode formed in the silicon, and it forms in the silicon a third area (III) and a fourth area (IV) which differ from each other in the potential condition. The first to fourth areas constitute a cell in the vertical direction. 24 and 25 are constructed similarly to 21 and 22, respectively, of the image sensing portion. However, the amounts of charge stored in 24 and 25 are about twice those stored in 21 and 25.
FIG. 3 shows the interior potential condition of the CCD of the construction shown in FIG. 2. Reference numerals 30 designate the poly-silicon electrodes of the image sensing portion which correspond to 21 in FIG. 2. All of the poly-silicon electrodes of the image sensing portion are commonly connected and a voltage for charge transfer may be applied thereto. The portion below these poly-silicon electrodes is divided into a first and a second potential area as described in connection with FIG. 2, and the first area (I) is higher in potential condition than the second area (II).
The dotted lines in FIG. 3 indicate the condition in which the poly-silicon electrodes 30 are in a high negative potential, and the solid lines indicate the potential in which the potentials of the poly-silicon electrodes 30 are slighly negative or positive.
The potential of the virtual electrode portion 22 of FIG. 2 is such that as shown in FIG. 3, the third area (III) is slightly higher in potential than the fourth area (IV). The potential of this portion does not depends on the voltage applied to the electrodes 30, but is always maintained constant. Accordingly, if a predetermined voltage is applied to the poly-silicon electrodes, charge will be stored and the charge will be successively transferred by a pulse-like voltage being applied.
In FIG. 3, reference numerals 32 denote the poly-silicon electrodes of the storing portion. The interior potential of this storing portion is formed substantially similarly to that of the image sensing portion.
The first to fourth areas of the storing portion are designated as I', II', III' and IV' correspondingly to the first to fourth areas of the potential of the image sensing portion.
In FIG. 3, reference numeral 33 designates a horizontal transfer register, one side of which is closed by a channel stopper. In FIG. 3, reference numeral 34 indicates the potential condition of the channel stopper portion.
Movement of charge will now be described by reference to FIGS. 1 to 3.
The charge stored in the image sensing portion is transferred by a pulse voltage being applied to the polysilicon electrodes 30 and enters the fourth potential area of 25 in FIGS. 2. If, at this time, a slightly negative or positive potential is applied to the poly-silicon electrodes 30, the potential condition indicated by the solid lines of FIG. 3 is brought about and the charge in the fourth area enters the second area through the first area. When a negative high potential is then applied to the electrodes 30, the charge in the second area (II) is transferred to the area IV' through the area III'. When, at this time, a slightly negative or positive potential is applied to the poly-silicon electrodes 32 of the storing portion, the potentials of the areas I' and II' fall from the area IV' and the charge in the area IV' is transferred to the area II'. When a pulse-like voltage is repetitively applied to the poly-silicon electrodes 32 of the storing portion, the above-described operation is repeated and the charge transferred to the storing portion is transferred to the horizontal transfer register. Then, also in the horizontal transfer register, the charge is read out by a similar operation. The construction of the horizontal transfer register is substantially similar to a transfer register designated by 123 in FIG. 8, but the vertical direction thereof is closed by a channel stopper so that transfer takes place only in the horizontal direction.
Reference is now had to FIGS. 4(a) and (b) to describe the operation when the device of the present invention is operated as an actual camera. FIG. 4(a) shows the operating condition when the device of the present invention is operated as a video still camera for obtaining a still picture, and FIG. 4(b) shows the condition when the device of the present invention is operated as a conventional video camera for obtaining a continuous picture (moving picture).
The condition (a-1) of FIG. 4(a) shows the all clear condition in which the unwanted charge stored by a dark current or the like immediately before the exposure operation is cleared through an anti-blooming drain or by operating the CCD at a high speed. An unillustrated shutter is then opened, whereupon the condition shifts to the exposure condition, namely, the storing conditiion (a-2) of the image sensing portion 1.
After the shutter has been closed, the condition shifts to condition (a-3) and the stored charges, for example, the signal charges stored in (1,1), (1,2), (1,3) and (1,4) of FIG. 1 are shifted to [4,1], [4,2], [4,3] and [4,4], the signal charges stored in (2,1), (2,2), (2,3) and (2,4) are shifted to (1,1), (1,2), (1,3) and (1,4), and the signal charges stored in the other picture elements are likewise shifted in the vertical direction by an amount corresponding to one cell. This is sequentially repeated, whereby the signal charges can be put out as time-serial signals from the horizontal shift register in the order of (1,1), (1,2), (1,3), (1,4); (2,1), (2,2), (2,3) . . . , (8,3), (8,4); (9,1), (9,2), (9,3), (9,4). In this case, the signal charges can also be transferred at a frequency different from the read-out frequency until the signal charges from (1,1) to (4,4) move from [1,1] to [4,4].
A stationary image signal corresponding to one frame at the same point of time for storing can be obtained by the above-described operation. Description will now be made of the operation when this device is operated as a video camera for usual continuous photography (moving picture). The condition (b-1) of FIG. 4(b) shows the all clear condition corresponding to the operation (a-1) of FIG. 4(a). However, this operation is not indispensable, because in case of a moving picture, even if the signal corresponding to the first field becomes noise, it is merely a part of the whole, and because this portion can also be constructed at the recording apparatus so that it is not used as a recording signal. Also, in this case, the shutter is not necessary, but storage and read-out are repeated alternately. (b-2), (b-2)', . . . show the stored conditions and the prime indicates the second field. That is, the charge stored in (b-2) is read out in (b-3), and the charge stored in (b-2)' is read out in (b-3)'.
The condition (b-4) is that in which the charge stored in the image sensing portion is transferred to the storing portion.
The frame transfer type CCD according to the present invention has 490 cells in the vertical direction of the image sensing portion and 245 cells in the storing portion and therefore, it differs from the conventional frame transfer type CCD in the operation of transferring the charge from the image sensing portion to the storing portion and the interlace method. This operation will be described by reference to FIG. 1.
In the first field, the charges stored in (1,1), (1,2), (1,3) and (1,4) are transferred to [4,1], [4,2], [4,3] and [4,4] of the storing portion 3. Subsequently, the charges in (2,1), (2,2), (2,3) and (2,4) are likewise transferred to [4,1], [4,2], [4,3] and [4,4]. If the apparatus is designed such that at this time, no pulse voltage is applied to the storing portion but the previous voltage remains therein, two rows of the image sensing portion will be added in this cell. Subsequently, the storing portion is transferred by one line, whereafter two lines of the image sensing portion are transferred in the same manner as described previously. When the first field is read out in this manner and thereafter the next field is read out, if the device is operated so that the cells to be added are shifted by one line each, that is, (2,1) and (3,1), (4,1) and (5,1) are added together, there can be obtained a signal interlaced with the previous field.
The driving circuit of the CCD shown in FIGS. 1-3 is shown in FIG. 5, and timing charts are shown in FIG. 6. FIG. 5 shows an example of the driving circuit of the CCD according to the first embodiment, FIG. 6A shows a timing chart of the various portions of FIG. 5 during the photographing of a stationary image, and FIG. 6B shows a timing chart of the various portions and FIG. 5 during the photographing of a moving image. It is to be understood that when the levels of the clock pulses φ 11 , φ 13 and φ 14 of FIGS. 6A and 6B are high, a slightly positive or negative potential is applied to the electrode and that when the levels of these clock pulses are low, a negative potential is applied to the electrode.
In FIG. 5, reference numeral 51 designates a start switch, reference numeral 52 denotes a one-shot multivibrator, reference numeral 53 designates a clock oscillator which generates a clock pulse of a predetermined frequency, reference numeral 54 denotes a counter, and reference numeral 55 designates a ROM which generates pulses φ 11 , φ 13 and φ 14 in accordance with the count value of the counter and which is programmed so as to generate the pulse signals shown in FIGS. 6A and 6B. Reference numeral 56 designates a change-over switch for still and movie, reference numeral 57 denotes a set-reset flip-flop, reference numeral 58 designates a shutter driver, reference numerals 59-61 denote CCD drivers, reference numeral 62 designates a shutter, and reference numeral 63 denotes a lens.
When the start switch 51 is depressed, the vibrator 52 generates a pulse and clears the content of the counter 54. The counter 54 effects count-up operation in accordance with the clock pulse from the clock oscillator 53. The count value of the counter 54 is applied as input to ROM 55, which puts out to the shutter driver 58 and CCD drivers 59-61 a signal corresponding to the mode selected by the switch 56. The ROM 55 puts out a signal following the time chart of FIG. 6A when the switch 56 is connected to a terminal S. The ROM 55 puts out a signal following the time chart of FIG. 6B when the switch 56 is connected to a terminal M. That is, a table for photographing a stationary image and a table for photographing a moving image are contained in the ROM 55. In the case of the photographing of a stationary image, if all the signal charge is once read out, the operation is terminated and therefore, a termination signal STP is put out from the ROM 55 to set the flip-flop 57 and then bring the counter 54 into its DISENABLE condition. In the case of the photographing of moving image, the same read-out operation is repeated as shown in FIG. 6B and therefore, the termination signal STP is not put out.
In FIG. 6, VS designates a video output signal.
The driving of the CCD during the photographing of a stationary image will be described by reference to FIG. 6A. For simplicity, it is to be understood that the image sensing portion of the CCD comprises nine vertical cells and four horizontal cells as shown in FIG. 1. First, the charges stored in the image sensing portion and the storing portion are discharged.
Nine clock pulses φ 11 are applied to the electrode of the image sensing portion 1 and all the charge in the image sensing portion is transferred to the storing portion 3. While the nine clock pulses φ 11 are being put out, four clock pulses φ 13 are applied to the electrode of the storing portion 3 and the dark current component in the storing portion 3 is transferred to the horizontal transfer register 5. Subsequently, four clock pulses φ 13 are applied to the electrode 4 of the storing portion 3, and the charge in the image sensing portion 1 transferred to the storing portion 3 is transferred to the horizontal transfer register 5. Each time a clock pulse φ 13 is generated, four clock pulses φ 14 are put out to the electrode of the horizontal transfer register 5, and the charge transferred to the horizontal transfer register 5 is discharged through the amplifier 7. In the present embodiment, the clear operation of the CCD is effected once for each cell, but where there is left a great deal of charge, several cycles of operation will be necessary. The condition of the apparatus shifts to the condition a-2 and, when a signal SD for opening the shutter is put out from the ROM 55, the shutter 62 is opened and the image sensing portion 1 is exposed to the object image. The shutter 62 is closed after it has been opened for a predetermined time, and in the meantime, a charge corresponding to the brightness of the object image is stored in each cell of the image sensing portion 1.
After the shutter has been closed, four clock pulses φ 11 and φ 13 are put out at a time, and (1,1)-(1,4) in FIG. 1 are transferred to [1,1]-[1,4], (2,1)-(2,4) to [2,1]-[2,4], . . . , (4,1)-(4,4) to [4,1]-[4,4], (5,1)-(5,4) to (1,1)-(1,4), . . . and, (9,1)-(9,4) to (5,1)-(5,4).
Thereafter, from time t 11 , four clock pulses φ 14 are put out and the unwanted charge in the horizontal transfer register 5 is put out. At time t 12 , φ 11 and φ 13 are put out and the charges stored in (1,1)-(1,4) during exposure are transferred to the horizontal transfer register 5, and are put out as the video output signal VS at the clock pulse φ 14 put out at time t 13 .
When this operation is repeated nine times, all the charge stored in the image sensing portion 1 during exposure is put out as the video output signal VS. At time t 15 , the termination signal STP is put out from the ROM 55, whereupon the driving operation of the CCD is terminated.
The operation during the photographing of a moving image will now be described by reference to FIG. 6B.
First, the start switch 51 is depressed and the counter 54 is cleared. Nine pulses φ 11 are put out during the period (b-1) and all the charge in the image sensing portion 1 is transferred to the storing portion 3. Clock pulse φ 3 is put out at every other clock pulse φ 11 and the charge in the storing portion 3 is transferred to the horizontal transfer register 5. During the period (b-2), clock pulse φ 14 is generated and all the unwanted charge is removed. Also, during the period (b-2), the exposure operation is excecuted in the image sensing portion 1. Subsequently, the signal charge stored in the image sensing portion 1 during the period b-4 is transferred to the storing portion 3. At time t 21 , the driving clock pulse φ 11 of the image sensing portion 1 and the driving clock pulse φ 13 of the storing portion 3 are put out simultaneously and then, one more clock pulse φ 11 is put out until clock pulse φ 13 is put out and thus, the charges of (1,1)-(1,4) of FIG. 1 and the charges of (2,1)-(2,4) are added together and stored in [4,1]-[4,4]. Likewise, (3,1)-(3,4) and (4,1)-(4,4), . . . , (7,1)-(7,4) and (8,1)-(8,4) are added together and stored in [4,1]-[4,4]. During the period b-4, five clock pulses φ 13 are put out and thus, the added charges in (1,1)-(1,4) and (2,1)-(2,4) are stored in the horizontal shift register 7 and the other added charges are stored in [1,1]-[1,4], [2,1]-[2,4] and [3,1]-[3,4] of the storing portion 3. The unadded charges of (9,1)-(9,4) are stored in [4,1]-[4,4]. The condition then shifts to the read-out period b-2' of the first field. The read-out period b-2', as previously mentioned, corresponds to the storing period of the second field and during this period, the storing operation is executed in the image sensing portion 1. In the storing portion 3, clok pulse φ 14 is first applied to the electrode of the horizontal transfer register, and the added charges of (1,1)-(1,4) are (2,1)-(2,4) stored in the horizontal transfer register 7 are read out. Subsequently, the added charges of (3,1)-(3,4) and (4,1)-(4,4) are read out. Finally, the charges of (9,1)-(9,4) are read out. However, this signal is not used as the video output signal VS.
Subsequently, the condition shifts to the second b-4 period and the charge of the second field is transferred to the storing portion 3. At this time, an operation different from the during the first b-4 period is effected. That is, pulse φ 13 is put out at time t 24 and the charges of (1,1)-(1,4) are transferred to [4,1]-[4,4]. Subsequently, at time t 25 , the charges of the image sensing portion are transferred line by line. Subsequently, at time t 26 , clock pulses φ 11 and φ 13 are put out simultaneously, and the added charges of (2,1)-(2,4) and (3,1)-(3,4) are stored in [4,1]-[4,4]. Thereafter, similar operation takes place, whereby the charges of (1,1)-(1,4) are stored in the horizontal transfer register, the added charges of (2,1)-(2,4) and (3,1)-(3,4) are stored in [1,1]-[1,4], and the added charges of (8,1)-(8,4) and (9,1)-(9,4) are stored in [4,1]-[4,4]. Then, the charge of the second field stored in the storing portion 3 during the period b-2 is read out. It is the charges of (1,1)-(1,4) that are read out by the first four clock pulses φ 14 at this time and therefore, these are not used as the video output signal.
As described above, the operation of (b-2)→(b-4)→(b-2')→(b-4) is repeated.
FIG. 7 shows the construction of a frame transfer type CCD according to a second embodiment of the present invention.
In FIG. 7, reference numeral 101 designates the image sensing portion of the frame transfer type CCD. In this image sensing portion, for example, in the case of the NTSC system, the number of cells in the vertical direction is set to a number substantially equal to the number of scanning lines, i.e., on the order of 490. That is, this CCD has a number of cells about twice that in the conventional frame transfer type CCD. As the number of cells in the horizontal direction of the image sensing portion 101, a number corresponding to the color sub-carrier frequency, i.e., a number on the order of 390 or 570, is usually adopted.
In the image sensing portion 101 of FIG. 7, there is shown an example in which nine elements in the vertical direction and four elements in the horizontal direction are arranged. In FIG. 7, reference numeral 102 designates an electrode for applying to this image sensing portion a voltage for effecting light reception and transfer.
In FIG. 7, reference numeral 103 denotes a storing portion, in which the number of cells in the vertical direction is about 1/2 of that of the image sensing portion and a number of cells equal to that of the image sensing portion 101 are arranged in the horizontal direction. Accordingly, this storing portion comprises a number of cells equal to that of the storing portion of the conventional frame transfer type CCD.
In FIG. 7, reference numeral 104 designates an electrode for applying a voltage for transferring charge as in the image sensing portion.
In FIG. 7, reference numeral 105 denotes a horizontal transfer register which comprises a row of charge transfer portion comprising a number of cells substantially equal to the number of cells in the horizontal direction of the image sensing portion or the storing portion.
Designated by 106 in FIG. 7 is an electrode for applying a voltage for transferring the charge of the horizontal transfer register 105.
Denoted by 107 in FIG. 7 is an amplifier for converting the charge transferred from the horizontal transfer register 105 into a voltage output.
This frame transfer type CCD does not greatly differ in construction from the conventional frame transfer type area sensor except that the number of cells in the vertical direction of the image sensing portion is twice that in the conventional frame transfer type area sensor. A great difference between the two is that a second horizontal transfer register 108 substantially identical to the horizontal transfer register 105 is provided between the image sensing porton 101 and the storing portion 103. Reference numeral 109 designates an electrode for applying a voltage for transferring the charge in the second horizontal transfer register, and reference numeral 110 denotes an amplifier for converting the transferred charge into a voltage.
There are several charge transfer methods such as single phase drive, two-phase drive, three-phase drive, four-phase drive, etc., and any of these is applicable, but taking the single phase drive method as an example for simplicity of description, the constructions of the second horizontal transfer register 108 and the storing portion 103 will hereinafter be described by reference to FIG. 8.
The single phase drive method herein referenced is described in the aforementioned U.S. Pat. No. 4,229,752 and the detailed operation thereof need not be described herein.
Referring to FIG. 8, reference numeral 120 designates a channel stopper for preventing leakage of charge between the cells in the horizontal direction.
Reference numeral 121 denotes the poly-silicon electrode of the image sensing portion, and the area to which this electrode is attached comprises an area A and an area B which differ from each other in the potential condition in the silicon. Reference numeral 122 designates an area in which a virtual electrode is formed in the silicon. The area 122 comprises an area C and an area D which differ from each other in the potential condition in the silicon.
In the vertical direction, one cell consists of these areas A, B, C and D.
Designated by 123 is a second horizontal transfer register area. In this area, a poly-silicon electrode is formed in the shape of comb-teeth indicated by hatching, and the portion below this poly-silicon electrode is divided into areas A', B' and C' which differ in the potential condition. The areas A' and A" are identical in potential, but are separated from each other by a channel stopper. The areas C' and D' are set to the same potential as the virtual electrode portion 122 of the image sensing portion. 124 and 125 are constructed similarly to 121 and 122, respectively, of the image sensing portion. The amounts of charge stored in 124 and 125 are about twice those stored in 121 and 122.
FIG. 9 shows the interior potential condition of the CCD of the construction shown in FIG. 8.
In FIG. 9, reference numeral 130 designates the poly-silicon electrodes of the image sensing portion corresponding to 121 of FIG. 8, and all of the poly-silicon electrodes of the image sensing portion are commonly connected so that a voltage for charge transfer is applied thereto. The portion below the poly-silicon electrodes 130 is divided into areas A and B as described in connection with FIG. 8, the area A being higher in potential condition than the area B. The dotted lines in FIG. 9 show the condition in which the poly-silicon electrodes 130 are at high negative potential, and the solid lines show the potential at which the potential of the poly-silicon electrodes 130 are slightly negative or positive.
The potential of the virtual electrode portion 122 of FIG. 8 is slightly higher in the area C than in the area D, as shown in FIG. 9. The potential of this portion does not depend on the voltage applied to the electrodes 130, but is always maintained constant. Accordingly, if a predetermined voltage is applied to the poly-silicon electrodes 130, charge will be stored and, if a pulse-like voltage is applied to the poly-silicon electrodes 130, charge will be transferred. Further description is not needed.
In FIG. 9, reference numeral 131 designates the poly-silicon electrode of the second horizontal transfer register. This electrode is separated from the other electrodes so that an independent voltage is applied thereto. The interior potential of this horizontal transfer register is as shown below the poly-silicon electrode 131 of FIG. 9.
In FIG. 9, reference numeral 132 designates the poly-silicon electrodes of the storing portion. The interior potential of this storing portion is similar to that of the image sensing portion. Reference numeral 133 denotes the electrode of the first horizontal transfer register (105 in FIG. 7). The first horizontal transfer register is similar in construction to the second horizontal transfer register, but the former differs slightly from the latter in that one side thereof is closed by a channel transfer. Reference numeral 134 shows the potential condition of the channel stopper.
The function of the charge in the second horizontal transfer register will hereinafter be described. The charge stored in the area B of the image sensing portion has its potentials in areas A and B increased as indicated by dotted lines in FIG. 9 by a pulse voltage of negative potential being applied to the poly-silicon electrodes 130 and is transferred into the potential well area D of 122 of FIG. 8. When, at this time, a slightly negative or positive potential is applied to the poly-silicon electrode 131 of the second horizontal transfer register, the potentials of the areas A' and B' assume the potential conditions indicated by solid lines in FIG. 9 and the charge in the area D enters the area B' through the area A'. Subsequently, when a negative high potential is applied to the electrode 131, the potentials of the areas A' and B' assume the conditions indicated by dotted lines and the charge in the area B' is transferred through the area C' (which has a predetermined potential indicated by dotted line) to the area D' (which has a predetermined potential indicated by dotted line). When, at this time, a slightly negative or positive voltage is applied to the poly-silicon electrodes 132 of the storing portion, the potentials of the area D' to the areas A'" and B" fall as indicated by solid lines and the charge in the area D' is transferred through the area A'" to the area B".
The charge thus transferred to the area B" of the image sensing portion is transferred through the area C" to the area D" because the potentials of the areas A'" and B" become as indicated by dotted lines by a pulse-like voltage of negative potential being applied to the poly-silicon electrodes 132 of the storing portion. Consequently, by a pulse voltage as the drive signal being applied to the electrodes 132, the stored charge is transferred to B"→D"→B" in succession and transferred to the first horizontal transfer register 105, and then can be read out through the first horizontal transfer register 105. The above-described flow of the charge shows that it is entirely equal in operation to that in the conventional frame transfer type CCD which does not have the second horizontal transfer register.
Description will now be made of the flow of the charge in a case where the signal is read out through the second horizontal transfer register.
The charge transferred to the area D' has been transferred to the storing portion by a slightly negative or positive potential being applied to the poly-silicon electrodes 132 of the storing portion in the above-described operation, but a negative high voltage is applied to these electrodes to hold the potentials of the areas A"' and B" as indicated by dotted lines and a pulse-like voltage is applied to the second horizontal transfer register 131 to cause the potentials of the areas A" and B' to alternately shift to the conditions indicated by solid lines and dotted lines, whereby the charge in the area D' is transferred to A"→B'→C'→D' in the horizontal direction and signal read-out operation is executed through the amplifier (110 in FIG. 1).
Reference is now made to FIG. 10 to describe the operation when the device of the present invention is operated as an actual camera.
FIG. 10(a) shows the operating condition when the device is operated as a video still camera, and FIG. 10(b) shows the operating condition when the device is operated as a video camera for photographing moving images.
Description will first be made of a case where the device is operated as a video still camera.
The condition S-1 of FIG. 10(a) shows the all clear condition in which the charge stored by a dark current or the like is cleared through an anti-blooming drain immediately before the exposure operation or in which the CCD is operated at a high speed to cause the charge to be discharged outwardly and cleared.
The shutter is then opened and the condition shifts to the exposure condition, i.e., the storing condition (S-2) of the image sensing portion. The condition then shifts to the first field read-out condition (S-3) of the horizontal transfer register 108.
In the condition (S-2), the shutter is closed in a predetermined exposure time and an image signal (charge) is stored on each cell shown in FIG. 7, whereafter in the condition (S-3), the charges stored in the cells of the image sensing portion are transferred in the vertical direction by two lines each. That is, in the case of the FIG. 7 embodiment, the charges stored in (1,1)-(1,4) are transferred to the cells [4,1]-[4,4] of the storing portion through the second horizontal transfer register 108, and the charges stored in (2,1)-(2,4) are transferred to the second horizontal transfer register 108. Likewise, the charges stored in the cells in the other lines are also transferred by two lines. Thereby, the charges stored in the sections (3,1)-(3,4), (4,1)-(4,4), (5,1)-(5,4), (6,1)-(6,4), (7,1)-(7,4), (8,1)-(8,4) and (9,1)-(9,4) are respectively transferred to the sections (1,1)-(1,4), (2,1)-(2,4), (3,1)-(3,4), (4,1)-(4,4), (5,1)-(5,4), (6,1)-(6,4) and (7,1)-(7,4).
After the charges have been transferred by two lines in this manner, the charges transferred to the second horizontal transfer register 108 are delivered outwardly through the amplifier 110. Thereby, the stored charges transferred to the horizontal transfer register 108 in the described manner, namely, the charges stored in (2,1)-(2,4) during exposure, are put out serially.
Thereafter, the stored charges in the cells of the image sensing portion are again transferred by two lines. Thereby, the charges transferred to the sections (1,1)-(1,4), namely, the charges stored in (3,1)-(3,4) during exposure, shift to the cells [4,1]-[4,4] of the storing portion through the horizontal transfer register, and the charges transferred to the sections (2,1)-(2,4), namely, the charges stored in (4,1)-(4,4) during exposure, are transferred to the horizontal transfer register 108. Also, at this time, the charges transferred to the cells in each line of the storing portion 103 are transferred by one line. Consequently, the charges previously transferred to the cells [4,1]-[4,4], namely, the charges stored in (4,1)-(4,4) during exposure, are transferred to the cells [3,1]-[3,4]. Thereafter, reading-out of the charges transferred to the horizontal transfer register is again effected, and the charges transferred to the horizontal transfer register 108 and stored in (4,1)-(4,4) during exposure as described above are delivered serially. Thereafter, in a similar manner, the operation of transferring by two lines the charges stored in the cells of the image sensing portion 101 and transferring by one line the charges transferred to the cells of the storing portion 103 and the operation of reading out the charges transferred to the horizontal transfer register 108 are executed alternately, whereby the charges stored in (2,1)-(2,4), (4,1)-(4,4), (6,1)-(6,4) and (8,1)-(8,4) during exposure are successively delivered from the second horizontal transfer register 108. That is, the first field read-out operation is executed. Also, the charges stored in (1,1)-(1,4), (3,1)-(3,4), (5,1)-(5,4) and (7,1)-(7,4) during exposure are respectively transferred to the cells [1,1]-[1,4], [2,1]-[2,4], [3,1]-[3,4] and [4,1]-[4,4] of the storing portion. After the first field read-out operation has thus been executed, the condition shifts to the second field read-out condition, namely, the condition S-4.
In the condition S-4, the charges transferred to the cells in each line of the storing portion are transferred by one line, whereafter the charges transferred to the first horizontal transfer register 105 are read out, whereby the charges stored in (1,4)-(4,4), (3,1)-(3,4), (5,1)-(5,4), (7,1)-(7,4) and (9,1)-(9,4) during exposure are delivered from the horizontal transfer register, thus terminating the second field read-out.
Thus, according to the present invention, it is possible for the image signals corresponding to one frame recorded at the same point of time to read out the first field, and then the interlaced second field as in the usual TV operation. At this time, the second horizontal transfer register 108 operates as a horizontal transfer shift register and a parallel-in parallel-out shift register.
Description will now be made of the operation when the present device is operated as an ordinary video camera for taking out video signals of moving pictures.
The condition M-1 of FIG. 10(b) corresponds to the operation S-1 of FIG. 10(a). However, this operation is not indispensable.
In this case, the shutter is not necessary and storage and read-out are repeated simultaneously. M-2, M-2', . . . show the storing conditions, and the prime (') indicates the second field. That is, the charge stored at M-2 (the first field) is read out at M-3, and the charge stored at M-2' (the second field) is read out at M-3'.
The condition M-4 shows the condition in which the charges stored in the image sensing portion are transferred to the storing portion.
The frame transfer type CCD of this second embodiment has 490 cells in the vertical direction of the image sensing portion and 245 cells in the storing portion and therefore differs from the conventional frame transfer type CCD in the operation of transferring charges from the image sensing portion of the storing portion and the interlace method. This operation will hereinafter be described by reference to FIG. 7.
First, after exposure and storage have been effected in the condition M-2, transfer of the charges stored in the image sensing portion to the storing portion is effected in the condition M-4. In this transfer operation, the charges stored in (1,1), (1,2), (1,3) and (1,4) are first transferred to [4,1], [4,2], [4,3] and [4,4] of the storing portion 3 through the second horizontal transfer register 108. Subsequently, the charges in (2,1), (2,2), (2,3) and (2,4) are likewise transferred to [4,1], [4,2], [4,3] and [4,4]. At this time, no pulse voltage is applied to the storing portion, and the charges stored in (1,1)-(1,4) during exposure are held in [4,1]-[4,4]. Thereby, the charges stored in two rows, i.e., (1,1)-(1,4) and (2,1)-(2,4) of the image sensing portion, are added to [4,1]-[4,4].
Subsequently, one line of the storing portion is transferred, that is, the charges added in [4,1]-[4,4] are transferred to [3,1]-[3,4], and in the manner described above, two lines of the image sensing portion, namely, the charges stored in (3,1)-(3,4) and (4,1)-(4,4) during exposure, are again transferred to [4,1]-[4,4] and added therein. Thereafter, the operation of transferring one line of the storing portion and the operation of transferring two lines of the image sensing portion to [4,1]-[4,4] and adding them therein are repeated in the same manner, whereby the added charges in (1,1)-(1,4) and (2,1)-(2,4) are transferred to [1,1]-[1,4] of the storing portion, the added charges in (3,1)-(3,4) and (4,1)-(4,4) are transferred to [2,1]-[2,4], the added charges in (5,1)-(5,4) and (6,1)-(6,4) are transferred to [3,1]-[3,4], and the added charges in (7,1)-(7,4) and (8,1)-(8,4) are transferred to [4,1]-[4,4].
Thereafter, the condition shifts to the conditions M-2' and M-3 and exposure and storage operations are executed while, at the same time, the signals transferred to the storing portion 103 as described above are transferred to the horizontal transfer register 105 line by line and the signals transferred to the horizontal transfer register are delivered from the horizontal transfer register. Thereby, the first field read-out operation is executed.
After the first field read-out operation has been terminated in this manner, the operation of transferring the charges stored in the image sensing portion 101 to the storing portion 103 by M-2' is executed at M-4. This is the second field read-out operation and therefore, transfer and addition of two rows of the image sensing portion are executed with the cells shifted by one line when the charges are transferred from the image sensing portion 101 to the cells [4,1]-[4,4].
That is, for the second field, the charges stored in the cells (2,1)-(2,4) and the cells (3,1)-(3,4), the charges stored in the cells (4,1)-(4,4) and the cells (5,1)-(5,4), and the charges stored in the cells (6,1)-(6,4) and (7,1)-(7,4) are respectively transferred to [4,1]-[4,4] and added therein, whereby the charges added to each line of the storing portion 103 are transferred and stored. Thereafter, by M-3', the charges stored in the storing portion 103 are delivered by the horizontal transfer register 105, whereby the second field read-out operation is terminated. When two rows of the image sensing portion cells are added in this manner, the first transfer and addition operation and the second transfer and addition operation are shifted by one line, whereby a signal interlaced with the first field can be obtained and image photographing can be executed as a video camera.
At this time, the second horizontal transfer register 108 is used as a parallel-in parallel-out shift register and does not have the horizontal transfer function.
The charges in the cells of the image sensing portion are added by two lines each and stored in the cells of the storing portion and therefore, the required capacity of each cell of the storing portion is about twice the capacity of each cell of the image sensing portion. Also, as the number of cells added together becomes greater, the capacity of each cell of the storing portion must be made greater. However, where the device is used exclusively for photographing stationary images, the capacity of the storing portion may be made substantially equal to the capacity of the image sensing portion.
FIG. 11 shows an example of the driving circuit of the second embodiment. In FIG. 11, elements similar in function to those of FIG. 5 are given similar reference numerals with a prime affixed thereto. FIGS. 12A and 12B are timing charts of the various portions of FIG. 11 during still photography and moving picture photography, respectively. In FIG. 12, the high level conditions of CCD driving clock pulses φ 11 ', φ 12 , φ 13 ' and φ 14 ' show the condition in which a slightly positive or negative potential is applied to the electrode, and the low level conditions of those clock pulses show the condition in which a negative high potential is applied to the electrode. In FIG. 11, reference numeral 70 designates a CCD driver which puts out the clock pulse φ 12 for driving the second horizontal transfer register 108. The operations of the various portions of FIG. 11 are substantially similar to those of FIG. 5, but ROM 55' contains the conversion tables during still photography and moving picture photography shown in the time charts of FIGS. 12A and 12B.
The operation during still photography will be described by reference to FIG. 12A.
When the start switch 51' is depressed, start pulse SP is put out and counter 54' is cleared and upon the output clock of clock oscillator 53', the counter 54' counts up. The output of the counter 54' is applied as input to ROM 55', which puts out a signal following the time chart of FIG. 12A because switch 56' is connected to a contact S. First, during period (S-1), the charge in each cell of CCD is cleared. Therefore, as indicated by clock pulse φ 13 ', clock pulses φ 11 ', and φ 12 of a frequency twice as high as that of φ 13 ', are applied with the electrode of the storing portion as a slightly positive or negative potential. Thereupon, the charges in the cells of the image sensing portion 101 are added by two cells each in the vertical direction and transferred to the cells of the storing portion. They are successively read out from the horizontal transfer register 105 by clock pulse φ 14 '. When the clear is terminated, the period shifts to period (S-2), and shutter 63' is opened, whereby the image sensing portion 101 is exposed and charge is stored in each cell thereof. Subsequently, the shutter 63' is closed, whereupon the exposure operation is terminated, and the period shifts to a first field read-out period (S-3). First, when the electrode of the storing portion 103 is at a slightly positive or negative potential, two pulses φ 11 ' and φ 12 are put out and the charges in (1,1)-(1,4) are transferred to [4,1]-[4,4] while the charges in (2,1)-(2,4) are transferred to the second horizontal transfer register 108. In this condition, the electrode potential of the storing portion 103 is a negative high potential. That is, a potential barrier is formed between the second horizontal transfer register 108 and the storing portion 103. By four clock pulses φ 12 being applied in this condition, the charges stored in (2,1)-(2,4) during exposure are read out from the second horizontal transfer register 108 through the amplifier 110. Subsequently, the potential barrier between the second horizontal transfer register 108 and the storing portion 103 is eliminated and two clock pulses φ 11 ' and φ 12 are put out, whereby the charges in (3,1)-(3,4) are transferred to [4,1]-[4,4] and the charges in (4,1)-(4,4) are transferred to the second horizontal transfer register 108.
The operation just described is repeated, whereby (2,1)-(2,4), (4,1)-(4,4), (6,1)-(6,4), . . . , (8,1)-(8,4) are successively read out from the second horizontal transfer register. That is, a first field signal VS1 is read out. At this time, the charges stored in (1,1)-(1,4) during exposure are transferred to the horizontal transfer register 105 by clock pulse φ 13 ', and the charges of the other odd lines are stored in the storing portion 103.
Subsequently, the period shifts to a second field read-out period (S-4). In (S-4), by four clock pulses φ 14 ' put out for one pulse φ 13 ', a second field signal VS2 is read out from the horizontal transfer register 105 through the amplifier 107. That is, the charges stored in (1,1)-(1,4), (3,1)-(3,4) and (9,1)-(9,4) during exposure are successively read out. Finally, after the charge in (9,4) has been put out, termination signal STP' is put out and the counter 54' terminates its counting operation.
The operation timing during moving picture photography will now be described by reference to FIG. 12B.
Start pulse SP is put out and the clear period (M-1) is first entered. The potential barrier between the second horizontal transfer register 108 and the storing portion 103 is eliminated by φ 13 ' and the charges in the image sensing portion 101 are successively transferred to the storing portion 103.
The charges stored in the storing portion 103 are successively put out from the horizontal transfer register 105 through the amplifier 107 by clock pulses φ 13 ' and φ 14 ' during the next first field exposure period (M-2).
During transfer period (M-4), nine clock pulses φ 11 ' and φ 12 are put out at the same timing, and the potential barrier between the second horizontal transfer register 108 and the storing portion 103 is eliminated by clock pulse φ 13 ', whereby charges are transferred to the storing portion 103 through the second horizontal transfer register 108. The potential barrier is eliminated while the first and second pulses P1 and P2 of the nine clock pulses φ 11 ' and φ 12 are being put out and therefore, charges are added and stored in [4,1]-[4,4] by the combinations of (1,1) and (2,1), (1,2) and (2,2), (1,3) and (2,3), (1,4) and (2,4) of FIG. 7. Thereafter, in a similar manner, the added charges in (3,1) and (4,1) are stored in [4,1] and the added charges in (5,1) and (6,1) are stored in [4,1]. When the period (M-4) is terminated, the added charges in (1,1)-(1,4) and (2,1)-(2,4) are stored in the horizontal transfer register 105, and the added charges in (3,1)-(3,4) and (4,1)-(4,4) are stored in [1,1]-[1,4]. Thereafter, similar operation takes place. The charges in (9,1)-(9,4) are stored in [4,1]-[4,4].
The period then shifts to a first field signal read-out period (M-2'). This period also in a second field signal exposure period (M-3). During this period, the charges stored in the horizontal transfer register 105 and the storing portion 103 are read out by clock pulses φ 13 ' and φ 14 '. These are used as the first field video output, but the charges stored in (9,1)-(9,4) during exposure are not added charges and therefore are not used.
Subsequently, the period shifts to a second field transfer period (M-4'). The difference between the operation during (M-4') and the operation (M-4) during the first field transfer period is that the generation phase of clock pulse φ 13 ' differs from that of clock pulses φ 11 ' and φ 12 '. That is, while the first pulse P' of clock pulses φ 11 ' and φ 12 ' is being put out, the potential barrier is eliminated and only the charges in (1,1)-(1,4) are transferred to [4,1]-[4,4]. Subsequently, while second and third pulses P2' and P3' are being put out, the potential barrier is eliminated and the charges in (2,1)-(2,4) and (3,1)-(3,4) are added respectively and stored in [4,1]-[4,4]. Thus, when the transfer period (M-4') is terminated, the charges stored in (1,1)-(1,4) during exposure are transferred to the horizontal transfer register 105 and the charges stored in (2,1)-(2,4) during exposure are added to the charges in (3,1)-(3,4) and stored in [1,1]-[1,4]. The charges added in (8,1)-(8,4) and (9,1)-(9,4) during exposure are stored in [4,1]-[4,4].
Subsequently, the period shifts to a second field read-out period (M-3') and in the manner as previously described, a second field signal is put out by clock pulses φ 13 ' and φ 14 '. However, the first output signal is one obtained from the charges stored in (1,1)-(1,4) during exposure and differs in signal level from the other signals obtained by addition and therefore is not used. Thus, the second horizontal transfer register 108 is handled not as a horizontal transfer register but as a parallel-in parallel-out shift register or just in the same way as the other cells during moving picture photography.
According to the present invention, as described above, image signals corresponding to one frame are obtained at a high quality when the device is operated as a video still camera for photographing stationary images. Also, by the second horizontal transfer register being provided between the image sensing portion and the storing portion, images obtained by the image sensing portion at the same point of time can be put out as a frame signal comprising a plurality of fields, namely, first and second fields. Accordingly, the device of the present invention is suitable for photographing a stationary image and can also be matched with a TV interlace operation, and the post-stage signal processing circuit is simplified.
The interlace scanning is generally effected by changing over the clock level condition during the storage time for each field, but the portion of the image sensing portion which is covered with the poly-silicon electrode is low in sensitivity and therefore the interlace effect becomes difficult to obtain. Also, in the level condition, the amount of generated dark current differs, which leads to very poor images. However, in the present invention, the charges stored in vertically adjacent cells are added and made into a signal corresponding to one picture element, and this leads to the possibility of obtaining image signals of high quality having a high interlace effect and moreover less susceptible to the influence of dark current.
Further, the first and second field signals are obtained by changing the combination of additions and this leads to the possibility of obtaining video signals of moving pictures matching the interlace operation of a TV signal, as well as to simplification of the post-stage signal processing circuit and recording circuit. Particularly, where it is desired to record the obtained signals, the device of the present invention can be used in conjunction with the conventional TV signal recording apparatus and this is very effective.
Furthermore, the solid state image sensing device of the present invention can be used for both still photography and moving picture photography and can provide interlaced video signals in either of the two types of photography. This leads to a great reduction in the cost of the image sensing device.
Further, where the object to be photographed is not in motion, if the clock level condition is changed over for each field and the picture element is moved in a cell for each field, it will also be possible to take out signals corresponding to two frames.
The present invention is not restricted to the above-described embodiments, but various modifications may be made thereto within the scope shown in the appended claims.
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A radiation sensing device includes radiation sensor for generating an electrical indication indicative of the distribution pattern of received radiation, a storing device for storing the electrical indication generated by the sensor, and a read-out device for reading out the stored electrical indication from the storing device. The sensor includes a first plurality of sensing elements, while the storing device includes a second plurality of storage elements. The second plurality is fewer than the first plurality.
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FIELD OF THE INVENTION
This invention relates to the field of digital signal synchronization. In particular, the invention relates to a digital phase locked loop (DPLL) with selectable fast-locking capability.
BACKGROUND OF THE INVENTION
In digital communications, where signal synchronization devices are used, there are often requirements for DPLLs that can meet certain standards which define their filter response, and also have the capability of fast locking to a reference signal. Fast locking is especially desired upon power-up and during manual clock reference rearrangement. The normal locking time for a DPLL is inversely proportional to its filter response, so fast locking is very useful when standards prescribe a slow response (small corner frequency).
In prior art DPLL implementations (e.g. the embedded DPLL in Zarlink's MT90866 H.110 Compatible Digital Switch), some instances of fast-locking have been achieved by pushing the DPLL corner frequency to the higher frequency range in the fast-locking mode. Quick response of the DPLL output clock to frequency changes of the active input reference clock could be achieved, as well as close alignment of the output clock edge to the active input reference clock edge. Locking time was very small for fairly large DPLL corner frequencies (i.e. greater than 1 kHz).
However, previous implementations fail to meet two major fast-locking mode requirements. Firstly, the holdover frequency could be far from the guaranteed holdover stability if holdover mode was entered shortly after the fast-locking time passes. In the holdover mode, the DPLL produces a stable output at the last locked frequency. Other techniques had to be used to prevent DPLL from entering holdover mode until the expiry of the normal DPLL locking time, which is defined by its filter response. Secondly, the final output clock was not aligned to the active input reference after this short, fast-locking time. The phase difference from the active input reference clock to the output clock was proportional to the sampling error of the active input reference clock by the internal clock used in DPLL. This misalignment could cause failures in a system where that DPLL was used as clock synchronizer, especially in systems with high clock and data rate, comparable to the sampling error.
SUMMARY OF THE INVENTION
The present invention provides a digital phase locked loop (DPLL), used for clock synchronization, which has a loop filter capable of providing a complete set of fast-locking functionality for a wide variety of filter responses. In addition, the DPLL provides normal locking functionality, prescribed by appropriate standards defining maximum output clock phase change, i.e. phase slope.
According to the present invention there is provided a digital phase locked loop with fast locking capability comprising a digitally controlled oscillator for producing an output clock phase locked to an input reference clock; a phase detector for measuring the phase difference between said input reference clock and a feedback clock; and a loop filter for producing a control signal for said digitally controlled oscillator, said loop filter comprising a proportional circuit for developing a first signal proportional to said phase difference; an integrator for developing a second integrated signal from said first signal; a weighting unit for selectively adding extra weight in a fast locking mode to said first signal at an input to said integrator to cause said integrator to build up its contents more rapidly and thereby shorten the locking time of the phase locked loop; and an adder for adding said first signal without said extra weight and said second signal developed by said integrator to develop said control signal for said digital controlled oscillator. Preferably, the weighting circuit is preferably a linear multiplier although it will be realized that other forms of weighting could be used.
The invention also permits the digital phase locked loop (DPLL) rapidly to achieve stable holdover frequency in holdover mode. The stable holdover frequency can be achieved within said fast locking time.
This invention resolves the issues regarding alignment of the output clock to the active input reference clock and holdover frequency stability in fast-locking mode. With this invention, both issues can be achieved in a very short period of time, called fast-locking time. The fast-locking time depends on the chosen DPLL filter response.
The resulting DPLL is capable of switching from one reference with a particular frequency offset to another reference with a different frequency offset that is far from the first reference frequency, in a very short time interval. The DPLL achieves the best possible alignment of the output clock to the active input reference clock and maintains guaranteed holdover stability. The same achievements can be accomplished upon system power up when local clocks must be synchronized to a network reference clock that has a large frequency offset.
A DPLL in accordance with the invention is capable of achieving almost absolute alignment of the output clock to the input reference signal within a very short time interval, for example, less than one second. The DPLL is also capable of achieving correct and accurate holdover frequency within the same short timeframe.
The DPLL can be used in different systems, such as the one defined by the ECTF H.110 standard, in which one synchronization device must be capable of locking to a network clock, performing jitter attenuation. The same device must be capable of locking to a backplane clock, where jitter attenuation is not permitted, and therefore allowing output clocks to be edge-synchronous to the backplane clock. Such a system requires error-free switching between the network and the backplane clocks, with holdover capabilities. The DPLL embodying the present invention enables the synchronization device to enter holdover mode after a very short period of time after switching reference inputs, thereby removing the necessity for any additional logic to be used to prevent entering holdover mode until expiring of normal locking time. This, in turn, reduces the cost of building such a system.
In accordance with the principles of the invention extra weight is added to the value of phase difference between the active input reference clock and the feedback clock, prior to passing it to an integrator. The same phase difference value, without extra weight, is passed to a proportional-integral adder. The adder output is a frequency offset used in a digital controlled oscillator (DCO) for desired output clock generation.
Adding extra weight to the integrator input in the DPLL loop filter allows the integrator to more quickly build up its content, which represents output clock frequency offset, based on changes of phase difference between the active input reference clock and the output (feedback) clock.
This technique becomes very efficient when quick filter response is chosen to speed up locking. In previous DPLL implementations, when the output clock was aligned to the active input reference clock within 1 LSB (Least Significant Bit), the quick filter response required elimination of phase detector sampling error noise of 1 LSB. To prevent amplification of the sampling error noise in accordance with the quick filter response, a non-linear transfer filter was used. In that case, depending on the filter response, the output clocks very quickly became aligned to the active input reference clock within 1 LSB. This alignment stopped amplification of the phase difference and slowed down the integrator from reaching its targeted value, therefore preventing final alignment of the output clocks to the active input reference clock. On the contrary, in the loop filter in accordance with the invention, the value of the phase difference on the integrator input will be given extra weight (additionally amplified), therefore allowing the integrator to reach its targeted value very quickly. Also, the final alignment of the output clock to the active input reference clock will, as usual, happen immediately after the integrator reaches its targeted value.
According to another aspect of the invention there is provided a method of controlling a digital phase locked loop wherein in a fast locking mode a loop filter applies a weighting factor to the proportional value of phase error (P-value), representing the phase difference between the an output clock and an active input reference clock, prior to passing it to an integrator, in order to achieve fast alignment of the output clock to the active input reference clock in a fast locking mode and fast achievement of stable holdover frequency in a holdover mode.
BRIEF DESCRIPTION OF THE DRAWINGS
Detailed description of the preferred embodiment of this invention is shown below, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a top-level block diagram of the DPLL circuit, according to the preferred embodiment;
FIG. 2 is a block diagram of the loop filter module in FIG. 1 ;
FIG. 3 is a block diagram of the non-linear multiplier with saturator in FIG. 2 ;
FIG. 4 is a block diagram of the linear multiplier with programmable saturator in FIG. 2 ; and
FIG. 5 is the limitation diagram of the locking speed limiter in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The DPLL modules that do not directly contain the invention, but are important for understanding of the invention, will be explained in lesser detail. The modules of the DPLL containing the invention will be explained in greater detail.
Referring to FIG. 1 , the DPLL circuit that is capable of providing a complete set of both normal and fast-locking functionality consists of the following modules: four Frequency Detectors and Reference Monitors 1 , State Machine 2 , Input Reference Multiplexer 3 , Maximum Time Interval Error (MTIE) module 4 , Phase Detector 5 , Loop Filter 6 , Digitally Controlled Oscillator (DCO) 7 , two Frequency Converters 8 and Output Divider with three Tapped Delay Lines (TDLs) 9 .
The Frequency Detectors 1 determine the frequency of the incoming reference clocks and send coded binary value to the State Machine 2 .
The Reference Monitor modules 1 monitor the existence and frequency offset of the input reference clocks and notify the State Machine module 2 about the reference clock reliability. Hysteresis functionality is implemented in the Reference Monitor modules 1 , such that bouncing among references is prevented when frequency offset of the preferred input reference clock is close to the reliability boundary.
The State Machine 2 controls the Input Reference Multiplexer 3 , selects appropriate frequency information corresponding to the selected reference, activates the measurement cycle of the MTIE (Maximum Time Interval Error) module 4 and switches the DPLL automatically to and from holdover mode. The four input references have equal priority and any one can be selected as the preferred reference. If the preferred reference fails specified timing criteria, the State machine 2 will lock the DPLL to the next non-failing reference, or switch the DPLL into the holdover mode if all four references fail.
The Input Reference Multiplexer 3 selects one of four input reference clocks as the input clock for the DPLL.
The MTIE module 4 compensates for the phase offset between the newly selected input reference clock and the DPLL output clock in case of a reference switch or a recovery from holdover mode. Immediately after the new input reference clock is selected to be the DPLL input clock, the MTIE module 4 is activated by the State Machine 2 to start a measurement process, in which the phase difference between the new reference clock and the DPLL feedback clock is recorded. After the measurement process is done, the measured phase difference is maintained between the new reference clock and the output clock. The ‘feedback clock’ signal is delayed inside the MTIE module 4 to match the active reference delay and passed to the Phase detector module 5 .
The Phase Detector 5 measures the difference in phase between the input reference clock and the output feedback clock on every reference clock edge and converts it to a signed binary number representation. The output value of the Phase Detector 5 is made to always be odd, to prevent the appearance of a ‘dead zone’ which could change the DPLL response and add uncertainty to the alignment of the DPLL output clock to the active input reference clock. The measured phase error, the Phase Detector output, is passed to the Loop Filter 6 .
The Loop Filter 6 is a central part of this invention and it will be explained in greater detail later. In general, for normal locking mode functionality, the Loop Filter 6 performs output phase slope limiting, filtering of the phase error generated in the Phase Detector 5 and conversion of the phase error to a frequency offset for the DCO 7 . When fast-locking mode is selected, the Loop Filter 6 multiplies the phase error from the Phase Detector 5 to achieve appropriate filter response, defined by the DPLL corner frequency, and performs additional multiplication of the proportional value (P-value) prior to its integration, therefore implementing fast-locking functionality. The non-multiplied proportional part is added to the integrated part and passed as frequency offset to the DCO (Digital Controlled Oscillator) module 7 . The Loop Filter 6 also allows software control over the frequency offset of the DPLL output clocks, when it is not desirable to match the active input reference frequency offset.
The DCO 7 generates a clock that is phase-locked to the input reference clock. The system clock and the center frequency number inside the DCO module 7 determine frequency of the generated clock. The frequency offset value from the Loop Filter 6 is added to the center frequency number such that phase of the feedback clock, coming from the generated clock, is shifted toward reducing the phase error.
The Frequency Converters 8 are used to generate output clocks that are not directly divisible from the DCO generated clock. The DCO value, representing the current phase of the DCO generated clock relative to its ideal position, is multiplied by a constant fraction, thereby generating a clock with a frequency that is a fraction of the DCO output clock frequency.
The TDLs (Tapped Delay Lines) 9 are used to minimize intrinsic jitter on the DCO generated clock and two clocks generated by Frequency Converters 8 . The intrinsic jitter on the TDL input represents DCO and Frequency Converters errors. The jitter is determined by the phase of the generated clocks relative to their ideal positions. The role of the TDLs 9 is to minimize intrinsic jitter by delaying the DCO and Frequency Converters' generated clocks to be as close as possible to the ideal clock position.
The Divider module 9 is used to generate all required output clocks and the DPLL feedback clock by dividing generated clocks from the DCO 7 and two Frequency Converters 8 . For proper alignment of the clocks coming from the Frequency Converters 8 with the clocks coming from the DCO 7 , a special technique is implemented:
The Divider module 9 is reset later than the rest of the DPLL, waiting for the TDL clocks to achieve initial stabilization. The counters used for dividing clocks from the Frequency Converters 8 are then preloaded with appropriate values. Since the relation of the DCO clocks and the Frequency Converters clocks is fixed and repeatable with a given time base (e.g. after every 125 microseconds), proper initialization of the counters is sufficient to maintain alignment of the clocks coming from the Frequency Converters 8 to the clocks coming from the DCO 7 , in the time base intervals. The feedback clock frequency is chosen to match the active input reference's clock frequency.
Loop Filter Module
The Loop Filter circuit 6 implements a first-order low-pass filter. Referring now to FIG. 2 , the Loop Filter module consists of the following sub-modules: Non-linear Multiplier with Saturator 10 , Phase Slope Limiter 11 , Locking Speed Limiter 13 , Linear Multiplier with Programmable Saturator 14 , Integrator 15 , P+I Adder 16 , Holdover Memory 17 , Subtractor 19 and three Multiplexers 12 , 18 and 20 .
The phase error from the Phase Detector module ‘phase’ is first multiplied in the Non-linear Multiplier 10 and saturated in the Saturator 10 to the maximum value, regardless of whether normal or fast-locking functionality is required. The multiplication factor ‘filter response select’ defines the DPLL filter response, i.e. its corner frequency. Functionality of the Non-linear Multiplier with Saturator 10 will be explained in more detail later.
The multiplied phase error value is limited inside Phase Slope Limiter 11 , such that modulo of the multiplied phase error is within a specified value defined by the ‘phase slope limit’. In normal locking mode, the proportional value of the P+I Adder (‘P-value’) is selected to be the output of the Phase Slope Limiter 11 . In fast-locking mode, the Phase Slope Limiter 11 is bypassed, and the multiplied phase error is selected to become ‘P-value’.
To achieve fast-locking functionality, the Linear Multiplier with Programmable Saturator module 14 performs additional multiplication of the ‘P-value’ prior to entering Integrator input, if fast-locking functionality is desired. In normal locking mode, the multiplication factor is 1 (no multiplication is performed).
The multiplication factor of the Linear Multiplier with Programmable Saturator module 14 comes from the Locking Speed Limiter module 13 . The ‘locking speed select’ value is limited using a special limiting algorithm, which will be explained in more detail below.
When the requirements of a standard for the DPLL output phase peaking are not too tight, the Linear Multiplier with Programmable Saturator 14 can be used together with the Phase Slope Limiter 11 to shorten normal-locking time, while the DPLL can still maintain required phase slope. The multiplication factor depends on required peaking.
The Integrator module 15 consists of an accumulator and an attenuator, i.e. divider. The ‘P-value’ is accumulated in the accumulator. The attenuation of the accumulated value is done to prevent oscillating of the DPLL. The output of the attenuator is an integral part of the P+I Adder (‘I-value’). The ‘I-value’ represents frequency offset of the active input reference clock when the DPLL is locked.
Adding of the ‘P-value’ to the ‘I-value’ in the P+I Adder 16 results in the frequency offset for the DCO module 7 , called ‘delta frequency’, if the DPLL is not in the holdover mode. The I-value is periodically stored in the Holdover memory 17 , and the ‘old’, previously stored value is used as the frequency offset when the DPLL is in the holdover mode.
The DPLL allows outside software control over the ‘delta frequency’, when ‘software control’ is active. The functionality is implemented by adding Subtractor module 19 , which subtracts the ‘I-value’ from provided ‘software frequency’, that represents the desired DPLL output clocks' frequency offset. This allows the DPLL, when under software control, to follow a chosen filter response and phase slope. The update interval of the ‘software frequency’ doesn't have limits and can be as small as the system requires.
Non-linear Multiplier with Saturator
The Role of the Non-linear Multiplier with Saturator sub-module 10 of the Filter module 6 is to provide 16 different filter responses of the DPLL, i.e. 16 different corner frequencies, ranging from 0.47 Hz to 15.5 kHz.
As shown in FIG. 3 , the Non-linear Multiplier with Saturator 10 consists of the following components: Barrel Shifter 21 , three Comparators 22 , 24 and 26 , and three Multiplexers 23 , 25 and 27 .
Non-linear functionality, represented by the fact that the ‘phase’ is not multiplied if its value is within +/−1 boundary, is necessary to stabilize the DPLL output frequency once the DPLL aligns its output clocks to the active input reference clock. Non-linear functionality is implemented by using Barrel Shifter 21 , Comparator 22 and Multiplexer 23 .
The multiplied phase value is then saturated to be within hard-coded +/−MAX Value, which is chosen to prevent overflow in the accumulator of the DCO module 7 . Two Comparators 24 and 26 , and two Multiplexers 25 and 27 are used to implement saturation function.
Linear Multiplier with Programmable Saturator
The fast-locking functionality is based on additional multiplication of the ‘P-value’, which speeds up the Integrator 15 in achieving its targeted value. The linear multiplication is used since the largest portion of the entire locking time belongs to the final phase alignment of the DPLL output clocks to the active input reference clock. During this final alignment, the ‘P-value’ is most often either +1 or −1. One value occurs more often than the other, depending which direction the final alignment must be performed. The absence of the multiplication factor for +1 and −1 values, if a non-linear filter is used, would result in the taking a similar amount of time for the final alignment regardless of DPLL filter response selection. The linear multiplication, used in this invention, assumes that the ‘P-value’ of +1 and −1 is additionally multiplied as well, causing a significant drop in locking time, compared to usage of a non-linear multiplier.
Referring now to FIG. 4 , the Linear Multiplier with Programmable Saturator sub-module 14 of the Filter module 6 consists of two Barrel Shifters 28 and 29 , two Comparators 30 and 32 , Inverter 31 and two Multiplexers 33 and 34 .
For the ‘P-value’ multiplication, the Barrel Shifter 28 is used. Another input of the Barrel Shifter 28 is ‘limited locking speed select’ input, which determines the fast-locking speed of the DPLL.
In order to stabilize the DPLL output clocks in fast-locking mode when a significant amount of jitter is present on the DPLL active input reference clock, the multiplied ‘P-value’ can be saturated to a maximum value, defined by ‘frequency stability select’. The Barrel Shifter 29 is used to generate maximum value for the ‘integrator in’, which is the input to the Integrator sub-module 15 of the Filter module 6 . Constant number ‘K’, which represents attenuation coefficient of the Integrator 15 , is used in the Barrel Shifter 29 .
The multiplied “P-value’ in the Barrel Shifter 28 is compared against the maximum value, calculated inside the Barrel Shifter 29 , and passed to the ‘integrator in’ if it is within +/− of the maximum value. If the multiplied ‘P-value’ is outside the maximum value, either the maximum value, or the inverted value in 2's complement is passed to the ‘integrator in’, depending on the sign of the ‘P-value’. The inversion of 2's complement ‘P-value’ is done inside the Inverter component 31 .
The ‘limited locking speed select’, generated inside the Locking Speed Limiter sub-module 13 of the Filter module 6 from ‘locking speed select’ and ‘filter response select’ values, is chosen such that stable DPLL output clocks are generated, regardless of what value for ‘locking speed select’ can be provided. The ‘locking speed select’ value is automatically limited depending on the ‘filter response select’ value, according to the curve shown in FIG. 5 .
Referring now to FIG. 5 , when a small value for ‘filter response select’ and a large value of ‘locking speed select’ is chosen, the DPLL appears to be unstable (i.e. oscillating). Under these circumstances, the ‘I-value’ becomes predominant over the ‘P-value’, which prevents the Integrator sub-module 15 of the Filter module 6 from stabilizing to the targeted value defined by the active input reference clock frequency offset, therefore preventing the DPLL from locking its output clocks to the active input reference clock.
When the ‘filter response select’ values are chosen to be large enough to prevent oscillation, there is still a limitation for the ‘locking speed select’ values. If a big ‘locking speed select’ value is chosen together with a big ‘filter response select’ value, the DPLL output clocks will gain extra intrinsic jitter, as a result of having excessively large values on the Integrator input. The Integrator content will stabilize around its targeted value defined by the active input reference clock frequency offset, but very small phase variation will cause the Integrator content to move up and down, causing false realignment of the output clocks to the active input reference clock, therefore adding extra jitter on the output clocks and less accurate holdover frequency.
The ‘maximum locking speed select curve’ consists of three parts: rising, straight and falling. The rising part is related to the small ‘filter response select’ values (i.e. up to 6) when the limit for the value linearly rises to the point where the ‘I-value’ becomes predominant. The straight part is related to the values of ‘filter response select’ where larger ‘locking speed select’ values would cause the input of the Integrator to be big enough such that a small phase change can cause changes in the output frequency offset, therefore gaining extra jitter on the output clocks. The last, falling part, is related to largest values of the ‘filter response select’ where increasing the ‘filter response select’ requires the maximum value of the ‘locking speed select’ to decrease in order to prevent additional jitter gain on the DPLL output clocks, caused by saturations of both ‘multiplied phase’ and ‘integrator in’ for small changes of the ‘phase’ value.
The DPLL in accordance with the invention includes a loop filter which is capable of providing complete fast-locking functionality over sixteen selectable corner frequencies, in addition to normal locking functionality that is prescribed by appropriate standards which define maximum output clock phase change (i.e. phase slope), maximum wander accumulation (i.e. peaking), etc.
The loop filter multiplies the proportional value of phase error (P-value), representing the phase difference between the DPLL output clocks and the active input reference clock, prior to passing it to an integrator in order to achieve fast alignment of the DPLL output clocks to the active input reference clock and fast achievement of stable holdover frequency, i.e. fast-locking functionality of the DPLL. A programmable multiplier of the phase error controls the fast-locking speed of the DPLL.
The combination of non-linear multiplication of the phase error, used to form frequency offset for the digitally controlled oscillator (DCO), with linear multiplication of the multiplied phase error, used as input to the integrator, achieve fast locking with stable holdover frequency of the DPLL.
The saturator with selectable saturation value limits the integrator input in order to achieve the DPLL output clock stability, depending on amount of jitter present on the DPLLs active input reference clock. The saturation of the multiplied phase error value prevents overflow of the accumulator of the DCO.
Limiting locking speed of the DPLL prevents oscillating and additional jitter gaining on the DPLL output clocks. The clocks coming from frequency converters of the DPLL to clocks coming from the DCO can be aligned in repeatable time intervals, e.g. every 125 microseconds.
Hysteresis functionality inside the reference monitors of the DPLL prevents bouncing among references when the frequency offset of the preferred input reference clock of the DPLL is close to the reliability boundary.
The invention permits software control over the DPLL output clocks' frequency, following chosen DPLL filter response and phase slope, with no limitation over frequency offset update interval.
This invention can form the embedded DPLL of a digital switch. The DPLL can be implemented in silicon or as an FPGA.
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A digital phase locked loop with fast locking capability includes a digitally controlled oscillator for producing an output signal phase locked to an input reference clock, a phase detector for measuring the phase difference between said input reference clock and a feedback clock, and a loop filter for producing a control signal for the digitally controlled oscillator The loop filter includes a proportional circuit for developing a first signal proportional to said phase difference, an integrator for developing a second integrated signal from said first signal, an adder for adding said first and second signals to develop said control signal, and a weighting circuit, preferably a linear multiplier, for selectively adding extra weight to the first signal at an input to the integrator to shorten the locking time of the phase locked loop in a fast locking mode and to rapidly achieve a stable frequency in holdover mode.
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BACKGROUND
[0001] 1. Field of Invention
[0002] The present disclosure relates in general to wellhead assemblies, and in particular to a seal and lock-down ring for use between inner and outer wellhead members.
[0003] 2. Description of Prior Art
[0004] Seals are typically provided in an annulus between coaxial wellhead tubular members to isolate internal well pressure. The inner wellhead member is sometimes a tubing hanger that supports a string of tubing extending into the well for the flow of production fluid. The tubing hanger lands in an outer wellhead member, which may be wellhead housing, a production tree, or tubing head. A packoff or seal typically forms a barrier between the tubing hanger and the outer wellhead member. In other times, the inner wellhead member is a casing hanger landed in a wellhead housing and that has a string of casing that depends down into the well. A seal or packoff usually seals between the casing hanger and the wellhead housing.
[0005] The seals may be set by a running tool, or they may be set in response to the weight of the string of casing or tubing. One type of seal has inner and outer legs separated by a slot; in which an energizing ring is inserted that deforms the inner and outer legs apart into sealing engagement with the inner and outer wellhead members. The energizing ring is usually a solid member. The seals with inner and outer legs typically plastically deform when pushed into sealing engagement with the inner and outer wellhead members.
SUMMARY OF THE INVENTION
[0006] Disclosed herein is a seal and lock-down system for use between downhole inner and outer tubulars. In an example the system includes a seal element having a body and inner and outer annular legs projecting from the body that are spaced radially apart to define a gap between the legs, a lock-down ring between the tubulars, and a nose ring on an end of the body of the seal element distal from the legs. In this example the nose ring is elongate and generally parallel with an axis of the tubulars. The nose ring is selectively changeable to a set configuration that is generally oblique with the axis when inserted between the lock-down ring and inner tubular. In one example, when the nose ring is inserted between the lock-down ring and inner tubular, the nose ring substantially occupies the space between the lock-down ring and inner tubular. In an alternate embodiment, when the nose ring is inserted between the lock-down ring and inner tubular, an outer radial portion of the lock-down ring projects into a profile in the outer tubular and an inner radial portion is disposed in a lock-down groove on the inner tubular thereby axially affixing together the inner and outer tubulars. Slots may be included that extend through sidewalls of the nose ring from an end of the nose ring distal from the seal element; and wherein fingers can be defined between adjacent slots. In an example embodiment, the inner radius of the lock-down ring projects radially inward proximate a side of the lock-down ring distal from the seal element. The outer tubular can be a wellhead housing that is part of a wellhead assembly, and the inner tubular can be a casing hanger. In one example, directing the energizing ring against the seal element with an energizing force that urges the nose ring between the lock-ring and the inner tubular, wherein inserting the energizing ring into the gap between the inner and outer legs with an energizing force to the energizing ring, drives the energizing ring into the gap and urges the legs radially outward into sealing contact with the tubulars, and wherein the energizing force for the seal element is greater than the energizing force for the lock-ring.
[0007] Also disclosed herein is a seal system for sealing between coaxial tubulars, where the tubulars are part of a wellhead assembly. In an example, the seal system includes an annular seal element having radially spaced apart inner and outer legs that define a gap therebetween, and that are in sealing contact with opposing surfaces of the tubulars. The seal system further includes a lock-down ring having opposing radial portions in interfering contact with oppositely facing profiles in the tubulars, so that portions of the tubulars adjacent the seal element are axially static, and a nose ring. In this embodiment, the nose ring has an end coupled with an end of the seal element, and a portion spaced from the seal element is wedged between the lock-down ring and one of the tubulars. When wedged as such, the nose ring projects along a path generally oblique to the seal element, and thereby retaining the lock-down ring in interfering contact with the tubulars. The one of the tubulars can be a casing hanger; in this example the portion of the nose ring projects radially inward. A notch can be scored on a radial surface of the nose ring so the nose ring can be changed from an elongate shape to the oblique shape when inserted between the lock-ring and the one of the tubulars. The nose ring can change from an elongate shape to the oblique shape when inserted between the lock-ring and the one of the tubulars, and wherein a force for inserting the nose ring between the lock-ring and the one of the tubulars is less than a force for energizing the seal element. The tubulars can be made up of an inner tubular and an outer tubular with oppositely facing profiles that include an upward facing pedestal defined by a lower surface of a lock-down groove formed along an outer circumference of the inner tubular. The outer tubular can have a downward facing shoulder defined by a profile formed along its inner circumference.
[0008] Further described herein is a system for sealing between tubulars in a wellhead assembly. In an example the system includes a seal element that is selectively inserted between the tubulars, and a lock-down ring selectively disposed on an profile on an outer surface of a one of the tubulars. The lock-down ring can be selectively urged to a position towards another one of the tubulars and into interfering contact with an oppositely facing profile on the another one of the tubulars. Further included in this example is a nose ring on an end of the seal element that selectively inserts between the lock-down ring and the one of the tubulars into a setting position to urge the lock-down ring into the interfering contact, so that forces resulting from relative axial movement of the tubulars are applied to the lock-down ring and bypass the seal element. In an example, the interfering contact of the lock-down ring maintains the portions of the tubulars adjacent the seal in relative static positions. Optionally, when the nose ring is in the setting position the nose ring substantially occupies the space between the lock-ring and the one of the tubulars. In an example, the one of the tubulars is a casing hanger and the another one of the tubulars is a wellhead housing.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a side sectional view of an example of a seal system being inserted between a pair of downhole tubulars in accordance with an embodiment of the present invention.
[0011] FIG. 2 is a side sectional view of the seal system of FIG. 1 being set and energized into a sealing and lock-down configuration in accordance with an embodiment of the present invention.
[0012] FIG. 3 is a side perspective view of an example of nose ring from the seal system of FIG. 1 in accordance with an embodiment of the present invention.
[0013] FIG. 4 is a side partial sectional view of an embodiment of the seal system and tubulars of FIG. 1 in a wellhead assembly in accordance with an embodiment of the present invention.
[0014] FIG. 5 is a plan view of an example of a lock-down ring from the seal system of FIG. 1 in accordance with an embodiment of the present invention.
[0015] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0016] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
[0017] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
[0018] Shown in a sectional view FIG. 1 is one example of a portion of a wellhead assembly 10 that includes a pair of coaxial tubulars 12 , 14 . In the example, tubular 14 is an inner tubular and proximate an axis A x of the wellhead assembly 10 . Further in the example, tubular 12 is an outer tubular which circumscribes tubular 14 . Examples exist, where tubular 12 is a wellhead housing, and tubular 14 is a casing hanger. Optionally, tubular 14 may also be a tubing hanger, wherein tubular 12 may be a casing hanger. A seal assembly 16 is shown being inserted into an annulus 18 formed between the tubulars 12 , 14 . The seal assembly 16 includes a seal element 19 shown having an elongate outer leg 20 oriented substantially parallel with axis A x . Seal element 19 further includes an inner leg 24 , which like outer leg 20 is elongate and projects along a path generally parallel with axis A x . Between legs 20 , 24 an annular gap 26 is defined that is elongate in an axial direction. Optional wickers 30 , 31 are formed respectively on portions of the outer and inner surfaces 28 , 22 . Seal element 19 further includes a body 31 on which the legs 20 , 24 mount; and the body 31 defines a bottom of the gap 26 .
[0019] Shown threadingly mounted to an end of the body 31 opposite from legs 20 , 24 is an annular nose ring 32 that is elongate in an axial direction and depends from body 31 deeper into the annulus 18 . Other means for mounting the nose ring 32 to the body 31 may be employed, such as a C-ring (not shown) and/or threaded fasteners. A lock-down groove 34 is illustrated circumscribing the inner tubular 14 formed into the outer surface 28 , and spaced downward from nose ring 32 . A wall of the lock-down groove 34 that is distal from an opening of the annulus 18 , projects radially outward to define a pedestal 36 . In the example of FIG. 1 , the pedestal 36 provides a support ledge on the tubular 14 shown supporting a lock-down ring 38 . An example embodiment of the lock-down ring 38 extends substantially the length of the lock-down groove 34 , such as a “C” ring. In the example of FIG. 1 , the radial section of the lock-down ring 38 has an outer surface substantially parallel with axis A x . While a portion of the inner surface of the lock-down ring 38 proximate pedestal 36 is substantially parallel with axis A x , the inner surface tapers radially outward with distance away from pedestal 36 . The angle of the taper changes to define a transition 39 , where angle of the taper between the transition 39 and the pedestal 36 is more oblique to axis A x than the angle of the taper between transition 39 and the end of the lock-down ring 38 distal from pedestal 36 . Optionally, the lock-down ring 38 can fully circumscribe lock-down groove 34 . Further illustrated in FIG. 1 is a profile on the inner surface 22 of tubular 12 that projects radially inward to define a shoulder 40 , wherein shoulder 40 is opposite from and faces pedestal 36 .
[0020] FIG. 2 illustrates a side sectional view of the seal assembly 16 being inserted deeper within the annulus 18 and wherein outer and inner radial surfaces of the legs 20 , 24 are in respective sealing engagement with the inner and outer surfaces 22 , 28 . Further, an energizing ring 42 which is inserted into the gap 26 provides a radial force for sealingly engaging legs 20 , 24 with inner and outer surfaces 20 , 28 . An axial force F applied to energizing ring 42 further downwardly urges the seal element 19 and nose ring 32 so that nose ring 32 is in contact with lock-down ring 38 . In this example, nose ring 32 is shown having a flexible portion that deforms when wedged between lock-down ring 38 and inner groove 34 in inner tubular 14 . When deformed, nose ring 32 is in a configuration generally oblique to the axis A x , which is in contrast to the elongate configuration of FIG. 1 that is generally parallel with axis A x . Lock-down ring 38 is shown being urged radially outward at least partially out of lock-down groove 34 and into interfering contact with tubular 12 while remaining in interfering contact with tubular 14 . More specifically, a surface of lock-down ring 38 distal from seal element 19 rests on and is in contact with the pedestal 36 of tubular 14 . Urging the lock-down ring 38 radially outward in the example of FIG. 2 , further positions a surface of lock-down ring 38 proximate seal element 19 into engaging contact with shoulder 40 . As such, relative axial movement between tubulars 12 , 14 is arrested by the presence of the interfering lock-down ring 38 . Additionally, substantially all axial forces resulting from respective axial movements of the tubulars 12 , 14 are transferred through the lock-down ring 38 . Thus, forces on the seal element 19 that result from forces that transfer between the tubulars 12 , 14 , can be minimized. The compound angle created by the transition 39 on the lock-down ring 38 also reduces relative movement between the seal assembly 16 and the inner tubular 14 . The more oblique surface between the transition 39 and pedestal 36 urges the lower terminal portion of the nose ring 32 radially inward, where it is wedged between the lock-down ring 38 and outer surface 28 of inner tubular 14 . Strategically profiling the inner surface of the lock-down ring 38 and outer surface 28 , in combination with the flexible nose ring 32 , directs forces from the lock-ring 38 to the nose ring 32 in a direction oblique to the axis A x , instead of parallel to the axis A x . Obliquely directing forces from the lock-ring 38 to the nose ring 32 , rather than directing the forces axially, creates a force coupling the nose ring 32 , and attached seal assembly 16 , to the inner tubular 14 , As such, during episodes of thermal expansion of the casing or casing hanger, seal integrity may be maintained between tubulars 12 , 14 by bypassing the resulting axial forces through lock-down ring 38 . Bending of the nose ring 32 may be facilitated by scoring an inner radial surface of lock-down ring 38 with a notch 43 , wherein notch 43 may extend along an entire circumference of nose ring 32 or along a portion thereof.
[0021] Referring now to FIG. 3 , shown in perspective view is an alternate embodiment of nose ring 32 A, that includes axial slots 44 that extend from an end of the nose ring 32 A distal from its attachment with seal element 19 into a mid-portion of the body of nose ring 32 A. The slots 44 can each have the same length, or as have different lengths as shown. Positioning of the slots 44 define elongate fingers 46 between adjacent slots 44 , where the absence of material due to slots 44 reduces the force required for deforming sidewalls of the nose ring 32 A, thereby facilitating its deformed setting position as illustrated in FIG. 2 . In an example, the axial force required for positioning the nose ring 32 , 32 A into the setting position illustrated in FIG. 2 is less than the axial force required for energizing the seal element 19 . In this example, the nose ring 32 would be in the set position of FIG. 2 and between the lock-down ring 38 and inner tubular 14 before the energizing ring 42 would set the legs 20 , 24 into sealing contact with the inner and outer tubulars 14 , 12 .
[0022] FIG. 4 provides a side partial sectional view one example of the seal assembly 16 set between tubulars 12 , 14 . The tubulars 12 , 14 are part of the wellhead assembly 10 , which is shown mounted on a surface 48 of a formation through which a wellbore 50 is formed. Casing 52 depends downward from tubular 14 , and a production tree 54 is shown mounted on tubular 12 . A main bore 56 extends through wellhead assembly 10 and into communication with wellbore 50 , wherein a swab valve 58 is disposed in main bore 56 for controlling access into the wellbore 50 . Also, wing valves 60 are shown set in lines that mount to the production tree 54 .
[0023] Shown in a plan view in FIG. 5 is an alternate embodiment of lock-down ring 38 A and shown having slots 62 formed axially from an outer terminal radius of lock-down ring 38 A approximately to a mid-portion of the body of the lock-down ring 38 A. In this example, slots 64 are formed axially through lock-down ring 38 A from its inner diameter that extend radially outward approximately to a mid-portion of the body of lock-down ring 38 A. In the example of FIG. 5 , slots 62 are offset from slots 64 , however, alternate embodiments exist where slots 62 , 64 are aligned or spaced apart at different angular locations than as shown.
[0024] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
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A seal system selectively set between coaxial downhole tubulars seals between the tubulars; the system also locks the tubulars together to resist relative axial movement from thermal expansion. The seal system includes a seal element with a nose ring that couples a lock-down ring to both the inner and outer tubulars. Before inserting the seal system between the tubulars, the lock-down ring is disposed in a groove on the inner tubular. Setting the seal system drives a lower tip of the nose ring between the lock-down ring and inner tubular, thereby urging the lock-down ring radially outward. A portion of the lock-down ring remains in the groove, while an outer radial portion of the lock-down ring inserts into a profile on the outer tubular. Axial movement of a tubular transfers force to the other tubular through the lock-down ring, while a minimal amount of force transfers through the seal system.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation of U.S. patent application Ser. No. 10/629,449, filed Jul. 29, 2003 now U.S. Pat. No. 7,355,992, which is a continuation-in-part of U.S. patent application Ser. No. 10/391,467, filed Mar. 18, 2003 now U.S. Pat. No. 7,545,793, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates in general to communication systems and subsystems therefor, and is particularly directed to a relay mechanism for a wireless packetized communication system of the type disclosed in the above-referenced '467 application. In that system enhanced throughput efficiency, wireless packetized data transport is provided by way of a limited acknowledged-based, communication path linking a data-reception site and a data-sourcing wireless transceiver site that is geographically remote relative to the data-reception site. The relay mechanism of the present invention serves to maximize throughput at each of one or more successive relay nodes interposed between the data-sourcing site and the data-reception site of such as system.
BACKGROUND OF THE INVENTION
The communications industry has developed a number of efficient throughput, wireless packet-based communication methodologies or protocols (such as IEEE standard 802.11a internet protocol) that are intended for use within an office or intra-building environment, where transmission distances are relatively short (e.g., on the order of one to several hundred feet). While these protocols work reasonably well for ‘nested’ or ‘quasi-nested’ local area networks (LANs), they are not readily suited for use with extended range applications (e.g., on the order of several tens of miles or more).
This latter type of environment suffers from the problem diagrammatically illustrated in FIG. 1 , specifically the substantial transport delay that results from having to return an acknowledgement (ACK or NACK) transmission for each successively transmitted packet. (For example, the MAC acknowledgement layer of the above-referenced 802.11a protocol returns an ACK for each packet.) This problem is particularly noticeable in networks containing a large number of transmitters that must communicate over large distances with a reception/processing or relay site.
In accordance with the invention detailed in the above-referenced '467 application, this problem is effectively obviated by providing a limited acknowledgement-based wireless communication methodology that substantially increases the transport efficiency of packetized data transmissions to a ‘master’ data-reception site from a ‘slave’ data-sourcing or transmission site, geographically remote relative to the data-reception site. Rather than requiring the master receiver to return an acknowledgement message in reply to each packet received by an interrogated transmitter, the invention of the '467 application returns an acknowledgement only upon receipt of a plurality or group of packets, the number of which is known by the master and the slave.
When returning an acknowledgement message, the master identifies which, if any, packets of the group were not successfully received. These missing packets are then retransmitted by the slave transmitter in a manner dictated by the master, either immediately, or in response to a subsequent poll of that site by the data recipient. When retransmitted, the missing packets of the previous transmission are prepended to any new packets awaiting transmission.
FIG. 2 diagrammatically illustrates a simplified, non-limiting example of a geographically dispersed wireless communication system with which the invention disclosed in the '467 application may be employed. As shown therein, a plurality of transmitter sites 10 - 1 , 10 - 2 , 10 - 3 , . . . , 10 -N are dispersed over a prescribed data-gathering region, and are geographically remote relative to a data-recipient and processing site 20 . By the phrase ‘geographically remote’ is meant a considerable wireless transmission distance (e.g., on the order of several to multiple tens of miles) relative to separations between the transmitter sites (which may be, but are not limited to, on the order of several to more than tens of feet apart).
Disposed at each transmitter site is an information source, shown as transducers 12 - 1 , 12 - 2 , 12 - 3 , . . . , 12 -N, which are respectively coupled to associated wireless transceiver units 13 - 1 , 13 - 2 , 13 - 3 , . . . , 13 -N. As a non-limiting example, the transducers may correspond to motion sensors, such as but not limited to acoustic transducers (e.g., geophones), optical sensors (e.g., infrared detectors), and the like, which are interfaced with supervisory and monitoring controllers 14 - 1 , 14 - 2 , 14 - 3 , . . . , 14 -N of their associated wireless transceiver units. The transceivers employed at the remote sites 10 and associated transceivers at the data-recipient site 20 may comprise conventional wireless transceiver units, such as those which are capable of operating at a data transport rate of 500 kbps or greater.
The remote site transceivers 13 serve as slave transmitter units, and are selectively polled by their associated master transceivers 21 , which are interfaced with an associated data processing station 22 , that may be co-located with the master transceivers or located at a separate facility. Alternatively, data-recipient site 20 may employ a single master transceiver that is operative to poll and collect information from the various slave transceivers at the remote sites. Communications between a slave transceiver and a master transceiver are performed as poll-acknowledgement communications, and may comprise system-associated communications, status-associated communications and data communications.
FIG. 3 diagrammatically illustrates the packet-handling architecture of a respective one of the remote site located, slave transceiver units 13 , that implements the interrogated or polled transmitter portion of the wireless packetized communication mechanism of the '467 application. As shown therein, a slave transceiver includes an output buffer 301 , which stores a group or plurality of packets intended for transmission to the data-recipient site. As a non-limiting example, a packet may be one kilobyte in length, and a packet group may comprise 150 packets, to realize a group size of 150 kbytes. Each packet contains a header field and a data field. The header field contains configuration parameters as well as variables used to process and control handling of the packet. The data field includes data to be transmitted, as may be derived from the transceiver's associated transducer. An input/output buffer 302 receives an interrogation packet (or Poll) from the data-recipient site.
Pursuant to the invention detailed in the '467 application, whenever an acknowledgement message is returned to a transmitter by the data-recipient transceiver, it identifies which packets of the group that were previously transmitted, if any, had not been successfully received. Rather than retransmit the entire group of packets, the interrogated transmitter transmits only the missing packets. For this purpose, the transmitter contains a resend buffer 303 and an associated resend matrix 304 . The resend buffer 303 has a storage capacity of one group. It should be noted that the loss of all packets results in a retransmission of all the packets (Resend All). In such an instance, nothing is loaded in the resend buffer. The transmission of data is limited to one group of data, so that the largest number of Resends will be a group size of data. Since only a group amount of data packets can be sent in a single transmission sequence, then the largest amount of possible Resends is a group sized amount of packets.
The resend matrix 304 is shown as comprising a dual or ping-pong buffer that stores the identification of packets that were not received by the data-recipient transceiver during a previous transmission, as identified in the acknowledge message. Each packet identification (PID) is associated with an index to a packet in the resend buffer. Being configured as a ping-pong buffer enables the resend matrix to accommodate the identification of both missing packets of a previously transmitted group, as well as the identification of any packets missing from the new group.
FIG. 4 diagrammatically illustrates the packet-handling architecture of the data-recipient transceiver 21 to implement the receiver portion of the wireless packetized communication mechanism of the '467 application. As shown therein, the data recipient receiver includes an input or receive buffer 401 , which stores all incoming data, and is sized to accommodate multiple groups of data being received from a transmitter site as it is selectively polled by a data-recipient transceiver. A respective one of the group sections of the receive buffer 401 includes a data buffer 402 and an associated resend matrix 403 . Data buffer 402 has a storage capacity sufficient to accommodate the currently configured number of packets that make up a single group.
The header portion of each packet (which may contain configuration parameters and member variables as shown at 404 ) is not stored in the data buffer, but is processed at the reception of the packets. The resend matrix 403 stores the identification of any missing packets of a received group. In addition to handling incoming packet group transmissions, the receiver further includes a status buffer 405 , which is a single packet in length and is used to store either status or System (dependent upon the requested type) information separate from received data. An output packet buffer 406 stores the contents of outgoing packets intended for the transmitter site.
FIG. 5 shows the manner in which the Improved Datagram Protocol or IDP packetized data transport mechanism of the '467 application may be interfaced with a standard, layered-protocol communication scheme. In particular, FIG. 5 shows the placement of an Improved Datagram Protocol or IDP layer 52 intermediate the application layer 51 , which interfaces data, such as that from the transducers 12 , and a user datagram protocol (UDP) transport layer 53 . The UDP layer 52 is encapsulated on an internet protocol (IP) network layer 54 , which is encapsulated on a data link layer comprised of an Ethernet 802.3 layer 55 or an 802.11 MAC layer 56 . The physical layer corresponds to PHY layer 57 .
Similarly, at the receiver (data-recipient site 20 ), an IDP layer 62 is interfaced with the application layer 61 , which interfaces received sensor data to a downstream processing operator, and a UDP transport layer 63 . The UDP layer 63 is encapsulated on an internet protocol (IP) network layer 64 which, in turn, is encapsulated on a data link layer comprised of an Ethernet 802.3 layer 65 or an 802.11 MAC layer 66 . Again, the physical layer 67 corresponds to a PHY layer.
As pointed out briefly above, communications between a slave transceiver and a master transceiver may comprise system-associated communications, status-associated communications and data communications. The manner in which extended range, data communications are carried out for bulk data transport may be understood by reference to FIG. 6 , which shows a data communication sequence that is conducted between a remote transmitter at a data sourcing site and a receiver at the data-recipient site.
In particular, FIG. 6 is a bulk data pipe flow diagram of a data communication sequence between a data transmitter and the data-recipient is initiated by an interrogation or polling message in the form of a Data-Poll packet 601 that is transmitted from the data recipient to a specifically polled transmitter. At the polled transmitter, the contents of the Data-Poll packet are captured in the transmitter's input/output buffer 302 for processing by the transceiver's communications controller. In response to the Data-Poll, the transmitter returns a poll acknowledgement message in the form of a Data Poll-Ack packet 602 , which indicates the total number of packets currently awaiting transmission in transmit buffer 301 . The receiver already has knowledge of any additional (missed or Resend) packets that are awaiting transmission in the transmitter's resend buffer 303 for a previous poll, since it will have identified those packets in a previous data transmission sequence associated with that poll. In may be assumed that there are no missing packets currently awaiting transmission. If Resend data did exist, it would be transmitted from the Resend buffer 303 .
In response to the Data Poll-Ack packet 602 , the receiver forwards a Data-Request packet 603 to the transmitter, the Data-Request packet indicating to the transmitter to send a group size of data. Namely, The Data-Request packet 603 only requests data, it does not indicate how many bytes are to be sent. The largest amount of data during a data transport message is the maximum capacity of a group of packets which, in the present example, is 150 packets (one kbyte each) corresponding to 150 kbytes. In response to the Data-Request packet 603 , the transmitter transmits a group of data packets as a Data message 604 to the receiver.
At the data-recipient receiver, the data fields of the received group of packets are captured in the group's data buffer 302 , while their header fields are processed. If any packets were not successfully received, they are tagged as such in the receiver's group specific resend matrix 303 . The receiver then returns a data acknowledgement (Data-Ack) packet 605 to the transmitter. The header portion of the Data-Ack packet is used to indicate whether all of the data packets were received without error, or if one or more packets need to be retransmitted. If any packets need to be retransmitted, they are identified by encapsulating the PIDs of the Resend packets (as identified in the current unfilled groups resend matrix) in the data field of the Data-Ack packet 605 .
A request to resend data may either identify which packets are to be resent or indicate that all packets with the exception of specifically enumerated packets are to be resent. The latter mechanism employs an error percentage configurable parameter (field) which identifies the percentage of packets that must be lost or failed to have been received in order to declare a catastrophic failure. The (Resend-All exception for any found Resend packets) capability is a configurable ON/OFF state parameter. If ON, then the Resends found are identified and are not to be resent. If OFF, then all the data is resent.
The header field of the Data-Ack packet 605 contains a Retransmit bit. The logical state of the Retransmit bit indicates whether the identified missing packets are to be immediately retransmitted, so as to effectively maintain an ongoing or ‘continuing’ transmission from the transmitter to the receiver, based upon a configurable percentage of valid data received in the last data communication sequence, or whether the transmitter is to wait for a further Data Poll packet from the receiver before retransmitting the missing packets). If the Retransmit bit is set (e.g., to a logical ‘1’), the transmitter immediately proceeds to transmit the next group of data packets to the receiver as it did in response to Send-Data packet 603 , described above. As an alternative option, the transmitter may be placed in a “Waiting for Data Request” state. In this mode the receiver sends a Data request immediately following the data-ACK. In addition, this next group of packets is prepended with the requested missing packets. If the Retransmit bit is not asserted (e.g., a logical ‘0’), the transmitter must wait until the next Data Poll before transmitting.
The continuing data is a configurable parameter. It may be turned ON or OFF. When turned ON, the receiver knows how many packets are available at the transmitter from the previous Data Poll_ACK 602 , so that the receiver can determine the maximum number of possible groups that can be obtained. This is readily accomplished by dividing the packets with the group size to determine the maximum number of groups available. The receiver therefore knows how many times to request data. The number of attempts may also be configurable, so that the receiver will selected the lesser of the two. The data must also be received within a certain percentage of error. The Continuing Data Percentage parameter is a configurable parameter and corresponds to the percentage of packets that must be received in order to allow continuing transmission.
In response to a Data Ack, the system begins preparation for the next data transmission, and the transmitter eliminates from the transmit buffer all packets that were not requested In the Data-Ack packet, and moves the packets that were identified as missing in the Data-Ack packet to the transmitter's resend buffer. The DATA_ACK packets are then processed through the Resend Matrix. Any packets that were not identified in the DATA_ACK packet 605 , but were originally in the Resend Matrix are assumed to be found packets by the receiver. The index associated with each is then used to clear that packet from the Resend Buffer 303 . This frees up this packet of information for new Resend Packets. Any Resends that were not found will have their PIDs and associated indices to the Resend Buffer moved to the next matrix in the Resend Matrix 403 . Any new Resends will be added to the new Matrix with the associated index to where they were moved in the Resend Buffer. On the next poll all resend packets are prepended to the front of the next group. Any packet space remaining is filled with new data packets. The requested missing packets are treated as a new group, but the original packet identifications are retained.
In the event of a further poll or continuing data transmission, the transmitter proceeds as described above, by transmitting the requested group of identified missing packets first (as that group of packets has been loaded in the front end of the new group) followed by any new groups of packets. In the present example, if there were 15 resends, then after a Poll, the transmitter would first transmit the 15 resends as identified in the Resend Matrix. The transmitter would then transmit 150−15=135 new packets from the transmit buffer, thus completing a full 150 group size transmission sequence. It may be noted that the new group is only 135 packets in size. If there were more resends, the most that could occur would be a group size or 150 in the present example.
As shown in the system sequence diagram of FIG. 7 (used for upper layer application-to-application communications), in addition to conducting data transport communications, the invention of the '467 application provides for the request of system and status information from the receiver to the transmitter. The status is a protocol status, corresponding to a request for information that is specific to the protocol (namely, configurable items, such as packet size). System communication provides for system-to-system communications between the transmitter-associated application and the receiver's associated application. Status is a Status Poll with a Status Poll_Ack. The Data portion of the Status Ack packet contains the requested status parameters.
As illustrated in FIG. 7 , in response to a system request 701 , the receiver transmits a system Poll packet (step 702 ) to the transmitter. In response to the system Poll, the transmitter forwards (step 703 ) the contents of the system request to the associated application, which then returns the requested system information to the transmitter in step 704 . This system information constitutes payload data for a System Poll-Ack packet 705 , which is returned to the receiver. The return of system information is a pass/fail operation, and is indicated to the attendant program at the receiver at step 706 . If system data is not received within a configurable period of time, the request will return an error to the application. If system data is received, then the application is informed that it is available. It is the responsibility of the application to read the buffer, as shown at step 707 .
In addition to data and system sequence communications, the communication scheme of the '467 application provides a status sequence to collect protocol parameterized data, as shown in the status pipe flow sequence of FIG. 8 . In response to a request for status at step 801 , the receiver forwards a status Poll packet in step 802 to the transmitter. The transmitter then responds with a status poll acknowledgement in step 803 . A status available indication is provided at step 804 , so that the status buffer may be read at step 805 .
Now although the limited acknowledgement-based communication mechanism detailed in the '467, described above, is very effective in increasing the transport efficiency of packetized data transmissions to a ‘master’ data-reception site from a ‘slave’ data-sourcing or transmission site, it does so by direct or point-to-point communications between the master data-recipient site and a relatively remote slave transmitter site. There may be occasions, however, where such a direct communication path is impossible or impractical, mandating the use of one or more intervening or relay sites between the data-sourcing site (original transmitter) and the data-recipient site (destination receiver). In this event it is imperative that the data relay mechanism not create a ‘bottleneck’, something which might happen if a relay site were to await for receipt of all packets of each group from the transmitter before forwarding the data to the downstream receiver.
SUMMARY OF THE INVENTION
In accordance with the present invention, the limited acknowledgement based signal transport functionality employed by the communication system described in the above-referenced '467 application is modified for use in communication system that contains one or more relay sites interposed between an upstream-most data-sourcing site and a downstream-most data-recipient site. As will be described, each successive pair of transceivers distributed along the communication path through one or more relays between a transmitter site and a destination site exchange messages with one another using the data communication exchange protocol of FIG. 6 , described above. The packet-handling architecture of the data-sourcing site is identical to that shown in FIG. 3 , while the packet-handling architecture of the data-recipient site is substantially identical to that shown in FIG. 4 . In addition, the data recipient site is augmented to include an additional data assembly buffer. This additional buffer is used to store and eventually release all successfully received data.
A relay site transceiver includes a receiver section for receiving data from the upstream data-source or an adjacent upstream relay and a transmitter section for transmitting data it has received via the receiver section to the downstream data-recipient site or an adjacent downstream relay. The receiver section of the relay includes a receive buffer, which is sized to accommodate multiple groups of data being received from an upstream source. The receive buffer is doubled to a X2 capacity to account for group numbering across the system. A respective one of the group sections of the receive buffer includes a data buffer and an associated resend matrix. The data buffer has a storage capacity sufficient to accommodate the currently configured number of packets that make up a single group.
The header portion of each packet, is stored in the data buffer, and is processed at the reception of the packets. The original header must be transmitted and is used by the destination to process and recombine the original data. Each relay will append its own header. When a relay receives a relayed packet, it strips the sending relay's header and appends its own header, but the IDP header is not stripped. This enables the data to be reconstituted at the destination. The resend matrix stores the identification of any missing packets of a received group. In addition to handling incoming packet group transmissions, the receiver further includes a status buffer which is a single group in length and is used to store either status or system depending upon the requested type information separate from received data. An output packet buffer stores the contents of outgoing packets intended for the next upstream site.
Within its transmitter section the relay includes an output or transmit buffer which stores a group or plurality of packets intended for transmission to the next downstream (e.g., data-recipient) site. Each packet contains a relay header field that is appended to the IDP header field, which is prepended to the data field. The header field has configuration parameters as well as variables used to process and control handling of the packet. The data field includes data to be transmitted. An input/output buffer receives an interrogation packet or poll from a downstream site (e.g., the data-recipient site).
When an acknowledgement (ACK) message is returned by the device, it identifies which packets of the group that were previously transmitted, if any, had not been successfully received. Rather than transmit the entire group of packets, the interrogated transceiver transmits only the missing packets. For this purpose, the transmit section of the relay comprises a resend buffer and an associated resend matrix. The resend buffer has a storage capacity of one group. The loss of all packets results in a retransmission of all the packets (Resend All). In such an instance, nothing is loaded in the resend buffer. The transmission of data is limited to one group of data, so that the largest number of Resends will be a group size of data. Also, since only a group amount of data packets can be sent in a single transmission sequence, then the largest quantity of possible Resends is a group sized amount of packets.
As in the transceiver at the transmit site, the resend matrix of the relay's transmitter section comprises a dual or ping-pong buffer that stores the identification of packets that were not received by the downstream (data-recipient) transceiver during a previous transmission, as identified in the acknowledge message. Each packet identification (PID) is associated with an index to a packet in the resend buffer. Being configured as a ping-pong buffer allows the resend matrix to accommodate the identification of both missing packets of a previously transmitted group, as well as the identification of any packets missing from the new group.
In order to maximize throughput from the data-sourcing site and the data-reception site, the relay mechanism of the present invention executes the limited acknowledged-based data transport mechanism detailed in the '467 application in the context of successive pairs of communication transceivers along the communication link. As a non-limiting example, considering the reduced complexity system of a single relay, there are two pairs of associated transceivers that exchange data gathering messages with one another via the limited acknowledged-based data transport mechanism detailed in the '467 application, and a flow diagram of which is shown in FIG. 6 . The first pair involves data request and transport messages between the data-sourcing site and the relay. The second pair involves data request and transport messages between the relay and the data reception site. In other words the system contains at least three communication units: 1) transmitter; 2) at least one relay; and 3) a receiver.
The operation of the relay-based system of the invention uses the same polling and acknowledgement scheme of the '467 application, but does so on an adjacent transceiver pair basis, wherein a polling message is selectively wirelessly transmitted from a downstream one of each pair of transceiver devices. In response to the polling message, the upstream device wirelessly transmits a poll acknowledgement message representative of whether that device has data to send and the quantity of data to be sent. In response to receipt of the poll acknowledgement message indicating that the queried device has data to send, the polling device transmits a data request message. In response to receipt of the data request message, the polled device transmits a data message containing a plurality of data packets.
In response to receipt of the data message at the data reception device, that device stored data contained in data packets of the data message, and stores information representative of any data packets missing from the data message. The polling device then transits a data acknowledgement message that includes information representative of any data packets missing from the data message, so that the polled device will retransmit only specifically identified packets and fill the remainder of the data message with new packets.
Because the relay-based architecture of the invention operates dynamically in terms of transceiver pairs along the relay path, it does not force a relay site to wait until it has received an entire set of contiguous packets before forwarding what it has received to the next downstream device. Packets are immediately forwarded along the (relayed) link as they are received and requested. Packets that are missing from a requested poll are indicated as such, and are forwarded as prepended packets to a further transmission, within a prescribed retry metric, once those packets have been received from an upstream source. Eventually, once the packet assembly buffer at the downstream-most destination site has received a contiguous string of packets, the transmission of which may have taken several retransmission intervals, it will release those packets.
In addition to a prescribed number of retries-based retransmission criteria, the present invention may optionally incorporate a time out mechanism. In accordance with this procedure a sequence number is appended to the header by the transmitter. The destination receiver (not an intervening relay) sets a timer for each new group it receives. If a group has not been completed (resends present) when the timer expires, the destination receiver will fill all remaining packets in the reassembly buffer as incomplete, and then release that portion of the reassembly buffer up to the next incomplete group in the buffer or the end of the buffer. The sequence number for each released group is then incremented. If a received packet has a sequence number lower than the current sequence number, that packet is ignored and discarded. In effect, since the packet will not be identified in the Data-Ack for the group, the sender will presumed it was received and it will be purged.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagrammatically illustrates the problem of transport delay associated with having to return an acknowledgement (ACK or NACK) transmission each of successively transmitted packets;
FIG. 2 diagrammatically illustrates a simplified example of a geographically dispersed wireless communication system in which the invention disclosed in the '467 application may be employed;
FIG. 3 diagrammatically illustrates a transmitter packet-handling architecture which implements the data-sourcing portion of the wireless packetized communication mechanism of the invention disclosed in the '467 application;
FIG. 4 diagrammatically illustrates a receiver packet-handling architecture which implements the data-recipient portion of the wireless packetized communication mechanism of the invention disclosed in the '467 application;
FIG. 5 shows the manner in which the wireless packetized data transport mechanism of the '467 application may be interfaced with a standard, layered-protocol wireless communication scheme;
FIG. 6 shows a data communication sequence (wherein the data pipe is used for bulk data transmission) between a remote transmitter and a receiver at the data-recipient site using improved datagram protocol;
FIG. 7 shows a system communication sequence (wherein the system pipe is used for upper layer application-to-application communication) between a remote transmitter and a receiver at the data-recipient site;
FIG. 8 shows a status communication sequence (wherein the status pipe is used for collection of protocol information from a respective IDP transmitter) between a remote transmitter and a receiver at the data-recipient site;
FIG. 9 diagrammatically illustrates a reduced complexity, non-limiting example of a geographically dispersed wireless communication system of the type shown in FIG. 2 , having a relay site interposed in the communication path established between a data-sourcing transmitter site and a data-recipient destination site;
FIG. 10 diagrammatically illustrates a destination receiver packet-handling architecture which implements the data-recipient portion of the wireless packetized communication mechanism of the present invention;
FIG. 11 diagrammatically illustrates the packet-handling architecture of a relay site transceiver;
FIG. 12 shows a source transmitter having packets awaiting transmission in response to a poll from a relay;
FIGS. 13-33 are transceiver/buffer content diagrams showing the manner in which packets propagate through the relay-based wireless packetized communication mechanism of FIG. 10 .
DETAILED DESCRIPTION
Before describing the relay-incorporating, extended range, wireless packetized data communication mechanism in accordance with the present invention, it should be observed that the invention resides primarily in what is effectively a prescribed augmentation of the architecture of the system disclosed in the above-referenced '467 application, to incorporate therein at least one relay, as well as the appropriate modification of control software employed by the micro-controllers of digital signaling and data-interface units of respective wireless transceivers located at geographically spaced apart data-sourcing and data-reception sites and the one or more relay sites therebetween.
As in the system of the '467 application, digital signaling and data interface units may comprise modular arrangements of conventional digital communication circuits and associated digital signal processing components and attendant supervisory control circuitry therefor, that controls the operations of such circuits and components. In a practical implementation that facilitates their incorporation into wireless communication equipment, these modular arrangements may be readily implemented as field programmable gate array (FPGA)-implemented, or application specific integrated circuit (ASIC) chip sets.
Consequently, the configuration of these units and the manner in which they are interfaced with other communication and transducer components have been illustrated in the drawings by readily understandable block diagrams, which show only those specific details that are pertinent to the present invention, so as not to obscure the disclosure with details which will be readily apparent to those skilled in the art having the benefit of the description herein. Thus, the block diagram illustrations of the Figures are primarily intended to illustrate the major components of the system in a convenient functional grouping, whereby the present invention may be more readily understood.
Attention is now directed to FIG. 9 , which diagrammatically illustrates a reduced complexity, non-limiting example of a geographically dispersed wireless communication system of the type shown in FIG. 2 , described above, but having a relay site 93 that is interposed in the communication path that is established between a data-sourcing transmitter site 91 and a data-recipient destination site 95 . While only a single relay has been illustrated in order to reduce the complexity of the drawings, it should be observed that the invention is not limited to only one or any particular number of relay sites. The manner in which the invention is readily incorporated in a system having multiple relay sites as a part of a communication path between the source and destination sites will become readily apparent from the description below.
In the system of FIG. 9 , each successive pair of transceivers that are distributed along the communication path through a single relay 95 between the source site 91 and the destination site 93 exchange messages with one another using the data communication exchange protocol of FIG. 6 , described above. In the illustrated example, there are two sequential pairs of transceivers, comprised of a transceiver pair 91 - 95 and a transceiver pair 95 - 93 . The remote transmitter site 91 and the data recipient site do not communication directly with one another; they communicate only with the relay 95 . However, since the relay site 95 uses the same protocol of FIG. 6 for both upstream and downstream communications, its participation is effectively a seamless operation between the transmitter and destination sites, as will be fully understood from the description below.
Within the system of FIG. 9 , the packet-handling architecture of the data-sourcing site 91 is identical to that shown in FIG. 3 , so that no additional description is necessary. Similarly, the packet-handling architecture of the data-recipient site 93 is substantially identical to that shown in FIG. 4 . In addition, the relay-based system of the present invention augments the data recipient site to include an additional data assembly buffer shown at 1010 in FIG. 10 . Otherwise, the data-recipient site is effectively the same as that shown in FIG. 4 . This additional buffer is used to store and eventually release all successfully received data. Namely, a data packet is successfully received from the relay site it will be loaded into its order of sequence location of the data assembly buffer. As will be described, the contents of the data assembly buffer are eventually released once complete data has been received.
FIG. 11 diagrammatically illustrates the packet-handling architecture of the relay site transceiver 95 . As shown therein, the relay transceiver includes a receiver section 1110 for receiving data from the upstream data-source 91 (or an adjacent upstream relay) and a transmitter section 1120 for transmitting data it has received via the receiver section 1110 to the downstream data-recipient site 93 (or an adjacent downstream relay). The receiver section 1110 of the relay includes a receive buffer 1111 , which is sized to accommodate multiple groups of data being received from an upstream source (e.g., transmitter site 91 ). The receive buffer is doubled to a X2 capacity to account for group numbering across the system. A respective one of the group sections of the receive buffer 1111 includes a data buffer 1112 and an associated resend matrix 1113 . Data buffer 1112 has a storage capacity sufficient to accommodate the currently configured number of packets that make up a single group.
The header portion of each packet (which may contain configuration parameters and member variables as shown at 1114 ) is stored in the data buffer, and is processed at the reception of the packets. The original header must be transmitted and is used by the destination to process and recombine the original data. Each relay will append its own header. When a relay receives a relayed packet it strips the sending relay's header and appends its own header but the IDP header is not stripped. This enables the data to be reconstituted at the destination. The resend matrix 1113 stores the identification of any missing packets of a received group. In addition to handling incoming packet group transmissions, the receiver further includes a status buffer 1115 , which is a single group in length and is used to store either status or System (dependent upon the requested type) information separate from received data. An output packet buffer 1116 stores the contents of outgoing packets intended for the next upstream site (e.g., transmitter site 91 in the present reduced complexity example).
Within its transmitter section 1120 , the relay includes an output or transmit buffer 1121 , which stores a group or plurality of packets intended for transmission to the next downstream (e.g., data-recipient) site. Each packet contains a relay header field that is appended to the IDP header field, which is prepended to the data field. As described above a header field has configuration parameters as well as variables used to process and control handling of the packet. The data field includes data to be transmitted. An input/output buffer 1122 receives an interrogation packet or poll from a downstream site (e.g., the data-recipient site 93 ).
As described above, when an acknowledgement message is returned by the device, it identifies which packets of the group that were previously transmitted, if any, had not been successfully received. Rather than transmit the entire group of packets, the interrogated transceiver transmits only the missing packets. For this purpose, the transmit section of the relay comprises a resend buffer 1123 and an associated resend matrix 1124 . The resend buffer 1123 has a storage capacity of one group. As noted earlier, the loss of all packets results in a retransmission of all the packets (Resend All). In such an instance, nothing is loaded in the resend buffer. The transmission of data is limited to one group of data, so that the largest number of Resends will be a group size of data. Also, as pointed out above, since only a group amount of data packets can be sent in a single transmission sequence, then the largest quantity of possible Resends is a group sized amount of packets.
As in the transceiver at the transmit site, the resend matrix 1124 of the relay's transmitter section 1120 comprises a dual or ping-pong buffer that stores the identification of packets that were not received by the downstream (data-recipient) transceiver during a previous transmission, as identified in the acknowledge message. Each packet identification (PID) is associated with an index to a packet in the resend buffer. Being configured as a ping-pong buffer allows the resend matrix 1124 to accommodate the identification of both missing packets of a previously transmitted group, as well as the identification of any packets missing from the new group.
Operation
As described briefly above, in order to maximize throughput from the data-sourcing site and the data-reception site, the relay mechanism of the present invention executes the limited acknowledged-based data transport mechanism detailed in the '467 application in the context of successive pairs of communication transceivers along the communication link. As noted above, for the reduced complexity example of FIG. 9 , which uses only a single relay, there are two pairs of associated transceivers that exchange data gathering messages with one another via the limited acknowledged-based data transport mechanism detailed in the '467 application, and a flow diagram of which is shown in FIG. 6 . The first pair involves data request and transport messages between the data-sourcing site 91 and the relay 95 . The second pair involves data request and transport messages between the relay 95 and the data reception site 93 .
The manner in which the limited acknowledged-based data transport mechanism of the '467 application may be employed in a relay-incorporating communication path will now be explained with referenced to FIGS. 12-34 . In order to reduce the complexity of the description and illustration of the present example, the number of relays within the source-to-destination communication path has been limited to a single relay, and the number of packets per group and number of retries per packet have been set at three each.
For the single relay embodiment of the present example, this means that the size of the receive buffer (or the lowest number of groups) that may be allocated prior to reuse in that portion of the communication path from the transmitter site 91 to the relay site 95 is seven. This number is realized by taking into account the highest number of retries to which a packet may be subjected in the course of its being successfully transported from the transmit site 91 , through the relay site 95 and eventually received at the destination site 93 . With each transmission site allowing for three retries each there are a total of four tries at the upstream (transmit) site comprised of an original transmit plus three retries, and three retries at the relay site for a total of seven for the illustrated example.
This may be expressed generally as follows:
Buffer size=(Number of tries)*(number of relays+1)−number of relays.
For the present example, there is a single relay 95 , so that the buffer size for the relay site is 4*(1+1)−1 or 7. Similarly, the buffer size for the destination site is 4*(0+1)−0 or 4. In order to avoid confusion, in the present example, transmissions from the transmit site 91 to the relay 93 will be identified with precursor group numbers of 1 - 7 , while transmissions from the relay 93 to the destination site 95 will be identified with precursor group letters A-D.
FIG. 12 shows a source transmitter 110 having packets awaiting transmission in response to a poll from relay 120 . In the present example, transmitter 110 is shown as having some arbitrary number of packets 1 - 27 . If transmission and relay operations were perfect (namely, no losses), then only nine sequences of three packets per group would be required to send all 27 packets to a destination receiver 130 . Because such a condition is straightforward it will not be described here. Instead, the present description will detail the occurrence of various losses in transmission, for which packet resends are required. For purposes of identification, transmissions from the source transmitter 110 to the relay 120 use precursor group numbers 1 - 7 , while transmissions from the relay 120 to destination receiver 130 use precursor group letters A-D.
FIG. 13 shows the state of the relay 120 as a result of the source transmitter 110 having transmitted an initial group 1 of three packets, namely packets 1 , 2 and 3 , labelled in the Figure with a precursor group number (here the number 1 ) followed—by the packet number, and what was received for that packet. In the present example, for the first transmission sequence from the source transmitter 110 , relay 120 did not successfully receive the first packet 1 , but did receive the next to packets 2 and 3 . This is represented in FIG. 13 , by identifying the first packet 1 of the first group 1 as lost, by the notation 1 - 1 , 1 LOST. The next two packets were successfully received and are denoted as such as packets 1 - 2 , 2 and 1 - 3 , 3 .
FIG. 14 shows the state of the destination receiver 130 as a result of the relay 120 having transmitted an initial group A of three packets to the destination receiver. As described above, the packets transmitted or relayed by the relay 120 to the destination receiver are based upon what the relay has to send when polled. In the present example, the relay's transmit buffer contains only the two packets that were successfully received from the source transmitter 110 during the first sequence therebetween, referenced above, namely packets 2 and 3 . In addition, it will be assumed that the first packet in group A was lost. As a result, the first transmission sequence from relay 120 to destination receiver 130 is identified as containing packet A- 1 ; 1 - 2 , 2 LOST, and packet A- 2 ; 1 - 3 , 3 . Packet 1 within the source transmitter 110 was not sent from the relay to the destination receiver within the first group A, since relay 120 has not yet successfully received this packet and therefore does currently have packet 1 to send.
FIG. 15 shows the state of the packet reassembly or release buffer 140 at the completion of the initial group A transmission for the state of the destination receiver shown in FIG. 14 , described above. Since only packet 3 has been successfully transmitted and relayed from source transmitter 110 to the destination receiver 130 (packets 1 and 2 having been lost by relay 120 and destination receiver 130 , respectively), the reassembly buffer 140 currently contains only packet 3 , stored in the third entry location 140 - 3 .
FIG. 16 shows the state of the relay 120 as a result of the source transmitter 110 having transmitted the next group of three packets following the initial transmission sequence described above. Since the first packet 1 of group 1 was lost, it will have been identified in the transmitter's resend buffer, so that it is sent as the first packet in the next group of three packets from the source. Thus, the second transmission sequence from the source 110 to the relay 120 contains the retransmitted packet 1 of group and the next two packets awaiting transmission, namely, packets 4 and 5 —the first two packets of group 2 . These respective packets are labelled in FIG. 16 as packets 1 - 1 , 1 LOST, 2 - 1 , 4 and 2 - 1 , 5 . Note that, once again, packet 1 has not been successfully received by the relay.
FIG. 17 shows the state of the destination receiver 130 as a result of the relay 120 having transmitted its next group of three packets to the destination receiver. Since the first packet of group A, i.e. original packet 2 of group 1 , was lost, it will have been identified in the relay's resend buffer, so that it is sent as the first packet in the next group of three packets from the relay to the destination receiver as packet A- 1 ; 1 - 2 , 2 LOST. Thus, the second transmission sequence from the relay 120 to the destination receiver 130 contains the retransmitted packet 2 of group A and the next two packets awaiting transmission that make up the next group B, namely, packets 4 and 5 of group 2 . These respective packets are labelled in FIG. 17 as packets A- 1 ; 1 - 2 , 2 LOST, B- 1 ; 2 - 1 , 4 and B- 2 ; 2 - 1 , 5 . It is again to be noted that neither packet 1 nor packet 2 has yet been successfully received by the destination receiver.
FIG. 18 shows the state of the packet reassembly buffer 140 at the completion of the second group transmission for the state of the destination receiver shown in FIG. 17 . Since packets 4 and 5 have been successfully transmitted and relayed from the source transmitter 110 to the destination receiver 130 (packets 1 and 2 having been lost at the relay 120 and the destination receiver 130 , respectively), the reassembly buffer 140 now contains packets 3 , 4 and 5 stored in its third, fourth and fifth entry locations 140 - 3 , 140 - 4 and 140 - 5 , respectively.
FIG. 19 shows the state of the relay 120 as a result of the source transmitter 110 having transmitted the next group of three packets following the second transmission sequence described above. Since the first packet 1 of group 1 was again lost, it will again be identified in the transmitter's resend buffer, so that it is sent as the first packet in the next group 3 of three packets from the source. Thus, the third transmission sequence from the source 110 to the relay 120 contains the retransmitted packet 1 of group 1 , namely packet 1 - 1 followed by the next two packets awaiting transmission, namely, packet 6 of group 2 and packet 7 of group 3 . These respective packets are labelled in FIG. 19 as packets 1 - 1 , 1 LOST, 3 - 1 , 6 and 3 - 2 , 7 . Note that, once again, packet 1 has not been successfully received by the relay.
FIG. 20 shows the state of the destination receiver 130 as a result of the relay 120 having transmitted its next group of three packets to the destination receiver. Since the first packet of group A, i.e. original packet 2 of group 1 , was again lost, it will have been identified in the relay's resend buffer, so that it is sent as the first packet in the next group of three packets from the relay to the destination receiver as packet A- 1 ; 1 - 2 , 2 LOST. Thus, the third transmission sequence from the relay 120 to the destination receiver 130 contains the retransmitted packet 2 of group A and the next two packets awaiting transmission, namely, packet 6 of group 2 and packet 7 of group 3 . These respective packets are labelled in FIG. 20 as packets A- 1 ; 1 - 2 , 2 LOST, C- 1 ; 3 - 1 , 6 and C- 2 ; 3 - 2 , 7 . It is again to be noted that neither packet 1 nor packet 2 has yet been successfully received by the destination receiver.
FIG. 21 shows the state of the packet reassembly buffer 140 at the completion of the third transmission sequence for the state of the destination receiver shown in FIG. 20 . Since packets 6 and 7 have been successfully transmitted and relayed from the source transmitter 110 to the destination receiver 130 (packets 1 and 2 currently still lost at the relay 120 and the destination receiver 130 , respectively), the reassembly buffer 140 now contains packets 3 - 7 .
FIG. 22 shows the state of the relay 120 as a result of the source transmitter 110 having transmitted the next group of three packets following the third transmission sequence described above. Again, since the first packet 1 of group 1 was lost it has been sent as the first packet in the next group 4 of three packets from the source transmitter. Thus, the fourth transmission sequence from the source 110 to the relay 120 contains the retransmitted packet 1 of group 1 , namely packet 1 - 1 followed by the next two packets awaiting transmission, namely, packets 8 and 9 of group 4 . These respective packets are labelled in FIG. 22 as packets 1 - 1 , 1 FOUND, 4 - 1 , 8 and 4 - 2 , 9 . Note that packet 1 has now been successfully received by the relay.
FIG. 23 shows the state of the destination receiver 130 as a result of the relay 120 having transmitted its next group of three packets to the destination receiver. Again, since the first packet of group A, i.e. original packet 2 of group 1 , was lost at the previous relay-to-destination transmission, it will have been identified in the relay's resend buffer, so that it has been sent as the first packet in the next group of three packets from the relay to the destination receiver. However, it will now be assumed that latest transmission of packet 2 was successful, so that it is identified as packet A- 1 ; 1 - 2 , 2 FOUND. In addition, since the previously lost first packet 1 of group 1 was successfully received by the relay, as described above with reference to FIG. 22 , that found packet will have been transmitted prior to the retransmitted packet 2 . Thus, the fourth transmission sequence from the relay 120 to the destination receiver 130 contains packet 1 of group 1 , followed by the retransmitted packet 2 of group A and the next packet in the relay awaiting transmission, namely, packet 8 of group 4 . It will be further assumed that the receiver has failed to successfully receive the first packet, so that packet will be identified in the receiver as lost. Thus, the three respective packets received by the receiver for the fourth relay to receiver sequence are labelled in FIG. 23 as packets A- 1 ; 1 - 2 , 2 FOUND, D- 1 ; 1 - 1 , 1 LOST and D- 2 ; 4 - 1 , 8 .
FIG. 24 shows the state of the packet reassembly buffer 140 at the completion of the fourth transmission sequence for the state of the destination receiver shown in FIG. 23 . Since packets 2 and 8 have been successfully transmitted and relayed from the source transmitter 110 to the destination receiver 130 (packet 1 currently being lost at the destination receiver 130 ) the reassembly buffer 140 now contains packets 2 - 8 .
FIG. 25 shows the state of the relay 120 as a result of the source transmitter 110 having transmitted the next group of three packets following the fourth transmission sequence described above. Since the first packet 1 of group 1 was successfully received by the relay during the previous sequence, and there are no other resends awaiting transmission by the source transmitter, the fifth transmission sequence from the source 110 to the relay 120 contains the next three packets awaiting transmission, namely packets 10 - 12 of group 5 . These respective packets are labelled in FIG. 25 as packets 5 - 1 , 10 , 5 - 2 , 11 and 5 - 3 , 12 .
FIG. 26 shows the state of the destination receiver 130 as a result of the relay 120 having transmitted its next group of three packets to the destination receiver. Since the first packet of group D, i.e. original packet 1 of group 1 , was lost at the previous relay-to-destination transmission, it will have been identified in the relay's resend buffer, so that it has been sent as the first packet in the next group of three packets from the relay to the destination receiver. Thus, the fifth transmission sequence from the relay 120 to the destination receiver 130 contains packet 1 of group 1 , followed by the next two packets in the relay awaiting transmission, namely, packet 8 of group 4 and packet 10 of group 5 . It will again be assumed that the receiver has failed to successfully receive the first packet, so that packet will be identified in the receiver as lost. Since the relay uses only four groups to transmit packets, the packet sequence identification rolls over from group D, back to group A. As pointed out above, since the number of groups takes into account the maximum number of retries per packet entry (three in the present example) there is no possibility of a reuse of group A, after four sequences. Thus, the three respective packets received by the receiver for the fifth relay to receiver sequence are labelled in FIG. 26 as packets D- 1 ; 1 - 1 , 1 LOST, A- 1 , 4 - 2 , 9 , and A- 2 ; 5 - 1 , 10 .
FIG. 27 shows the state of the packet reassembly buffer 140 at the completion of the fifth transmission sequence for the state of the destination receiver shown in FIG. 26 . Since packets 9 and 10 have been successfully transmitted and relayed from the source transmitter 110 to the destination receiver 130 (packet 1 currently still being lost at the destination receiver 130 ) the reassembly buffer 140 now contains packets 2 - 10 .
FIG. 28 shows the state of the relay 120 as a result of the source transmitter 110 having transmitted the next group of three packets following the fifth transmission sequence described above. Since there are no resends awaiting transmission by the source transmitter, the sixth transmission sequence from the source 110 to the relay 120 contains the next three packets awaiting transmission, namely packets 13 - 15 of group 6 . These respective packets are labelled in FIG. 28 as packets 6 - 1 , 13 , 6 - 2 , 14 and 6 - 3 , 15 .
FIG. 29 shows the state of the destination receiver 130 as a result of the relay 120 having transmitted its next group of three packets to the destination receiver. Since the first packet of group D, i.e. original packet 1 of group 1 , was lost at the previous relay-to-destination transmission, it will have been identified in the relay's resend buffer, so that it has been sent as the first packet in the next group of three packets from the relay to the destination receiver. Thus, the sixth transmission sequence from the relay 120 to the destination receiver 130 contains packet 1 of group 1 , followed by the next two packets in the relay awaiting transmission, namely, packets 11 and 12 of group 5 . It will again be assumed that the receiver has failed to successfully receive the first packet, so that packet will be identified in the receiver as lost. The three respective packets received by the receiver for the sixth relay to receiver sequence are labelled in FIG. 29 as packets D- 1 ; 1 - 1 , 1 LOST, B- 1 , 5 - 2 , 11 , and B- 2 ; 5 - 3 , 12 .
FIG. 30 shows the state of the packet reassembly buffer 140 at the completion of the sixth transmission sequence for the state of the destination receiver shown in FIG. 29 . Since packets 11 and 12 have been successfully transmitted and relayed from the source transmitter 110 to the destination receiver 130 (packet 1 currently still being lost at the destination receiver 130 ) the reassembly buffer 140 now contains packets 2 - 12 .
FIG. 31 shows the state of the relay 120 as a result of the source transmitter 110 having transmitted the next group of three packets following the fifth transmission sequence described above. Since there are no resends awaiting transmission by the source transmitter, the sixth transmission sequence from the source 110 to the relay 120 contains the next three packets awaiting transmission, namely packets 16 - 18 of group 7 . These respective packets are labelled in FIG. 31 as packets 7 - 1 , 16 , 7 - 2 , 17 and 7 - 3 , 18 .
FIG. 32 shows the state of the destination receiver 130 as a result of the relay 120 having transmitted its next group of three packets to the destination receiver. Since the first packet of group D, i.e. original packet 1 of group 1 , was lost at the previous relay-to-destination transmission, it will have been identified in the relay's resend buffer, so that it will have been sent as the first packet in the next group of three packets from the relay to the destination receiver. Thus, the seventh transmission sequence from the relay 120 to the destination receiver 130 contains packet 1 of group 1 , followed by the next two packets in the relay awaiting transmission, namely, packets 13 and 14 of group 6 . It will be assumed that the receiver has successfully received the first packet, but not packet 14 , so that packet 1 will be identified in the receiver as found, while packet 14 will be identified as lost. The three respective packets received by the receiver for the seventh relay to receiver sequence are labelled in FIG. 32 as packets D- 1 ; 1 - 1 , 1 FOUND, C- 1 , 6 - 1 , 13 , and C- 2 ; 6 - 2 , 14 LOST.
FIG. 33 shows the state of the packet reassembly buffer 140 at the completion of the seventh transmission sequence for the state of the destination receiver shown in FIG. 32 . Packets 1 and 13 have now been successfully transmitted and relayed from the source transmitter 110 to the destination receiver 130 . The destination receivers 5 reassembly buffer 140 contains an entire continuous set of packets ( 1 - 13 ). Packets 1 - 12 complete groups 1 - 5 . Since they are complete groups, then they can be released as complete, but packet 13 is in group 6 and it is incomplete. Packet 13 will not be released until the missing packets for group 6 are received and it is complete.
In addition to the foregoing number of retries-based retransmission criteria, the present invention may optionally incorporate a time out mechanism. In accordance with this procedure a sequence number is appended to the header by the transmitter. The destination receiver (not an intervening relay) sets a timer for each new group it receives. If a group has not been completed (resends present) when the timer expires, the destination receiver will fill all remaining packets in the reassembly buffer as incomplete, and then release that portion of the reassembly buffer up to the next incomplete group in the buffer or the end of the buffer. It may be noted that the process of releasing data from the input buffer is termed ‘flushing’ the buffer. Then the sequence number for each released group is incremented. If a received packet has a sequence number lower than the current sequence number, that packet is ignored and discarded. In effect, since the packet will not be identified in the Data-Ack for the group, the sender will presumed it was received and it will be purged.
As will be appreciated from the foregoing description, the limited acknowledgement based signal transport functionality employed by the communication system described in the above-referenced '467 application may be readily modified for use in communication system that contains one or more relay sites interposed between an upstream-most data-sourcing site and a downstream-most data-recipient site. By applying the data communication exchange protocol of the '467 application to each successive pair of transceivers distributed along the communication path through one or more relays between a transmitter site and a destination site, the present invention is able to prevent the occurrence bottlenecks and enhance throughput.
While we have shown and described an embodiment in accordance with the present invention, it is to be understood that the same is not limited thereto but is susceptible to numerous changes and modifications as known to a person skilled in the art. We therefore do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications as are obvious to one of ordinary skill in the art.
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A limited acknowledgement-based communication methodology increases the throughput efficiency of a relay-based, extended range, wireless packetized data transmissions to a data-reception site from a data-sourcing site, geographically remote with respect to the data-reception site. Rather than return an acknowledgement for each received packet, the data-reception site returns an acknowledgement only after receipt of a group of packets. When returning an acknowledgement, the data-reception site identifies which packets of the group were not successfully received. Missing packets may be retransmitted by the data-sourcing transmitter either immediately, or in response to a subsequent poll.
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TECHNICAL FIELD
[0001] The subject matter described herein relates to database applications, and more particularly to achieving zero downtime during system upgrades while keeping memory and CPU consumption low.
BACKGROUND
[0002] An upgrade is the procedure to transform a productive software system from one major software version to a newer version. As shown in FIG. 1 , the system 100 includes one or more application core servers 102 . Each core server 102 hosts sessions and runs services and applications (short: programs). Sessions are initiated from outside of the system. A core server infrastructure 104 routes the incoming request to an application server of the core servers 102 , which then creates the session. Subsequent requests in the context of the session will be routed to the same core server 102 . New requests without session will be distributed again to one of the core servers.
[0003] It can be assumed that the systems expose singletons, which are programs that can only run once throughout the entire system (regardless of the number of core servers) since they rely on unique data kept in memory local to a core server. Upgrades depend heavily on the classification of data in a database 106 . For the upgrade there is a need to classify the data in the database 106 along multiple orthogonal dimensions.
[0004] Along the functional dimension, the data can be classified as follows:
program data (short: data): comprising all data created by the programs' operation incl. master data Configuration: business configuration (customizing) and technical configuration. Insomuch as master data influences the functional behavior/flow of programs and thus behaves like configuration, master data may also be classified as configuration. Code: code of programs (services and applications) including generated code. This is the data interpreted by the core server and maybe even services in order to actually run the program
[0008] Code and configuration data are combined into an empty, but runnable program. This means that the program can run without errors and provide the functionality it was designed for with program data tables basically being empty. The term data as used herein also includes the data structures (e.g. table layouts, DDIC entries).
[0009] Along the upgrade-impact dimension the data can be classified as follows:
To-remain-unchanged data: Data that is kept without change imposed by the upgrade. To-Be-Changed data: Data that needs to be transformed by the upgrade. In general, change is associated with physical changes such as structural changes (i.e. differing table layout), exchanging or altering data (i.e. exchange old with new code or replacing a default value, deleting old and adding new example data, . . . ). For the upgrade it is important to understand that also semantical or logical changes play a non-neglectable role. Semantical changes manifest in the worst case such that even physically unchanged data is interpreted differently by original and target programs and therefore have to be treated as changed data during upgrade in order to avoid inconsistencies when reading and writing to the data.
[0012] Along the changeable-by-customer dimension the data can be classified as follows:
Unchangeable data: Data delivered by a system provider, such as SAP, that cannot be changed by a customer (in general this is code) Changeable data: Data delivered by the system provider that is changed by the customer (e.g. configuration entries) Customer-created data: Data that is perceived as singletons by the upgrade since they have solely been created by the customer (e.g. business data entered by means of the various applications). The data is singleton since the consistency of the business operation of the system assumes no copies of individual data records.
[0016] Conventional upgrades, however, always require interruption of all end user work, leading to business and technical downtime perceived by the end user while keeping the central processing unit (CPU) and memory consumption low.
SUMMARY
[0017] This document describes a system and method to achieve full business continuity without business downtime for the end-user. In other words, the end user is capable to continue work even during upgrade of the system. The term “original” is used herein to identify entities of the system of the current version, and the term “target” is used herein for entities of the new version. This is achieved by keeping the additional, upgrade-induced CPU and memory consumption low.
[0018] In one aspect, a method, computer program product, and system for upgrading an application system without downtime are presented. The application system has a database and a plurality of original application core servers. The computer program product and system execute a method, which includes creating a target system in a database. The target system has a persistence. The method further includes creating a set of target application servers in the target system. The set of target application servers keeps a sum of original application core servers and target servers constant.
[0019] The method further includes locking each of the plurality of original application core servers to prevent configuration changes to the application system, and copying configuration data and application data associated with one of the plurality of original application core servers to the persistence associated with the target system. The configuration data and application data remain accessible from the plurality of original application core servers. The method further includes running each of the set of target application servers after the configuration data and application data associated with an associated one of the plurality of original application core servers is copied and transformed to the persistence associated with the target system. The method further includes distributing new requests to the application system from each of the plurality of original application core servers to one of the target application servers in the target system.
[0020] Implementations of the current subject matter can include, but are not limited to, systems and methods consistent including one or more features are described as well as articles that comprise a tangibly embodied machine-readable medium operable to cause one or more machines (e.g., computers, etc.) to result in operations described herein. Similarly, computer systems are also described that may include one or more processors and one or more memories coupled to the one or more processors. A memory, which can include a computer-readable storage medium, may include, encode, store, or the like one or more programs that cause one or more processors to perform one or more of the operations described herein. Computer implemented methods consistent with one or more implementations of the current subject matter can be implemented by one or more data processors residing in a single computing system or multiple computing systems. Such multiple computing systems can be connected and can exchange data and/or commands or other instructions or the like via one or more connections, including but not limited to a connection over a network (e.g. the Internet, a wireless wide area network, a local area network, a wide area network, a wired network, or the like), via a direct connection between one or more of the multiple computing systems, etc.
[0021] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. While certain features of the currently disclosed subject matter are described for illustrative purposes in relation to an enterprise resource software system or other business software solution or architecture, it should be readily understood that such features are not intended to be limiting. The claims that follow this disclosure are intended to define the scope of the protected subject matter.
DESCRIPTION OF DRAWINGS
[0022] The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings,
[0023] FIG. 1 illustrates a running software system.
[0024] FIG. 2 depicts a system during upgrade.
[0025] FIG. 3 depicts upgrade of a core server.
[0026] FIG. 4 is a flowchart of a method for upgrading a multi-version system for zero-downtime upgrade.
[0027] When practical, similar reference numbers denote similar structures, features, or elements.
DETAILED DESCRIPTION
[0028] To address these and potentially other issues with currently available solutions, methods, systems, articles of manufacture, and the like consistent with one or more implementations of the current subject matter can, among other possible advantages, achieve zero downtime during upgrades while keeping memory and CPU consumption low.
[0029] FIG. 2 depicts an upgrade system 200 that includes an original system 202 architecture in addition to a target system architecture 204 . Not all depicted entities are active or existent at all times. There are four main parts of the upgrade system 200 that need to be exchanged during the upgrade: a core server infrastructure 206 (being the façade to the requestors of the system), application servers 208 A and 208 B (executing the programs), a persistency 210 A and 210 B (storing the programs and the application data) and a database system 212 .
[0030] As depicted in FIG. 2 , the upgrade system 200 further includes and provides a number of different data sets that are relevant for the upgrade, and which each have unique handling requirements. (Note that the data sets are combinations of the earlier described data classification dimensions.)
[0000] 1) data that is not changed due to the upgrade that could be read and written both by original and target system. This is in general application transactional data and some unchanged code:
data set 1=(remain unchanged∩unchangeable by customer)∪(remain unchanged ∩customer created∩ program)∪(remain unchanged∩customer changed∩ program)
2) data that is not changed due to the upgrade but essential for proper execution of a program, it may also be data that controls the execution behavior. This is mainly configuration and master data. This data must not change during the upgrade in order to assure the same behavior of original and target system.
data set 2=(remain unchanged∩customer created∩program)∪(remain unchanged ∩customer changed∪program)
3) data that is subject to change by the upgrade, but cannot be changed by the customer. This is mostly code. This data will be exchanged by the upgrade.
data set 3=(to be changed∩unchangeable by customer)
4) data that is subject to change by the upgrade, is relevant for program execution, but has to be perceived as singleton due to the fact that the customer has created or changed it. During the upgrade it would be copied and transformed according to the new target structures. This data set must also not be changed by the customer during the upgrade in order to keep the same behavior of original and target system. In general this data is master data and configuration.
data set 4=(to be changed∩customer created∩program)∪(to be changed∩customer changed∩program)
5) data that is subject to change by the upgrade, but not relevant for the program execution. This is transactional data and master data. The data can also be perceived as a singleton due to the fact that the customer has created or changed it. During the upgrade it can be copied and transformed according to the new target structures. This is the most critical data during upgrade, since the customer would expect to still read and write this data during his normal business operation. Any restrictions for read and write have to be applied carefully since then normal work with the system is not possible and the system under upgrade would be perceived as being in business downtime (which is not the purpose of the proposed procedure). In essence, write access to already existing records of this data set by the target system would result in write locks (here called: reverse write locks) to the original system. Any write access to this data set by the original system also requires an instant transformation to its copy at the target persistency.
data set 5=(to be changed∩customer created∩ program)∪(to be changed∩customer changed∩ program)
[0036] Upgrade of Core Server
[0037] With reference to FIG. 3 , an upgrade of a the core server will now be described in detail, as well as a rolling upgrade variant that can also be used to upgrade the core server. The upgrade of the core server can be implemented in several ways:
n+1 servers (n original+1 target) (requires additional hardware, but maybe preferable for small number of servers) n−1+1 server (n−1 original+1 target) (no additional hardware needed, but performance degradation due to one server not available temporarily).
[0040] External executables are not relevant for the upgrade (e.g. for start/stop of server in normal operation). It is preferred that the core server infrastructure (perceived as singletons) is available in fail-over mode, and that at least two core servers are expected to run in the system. Requests to the system go initially (at a start of a session) through the core server infrastructure.
[0041] It is not possible to initially address the core servers directly, and therefore the core infrastructure needs to have knowledge of sessions or clients in order to understand which request is new to the server and be routed appropriately during the upgrade. If such a mechanism is not available, we have to expect that requests to original servers, which would be down during replacement by a target server, cannot be satisfied.
[0042] It is assumed that there are operating system resources (ports, memory, . . . ) to the core server that are singletons and which are not shared by two core servers. External programs attached to application servers can only be attached to one server. It is assumed that these external programs can handle the non-availability of the core server to which they are attached. Finally, disk-space must be available without ‘limits’, while CPUs and memory are only available in restricted amounts.
[0043] If the target data format and persistence are already installed, prepared, and ready to use, the upgrade procedure of the core server can be executed as follows. First, the target server is installed and prepared in parallel to the original server. Next, the core server infrastructure 206 is exchanged. It is assumed that the target core server infrastructure has been installed with the first target core server. Note also that the core-server infrastructure in fail-over layout means that there is an active component and a fail-over component operating in hot-stand-by that takes over as soon as the active component cannot be active for any reason (crash, shut-down, etc.). It appears as a singleton to the clients of the system, and is reachable under one address.
[0044] This requires the following steps: shut down the fail-over source component, start the target component (as fail-over component and attach it to the still active source component) in a compatible mode with source component and core servers, and shut down the active original component. Then, the target fail-over component takes over and the fail-over component (in the target version) receives all incoming requests). Now the active target component is started, and the fail-over component is again attached to the active target component and the core server infrastructure is now operating in the target version compatible the original core servers. If fail-over of core server infrastructure components is not available, a short unreachability of the system will occur when the source component is stopped and the target component is started. Still, singletons have to work together with the original and target core server and services.
[0045] For the first server, using the above-mentioned n−1+1 server strategy, the target core server is configured according to the original server it shall replace. The original server is then stopped once original services, applications and sessions are depleted (i.e. now new request leading to new sessions or new transactions are accepted, only already begun transactions are finalized). If the original system is only configured with one server, a second core server needs to be added temporarily (i.e., installed in the target version of the system and registered with the core server infrastructure), such that no business downtime appears.
[0046] The following steps of an upgrade procedure are independent of any upgrade strategy being used, and the target applications and services have to be prepared in order to test. First, the original servers are tested against target persistence (i.e., according to a new test case), the target core server is tested, and the target and original sessions, applications and services are tested against both persistencies. New requests are then accepted. It may be necessary to also route new requests to source servers if the target server is overloaded. The servers or the singletons of the core infrastructure have to ensure that new requests up for distribution to the servers are only routed to the target core server.
[0047] For each n-th core server, the procedure is repeated: the n-th original core server is stopped once depleted (with certain performance degradation due to temporarily missing n-th server), and the n-th target server is started (by connecting/using the same resources) with new services and sessions, and operated on the new persistence.
[0048] With each n-th server: a “smoke test,” i.e. preliminary tests to determine if there are any basic or simple failures, is performed on the n-th target core server, and server specifics (e.g. attached executables) can also be tested. New requests can thereafter be accepted for each n-th server.
[0049] Upgrade of System
[0050] In other implementations, an upgrade of an entire system can be accomplished, where the entire system except the core server is in the database. It is assumed that the database system can manage two versions of the schema at a time, and that unchanged data can be consumed from both target and original systems (i.e. applications and services).
[0051] Original and target applications and services must be able to be run in parallel on the same customer created data. Thus, they are not running as singletons. If singletons are unavoidable (e.g., number range creation, having only one in-memory state and not synchronizing by means of the database), they must be implemented and consumed as true services (i.e. consumed via lookup and not via reference in the library). Applications using the service will consume it via lookup, and be fault tolerant if the service is not able to return results while being switched over from original to target system.
[0052] It is also preferred that customer configuration is “read-only” during the upgrade to avoid that service/application/business processes behavior is changed. Thus coding related to configuration has to accommodate not being able to write to the configuration. This means that target and original system behave semantically the same. In case of correcting a bug the behavior may change also on the semantical level. These semantical changes are not supported, and need to be classified upfront by the applications and their usage is prohibited.
[0053] The transformation requires that data can be separated into consistent and thus atomic chunks of data (in the easiest case this is just one record of a table, in more complex cases, the data is chunked into multiple records of one or more tables). These atomic chunks are then also subject to the reverse write lock in order to keep the data semantically consistent even if changed by the target system. In other words, there is a clearly defined and persisted bi-jective mapping between original chunks of data and target chunks of data.
[0054] To setup the transformation of the database, new deliveries are installed according to a versioning scheme of the database. For example, HANA by SAP AG has a particular versioning scheme that needs to be adhered to. To establish persistency, target structures can be created according to an alias naming scheme of the database. For instance, some databases do not allow appending an alias name to existing structures. Thereafter, upgrade mode is entered, and configuration changes and modifications are not allowed.
[0055] Next, target system that can be run is created. The target system includes data sets that are the intersection set of (Created by Customer+Changed by Customer) and the associated application, as well as customer-specific configuration or generated code. These are provided in the target version format such that the target version of the application can run as configured by the customer. This may include customer modifications and customer code. This type of data should be classified during the application development process, and is preferably read-only during upgrade, given the complexity of keeping consistency (e.g. active code branches, testing, . . . ) of running applications in original and target version. Thus, the target systems behaves the same as the original system, if different behavior is not explicitly intentional and thus mandatorily and automatically introduced by the upgrade. The result is two systems, the original system and a target system without business data, that are ready to be run.
[0056] The to-be-changed data that is not part of the empty application (i.e. upgrade data set 5) is copied by transforming that data from the original system to a new data structure. The transformation is carried out one data chunk after the other. The resulting data for the productive systems is then tested.
[0057] The target core server next needs to be in place. Reverse write locks for transformed data (data set 5) are added and activated, and the transformation continues as new data is written by the original system. Original singleton services are shut down and the target singleton service is started. Transforming data of data set 5 continues whenever new data is created at the original system. Thereafter, testing of the target system can happen, and the successful execution of which allows new end user requests to be productively served by the new system, while the sessions of the original servers are depleted.
[0058] Transformation and Reverse Locking on Data Set 5:
[0059] Read/write access of the original and target systems, during the original and target sessions operating in parallel, are as follows. Read access by original services:
Read directly from original data structures; Forbidden: Read from target data structures Reason: avoidance of semantical inconsistency. Consider a workflow that stretches over time and can lead to semantical inconsistencies (e.g. one step vs. two-step approval). This restriction may not apply to all singleton data that changes structure. There may be simple changes from original to target structure for which such cross-persistency read-access may be possible, but this is an optimization and requires appropriate metadata created by the programming model and accessible to the data base as well as additional testing.
[0062] Original sessions may not see data created in target sessions. The risk is that collaboration of users in original and target sessions will not be possible if the data that is subject to the collaboration is created in the target persistency. This is why the session switch based solely on input parameters is important. Users need to be aware of this situation, and can either be notified (i.e. by having the database returning a notification in case of attempting such access), or they are aware of the situation and terminate the original session and create a target session.
[0063] Write Access Original Sessions:
[0064] Table Insert:
New data record can be written to original data structures. A copy of the record is created for the target applications by transforming the new record to the target structure and persist with the target persistence. Forbidden—Table Update of data inserted by target session: The application will receive an exception to logon again. This is indicated by the reverse write locks that are set by the target system and thus exclude these data sets from updates of the original application. Writing to a target record will possible leave inconsistent data if additional fields have been filled by a target session, regardless of whether fields are optional or mandatory.
[0069] A session can end with the commit of a transaction. The session input parameters are moveable to the target session. The target session can be created automatically for the user. The point in time of the original session termination can be selected such that the transfer of the session input parameters is possible and, consequently, the target session state can be constructed only on the basis of the session input parameters without semantical loss of information compared to the original session.
[0070] Read Access Target Sessions:
Read directly from the already transformed target data structures
[0072] Write Access Target Sessions:
Insert: Write to target data structures, and original sessions will not be able to read this data, which is acceptable given the limited amount of time that original session may require access to this data. Update of data inserted by original session (originating from original persistence). The process entails: (1) Write to target data structures (2) Determine original data set and set write lock to original data set. Steps (1) and (2) above must be treated as one transaction, e.g. a read from an original session to the to-be-updated record must not happen between inserting new record into target persistence and locking the old record at the original persistency. If this temporary data inconsistency cannot be accepted, the updated record has to be deleted from the original persistency.
[0078] FIG. 4 is a flowchart of a method 400 for upgrading multi-version database and application systems with zero downtime. At 402 , the target system including a persistence is created in a database, and at 404 the first target application server is created. At 406 , the configuration of the original system is locked in order to prevent changes to the configuration of the original system. At 408 , application configuration and upgrade-affected application data is copied and transformed to the target persistence, and at 410 and following, the upgrade-affected application data is continuously transformed to the target persistence.
[0079] At 412 the first target application server is started and run. At 414 , the target system is tested, as described above. New sessions are thereafter only started on the target application servers, at 416 . At 418 , write accesses to the original persistence are replicated to the target persistence as well, and write accesses to the target persistence lock the corresponding record of the original persistence. At 420 , the depleted original server is shut down, and a target application server is created, started and run. Thus, each original server is exchanged for a tartet server. At 422 , the system configuration is unlocked when the last original server is terminated. Finally, at 424 , superfluous and still-remaining parts of the original system are deleted. Accordingly, the method 400 allows for an upgrade of a multi-version system without downtime to productive use of the system.
[0080] One or more aspects or features of the subject matter described herein can be realized in digital electronic circuitry, integrated circuitry, specially designed application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs) computer hardware, firmware, software, and/or combinations thereof. These various aspects or features can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device. The programmable system or computing system may include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
[0081] These computer programs, which can also be referred to as programs, software, software applications, applications, components, or code, include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the term “machine-readable medium” refers to any computer program product, apparatus and/or device, such as for example magnetic discs, optical disks, memory, and Programmable Logic Devices (PLDs), used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor. The machine-readable medium can store such machine instructions non-transitorily, such as for example as would a non-transient solid-state memory or a magnetic hard drive or any equivalent storage medium. The machine-readable medium can alternatively or additionally store such machine instructions in a transient manner, such as for example as would a processor cache or other random access memory associated with one or more physical processor cores.
[0082] To provide for interaction with a user, one or more aspects or features of the subject matter described herein can be implemented on a computer having a display device, such as for example a cathode ray tube (CRT), a liquid crystal display (LCD) or a light emitting diode (LED) monitor for displaying information to the user and a keyboard and a pointing device, such as for example a mouse or a trackball, by which the user may provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well. For example, feedback provided to the user can be any form of sensory feedback, such as for example visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including, but not limited to, acoustic, speech, or tactile input. Other possible input devices include, but are not limited to, touch screens or other touch-sensitive devices such as single or multi-point resistive or capacitive trackpads, voice recognition hardware and software, optical scanners, optical pointers, digital image capture devices and associated interpretation software, and the like.
[0083] The subject matter described herein can be embodied in systems, apparatus, methods, and/or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and subcombinations of the disclosed features and/or combinations and subcombinations of several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.
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An upgrade procedure for an application system without downtime is presented. The upgrade procedure includes a mix of a rolling upgrade of application servers, shadow systems, and record and replay mechanisms that employ transformation and locking, for the upgrade of the applications on the application system. Application servers are upgraded one after another. A target version of the system is simultaneously added to the original system and a shadow, or target, system. Data changes are not only carried out in the original system, but are also carried out in the target system, so that a customer realizes no downtime for their data requests to the applications.
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FIELD OF INVENTION
[0001] The present invention relates to new compositions of wallboard cores and the processes for fabricating such cores and in particular to cores and processes which reduce the energy required to manufacture the wallboards when compared to the energy required to manufacture traditional gypsum wallboard.
BACKGROUND OF THE INVENTION
[0002] Gypsum wallboard is used in the construction of residential and commercial buildings to form interior walls and ceilings and also exterior walls in certain situations. Because it is relatively easy to install and requires minimal finishing, gypsum wallboard is the preferred material to be used for this purpose in constructing homes and offices.
[0003] Gypsum wallboard consists of a hardened gypsum-containing core surfaced with paper or other fibrous material suitable for receiving a coating such as paint. It is common to manufacture gypsum wallboard by placing an aqueous core slurry comprised predominantly of calcined gypsum between two sheets of paper thereby forming a sandwich structure. Various types of cover paper are known in the art. The aqueous gypsum core slurry is allowed to set or harden by rehydration of the calcined gypsum, usually followed by heat treatment in a dryer to remove excess water. After the gypsum slurry has set (i.e., reacted with water present in the aqueous slurry) and dried, the formed sheet is cut into required sizes. Methods for the production of gypsum wallboard are well known in the art.
[0004] A conventional process for manufacturing the core composition of gypsum wallboard initially includes the premixing of dry ingredients in a high-speed mixing apparatus. The dry ingredients often include calcium sulfate hemihydrate (stucco), an accelerator, and an antidesiccant (e.g., starch). The dry ingredients are mixed together with a “wet” (aqueous) portion of the core composition in a mixer apparatus. The wet portion can include a first component that includes a mixture of water, paper pulp, and, optionally, one or more fluidity-increasing agents, and a set retarder. The paper pulp solution provides a major portion of the water that forms the gypsum slurry of the core composition. A second wet component can include a mixture of the aforementioned strengthening agent, foam, and other conventional additives, if desired. Together, the aforementioned dry and wet portions comprise an aqueous gypsum slurry that eventually forms a gypsum wallboard core.
[0005] A major ingredient of the gypsum wallboard core is calcium sulfate hemihydrate, commonly referred to as “calcined gypsum,” “stucco,” or “plaster of Paris.” Stucco has a number of desirable physical properties including, but not limited to, fire resistance, thermal and hydrometric dimensional stability, compressive strength, and neutral pH. Typically, stucco is prepared by drying, grinding, and calcining natural gypsum rock (i.e., calcium sulfate dihydrate). The drying step in the manufacture of stucco includes passing crude gypsum rock through a rotary kiln to remove any moisture present in the rock from rain or snow, for example. The dried rock then is ground to a desired fineness. The dried, fine-ground gypsum can be referred to as “land plaster” regardless of its intended use. The land plaster is used as feed to calcination processes for conversion to stucco.
[0006] The calcination (or dehydration) step in the manufacture of stucco is performed by heating the land plaster which yields calcium sulfate hemihydrate (stucco) and water vapor.
[0007] This calcination process step is performed in a “calciner”, of which there are several types known by those of skill in the art.
[0008] Calcined gypsum reacts directly with water and can “set” when mixed with water in the proper ratios. However, the calcining process itself is energy intensive. Several methods have been described for calcining gypsum using single and multi staged apparatus, such as that described in U.S. Pat. No. 5,954,497.
[0009] Conventionally in the manufacture of gypsum board, the gypsum slurry, which may consist of several additives to reduce weight and add other properties, is deposited upon a moving paper (or fiberglass matt) substrate, which, itself, is supported on a long moving belt. A second paper substrate is then applied on top of the slurry to constitute the second face of the gypsum board and the sandwich is passed through a forming station, which determines the width and thickness of the gypsum board. In such a continuous operation the gypsum slurry begins to set after passing through the forming station. When sufficient setting has occurred the board is cut into commercially acceptable lengths and then passed into a board dryer. Thereafter the board is trimmed if desired, taped, bundled, shipped, and stored prior to sale.
[0010] The majority of gypsum wallboard is sold in sheets that are four feet wide and eight feet long. The thicknesses of the sheets vary from one-quarter inch to one inch depending upon the particular grade and application, with a thickness of ½″ or ⅝″ being common. A variety of sheet sizes and thicknesses of gypsum wallboard are produced for various applications. Such boards are easy to use and can be easily scored and snapped to break them in relatively clean lines.
[0011] The process to manufacture gypsum wallboard is by some accounts over 100 years old. It was developed at a time when energy was plentiful and cheap, and greenhouse gas issues were unknown. This is an important attribute. While gypsum wallboard technology has improved over the years to include fire resistance as an attribute of certain wallboards, and gypsum wallboard testing has been standardized (such as in ASTM C1396), there has been little change in the major manufacturing steps, and the majority of wallboard is still made from calcined gypsum.
[0012] As shown in FIG. 1 , which depicts the major steps in a typical process to manufacture gypsum wallboard, gypsum wallboard requires significant energy to produce. “Embodied Energy” is defined as “the total energy required to produce a product from the raw materials stage through delivery” of finished product. As shown in FIG. 1 , four of the steps (drying gypsum, calcining gypsum, mixing the slurry with hot water and drying the boards) in the manufacture of gypsum wallboard take considerable energy. Thus the Embodied Energy of gypsum, and the resultant greenhouse gasses, are very high. However few other building materials exist today to replace gypsum wallboard.
[0013] Energy is used throughout the gypsum process. After the gypsum rock is pulled from the ground it must be dried, typically in a rotary or flash dryer. Then it must be crushed and then calcined (though crushing often comes before drying). All of these processes require significant energy just to prepare the gypsum for use in the manufacturing process. After it has been calcined, it is then mixed typically with water to form a slurry which begins to set, after which the boards (cut from the set slurry) are dried in large board driers for about 40 to 60 minutes to evaporate the residual water, using significant energy. Often up to one pound (1 lb) per square foot of water needs to be dried back out of the gypsum board prior to packing. Thus, it would be highly desirable to reduce the total Embodied Energy of gypsum wallboard, thus reducing energy costs and greenhouse gasses.
[0014] Greenhouse gasses, particularly CO 2 , are produced from the burning of fossil fuels and also as a result of calcining certain materials, such as gypsum. Thus the gypsum manufacturing process generates significant amounts of greenhouse gasses due to the requirements of the process.
[0015] According to the National Institute of Standards and Technology (NIST—US Department of Commerce), specifically NISTIR 6916, the manufacture of gypsum wallboard requires 8,196 BTU's per pound. With an average ⅝″ gypsum board weighing approximately 75 pounds, this equates to over 600,000 BTU's per board total Embodied Energy. Other sources suggest that Embodied Energy is much less than 600,000 BTU's per board, and may be closer to 100,000 BTU per ⅝″ board in a modern plant. Still, this is quite significant. It has been estimated that Embodied Energy constitutes over 30% of the cost of manufacture. As energy costs increase, and if carbon taxes are enacted, the cost of manufacturing wallboard from calcined gypsum will continue to go up directly with the cost of energy. Moreover, material producers carry the responsibility to find less-energy dependent alternatives for widely used products as part of a global initiative to combat climate change.
[0016] The use of energy in the manufacture of gypsum wallboard has been estimated to be 1% or more of all industrial energy usage (in BTU's) in the US. With 40 to 50 billion square feet of wallboard used each year in the US, some 300 trillion BTU's may be consumed in the manufacture of same. And as such, more than 25 million tons of greenhouse gasses are released into the atmosphere through the burning of fossil fuels to support the heat intensive processes, thus harming the environment and contributing to global warming.
[0017] Prior art focuses on reducing the weight of gypsum board or increasing its strength, or making minor reductions in energy use. For example in U.S. Pat. No. 6,699,426, a method is described which uses additives in gypsum board to reduce the drying time and thus reduce energy usage at the drying stage. These attempts generally assume the use of calcined gypsum (either natural or synthetic), since gypsum wallboard manufacturers would find that redesigning the materials and mining procedures from scratch would potentially throw away billions of dollars of infrastructure and know-how, and render their gypsum mines worthless.
[0018] However, given concerns about climate change, it would be desirable to manufacture wallboard which requires dramatically less energy usage during manufacture including elimination of calcining, hot water, and drying steps common to gypsum wallboard manufacturing.
SUMMARY OF INVENTION
[0019] In accordance with the present invention, new methods of manufacturing novel wallboards (defined herein as “EcoRock™” wallboards), are provided. The resulting novel EcoRock wallboards can replace gypsum wallboard or water-resistant cement boards in most applications. Wallboards formulated in such a way significantly reduce the Embodied Energy associated with the wallboards, thus substantially reducing greenhouse gas emissions that harm the environment.
[0020] This invention will be fully understood in light of the following detailed description taken together with the drawings.
DRAWINGS
[0021] FIG. 1 shows certain standard gypsum drywall manufacturing steps, specifically those which consume substantial amounts of energy.
[0022] FIG. 2 shows the EcoRock manufacturing steps which as shown require little energy.
DETAILED DESCRIPTION
[0023] The following detailed description of embodiments of the invention is illustrative only and not limiting. Other embodiments will be obvious to those skilled in the art in view of this description. The example embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; but, on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. Various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention. The detailed descriptions below are designed to make such embodiments obvious to a person of ordinary skill in the art.
[0024] The novel processes as described herein for manufacturing wallboard eliminate the most energy intensive prior art processes in the manufacture of gypsum wallboard such as gypsum drying, calcining, and board drying. The new processes allow wallboard to be formed from non-calcined materials which are plentiful and safe and which can react naturally to form a strong board that is also fire resistant. Wallboard may be produced to meet both interior and exterior requirements. Other shapes may also be produced for use in constructing buildings or infrastructure using these same methods.
[0025] This new EcoRock wallboard contains a binder of a metal silicate (calcium silicate, magnesium silicate, zirconium silicate) or calcium aluminate and a solution of acid phosphate (phosphoric acid, sodium dihydrogen phosphate, monopotassium phosphate, potassium dihydrogen phosphate, tripotassium phosphate, triple super phosphate, calcium dihydrogen phosphate, or dipotassium phosphate). The powdered binder materials, often together with fillers, are mixed together at the start of the particular EcoRock manufacturing process or processes selected to be used to form the EcoRock wallboard or wallboards. Prior to the addition of liquids, such as water and phosphoric acid, this mix of binder component(s) and filler powders is called the “dry mix.”
[0026] U.S. Pat. No. 4,956,321 discusses the treatment of wollastonite (calcium silicate) with a low percentage solution of either sulfuric acid, acetic acid or carbonic acid to create a surface pacified wollastonite. The purpose of this is to make the wollastonite inert when the treated wollastinate is used in applications requiring an inert filler or thickener, and in no way is mentioned as a binding agent or in wallboard applications. Similarly, U.S. Pat. No. 3,642,511 which uses an acid and wollastonite mixture to achieve low density, passive, brighter pigments yet again is not intended as a binder or in wallboard applications.
[0027] U.S. Pat. No. 4,375,516 creates a formulation for making water resistant phosphate ceramics by use of a silicate, phosphoric acid and powder metal. While these are similar binder ingredients to those used in the EcoRock wallboard, a wallboard for use in building construction is not described nor contemplated. Nor does this patent describe any embodiment with properties that would be characteristic of wallboards (such as score and snap ability). The same is true for World Patent WO 97-19033 (controlling set times in resin compounds) and World Patent WO 00-024690 (improved patent of the aforementioned.) NOTE: The above-mentioned patent mixes cannot be applied over existing wallboards, and thus this example is simply showing prior art and the vast differences of EcoRock wallboard.
[0028] Lastly, in U.S. Pat. Nos. 6,342,284; 6,632,550; 6,815,049; 6,800,161; 6,822,033; United States Gypsum Company discusses wallboard mixes containing phosphoric acid. However, a metal silicate is not required and all claims require the addition of calcium sulfate (gypsum or synthetic gypsum,). Thus the energy consuming processing required of gypsum and synthetic gypsum are present in the production. The removal of gypsum and synthetic gypsum from wallboard slurries (and thus the removal of the embodied energy contained thereof) is a significant advantage of EcoRock wallboards. This advantage is not present in the gypsum-containing structures described in these patents.
[0029] Phosphoric acid is commonly used as a rust remover or plant nutrient at low percentage solutions. Calcium silicate, most commonly used as an antacid or anti-caking agent, is derived from naturally occurring limestone and diatomaceous rock (sedimentary rock). Calcium silicate could likely be used in a calcined or non-calcined state, however this has not been tested, since the purpose of this new wallboard is to reduce energy and thus use the non-calcined material. These ingredients may be combined in many different ratios to each other, resulting in various set times and strengths.
[0030] A process in accordance with this invention based on phosphoric acid (H 3 PO 4 ) will now be described. Calcium silicate (CaSiO 3 ) and phosphoric acid (H 3 PO 4 ) form a reaction product, namely calcium hydrogen phosphate hydrate (CaHPO 4 .H 2 O) and silica (SiO 2 ) that is formed by dissolution of CaSiO 3 in the solution of H 3 PO 4 and its eventual reaction to form a solidified product. This reaction product is referred to as “binder” hereinafter. Note that a binder does not include water.
[0031] While cement boards have been described in the prior art using both Portland cement and using, in part, calcined magnesia (such as in U.S. Pat. No. 4,003,752), these boards have several issues in comparison to standard gypsum wallboard including weight, processing and score/snap capability. These boards are not manufactured using an exothermic reaction with certain phosphates as used in this invention to create the binder.
[0032] In the processes of this invention, an exothermic reaction between the binder components naturally starts and heats the slurry. The reaction time can be controlled by many factors including total composition of slurry, percent (%) binder by weight in the slurry, the fillers in the slurry, the amount of water or other liquids in the slurry and the addition of a retarder such as boric acid to the slurry. Retarders slow down the reaction. Alternate retardants can include borax, sodium tripolyphosphate, sodium sulfonate, citric acid and many other commercial retardants common to the industry. FIG. 2 shows the simplicity of the process of this invention in that FIG. 2 shows two steps: namely mixing the slurry with unheated water and then forming the wallboards from the slurry. The wallboards can either be formed in molds or formed using a conveyor system of the type used to form gypsum wallboards and then cut to the desired size.
[0033] In the process of FIG. 2 , the slurry starts thickening quickly, the exothermic reaction proceeds to heat the slurry and eventually the slurry sets into a hard mass. Typically maximum temperatures of 40° C. to 90° C. have been observed depending on filler content and size of mix. The hardness can also be controlled by fillers, and can vary from extremely hard and strong to soft (but dry) and easy to break. Set time, strength required to remove the boards from molds or from a continuous slurry line, can be designed from twenty (20) seconds to days, depending on the additives or fillers. For instance boric acid can extend the set time from seconds to hours where powdered boric acid is added to the binder in a range of 0% (seconds) to 4% (hours). While a set time of twenty (20) seconds leads to extreme productivity, the slurry may begin to set too soon for high quality manufacturing, and thus the set time should be adjusted to a longer period of time typically by adding boric acid. The use of one and two tenths percent (1.2%) of boric acid gives approximately a four minute set time.
[0034] Many different configurations of materials are possible in accordance with this invention, resulting in improved strength, hardness, score/snap capability, paper adhesion, thermal resistance, weight and fire resistance. The binder is compatible with many different fillers including calcium carbonate (CaCO 3 ), cornstarch, wheat starch, tapioca starch, potato starch, ceramic microspheres, perlite, foam, fibers, fly ash, slag, waste products and other low-embodied energy materials. Uncalcined gypsum may also be used as a filler but is not required as part of the binder. By carefully choosing low-energy, plentiful, biodegradable materials as fillers, such as those listed above, the wallboard begins to take on the characteristics of gypsum wallboard. These characteristics (weight, structural strength so as to be able to be carried, the ability to be scored and then broken along the score line, the ability to resist fire, and the ability to be nailed or otherwise attached to other materials such as studs) are important to the marketplace and are required to make the product a commercial success as a gypsum wallboard replacement.
[0035] Calcium carbonate (CaCO 3 ) is plentiful and non-toxic. Cornstarch (made from corn endosperm), wheat starch (by-product of wheat gluten production), tapioca starch (extracted from tapioca plant roots), and potato starch (extracted from potato plant roots) are plentiful and non toxic. Ceramic microspheres are a waste product of coal-fired power plants, and can reduce the weight of materials as well as increase thermal and fire resistance of the wallboards that incorporate these materials. Fly ash is a waste product of coal-fired power plants which can be effectively reutilized here. Slag is a waste product produced in steel manufacturing which also can be used as filler in EcoRock wallboards. Biofibers (i.e. biodegradable plant-based fibers) are used for tensile and flexural strengthening in this embodiment; however other fibers, such as cellulose or glass, may also be used. The use of specialized fibers in cement boards is disclosed in U.S. Pat. No. 6,676,744 and is well known to those practicing the art.
EXAMPLE 1
[0036] In one embodiment of the present invention, a dry mix of powders is prepared by mixing calcium silicate, biofibers and boric acid. Then phosphoric acid diluted by water is added to the dry mix followed by the addition of foam resulting in the following materials by approximate weight in percentages:
[0000]
Phosphoric acid
17%
Water
19%
Calcium silicate
57%
Foam
5.0%
Biofibers
0.5%
Boric acid
1.5%
[0037] Phosphoric acid and calcium silicate together form a binder in the slurry and thus are present in the to-be-formed core of the EcoRock wallboard. Perlite and/or fly ash can be added to the slurry if desired in quantities up to approximately twenty percent (20%) by weight of the resulting product. Along with the foam, these materials form a filler in the slurry. The biofibers add flexural strength to the core when the slurry has hardened. Boric acid is a retardant used to slow the exothermic reaction and thus slow down the setting of the slurry.
[0038] The wet mix (the “Initial Slurry”) is mixed by the mixer in one embodiment from approximately five (5) seconds to five (5) minutes. Mixers of many varieties may be used, such as a pin mixer, provided the mix can be quickly removed from the mixer prior to hardening.
[0039] The foam is premixed separately with water (typically in a foam generator) in a concentration of 0.1% to 5% foamer agent (a soap or surfactant) by weight to the combination of foamer and water, depending on the desired elasticity. In one embodiment three-tenths of one percent (0.3%) foamer agent by weight of the resulting combination of water and roamer is used. The gypsum wallboard industry typically uses two-tenths of one percent (0.2%) roamer agent by weight. The resulting foam is added to the wet mix and as shown in paragraph [0036] above. In this example, the foam is five percent (5%) by weight of the total weight of the entire mix. The amount of foam depends on the desired density and strength of the hardened core, with 2%-15% foam by weight being optimal. Examples of foam used in gypsum wallboards include those described in U.S. Pat. No. 5,240,639, U.S. Pat. No. 5,158,612, U.S. Pat. No. 4,678,515, U.S. Pat. No. 4,618,380 and U.S. Pat. No. 4,156,615. The use of such agents is well known to those manufacturing gypsum wallboard.
[0040] The slurry may be poured onto a paper facing, which can be wrapped around the sides as in a standard gypsum process. Neither backing paper nor paper adhesives are required with this embodiment, but can be added if desired.
[0041] An exothermic reaction will begin almost immediately after removal from the mixer and continue for several hours, absorbing most of the water into the reaction. Boards can be cut and removed in less than thirty (30) minutes, depending on handling equipment available. All of the water has not yet been used in the reaction, and some absorption of the water will continue for many hours. Within twenty-four to forty-eight (24-48) hours, the majority of water has been absorbed, with some evaporation occurring as well. When paper facing is used, it is recommended that the boards be left to individually dry for 24 hours so as to reduce the possibility of mold forming on the paper. This can be accomplished on racks at room temperature with no heat required. Drying time will be faster at higher temperatures and slower at lower temperatures above freezing. Temperatures above 80° F. were tested but not considered since the design targets a low energy process. Residual drying will continue to increase at higher temperatures, however it is not beneficial to apply heat (above room temperature) due to the need of the exothermic reaction to utilize the water that would thus be evaporated too quickly. While the exothermic reaction will occur below freezing, the residual water will be frozen within the core until the temperature rises above freezing. It is presumed that ambient humidity levels will affect residual dry time as well, though this has not been investigated.
[0042] The resulting boards (the “Finished Product”) have strength characteristics similar to or greater than the strength characteristics of gypsum wallboards, and can be easily scored and snapped in the field. This binder creates the unique ability to lightly (or strongly) bond certain fillers (as compared to Portland cement, commonly used for cement boards). Cement boards (which are often used for tile backing and exterior applications) do not exhibit many of the appealing aspects of gypsum boards for internal use such as low weight, score and snap, and paper facing.
EXAMPLE 2
[0043] In another embodiment, the same amounts of dry powders as in Example 1 are mixed together in the same proportions, but the boric acid is left out. In this case, the reaction occurs much more rapidly such that the boards may be cut and removed in under 2 minutes
EXAMPLE 3
[0044] In another embodiment, the same proportions of materials as in Example 1 are mixed together, but the foam is substituted with flyash. This produces a board of increased strength and weight. This board utilizes recycled materials and thus may cater even more to national environmental building programs such as LEED, developed by the United States Green Building Council.
EXAMPLE 4
[0045] In another embodiment, a board is made for exterior use (may substitute for cement board or high density gypsum board) by increasing the phosphoric acid and removing the foam in the slurry and thus in the core of the to-be-formed wallboard. This gives to the resulting EcoRock wallboard additional strength and water resistance. In addition, in this embodiment, no paper facing or wrap is used because the wallboard will be exposed to the environment. The weight of this embodiment is as follows:
[0000]
Phosphoric Acid
19%
Water
19%
Calcium Silicate
55%
Perlite
5.0%
Biofibers
0.5%
Boric acid
1.5%
[0046] While the percentage binder by weight in the formulations of Examples 1 and 4 are both approximately seventy four percent (74%), the ratio of phosphoric acid to calcium silicate increases from Example 1 to Example 4. In addition it should be recognized that the percentage by weight of binder to the total weight of the resulting product can be varied from percentages as high as approximately ninety five percent (95%) down to as low as approximately fifty five percent (55%). Formulations with binders between approximately seventy percent (70%) and eighty five percent (85%), by weight of the total weight of the resulting product are preferred.
[0047] The processing of the slurry may occur using several different techniques depending on a number of factors such as quantity of boards required, manufacturing space and familiarity with the process by the current engineering staff. The normal gypsum slurry method using a conveyor system, which is a continuous long line that wraps the slurry in paper, is one acceptable method for fabricating most embodiments of the EcoRock wallboards of this invention. This process is well known to those skilled in manufacturing gypsum wallboard. Also the Hatscheck method, which is used in cement board manufacturing, is acceptable to manufacture the wallboards of this invention, specifically those that do not require paper facing or backing, and is well known to those skilled in the art of cement board manufacturing. Additional water is required to thin the slurry when the Hatscheck method is used because the manufacturing equipment used often requires a lower viscosity slurry. Alternatively as another manufacturing method, the slurry may be poured into pre-sized molds and allowed to set. Each board can then be removed from the mold, which can be reused.
[0048] Also, due to the inherent strength that can be achieved with a higher binder to filler ratio, other cementitious objects can be formed which can be used in construction or potentially other fields. These objects may not be in the form of panels but could be in the form of any cementitious objects normally made using Portland cement. Such objects can be poured and dry quickly, setting within a few minutes either in molds or on site.
[0049] Other embodiments of this invention will be obvious in view of the above disclosure.
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Wallboards, as well as cement boards, are produced by methods which use significantly reduced Embodied Energy when compared with the energy used to fabricate gypsum wallboard. A novel binder, consisting in one embodiment of phosphoric acid and calcium silicate, and combined with various fillers, is used to provide a controlled exothermic reaction to create a gypsum-board-like core which can be wrapped in a selected material such as recycled paper and manufactured on a conveyor system to appear and handle like gypsum wallboard, but without the large amounts of energy required to make gypsum wallboard. The resulting product may be used in interior or exterior applications and may possess fire resistance, sound ratings and other important properties of gypsum wallboard. As energy costs increase, the novel wallboards of this invention can become less expensive to manufacture than traditional wallboard. The manufacturing process results in much lower greenhouse gas emissions than the processes used to make gypsum wallboard.
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FIELD OF THE INVENTION
[0001] The invention generally relates to miRNA profiling for the diagnosis, prognosis, and management of melanoma and differentiation of melanoma from nevi.
BACKGROUND OF THE INVENTION
[0002] The following discussion of the background of the invention is merely provided to aid the reader in understanding the invention and is not admitted to describe or constitute prior art to the present invention.
[0003] Skin cancer is the most common of all cancers, afflicting more than a million Americans each year, a number that is rising rapidly. It is also the easiest to cure, if diagnosed and treated early. If allowed to progress to the point where it spreads to other sites (metastasizes), the prognosis (forecast) is very poor. More than 8,000 melanoma deaths now occur per year.
[0004] Melanoma most often appears as an asymmetrical, irregularly bordered, multicolored or tan/brown spot or growth that continues to increase in size over time. It may begin as a flat spot and become more elevated. In rare instances, it may not be pigmented.
[0005] Dysplastic nevi (atypical moles) are unusual or benign moles that may resemble melanoma. People who have them are at increased risk of developing single or multiple melanomas. The higher the number of these moles someone has, the higher the risk; those who have 10 or more have 12 times the risk of developing melanoma compared to the general population. Dysplastic nevi are found significantly more often in melanoma patients than in the general population.
[0006] Melanoma is distinguished from nevi, other forms of cancer, and normal skin on the basis of clinical presentation and histopathological examination of a skin biopsy, usually a formalin fixed, paraffin embedded (FFPE) sample. Considerable expertise is required to reliably distinguish between nevi and melanoma.
[0007] This application describes novel microRNA biomarkers with microRNA array and RT-PCR to better characterize dysplastic nevi, malignant melanoma and metastatic melanoma. miRNA can therefore serve as an adjunct to histopathology for correct classification of melanoma. nevi and other conditions, especially where there is doubt as to the diagnosis.
SUMMARY OF THE INVENTION
[0008] The present invention is based on the discovery that melanoma can be distinguished from nevi by measuring changes in the levels of as little as two miRNAs.
[0009] In one aspect, the invention provides a method for differentially diagnosing melanoma from nevi, by (a) measuring the level of two or more miRNAs selected from the group consisting of: miR-132, miR-150, miR-339-5p, miR-15b, miR-342-3p, miR-572, miR-155, miR-425, miR-1202, miR-1268, HBII-382_s, miR-1225-5p, miR-30c, miR-106b-star, miR-125a-5p, mgU6-53B, miR-25, miR-149-star, miR-939, miR-92b-star, miR-500-star, miR-22, HBII-142_x, miR-181b, HBII-142, U38B, miR-663, miR-1224-5p, miR-23a, HBII-85-6_x, miR-1207-5p, miR-1301, miR-1228-star, miR-345, miR-30a-star, ENSG00000199411, ENSG00000202327, miR-92a, miR-127-3p, HBII-85-26, miR-1308, miR-31, miR-921, miR-146b-5p, miR-768-3p, miR-708, miR-139-5p, ACA24_x, miR-501-3p, miR-502-3p, miR-923, and miR-191; and (b) diagnosing the skin sample as containing melanoma when a difference in the level of the two or more miRNAs compared to a reference level indicates melanoma in the sample. The level of two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, thirteen, fourteen, or more, miRNAs are measured.
[0010] In specific embodiments, the miRNAs to be measured include the following combinations (i) miR-150 and miR-149-star; (ii) miR-150, miR-149-star and miR-1308; (iii) miR-150, miR-149-star, miR-1308, and miR-191; (iv) miR-150, miR-149-star, miR-1308, miR-191, and miR-1228-star; (v) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, and ENSG00000199411; (vi) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, and miR-1268; (vii) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, miR-1268, and miR-923; (viii) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, miR-1268, miR-923, and miR-23a; (ix) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, miR-1268, miR-923, miR-23a, and miR-132; (x) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, miR-1268, miR-923, miR-23a, miR-132, and miR-1207.5p; (xi) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, miR-1268, miR-923, miR-23a, miR-132, miR-1207.5p, and miR-342.3p; (xii) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, miR-1268, miR-923, miR-23a, miR-132, miR-1207.5p, miR-342.3p, and U38B; (xiii) miR-150, miR-149-star, miR-1308, miR-191, miR-1228-star, ENSG00000199411, miR-1268, miR-923, miR-23a, miR-132, miR-1207.5p, miR-342.3p, U38B, and miR-155.
[0011] In specific embodiments, melanoma is diagnosed in the skin sample by alterations in the level of an miRNA compared to a reference level, with the following alterations observed in at least two miRNA selected from the group consisting of: (i) miR-150 increase; (ii) miR-149-star decrease; (iii) miR-1308 decrease; (iv) miR-191 increase; (v) miR-1228-star decrease; (vi) ENSG00000199411_s decrease; (vii) miR-1268 decrease; (viii) miR-923 decrease; (ix) miR-23a increase; (x) miR-132 increase; (xi) miR-1207.5p decrease; (xii) miR-342.3p increase; (xiii) 1U38B decrease; and (xiv) miR-155 increase.
[0012] In one aspect, the invention provides a method for differentially diagnosing melanoma from nevi, by (a) measuring the level of two or more miRNAs selected from the group consisting of: miR-1268, miR-1228-star, miR-92b-star, miR-155, miR-345, miR-425, miR-132, miR-1207-5p, miR-1301, miR-663, miR-339-5p, miR-149-star, miR-150, miR-18a, miR-103, miR-191, miR-296-3p, miR-31, miR-107*, miR-93*, miR-1275*, miR-181B*, miR-921*, miR-1225-5p, miR-1202, and miR-342-3p and (b) diagnosing the skin sample as containing melanoma when a difference in the level of the two or more miRNAs compared to a reference level indicates melanoma in the sample.
[0013] In specific embodiments, melanoma is diagnosed in the skin sample by alterations in the level of an miRNA compared to a reference level, with the following alterations observed in at least two miRNA selected from the group consisting of: miR-1268 decrease, miR-1228-star decrease, miR-92b-star decrease, miR-155 increase, miR-345 increase, miR-425 increase, miR-132 increase, miR-1207-5p decrease, miR-1301 increase, miR-663 decrease, miR-339-5p increase, miR-149-star decrease, miR-150 increase, miR-18a increase, miR-103 increase, miR-191 increase, miR-296-3p decrease, miR-31 increase, miR-107* increase, miR-93* increase, miR-1275* decrease, miR-181B* increase, miR-921* decrease, miR-1225-5p increase, miR-1202 decrease, and miR-342-3p increase.
[0014] The method of the invention may further include internal controls, such as measuring the level of an miRNA selected from miR-27b, miR-195, miR-199b-3p, and miR-199a-3p.
[0015] In yet further embodiments, the level of two or more miRNAs are used to distinguish melanoma from normal skin, and nevi from normal skin. Additional miRNA levels may be assayed for this purpose.
[0016] The level of miRNA in the sample can be determined by microarray and/or quantitative real-time PCR. The method of the invention may be performed on a fresh skin sample, on a fixed and/or paraffin-embedded sample. In one embodiment the skin sample is formalin-fixed and paraffin-embedded.
[0017] The method of the invention may further comprise other steps in the diagnosis of melanoma, and the differentiation between nevi and melanoma, including histopathological assessment, and clinical assessment. In related embodiments, the clinical and/or histopathological evaluations may be converted into a score that can be combined with a score derived from miRNA levels, resulting in a diagnostic score that reflects the likelihood of melanoma.
[0018] The method of the invention may further include a step of isolating nucleic acids from the sample. An additional step may include amplification of the nucleic acid.
[0019] In further embodiments, the invention comprise a kit. In one embodiment, a kit for differentially diagnosing between melanoma and nevus in a skin sample comprises primers for the amplification of at least two miRNA selected from the group consisting of: miR-150, miR-149-star, miR-1308; miR-191.; miR-1228-star; ENSG00000199411_s; miR-1268; miR-923; miR-23a; miR-132; miR-1207.5p; miR-342.3p; U38B; and miR-155.
[0020] In another embodiment, the kit comprises primers for the amplification of at least two miRNAs selected from the group consisting of: miR-1268, miR-1228-star, miR-92b-star, miR-155, miR-345, miR-425, miR-132, miR-1207-5p, miR-1301, miR-663, miR-339-5p, miR-149-star, miR-150, miR-18a, miR-103, miR-191, miR-296-3p, miR-31, miR-107*, miR-93*, miR-1275*, miR-181B*, miR-921*, miR-1225-5p, miR-1202, and miR-342-3p.
[0021] The kit may also primers for amplification of controls, such as miR-27b, miR-195, miR-199b-3p, and miR-199a-3p.
[0022] The kit may also include suitable buffers, reagents for isolating nucleic acid, and instructions for use Kits may also include a microarray for measuring miRNA levels.
BRIEF DESCRIPTION OF THE FIGURE
[0023] FIGS. 1-10 show, respectively, the best 2-10 miRNA combinations for differentiating melanoma (MM) from normal skin (NS), and the relevant error rates and AUC, as determined by different statistical algorithms.
[0024] FIGS. 11-23 show, respectively, the best 2-14 miRNA combinations for differentiating melanoma (MM) from nevi (NV), and the relevant error rates and AUC, as determined by different statistical algorithms.
[0025] FIG. 24 shows the log 2 signal for three miRNA; miR-150 (miR-150), miR-149-star (miR-149-star), and hsa-miR-1308 (miR-1308) across 137 samples. Samples 1-19 are normal skin (NS), 20-57 nevi (NV), 58-115 melanoma (MM) and 116-137 metastatic melanoma (Mets). As can be appreciated, miR-150, miR-149-star and miR-1308 distinguish normal skin and nevi from melanoma and metastatic.
[0026] FIG. 25 shows an example of error rate and AUC from 9 programs analyzing the ability of groups of miRNA analytes to differentiate between melanoma and nevi.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present inventors have discovered that the levels of miRNAs in skin samples is a powerful tool to differentiate melanoma from non-tumorous nevi and, thereby, replace or supplement traditional clinical and histological methods of diagnosis.
DEFINITIONS
[0028] The present technology is described herein using several definitions, as set forth throughout the specification. As used herein, unless otherwise stated, the singular forms “a,” “an,” and “the” include plural reference. Thus, for example, a reference to “a nucleic acid” is a reference to one or more nucleic acids.
[0029] As used herein, “about” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, the term “about” in reference to quantitative measurements or values will mean up to plus or minus 10% of the enumerated value.
[0030] The term “amplification” or “amplify” as used herein means one or more methods known in the art for copying a target nucleic acid, thereby increasing the number of copies of a selected nucleic acid sequence. Amplification may be exponential or linear. A target nucleic acid may be either DNA or RNA. The sequences amplified in this manner form an “amplicon.” While the exemplary methods described hereinafter relate to amplification using the polymerase chain reaction (“PCR”), numerous other methods are known in the art for amplification of nucleic acids (e.g., isothermal methods, rolling circle methods, etc.). The skilled artisan will understand that these other methods may be used either in place of, or together with, PCR methods. See, e.g., Saiki, “Amplification of Genomic DNA” in PCR Protocols , Innis et al., Eds., Academic Press. San Diego, Calif. 1990, pp. 13-20; Wharam et al., Nucleic Acids Res., 2001, 29(11):E54-E54; Hafner et al., Biotechniques 2001, 30(4):852-6, 858, 860; Zhong et al., Biotechniques, 2001, 30(4):852-6, 858, 860.
[0031] The terms “determining,” “measuring,” “assessing,” and “assaying” are used interchangeably and include both quantitative and qualitative measurement, and include determining if a characteristic, trait, or feature is present or not. Assessing may be relative or absolute. “Assessing the presence of” includes determining the amount of something present, as well as determining whether it is present or absent.
[0032] The term “clinical factors” as used herein, refers to any data that a medical practitioner may consider in determining a diagnosis of melanoma. Such factors include, but are not limited to, the patient's medical history, age, gender, skin color, a physical examination of the patient, and histopathology.
[0033] The term “complement” as used herein means the complementary sequence to a nucleic acid according to standard Watson/Crick base pairing rules. A complement sequence can also be a sequence of RNA complementary to the DNA sequence or its complement sequence, and can also be a cDNA. The term “substantially complementary” as used herein means that two sequences hybridize under stringent hybridization conditions. The skilled artisan will understand that substantially complementary sequences need not hybridize along their entire length. In particular, substantially complementary sequences comprise a contiguous sequence of bases that do not hybridize to a target or marker sequence, positioned 3′ or 5′ to a contiguous sequence of bases that hybridize under stringent hybridization conditions to a target or marker sequence.
[0034] As used herein, the term “diagnosis” means detecting melanoma or the presence of melanoma cells. Usually, a diagnosis of a disease or disorder is based on the evaluation of one or more factors and/or symptoms that are indicative of the disease. That is, a diagnosis can be made based on the presence, absence or amount of a factor which is indicative of presence or absence of the disease or condition. Each factor or symptom that is considered to be indicative for the diagnosis of a particular disease does not need be exclusively related to the particular disease; i.e. there may be differential diagnoses that can be inferred from a diagnostic factor or symptom. Likewise, there may be instances where a factor or symptom that is indicative of a particular disease is present in an individual that does not have the particular disease. The term “diagnosis” also encompasses determining the therapeutic effect of a drug therapy, or predicting the pattern of response to a drug therapy. The diagnostic methods may be used independently, or in combination with other diagnosing and/or staging methods known in the medical art for a particular disease or disorder, particularly melanoma.
[0035] As used herein, the phrase “difference of the level” refers to differences in the quantity of a particular marker, such as a nucleic acid or a protein, in a sample as compared to a control or reference level. For example, the quantity of a particular biomarker may be present at an elevated amount or at a decreased amount in samples of patients with a neoplastic disease compared to a reference level. In one embodiment, a “difference of a level” may be a difference between the quantity of a particular biomarker present in a sample as compared to a control of at least about 1%, at least about 2%, at least about 3%, at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 50%, at least about 60%, at least about 75%, at least about 80% or more. In one embodiment, a “difference of a level” may be a statistically significant difference between the quantity of a biomarker present in a sample as compared to a control. For example, a difference may be statistically significant if the measured level of the biomarker falls outside of about 1.0 standard deviations, about 1.5 standard deviations, about 2.0 standard deviations, or about 2.5 stand deviations of the mean of any control or reference group.
[0036] By “isolated”, when referring to a nucleic acid (e.g., an oligonucleotide such as RNA, DNA, or a mixed polymer) is meant a nucleic acid that is apart from a substantial portion of the genome in which it naturally occurs and/or is substantially separated from other cellular components which naturally accompany such nucleic acid. For example, any nucleic acid that has been produced synthetically (e.g., by serial base condensation) is considered to be isolated. Likewise, nucleic acids that are recombinantly expressed, cloned, produced by a primer extension reaction (e.g., PCR), or otherwise excised from a genome are also considered to be isolated. In some embodiments, the nucleic acid is isolated from the skin sample before further processing, such as PCR.
[0037] The term “label” as used herein, refers to any physical molecule directly or indirectly associated with a specific binding agent or antigen which provides a means for detection for that antibody or antigen. A “detectable label” as used herein refers any moiety used to achieve signal to measure the amount of complex formation between a target and a binding agent. These labels are detectable by spectroscopic, photochemical, biochemical, immunochemical, electromagnetic, radiochemical, or chemical means, such as fluorescence, chemifluoresence, or chemiluminescence, electrochemiluminescence or any other appropriate means. Suitable detectable labels include fluorescent dye molecules or fluorophores.
[0038] As used herein interchangeably, a “microRNA,” “miR,” or “miRNA” refers to the unprocessed or processed RNA transcript from a miRNA gene. MicroRNAs (miRNAs) are non-coding RNAs of 19-25 nucleotides in length that regulate gene expression by inducing translational inhibition or cleavage of their target mRNA through base pairing to partially or fully complementary sites. The unprocessed miRNA gene transcript is also called a “miRNA precursor,” and typically comprises an RNA transcript of about 70-100 nucleotides in length. The miRNA precursor can be processed by digestion with an RNAse (for example, Dicer. Argonaut, or RNAse 111) into an active 19-25 nucleotide RNA molecule. This active 19-25 nucleotide RNA molecule is also called the “processed” miRNA gene transcript or “mature” miRNA
[0039] As used herein, “nucleic acid” refers broadly to segments of a chromosome, segments or portions of DNA, cDNA, and/or RNA. Nucleic acid may be derived or obtained from an originally isolated nucleic acid sample from any source (e.g., isolated from, purified from, amplified from, cloned from, or reverse transcribed from sample DNA or RNA).
[0040] As used herein, the term “oligonucleotide” refers to a short polymer composed of deoxyribonucleotides, ribonucleotides or any combination thereof. Oligonucleotides are generally between about 10 and about 100 nucleotides in length. Oligonucleotides are typically 15 to 70 nucleotides long, with 20 to 26 nucleotides being the most common. An oligonucleotide may be used as a primer or as a probe. An oligonucleotide is “specific” for a nucleic acid if the oligonucleotide has at least 50% sequence identity with a portion of the nucleic acid when the oligonucleotide and the nucleic acid are aligned. An oligonucleotide that is specific for a nucleic acid is one that, under the appropriate hybridization or washing conditions, is capable of hybridizing to the target of interest and not substantially hybridizing to nucleic acids which are not of interest. Higher levels of sequence identity are preferred and include at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% sequence identity.
[0041] As used herein, a “primer” for amplification is an oligonucleotide that specifically anneals to a target or marker nucleotide sequence. The 3′ nucleotide of the primer should be identical to the target or marker sequence at a corresponding nucleotide position for optimal primer extension by a polymerase. As used herein, a “forward primer” is a primer that anneals to the anti-sense strand of double stranded DNA (dsDNA). A “reverse primer” anneals to the sense-strand of dsDNA.
[0042] As used herein, the term “reference level” refers to a level of a substance which may be of interest for comparative purposes. In one embodiment, a reference level may be the miRNA levels expressed as an average of the level of miRNA from an area of normal skin or skin containing nevi and not melanoma. Nucleic acid samples may also be normalized relative to an internal control nucleic acid.
[0043] As used herein, the term “sample” refers to a skin biopsy from the subject, such at would typically be used for histopathological examination, or any section derived from such a sample. That is, a suspected melanoma may be entirely excised from the skin, but the biopsy is fixed and embedded in paraffin, and sectioned for further examination.
[0044] As used herein, the term “subject” refers to a mammal, such as a human, but can also be another animal such as a domestic animal (e.g., a dog, cat, or the like), a farm animal (e.g., a cow, a sheep, a pig, a horse, or the like) or a laboratory animal (e.g., a monkey, a rat, a mouse, a rabbit, a guinea pig, or the like). The term “patient” refers to a subject who is, or is suspected to be, afflicted with melanoma.
[0045] The phrase “substantially the same as” in reference to a comparison of one value to another value for the purposes of clinical management of a disease or disorder means that the values are statistically not different. Differences between the values can vary, for example, one value may be within 20%, within 10%, or within 5% of the other value.
[0046] As used herein, the term “diagnostic score” refers to a single number or score, based on a statistical analysis of the measured level of one or more biomarkers that reflects a relationship of a specific subject to any one particular group of individuals, such as normal individuals or individuals having a disease or any progressive state thereof. In some embodiments, the diagnostic score is derived from a quantitative multivariate analysis, which reflects the overall statistical assessment of an individual patient's clinical condition based upon an integrated statistical calculation of a plurality of qualitatively unique factors, e.g., levels of diagnostic miRNA, combined with clinical presentation, etc.
Melanoma and Nevi
[0047] Nevus (or naevus, plural nevi or naevi, from navus, Latin for “birthmark”) is the medical term for sharply-circumscribed and chronic lesions of the skin. These lesions are commonly named birthmarks and moles. Nevi are benign by definition.
[0048] A melanocytic nevus (nevomelanocytic nevus, nevocellular nevus) is a benign proliferation of melanocytes, and are very common; almost all adults have at least one, usually more. A melanocytic nevus may be congenital or acquired.
[0049] A dysplastic nevus usually an acquired melanocytic nevus with abnormal features making it difficult to distinguish from a melanoma. It can be a marker for an individual at risk for developing melanomas.
[0050] Melanoma is a malignant tumor of melanocytes. Melanocytes predominantly occur in skin, between the outer layer of the skin (the epidermis) and the next layer (the dermis), but are also found in other parts of the body, including the bowel and the eye (see uveal melanoma). Melanoma can occur in any part of the body that contains melanocytes. Melanoma is less common than other skin cancers but is much more dangerous and causes the majority (75%) of deaths related to skin cancer
[0051] Melanoma arises from DNA damage to melanocytcs. The early stage of the disease is called the radial growth phase, and the tumour is less than 1 mm thick. Next is the invasive radial growth phase, when individual cells start to acquire invasive potential. The Breslow's depth of the lesion is usually less than 1 mm (0.04 in), the Clark level is usually 2. The following step is invasive melanoma, “vertical growth phase” (VGP). The tumour attains invasive potential, growing into the surrounding tissue and can spread around the body through blood or lymph vessels to form metastases. The tumour thickness is usually more than 1 mm (0.04 in), and the tumour involves the deeper parts of the dermis.
[0052] An immunological reaction against the tumour during the VGP may be judged by the presence and activity of the tumour infiltrating lymphocytes (TILs). These cells sometimes completely destroy the primary tumour, this is called regression, which is the latest stage of the melanoma development. In certain cases, the primary tumour is completely destroyed and only the metastatic tumour is discovered.
[0053] Melanoma may also have a genetic predisposition. Mutations in CDKN2A, CDK4, MC1R, MDM2 SNP309 and those associated with xeroderma pigmentosum (XP) predispose one to melanoma. Familial melanoma is genetically heterogeneous,[10] and loci for familial melanoma have been identified on the chromosome arms 1p, 9p and 12q. Multiple genetic events have been related to the pathogenesis (disease development) of melanoma.
Clinical and Pathological Diagnosis
[0054] Melanoma is usually first detected by visual examination of the skin, notably (A) asymmetry, (B) a border that is uneven, ragged, or notched, (C) coloring of different shades of brown, black, or tan and (D) diameter that had changed in size. Normal moles are symmetrical, have an even border, even color, and no change in diameter. The main concern is distinguishing between a benign nevus, a dysplastic nevus, and a melanoma. Moles that are irregular in color or shape are often treated as candidates of melanoma. Following a visual examination and a dermatoscopic exam, or in vivo diagnostic tools such as a confocal microscope, a sample (biopsy) of the suspicious mole may be obtained.
Sample Preparation
[0055] When an atypical mole has been identified, a skin biopsy takes place in order to best diagnose it. Local anesthetic is used to numb the area, then the mole is biopsied. The biopsy material is then sent to a laboratory to be evaluated by a pathologist. A skin biopsy can be a punch, shave, or complete excision. The complete excision is the preferred method, but a punch biopsy can suffice if the patient has cosmetic concerns (i.e. the patient does not want a scar) and the lesion is small. A scoop or deep shave biopsy is often advocated, but should be avoided due to risk of a recurrent nevus, which can complicate future diagnosis of a melanoma, and the possibility that resulting scar tissue can obscure tumor depth if a melanoma is found to be present and re-excised.
[0056] Most dermatologists and dermatopathologists use a system devised by the NIH for classifying melanocytic lesions. In this classification, a nevus can be defined as benign, having atypia, or being a melanoma. A benign nevus is read as (or understood as) having no cytologic or architectural atypia. An atypical mole is read as having architectural atypia, and having (mild, moderate, or severe) cytologic (melanocytic) atypia. Usually, cytologic atypia is of more important clinical concern than architectural atypia. Usually, moderate to severe cytologic atypia will require further excision to make sure that the surgical margin is completely clear of the lesion.
[0057] The most important aspect of the biopsy report is that the pathologist indicates if the margin is clear (negative or free of melanocytic nevus), or if further tissue (a second surgery) is required. If this is not mentioned, usually a dermatologist or clinician will require further surgery if moderate to severe cytologic atypia is present—and if residual nevus is present at the surgical margin.
[0000] miRNA Markers to Distinguish Nevi from Melanoma
[0058] Distinguishing nevi from melanoma requires a high degree of skill. Misdiagnosis of a melanoma as a nevus can result in delay in treatment, which can be lethal because melanoma is an aggressive cancer that requires prompt intervention. Conversely, incorrectly identifying a nevus as a melanoma may subject a patient to aggressive treatment that is unnecessary and harmful. The present inventors have established that melanoma may be distinguished from nevi by monitoring the levels of select miRNA.
[0059] The methods described herein can distinguish melanoma, normal skin, nevi and malignant melanoma. Most importantly, the method is suitable for differentiating nevi from melanoma, and therefore fill a need for diagnosis that it not fully met by histology. As such, the methods of the invention can replace, supplement, or confirm histology. A particular advantage of the methods of the invention is that they provide independent objective evidence.
[0060] An additional advantage of the invention is that they can be performed on formalin fixed paraffin embedded (FFPE) tissue, and therefore can be used on the same samples that are processed for standard histopathological examination, and thus do not require a separate sample, or special handling. Another advantage is that the inventors have found that the miRNAs are stable in FFPE tissue and can be detected some time after fixing and embedding.
[0061] Another advantage of the invention is that the mRNA's chosen do not require a relatively pure sample of melanoma cells, and can detect melanoma in a sample that also contains normal skin, nevi and other skin cells. Thus, the miRNA assay is not overly sensitive to contamination nor require special handling beyond that which is normally used for preparation of FFPE tissue for regular histology.
[0062] The inventors have identified 50 miRNAs that can readily distinguish melanoma from nevi. Through statistical modeling and analysis, groups of the best 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 and 14 markers have been identified. An increase in the number of markers used may improve sensitivity and accuracy, but comes with increased cost and complexity.
[0063] Additional diagnostic markers may be combined with the miRNA measurements to further aid diagnosis. For example, the clinical and/or histopathological results can be converted into a score, which is then combined with a score derived from the miRNA data. The combination of scores can be used to obtain a single “diagnostic score” that reflects the likelihood of melanoma.
Nucleic Acid Extraction and Detection
[0064] The level of a miRNA gene product in a sample can be measured using any technique that is suitable for detecting RNA expression levels in a biological sample. Suitable techniques for determining RNA expression levels in a biological sample are well known to those of skill in the art. These include, for example, Northern blot analysis. RT-PCR, and in situ hybridization.
[0065] The nucleic acid to be detected may be from a biological sample such as a tissue sample and the like. Various methods of extraction are suitable for isolating the DNA or RNA. Suitable methods include phenol and chloroform extraction. See Maniatis et al., Molecular Cloning, A Laboratory Manual, 2d, Cold Spring Harbor Laboratory Press, pp. 16-54 (1989). Numerous commercial kits also yield suitable DNA and RNA including, but not limited to, QIAamp™ mini blood kit, Agencourt Genfind™, Roche Cobas® Roche MagNA Pure® or phenol:chloroform extraction using Eppendorf Phase Lock Gels®, and the NucliSens extraction kit (Biomerieux, Marcy l'Etoile, France). In an illustrative embodiment, RNA is isolated from patient serum on the NucliSens easyMAG system (Biomeriux SA, France) according to the manufacturer's protocol.
[0066] In one embodiment, the level of at least one miRNA gene product is detected using Northern blot analysis. For example, total RNA can be purified from a sample in the presence of nucleic acid extraction buffer, followed by centrifugation. Nucleic acids are precipitated, and DNA is removed by treatment with DNase and precipitation. The RNA molecules are then separated by gel electrophoresis on agarose gels according to standard techniques, and transferred to nitrocellulose filters. The RNA is then immobilized on the filters by heating. Detection and quantification of specific RNA is accomplished using appropriately labeled DNA or RNA probes complementary to the RNA in question. See, for example, Molecular Cloning: A Laboratory Manual , J. Sambrook et al., eds., 2nd edition, Cold Spring Harbor Laboratory Press, 1989, Chapter 7.
[0067] Suitable probes (e.g., DNA probes or RNA probes) for Northern blot hybridization of a given miRNA gene product can be produced from the known nucleic acid sequences and include, but are not limited to, probes having at least about 70%, 75%, 80%, 85%, 90%, 95%, 98% or 99% complementarity to a miRNA gene product of interest, as well as probes that have complete complementarity to a miRNA gene product of interest. Methods for preparation of labeled DNA and RNA probes, and the conditions for hybridization thereof to target nucleotide sequences, are described in Molecular Cloning: A Laboratory Manual , J. Sambrook et al., eds., 2nd edition. Cold Spring Harbor Laboratory Press, 1989, Chapters 10 and 11.
[0068] For example, the nucleic acid probe can be labeled with, e.g., a radionuclide, such as 3 H, 32 P, 33 P, 14 C, or 35 S; a heavy metal; a ligand capable of functioning as a specific binding pair member for a labeled ligand (e.g., biotin, avidin or an antibody); a fluorescent molecule; a chemiluminescent molecule; an enzyme or the like. Probes can be labeled to high specific activity by either the nick translation method or by the random priming method. Autoradiographic detection of hybridization can then be performed by exposing hybridized filters to photographic film. Densitometric scanning of the photographic films exposed by the hybridized filters provides an accurate measurement of miRNA levels. Using another approach, miRNA gene transcript levels can be quantified by computerized imaging systems.
[0069] In one embodiment, the miRNA is detected using a nucleic acid amplification process. Nucleic acid extracted from a sample can be amplified using nucleic acid amplification techniques well known in the art. By way of example, but not by way of limitation, these techniques can include the polymerase chain reaction (PCR), reverse transcriptase polymerase chain reaction (RT-PCR), nested PCR, ligase chain reaction. See Abravaya, K., et al., Nucleic Acids Research, 23:675-682, (1995), branched DNA signal amplification, Urdea, M. S., et al., AIDS, 7 (suppl 2):S11-S14, (1993), amplifiable RNA reporters, Q-beta replication, transcription-based amplification, boomerang DNA amplification, strand displacement activation, cycling probe technology, isothermal nucleic acid sequence based amplification (NASBA). See Kievits, T. et al., J Virological Methods, 35:273-286, (1991), Invader Technology, or other sequence replication assays or signal amplification assays may also be used.
[0070] Some methods employ reverse transcription of RNA to cDNA. The method of reverse transcription and amplification may be performed by previously published or recommended procedures. Various reverse transcriptases may be used, including, but not limited to, MMLV RT, RNase H mutants of MMLV RT such as Superscript and Superscript II (Life Technologies, GIBCO BRL, Gaithersburg, Md.), AMV RT, and thermostable reverse transcriptase from Thermus thermophilus . For example, one method which may be used to convert RNA to cDNA is the protocol adapted from the Superscript II Preamplification system (Life Technologies, GIBCO BRL, Gaithersburg, Md.; catalog no. 18089-011), as described by Rashtchian, A., PCR Methods Applic., 4:S83-S91, (1994).
[0071] In a suitable embodiment. PCR is used to amplify a target sequence of interest. PCR is a technique for making many copies of a specific template DNA sequence. The reaction consists of multiple amplification cycles and is initiated using a pair of primer sequences that hybridize to the 5′ and 3′ ends of the sequence to be copied. The amplification cycle includes an initial denaturation, and typically up to 50 cycles of annealing, strand elongation and strand separation (denaturation). In each cycle of the reaction, the DNA sequence between the primers is copied. Primers can bind to the copied DNA as well as the original template sequence, so the total number of copies increases exponentially with time. PCR can be performed as according to Whelan et al., J of Clin Micro, 33(3):556-561 (1995). Briefly, a PCR reaction mixture includes two specific primers, dNTPs, approximately 0.25 U of Taq polymerase, and 1×PCR Buffer.
[0072] The skilled artisan is capable of designing and preparing primers that are appropriate for amplifying a target or marker sequence. The length of the amplification primers depends on several factors including the nucleotide sequence identity and the temperature at which these nucleic acids are hybridized or used during in vitro nucleic acid amplification. The considerations necessary to determine a preferred length for an amplification primer of a particular sequence identity are well-known to a person of ordinary skill. For example, the length of a short nucleic acid or oligonucleotide can relate to its hybridization specificity or selectivity.
[0073] In some embodiments, the amplification may include a labeled primer or probe, thereby allowing detection of the amplification products corresponding to that primer or probe. In particular embodiments, the amplification may include a multiplicity of labeled primers or probes; such primers may be distinguishably labeled, allowing the simultaneous detection of multiple amplification products. Oligonucleotide probes can be designed which are between about 10 and about 100 nucleotides in length and hybridize to the amplified region. Oligonucleotides probes are preferably 12 to 70 nucleotides; more preferably 15-60 nucleotides in length; and most preferably 15-25 nucleotides in length. The probe may be labeled.
[0074] In one embodiment, a primer or probe is labeled with a fluorogenic reporter dye that emits a detectable signal. While a suitable reporter dye is a fluorescent dye, any reporter dye that can be attached to a detection reagent such as an oligonucleotide probe or primer is suitable for use in the invention. Such dyes include, but are not limited to, Acridine, AMCA, BODIPY, Cascade Blue, Cy2, Cy3, Cy5, Cy7, Edans, Eosin, Erythrosin, Fluorescein, 6-Fam, Tet, Joc, Hex, Oregon Green, Rhodamine, Rhodol Green, Tamra. Rox, and Texas Red.
[0075] In yet another embodiment, the detection reagent may be further labeled with a quencher dye such as Tamra, Dabcyl, or Black Hole Quencher® (BHQ), especially when the reagent is used as a self-quenching probe such as a TaqMan® (U.S. Pat. Nos. 5,210,015 and 5,538,848) or Molecular Beacon probe (U.S. Pat. Nos. 5,118,801 and 5,312,728), or other stemless or linear beacon probe (Livak et al., 1995 , PCR Method Appl., 4:357-362; Tyagi et al, 1996 , Nature Biotechnology, 14:303-308; Nazarenko et al., 1997 , Nucl. Acids Res., 25:2516-2521; U.S. Pat. Nos. 5,866,336 and 6,117,635).
[0076] Nucleic acids may be amplified prior to detection or may be detected directly during an amplification step (i.e., “real-time” methods). For example, amplified fragments may be detected using standard gel electrophoresis methods. In some embodiments, amplified fractions are separated on an agarose gel and stained with ethidium bromide by methods known in the art to detect amplified fragments. In some embodiments, the target sequence is amplified using a labeled primer such that the resulting amplicon is detectably labeled. In some embodiments, the primer is fluorescently labeled.
[0077] In one embodiment, detection of a miRNA, such as a nucleic acid from an a miR-16 or miR-199a, is performed using the TaqMan® assay, which is also known as the 5′ nuclease assay (U.S. Pat. Nos. 5,210,015 and 5,538,848). The TaqMan® assay detects the accumulation of a specific amplified product during PCR. The TaqMan® assay utilizes an oligonucleotide probe labeled with a fluorescent reporter dye and a quencher dye. The reporter dye is excited by irradiation at an appropriate wavelength, it transfers energy to the quencher dye in the same probe via a process called fluorescence resonance energy transfer (FRET). When attached to the probe, the excited reporter dye does not emit a signal. The proximity of the quencher dye to the reporter dye in the intact probe maintains a reduced fluorescence for the reporter. The reporter dye and quencher dye may be at the 5′ most and the 3′ most ends, respectively or vice versa. Alternatively, the reporter dye may be at the 5′ or 3′ most end while the quencher dye is attached to an internal nucleotide, or vice versa. In yet another embodiment, both the reporter and the quencher may be attached to internal nucleotides at a distance from each other such that fluorescence of the reporter is reduced.
[0078] During PCR, the 5′ nuclease activity of DNA polymerase cleaves the probe, thereby separating the reporter dye and the quencher dye and resulting in increased fluorescence of the reporter. Accumulation of PCR product is detected directly by monitoring the increase in fluorescence of the reporter dye. The DNA polymerase cleaves the probe between the reporter dye and the quencher dye only if the probe hybridizes to the target-containing template which is amplified during PCR.
[0079] TaqMan® primer and probe sequences can readily be determined using the nucleic acid sequence information of the miRNA of interest. A number of computer programs, such as Primer Express (Applied Biosystems, Foster City, Calif.), can be used to rapidly obtain optimal primer/probe sets. It will be apparent to one of skill in the art that such primers and probes for detecting the target nucleic acids are useful in diagnostic assays for neoplastic disorders, such as HCC, and can be readily incorporated into a kit format. The present invention also includes modifications of the TaqMan® assay well known in the art such as the use of Molecular Beacon probes (U.S. Pat. Nos. 5,118,801 and 5,312,728) and other variant formats (U.S. Pat. Nos. 5,866,336 and 6,117,635).
[0080] In an illustrative embodiment, real time PCR is performed using TaqMan® Assays in combination with a suitable amplification/analyzer such as the ABI Prism® 7900HT Sequence Detection System. The ABI PRISM® 7900HT Sequence Detection System is a high-throughput real-time PCR system that detects and quantitates nucleic acid sequences. Real-time detection on the ABI Prism 7900HT or 7900HT Sequence Detector monitors fluorescence and calculates Rn during each PCR cycle. The threshold cycle, or Ct value, is the cycle at which fluorescence intersects the threshold value. The threshold value is determined by the sequence detection system software or manually. The Ct can be correlated to the initial amount of nucleic acids or number of starting cells using a standard curve.
[0081] In one embodiment, TaqMan® MicroRNA Assays are used to detect the miRNA. TaqMan® MicroRNA Assays are predesigned assays that are available for the majority of content found on the miRBase miRNA sequence repository. In another embodiment, the mirVana™ qRT-PCR miRNA Detection Kit (Ambion) is a used to detect and quantify the miRNA. This is a quantitative reverse transcription-PCR (qRT-PCR) kit enabling sensitive, rapid quantification of miRNA (miRNA) expression from total RNA samples.
[0082] As a quality control measure, an internal amplification control may be included in one or more samples to be extracted and amplified. The skilled artisan will understand that any detectable sequence that is not typically present in the sample can be used as the control sequence. A control sequence can be produced synthetically. If PCR amplification is successful, the internal amplification control amplicons can then be detected. Additionally, if included in the sample prior to purification of nucleic acids, the control sequences can also act as a positive purification control.
Statistical Methods
[0083] Statistical methods can be used to set thresholds for determining when the level in a subject can be considered to be different than or similar to a reference level. In addition, statistics can be used to determine the validity of the difference or similarity observed between a patient's circulating miRNA level and the reference level. Useful statistical analysis methods are described in L. D. Fisher & G. vanBelle, Biostatistics: A Methodology for the Health Sciences (Wiley-Interscience, NY, 1993). For instance, confidence (“p”) values can be calculated using an unpaired 2-tailed t test, with a difference between groups deemed significant if the p value is less than or equal to 0.05. As used herein a “confidence interval” or “CI” refers to a measure of the precision of an estimated or calculated value. The interval represents the range of values, consistent with the data that is believed to encompass the “true” value with high probability (usually 95%). The confidence interval is expressed in the same units as the estimate or calculated value. Wider intervals indicate lower precision; narrow intervals indicate greater precision. Preferred confidence intervals of the invention are 90%, 95%, 97.5%, 98%, 99%, 99.5%, 99.9% and 99.99%. A “p-value” as used herein refers to a measure of probability that a difference between groups happened by chance. For example, a difference between two groups having a p-value of 0.01 (or p=0.01) means that there is a 1 in 100 chance the result occurred by chance. Preferred p values are 0.1, 0.05, 0.025, 0.02, 0.01, 0.005, 0.001, and 0.0001. Confidence intervals and p-values can be determined by methods well-known in the art. See, e.g., Dowdy and Wearden, Statistics for Research , John Wiley & Sons, New York, 1983.
[0084] On linear model for assessing differential expression in microarray experiments: Smith G K (2004) “Linear models and empirical bayes method for assessing differential expression in microarray experiments” Statistical Applications in Genetics and Molecular Biology , For AUC calculation: Mason S J and Graham N E (1982) “Areas beneath the relative operating characteristics (ROC) and relative operating levels (ROL) curves: Statistical significance and interpretation,” Q. J. R. Meteorol. Soc . textbf30 291-303. Multiple algorithms program for marker combination selection: An R based program with nine algorithms including random forest, ada boosting, svm, bagging, logistic regression, lasso, matt, cart, ctree is available, for example, as open-source software from the R Foundation. Random forests were also conducted according to Breiman, L. (2001). Random Forests , Machine Learning 45(1), 5-32. See also Breiman, L (2002), “Manual On Setting Up, Using, And Understanding Random Forests V3.1.
[0085] In connection with miRNA used to diagnose melanoma, one may seek levels that are lower or higher than a control. The term “elevated levels” or “higher levels” as used herein refers to levels of an miRNA that are higher than what would normally be observed in a comparable sample from control or normal subjects or normal tissue from the patient (i.e., a reference value). Similarly, “reduced levels” or “lower levels” as used herein refer to levels of that are lower than what would normally be observed in a comparable sample from control or normal subjects, or normal tissue from the patient (i.e., a reference value). In some embodiments, “control levels” (i.e., normal levels) refer to a range of miRNA levels that would be normally be expected to be observed in nevi, or normal skin. A control level may be used as a reference level for comparative purposes. The ranges accepted as outside “control levels” are dependent on a number of factors. For example, one laboratory may routinely determine the level of circulating miRNA in a sample that is different than the miRNA obtained for the same sample by another laboratory. Also, different assay methods may achieve different value ranges. Value ranges may also differ in various sample types, for example, different body fluids or by different treatments of the sample. One of ordinary skill in the art is capable of considering the relevant factors and establishing appropriate reference ranges for “control values” and “elevated/reduced values” of the present invention. For example, a series of samples from control subjects and subjects diagnosed with melanoma can be used to establish ranges that are “normal” or “control” levels and ranges that are “elevated” or “reduced” than the control range.
[0086] The level of one or more miRNAs measured in the test sample is normalized, such as by comparison to an internal reference nucleic acid, e.g., U44 or small RNA U6. The levels of the one or more miRNAs may then be compared to a reference value to determine if the levels of the one or more miRNAs are elevated or reduced relative to the reference value. Typically, the reference value is the level measured in a comparable sample from one or more healthy individuals. An increase or decrease in the level of the one or more miRNAs may be used in conjunction with clinical factors to diagnose melanoma.
[0087] In some embodiments, the level of one or more miRNAs is combined with one or more additional markers to improve diagnostic sensitivity and specificity. Exemplary markers include, but are not limited to, any useful diagnostic marker associated with melanoma including those which may be assessed by fluorescence in-situ hybridization (FISH) and/or comparative genomic hybridization (CGH).
Kits
[0088] A kit may be used for conducting the diagnostic and prognostic methods described herein. Typically, the kit should contain, in a carrier or compartmentalized container, reagents useful in any of the above-described embodiments of the diagnostic method. The carrier can be a container or support, in the form of, e.g., bag, box, tube, rack, and is optionally compartmentalized. The carrier may define an enclosed confinement for safety purposes during shipment and storage. In one embodiment, the kit includes one or more PCR primers capable of amplifying miRNA selected from miR-132, miR-150, miR-339-5p, miR-15b, miR-342-3p, miR-572, miR-155, miR-425, miR-1202, miR-1268, HBII-382_s, miR-1225-5p, miR-30c, miR-106b-star, miR-125a-5p, mgU6-53B, miR-25, miR-149-star, miR-939, miR-92b-star, miR-500-star, miR-22, HBII-142_x, miR-181b, HBII-142, U38B, miR-663, miR-1224-5p, miR-23a, HBII-85-6_x, miR-1207-5p, miR-1301, miR-1228-star, miR-345, miR-30a-star. ENSG00000199411_s, ENSG00000202327, miR-92a, miR-127-3p, HBII-85-26, miR-1308, miR-31, miR-921, miR-146b-5p, miR-768-3p, miR-708, miR-139-5p, ACA24_x, miR-501-3p, miR-502-3p, miR-923, and miR-191.
[0089] In further embodiments, the invention comprise a kit. In one embodiment, a kit for differentially diagnosing between melanoma and nevus in a skin sample comprises primers for the amplification of at least two miRNA selected from the group consisting of: miR-150, miR-149-star, miR-1308; miR-191.; miR-1228-star; ENSG0000019941_s: miR-1268; miR-923; miR-23a; miR-132; miR-1207.5p; miR-342.3p; U38B; and miR-155.
[0090] In another embodiment, the kit comprises primers for the amplification of at least two miRNAs selected from the group consisting of: miR-1268, miR-1228-star, miR-92b-star, miR-155, miR-345, miR-425, miR-132, miR-1207-5p, miR-1301, miR-663, miR-339-5p, miR-149-star, miR-150, miR-18a, miR-103, miR-191, miR-296-3p, miR-31, miR-107*, miR-93*, miR-1275*, miR-181B*, miR-921*, miR-1225-5p, miR-1202, and miR-342-3p.
[0091] The kit may also primers for amplification of controls, such as miR-27b, miR-195, miR-199b-3p, and miR-199a-3p.
[0092] The kit may also include suitable buffers, reagents for isolating nucleic acid, and instructions for use Kits may also include a microarray for measuring miRNA level
[0093] The primers may be labeled with a detectable marker such as radioactive isotopes, or fluorescence markers. Instructions for using the kit or reagents contained therein are also included in the kit.
EXAMPLES
[0094] The present methods and kits, thus generally described, will be understood more readily by reference to the following examples, which are provided by way of illustration and are not intended to be limiting of the present methods and kits. The following is a description of the materials and experimental procedures used in the example.
Example 1
[0095] 137 samples were examined: (1) 19 normal skin; (2) 38 nevi, of which 20 were intradermal, where the nevus cells are located in the dermis only, and 18 were compound nevus, which is a mixture of junctional and intradermal proliferation and are slightly raised and brown to black; (3) 58 primary melanoma; (4) 22 metastatic melanoma.
[0096] Total RNA, including low molecular weight RNA, was isolated from ten 10 μm-FFPE sections with RecoverAll RNA extraction kit (Applied Biosystems), according to the manufacturer's protocol.
[0097] The Affymetrix GeneChip® miRNA array was used, according to the manufacturer's protocol, to evaluate miRNA expression in FFPE samples. The miRNA array covers 71 organisms, including human, mouse, rat, and monkey, and contains 1801 sets of human miRNA, snoRNAs and scaRNAs. Samples were labeled using the Genisphere FlashTag™ Biotin Labeling Assay, which utilizes the 3DNA™ technology. The 3DNA™ dendrimer was ligated to samples to allow multiple biotin molecules (˜15) to bind to each poly-A tailed RNA molecule. Following FlashTag™ ligation, samples were hybridized on the Affymetrix GeneChip® miRNA array overnight. The hybridized chips were washed and processed to scan in an Affimatrix GeneChip Scanner 3000 7G.
Statistical Analyses
[0098] The raw microarray data was analyzed using the miRNA QC tool which performed an RNA normalization and extracted signals for data analysis. Log 2 values were used for miRNA expression in each group. The log 2 fold change (log 2 FC) was calculated by subtracting the mean of log 2 of group1 from the mean log 2 of group 2. Student's t test was used to compare the miRNA expression level of each miRNA between normal skin, nevi, melanoma, and metastatic melanoma. P<0.05 was used as statistical significance. The area under ROC (AUC) was calculated to reflect the separation between each group. The default AUC value is 0.5 meaning no separation, and the maximum possible value is 1.0, meaning complete separation between each group.
[0099] A screen on probe signal detection in samples was performed having of 137 samples at least >30 samples with signal detectable. There are 729 of 1801 human probes satisfying such condition. These 729 candidate markers were analyzed using multiple algorithm programs.
[0100] Two or three markers completely separate these melanoma from nevi, as confirmed by multiple algorithms. The best 15 miRNA markers from randomForest share 14 markers overlap with the best 15 markers from boosting. In addition, these 14 best overlap markers include 6 of 7 best markers from previous analyses of 40 melanoma vs 20 nevi. These results therefore show consistency across different assays at different times.
Example 2
[0101] Additional experiments were performed to identify miRNA that can distinguish between different skin conditions.
[0102] For melanoma vs nevus, specimens (n=380) included a training set of 20 paraffin-embedded blocks of normal skin, 60 paraffin-embedded blocks of skin biopsies with benign nevus, 60 paraffin-embedded blocks of skin biopsies with malignant melanoma. Next, a validation set of 100 paraffin-embedded blocks of skin biopsies with benign nevus, 100 paraffin-embedded blocks of skin biopsies with malignant melanoma and 50 paraffin-embedded blocks of dysplastic nevus.
[0103] To distinguish between primary melanoma and metastatic melanoma, 180 study specimens included a training set of 60 paraffin-embedded blocks of skin biopsies with malignant melanoma and 30 paraffin-embedded blocks of metastatic melanoma. The validation set comprised 60 paraffin-embedded blocks of skin biopsies with malignant melanoma and 30 paraffin-embedded blocks of metastatic melanoma.
[0104] The subject population targeted all ethnicities and was approximately 50% male and 50% female. Specimens of adults 18 year and younger, and all subjects 89 years or older (“>90”) were discarded.
[0105] Tissues (normal benign, nevi and indeterminate nevus, malignant melanoma and metastatic melanoma) were collected at DermaPath. 240 nevi and 40 melanoma FFPEs were purchased from BioTheme.
[0106] Total RNA, including low molecular weight RNA, was isolated from ten 10 μm-FFPE sections with RecoverAll RNA extraction kit from Applied Biosystems according to the manufacturer's protocol.
[0107] The Affymetrix GeneChip® miRNA array was used to evaluate miRNA expression in FFPE samples. The miRNA array covers 71 organisms, including human, mouse, rat, and monkey, and contains 1801 sets of human miRNA, snoRNAs and scaRNAs.
[0108] The experiment procedure was according to the Affymetrix miRNA expression analysis manual. Samples were labeled with the Genisphere FlashTag™ Biotin Labeling Assay, which utilizes the 3DNA™ technology. The 3DNA™ dendrimer was ligated to samples to allow multiple biotin molecules (˜15) to bind to each poly-A tailed RNA molecule. Following FlashTag™ ligation, samples were hybridized on the Affymetrix GeneChip® miRNA array overnight. The hybridized chips were washed and processed to scan in an Affimatrix GeneChip Scanner 3000 7G.
Statistical Analyses
[0109] Log 2 values were used for miRNA expression in each group. The log 2 fold change (log 2 FC) was calculated by subtracting the mean of log 2 of group1 from the mean log 2 of group 2. Student's t test was used to compare the miRNA expression level of each miRNA between normal skin, nevi, melanoma, and metastatic melanoma. P<0.05 was used as statistical significance. The area under ROC (AUC) was calculated to reflect the separation between each group. The default AUC value is 0.5 meaning no separation, and the maximum possible value is 1.0, meaning complete separation between each group.
[0000] Semi-Quantitative Reverse-Transcriptase PCR Analysis of miRNA
[0110] Two-step TaqMan reverse-transcriptase PCR analysis was performed for analysis of miRNAs. Reverse transcription was performed in a 15-μl reaction volume using specific primers for each miRNA contained in the TaqMan MicroRNA Reverse Transcription kit (Applied Biosystems, Foster City, Calif.) by sequentially incubating at 16° C. for 30 min, 42° C. for 30 min, and 85° C. for 5 min. Real-time PCR was done using the standard TaqMan MicroRNA assay protocol on an Applied Biosysytems 7900 system (Applied Biosystems). Each PCR mixture (20 μl) included the reverse transcription products, TaqMan 2X Universal PCR Master Mix without UNG Amperase, miRNA-specific TaqMan probes, and primers supplied by Applied Biosystems. The reactions were incubated in a 96-well plate with an initial denaturation at 95° C. for 10 min, followed by 40 cycles of 95° C. for 15 s and 60° C. for 1 min. The level of miRNA expression was measured using the threshold cycle (Ct), the fractional cycle number at which the fluorescence of each sample passes a fixed threshold, miRNA expression levels were normalized using an endogenous small RNA control U44 (Applied Biosystems). The expression of miRNA relative to small RNA U44 is reported as ΔCt, which was calculated by subtracting the Ct of U44 RNA from the Ct of target miRNA.
4. Results
[0111] MiRNA expression was analyzed between each group. Table 1 shows 523 miRNAs which have significant expression level, either over or less expression, between melanoma and nevi groups (p<0.05). Table 2 showed 50 miRNAs with the most significant expression between the two groups. Table 3 showed 378 miRNAs which have significant expression differences between melanoma and normal skin groups (p<0.05). Table 4 showed 50 miRNAs with the most significant expression differences between the two groups. Table 5 showed 174 miRNAs which have significant expression differences between melanoma and metastatic melanoma groups (p<0.05). Table 6 showed 50 miRNAs with the most significant expression differences between the two groups. Table 7 showed 442 miRNAs which have significant expression differences between nevi and normal skin groups (p<0.05). Table 8 showed 50 miRNAs with the most significant expression differences between the two groups.
[0000]
TABLE 1
miRNAs significantly expressed between melanoma and nevi
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
miR-132
2.98
1.2728E−32
0.994
miRNA
96
miR-150
3.27
5.83192E−30
1.000
miRNA
117
miR-339-5p
2.73
1.69388E−27
0.988
miRNA
75
miR-15b
3.02
6.41784E−27
0.978
miRNA
125
miR-342-3p
2.23
7.03798E−26
0.993
miRNA
136
miR-572
−2.78
1.00008E−25
0.970
miRNA
116
miR-155
4.14
1.28454E−25
0.981
miRNA
123
miR-425
2.74
8.13135E−25
0.975
miRNA
114
miR-1202
−2.63
2.97795E−23
0.986
miRNA
57
miR-1268
−2.68
6.05905E−23
0.997
miRNA
133
HBII-382_s
−1.71
6.58931E−22
0.971
scaRna
126
miR-1225-5p
−2.36
1.05361E−21
0.953
miRNA
90
miR-30c
2.39
2.58594E−21
0.980
miRNA
125
miR-106b-star
2.24
3.48507E−21
0.961
miRNA
72
miR-125a-5p
2.39
6.90609E−21
0.967
miRNA
128
mgU6-53B
−1.51
1.74782E−20
0.973
CDBox
99
miR-25
2.57
1.52769E−19
0.956
miRNA
118
miR-149-star
−2.03
1.64858E−19
1.000
miRNA
135
miR-939
−2.21
1.9129E−19
0.973
miRNA
57
miR-92b-star
−2.30
2.05085E−19
0.969
miRNA
111
miR-500-star
2.38
3.11256E−19
0.956
miRNA
97
miR-22
2.69
3.8844E−19
0.965
miRNA
120
HBII-142_x
−1.22
4.93318E−19
0.981
CDBox
135
miR-181b
2.41
1.00639E−18
0.960
miRNA
130
HBII-142
−1.33
1.18794E−18
0.988
CDBox
135
U38B
−1.95
1.35964E−18
0.975
CDBox
134
miR-663
−2.10
2.04672E−18
0.984
miRNA
134
miR-1224-5p
−2.54
2.91169E−18
0.946
miRNA
78
miR-23a
1.18
2.99523E−18
0.967
miRNA
137
HBII-85-6_x
−1.73
4.78418E−18
0.939
CDBox
137
miR-1207-5p
−2.14
4.98991E−18
0.995
miRNA
133
miR-1301
2.36
5.22389E−18
0.931
miRNA
54
miR-1228-star
−2.41
5.51513E−18
0.997
miRNA
134
miR-345
2.45
6.43552E−18
0.942
miRNA
75
miR-30a-star
2.32
6.92165E−18
0.932
miRNA
64
ENSG00000199411_s
−1.97
7.23325E−18
0.991
snoRNA
135
ENSG00000202327
−1.40
8.75839E−18
0.938
snoRNA
54
miR-92a
1.67
9.49427E−18
0.979
miRNA
136
miR-127-3p
2.43
9.84615E−18
0.936
miRNA
89
HBII-85-26
−2.07
1.50619E−17
0.951
CDBox
136
miR-1308
−2.14
1.99888E−17
0.999
miRNA
135
miR-31
3.29
2.46697E−17
0.913
miRNA
103
miR-921
−1.46
2.61089E−17
0.928
miRNA
49
miR-146b-5p
2.37
6.10422E−17
0.918
miRNA
83
miR-768-3p
−1.05
6.66153E−17
0.949
miRNA
137
miR-708
2.29
6.86187E−17
0.929
miRNA
102
miR-139-5p
2.23
2.78962E−16
0.922
miRNA
80
ACA24_x
1.33
3.37973E−16
0.925
HAcaBox
98
miR-501-3p
1.83
4.76751E−16
0.923
miRNA
80
miR-502-3p
2.16
5.19509E−16
0.925
miRNA
110
miR-923
−1.86
5.55191E−16
0.996
miRNA
135
U94
−1.17
6.40118E−16
0.926
CDBox
109
miR-574-3p
2.32
8.68105E−16
0.946
miRNA
122
miR-135a-star
−1.90
1.03062E−15
0.914
miRNA
44
ENSG00000207098_x
−1.03
1.25346E−15
0.924
snoRNA
86
U38B_x
−1.55
2.54255E−15
0.958
CDBox
133
miR-423-3p
1.83
2.74508E−15
0.932
miRNA
107
miR-198
−1.79
3.57486E−15
0.909
miRNA
31
ACA16
1.43
4.07871E−15
0.919
HAcaBox
47
ACA25
1.06
4.62028E−15
0.910
HAcaBox
73
miR-769-5p
1.63
4.79679E−15
0.920
miRNA
56
ENSG00000212523_x
−1.38
6.22717E−15
0.927
snoRNA
135
mgU6-53B_x
−0.99
6.32629E−15
0.919
CDBox
121
Z17B
0.97
1.1349E−14
0.903
CDBox
117
U81_x
1.22
1.25935E−14
0.913
CDBox
120
miR-532-5p
2.10
1.27686E−14
0.933
miRNA
113
ENSG00000200879
1.27
1.49096E−14
0.917
snoRNA
120
HBII-419
−1.07
2.02184E−14
0.938
CDBox
133
U58B_x
0.96
9.25535E−14
0.898
CDBox
132
ENSG00000201619
−1.66
1.14582E−13
0.911
snoRNA
62
miR-28-3p
2.15
1.17402E−13
0.900
miRNA
94
miR-1300
−1.86
1.21666E−13
0.892
miRNA
32
miR-191
1.18
1.2767E−13
0.983
miRNA
135
miR-181a-2-star
1.93
2.91245E−13
0.898
miRNA
99
U38A
−1.52
3.04032E−13
0.971
CDBox
134
U59A
−1.01
3.86379E−13
0.948
CDBox
135
ENSG00000212397
−1.21
4.58111E−13
0.902
snoRNA
134
HBII-85-26_x
−1.13
4.73092E−13
0.897
CDBox
135
miR-638
−1.62
5.93273E−13
0.967
miRNA
135
miR-421
1.84
6.09941E−13
0.881
miRNA
68
miR-21
2.62
6.26336E−13
0.888
miRNA
79
miR-24-2-star
1.81
8.95923E−13
0.879
miRNA
63
U36C
−0.92
1.1248E−12
0.931
CDBox
135
miR-92b
1.43
1.15239E−12
0.901
miRNA
91
miR-199a-5p
1.69
1.22362E−12
0.901
miRNA
129
ACA24_s
1.36
1.86137E−12
0.880
HAcaBox
128
ACA9
1.36
1.92813E−12
0.888
HAcaBox
82
ENSG00000199411_x
−0.87
2.22903E−12
0.868
snoRNA
132
ENSG00000199435
−0.94
2.45067E−12
0.903
snoRNA
63
miR-182
1.80
3.73608E−12
0.905
miRNA
113
miR-1275
−1.56
3.97629E−12
0.888
miRNA
127
miR-150-star
−1.70
4.59839E−12
0.897
miRNA
48
ACA48_x
1.08
5.05927E−12
0.881
HAcaBox
130
HBII-85-8_x
−1.09
5.47576E−12
0.877
CDBox
135
miR-99b
1.33
5.48764E−12
0.907
miRNA
129
U74_x
−1.00
6.23625E−12
0.941
CDBox
135
miR-1271
1.71
6.2815E−12
0.885
miRNA
70
ENSG00000206637_x
−0.86
6.43179E−12
0.878
snoRNA
59
miR-20b
2.16
1.13294E−11
0.892
miRNA
99
ENSG00000200652
−0.93
1.18064E−11
0.876
snoRNA
40
U13
−0.94
1.19458E−11
0.899
CDBox
135
ENSG00000201660
−1.13
1.27245E−11
0.903
snoRNA
132
HBII-85-23_x
1.18
1.36679E−11
0.883
CDBox
58
miR-149
1.85
1.38908E−11
0.896
miRNA
100
ACA9_x
1.14
2.05352E−11
0.877
HAcaBox
77
miR-1234
−1.10
2.16855E−11
0.856
miRNA
68
miR-1180
1.50
2.61371E−11
0.878
miRNA
37
miR-30a
1.80
3.39494E−11
0.861
miRNA
113
U44_x
1.13
3.71768E−11
0.953
CDBox
135
miR-181c
1.54
4.41605E−11
0.861
miRNA
59
ENSG00000202498_x
−1.07
4.69703E−11
0.855
snoRNA
137
miR-940
−1.22
5.55177E−11
0.861
miRNA
53
miR-500
1.76
6.23662E−11
0.854
miRNA
86
ENSG00000212627
−0.78
6.92771E−11
0.871
snoRNA
69
ENSG00000207027
−0.84
8.23933E−11
0.879
snoRNA
36
miR-27a-star
1.63
8.66657E−11
0.856
miRNA
40
miR-128
1.66
9.46068E−11
0.858
miRNA
44
snR38C
−1.01
9.50785E−11
0.926
CDBox
134
ENSG00000212266
−0.93
9.6633E−11
0.848
snoRNA
93
miR-185
1.76
1.06661E−10
0.922
miRNA
132
ACA64
−0.97
1.08821E−10
0.858
HAcaBox
33
miR-151-3p
1.71
1.37187E−10
0.884
miRNA
117
miR-130b
2.12
1.55732E−10
0.870
miRNA
90
miR-27b-star
1.70
1.72122E−10
0.849
miRNA
51
miR-665
−1.43
1.78835E−10
0.853
miRNA
47
miR-18a
2.01
1.91068E−10
0.854
miRNA
77
ACA36_x
−1.03
2.0756E−10
0.875
HAcaBox
88
ENS00000212432_s
−0.94
2.08962E−10
0.882
snoRNA
75
ENSG00000202093_x
1.01
4.04338E−10
0.873
snoRNA
125
miR-487b
1.41
4.22069E−10
0.848
miRNA
58
U65
−0.98
4.31315E−10
0.847
HAcaBox
128
miR-532-3p
1.19
4.73885E−10
0.881
miRNA
95
U101
−0.79
5.89958E−10
0.845
CDBox
134
miR-138
2.09
6.68933E−10
0.839
miRNA
82
HBII-99
1.01
7.89663E−10
0.847
CDBox
122
miR-222
1.12
9.21171E−10
0.913
miRNA
135
miR-652
1.46
9.82734E−10
0.862
miRNA
119
miR-10a
1.82
9.97674E−10
0.843
miRNA
69
miR-625
1.46
1.06062E−09
0.833
miRNA
59
ENSG00000212182
−0.89
1.13997E−09
0.828
snoRNA
59
miR-331-3p
1.47
1.22124E−09
0.834
miRNA
64
miR-1281
−1.46
1.31027E−09
0.843
miRNA
137
miR-28-5p
1.53
1.35526E−09
0.863
miRNA
105
ACA23
0.76
2.45172E−09
0.837
HAcaBox
113
U27
1.04
2.55698E−09
0.874
CDBox
134
miR-339-3p
1.12
2.9234E−09
0.836
miRNA
60
U68_x
1.00
3.99716E−09
0.861
HAcaBox
133
miR-92a-2-star
−1.06
4.67209E−09
0.830
miRNA
46
miR-107
1.08
5.05068E−09
0.946
miRNA
135
U104
−0.79
5.07142E−09
0.918
CDBox
135
miR-671-5p
−1.16
6.05404E−09
0.877
miRNA
69
miR-193b
1.22
6.27171E−09
0.852
miRNA
130
miR-1272
−1.13
6.29028E−09
0.826
miRNA
67
miR-221
1.23
6.5716E−09
0.911
miRNA
135
14qII-14
1.27
6.8516E−09
0.828
CDBox
56
miR-1288
−0.92
6.95468E−09
0.804
miRNA
43
ENSG00000212458
−0.80
7.62772E−09
0.853
snoRNA
95
miR-584
1.61
7.63622E−09
0.815
miRNA
57
U106
0.64
8.00299E−09
0.821
CDBox
112
miR-152
1.58
8.26552E−09
0.885
miRNA
122
ENSG00000212551
−0.72
9.08023E−09
0.841
snoRNA
73
U96a_x
−0.89
1.00143E−08
0.863
CDBox
134
ENSG00000212139_x
−0.74
1.22887E−08
0.811
snoRNA
124
miR-409-3p
1.14
1.25923E−08
0.832
miRNA
92
miR-214-star
1.59
1.34912E−08
0.830
miRNA
47
ACA20
0.91
1.36416E−08
0.873
HAcaBox
131
HBII-82
−0.73
1.52532E−08
0.823
CDBox
90
U49A
−0.86
1.55769E−08
0.856
CDBox
135
miR-362-5p
1.63
1.67441E−08
0.824
miRNA
94
ACA40_x
1.17
1.68127E−08
0.872
HAcaBox
134
U63
−0.98
1.83203E−08
0.916
CDBox
135
HBII-436
0.76
1.85498E−08
0.810
CDBox
102
miR-15a
1.74
1.8639E−08
0.826
miRNA
80
U103_s
0.83
2.02002E−08
0.809
CDBox
111
miR-1185
−0.96
2.35573E−08
0.822
miRNA
42
ACA15_s
0.74
2.84086E−08
0.812
HAcaBox
116
miR-30b
1.37
3.22874E−08
0.843
miRNA
128
spike_in-control-21
−0.70
3.25874E−08
0.832
Oligonucleotide
42
spike-in
controls
U15B
0.71
3.51612E−08
0.825
CDBox
129
miR-143
1.99
3.72999E−08
0.820
miRNA
126
U67_x
0.79
4.12783E−08
0.813
HAcaBox
50
miR-10b
1.41
4.29563E−08
0.821
miRNA
106
U99
−0.65
4.50576E−08
0.817
HAcaBox
137
miR-194
1.27
5.18787E−08
0.813
miRNA
54
miR-324-5p
1.14
5.23291E−08
0.804
miRNA
102
miR-125b-2-star
1.19
5.54514E−08
0.819
miRNA
58
HBII-52-37_x
−0.76
8.93997E−08
0.805
CDBox
37
ACA48
0.72
9.13165E−08
0.825
HAcaBox
121
miR-103
0.97
9.25296E−08
0.931
miRNA
135
miR-342-5p
1.32
9.27998E−08
0.827
miRNA
98
miR-93
1.08
9.93604E−08
0.896
miRNA
134
miR-296-3p
−1.00
1.10115E−07
0.818
miRNA
90
miR-200b-star
1.30
1.13507E−07
0.791
miRNA
74
U44
0.87
1.17791E−07
0.897
CDBox
134
ENSG00000207016_x
−0.63
1.23122E−07
0.803
snoRNA
48
spike_in-control-31
−0.14
1.24357E−07
0.798
Oligonucleotide
137
spike-in
controls
U68
0.83
1.72086E−07
0.856
HAcaBox
130
U24
−0.55
2.39582E−07
0.822
CDBox
133
U83
0.62
2.42808E−07
0.846
CDBox
135
ENSG00000212273_x
−0.80
2.45728E−07
0.811
snoRNA
126
14qII-14_x
1.03
2.59298E−07
0.797
CDBox
56
miR-660
1.26
2.65402E−07
0.788
miRNA
71
14qII-7
−0.70
2.89281E−07
0.762
CDBox
77
U78_s
1.01
3.07849E−07
0.836
CDBox
135
miR-744
−1.03
3.11141E−07
0.818
miRNA
133
U22
−0.54
3.14269E−07
0.793
CDBox
135
ACA11
0.70
3.50307E−07
0.793
HAcaBox
48
ENSG00000212553_x
−0.69
3.51184E−07
0.794
snoRNA
60
U67
0.76
3.78503E−07
0.796
HAcaBox
44
miR-382
1.35
3.83783E−07
0.787
miRNA
47
miR-212
1.58
3.89653E−07
0.854
miRNA
62
miR-93-star
1.26
4.02443E−07
0.808
miRNA
48
U18C_x
0.74
4.1571E−07
0.794
CDBox
74
miR-1274a
1.22
4.1577E−07
0.788
miRNA
48
ACA25_x
0.77
4.42948E−07
0.799
HAcaBox
114
U15A
−0.74
4.57833E−07
0.821
CDBox
128
14qI-1
−0.77
5.08646E−07
0.784
CDBox
70
ENSG00000201816
−0.60
5.51521E−07
0.789
snoRNA
49
miR-145
1.56
6.30644E−07
0.775
miRNA
135
HBII-420
−0.75
7.96309E−07
0.828
CDBox
131
ACA2b
−0.66
8.56351E−07
0.787
HAcaBox
47
miR-1273
−0.94
1.01224E−06
0.768
miRNA
47
miR-641
−0.85
1.0165E−06
0.765
miRNA
39
ENSG00000202216
−0.60
1.02726E−06
0.778
snoRNA
53
U97
−0.72
1.06795E−06
0.794
CDBox
133
EN8G00000200706_x
−0.66
1.06937E−06
0.778
snoRNA
43
miR-363
1.33
1.20135E−06
0.806
miRNA
44
ENSG00000201348
−0.48
1.23741E−06
0.779
snoRNA
94
U83A
0.75
1.32496E−06
0.818
CDBox
127
miR-197
1.27
1.3431E−06
0.807
miRNA
103
miR-106b
1.23
1.49024E−06
0.805
miRNA
127
HBII-180A_x
0.60
1.62491E−06
0.784
CDBox
123
snR38B
−0.76
1.68966E−06
0.803
CDBox
126
snR38A
−0.87
1.99208E−06
0.838
CDBox
130
miR-134
1.15
2.09717E−06
0.774
miRNA
61
miR-29b-1-star
1.41
2.20964E−06
0.764
miRNA
46
mgh18S-121
−0.66
2.37986E−06
0.833
CDBox
134
mgU6-77
0.59
2.38866E−06
0.742
CDBox
129
HBII-52-25_x
−0.60
2.44738E−06
0.767
CDBox
57
U48
0.83
2.51688E−06
0.777
CDBox
129
14qII-19
−0.73
2.52816E−06
0.770
CDBox
43
miR-552
−0.66
2.70576E−06
0.760
miRNA
34
miR-424-star
1.31
2.79344E−06
0.762
miRNA
41
HBII-316
−0.60
3.06016E−06
0.795
CDBox
130
U35B
−0.64
3.21695E−06
0.811
CDBox
128
miR-30d
1.02
3.25088E−06
0.817
miRNA
131
miR-1248
−0.72
3.27937E−06
0.746
miRNA
39
ENSG00000212579_x
−0.65
3.55239E−06
0.758
snoRNA
100
hsa-let-7b
0.90
3.76667E−06
0.919
miRNA
136
miR-29b-2-star
−0.78
3.86015E−06
0.760
miRNA
126
miR-148a
1.04
4.16979E−06
0.773
miRNA
41
miR-629
1.16
4.35623E−06
0.776
miRNA
64
HBII-295
−0.58
4.36224E−06
0.767
CDBox
128
miR-877
−1.00
4.43293E−06
0.794
miRNA
126
ACA62
−0.61
4.43469E−06
0.774
HAcaBox
88
ENSG00000207100_x
−0.50
4.49659E−06
0.765
snoRNA
72
HBII-180C
0.62
4.78509E−06
0.780
CDBox
115
HBII-115
−0.57
5.03448E−06
0.768
CDBox
117
miR-192
1.14
5.73989E−06
0.763
miRNA
32
miR-505-star
1.23
5.74055E−06
0.762
miRNA
58
spike_in-control-7
−0.80
5.89851E−06
0.790
Oligonucleotide
54
spike-in
controls
miR-422a
1.17
5.96437E−06
0.782
miRNA
84
U83B
−0.56
6.55847E−06
0.842
CDBox
135
ENSG00000212134_x
−0.65
6.92676E−06
0.752
snoRNA
88
U50B_x
−0.67
7.13703E−06
0.783
CDBox
135
miR-193a-3p
0.91
8.82408E−06
0.747
miRNA
42
ENSG00000201848
−0.62
9.39369E−06
0.759
snoRNA
34
miR-148b
0.93
9.94696E−06
0.757
miRNA
32
miR-483-5p
−1.10
1.1191E−05
0.756
miRNA
48
ACA58_x
0.62
1.17327E−05
0.766
HAcaBox
89
miR-1260
0.94
1.21296E−05
0.776
miRNA
120
U108_x
−0.50
1.23481E−05
0.763
HAcaBox
87
ACA61
−0.60
1.27104E−05
0.839
HAcaBox
135
14q-0
−0.58
1.39356E−05
0.767
CDBox
49
ACA16_x
0.55
1.40972E−05
0.763
HAcaBox
98
miR-30b-star
1.22
1.61096E−05
0.755
miRNA
61
ENSG00000201848_x
−0.58
2.11059E−05
0.740
snoRNA
40
U3-2_s
−0.57
2.19611E−05
0.800
CDBox
135
spike_in-control-2
−0.31
2.25868E−05
0.747
Oligonucleotide
137
spike-in
controls
miR-933
−0.56
2.89505E−05
0.776
miRNA
100
miR-181d
1.03
2.90988E−05
0.750
miRNA
61
HBII-239
0.45
2.92435E−05
0.744
CDBox
135
miR-497
1.17
2.92719E−05
0.730
miRNA
104
HBII-251
−0.48
3.04823E−05
0.797
CDBox
135
U51
−0.73
3.10371E−05
0.809
CDBox
134
miR-211
1.45
3.41149E−05
0.759
miRNA
84
miR-29a
1.10
3.68833E−05
0.777
miRNA
128
ENSG00000212538
−0.54
3.71864E−05
0.746
snoRNA
35
miR-886-3p
1.11
4.28603E−05
0.711
miRNA
110
miR-361-5p
0.58
4.51572E−05
0.859
miRNA
135
U51_x
−0.48
4.6523E−05
0.773
CDBox
130
U46
0.59
4.67792E−05
0.744
CDBox
133
HBII-85-11
0.73
4.72933E−05
0.743
CDBox
31
ENSG00000207410_x
−0.51
4.76931E−05
0.731
snoRNA
55
ENSG00000200492
−0.51
5.13688E−05
0.756
snoRNA
60
miR-503
1.05
5.22927E−05
0.730
miRNA
41
HBII-85-21_x
0.68
5.24419E−05
0.749
CDBox
39
miR-506
1.27
5.49222E−05
0.750
miRNA
76
ENSG00000212206_x
−0.55
5.68573E−05
0.730
snoRNA
74
U64
0.49
5.7913E−05
0.755
HAcaBox
101
miR-629-star
1.07
5.89793E−05
0.745
miRNA
46
ENSG00000212284
−0.62
6.56826E−05
0.740
snoRNA
89
ENSG00000212423_x
−0.60
6.59628E−05
0.728
snoRNA
115
U14B_x
0.58
6.71139E−05
0.714
CDBox
53
miR-324-3p
0.78
6.71385E−05
0.766
miRNA
100
miR-1287
0.79
7.37546E−05
0.733
miRNA
40
ENSG00000200897
−0.49
7.55587E−05
0.730
snoRNA
38
miR-498
−0.68
8.15427E−05
0.730
miRNA
56
U80
0.53
8.25012E−05
0.750
CDBox
132
14qI-8_x
−0.55
8.60271E−05
0.740
CDBox
74
miR-181a
0.82
8.99722E−05
0.766
miRNA
134
HBII-166
−0.46
9.07119E−05
0.782
CDBox
134
miR-181a-star
1.03
9.30754E−05
0.727
miRNA
35
U17b
0.85
9.69173E−05
0.854
HAcaBox
135
U55
0.61
0.000102241
0.749
CDBox
135
ENSG00000207407
−0.43
0.000115453
0.706
snoRNA
56
ENSG00000212206
−0.50
0.000123184
0.701
snoRNA
46
miR-489
0.86
0.000125451
0.724
miRNA
58
hsa-let-7g
1.09
0.000128044
0.820
miRNA
127
ENSG00000199363
0.63
0.000135904
0.722
snoRNA
42
miR-27a
0.72
0.000140934
0.687
miRNA
136
ACA32
−0.40
0.000144838
0.746
HAcaBox
135
ENSG00000207022
−0.51
0.000149628
0.733
snoRNA
36
miR-371-5p
−0.86
0.000152576
0.706
miRNA
64
miR-559
−0.73
0.000161415
0.728
miRNA
72
miR-193a-5p
0.92
0.000163281
0.777
miRNA
121
U23
0.46
0.00016459
0.724
HAcaBox
127
miR-196a-star
−0.69
0.000167433
0.695
miRNA
37
U52
0.47
0.00016782
0.770
CDBox
135
ACA38
0.50
0.000170509
0.713
HAcaBox
42
miR-30e-star
0.82
0.000173654
0.736
miRNA
35
U49A_x
−0.61
0.000183863
0.785
CDBox
135
U49B_x
−0.54
0.000189603
0.729
CDBox
122
U71a
0.50
0.000191925
0.721
HAcaBox
50
HBII-95
0.42
0.000194646
0.724
CDBox
78
ENSG00000212587
−0.55
0.000201583
0.711
snoRNA
45
ENSG00000212401
−0.45
0.000208666
0.714
snoRNA
41
HBII-296A
−0.45
0.000214033
0.713
CDBox
78
ACA67_x
0.49
0.000214513
0.730
HAcaBox
54
miR-494
0.79
0.000221314
0.725
miRNA
135
miR-17
0.77
0.00024803
0.782
miRNA
134
HBII-85-4_x
−0.49
0.000264241
0.714
CDBox
125
miR-16
0.67
0.000270072
0.819
miRNA
135
miR-135b-star
−0.68
0.000271929
0.710
miRNA
38
ACA37_x
0.47
0.00028645
0.718
HAcaBox
84
miR-126
0.82
0.000326027
0.780
miRNA
133
miR-200b
0.93
0.000339327
0.714
miRNA
109
miR-320d
0.89
0.000373646
0.811
miRNA
134
U100
0.41
0.000374728
0.702
scaRna
80
HBII-85-27_x
−0.40
0.000383642
0.706
CDBox
56
HBII-85-15_x
0.60
0.000397454
0.706
CDBox
49
miR-885-3p
−1.11
0.000407264
0.692
miRNA
73
miR-23b-star
0.76
0.000423736
0.723
miRNA
52
ENSG00000206909_x
−0.46
0.000424153
0.710
snoRNA
47
U92
−0.50
0.000428521
0.750
scaRna
129
miR-628-3p
0.86
0.000458761
0.702
miRNA
38
miR-27b
0.70
0.00047114
0.718
miRNA
133
U88
−0.43
0.000500023
0.708
scaRna
69
miR-130a
1.00
0.000518644
0.729
miRNA
122
ACA4
0.42
0.00055437
0.673
HAcaBox
117
miR-151-5p
0.60
0.00055594
0.790
miRNA
135
ENSG00000200394
0.46
0.000561813
0.692
snoRNA
119
ACA5
0.48
0.000585113
0.708
HAcaBox
85
miR-1285
−0.74
0.000607741
0.698
miRNA
54
miR-664-star
−0.82
0.000652475
0.686
miRNA
96
U56
−0.57
0.000672557
0.787
CDBox
135
ENSG00000200307
−0.44
0.000679263
0.686
snoRNA
86
miR-18b
0.81
0.000708619
0.688
miRNA
32
U76
0.38
0.000723275
0.712
CDBox
135
miR-378
0.75
0.000726542
0.769
miRNA
131
ENSG00000200307_x
−0.43
0.000739867
0.716
snoRNA
50
miR-513b
1.02
0.000775353
0.701
miRNA
64
U56_x
0.54
0.000779671
0.716
CDBox
134
miR-642
−0.59
0.000808799
0.695
miRNA
69
miR-106a
0.66
0.000811882
0.788
miRNA
135
miR-379
0.94
0.000829873
0.702
miRNA
57
miR-570
−0.61
0.000842848
0.697
miRNA
88
ACA3-2
0.46
0.000855145
0.720
HAcaBox
135
U55_x
0.50
0.000899835
0.746
CDBox
135
ACA7_s
−0.34
0.000995798
0.703
HAcaBox
133
miR-1228
−0.67
0.001047707
0.730
miRNA
114
miR-199a-3p
0.75
0.001282519
0.729
miRNA
134
ENSG00000212508
−0.59
0.001303596
0.687
snoRNA
122
ENSG00000200961
−0.41
0.001335597
0.699
snoRNA
41
miR-23b
0.45
0.00142683
0.817
miRNA
137
ENSG00000207177
−0.34
0.001464718
0.697
snoRNA
59
ACA50
0.41
0.001642667
0.674
HAcaBox
88
miR-550-star
0.75
0.001687411
0.692
miRNA
58
miR-617
−0.56
0.001827038
0.676
miRNA
64
U75
−0.57
0.001850734
0.729
CDBox
134
HBII-85-2_x
−0.41
0.001956673
0.706
CDBox
135
miR-508-5p
0.77
0.001978936
0.711
miRNA
92
miR-200a
0.66
0.002095909
0.676
miRNA
33
miR-574-5p
0.79
0.002104165
0.749
miRNA
103
ACA49
−0.37
0.00221029
0.692
HAcaBox
127
miR-1826
0.46
0.002224183
0.799
miRNA
137
ENSG00000212377
−0.45
0.002249473
0.676
snoRNA
31
U45A
−0.44
0.002283826
0.686
CDBox
74
miR-34a-star
0.61
0.002356105
0.682
miRNA
39
miR-378-star
0.71
0.002495647
0.710
miRNA
82
miR-509-5p
0.98
0.002612774
0.705
miRNA
81
miR-34a
0.79
0.00270219
0.676
miRNA
132
ACA2a
0.41
0.002741773
0.690
HAcaBox
55
miR-98
0.63
0.002795533
0.698
miRNA
47
miR-337-3p
−0.59
0.002924904
0.709
miRNA
94
U58A
−0.37
0.002957231
0.667
CDBox
129
miR-30e
0.66
0.003008812
0.673
miRNA
57
miR-196a
0.99
0.003061353
0.686
miRNA
77
miR-17-star
0.87
0.003088295
0.675
miRNA
56
HBII-429
−0.26
0.003238494
0.681
CDBox
137
HBII-85-5_x
0.38
0.003305314
0.678
CDBox
31
miR-191-star
−0.50
0.003313493
0.701
miRNA
54
U102
−0.32
0.003411715
0.662
CDBox
124
ACA57
−0.35
0.003594842
0.737
scaRna
135
HBII-234_x
−0.33
0.003636016
0.676
CDBox
102
hsa-let-7i
0.62
0.003881627
0.748
miRNA
135
spike_in-control-23
−0.30
0.003884651
0.673
Oligonucleotide
137
spike-in
controls
HBII-276
0.37
0.003895578
0.676
CDBox
132
mgU6-53
−0.37
0.004017934
0.667
CDBox
94
miR-575
−0.55
0.004110263
0.666
miRNA
41
miR-486-5p
1.06
0.004302169
0.672
miRNA
65
HBII-85-20_x
0.37
0.004413582
0.662
CDBox
42
U43
0.49
0.004416752
0.847
CDBox
135
miR-199b-3p
0.64
0.00460804
0.711
miRNA
134
U50B
−0.47
0.004646908
0.678
CDBox
135
HBII-202
−0.37
0.004720422
0.711
CDBox
135
U32A_x
0.30
0.004742469
0.634
CDBox
136
U28_x
0.43
0.005077583
0.733
CDBox
133
miR-223
0.54
0.005512872
0.635
miRNA
83
U36A
0.26
0.005677159
0.654
CDBox
132
miR-548a-3p
−0.65
0.005852929
0.669
miRNA
65
U82
−0.43
0.005931718
0.686
CDBox
131
ACA13
−0.40
0.005934282
0.697
HAcaBox
134
ENSG00000208308_x
0.48
0.005982879
0.755
snoRNA
129
14qI-8
−0.41
0.006020932
0.647
CDBox
61
ACA41_x
0.38
0.006458897
0.687
HAcaBox
122
U20
0.34
0.006504359
0.665
CDBox
117
HBII-210
−0.33
0.006967845
0.684
CDBox
135
ACA53
0.33
0.007009476
0.656
HAcaBox
105
miR-188-5p
0.59
0.00730559
0.668
miRNA
51
miR-653
−0.48
0.007396776
0.652
miRNA
50
ACA18_x
0.33
0.007506763
0.656
HAcaBox
135
ENSG00000202440_x
−0.29
0.007646916
0.654
snoRNA
91
HBII-180C_x
0.33
0.007676115
0.666
CDBox
131
ENSG00000200235_x
−0.29
0.007854884
0.650
snoRNA
59
HBII-85-17_x
0.43
0.008991412
0.650
CDBox
57
miR-205
0.39
0.009048012
0.665
miRNA
135
ACA27_x
0.24
0.009084132
0.676
HAcaBox
130
ACA52
0.31
0.009338308
0.664
HAcaBox
121
U8_x
0.37
0.00950871
0.638
CDBox
135
ENSG00000201229
0.35
0.009710558
0.662
snoRNA
32
miR-423-5p
−0.49
0.009884603
0.704
miRNA
132
U72_x
0.27
0.009902439
0.642
HAcaBox
103
U50
0.37
0.010130893
0.679
CDBox
134
miR-34b
0.95
0.010634429
0.647
miRNA
32
U60
0.33
0.010937468
0.653
CDBox
103
ACA26
−0.38
0.011152582
0.688
scaRna
125
ACA21
−0.44
0.011353671
0.661
HAcaBox
133
U47
0.30
0.01143234
0.651
CDBox
74
miR-26a
0.40
0.011704306
0.793
miRNA
136
miR-21-star
0.54
0.012900809
0.648
miRNA
64
U43_x
0.42
0.013355042
0.808
CDBox
135
HBII-55
0.27
0.013604568
0.636
CDBox
135
ACA19
−0.29
0.013694584
0.634
HAcaBox
118
ENSG00000200897_x
−0.34
0.013964134
0.628
snoRNA
70
ENSG00000207118
0.42
0.01420542
0.652
snoRNA
93
U31
−0.42
0.014421405
0.684
CDBox
132
miR-204
0.70
0.015040931
0.620
miRNA
53
miR-195
0.59
0.01545596
0.646
miRNA
132
miR-432
0.70
0.015655418
0.649
miRNA
51
hsa-let-7c
0.48
0.015958151
0.801
miRNA
135
ACA10_s
0.33
0.015973764
0.658
HAcaBox
113
miR-1825
−0.60
0.016002367
0.679
miRNA
132
14qII-1
−0.53
0.016171959
0.621
CDBox
128
14qII-21_x
0.32
0.017134601
0.670
CDBox
51
U34
0.24
0.017406393
0.609
CDBox
137
miR-138-1-star
0.64
0.017790103
0.611
miRNA
91
miR-1257
−0.40
0.018052873
0.633
miRNA
31
ACA51_x
−0.23
0.018226343
0.656
HAcaBox
135
14qII-1_x
−0.50
0.018262482
0.626
CDBox
131
ACA43
0.31
0.018272258
0.620
HAcaBox
114
hsa-let-7d
0.38
0.01921824
0.855
miRNA
135
14qII-12_x
0.40
0.020581734
0.652
CDBox
85
14qII-28_x
0.34
0.02070105
0.641
CDBox
51
spike_in-control-30
−0.36
0.02072199
0.657
Oligonucleotide
53
spike-in
controls
U49B_s
−0.38
0.021350114
0.648
CDBox
129
U45B_x
−0.32
0.022203975
0.615
CDBox
46
miR-125b
0.42
0.022489574
0.718
miRNA
135
ENSG00000202252
−0.23
0.023928736
0.654
snoRNA
135
miR-1324
−0.37
0.024126574
0.638
miRNA
57
HBI-61
−0.34
0.024172419
0.639
HAcaBox
134
miR-99b-star
0.34
0.024194238
0.626
miRNA
74
miR-20a
0.51
0.024441924
0.640
miRNA
134
U54
0.36
0.02454759
0.749
CDBox
135
ENSG00000200932
−0.31
0.024839208
0.656
snoRNA
47
ENSG00000212326
0.34
0.024965859
0.611
snoRNA
104
U95
−0.35
0.026080784
0.723
CDBox
135
miR-193b-star
0.57
0.028801534
0.684
miRNA
77
ACA5_x
0.29
0.0293861
0.662
HAcaBox
103
ACA1_x
−0.30
0.029505966
0.627
HAcaBox
51
mgU6-53_x
−0.26
0.03076806
0.618
CDBox
113
U26
−0.36
0.030778322
0.608
CDBox
135
miR-24
0.36
0.031162316
0.771
miRNA
135
spike_in-control-29
−0.24
0.03150161
0.615
Oligonucleotide
137
spike-in
controls
miR-19b
0.57
0.03221182
0.612
miRNA
124
miR-513c
0.78
0.032937767
0.632
miRNA
73
U42B_x
0.27
0.033688384
0.613
CDBox
109
miR-20a-star
−0.90
0.033742183
0.639
miRNA
61
U25
−0.30
0.035318167
0.655
CDBox
135
miR-455-3p
0.34
0.036186611
0.643
miRNA
136
U109
0.32
0.036189693
0.634
scaRna
69
miR-938
−0.32
0.037572276
0.639
miRNA
45
ENSG00000207503
−0.27
0.037791965
0.622
snoRNA
42
HBII-289
−0.24
0.041306388
0.652
CDBox
135
U17b_x
0.34
0.041402099
0.728
HAcaBox
135
ACA8_x
−0.28
0.042136422
0.624
HAcaBox
125
ACA44
0.29
0.043557966
0.693
HAcaBox
135
U45C_x
−0.33
0.043838427
0.586
CDBox
72
ENSG00000201133
−0.27
0.045035669
0.645
snoRNA
35
ACA55
−0.26
0.045152107
0.606
HAcaBox
85
miR-451
0.53
0.046730942
0.628
miRNA
72
14qII-26
−0.32
0.047726134
0.619
CDBox
32
miR-141
0.44
0.049534195
0.627
miRNA
69
[0000]
TABLE 2
50 miRNAs most significantly expressed between melanoma and nevi
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
miR-132
2.98
1.2728E−32
0.994
miRNA
96
miR-150
3.27
5.83192E−30
1.000
miRNA
117
miR-339-5p
2.73
1.69388E−27
0.988
miRNA
75
miR-15b
3.02
6.41784E−27
0.978
miRNA
125
miR-342-3p
2.23
7.03798E−26
0.993
miRNA
136
miR-572
−2.78
1.00008E−25
0.970
miRNA
116
miR-155
4.14
1.28454E−25
0.981
miRNA
123
miR-425
2.74
8.13135E−25
0.975
miRNA
114
miR-1202
−2.63
2.97795E−23
0.986
miRNA
57
miR-1268
−2.68
6.05905E−23
0.997
miRNA
133
HBII-382_s
−1.71
6.58931E−22
0.971
scaRna
126
miR-1225-5p
−2.36
1.05361E−21
0.953
miRNA
90
miR-30c
2.39
2.58594E−21
0.980
miRNA
125
miR-106b-star
2.24
3.48507E−21
0.961
miRNA
72
miR-125a-5p
2.39
6.90609E−21
0.967
miRNA
128
mgU6-53B
−1.51
1.74782E−20
0.973
CDBox
99
miR-25
2.57
1.52769E−19
0.956
miRNA
118
miR-149-star
−2.03
1.64858E−19
1.000
miRNA
135
miR-939
−2.21
1.9129E−19
0.973
miRNA
57
miR-92b-star
−2.30
2.05085E−19
0.969
miRNA
111
miR-500-star
2.38
3.11256E−19
0.956
miRNA
97
miR-22
2.69
3.8844E−19
0.965
miRNA
120
HBII-142_x
−1.22
4.93318E−19
0.981
CDBox
135
miR-181b
2.41
1.00639E−18
0.960
miRNA
130
HBII-142
−1.33
1.18794E−18
0.988
CDBox
135
U38B
−1.95
1.35964E−18
0.975
CDBox
134
miR-663
−2.10
2.04672E−18
0.984
miRNA
134
miR-1224-5p
−2.54
2.91169E−18
0.946
miRNA
78
miR-23a
1.18
2.99523E−18
0.967
miRNA
137
HBII-85-6_x
−1.73
4.78418E−18
0.939
CDBox
137
miR-1207-5p
−2.14
4.98991E−18
0.995
miRNA
133
miR-1301
2.36
5.22389E−18
0.931
miRNA
54
miR-1228-star
−2.41
5.51513E−18
0.997
miRNA
134
miR-345
2.45
6.43552E−18
0.942
miRNA
75
miR-30a-star
2.32
6.92165E−18
0.932
miRNA
64
ENSG00000199411_s
−1.97
7.23325E−18
0.991
snoRNA
135
ENSG00000202327
−1.40
8.75839E−18
0.938
snoRNA
54
miR-92a
1.67
9.49427E−18
0.979
miRNA
136
miR-127-3p
2.43
9.84615E−18
0.936
miRNA
89
HBII-85-26
−2.07
1.50619E−17
0.951
CDBox
136
miR-1308
−2.14
1.99888E−17
0.999
miRNA
135
miR-31
3.29
2.46697E−17
0.913
miRNA
103
miR-921
−1.46
2.61089E−17
0.928
miRNA
49
miR-146b-5p
2.37
6.10422E−17
0.918
miRNA
83
miR-768-3p
−1.05
6.66153E−17
0.949
miRNA
137
miR-708
2.29
6.86187E−17
0.929
miRNA
102
miR-139-5p
2.23
2.78962E−16
0.922
miRNA
80
ACA24_x
1.33
3.37973E−16
0.925
HAcaBox
98
miR-501-3p
1.83
4.76751E−16
0.923
miRNA
80
miR-502-3p
2.16
5.19509E−16
0.925
miRNA
110
miR-923
−1.86
5.55191E−16
0.996
miRNA
135
[0000]
TABLE 3
miRNAs significantly expressed between melanoma and normal skin
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
miR-146a
4.6
9.43624E−20
0.983
miRNA
129
miR-509-3p
5.2
5.61558E−17
0.969
miRNA
116
14qII-14
−2.6
1.16829E−14
0.978
CDBox
56
miR-25
2.4
2.08E−14
0.949
miRNA
118
miR-138
3.2
2.51219E−13
0.954
miRNA
82
miR-509-3-5p
3.6
2.94532E−13
0.963
miRNA
107
miR-506
3.4
6.99753E−13
0.954
miRNA
76
14qII-14_x
−2.2
8.36026E−13
0.970
CDBox
56
14qI-4
−2.1
8.9267E−13
0.964
CDBox
80
miR-30b
2.2
2.43822E−12
0.957
miRNA
128
miR-513a-5p
3.5
3.17158E−12
0.939
miRNA
105
miR-21
3.3
4.58391E−12
0.926
miRNA
79
Z17B
−1.0
6.92137E−12
0.956
CDBox
117
U33
−0.9
8.19977E−12
0.968
CDBox
137
miR-20b
2.8
2.24496E−11
0.939
miRNA
99
hsa-let-7i
2.3
3.27742E−11
0.973
miRNA
135
HBII-239
−1.0
3.9295E−11
0.920
CDBox
135
miR-146b-5p
2.3
8.71488E−11
0.910
miRNA
83
14qII-26_x
−1.8
9.17329E−11
0.914
CDBox
41
miR-155
2.8
1.12361E−10
0.940
miRNA
123
miR-151-3p
1.8
1.7141E−10
0.922
miRNA
117
HBII-289
−1.1
1.76712E−10
0.963
CDBox
135
14qII-12_x
−1.7
1.9475E−10
0.907
CDBox
85
miR-1274a
1.9
3.28343E−10
0.928
miRNA
48
HBII-180A_x
−0.8
4.68853E−10
0.933
CDBox
123
miR-1301
2.0
7.22101E−10
0.896
miRNA
54
14qII-1_x
−1.7
7.72545E−10
0.965
CDBox
131
miR-193b
−1.4
8.7852E−10
0.974
miRNA
130
miR-510
2.7
1.03096E−09
0.914
miRNA
82
miR-126
2.1
1.35297E−09
0.959
miRNA
133
miR-24-2-star
1.8
1.36986E−09
0.895
miRNA
63
miR-106b
2.1
1.91606E−09
0.930
miRNA
127
HBII-276
−1.0
2.06051E−09
0.908
CDBox
132
miR-532-5p
1.8
2.9654E−09
0.887
miRNA
113
14qII-12
−1.7
3.71443E−09
0.859
CDBox
58
miR-19b
2.1
3.71682E−09
0.908
miRNA
124
miR-30a
1.6
6.61873E−09
0.894
miRNA
113
HBII-85-26_x
−1.1
7.76845E−09
0.895
CDBox
135
miR-150
1.7
1.08172E−08
0.894
miRNA
117
14qII-26
−1.5
1.16704E−08
0.869
CDBox
32
miR-324-5p
1.6
1.24724E−08
0.880
miRNA
102
14qI-8
−1.2
1.39067E−08
0.894
CDBox
61
miR-185
1.6
1.44139E−08
0.952
miRNA
132
miR-194
1.8
1.72961E−08
0.883
miRNA
54
14qII-1
−1.5
2.76507E−08
0.928
CDBox
128
HBII-202
−1.0
2.89826E−08
0.946
CDBox
135
miR-768-5p
−1.6
3.1365E−08
0.986
miRNA
135
miR-421
1.6
4.42916E−08
0.872
miRNA
68
miR-28-5p
1.7
5.45027E−08
0.877
miRNA
105
miR-151-5p
1.2
5.48542E−08
0.968
miRNA
135
miR-15a
2.0
5.77662E−08
0.889
miRNA
80
miR-26a
1.3
6.8712E−08
0.968
miRNA
136
U25
−1.0
7.35643E−08
0.976
CDBox
135
HBII-180C
−0.9
7.47464E−08
0.836
CDBox
115
miR-584
1.9
8.0812E−08
0.863
miRNA
57
hsa-let-7f
2.2
1.05873E−07
0.924
miRNA
130
miR-1268
−1.7
1.09503E−07
0.954
miRNA
133
miR-572
−1.4
1.12523E−07
0.886
miRNA
116
ENSG00000200897
−0.9
1.38587E−07
0.843
snoRNA
38
miR-508-5p
1.8
1.57345E−07
0.873
miRNA
92
hsa-let-7g
1.8
1.57818E−07
0.916
miRNA
127
miR-20a
1.7
1.58351E−07
0.926
miRNA
134
miR-1225-5p
−1.3
6.2291E−07
0.890
miRNA
90
U55
−0.8
1.8721E−07
0.942
CDBox
135
miR-509-5p
2.3
1.95354E−07
0.864
miRNA
81
HBII-85-6_x
−1.1
2.0107E−07
0.872
CDBox
137
U99
−0.7
2.22915E−07
0.872
HAcaBox
137
miR-501-3p
1.4
2.27557E−07
0.858
miRNA
80
miR-29a
1.8
2.42514E−07
0.907
miRNA
128
miR-1274b
1.6
2.6096E−07
0.863
miRNA
112
miR-210
−1.2
2.81748E−07
0.895
miRNA
130
HBII-85-26
−1.4
3.5949E−07
0.896
CDBox
136
miR-199a-5p
−0.8
3.93185E−07
0.870
miRNA
129
miR-149
−1.6
5.63545E−07
0.920
miRNA
100
miR-1307
−0.9
5.6459E−07
0.907
miRNA
97
miR-744
−1.1
5.78243E−07
0.971
miRNA
133
miR-92b-star
−1.4
6.45948E−07
0.907
miRNA
111
ACA11
0.8
7.08497E−07
0.842
HAcaBox
48
miR-27a
1.0
7.17204E−07
0.887
miRNA
136
miR-34a-star
1.4
8.89848E−07
0.842
miRNA
39
U46
−0.8
9.2248E−07
0.884
CDBox
133
miR-214
−1.2
1.02234E−06
0.930
miRNA
135
miR-132
1.2
1.15319E−06
0.808
miRNA
96
miR-18a
2.0
1.3554E−06
0.866
miRNA
77
miR-125a-5p
−1.0
1.86884E−06
0.934
miRNA
128
14qI-8_x
−0.9
1.95428E−06
0.831
CDBox
74
miR-663
−1.3
1.9913E−06
0.910
miRNA
134
miR-16
1.1
2.78721E−06
0.955
miRNA
135
HBII-142_x
−0.8
2.95334E−06
0.909
CDBox
135
U103_s
−0.8
3.6466E−06
0.825
CDBox
111
U55_x
−0.8
3.84586E−06
0.958
CDBox
135
HBII-142
−0.8
3.88875E−06
0.917
CDBox
135
miR-130b
1.9
4.19812E−06
0.858
miRNA
90
miR-339-3p
1.1
4.25751E−06
0.796
miRNA
60
miR-30d
1.2
4.40714E−06
0.902
miRNA
131
miR-196a
2.0
4.53608E−06
0.833
miRNA
77
miR-199a-3p
1.4
5.28457E−06
0.889
miRNA
134
miR-211
2.1
5.7974E−06
0.859
miRNA
84
miR-30e
1.2
5.88414E−06
0.839
miRNA
57
ACA54
−0.6
7.09713E−06
0.861
HAcaBox
133
miR-106b-star
1.1
7.86756E−06
0.720
miRNA
72
14qII-3
−1.1
8.39354E−06
0.832
CDBox
95
HBII-55
−0.6
8.41728E−06
0.860
CDBox
135
miR-486-5p
−2.2
1.02088E−05
0.829
miRNA
65
miR-145
−1.3
1.03604E−05
0.831
miRNA
135
miR-34a
1.4
1.04763E−05
0.868
miRNA
132
miR-106a
1.2
1.06568E−05
0.919
miRNA
135
miR-1271
1.3
1.06608E−05
0.829
miRNA
70
miR-500
1.3
1.07278E−05
0.816
miRNA
86
miR-625
1.4
1.08708E−05
0.800
miRNA
59
14qII-9_x
−0.8
1.14849E−05
0.821
CDBox
36
14qII-21_x
−0.9
1.17647E−05
0.797
CDBox
51
U83
−0.6
1.19481E−05
0.889
CDBox
135
miR-638
−1.3
1.34963E−05
0.914
miRNA
135
HBII-180C_x
−0.6
1.39632E−05
0.841
CDBox
131
ENSG00000212139_x
−0.6
1.67825E−05
0.831
snoRNA
124
miR-628-3p
1.4
1.76296E−05
0.811
miRNA
38
U104
−0.8
1.84466E−05
0.886
CDBox
135
miR-10b
1.2
2.02886E−05
0.829
miRNA
106
U34
−0.4
2.06445E−05
0.807
CDBox
137
miR-127-3p
−1.1
2.16929E−05
0.799
miRNA
89
14qII-28_x
−0.9
2.21554E−05
0.815
CDBox
51
miR-1207-5p
−1.2
2.25272E−05
0.917
miRNA
133
miR-199b-3p
1.3
2.29577E−05
0.863
miRNA
134
U35A
−0.7
2.50745E−05
0.900
CDBox
135
U91_s
−0.8
2.92768E−05
0.806
scaRna
132
spike_in-control-36
0.6
2.95775E−05
0.865
Oligonucleotide
137
spike-in
controls
U32A_x
−0.4
3.05381E−05
0.827
CDBox
136
miR-21-star
1.2
3.24139E−05
0.808
miRNA
64
miR-149-star
−1.1
4.06943E−05
0.888
miRNA
135
miR-193b-star
−1.4
4.09065E−05
0.831
miRNA
77
U67_x
0.8
4.09255E−05
0.792
HAcaBox
50
ACA20
−0.8
4.42355E−05
0.839
HAcaBox
131
miR-1287
1.2
4.69003E−05
0.775
miRNA
40
ACA64
−0.7
4.84198E−05
0.802
HAcaBox
33
U57
−0.8
5.04018E−05
0.944
CDBox
135
miR-193a-3p
1.1
5.08442E−05
0.766
miRNA
42
miR-371-5p
1.1
5.19682E−05
0.775
miRNA
64
HBII-85-8_x
−0.7
5.46471E−05
0.782
CDBox
135
miR-503
1.4
5.4991E−05
0.794
miRNA
41
miR-138-1-star
1.5
5.60721E−05
0.877
miRNA
91
ACA67_x
0.7
5.78125E−05
0.790
HAcaBox
54
miR-1228-star
−1.3
5.81565E−05
0.895
miRNA
134
U41
−0.8
5.85491E−05
0.875
CDBox
135
miR-193a-5p
−1.2
5.98826E−05
0.897
miRNA
121
ENSG00000202252
−0.5
6.64141E−05
0.839
snoRNA
135
14qI-4_x
−1.0
6.7457E−05
0.760
CDBox
51
miR-508-3p
1.7
6.91432E−05
0.801
miRNA
74
miR-200b
1.4
7.07093E−05
0.779
miRNA
109
miR-660
1.2
7.13979E−05
0.791
miRNA
71
U67
0.8
7.16134E−05
0.774
HAcaBox
44
U50B
−0.8
7.249E−05
0.869
CDBox
135
miR-513c
1.9
7.46404E−05
0.771
miRNA
73
14qI-9_x
−0.7
7.67649E−05
0.772
CDBox
34
U60
−0.6
8.34902E−05
0.779
CDBox
103
U102
0.5
8.47602E−05
0.772
CDBox
124
EN8G00000200235_x
−0.5
9.4306E−05
0.793
snoRNA
59
miR-17
1.0
9.79941E−05
0.910
miRNA
134
U36C
−0.6
0.000107866
0.854
CDBox
135
miR-491-5p
0.9
0.000121664
0.753
miRNA
92
miR-425
1.0
0.000138461
0.771
miRNA
114
miR-500-star
1.0
0.000148221
0.761
miRNA
97
U78_x
1.0
0.000150233
0.872
CDBox
134
ENSG00000202327
−0.6
0.000153478
0.783
snoRNA
54
miR-181c
1.1
0.000156102
0.772
miRNA
59
ENSG00000212523_x
−0.8
0.000165203
0.772
snoRNA
135
mgU6-53B_x
−0.5
0.00016649
0.784
CDBox
121
miR-99b-star
0.8
0.00017311
0.743
miRNA
74
U53
−0.7
0.000175804
0.763
CDBox
126
miR-296-3p
−1.0
0.000180884
0.771
miRNA
90
U50B_x
−0.7
0.000181435
0.829
CDBox
135
miR-30a-star
1.2
0.00018331
0.766
miRNA
64
U46_x
−0.8
0.000183742
0.819
CDBox
131
ENSG00000207410_x
−0.5
0.000198904
0.779
snoRNA
55
miR-99a
−0.8
0.000204711
0.829
miRNA
135
miR-513b
1.4
0.000214575
0.781
miRNA
64
miR-23a
0.6
0.000218135
0.908
miRNA
137
miR-31
1.7
0.00023269
0.721
miRNA
103
miR-345
1.2
0.000250483
0.782
miRNA
75
miR-212
1.5
0.000254534
0.831
miRNA
62
ENSG00000212266
−0.6
0.000255339
0.777
snoRNA
93
miR-152
1.1
0.000260732
0.813
miRNA
122
U19
0.6
0.000277432
0.757
HAcaBox
118
miR-886-3p
1.0
0.000298839
0.768
miRNA
110
U73a
−0.6
0.000338569
0.846
CDBox
135
miR-423-3p
−0.7
0.000347496
0.848
miRNA
107
mgh28S-2411
−0.6
0.00034785
0.901
CDBox
135
miR-103
0.8
0.000430411
0.930
miRNA
135
miR-629
1.1
0.000473215
0.769
miRNA
64
U65
−0.6
0.000562655
0.778
HAcaBox
128
14qI-7
−0.7
0.000569692
0.803
CDBox
51
miR-933
−0.6
0.000572446
0.769
miRNA
100
miR-205
−0.6
0.000653671
0.767
miRNA
135
U105
−0.4
0.000692027
0.749
CDBox
126
miR-378-star
1.1
0.000731339
0.769
miRNA
82
miR-939
−0.9
0.000748523
0.822
miRNA
57
hsa-let-7d
0.8
0.000759497
0.978
miRNA
135
miR-362-5p
1.2
0.000775756
0.762
miRNA
94
ACA9
0.7
0.000834583
0.739
HAcaBox
82
miR-10a
1.1
0.000844868
0.759
miRNA
69
miR-877
−0.9
0.000845569
0.789
miRNA
126
miR-128
1.1
0.000865867
0.762
miRNA
44
miR-27b
0.8
0.000876954
0.799
miRNA
133
miR-17-star
1.2
0.000905238
0.748
miRNA
56
mgh18S-121
−0.5
0.000964406
0.789
CDBox
134
ENSG00000200394
0.5
0.000968073
0.772
snoRNA
119
ENSG00000212315
0.6
0.000971189
0.757
snoRNA
117
ENSG00000212615_x
−0.5
0.000998331
0.707
snoRNA
102
miR-148a
0.9
0.001014157
0.733
miRNA
41
miR-923
−0.9
0.001032772
0.826
miRNA
135
ACA20_x
−0.6
0.001087206
0.830
HAcaBox
134
ENSG00000212579_x
−0.6
0.001126846
0.765
snoRNA
100
miR-589-star
0.5
0.001225281
0.703
miRNA
43
miR-107
0.7
0.001260426
0.932
miRNA
135
ENSG00000199363
0.6
0.001425983
0.750
snoRNA
42
ACA55
0.5
0.001430114
0.746
HAcaBox
85
U54
−0.7
0.001511402
0.868
CDBox
135
U36A
−0.4
0.001519955
0.759
CDBox
132
U95
−0.7
0.001551616
0.929
CDBox
135
14qII-22_x
−0.7
0.001591836
0.701
CDBox
50
U58B_x
−0.5
0.001603166
0.726
CDBox
132
miR-720
0.7
0.001622509
0.760
miRNA
137
ENSG00000200394_x
0.5
0.001742151
0.711
snoRNA
115
HBII-166
−0.5
0.001874456
0.769
CDBox
134
miR-29b-1-star
1.3
0.001938943
0.736
miRNA
46
HBII-436
−0.5
0.001978078
0.731
CDBox
102
U23
−0.5
0.002014594
0.748
HAcaBox
127
miR-346
−0.9
0.002054981
0.774
miRNA
55
U58A
−0.5
0.002095349
0.735
CDBox
129
HBII-95
0.5
0.00219824
0.703
CDBox
78
miR-339-5p
0.7
0.002357824
0.693
miRNA
75
ACA25
0.4
0.002440171
0.724
HAcaBox
73
miR-363
1.1
0.002716266
0.735
miRNA
44
miR-432
−1.1
0.002752773
0.738
miRNA
51
miR-424-star
1.1
0.002765097
0.718
miRNA
41
U27
−0.6
0.002765603
0.792
CDBox
134
miR-30c
0.6
0.002778453
0.770
miRNA
125
miR-93
0.7
0.002813996
0.863
miRNA
134
hsa-let-7a
0.8
0.002856983
0.911
miRNA
136
miR-181d
1.0
0.002954008
0.748
miRNA
61
miR-99b
−0.5
0.00296227
0.757
miRNA
129
miR-550-star
0.9
0.003086147
0.740
miRNA
58
U43
−0.7
0.00327637
0.865
CDBox
135
U52
−0.5
0.003332494
0.783
CDBox
135
miR-502-3p
0.8
0.003628993
0.775
miRNA
110
spike_in-control-29
−0.4
0.003663934
0.723
Oligonucleotide
137
spike-in
controls
14qII-17
−0.7
0.003689916
0.703
CDBox
71
ENSG00000212302_x
−0.4
0.003876466
0.676
snoRNA
56
miR-574-3p
−0.7
0.003955226
0.842
miRNA
122
miR-320d
−0.8
0.004248663
0.868
miRNA
134
miR-1246
1.0
0.004275913
0.772
miRNA
131
ACA7_s
−0.4
0.004475709
0.719
HAcaBox
133
miR-15b
0.6
0.004714973
0.792
miRNA
125
HBII-52-37_x
−0.5
0.004773282
0.714
CDBox
37
gi555853_copy0
−0.6
0.004784885
0.799
5.8s rRNA
137
miR-30e-star
0.8
0.00500785
0.717
miRNA
35
miR-18a-star
0.8
0.005024206
0.723
miRNA
40
ENSG00000201847_x
−0.4
0.005059414
0.688
snoRNA
48
gi555853_copy5
−0.5
0.005220274
0.809
5.8s rRNA
137
U24
−0.4
0.005634443
0.708
CDBox
133
miR-1280
−0.4
0.005689807
0.740
miRNA
134
miR-1231
−0.8
0.005810993
0.676
miRNA
79
ENSG00000202498_x
−0.5
0.005898128
0.701
snoRNA
137
gi555853_copy7
−0.5
0.006325433
0.804
5.8s rRNA
137
miR-28-3p
0.9
0.006506887
0.711
miRNA
94
ENSG00000199435
0.4
0.006656491
0.706
snoRNA
63
gi555853_copy2
−0.5
0.00671481
0.800
5.8s rRNA
137
U43_x
−0.6
0.006913554
0.854
CDBox
135
ENSG00000212273_x
−0.5
0.007104981
0.725
snoRNA
126
ENSG00000200961
−0.4
0.007247826
0.716
snoRNA
41
U38A
−0.7
0.007390068
0.814
CDBox
134
E3_x
−0.4
0.007704052
0.779
HAcaBox
135
gi555853_copy8
−0.5
0.00776022
0.799
5.8s rRNA
137
HBII-234_x
−0.3
0.007814833
0.703
CDBox
102
U28
−0.5
0.008026327
0.771
CDBox
135
ENSG00000212587
−0.5
0.008211191
0.685
snoRNA
45
ENSG00000212149_x
−0.5
0.008233504
0.678
snoRNA
77
HBII-420
−0.5
0.00828299
0.771
CDBox
131
gi555853_copy1
−0.5
0.008395769
0.791
5.8s rRNA
137
HBII-85-21_x
0.5
0.008439987
0.717
CDBox
39
gi555853_copy4
−0.5
0.008541113
0.793
5.8s rRNA
137
gi555853_copy6
−0.5
0.008815947
0.792
5.8s rRNA
137
ENSG00000200897_x
−0.5
0.009024011
0.686
snoRNA
70
ENSG00000207002
−0.4
0.009046282
0.706
snoRNA
35
ENSG00000212627
−0.4
0.009345896
0.714
snoRNA
69
gi555853_copy3
−0.5
0.009628403
0.777
5.8s rRNA
137
HBII-85-17_x
0.5
0.009677702
0.685
CDBox
57
miR-92b
0.5
0.009817789
0.672
miRNA
91
HBII-210
−0.4
0.009959111
0.756
CDBox
135
ACA3
−0.5
0.010166004
0.740
HAcaBox
134
miR-769-5p
0.7
0.010207709
0.622
miRNA
56
U100
0.4
0.010232137
0.645
scaRna
80
U13
−0.4
0.010247574
0.720
CDBox
135
miR-181b
0.6
0.010316868
0.816
miRNA
130
ACA46
0.4
0.010365242
0.699
HAcaBox
124
gi555853_copy9
−0.5
0.010460125
0.788
5.8s rRNA
137
U70_x
−0.5
0.011265988
0.704
HAcaBox
53
HBII-85-15_x
0.5
0.011411104
0.695
CDBox
49
miR-203
0.7
0.01182754
0.822
miRNA
132
miR-320c
−0.6
0.011901129
0.845
miRNA
135
miR-191-star
−0.6
0.012197187
0.680
miRNA
54
ACA18_x
−0.4
0.012258626
0.694
HAcaBox
135
miR-27a-star
0.8
0.013060406
0.702
miRNA
40
miR-192
0.7
0.013123545
0.703
miRNA
32
U74_x
0.5
0.013418084
0.804
CDBox
135
ACA15_x
−0.3
0.013532632
0.691
HAcaBox
124
miR-198
−0.6
0.013839541
0.687
miRNA
31
U28_x
−0.5
0.013863106
0.711
CDBox
133
ACA28
0.4
0.013886424
0.685
HAcaBox
120
U97
−0.4
0.013970203
0.692
CDBox
133
ACA4
0.3
0.014571497
0.655
HAcaBox
117
miR-423-5p
−0.6
0.015447652
0.754
miRNA
132
ACA25_x
0.4
0.015584731
0.701
HAcaBox
114
HBII-382_s
−0.4
0.016066802
0.670
scaRna
126
miR-34b
1.2
0.016083233
0.693
miRNA
32
miR-181a-2-star
0.7
0.016427521
0.646
miRNA
99
U15B
−0.3
0.017584552
0.689
CDBox
129
miR-361-5p
0.4
0.017617483
0.783
miRNA
135
ACA9_x
0.5
0.017621407
0.669
HAcaBox
77
ACA15_s
−0.3
0.017633335
0.738
HAcaBox
116
miR-23b-star
0.7
0.018210894
0.672
miRNA
52
ACA60
−0.3
0.018634054
0.702
HAcaBox
129
14q-0
−0.4
0.019666039
0.681
CDBox
49
HBII-85-22_x
0.5
0.019999179
0.673
CDBox
42
miR-30b-star
0.9
0.020172985
0.686
miRNA
61
miR-125b
−0.5
0.020376572
0.707
miRNA
135
ENSG00000199411_s
−0.6
0.020504379
0.779
snoRNA
135
HBII-251
−0.3
0.020538747
0.679
CDBox
135
miR-483-3p
0.9
0.020547545
0.666
miRNA
40
ACA23
−0.3
0.021199129
0.685
HAcaBox
113
ENSG00000212432_s
−0.4
0.021742945
0.649
snoRNA
75
miR-25-star
0.7
0.022483461
0.671
miRNA
52
ENSG00000200932
−0.3
0.023007003
0.687
snoRNA
47
U49B_s
0.5
0.023157964
0.726
CDBox
129
ENSG00000212214_x
0.4
0.023504965
0.687
snoRNA
88
U83B
−0.4
0.024471226
0.745
CDBox
135
miR-320b
−0.6
0.025686249
0.790
miRNA
135
miR-489
0.6
0.025963923
0.680
miRNA
58
miR-26b
0.7
0.026201573
0.682
miRNA
45
U14B
−0.4
0.027046414
0.632
CDBox
51
HBII-115
−0.3
0.027115569
0.730
CDBox
117
ENSG00000207027
−0.4
0.028391297
0.621
snoRNA
36
miR-494
0.5
0.029570695
0.689
miRNA
135
miR-181a-star
0.7
0.030787798
0.668
miRNA
35
U49A_x
0.4
0.03088655
0.750
CDBox
135
ACA14b_x
−0.3
0.030912946
0.693
HAcaBox
105
U21
−0.4
0.031731894
0.691
CDBox
134
HBII-135_x
0.6
0.032076241
0.663
CDBox
132
miR-382
0.8
0.032245385
0.651
miRNA
47
miR-532-3p
0.4
0.032767036
0.697
miRNA
95
miR-214-star
0.8
0.032818193
0.670
miRNA
47
mgU6-53B
−0.3
0.033293267
0.663
CDBox
99
miR-200c
−0.7
0.033609817
0.659
miRNA
134
miR-575
0.5
0.034489882
0.657
miRNA
41
mgU6-53
−0.3
0.034658143
0.674
CDBox
94
miR-422a
0.8
0.035772116
0.674
miRNA
84
ENSG00000201848
−0.3
0.036190647
0.652
snoRNA
34
ACA45
0.3
0.036575475
0.653
scaRna
53
miR-559
−0.5
0.036810259
0.647
miRNA
72
ACA61
−0.4
0.037187144
0.716
HAcaBox
135
snR38C
−0.4
0.037656608
0.721
CDBox
134
HBII-85-23_x
0.5
0.037660456
0.650
CDBox
58
miR-551b-star
−0.5
0.037971736
0.645
miRNA
61
miR-27b-star
0.7
0.041289539
0.663
miRNA
51
U50
−0.4
0.041514005
0.696
CDBox
134
ACA58_x
0.3
0.041793061
0.653
HAcaBox
89
ACA53
−0.3
0.0421874
0.635
HAcaBox
105
U49A
0.4
0.042284609
0.694
CDBox
135
ACA16
−0.4
0.042968027
0.658
HAcaBox
47
ACA13
−0.4
0.043493352
0.722
HAcaBox
134
miR-320a
−0.5
0.043683231
0.755
miRNA
135
ENSG00000200969
−0.4
0.043904585
0.663
snoRNA
67
miR-642
−0.4
0.04542452
0.640
miRNA
69
miR-148b
0.5
0.046811178
0.645
miRNA
32
U84
−0.2
0.046963896
0.683
CDBox
131
U56_x
0.4
0.047943262
0.701
CDBox
134
miR-451
0.7
0.049304242
0.632
miRNA
72
miR-195
0.6
0.049397144
0.698
miRNA
132
[0000]
TABLE 4
50 miRNAs most significantly expressed
between melanoma and normal skin
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
miR-146a
4.6
9.43624E−20
0.983
miRNA
129
miR-509-3p
5.2
5.61558E−17
0.969
miRNA
116
14qII-14
−2.6
1.16829E−14
0.978
CDBox
56
miR-25
2.4
2.08E−14
0.949
miRNA
118
miR-138
3.2
2.51219E−13
0.954
miRNA
82
miR-509-3-5p
3.6
2.94532E−13
0.963
miRNA
107
miR-506
3.4
6.99753E−13
0.954
miRNA
76
14qII-14_x
−2.2
8.36026E−13
0.970
CDBox
56
14qI-4
−2.1
8.9267E−13
0.964
CDBox
80
miR-30b
2.2
2.43822E−12
0.957
miRNA
128
miR-513a-5p
3.5
3.17158E−12
0.939
miRNA
105
miR-21
3.3
4.58391E−12
0.926
miRNA
79
Z17B
−1.0
6.92137E−12
0.956
CDBox
117
U33
−0.9
8.19977E−12
0.968
CDBox
137
miR-20b
2.8
2.24496E−11
0.939
miRNA
99
hsa-let-7i
2.3
3.27742E−11
0.973
miRNA
135
HBII-239
−1.0
3.9295E−11
0.920
CDBox
135
miR-146b-5p
2.3
8.71488E−11
0.910
miRNA
83
14qII-26_x
−1.8
9.17329E−11
0.914
CDBox
41
miR-155
2.8
1.12361E−10
0.940
miRNA
123
miR-151-3p
1.8
1.7141E−10
0.922
miRNA
117
HBII-289
−1.1
1.76712E−10
0.963
CDBox
135
14qII-12_x
−1.7
1.9475E−10
0.907
CDBox
85
miR-1274a
1.9
3.28343E−10
0.928
miRNA
48
HBII-180A_x
−0.8
4.68853E−10
0.933
CDBox
123
miR-1301
2.0
7.22101E−10
0.896
miRNA
54
14qII-1_x
−1.7
7.72545E−10
0.965
CDBox
131
miR-193b
−1.4
8.7852E−10
0.974
miRNA
130
miR-510
2.7
1.03096E−09
0.914
miRNA
82
miR-126
2.1
1.35297E−09
0.959
miRNA
133
miR-24-2-star
1.8
1.36986E−09
0.895
miRNA
63
miR-106b
2.1
1.91606E−09
0.930
miRNA
127
HBII-276
−1.0
2.06051E−09
0.908
CDBox
132
miR-532-5p
1.8
2.9654E−09
0.887
miRNA
113
14qII-12
−1.7
3.71443E−09
0.859
CDBox
58
miR-19b
2.1
3.71682E−09
0.908
miRNA
124
miR-30a
1.6
6.61873E−09
0.894
miRNA
113
HBII-85-26_x
−1.1
7.76845E−09
0.895
CDBox
135
miR-150
1.7
1.08172E−08
0.894
miRNA
117
14qII-26
−1.5
1.16704E−08
0.869
CDBox
32
miR-324-5p
1.6
1.24724E−08
0.880
miRNA
102
14qI-8
−1.2
1.39067E−08
0.894
CDBox
61
miR-185
1.6
1.44139E−08
0.952
miRNA
132
miR-194
1.8
1.72961E−08
0.883
miRNA
54
14qII-1
−1.5
2.76507E−08
0.928
CDBox
128
HBII-202
−1.0
2.89826E−08
0.946
CDBox
135
miR-768-5p
−1.6
3.1365E−08
0.986
miRNA
135
miR-421
1.6
4.42916E−08
0.872
miRNA
68
miR-28-5p
1.7
5.45027E−08
0.877
miRNA
105
miR-151-5p
1.2
5.48542E−08
0.968
miRNA
135
[0000]
TABLE 5
miRNAs significantly expressed between metastatic melanoma and melanoma
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
miR-31
−2.4
6.23649E−09
0.891
miRNA
103
miR-150
−1.2
4.84574E−06
0.783
miRNA
117
miR-203
−2.0
2.77555E−05
0.764
miRNA
132
ENSG00000212139_x
0.6
2.83257E−05
0.799
snoRNA
124
mgU6-53
0.6
3.8628E−05
0.828
CDBox
94
U72_x
0.5
4.47709E−05
0.783
HAcaBox
103
U94
0.6
7.34024E−05
0.776
CDBox
109
HBII-85-15_x
0.8
0.000176472
0.767
CDBox
49
HBII-85-29_x
0.8
0.000274959
0.734
CDBox
85
HBII-55
0.5
0.000331716
0.806
CDBox
135
snR38B
0.8
0.000374886
0.750
CDBox
126
miR-200c
−1.6
0.00042063
0.718
miRNA
134
U61
0.7
0.000440758
0.785
CDBox
116
HBII-316
0.6
0.000548042
0.744
CDBox
130
U32A_x
0.4
0.000553879
0.748
CDBox
136
U81_x
0.6
0.000598062
0.720
CDBox
120
U15A
0.7
0.000649777
0.785
CDBox
128
ACA14b_x
0.4
0.000764147
0.748
HAcaBox
105
miR-182
−0.9
0.000868427
0.762
miRNA
113
miR-455-3p
−0.7
0.000874654
0.718
miRNA
136
miR-532-5p
−0.8
0.000883675
0.752
miRNA
113
mgU6-53_x
0.5
0.001038416
0.783
CDBox
113
ACA46
0.4
0.001076758
0.746
HAcaBox
124
miR-1234
−0.5
0.001112272
0.756
miRNA
68
U53
0.6
0.001130502
0.769
CDBox
126
HBII-85-29
0.7
0.001192467
0.702
CDBox
82
U47
0.5
0.001218674
0.702
CDBox
74
U42B_x
0.5
0.001412559
0.735
CDBox
109
miR-155
−1.3
0.001425842
0.716
miRNA
123
U64
0.5
0.001493551
0.728
HAcaBox
101
ACA28
0.5
0.001565276
0.692
HAcaBox
120
U13
0.6
0.001630341
0.748
CDBox
135
U84
0.4
0.001673776
0.769
CDBox
131
U22
0.5
0.001739769
0.714
CDBox
135
U46_x
0.6
0.001758635
0.755
CDBox
131
ACA17_x
0.6
0.001827243
0.705
HAcaBox
44
ENSG00000200897
0.4
0.001857043
0.735
snoRNA
38
U36A_x
0.4
0.00192703
0.728
CDBox
133
HBII-180C
0.4
0.001987135
0.757
CDBox
115
HBII-251
0.4
0.0020213
0.741
CDBox
135
ACA49
0.4
0.002175278
0.744
HAcaBox
127
U19
0.6
0.00221226
0.696
HAcaBox
118
miR-940
−0.6
0.002377881
0.713
miRNA
53
U76
0.6
0.002408733
0.755
CDBox
135
HBII-13_x
0.7
0.002521867
0.730
CDBox
60
HBII-382_s
0.6
0.002554678
0.770
scaRna
126
miR-205
−1.1
0.002610442
0.603
miRNA
135
U21
0.7
0.002613305
0.774
CDBox
134
miR-342-3p
−0.5
0.002621512
0.706
miRNA
136
ENSG00000212326
0.5
0.002879558
0.728
snoRNA
104
U82
0.7
0.002979246
0.828
CDBox
131
HBII-234_x
0.3
0.003087142
0.734
CDBox
102
HBII-85-24_x
0.4
0.003172633
0.703
CDBox
34
U101
0.5
0.003644287
0.672
CDBox
134
U46
0.5
0.003690792
0.747
CDBox
133
U58A
0.5
0.003778891
0.735
CDBox
129
HBII-210
0.5
0.003785668
0.767
CDBox
135
U102
0.4
0.00401337
0.705
CDBox
124
HBII-85-3_x
0.5
0.004030857
0.694
CDBox
72
U92
0.4
0.004575813
0.712
scaRna
129
spike_in-control-31
0.1
0.004779896
0.705
Oligonucleotide
137
spike-in
controls
snR38C
0.6
0.005413855
0.779
CDBox
134
HBII-99
0.5
0.005634509
0.714
CDBox
122
ACA47
0.5
0.006095831
0.696
scaRna
77
HBII-420
0.6
0.006404916
0.824
CDBox
131
ENSG00000212423_x
0.5
0.006424898
0.684
snoRNA
115
HBII-85-17_x
0.6
0.006577979
0.678
CDBox
57
ACA27_x
0.3
0.006580858
0.725
HAcaBox
130
U79
0.6
0.007498133
0.748
CDBox
134
U107
0.4
0.00761608
0.707
HAcaBox
129
HBI-43
0.3
0.007872874
0.691
CDBox
122
U49B_x
0.5
0.008037057
0.736
CDBox
122
miR-548i
−0.5
0.008242048
0.684
miRNA
36
miR-500-star
−0.6
0.008434274
0.697
miRNA
97
HBII-85-2_x
0.4
0.008511275
0.708
CDBox
135
ACA41
0.5
0.008991193
0.723
HAcaBox
115
ACA3
0.5
0.009231708
0.737
HAcaBox
134
U49A
0.6
0.009381377
0.745
CDBox
135
HBII-85-20_x
0.5
0.00942941
0.672
CDBox
42
ENSG00000212508
−0.5
0.009471802
0.712
snoRNA
122
U38B_x
0.7
0.009547747
0.837
CDBox
133
ACA51_x
0.3
0.009599762
0.686
HAcaBox
135
ENSG00000200879
0.5
0.009860049
0.697
snoRNA
120
miR-181a
−0.6
0.009890715
0.730
miRNA
134
ENSG00000200932
0.4
0.010075893
0.740
snoRNA
47
miR-589-star
−0.4
0.010240715
0.650
miRNA
43
ENSG00000199262
0.4
0.010309025
0.694
snoRNA
59
miR-1324
−0.5
0.010648472
0.724
miRNA
57
U91_s
0.5
0.010903574
0.695
scaRna
132
U3-2_s
0.5
0.011269742
0.729
CDBox
135
U51_x
0.4
0.011519055
0.713
CDBox
130
ACA9
0.5
0.012046848
0.703
HAcaBox
82
miR-1825
−0.8
0.01292318
0.738
miRNA
132
mgU6-47
0.4
0.013536315
0.710
CDBox
47
miR-1281
−0.7
0.014086281
0.701
miRNA
137
U71d_x
0.5
0.01413005
0.678
HAcaBox
99
ACA42
0.4
0.014283243
0.786
HAcaBox
117
ACA34
0.3
0.014399902
0.637
HAcaBox
109
U48
0.4
0.014650847
0.654
CDBox
129
ENSG00000202093
0.5
0.014675533
0.689
snoRNA
97
miR-665
0.5
0.014853517
0.678
miRNA
47
miR-141
−0.7
0.015316578
0.647
miRNA
69
U23
0.4
0.015408258
0.701
HAcaBox
127
U15B
0.4
0.015684928
0.719
CDBox
129
miR-1274b
0.6
0.01695735
0.679
miRNA
112
U31_x
0.5
0.017818548
0.771
CDBox
135
ENSG00000200394_x
0.4
0.017859341
0.682
snoRNA
115
ACA67_x
0.4
0.018242565
0.663
HAcaBox
54
U80
0.4
0.019116778
0.683
CDBox
132
HBII-85-18_x
0.4
0.019329528
0.661
CDBox
48
U106
0.3
0.019924806
0.653
CDBox
112
U99
0.3
0.01993828
0.674
HAcaBox
137
U24
0.3
0.020062119
0.673
CDBox
133
miR-20a-star
1.0
0.020518991
0.694
miRNA
61
U16
0.4
0.0213066
0.669
CDBox
131
U49B_s
0.5
0.0213349
0.716
CDBox
129
miR-885-3p
0.7
0.021367498
0.694
miRNA
73
U36B
0.4
0.021413004
0.669
CDBox
121
HBII-295
0.3
0.021589703
0.678
CDBox
128
miR-148b
0.6
0.021711762
0.661
miRNA
32
U38B
0.7
0.022451358
0.834
CDBox
134
U31
0.6
0.023045818
0.738
CDBox
132
ACA8_x
0.4
0.023508719
0.697
HAcaBox
125
HBI-6_x
0.5
0.02438732
0.675
HAcaBox
115
mgU6-53B
0.3
0.024830223
0.687
CDBox
99
ACA62
0.4
0.024948935
0.714
HAcaBox
88
miR-23b
−0.5
0.025010006
0.658
miRNA
137
mgh18S-121
0.4
0.02717981
0.773
CDBox
134
miR-134
−0.6
0.027498011
0.648
miRNA
61
ENSG00000202216
−0.3
0.02787169
0.654
snoRNA
53
snR38A
0.5
0.028058616
0.706
CDBox
130
ACA54
0.4
0.028079033
0.741
HAcaBox
133
U83
0.4
0.028849489
0.733
CDBox
135
U56_x
0.5
0.03056515
0.673
CDBox
134
ENSG00000207118
0.5
0.030731527
0.642
snoRNA
93
U71b_x
0.3
0.031331331
0.639
HAcaBox
117
U104
0.5
0.031533136
0.750
CDBox
135
miR-26b
0.6
0.031546885
0.666
miRNA
45
ENSG00000201129
0.4
0.031647545
0.658
snoRNA
54
HBII-180C_x
0.3
0.031765824
0.686
CDBox
131
miR-1257
−0.4
0.032490122
0.676
miRNA
31
miR-1285
0.6
0.032817723
0.656
miRNA
54
ACA6
0.4
0.033332825
0.706
HAcaBox
126
HBII-166
0.3
0.033479679
0.715
CDBox
134
U20
0.3
0.033581135
0.659
CDBox
117
U49A_x
0.5
0.034235707
0.734
CDBox
135
HBII-85-11
0.5
0.034401945
0.626
CDBox
31
miR-198
0.5
0.035071443
0.673
miRNA
31
miR-1273
0.4
0.035126423
0.649
miRNA
47
U8_x
0.4
0.035369399
0.661
CDBox
135
miR-127-3p
−0.5
0.035478749
0.646
miRNA
89
U36C
0.3
0.036400622
0.690
CDBox
135
miR-502-3p
−0.5
0.036440109
0.696
miRNA
110
U97
0.4
0.036556318
0.713
CDBox
133
HBII-13
0.5
0.038037592
0.639
CDBox
52
miR-148a
0.6
0.038972124
0.647
miRNA
41
hsa-let-7b
−0.7
0.040092161
0.713
miRNA
136
U55
0.3
0.041929175
0.687
CDBox
135
HBII-85-5_x
0.3
0.04234391
0.645
CDBox
31
U105
0.3
0.043199784
0.658
CDBox
126
U90
0.3
0.043617609
0.701
scaRna
114
ENSG00000202252
0.3
0.044418964
0.647
snoRNA
135
ENSG00000201467_x
−0.3
0.04502792
0.628
snoRNA
31
ACA21
0.5
0.045481211
0.754
HAcaBox
133
U52
0.4
0.045645643
0.708
CDBox
135
U18C_x
0.4
0.046127928
0.637
CDBox
74
HBII-296B
0.3
0.046365102
0.657
CDBox
98
ENSG00000200307
0.3
0.048211492
0.613
snoRNA
86
miR-509-3p
−1.2
0.048257749
0.574
miRNA
116
miR-1202
0.5
0.048318042
0.661
miRNA
57
ACA36_x
0.4
0.048990385
0.670
HAcaBox
88
ENSG00000207016_x
0.3
0.049618219
0.660
snoRNA
48
miR-30c
0.3
0.049698
0.709
miRNA
125
ACA19
0.3
0.049825075
0.655
HAcaBox
118
[0000]
TABLE 6
50 miRNAs most significantly expressed between
metastatic melanoma and melanoma
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
miR-31
−2.4
6.23649E−09
0.891
miRNA
103
miR-150
−1.2
4.84574E−06
0.783
miRNA
117
miR-203
−2.0
2.77555E−05
0.764
miRNA
132
ENSG00000212139_x
0.6
2.83257E−05
0.799
snoRNA
124
mgU6-53
0.6
3.8628E−05
0.828
CDBox
94
U72_x
0.5
4.47709E−05
0.783
HAcaBox
103
U94
0.6
7.34024E−05
0.776
CDBox
109
HBII-85-15_x
0.8
0.000176472
0.767
CDBox
49
HBII-85-29_x
0.8
0.000274959
0.734
CDBox
85
HBII-55
0.5
0.000331716
0.806
CDBox
135
snR38B
0.8
0.000374886
0.750
CDBox
126
miR-200c
−1.6
0.00042063
0.718
miRNA
134
U61
0.7
0.000440758
0.785
CDBox
116
HBII-316
0.6
0.000548042
0.744
CDBox
130
U32A_x
0.4
0.000553879
0.748
CDBox
136
U81_x
0.6
0.000598062
0.720
CDBox
120
U15A
0.7
0.000649777
0.785
CDBox
128
ACA14b_x
0.4
0.000764147
0.748
HAcaBox
105
miR-182
−0.9
0.000868427
0.762
miRNA
113
miR-455-3p
−0.7
0.000874654
0.718
miRNA
136
miR-532-5p
−0.8
0.000883675
0.752
miRNA
113
mgU6-53_x
0.5
0.001038416
0.783
CDBox
113
ACA46
0.4
0.001076758
0.746
HAcaBox
124
miR-1234
−0.5
0.001112272
0.756
miRNA
68
U53
0.6
0.001130502
0.769
CDBox
126
HBII-85-29
0.7
0.001192467
0.702
CDBox
82
U47
0.5
0.001218674
0.702
CDBox
74
U42B_x
0.5
0.001412559
0.735
CDBox
109
miR-155
−1.3
0.001425842
0.716
miRNA
123
U64
0.5
0.001493551
0.728
HAcaBox
101
ACA28
0.5
0.001565276
0.692
HAcaBox
120
U13
0.6
0.001630341
0.748
CDBox
135
U84
0.4
0.001673776
0.769
CDBox
131
U22
0.5
0.001739769
0.714
CDBox
135
U46_x
0.6
0.001758635
0.755
CDBox
131
ACA17_x
0.6
0.001827243
0.705
HAcaBox
44
ENSG00000200897
0.4
0.001857043
0.735
snoRNA
38
U36A_x
0.4
0.00192703
0.728
CDBox
133
HBII-180C
0.4
0.001987135
0.757
CDBox
115
HBII-251
0.4
0.0020213
0.741
CDBox
135
ACA49
0.4
0.002175278
0.744
HAcaBox
127
U19
0.6
0.00221226
0.696
HAcaBox
118
miR-940
−0.6
0.002377881
0.713
miRNA
53
U76
0.6
0.002408733
0.755
CDBox
135
HBII-13_x
0.7
0.002521867
0.730
CDBox
60
HBII-382_s
0.6
0.002554678
0.770
scaRna
126
miR-205
−1.1
0.002610442
0.603
miRNA
135
U21
0.7
0.002613305
0.774
CDBox
134
miR-342-3p
−0.5
0.002621512
0.706
miRNA
136
ENSG00000212326
0.5
0.002879558
0.728
snoRNA
104
[0000]
TABLE 7
miRNAs significantly expressed between nevi and normal skin
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
14qII-14
−3.87
3.6592E−27
1.000
CDBox
56
14qII-14_x
−3.21
3.815E−24
1.000
CDBox
56
U74_x
1.46
3.89068E−23
1.000
CDBox
135
miR-509-3p
5.78
1.67661E−22
0.997
miRNA
116
miR-768-5p
−1.46
5.23441E−22
1.000
miRNA
135
ENSG00000199411_s
1.36
1.56796E−21
1.000
snoRNA
135
Z17B
−1.94
2.89347E−20
0.997
CDBox
117
miR-149
−3.46
1.55425E−19
1.000
miRNA
100
miR-125a-5p
−3.44
1.86526E−19
1.000
miRNA
128
U43
−1.19
3.32514E−19
1.000
CDBox
135
miR-1308
1.55
8.1184E−19
0.964
miRNA
135
U59A
1.13
9.99768E−18
0.993
CDBox
135
miR-146a
4.44
3.16232E−17
0.975
miRNA
129
miR-513a-5p
3.77
1.05679E−16
0.972
miRNA
105
ACA20
−1.74
1.56297E−16
0.993
HAcaBox
131
U43_x
−1.05
1.04459E−15
1.000
CDBox
135
U44_x
−1.37
5.54123E−15
0.994
CDBox
135
miR-127-3p
−3.56
7.53549E−15
0.988
miRNA
89
miR-193b
−2.57
7.81928E−15
1.000
miRNA
130
U83
−1.25
9.30493E−15
0.993
CDBox
135
miR-768-3p
0.98
2.39925E−14
0.972
miRNA
137
U33
−1.02
2.44194E−14
0.997
CDBox
137
miR-574-3p
−3.05
3.0433E−14
0.974
miRNA
122
ACA16
−1.86
3.35128E−14
0.968
HAcaBox
47
14qI-4
−2.43
3.96317E−14
0.979
CDBox
80
hsa-let-7c
−1.01
4.99111E−14
0.986
miRNA
135
miR-342-3p
−2.06
1.67074E−13
0.996
miRNA
136
hsa-let-7b
−1.01
2.25904E−13
0.964
miRNA
136
miR-423-3p
−2.52
2.97967E−13
1.000
miRNA
107
HBII-239
−1.41
3.2162E−13
0.975
CDBox
135
U38B_x
1.52
3.80613E−13
0.968
CDBox
133
miR-320b
−0.63
6.31909E−13
0.971
miRNA
135
miR-923
0.93
6.48332E−13
0.990
miRNA
135
U54
−1.06
1.17197E−12
0.975
CDBox
135
U38B
1.80
1.18885E−12
0.976
CDBox
134
U44
−1.07
1.28887E−12
0.981
CDBox
134
miR-139-5p
−2.70
2.74261E−12
0.940
miRNA
80
miR-1826
−0.71
2.83317E−12
0.958
miRNA
137
ENSG00000199435
1.38
2.88249E−12
0.954
snoRNA
63
miR-26a
0.89
2.88328E−12
0.960
miRNA
136
U58B_x
−1.47
3.60008E−12
0.940
CDBox
132
HBII-180A_x
−1.43
4.25614E−12
0.992
CDBox
123
14qII-12_x
−2.09
4.30741E−12
0.949
CDBox
85
miR-509-3-5p
3.46
5.53398E−12
0.953
miRNA
107
U55_x
−1.35
6.7836E−12
0.996
CDBox
135
miR-149-star
0.93
9.6022E−12
0.940
miRNA
135
HBII-276
−1.41
1.19464E−11
0.964
CDBox
132
miR-23b
−0.75
1.72105E−11
0.968
miRNA
137
miR-15b
−2.42
1.7823E−11
0.968
miRNA
125
miR-921
1.73
1.93285E−11
0.954
miRNA
49
miR-191
−0.85
2.0881E−11
0.972
miRNA
135
U103_s
−1.60
2.57483E−11
0.943
CDBox
111
miR-486-5p
−3.27
2.90873E−11
0.942
miRNA
65
U27
−1.61
3.28995E−11
0.960
CDBox
134
miR-1202
2.18
4.44562E−11
0.945
miRNA
57
U49A
1.25
4.51441E−11
0.970
CDBox
135
ACA24_x
−1.50
5.61856E−11
0.922
HAcaBox
98
HBII-382_s
1.30
5.89071E−11
0.953
scaRna
126
U52
−0.92
1.05668E−10
0.976
CDBox
135
miR-99b
−1.84
1.06853E−10
0.988
miRNA
129
U38A
0.84
1.30902E−10
0.936
CDBox
134
U46
−1.44
1.33613E−10
0.965
CDBox
133
U57
−1.10
1.66897E−10
0.967
CDBox
135
U3-2_s
0.70
1.79537E−10
0.925
CDBox
135
14qII-26_x
−1.60
1.92804E−10
0.922
CDBox
41
ENSG00000207098_x
1.21
2.17044E−10
0.956
snoRNA
86
miR-320c
−0.84
2.33286E−10
0.994
miRNA
135
miR-199a-5p
−2.53
2.85196E−10
0.994
miRNA
129
HBII-180C
−1.55
3.80017E−10
0.924
CDBox
115
U63
0.94
4.46838E−10
0.945
CDBox
135
HBII-436
−1.22
4.98357E−10
0.929
CDBox
102
U81_x
−1.25
6.27975E−10
0.928
CDBox
120
HBII-419
1.10
6.92884E−10
0.932
CDBox
133
U17b
−1.32
8.76094E−10
0.996
HAcaBox
135
miR-506
2.11
1.46252E−09
0.931
miRNA
76
miR-1268
1.02
1.54826E−09
0.909
miRNA
133
miR-671-5p
1.38
1.60795E−09
0.914
miRNA
69
miR-339-5p
−2.03
1.92249E−09
0.907
miRNA
75
ACA48_x
−1.25
1.98889E−09
0.945
HAcaBox
130
14qII-21_x
−1.20
2.04198E−09
0.907
CDBox
51
ENSG00000202093_x
−1.37
2.13676E−09
0.902
snoRNA
125
U73a
−0.76
3.11274E−09
0.924
CDBox
135
miR-1228-star
1.09
3.32612E−09
0.925
miRNA
134
miR-193b-star
−1.99
3.54373E−09
0.925
miRNA
77
miR-145
−2.87
3.67076E−09
0.986
miRNA
135
miR-1207-5p
0.91
3.82606E−09
0.936
miRNA
133
miR-23a
−0.62
4.38608E−09
0.950
miRNA
137
14qII-3
−1.37
5.04275E−09
0.938
CDBox
95
U56
0.82
5.34057E−09
0.910
CDBox
135
miR-320a
−0.50
5.87182E−09
0.917
miRNA
135
HBII-289
−0.82
6.53343E−09
0.975
CDBox
135
mgU6-53B
1.17
6.66322E−09
0.946
CDBox
99
miR-222
−1.42
6.66965E−09
1.000
miRNA
135
miR-135a-star
1.78
6.83122E−09
0.914
miRNA
44
HBII-142
0.50
6.91032E−09
0.911
CDBox
135
14qII-12
−1.90
7.3584E−09
0.896
CDBox
58
ACA23
−1.07
9.00722E−09
0.922
HAcaBox
113
miR-1224-5p
2.00
9.14764E−09
0.902
miRNA
78
U17b_x
−0.78
9.16941E−09
0.917
HAcaBox
135
U41
−0.89
1.0052E−08
0.928
CDBox
135
U55
−1.40
1.07645E−08
0.988
CDBox
135
U101
1.01
1.22325E−08
0.911
CDBox
134
miR-193a-5p
−2.09
1.43928E−08
0.954
miRNA
121
miR-720
0.87
1.45059E−08
0.918
miRNA
137
miR-205
−1.04
1.53388E−08
0.956
miRNA
135
mgh28S-2411
−0.86
1.81685E−08
0.965
CDBox
135
miR-1300
1.84
1.83075E−08
0.911
miRNA
32
miR-22
−2.31
1.87992E−08
0.943
miRNA
120
ACA40_x
−1.14
1.89306E−08
0.935
HAcaBox
134
miR-92a
−1.48
1.96388E−08
1.000
miRNA
136
14qII-28_x
−1.20
2.08991E−08
0.911
CDBox
51
U23
−0.93
2.35134E−08
0.913
HAcaBox
127
snR38C
0.62
2.69211E−08
0.902
CDBox
134
miR-939
1.33
2.8172E−08
0.947
miRNA
57
miR-214
−0.88
2.85157E−08
0.921
miRNA
135
U94
1.03
3.14773E−08
0.898
CDBox
109
miR-510
2.20
3.61106E−08
0.899
miRNA
82
miR-181b
−1.85
5.28195E−08
0.961
miRNA
130
U15B
−1.06
5.57521E−08
0.898
CDBox
129
gi555853_copy5
−0.51
7.13438E−08
0.910
5.8s rRNA
137
miR-432
−1.83
7.49361E−08
0.902
miRNA
51
HBII-142_x
0.47
8.53374E−08
0.886
CDBox
135
snR38B
1.11
8.92959E−08
0.899
CDBox
126
ACA36_x
1.12
9.60154E−08
0.885
HAcaBox
88
miR-320d
−1.66
1.03365E−07
0.997
miRNA
134
hsa-let-7i
1.72
1.07923E−07
0.947
miRNA
135
miR-125b-2-star
−1.66
1.09644E−07
0.881
miRNA
58
miR-572
1.35
1.13617E−07
0.906
miRNA
116
U102
0.87
1.2385E−07
0.874
CDBox
124
gi555853_copy8
−0.51
1.25699E−07
0.903
5.8s rRNA
137
miR-371-5p
1.93
1.26302E−07
0.886
miRNA
64
miR-125b
−0.97
1.35947E−07
0.988
miRNA
135
ENSG00000201619
1.40
1.4629E−07
0.892
snoRNA
62
U78_x
1.11
1.62568E−07
0.921
CDBox
134
ENSG00000212397
0.90
1.65415E−07
0.898
snoRNA
134
ENSG00000212182
1.09
1.80486E−07
0.884
snoRNA
59
hsa-let-7f
1.99
2.0615E−07
0.909
miRNA
130
HBII-55
−0.82
2.17315E−07
0.940
CDBox
135
gi555853_copy2
−0.49
2.37022E−07
0.893
5.8s rRNA
137
ACA15_s
−1.09
2.48572E−07
0.875
HAcaBox
116
U28_x
−0.90
2.5645E−07
0.896
CDBox
133
gi555853_copy0
−0.50
2.65495E−07
0.889
5.8s rRNA
137
gi555853_copy4
−0.48
2.85254E−07
0.898
5.8s rRNA
137
ENSG00000201816
0.83
3.19058E−07
0.878
snoRNA
49
gi555853_copy1
−0.48
3.26181E−07
0.886
5.8s rRNA
137
U60
−0.97
3.26261E−07
0.871
CDBox
103
gi555853_copy6
−0.47
3.40126E−07
0.900
5.8s rRNA
137
miR-132
−1.77
3.42625E−07
0.870
miRNA
96
U68_x
−1.05
3.51611E−07
0.910
HAcaBox
133
gi555853_copy7
−0.48
4.04469E−07
0.892
5.8s rRNA
137
ENSG00000201660
1.12
4.27296E−07
0.896
snoRNA
132
miR-150-star
1.63
4.51511E−07
0.874
miRNA
48
miR-665
1.55
5.14634E−07
0.871
miRNA
47
miR-150
−1.60
6.5278E−07
0.884
miRNA
117
miR-210
−1.24
6.58793E−07
0.911
miRNA
130
miR-664-star
1.38
6.79224E−07
0.864
miRNA
96
U49A_x
1.03
7.09035E−07
0.911
CDBox
135
miR-30c
−1.75
7.10279E−07
0.911
miRNA
125
ENSG00000212458
0.92
7.71477E−07
0.871
snoRNA
95
ENSG00000200879
−1.08
7.74449E−07
0.868
snoRNA
120
hsa-let-7d
0.39
8.11829E−07
0.886
miRNA
135
14qII-1_x
−1.24
9.36723E−07
0.899
CDBox
131
14qII-26
−1.14
1.46915E−06
0.827
CDBox
32
hsa-let-7a
0.51
1.65358E−06
0.841
miRNA
136
U28
−0.75
1.71566E−06
0.874
CDBox
135
U68
−0.88
1.83186E−06
0.892
HAcaBox
130
HBII-180C_x
−0.95
2.06263E−06
0.882
CDBox
131
gi555853_copy3
−0.45
2.14632E−06
0.863
5.8s rRNA
137
miR-200b-star
−1.70
2.20935E−06
0.861
miRNA
74
miR-1234
1.03
2.2168E−06
0.861
miRNA
68
U95
−0.36
2.37891E−06
0.852
CDBox
135
U46_x
−0.98
2.42909E−06
0.873
CDBox
131
spike_in-control-21
0.74
2.57369E−06
0.827
Oligonucleotide
42
spike-in
controls
miR-1248
1.03
3.51695E−06
0.874
miRNA
39
U36A
−0.61
3.61256E−06
0.882
CDBox
132
U13
0.50
4.36581E−06
0.834
CDBox
135
miR-92a-2-star
1.02
4.99387E−06
0.859
miRNA
46
miR-663
0.77
5.24563E−06
0.859
miRNA
134
miR-409-3p
−1.42
5.63777E−06
0.837
miRNA
92
U34
−0.68
5.88695E−06
0.852
CDBox
137
U25
−0.71
6.25404E−06
0.896
CDBox
135
U32A_x
−0.75
6.51615E−06
0.882
CDBox
136
U96a_x
0.68
6.70342E−06
0.849
CDBox
134
gi555853_copy9
−0.42
7.0704E−06
0.863
5.8s rRNA
137
ENSG00000199411_x
0.77
7.82781E−06
0.846
snoRNA
132
spike_in-control-7
1.00
7.92241E−06
0.848
Oligonucleotide
54
spike-in
controls
miR-198
1.24
8.11341E−06
0.846
miRNA
31
14qI-9_x
−0.81
8.29164E−06
0.820
CDBox
34
miR-425
−1.72
8.48515E−06
0.846
miRNA
114
HBII-82
0.77
8.59528E−06
0.839
CDBox
90
miR-1180
−1.22
9.75327E−06
0.828
miRNA
37
ENSG00000206637_x
0.74
1.15035E−05
0.850
snoRNA
59
miR-502-3p
−1.41
1.18784E−05
0.831
miRNA
110
14qII-22_x
−0.97
1.49319E−05
0.792
CDBox
50
ACA18_x
−0.72
1.77602E−05
0.837
HAcaBox
135
miR-1274b
1.66
1.82625E−05
0.813
miRNA
112
HBII-99
−0.94
1.84996E−05
0.837
CDBox
122
U35B
0.78
1.93006E−05
0.837
CDBox
128
ACA20_x
−0.84
2.02452E−05
0.882
HAcaBox
134
miR-143
−2.21
2.0661E−05
0.864
miRNA
126
ENSG00000200652
0.81
2.09666E−05
0.824
snoRNA
40
HBII-202
−0.59
2.32067E−05
0.886
CDBox
135
miR-708
−1.81
2.34758E−05
0.816
miRNA
102
miR-182
−1.64
2.56273E−05
0.791
miRNA
113
miR-345
−1.28
3.1705E−05
0.816
miRNA
75
ACA62
0.82
3.35475E−05
0.817
HAcaBox
88
miR-1273
1.12
3.38999E−05
0.827
miRNA
47
ACA24_s
−1.10
3.44078E−05
0.823
HAcaBox
128
miR-1272
0.97
3.51756E−05
0.820
miRNA
67
14qI-4_x
−1.11
3.64993E−05
0.796
CDBox
51
14qII-9_x
−0.89
3.72476E−05
0.820
CDBox
36
U106
−0.62
3.79813E−05
0.817
CDBox
112
miR-1285
1.22
4.16925E−05
0.796
miRNA
54
ENSG00000200492
0.77
4.61258E−05
0.838
snoRNA
60
ENSG00000202327
0.77
4.61736E−05
0.812
snoRNA
54
miR-126
1.24
4.86215E−05
0.845
miRNA
133
U49B_x
0.62
4.92521E−05
0.795
CDBox
122
ENSG00000207016_x
0.74
5.4547E−05
0.794
snoRNA
48
HBII-52-25_x
0.68
5.50793E−05
0.827
CDBox
57
U49B_s
0.90
5.94839E−05
0.848
CDBox
129
U53
−0.97
6.07982E−05
0.809
CDBox
126
miR-1246
1.19
7.10577E−05
0.799
miRNA
131
ENSG00000212615_x
−0.67
7.76933E−05
0.798
snoRNA
102
miR-575
1.09
8.31223E−05
0.794
miRNA
41
snR38A
0.69
8.40239E−05
0.807
CDBox
130
14qI-7
−0.78
8.70579E−05
0.825
CDBox
51
miR-29b-2-star
0.86
8.9139E−05
0.802
miRNA
126
U80
−0.60
9.75089E−05
0.825
CDBox
132
miR-1225-5p
1.04
9.99249E−05
0.830
miRNA
90
miR-92b-star
0.94
0.000102055
0.809
miRNA
111
ACA53
−0.61
0.000103826
0.814
HAcaBox
105
ACA55
0.79
0.000105025
0.805
HAcaBox
85
U51
0.58
0.000112048
0.802
CDBox
134
U108_x
0.55
0.000112181
0.798
HAcaBox
87
U48
−1.07
0.000118819
0.875
CDBox
129
miR-221
−1.06
0.00013613
0.911
miRNA
135
HBII-13
0.74
0.000139215
0.798
CDBox
52
miR-19b
1.53
0.0001409
0.795
miRNA
124
ACA3-2
−0.76
0.000143105
0.819
HAcaBox
135
HBII-85-23_x
−0.73
0.000143482
0.787
CDBox
58
14qI-8
−0.75
0.000167587
0.802
CDBox
61
miR-138-1-star
0.88
0.000190948
0.798
miRNA
91
spike_in-control-28
0.63
0.000200982
0.802
Oligonucleotide
76
spike-in
controls
miR-500-star
−1.36
0.000204792
0.803
miRNA
97
ENSG00000212423_x
0.75
0.000232739
0.789
snoRNA
115
ENSG00000201348
0.50
0.000243216
0.778
snoRNA
94
miR-1275
1.09
0.000244874
0.821
miRNA
127
miR-30a-star
−1.14
0.000247652
0.758
miRNA
64
miR-93-star
−1.16
0.000248272
0.777
miRNA
48
ACA25
−0.64
0.000248534
0.802
HAcaBox
73
U50
−0.73
0.000255129
0.853
CDBox
134
14qII-1
−1.00
0.000255606
0.807
CDBox
128
U14B_x
−0.79
0.000258746
0.788
CDBox
53
miR-638
0.35
0.000261809
0.823
miRNA
135
U51_x
0.57
0.000299812
0.820
CDBox
130
miR-99a
−0.87
0.000321188
0.832
miRNA
135
miR-491-5p
1.04
0.000341416
0.756
miRNA
92
miR-508-3p
1.23
0.000350578
0.778
miRNA
74
miR-508-5p
1.02
0.000377448
0.783
miRNA
92
miR-641
0.88
0.000391728
0.774
miRNA
39
miR-885-5p
−1.23
0.00039874
0.801
miRNA
100
miR-497
−1.48
0.00041742
0.780
miRNA
104
U31_x
−0.65
0.000420569
0.795
CDBox
135
miR-498
0.85
0.000424439
0.787
miRNA
56
miR-20a
1.21
0.000429079
0.807
miRNA
134
miR-509-5p
1.35
0.000476275
0.776
miRNA
81
miR-331-3p
−1.11
0.000481237
0.777
miRNA
64
HBII-295
0.53
0.000526137
0.785
CDBox
128
ACA27_x
−0.45
0.000528795
0.778
HAcaBox
130
miR-155
−1.29
0.000530869
0.751
miRNA
123
miR-652
−1.30
0.000593692
0.774
miRNA
119
ENSG00000208308_x
−0.58
0.000595144
0.758
snoRNA
129
miR-1281
0.98
0.000606821
0.766
miRNA
137
E3_x
−0.53
0.000619964
0.819
HAcaBox
135
miR-27a-star
−0.88
0.000656179
0.773
miRNA
40
miR-92b
−0.90
0.0006705
0.773
miRNA
91
miR-570
0.93
0.000670846
0.776
miRNA
88
miR-181a-2-star
−1.19
0.000676824
0.753
miRNA
99
miR-1185
0.76
0.000680122
0.752
miRNA
42
ACA33
0.57
0.000718022
0.780
HAcaBox
133
ENSG00000212401
0.57
0.000773614
0.799
snoRNA
41
U20
−0.51
0.000816772
0.758
CDBox
117
U19
0.84
0.00082895
0.759
HAcaBox
118
miR-203
0.69
0.000839225
0.878
miRNA
132
ENSG00000212508
0.83
0.000873066
0.801
snoRNA
122
ACA54
−0.54
0.000880465
0.817
HAcaBox
133
ACA9_x
−0.68
0.001025389
0.752
HAcaBox
77
14qI-1
0.61
0.001136212
0.729
CDBox
70
miR-940
0.87
0.001164857
0.737
miRNA
53
U14B
−0.69
0.001178164
0.738
CDBox
51
mgU6-77
−0.62
0.001238112
0.760
CDBox
129
spike_in-control-30
0.54
0.001290622
0.753
Oligonucleotide
53
spike-in
controls
miR-629-star
−0.92
0.00138462
0.756
miRNA
46
ACA49
0.56
0.001394857
0.791
HAcaBox
127
miR-483-5p
0.96
0.001461794
0.738
miRNA
48
ENSG00000212214_x
0.51
0.001505107
0.748
snoRNA
88
miR-574-5p
−0.99
0.00156768
0.766
miRNA
103
miR-28-3p
−1.29
0.001658961
0.747
miRNA
94
U36C
0.34
0.001694833
0.849
CDBox
135
miR-1288
0.73
0.001697813
0.738
miRNA
43
ACA37_x
−0.59
0.001721183
0.742
HAcaBox
84
miR-1280
−0.72
0.001869035
0.777
miRNA
134
miR-487b
−0.96
0.001988497
0.731
miRNA
58
miR-532-3p
−0.80
0.00199381
0.766
miRNA
95
miR-346
−0.91
0.0020172
0.749
miRNA
55
miR-27b-star
−1.04
0.00209985
0.742
miRNA
51
ACA32
0.34
0.002161552
0.785
HAcaBox
135
ENSG00000212206_x
0.58
0.002337296
0.740
snoRNA
74
ACA51_x
0.43
0.002449336
0.742
HAcaBox
135
ENSG00000201847_x
−0.53
0.002461896
0.729
snoRNA
48
miR-513c
1.13
0.002510473
0.749
miRNA
73
miR-455-3p
−0.62
0.00258213
0.785
miRNA
136
miR-188-5p
−0.90
0.002825937
0.730
miRNA
51
ENSG00000207027
0.48
0.002903474
0.704
snoRNA
36
ENSG00000202498_x
0.56
0.002908782
0.735
snoRNA
137
HBII-85-26
0.66
0.003001767
0.741
CDBox
136
miR-337-3p
0.80
0.003015225
0.740
miRNA
94
U35A
−0.47
0.003204612
0.723
CDBox
135
miR-106b-star
−1.10
0.003210131
0.717
miRNA
72
ENSG00000202216
0.55
0.003292357
0.758
snoRNA
53
HBII-316
0.63
0.003333247
0.705
CDBox
130
miR-31
−1.63
0.003410838
0.720
miRNA
103
U22
0.43
0.003510102
0.699
CDBox
135
miR-34a-star
0.77
0.003765001
0.715
miRNA
39
HBII-85-6_x
0.62
0.003870576
0.735
CDBox
137
ACA15_x
−0.50
0.003952375
0.734
HAcaBox
124
ENSG00000200706_x
0.48
0.00407636
0.762
snoRNA
43
ENSG00000212627
0.41
0.00409948
0.726
snoRNA
69
14qII-7
0.59
0.004220389
0.719
CDBox
77
ENSG00000212432_s
0.52
0.004352612
0.745
snoRNA
75
miR-214-star
−0.82
0.004514439
0.708
miRNA
47
miR-106a
0.58
0.004682448
0.724
miRNA
135
ACA42
−0.54
0.004759271
0.720
HAcaBox
117
mgU6-53B_x
0.46
0.0048197
0.720
CDBox
121
ACA19
0.38
0.005153495
0.733
HAcaBox
118
ACA50
−0.53
0.005300761
0.738
HAcaBox
88
miR-138
1.07
0.005618175
0.716
miRNA
82
U47
−0.47
0.005755719
0.729
CDBox
74
ENSG00000212551
0.48
0.005885716
0.740
snoRNA
73
miR-769-5p
−0.93
0.005951319
0.687
miRNA
56
miR-1228
0.82
0.006114287
0.724
miRNA
114
miR-30b
0.87
0.00634299
0.748
miRNA
128
ENSG00000212315
0.54
0.006470787
0.752
snoRNA
117
ENSG00000212538
0.48
0.006558923
0.735
snoRNA
35
ACA2b
0.39
0.007073038
0.756
HAcaBox
47
ENSG00000212523_x
0.59
0.007115341
0.716
snoRNA
135
miR-196a
1.04
0.007138032
0.705
miRNA
77
HBII-429
0.22
0.007262326
0.720
CDBox
137
miR-16
0.46
0.007360456
0.749
miRNA
135
mgh28S-2409
0.27
0.007642791
0.741
CDBox
135
ENSG00000200307_x
0.54
0.007656242
0.695
snoRNA
50
U76
−0.27
0.008469646
0.734
CDBox
135
14qII-17
−0.54
0.008809376
0.698
CDBox
71
miR-324-3p
−0.67
0.009111464
0.726
miRNA
100
ACA48
−0.49
0.009193835
0.798
HAcaBox
121
miR-200c
−0.31
0.009670586
0.625
miRNA
134
miR-1260
−0.78
0.010502121
0.726
miRNA
120
miR-130a
−0.94
0.010557093
0.687
miRNA
122
U17a
−0.52
0.010593144
0.702
HAcaBox
105
ACA52
−0.45
0.010843862
0.708
HAcaBox
121
miR-197
−0.79
0.011117393
0.724
miRNA
103
U66
−0.54
0.011246742
0.705
HAcaBox
119
ENSG00000202252
−0.30
0.011273976
0.699
snoRNA
135
ACA61
0.22
0.011490951
0.730
HAcaBox
135
miR-151-5p
0.56
0.01153084
0.830
miRNA
135
ACA16_x
−0.47
0.011881173
0.727
HAcaBox
98
U18C_x
−0.45
0.012073238
0.691
CDBox
74
U15A
0.45
0.012634875
0.706
CDBox
128
miR-1274a
0.71
0.012698242
0.684
miRNA
48
ACA9
−0.62
0.01271037
0.691
HAcaBox
82
U91_s
−0.54
0.012949986
0.733
scaRna
132
ENSG00000207002
−0.52
0.013212929
0.702
snoRNA
35
miR-129-3p
−0.54
0.013303701
0.705
miRNA
59
spike_in-cortrol-17
0.48
0.013556785
0.705
Oligonucleotide
33
spike-in
controls
spike_in-control-2
0.19
0.014699249
0.684
Oligonucleotide
137
spike-in
controls
ENSG00000212206
0.49
0.014866744
0.670
snoRNA
46
miR-107
−0.39
0.015131674
0.669
miRNA
135
ACA63
0.42
0.01519582
0.695
HAcaBox
66
ENSG00000212553_x
0.45
0.015776333
0.684
snoRNA
60
U50B
−0.37
0.016500241
0.704
CDBox
135
ENSG00000207100_x
0.36
0.016825837
0.666
snoRNA
72
U78_s
−0.55
0.016840855
0.702
CDBox
135
miR-551b-star
−0.65
0.016907402
0.686
miRNA
61
ACA47
0.45
0.017340107
0.666
scaRna
77
U92
0.45
0.017435918
0.760
scaRna
129
miR-342-5p
−0.78
0.01779742
0.695
miRNA
98
miR-128
−0.56
0.017820912
0.699
miRNA
44
U17a_x
−0.46
0.018370462
0.720
HAcaBox
115
ENSG00000206909_x
0.44
0.018373221
0.706
snoRNA
47
U30
−0.35
0.018607695
0.729
CDBox
135
miR-98
−0.57
0.019510485
0.677
miRNA
47
miR-21-star
0.62
0.019769732
0.686
miRNA
64
miR-135b-star
0.57
0.0198019
0.704
miRNA
38
ACA2a
−0.42
0.019986353
0.677
HAcaBox
55
U88
0.44
0.020351208
0.672
scaRna
69
HBII-85-29_x
0.39
0.020664805
0.666
CDBox
85
14qII-19
0.47
0.02089152
0.695
CDBox
43
U83B
0.19
0.020956657
0.677
CDBox
135
miR-134
−0.86
0.020986754
0.681
miRNA
61
U83A
−0.40
0.021328386
0.698
CDBox
127
ENSG00000202370
0.53
0.02172281
0.651
snoRNA
88
U72_x
−0.35
0.021862862
0.697
HAcaBox
103
ACA38
−0.38
0.023364662
0.688
HAcaBox
42
ENSG00000200394_x
0.42
0.023498919
0.661
snoRNA
115
miR-1324
0.50
0.023518344
0.684
miRNA
57
miR-106b
0.85
0.023747964
0.670
miRNA
127
miR-589-star
0.56
0.023792146
0.675
miRNA
43
ACA6
−0.36
0.024014637
0.673
HAcaBox
126
ACA28
0.36
0.02403059
0.687
HAcaBox
120
ACA57
0.36
0.024679323
0.748
scaRna
135
HBII-85-4_x
0.36
0.024717662
0.711
CDBox
125
ENSG00000200897
−0.41
0.024775335
0.662
snoRNA
38
U16
0.42
0.024969966
0.712
CDBox
131
ENSG00000200418
−0.41
0.025790882
0.668
snoRNA
31
U105
−0.31
0.026442326
0.673
CDBox
126
spike_in-control-34
0.44
0.026481739
0.665
Oligonucleotide
58
spike-in
controls
spike_in-control-23
0.24
0.027477358
0.645
Oligonucleotide
137
spike-in
controls
miR-196a-star
0.61
0.028243677
0.677
miRNA
37
HBII-296A
0.33
0.02845867
0.659
CDBox
78
U82
0.43
0.028925335
0.681
CDBox
131
ENSG00000212558_x
−0.35
0.029963606
0.662
snoRNA
31
miR-21
0.67
0.030060673
0.668
miRNA
79
ACA31
0.37
0.030929941
0.702
HAcaBox
123
miR-1257
0.55
0.031016296
0.676
miRNA
31
ACA14b_x
−0.37
0.031018594
0.688
HAcaBox
105
ACA33_x
0.38
0.033957171
0.687
HAcaBox
129
miR-199b-3p
0.64
0.034530062
0.737
miRNA
134
miR-100
−0.61
0.034553062
0.681
miRNA
133
U64
−0.38
0.034971581
0.633
HAcaBox
101
miR-10a
−0.67
0.037624151
0.666
miRNA
69
miR-30e
0.56
0.037770496
0.683
miRNA
57
miR-199a-3p
0.62
0.038490813
0.704
miRNA
134
HBII-85-11
−0.37
0.038507691
0.687
CDBox
31
miR-505-star
−0.62
0.039242017
0.647
miRNA
58
hsa-let-7f-1-star
0.44
0.042251211
0.658
miRNA
64
spike_in-control-29
−0.19
0.043064083
0.684
Oligonucleotide
137
spike-in
controls
miR-20b
0.64
0.043397678
0.655
miRNA
99
ACA5
−0.40
0.044405124
0.693
HAcaBox
85
miR-628-3p
0.57
0.044447799
0.652
miRNA
38
HBII-85-8_x
0.40
0.045108021
0.681
CDBox
135
HBII-85-27_x
0.29
0.045678744
0.651
CDBox
56
miR-99b-star
0.49
0.049531821
0.651
miRNA
74
[0000]
TABLE 8
50 miRNAs most significantly expressed between nevi and normal skin
Log2-
#Sample
Probe Name
FC
P value
AUC
ProbeType
Detected
14qII-14
−3.87
3.6592E−27
1.000
CDBox
56
14qII-14_x
−3.21
3.815E−24
1.000
CDBox
56
U74_x
1.46
3.89068E−23
1.000
CDBox
135
miR-509-3p
5.78
1.67661E−22
0.997
miRNA
116
miR-768-5p
−1.46
5.23441E−22
1.000
miRNA
135
ENSG00000199411_s
1.36
1.56796E−21
1.000
snoRNA
135
Z17B
−1.94
2.89347E−20
0.997
CDBox
117
miR-149
−3.46
1.55425E−19
1.000
miRNA
100
miR-125a-5p
−3.44
1.86526E−19
1.000
miRNA
128
U43
−1.19
3.32514E−19
1.000
CDBox
135
miR-1308
1.55
8.1184E−19
0.964
miRNA
135
U59A
1.13
9.99768E−18
0.993
CDBox
135
miR-146a
4.44
3.16232E−17
0.975
miRNA
129
miR-513a-5p
3.77
1.05679E−16
0.972
miRNA
105
ACA20
−1.74
1.56297E−16
0.993
HAcaBox
131
U43_x
−1.05
1.04459E−15
1.000
CDBox
135
U44_x
−1.37
5.54123E−15
0.994
CDBox
135
miR-127-3p
−3.56
7.53549E−15
0.988
miRNA
89
miR-193b
−2.57
7.81928E−15
1.000
miRNA
130
U83
−1.25
9.30493E−15
0.993
CDBox
135
miR-768-3p
0.98
2.39925E−14
0.972
miRNA
137
U33
−1.02
2.44194E−14
0.997
CDBox
137
miR-574-3p
−3.05
3.0433E−14
0.974
miRNA
122
ACA16
−1.86
3.35128E−14
0.968
HAcaBox
47
14qI-4
−2.43
3.96317E−14
0.979
CDBox
80
hsa-let-7c
−1.01
4.99111E−14
0.986
miRNA
135
miR-342-3p
−2.06
1.67074E−13
0.996
miRNA
136
hsa-let-7b
−1.01
2.25904E−13
0.964
miRNA
136
miR-423-3p
−2.52
2.97967E−13
1.000
miRNA
107
HBII-239
−1.41
3.2162E−13
0.975
CDBox
135
U38B_x
1.52
3.80613E−13
0.968
CDBox
133
miR-320b
−0.63
6.31909E−13
0.971
miRNA
135
miR-923
0.93
6.48332E−13
0.990
miRNA
135
U54
−1.06
1.17197E−12
0.975
CDBox
135
U38B
1.80
1.18885E−12
0.976
CDBox
134
U44
−1.07
1.28887E−12
0.981
CDBox
134
miR-139-5p
−2.70
2.74261E−12
0.940
miRNA
80
miR-1826
−0.71
2.83317E−12
0.958
miRNA
137
ENSG00000199435
1.38
2.88249E−12
0.954
snoRNA
63
miR-26a
0.89
2.88328E−12
0.960
miRNA
136
U58B_x
−1.47
3.60008E−12
0.940
CDBox
132
HBII-180A_x
−1.43
4.25614E−12
0.992
CDBox
123
14qII-12_x
−2.09
4.30741E−12
0.949
CDBox
85
miR-509-3-5p
3.46
5.53398E−12
0.953
miRNA
107
U55_x
−1.35
6.7836E−12
0.996
CDBox
135
miR-149-star
0.93
9.6022E−12
0.940
miRNA
135
HBII-276
−1.41
1.19464E−11
0.964
CDBox
132
miR-23b
−0.75
1.72105E−11
0.968
miRNA
137
miR-15b
−2.42
1.7823E−11
0.968
miRNA
125
miR-921
1.73
1.93285E−11
0.954
miRNA
49
Example 4
[0112] The data from Example 3 was further analyzed to identify the combination of markers best able to distinguish (A) melanoma from normal skin and (B) melanoma from nevi. Each miRNA (“analyte”) was examined by svm, random forest, boosting, lasso, baggin, cart, matt, logistic regression, and ctree analyses. The use of multiple statistical method demonstrates that the best combination of markers identified by one statistical method is validated by every other method, making the choice of marker combinations less subject to the specific weaknesses of any one statistical algorithm.
[0113] FIGS. 1-10 show, respectively, the best 2-10 miRNA combinations for differentiating melanoma (MM) from normal skin (“NS”) and the relevant error rates, as determined by different statistical algorithms.
[0114] FIGS. 11-23 show, respectively, the best 2-14 miRNA combinations for differentiating melanoma (MM) from nevi (NV), and the relevant error rates, as determined by different statistical algorithms.
[0115] FIG. 24 shows the log 2 signal for three miRNA: miR-150 (miR-150), miR-149-star (miR-149-star), and hsa-miR-1308 (miR-1308) across 137 samples. Samples 1-19 are normal skin (NS), 20-57 nevi (NV), 58-115 melanoma (MM) and 116-137 metastatic melanoma (Mets). As can be appreciated, miR-150, miR-149-star and miR-1308 distinguish normal skin and nevi from melanoma and metastatic melanoma
Example 5
[0116] In a follow up study, a total of 78 melanoma and 98 nevi (Intradermal-20, Compound-18, Junctional-20, Blue-20, Spitz-20) were studied on microarray. The candidate microRNAs were chosen based on AUC, p value, log 2 fold change, and 9 analysis programs, as before. A example of error rate and AUC from 9 programs is set forth in FIG. 25 . The candidate microRNAs identified from 2 programs (random forest and boosting) are listed in Table 9, below.
[0000]
TABLE 9
MicroRNA candidates from 78 melanoma and 98 nevi
microrna
adj.P.Val (FDR)
AUC
Log2FC
Order in program
miR-1268
1.45E−19
0.89
−1.80
5
miR-1228-star
2.87E−19
0.91
−1.77
2
miR-92b-star
4.62E−18
0.88
−1.73
3
miR-155
5.56E−18
0.86
2.85
4
miR-345
1.19E−16
0.85
1.83
7
miR-425
5.11E−16
0.85
1.80
miR-132
5.24E−16
0.85
1.75
10
miR-1207-5p
1.18E−15
0.86
−1.40
miR-1301
2.17E−15
0.83
1.70
miR-663
2.26E−15
0.85
−1.43
miR-339-5p
2.26E−15
0.85
1.60
9
miR-149-star
5.28E−15
0.85
−1.32
miR-150
5.25E−14
0.82
2.10
6
miR-18a
5.80E−13
0.8
0.84
miR-103
1.52E−11
0.86
0.93
8
miR-191
7.32E−13
0.9
0.85
1
miR-296-3p
1.05E−09
0.79
−0.85
11
miR-31
1.39E−12
0.79
2.46
miR-107*
3.27E−10
0.85
0.86
miR-93*
1.05E−09
0.85
1.14
miR-1275*
4.59E−11
0.8
−1.16
miR-181B*
3.69E−12
0.83
1.69
miR-921*
7.21E−12
0.81
−0.89
miR-1225-5p
7.63E−10
0.78
−1.3
miR-1202
1.08E−09
0.76
−1.34
miR-342-3p
1.55E−10
0.78
1.29
Internal control candidates
miR-27b
0.72
0.07
0.501
miR-195
0.95
0.01
0.506
miR-199b-3p
0.78
0.05
0.509
miR-199a-3p
0.86
0.03
0.511
REFERENCES
[0000]
1. Leidinger P, Keller A, Borries A, Reichrath J, Rass K, Jager S U. Lenhof H P, Meese E. High-throughput miRNA profiling of human melanoma blood samples. BMC Cancer. 2010 Jun. 7; 10:262.
2. Demetra Philippidou, Martina Schmitt, Dirk Moser, Christiane Margue, Petr V Nazarov, Arnaud Muller, Laurent Vallar, Dorothee Nashan, Iris Behrmann and Stephanie Kreis Signatures of MicroRNAs and Selected MicroRNA Target Genes in Human Melanoma. Cancer Res 2010 May 70(10); 4163-4173
3. Segura F, Ilana Belitskaya-Lévy I, Rose A, Zakrzewski J, Gaziel A. Melanoma MicroRNA Signature Predicts Post-Recurrence Survival Clinical Cancer Research 2020 Mar. 16(5): 1577-1586
[0120] The contents of the articles, patents, and patent applications, and all other documents and electronically available information mentioned or cited herein, are hereby incorporated by reference in their entirety to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. Applicants reserve the right to physically incorporate into this application any and all materials and information from any such articles, patents, patent applications, or other physical and electronic documents.
[0121] The inventions illustratively described herein may suitably be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms “comprising”, “including,” containing”, etc. shall be read expansively and without limitation. Additionally, the terms and expressions employed herein have been used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the inventions embodied therein herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention.
[0122] The invention has been described broadly and generically herein. Each of the narrower species and subgeneric groupings falling within the generic disclosure also form part of the invention. This includes the generic description of the invention with a proviso or negative limitation removing any subject matter from the genus, regardless of whether or not the excised material is specifically recited herein.
[0123] Other embodiments are within the following claims. In addition, where features or aspects of the invention are described in terms of Markush groups, those skilled in the art will recognize that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.
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Provided herein are methods for miRNA profiling for the diagnosis, prognosis, and management of melanoma and differentiation of melanoma from nevi.
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FIELD OF THE INVENTION
[0001] The present invention relates to an erosion barrier wastewater treatment system and in particular to a liner for a wastewater treatment lagoon. The lagoon may be any earthen basin for containing a body of water, for instance wastewater, and the liner is utilized mainly for reducing the erosion of the lagoon walls due to water turbulence.
BACKGROUND OF THE INVENTION
[0002] Conventional lagoon based wastewater treatment systems rely generally on open air lagoons to permit aerobic and anaerobic treatment of wastewater. A lagoon is any earthen basin for containing a body of water, such as a treatment reactor cell. Lagoons and other wastewater treatment ponds or basins are typically constructed by excavating land to create a reservoir area. If desired, berms can then be built around the perimeter of the reservoir area to extend the walls of the reservoir above ground level. Quite often, a lagoon is lined with a layer of clay to serve as a barrier. For example, environmental regulations typically require a subgrade clay layer of uniform thickness, for example 5 feet thick and having uniform water content. Often times a plastic liner made of high-density polyethylene may be placed over the entire interior surface defined by the reservoir and the berm area. The liner is made of sheet strips of high density polyethylene (HDPE) which overlap in an abutting fashion and are then welded or cemented together to create a water impermeable and erosion control line.
[0003] Once the lagoon is constructed and lined the wastewater liquid or sludge material is then pumped into the lagoon on top of the liner and/or the clay which is lining the lagoon. This liner facilitates not only maintaining the wastewater in the reservoir or lagoon but also in maintaining any turbulent water flow in the surface from eroding the berm and banking of the lagoon. The lagoon or pond is the subject to water fluid level changes as well as a turbulence of the surface in particular from aeration of the wastewater which can erode the banking and the berm. The liner is instrumental in protecting the underlying clay and soil lining forming the lagoon particularly where the turbulent water contacts the berm and banking.
[0004] Lagoon based water treatment systems require a large amount of space, on the order of several acres and often necessitate the large interior encompassing liner in conjunction with the lagoon construction to facilitate containment of the wastewater and to prevent erosion of the banking around the lagoon. This is tremendously expensive where an entire lagoon system must be covered with a liner, not only upon initial construction but upon replacement or fixing of a compromised liner.
[0005] Such traditional lagoon-based liner systems have several shortcomings. Because of the large size of the liners where the liners cover the entire interior of the lagoon, the liners which are generally impermeable material must be constructed on-site usually in large strips, where the strips are heat sealed together along their edges after being placed in an empty a lagoon. This of course means that the lagoon must be emptied and cannot be used for the time period in which the new liner material is placed inside. It is tremendously labor intensive, time-consuming and expensive to assemble such liners and empty the lagoons if a liner needs to be fixed or replaced.
SUMMARY OF THE INVENTION
[0006] The liner system of the present invention is a significant savings in material and man-hours to implement because the lagoon does not need to be drained, or operation even interrupted in most cases to construct and implement the erosion liner system. The liner is in effect a skirt which entirely surrounds the lagoon but does not need to extend and cover throughout the entire interior surface area of the lagoon. However, it is to be appreciated that the liner may extend to any length necessary to cover an interior surface as required. The skirt may be placed around the outside edge, banking and berm of the lagoon so that the there is no down time for the wastewater treatment facility. Also, the panels of the skirt may be fit together by a simpler less labor intensive means because all the edges do not have to be sealed between all the panels such as in the prior art liners.
[0007] In general the skirt is manufactured in manageable sections for instance in 50×20 foot rectangular sections which can be manufactured off-site, brought to the site and connected together along their edges with stainless steel bolts. The side edges of each section do not need to be entirely sealed because the skirt is concerned mainly with preventing erosion and ensuring that such erosion does not occur along the top of the lagoon wall where turbulence from aeration or other mechanical processes to the wastewater may erode the lagoon banking or berm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Several embodiments of the present invention will now be described by way of example only, with reference to the accompanying drawings in which:
[0009] FIG. 1 is a diagrammatic representation of a wastewater treatment plant;
[0010] FIG. 2 is a cross section of a lagoon;
[0011] FIG. 3 is a first embodiment of a panel of the present invention;
[0012] FIGS. 4A-4B are further embodiments of a panel of the present invention;
[0013] FIGS. 5A-5B are embodiments of a corner panel of the present invention;
[0014] FIGS. 6A-6C are further embodiments of a panel of the present invention;
[0015] FIG. 7 is the affixed panels of FIGS. 6A-6C ;
[0016] FIG. 8 is a diagrammatic plan view of an embodiment of a plurality of panels of the present invention;
[0017] FIG. 9 is a perspective view of a lagoon with an embodiment of the present invention; and
[0018] FIG. 10 is a cross section of an embodiment of a panel of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 is a diagrammatic representation of a wastewater treatment plant having a pretreatment process 110 , a primary treatment process 120 and a secondary treatment process 130 . The pretreatment 110 removes heavy materials such as trash, leaves, branches, etc., that can easily be collected from raw wastewater before damage is caused by clogging pumps are skimmers in the primary and secondary treatment processes. Pre-treatment may include screening the wastewater for such heavy materials by use of a screen or a rake passed through the wastewater to accumulate the heavier material on the screen which can then be removed manually or mechanically. Also, the flow of the wastewater may be adjusted to allow settlement of sand gravel, stones and broken glass for example. Particles of this type or kind can also damage pumps and other equipment in the treatment facility.
[0020] In primary treatment 120 the wastewater generally flows into large tanks called clarifiers, or sedimentation tanks, and these are used to initially settle sludge and to allow grease and oil accumulating on the surface where it can be skimmed off. The primary treatment 120 can include settling tanks equipped with the mechanically driven scrapers to drive the sludge towards a hopper in the base of the tank and skimmers at the surface for collecting the grease and oil, often times referred to as sapofication.
[0021] The wastewater is then transferred generally via a pump to a secondary treatment process 130 which often entails a lagoon or pool where most conventional water treatment facilities use aerobic biological processes to break down the biological materials in the wastewater. These aerobic processes require sufficient oxygen and food so that this aeration can take place for example in the lagoon. The aerators are often motor driven aerators floating on the surface of the wastewater in the lagoon. This aeration often causes a significant turbulence on the surface of the water which then of course propagates outwards to the edges of the lagoon. Over time this turbulence if significant can wear away the banking and berm potentially compromising the lagoon. The liner and fasteners described in further detail below ensures that such turbulence does not erode the banking of the lagoon and that installation of this device does not impact the operation or efficiency of the lagoon.
[0022] FIG. 2 is a cross-section of a lagoon 10 with the cross-hatching indicating a soil layer 12 which can be a clay layer or other type of porous, semi-porous or non-porous soil defining the lagoon itself. The lagoon 10 has a bottom 14 , a banking 16 and a berm 18 is built up to form a rim around the lagoon 10 which helps contain the wastewater 22 and a lagoon liner 24 is set in place covering the entire interior surface area of the lagoon 10 and the berm 18 . As shown in FIG. 2 the liner 24 stretches across the entire bottom 14 , banking 16 and berm 18 of the lagoon 10 and is fastened to a retaining wall 26 which encircles the lagoon 10 and supports the berm 18 . The banking 16 and berm 18 maybe at any slope and commonly a trench 28 is built within which the retaining wall 26 is positioned.
[0023] An aerator 32 may be positioned in the lagoon 10 to supply oxygen to the wastewater 22 . An ample oxygen supply in a wastewater lagoon is the key to rapid and effective wastewater treatment. Oxygen is needed by the bacteria to allow their respiration reactions to proceed rapidly. The oxygen is combined by the bacteria with carbon to form carbon dioxide. Without sufficient oxygen being present, bacteria are not able to quickly biodegrade the incoming organic matter. In the absence of dissolved oxygen, degradation must occur under septic conditions which are slow, odorous and yield incomplete conversions of pollutants. Under septic conditions without aeration, some of the carbon will react with hydrogen and sulfur to form sulfuric acid and methane. Other carbon will be converted to organic acids that create low pH conditions in the ponds and make the water more difficult to treat. For example, treated ponds designed to biodegrade wastewater pollutants without oxygen often must hold the incoming sewage for six months or longer to achieve acceptable levels of pollution removal. This is because the biodegradation of organic matter in the absence of oxygen is a very slow kinetic process.
[0024] Motor driven, mechanical aerators provide a combination of liquid aeration and mixing. Some mechanical aerators produce the gas-liquid interface by entraining air from the atmosphere and dispersing it into bubbles. Other types disperse liquid in the form of droplets or they produce jets or thin films as a spray that contact the ambient air. Some other types even generate both liquid droplets and air bubbles. Mechanical aerators create turbulence on the surface of the pond, this turbulence is beneficial in that turbulence facilities gas-liquid interface however, the turbulence has consequential side effects where the turbulence reaches to the banking and berms of the lagoon and creates erosion where no liner is utilized. Until now, the only solution to such erosion has been to ameliorate the effects by using a full lagoon liner as shown and described in FIG. 2 .
[0025] Turning to FIG. 3 , a single panel 30 of the present invention is shown having a substantially rectangular shape defined by a top edge 33 , a bottom edge 34 and opposing side edges 36 . The top and bottom edges 33 , 34 are reinforced with 2 inch nylon webbing 35 sewn along the entire length of the panel 30 and the side edges 36 are similarly reinforced with 3 inch nylon webbing 39 sewn along each the length of the sides 36 . Other sizes and material reinforcements may be used as well. The side edges 36 are further provided with a plurality of grommets 38 , for example stainless steel grommets, defining holes in and through the nylon webbing 39 and panel material. These holes align with the holes on adjacent panels and provide fastening points through which fasteners, such as stainless steel nuts and bolts for example, can secure adjacent panels 30 together.
[0026] Along the entire bottom edge 34 of the panel 30 is a pocket 40 sewn into the panel by overlapping the lowermost edge of the panel on itself and sewing the lowermost edge along a stitch line 41 to define the pocket 40 . The overlap of the lowermost edge 34 can be in the range of about 1-3 inches so that the pocket 40 can accommodate a ½ to 1 inch chain or other ballast 42 inserted into the pocket 40 along the entire bottom edge 34 of the panel. The chain or ballast 42 is stretched through the pocket 40 so that the weight of the chain 42 is essentially uniform along the length of the panel 30 and so that the panel lies evenly and uniformly along the berm 18 and banking 16 of the lagoon 10 as described in further detail below. The reinforcing nylon webbing 44 at the bottom edge of the panel 30 is, in one embodiment, sewn in conjunction with the stitch line 41 which defines the overlap and joining of the lowermost edge of the panel 34 to the panel to define the pocket 40 . Thus the pocket 40 actually hangs below the nylon webbing 44 at the bottom edge 34 of the panel 30 . This arrangement of the lower reinforcing nylon webbing 44 is important because the panel 30 is most susceptible to failure along the stitch line 41 which defines the pocket 40 . While there is some potential wear of the panel 30 material along the pocket portion of the panel 30 , a hole or abrasion here which exposes the chain or ballast 42 will not cause failure of the panel 30 . On the other hand failure of the stitching along the pocket 40 can compromise the entire pocket 40 and permit the chain or ballast 42 to fall entirely out of the pocket.
[0027] It is to be appreciated that lagoons may be of any size and shape, but are generally circular, square or rectangular. The size and shape of different lagoons may determine the specific size and shape of the panels used in a certain lagoon. For example as seen in FIGS. 4A and 4B a variety of shapes may be formed to accommodate corners, lengths and angles of various shaped lagoons. In FIG. 4B a side edge 37 of a corner panel 41 may be cut at an angle, here a 45 degree angle, to mate with a similar angled side edge 37 of an adjacent corner panel 41 to complete the right angle corner as shown in FIG. 5A . Alternatively a complete corner panel 43 may be sewn and reinforced with webbing 45 along an angled intermediate stitch line 49 as seen in FIG. 5B so that the side edges of the corner panel are at 90 degrees relative to one another.
[0028] An alternative panel shape shown in FIG. 6A shows the panel 53 in another embodiment being trapezoidal in nature to account for the slope and change in diameter between the upper most lip of a lagoon and a point lower down on the banking 16 where the bottom edge 54 of the panel rests. The diameter of the lagoon changes as the banking 16 slopes down into the lagoon and has a smaller diameter than that of the upper lip of the bank or berm 18 . To determine the appropriate trapezoidal shape for such a panel, the difference between the length of the circumferential top lip 52 and the circumferential length y of the desired banking point where the bottom edge 54 of the panel will lie, is determined by any conventional measurement process. This difference, divided by the number of panels required to encircle the lagoon, gives the approximate unit of measurement difference between the top edge length t and the bottom edge length b for each panel required to circumscribe the lagoon or pond and account for the slope of the banking 16 and berm 18 . An intermediate panel 51 shown in 6 B may be formed with a first side edge 47 that matches the side edge 47 of the trapezoidal panel 53 and a second straight edge 36 that matches the side edge of a panel 30 . The side edge 47 of the trapezoidal shape of panel 53 and the intermediate panel 51 may be at an angle of 0 to 45 degrees to match the measurement difference of the top edge t to the bottom edge b of a required corner or rounded banking of the lagoon. The top edge 56 and bottom edge 58 of the intermediate panel may be of any length that maintains a flat seam along the side edge 36 and side edge 47 . The intermediate panel 51 may mate with the trapezoidal panel 53 and the rectangular panel 30 as shown in FIG. 7 . Flexibility in panel shape is an important aspect of the present invention thus allowing the panels to be closely aligned without creating rolls or ridges within the panel that could form gaps and cause water seepage and erosion below a panel.
[0029] Separate panels are secured together along adjacent side edges by overlapping the side edges and aligning the respective grommets and holes in the adjacent panels. One manner of securing the side edges is the insertion of a bolt through each aligned hole and securing of the bolt in the hole by a nut. The bolt head and nut of course being larger than the hole in the side edge of the panel. Other methods of fastening the aligned side edges of the panels such as with clips or other fasteners are also contemplated.
[0030] It is an important aspect of the present invention that the liner system and panels can be placed in position and into operation without having to interrupt operation of the wastewater treatment system and lagoon. Because, while it is to be appreciated that the panels may extend to any length within the lagoon, the panels do not need extend entirely across and along the bottom of the lagoon, the entire circumferential ring of panels can be assembled around the edge of the lagoon and placed into position in the lagoon while the treatment plant or system continues to operate.
[0031] In FIG. 8 a diagrammatic plan view of a plurality of panels attached together and forming a complete ring for encircling a substantially rectangular lagoon is shown. A perspective view of a lagoon with an embodiment of the present invention is shown in FIG. 9 . In these examples, trapezoidal panels 53 and intermediate panels 51 are used to enclose the corners of the rectangular lagoon and rectangular panels 30 cover the other portions of the lagoon berm 18 and banking 16 . Each panel may be at only a short distance below the water's surface 48 or may extend further into the lagoon to any distance depending on the solubility of the banking 16 and the turbulence of water within the lagoon. The tops of the panels may extend over the retaining wall 26 and be secured within a trench 28 encircling the lagoon. Pretreatment sedimentation tanks 52 are also shown.
[0032] An embodiment of panel dimensions is shown in FIG. 10 . As seen in this embodiment, a cross-section of the panel has a first portion of the panel which is secured within the trench 28 and extending up and around the retaining wall 26 along the circumference of the lagoon. Where a panel is provided for example with a width of 20 feet, 3 feet of the width generally defines this first portion which is secured by entraining this first portion of the panel within a trench 28 under, and partially around the retaining wall. An intermediate section of approximately 2 feet extends across the top of the berm 18 , and a majority of the panel of approximately 15′ then depends down the slope of the banking into the lagoon where the bottom edge of the panel including the pocket 40 having the chain or ballast 42 therein. Again, because each panel comprising the liner can be attached to the adjacent panel and then positioned down into the lagoon even below the water level, the treatment and operation of the wastewater lagoon and facility is not interrupted.
[0033] In this way an erosion control lagoon liner can be constructed and implemented inexpensively and without interruption of facility operation for installation of the device. Additionally, a single panel can be easily replaced by disengaging the side edges removing the panel and replacing with a similar replacement panel, all without interruption of facility operation. One embodiment of the liner and panels involves the use of 3028 XR5® material a highly resistant, non-degradable membrane surface with extreme puncture and tear resistance as well as dimensional stability under high loads and extreme temperature fluctuations. Other containment and liner materials can be used as well.
[0034] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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An erosion barrier wastewater treatment system and in particular a liner for a wastewater treatment lagoon wherein the lagoon may be any earthen basin for containing a body of water, for instance wastewater, and the liner is utilized mainly for reducing the erosion of the lagoon walls due to water turbulence, the liner being formed from panels of material that can be constructed and implemented inexpensively and without interruption of facility operation for installation of the device.
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CROSS REFERENCE TO RELATED
[0001] This application claims priority under 35 U.S.C. 120 to U.S. Ser. No. 11/161,637 entitled PUSH PUTTER filed Aug. 10, 2005.
FIELD OF THE INVENTION
[0002] The field of the invention involves sporting goods, and namely an improved golf putter.
BACKGROUND OF THE INVENTION
[0003] Historically, golf putters have been designed along the lines of a pendulum, wherein a golfer is required to stand over his or her golf ball and swing his arms at the shoulders. Using traditional equipment, golfers who wished to be good at putting are required to learn to keep their head still, to keep a good “frame” by avoiding bending their arms at the wrist or elbows, and to correctly judge both the speed and direction of the putt. However, judging speed and direction is complicated by the design of existing putters, namely, requiring golfers to stand over the ball instead of behind the ball and to learn how to properly strike a ball using an offset piece of equipment. The offset in traditional designs is caused by having a “leaning L” shaped putter which adds an unnecessary source of variability to a golfers putting stroke. In golfers who become successful putters, an investment of literally thousands of hours is required in order to achieve “muscle memory” and to reduce the variability caused, in part, by the difficulties inherent in the traditional design.
[0004] The prior art discloses various attempts to reduce the variability caused by the inability of golfers to maintain a smooth stroke during the pendulum-like swing of a traditional putter. Some prior art patents have included a roller mechanism within their design in order to avoid any arc-like swinging motion and instead to keep the club face in constant contact with the ground, thereby achieving a more linear stroke motion while minimizing the traditional up-and-down component of an arc-like pendulum motion.
[0005] Some patents include U.S. Pat. Nos. 5,577,965; 5,603,665; 6,066,053; 4,688,799; and 5,527,035. All of these describe an offset, “leaning L” putter design along with a roller feature. The '965 patent includes a roller within the putter head wherein the contact face of the putter is the roller itself which runs the length of the club head, i.e. the roller feature is at the front for contact with the ball. The '665 patent includes a removable roller held on the bottom of a traditional putter by brackets for contact with the ground. The '053 patent describes a putter head wherein the entire head rolls around a central shaft. The '799 patent has a rolling disc attached to the heel of a traditional putter. The '035 patent describes a putter head where the roller feature runs length-wise to contact the ground and provide re-alignment feedback and is located behind the putter clubface. However, putters of this design still require a golfer to stand over the ball and to use an offset design.
[0006] Another patent in the prior art which discloses a roller feature is U.S. Pat. No. 4,756,535. The '535 patent discloses a centrally disposed roller wheel directly behind the center portion of the club face, or “sweetspot”, to aid putting alignment. However, it does not appear to be disclosed where the roller maintains contact with the ground throughout the stroke.
[0007] There is also in the prior art various disclosures of golf clubs with markings on the head for aligning the head with the ball and for indicating the direction of the swing, such as U.S. Pat. Nos. 3,199,873 and 3,680,868 mentioned above as well as U.S. Pat. Nos. 2,781,197 and 2,865,635. However, the problem of putting alignment is well known among both professional and amateur golfers, especially for putts wherein the target destination, i.e. hole or cup, is located beyond the peripheral field of vision of the golfer.
SUMMARY OF THE INVENTION
[0008] The Push Putter™ golf club is designed for a right or left-handed golfer to putt the ball while standing behind the ball, providing a direct view to the hole. The golfer pushes the putter forward to make contact with the ball. The player may stand or kneel down for the best view to the hole.
[0009] Some of the advantages of the golf club include improving a golfers putting game. In operation, a player stands behind the ball to provide the direct view to the hole. As he putts, his putter is pointing directly to the target. The player only needs to use one of his arms to push the putter; this reduces unnecessary movement. The golfer does not have to lift the putter off the ground. Further, the putter shaft is adjustable for various positions.
[0010] In contrast, traditional putters suffer the following disadvantages. The player doesn't have the direct view to the target. The top view on the ball does not provide an accurate ‘line’ alignment or distance determination. Players are forced to putt with both hands and shoulder movement. This creates more variables to putt accurately. The player is required to elevate the club while making a backward and forward swing. The push putter only requires a forward push.
[0011] Accordingly, one preferred embodiment of the golf club comprises a club shaft having an upper portion, a lower portion, and a hosel, said upper portion having a top end and a bottom end, said lower portion being formed in an “S” shape and having a proximal end and a distal end wherein the bottom end of the upper portion is attached to the proximal end of the lower portion, said hosel having a first end and a second end wherein the distal end of the lower portion is attached to the first end of the hosel, a roller mounted on the lower portion of the club shaft by one or more fasteners, and a club head attached to the second end of the hosel in alignment with the roller and forming a sighting line lining up the desired path of a golf ball struck by said club head.
[0012] In another preferred embodiment, the roller is a cylinder with a central axially extending bore having the lower portion of the club shaft disposed therein, said roller having an external surface for engaging the ground to assist putting alignment.
[0013] In another preferred embodiment, the roller further comprises bearing means operatively engaged between the lower portion of the club shaft and the roller, wherein the bearing means comprises one or more bearings disposed within the central axially extending bore of the cylinder.
[0014] In another preferred embodiment, the roller is removable from the lower portion of the club shaft.
[0015] In another preferred embodiment, the roller is mounted for rotation on the lower portion of the club shaft by one or more fasteners, said roller having an external surface for engaging the ground to assist putting alignment and said roller having an axle operatively attached to the one or more fasteners.
[0016] In another preferred embodiment, the roller further comprises bearing means operatively engaged between the axle and the roller.
[0017] In another preferred embodiment, the club head further comprises a hosel receiving cavity.
[0018] In another preferred embodiment, the club head has a heel portion, central portion, and toe portion, and said hosel receiving cavity located at the central portion of the club head or alternatively at the heel portion of the club head.
[0019] In another preferred embodiment, the club head further comprises alignment indicia.
[0020] In another preferred embodiment, the club head is centrally weighted or alternatively the club head is perimeter weighted.
FIGURES
[0021] FIG. 1 is a perspective view of the golf club. FIG. 1 shows a roller in a cylindrical embodiment wherein the club shaft is disposed within a central axially extending bore of a cylinder.
[0022] FIG. 2 is a perspective view of the golf club. FIG. 2 shows a roller wherein the roller is attached by fasteners and mounted to the outside of the club shaft.
[0023] FIG. 3 is a perspective view of the roller and club head portion of the golf club. FIG. 3 shows the club shaft attached to a centrally located portion of the club head.
[0024] FIG. 4 is a perspective view of the roller and club head portion of the golf club. FIG. 4 shows the club shaft attached to a off-center or heel portion of the club head.
[0025] FIG. 5 is a front view of a roller and fastener assembly. FIG. 5 shows a roller embodiment that is attached by fasteners and mounted to the outside of the club shaft.
[0026] FIG. 6 is a top view of the lower portion of the club shaft. FIG. 6 shows fasteners attached to the club shaft for the cylindrical embodiment of the roller.
[0027] FIG. 7 is a side view of the cylindrical roller and club head. FIG. 7 shows a ball-bearing mechanism within central axial extending bore for the cylindrical embodiment.
[0028] FIG. 8 is a perspective view of the golf club. FIG. 8 shows an embodiment having a perimeter weighted club head.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring now to FIG. 1 , the golf club ( 10 ) comprises a club shaft ( 12 ) having an upper portion ( 14 ), a lower portion ( 16 ), and a hosel ( 18 ), said upper portion ( 14 ) having a top end ( 14 a ) and a bottom end ( 14 b ), said lower portion ( 16 ) being formed in an “S” shape and having a proximal end ( 16 a ) and a distal end ( 16 b ) wherein the bottom end of the upper portion ( 14 b ) is attached to the proximal end of the lower portion ( 16 a ), said hosel ( 18 ) having a first end ( 18 a ) and a second end ( 18 b ) wherein the distal end of the lower portion ( 16 b ) is attached to the first end of the hosel ( 18 a ), a roller ( 20 ) mounted on the lower portion of the club shaft ( 12 ) by one or more fasteners ( 22 ), and a club head ( 24 ) attached to the second end of the hosel ( 18 b ) in alignment with the roller ( 20 ) and forming a sighting line lining up the desired path of a golf ball struck by said club head ( 24 ).
[0030] In FIGS. 2 and 5 , the roller ( 20 ) is alternatively mounted for rotation on the lower portion of the club shaft ( 12 ) by one or more fasteners ( 36 ), said roller ( 20 ) having an external surface ( 28 ) for engaging the ground to assist putting alignment and said roller ( 20 ) having an axle ( 38 ) operatively attached to the one or more fasteners ( 36 ).
[0031] In FIGS. 3 , and 4 , the club head ( 24 ) itself can include a hosel receiving cavity ( 42 ). FIG. 4 shows the club head ( 24 ) having an off-center hosel receiving cavity ( 42 ), the club head ( 24 ) has a heel portion ( 24 a ), central portion ( 24 b ), and toe portion ( 24 c ), and said hosel receiving cavity ( 42 ) can be located at the central portion of the club head ( 24 b ) as in FIG. 3 , or alternatively, at the heel portion of the club head ( 24 a ), as in FIG. 4 .
[0032] As shown in FIGS. 3 , and 4 , the club head ( 24 ) may also include alignment indicia ( 44 ).
[0033] FIG. 4 , the roller ( 20 ) is shown as a cylinder ( 20 a ) with a central axially extending bore ( 26 ) having the lower portion of the club shaft ( 12 ) disposed therein, said roller ( 20 a ) having an external surface ( 28 ) for engaging the ground to assist putting alignment.
[0034] In FIG. 5 , the roller ( 20 ) is shown having bearing means ( 40 ) operatively engaged between the axle ( 38 ) and the roller ( 20 ).
[0035] In FIGS. 5 , and 6 , the roller ( 20 or 20 a ) may also be removable from the lower portion of the club shaft ( 12 ) by operation of fasteners ( 22 or 36 ).
[0036] FIG. 7 discloses the roller as a cylinder ( 20 a ) having bearing means ( 30 ) operatively engaged between the lower portion of the club shaft ( 12 ) and the roller ( 20 a ), wherein the bearing means ( 30 ) comprises one or more bearings ( 32 ) disposed within the central axially extending bore ( 26 ) of the cylinder ( 20 a ).
[0037] In FIG. 8 , the club head can be perimeter weighted ( 48 ) as an alternative embodiment to FIGS. 1-4 , where the club head ( 24 ) is shown as centrally weighted ( 46 ).
[0038] In one example, the push putter has a plastic roller 1.5 inch in diameter and 3 inch in length. Both ends of the roller are cap with plastic barring. A rod, 0.25 inch diameter, is threaded through the center making an “S” shape. One end of the “S” is attached to a putter head and the other end is connected to the shaft. The shaft and the putter head are exactly center to the roller length's center. The shaft is adjustable for various heights. The shaft grip is same as traditional golf clubs.
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The invention involves sporting goods, and namely an improved golf putter having a roller which allows a golfer to make contact with the ball by pushing the putter while in direct visual alignment of the hole.
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CROSS-REFERENCE TO RELATED APPLICATION DATA
[0001] This application claims the benefit of the earlier filed parent international application number PCT/AT2006/000096 having an international filing date of Mar. 7, 2006, that claims the benefit of A 412/2005 having a filing date of Mar. 11, 2005.
FIELD OF THE INVENTION
[0002] The invention refers to an internal combustion engine in which the hot gas continuously produced through combustion is relaxed in an exhaust gas turbine and in which the necessary hot gas overpressure is generated before the exhaust gas turbine at least partially by means of an ejector pump. Downstream the exhaust gas turbine is a recuperator-heat exchanger, which transfers the residual heat from the discharged exhaust gas to the medium flowing into the internal combustion engine.
BACKGROUND
[0003] Such an internal combustion engine is known from the document U.S. Pat. No. 5,687,560 A1. This shows an exhaust gas turbine with a continuously operated combustion chamber upstream and a two level exhaust turbine. To the exhaust gas turbine with a mechanical compaction level a first heat exchanger is assigned, in which fuel is pre-heated which afterwards flows into the combustion chamber. In a second heat exchanger heat is withdrawn from the exhaust gas and is transferred to the combustion air previously cooled down in the first heat exchanger. In this application the compaction occurs without using a jet pump; hence the exhaust gas turbine shows a mechanical compaction level.
[0004] From the document GB 642 118 A an internal combustion engine is known, to which heat-exchangers are connected downstream, in which the combustion air is pre-heated for the continuous combustion in the exhaust gas turbine. Moreover steam for a steam generator is generated in the heat exchangers. A mixture of oil and steam is conveyed to the nozzles of the burner but the compaction is carried out likewise without a jet pump and therefore a mechanical compaction level is necessary.
[0005] From the document GB 1 282 555 it can be seen that an external heat source is designed before the Laval-nozzle for steam generation. The scope of this measure is the development of a high vacuum depression pump. Designing an external heat source for steam generation before the Laval-nozzle serves to obtain a higher negative pressure.
[0006] Basically there are known a multitude of gas turbines with recuperator waste heat utilization. Likewise are also known applications of steam processes in such machines. The following documents show exemplary state-of-the-art: DE 69528871 T2 and DE 69432191 T2 and DE 6923198 T2. But all these applications don't use the concurrence of injectors in gas turbines with recuperator waste heat utilization as per this invention.
SUMMARY
[0007] The task of this invention is to develop an internal combustion engine with a continuous combustion and a maximum possible physical recuperative waste heat utilization and to accomplish a compaction of the combustion air using exclusively an ejector pump. It will be possible to renounce completely the use of a mechanical compaction level.
[0008] The Laval-nozzle in this invention will have to differ considerably from a conventional Laval-nozzle. Its driving steam will have to have an exorbitantly increased kinetic energy at the spray hole compared to a usual injector. This driving steam has to be able to compact the combustion air, respectively in the embodiment according to this invention, the smoke gas in the same degree as a mechanical compaction level.
[0009] If, by way of comparison, the use of the therefore necessary ejector pump, modified according to this invention, were abandoned and a conventional ejector pump were used, such plethora of driving steam would be necessary for achieving a sufficient compaction pressure of the combustion air, that, the other way around, in the exhaust gas after the recuperator-heat exchanger so much irreversibly lost residual heat would exist, that no practically usable degree of efficiency of the combustion engine would be accomplished. Furthermore this plethora of steam would bring so much water into the combustion chamber that igniting a flame wouldn't be possible.
[0010] According to this invention all fluid and gaseous media, which flow into the internal combustion engine are led to the exhaust gas recuperator-heat exchanger and from the exhaust gas a maximum possible physical waste heat is extracted and is transferred on the flowing media.
[0011] This counter current heat exchanger has to be designed with regard to the size of the exchange surface in such a way, that the entire available residual heat from the exhaust gas is transferred on the driving steam. Out of physical reasons a part of the condensation heat contained in the steam of the exhaust gas is not transferable because the feed water flowing in must have a far higher pressure than the steam flowing off. The evaporation heat for the conversion into steam of the feed water flowing in is absorbed only at far over 100°, while the other way around the steam flowing off releases the adequate condensation heat at atmospheric pressure and at about 100°.
[0012] In another embodiment of the invention an internal combustion engine of the initially mentioned type is provided especially for burning solid fuel as piece goods. Solid fuel as piece goods can, by nature, burn only at a pressure in the burner close to the atmospheric pressure. For this type of combustion an exhaust gas turbine according to this invention shall be made serviceable. But it has to be usable in equal measure for gaseous and fluid fuel likewise at a pressure in the burner close to atmospheric pressure.
[0013] In another embodiment of the invention an internal combustion engine of the initially mentioned type has to be made serviceable, in order to be able to use the breaking energy of a car in a recuperative manner and in the same time to power this car. The breaking energy of the vehicle will be stored in a heat accumulator in the form of heat. When needed, it has to be possible to feed this again into the internal combustion engine.
[0014] In a further embodiment of this invention an internal combustion engine of the initially mentioned type has to be made serviceable in order to pre-compact the combustion air of a conventional internal-combustion piston engine, similar to the effect of the exhaust gas turbocharger. The conventional mechanical turbocharger is also replaced and instead the combustion air is pre-compacted only using steam, without any mechanically operated part.
[0015] The requirements are met by the fact that during the expansion in the Laval-nozzle the driving steam of the ejector pump is continuously renewed through heat transfer from a water tank from outside the injector.
[0016] As opposed to the conventional Laval-nozzle, inside the Laval-nozzle heated according to this invention no isentropic expansion of the steam takes place, but an at least approximate isotherm expansion within a Laval-nozzle heated from outside takes place. This polytrope (almost isotherm) expansion within the heated Laval-nozzle has as effect, that the steam coming from the nozzle is not inhomogeneously, partially condensed as in case of the conventional Laval-nozzle, or even partially transformed into ice, but it escapes as homogeneous, overheated medium, as specifically lighter superheated steam.
[0017] The superheated steam, which escapes from the heated Laval-nozzle, has a considerably higher speed compared to the steam escaping from conventional Laval-nozzles. Superheated steam, which escapes the Laval-nozzle as per this invention has due to its higher speed an adequately increased velocity impulse compared to the steam, which escapes from a conventional Laval-nozzle. A velocity of vapor achieved this way cannot be achieved by conventional nozzle due to physical conditions.
[0018] The steam in the Laval-nozzle heated as per this invention from the inlet to the outlet at a continuously dropping pressure and at least approximately constant temperature (through heat supply from outside to isothermal expansion) experiences an enlargement of the volume corresponding to the dropping pressure at an at least constant temperature. Thus the steam enthalpy increases during the expansion in the Laval-nozzle and in the same time damaging entropy switches are avoided. In conventional Laval-nozzles multiple shock section like condensation switches occur during the steam expansion, that is multiple damaging entropy switches.
[0019] The highly accelerated steam molecules which escape from the Laval-nozzle heated as per this invention have that much kinetic energy, that at a subsequent pulse transmission to the medium to be pumped a pressure is reached in the mixture of fuel and medium to be pumped, which could operate the one-stage gas turbine according to this invention with an efficiency corresponding at least to the efficiency of a conventional two-stage ISO-norm gas turbine with recuperator waste heat utilization. This isn't possible neither with a conventional, unheated Laval-nozzle, nor with a conventional Laval-nozzle with just a steam superheater connected upstream.
[0020] The driving steam which is renewed through heat during the expansion within the Laval-nozzle draws this heat directly or indirectly from the burner. The cladding of the Laval-nozzle transfers this heat to the driving steam streaming through this nozzle. The Laval-nozzle is mounted directly to the burner respectively to the smoke tube. The temperature of the heat tank in the burner respectively in the smoke tube is permanently a few hundred degrees over the temperature of the driving steam. This way the driving steam remains superheated despite its expansion; it is continuously renewed and escapes also superheated at the nozzle outlet.
[0021] The driving steam is heated before entering the Laval-nozzle by a recuperator-heat exchanger, which re-extracts heat from the exhaust gas after the exhaust gas turbine. Subsequently the driving gas is superheated through the steam superheater, which absorbs heat from the burnout at the burner respectively at the smoke tube downstream.
[0022] The steam in the steam superheater experiences at a constant pressure and at an irrelevant increase of its subsonic-flow rate an increase of its volume corresponding to the temperature increase. This form of heat supply represents an isobaric increase of the enthalpy.
[0023] The materials from the burner respectively smoke tube towards the Laval-nozzles have a high heat transfer coefficient. The materials consist preferably of high heat-conductive and appropriate temperature-resistant metal.
[0024] The heat transfer for the steam renewing of the driving steam within the Laval-nozzle as well as for the superheating of the driving steam in the steam superheater occurs over these thermal conductive connections to the burner respectively through the thermal conductive connections to the smoke tube downstream.
[0025] The compaction of the combustion air respectively of the smoke gas, which flows towards the exhaust gas turbine, occurs exclusively and solely by means of the ejector pump according to this invention without any requirement for a mechanical compactor.
[0026] In a conventional Laval-nozzle the water vapors reaches within the Laval-nozzle the stage of saturation and during the expansion of the steam pressure several shock section like condensation switches occur. These are multiple small entropy switches. Thereby the ice point of the condensate is partially undercut and ice crystals develop. Disequilibrium effects in the steam lead altogether to a considerable entropy increase of the driving steam in the Laval-nozzle. Its efficiency falls far below a value which could make the use of the Laval-nozzle instead of a mechanical compaction level for an exhaust gas turbine possible.
[0027] On the other hand, by heating the Laval-nozzle, the water vapors within the Laval-nozzle never reaches the stage of saturation, and no condensation switches occur during the expansion of the steam pressure. Disequilibrium effects in the steam entirely disappear. The other way around the heating of the driving gas leads to a considerable increase of the enthalpy of the driving steam within the Laval nozzle. Its efficiency reaches a value which makes the use of the Laval-nozzle instead of a mechanical compaction level for an exhaust gas turbine possible.
[0028] The entire heat used for the pre-heating of the medium to be pumped is fed into the medium to be pumped in the recuperator-heat exchanger respectively in the burner before its compaction in the injector. The type of compaction in an injector as a pulse transmission between the propellant to the medium to be pumped allows a heating of the air to be pumped already before the compaction.
[0029] Using this pumping force of the ejector pump it is possible to compact heated air to such extent as it is also required for exhaust gas turbines. Hot air can be pumped like cold air without any loss of efficiency. Combustion air can be conducted into the recuperator-heat exchanger at atmospheric pressure and ambient temperature in order to be compacted by means of pulse transmission after it has absorbed maximum heat. The increased temperature of the medium doesn't play a damaging role with regard to the efficiency. This will be explained as follows:
[0030] In case of all conventional mechanical compactors a higher counter pressure develops on the compressor piston with the increased temperature of the medium to be compacted. Completely opposed to that, in the injector cannot occur a retroaction through a counter pressure. The driving pressure of the driving steam is completed in the Laval-nozzle and is fully converted into speed of the accelerated propellant. This leaves non-braked the Laval-nozzle and completely independent of the temperature of the compacted medium.
[0031] The molecules of the propulsion jet prepare for a free flight to the suction tube, where they collide only little by little with the molecules from the propellant, far away from the source nozzle. It is not important at all if now a molecule hit in such a way is itself in a strong or weak Brownian molecular movement, namely if the propellant is hot or cold. The process of compaction occurs advantageous that is only as pulse transmission.
[0032] All gaseous and liquid media flowing into an internal combustion engine are directed against the exhaust gas mixture flowing out in the recuperator-heat exchanger designed as a counter current heat exchanger in adequate heat exchange parts. The effective heat capacity of the flowing in media corresponds in essence to the exhaust gas mixture flowing out. Hence the medium flowing in its whole, consisting of feed water, fuel and combustion air, with exception of the condensation heat of the steam flowing out, can absorb the whole residual heat of the medium flowing out.
[0033] For the reason that each medium can absorb without any losses already before its compaction any amount of heat, reversely the conclusion can be reached that all waste heat which can be extracted recuperatively can actually be fed into the internal combustion engine. At a higher recirculation of residual heat the efficiency of this internal combustion engine increases adequately.
[0034] Assuming that the dimensions of the heat exchange surfaces of the recuperator-heat exchanger are designed adequately, until the exhaust gas exits, its temperature drops to the condensation temperature of the steam contained in the mixture flowing off; this is of 100° C. A further cooling down of the exhaust gas is not possible because the pressure of the mixture flowing off is atmospheric whereas the pressure of the feed water has to be far higher. Thereby the feed water evaporates at far over 100° and thus can not absorb the evaporation heat from the condensation heat of the steam flowing off at atmospheric pressure. This residual heat of the condensation heat is thus irreversibly lost for the internal combustion engine.
[0035] An ejector pump produces negative pressure in the injector, which in one embodiment of this invention drives the smoke gas from the burner operated at an almost atmospheric pressure. This smoke gas is subsequently compacted in the diffuser of the injector prior to the transition to the exhaust gas turbine. The compacted exhaust gas is subsequently relaxed in the one-stage exhaust gas turbine.
[0036] The said burner in this invention may be operated with wood piece goods, particularly because until now no technical device is known, that can make smoke gas, which was produced in a boiler at atmospheric pressure, directly serviceable for the drive of an exhaust gas turbine. The burner can be operated instead of with wood, with fluid, gaseous, or other solid fuels. In each case the combustion air flowing into the burner is previously heated in the recuperator-heat exchanger.
[0037] The smoke gas from the combustion of wood or coal has to be cleaned with a smoke gas filter connected between the combustion chamber and the exhaust gas turbine. Particularly the ashes of this combustion have to remain in the combustion chamber. If the ashes were to reach the heat exchanger and the exhaust gas turbine with the exhaust gas, these would be decommissioned and respectively they would degrade by degrees. Therefore the smoke gas is cleaned of soot and flue ash also with a filter between the combustion chamber and the exhaust gas turbine, and under the kiln run an ash bin is built-in, which separates ashes through a grid.
[0038] If fluid fuel is used, which can be vaporized without any residue, the fuel can be conducted together with the feed water by use of a pump as a homogeneous mixture through the recuperator-heat exchanger, subsequently through the steam superheater and subsequently through the Laval-nozzle to the pressure burner. Because the flow rate of the mixture consisting of water steam and fuel steam to the burner never drops under the burning flow rate of the fuel steam, the fuel never ignites. The mixture of water steam and fuel steam reaches the ignition flow rate of the fuel only in the diffuser of the burner.
[0039] Thus in the presented embodiment the fuel can be used as propellant together with the feed water. Thereby, in an advantageous manner, accordingly lesser feed water is needed for reaching a certain pressure. Lesser feed water means that lesser irreversibly wasted residual heat accumulates after the recuperator-heat exchanger. The efficiency of the internal combustion engine increases, this embodiment reaches its best efficiency as compared to all shown embodiments.
[0040] In the heated Laval nozzle we have in the divergent part of the nozzle in any case ultrasonic speed, if required or not. A gaseous medium which flows with ultrasonic speed is not allowed under any circumstances to be bent in its linear flow center line within the Laval-nozzle, because otherwise extremely damaging compaction switches would occur, which would increase the gas entropy with an extreme damaging effect.
[0041] Out of this the necessary solutions result, according to which the heat exchange surface of the Laval-nozzle is to be designed absolutely linearly and the possible heat exchanging surface of the Laval-nozzle towards the driving steam has to be multiply enhanced compared to a conventional Laval-nozzle, because considerable amounts of heat have to be transferred to the driving steam. The surface of a conventional Laval-nozzle, initially not designed as a heat exchanging surface, would be several fold too small.
[0042] Such an enhancement of the heat exchanging surface in the Laval-nozzle is effected according to this invention amongst others by distributing the driving steam to more parallel aligned Laval-nozzles, which absorb each a part of the entire steam stream. The entire steam stream is therefore distributed to more such Laval-nozzles as component gas flows.
[0043] A further enhancement of the heat exchanging surface in the Laval-nozzle is amongst others therefore possible, because the circumference of the nozzle is enhanced compared to a round nozzle section by flattening the nozzle section and at corresponding diminishing heights.
[0044] A further enhancement of the heat exchanging surface in the Laval-nozzle occurs amongst others through the flattening of the angle of rise of the divergent nozzle parts to less than 3°. This leads to an adequate extension of the longitudinal axis of the divergent nozzle parts with a subsequent enhancement of the heat exchange surface. Thus the divergent part of the Laval-nozzle has to be flattened to a high extent in order to achieve an enhancement of the heat exchange surface.
[0045] In another typical embodiment of this invention the heated Laval-nozzle is used for the pre-compaction of the charge air of a conventional internal-combustion piston engine. By means of the driving steam which was previously superheated in a steam superheater and then conducted through the heated Laval-nozzle which pre-compacts the combustion air before entering the conventional internal combustion engine. This function replaces the conventional exhaust gas turbocharger for the pre-compaction of the combustion air.
[0046] In another embodiment of this invention the gas flow is conducted after the heated Laval-nozzle and the injector through a heated bypass-heat accumulator. This gas flow is adjustable by use of a control valve; it can be amplified, diminished or cut off.
[0047] The bypass-heat accumulator manufactured preferably of mineral is heated by the breaking energy of a vehicle, which is transformed in the generator into electric current. The generator on this part is driven by one or more wheels of the vehicle. So the bypass-accumulator can be heated electrically using an external energy source. Through this bypass-accumulator more or less controlled driving gas which flows towards the burner is conducted. In doing so the gas mixture is heated and to the same extent to which it can absorb heat from the bypass-accumulator it saves fuel.
[0048] Through another heat exchanger a part of the residual heat after the recuperator-heat exchanger, into which previously all fluid and gaseous media which flow into the internal combustion engine had been conducted, can be used for heating or as process heat. In the recuperator-heat exchanger not only residual heat is returned to the maximum physical extent to the process but also the not usable condensation heat of the steam in the exhaust gas is used for heating purposes.
[0049] The heat exchange surface in the interior of the pressure burner in the embodiment of this invention respectively of the smoke tube with its attached steam superheater and the attached Laval-nozzles is enhanced by the fact that this surface shows a fissure which is preferably shaped as longitudinal rills. The heat transfer coefficient increases about to the same extent to which an enhancement of the surface is created opposed to a smooth, not uncleft surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Further advantages and details of the invention are explained in the following by means of the embodiments of the invention represented in the drawings below:
[0051] FIG. 1 shows a schematic section of the internal combustion engine using an evaporable fuel and subsequently the residual heat for heating purposes. In this section also a use of feed water in a closed cycle is represented.
[0052] FIG. 2 shows a schematic section of the internal combustion engine when used with especially a solid fuel and at atmospheric combustion.
[0053] FIG. 3 shows a schematic section of the internal combustion engine in a set use, in which instead of an exhaust gas turbine 38 a conventional combustion engine 58 is used, which is charged with an injector 30 , analogous to a turbocharger.
[0054] FIG. 4 shows a schematic section of the internal combustion engine used in vehicles with recuperator intermediate storage 43 of breaking energy.
[0055] FIG. 5 shows a schematic longitudinal section for the enhancement of the heat exchange surface in the Laval-nozzle with the constructive characteristic of the flattening of the aperture angle 27 of the divergent nozzle parts 24 .
[0056] FIG. 6 shows a schematic longitudinal section for the enhancement of the heat exchanging surface in the Laval-nozzle with the constructive characteristic of the multiplication of the Laval-nozzles 22 .
[0057] FIG. 8 shows a schematic section through the burner 8 with enhanced surface respectively the smoke tube 19 with enhanced surface and the multiple nozzles 22 on the burner 8 respectively on the smoke tube 19 . Also shown in this representation is the enhancement of the heat exchange surface of the nozzles by flattening the admission section 29 of the Laval-nozzle 22 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0058] FIG. 1 shows how in this internal combustion engine the compaction achieved without any mechanical compaction level only with an ejector pump 30 . This type of compaction with an ejector pump could be used technically meaningful only additionally to mechanical compactors as a pre-compactor. The conventional steam jet compactor as sole compacting level would bring too much steam into the combustion air. Disproportional much not recaptured condensation heat would be lost and hence a low efficiency would be achieved. If alternatively the quantity of driving steam were reduced to an acceptable extent, the compaction pressure would drop to a technically non applicable level, therefore this would be not feasible.
[0059] According to this invention the compaction of the combustion air with sufficient pressure and a minimized water supply initially succeeds by exorbitantly superheating the steam, as represented, in the steam superheater 11 respectively 21 and afterwards by heating it especially in the Laval-nozzle 22 , during the isentropic relaxation. This permanent heating occurs by the supply of a supplementary, saturated heat flow volume conveyed from burner 8 or the smoke tube 19 , respectively, to the Laval-nozzle 22 and the steam superheater 11 respectively 21 . This way damaging accumulation of saturated steam is completely avoided until leaking from the nozzle 26 . The efficiency of the injector drops as is generally known to the same extent to which a condensate rate accumulates in the driving steam.
[0060] By means of the two represented procedures 11 + 22 a doubling of the speed of the driving steam at the exit 26 of the Laval-nozzle 22 compared to a conventional Laval-nozzle is achieved. Basically the steam superheaters 11 , 21 could optionally also be abandoned, but in this case the Laval-nozzle 22 would have to be built accordingly bigger with disproportionately increased effort to achieve the transfer of the necessary heat flow volume.
[0061] The additional heat supplied for heating the steam superheater 11 , 12 and the Laval-nozzle 22 happens by heat extraction from the burner 8 , 13 . To this end the steam superheater 11 , 21 and the Laval-nozzle 22 , as represented, is attached with a sufficient thermal contact as close as possible to the burner 8 , and to the smoke tube 19 .
[0062] In conventional (unheated) Laval-nozzles the temperature of the steam drops until the spray hole to the condensation temperature of the driving steam, during the isentropic relaxation in the Laval-nozzle.
[0063] Unlike this in case of the Laval-nozzle 22 an outlet temperature of the steam of 700° C. at the outlet nozzle 26 can be reached by a continuous supply of heat from the burner 8 from the exhaust gas in the smoke tube 19 at for instance a combustion temperature of 1000° C.
[0064] The heat extracted from the burner 8 , 13 for increasing the enthalpy of the steam in the nozzle 22 and the steam superheater 11 , 21 , with subsequent entropy of the driving steam empties through the injector 31 again into the burner 8 , 13 . The heat extraction from the burner 8 , 13 is also returned in an inner cycle to the burners 8 , 13 , always in a proportion of approximately 100%.
[0065] In other words: enthalpy from the burner 8 , 13 is used in order to increase the pressure of the medium to be pumped, but the enthalpy flows back in an engine internal, closed circuit in a proportion of approximately 100% towards the starting point, the burner 8 respectively 13 .
[0066] The recuperator-heat exchanger 1 offers the most different variants for the choice of the media conducted through the counter current flow-heat exchanger and the pressures selected thereby, which are substantiated by the particularities of the used fuel.
[0067] The represented FIG. 1 shows the best possible case with regard to the efficiency: when using evaporable fuels free of residue (alcohols, benzines etc:) the feed water can be mixed with the liquid fuel already before the single pressure pump 63 and conducted together under high pressure through the heat exchanger 6 and through the steam superheater 11 as well as through the heated Laval-nozzle 22 . By using fuel as part of the driving steam the requirement of feed water decreases.
[0068] By reduced feed water demand similarly less condensation heat is needed after the exhaust 7 from the heat exchanger 1 and the efficiency of the internal combustion engine reaches its highest possible value of all shown embodiments.
[0069] After the represented cycle of the exhaust gas through the recuperator-heat exchanger 1 this shows a temperature of about 100° C., which corresponds to the condensation temperature of the driving steam. In the condensate of the driving steam there still is the biggest part of the condensation heat, which can not be used for the conversion into kinetic energy, it is irreversible.
[0070] This residual heat can be used as process heat of for heating purposes through a radiator 57 . To this end the exhaust gas is cooled down in an additional heat exchanger 56 below the condensation temperature of the feed water. The water which is precipitating in the exhaust steam is separated after the cycle from the exhaust gas through the heat exchanger 2 in a water separator 51 , in order to be subsequently freed from impurities from the fuel combustion in a filter 50 . After that the regained feed water flows into a feed water tank 49 . Because the feed water accumulates with the combustion water, superset results and is discharged from the tank 49 .
[0071] After the conical suction pipe 33 of the injector 31 a straight mixing tube 35 with constant section is connected downstream. The tube opens out in a tube elbow 28 , which conducts back the gas mixture to the burner 3 . Another mixing tube 35 follows the tube elbow 36 .
[0072] With the entry of the gas mixture into the diffuser 9 of the burner this is strongly decelerated. The flow rate of the fuel/steam/mixture of combustion air is reduced under the burning rate. The other way around the pressure increases at its highest possible level. This way the mixture is ignited at the beginning of this diffuser 9 in this specific embodiment in which the fuel is mixed with the driving steam and the combustion air.
[0073] The mixture, combustible in itself, could not be ignited previously either in the suction chamber, or in a mixing tube 35 or in the tube elbow 36 , because the section of these components is always chosen in a way, that the flow rate of the burning gas mixture is permanently higher than the burning rate of the same.
[0074] FIG. 2 shows the invention when using preferably solid fuel which is burned especially at atmospheric pressure. The combustion is carried out with few ashes. In the heat exchanger 1 flows smoke gas freed of flue ash and soot due to the filter 20 inserted between the burner 21 and the exhaust gas turbine 38 .
[0075] The feed water of the driving steam is pressed by the force pump 52 under maximum pressure through the recuperator-heat exchanger 1 and through the steam superheater 21 as well as through the heated Laval-nozzle 22 .
[0076] According to the represented cycle of the exhaust gas through the recuperator-heat-exchanger 1 this shows a temperature of about 100° C. which corresponds to the condensation temperature of the driving steam. But a big part of the condensation heat, which can not be used any longer for the conversion into kinetic energy, is still in the condensate of the driving steam. This heat is irreversibly lost.
[0077] The other way around, the combustion air and the feed water are heated to a targeted maximum technical degree. The pre-heated feed water flows into the steam superheater 21 and the pre-heated combustion air flows into the burner 13 . The suction of combustion air occurs by the suction effect of the suction chamber 33 of the injector. In the suction chamber 33 a transporting negative pressure is created through the exhaustion of the driving stream.
[0078] The residual heat in the exhaust gas, after the heat exchanger 2 , can be used as process heat or, as represented, for heating purposes through a heat exchanger 56 and a radiator 57 . For this purpose the exhaust gas is cooled down in the heat exchanger 2 under the condensation temperature of the feed water.
[0079] The feed water is separated from the exhaust gas in a water separator 51 after the cycle through the heat exchanger 2 , in order to be cleaned in a filter 50 from the impurities of the fuel combustion. After that the recuperated feed water flows into the feed water tank 49 for re-use. Because with the feed water also accumulates with the combustion water, superset results and is discharged from the tank 49 .
[0080] After the conical suction pipe 34 of the injector 31 a straight mixing tube 35 with constant section is connected downstream. The pipe opens out in the diffuser 37 . There the pressure of the mixture increases to its highest possible level. After the injector 31 the steam/exhaust gas mixtures flows into the exhaust gas turbine 38 .
[0081] By using the burner 13 , in which ashes fall and the exhaust gas flows with few ashes, the use of solid fuel for operating the exhaust gas turbine 38 is possible. Additionally, the smoke gas is cleaned of flue ash and soot due by means of a filter 20 inserted between the burner 21 and the exhaust gas turbine 38 .
[0082] Had rust existed in the exhaust gas, the exhaust gas turbine 38 would be damaged in time by the grading effect of the rust particles. Flue ashes would deposit extremely disadvantageously in the heat exchangers 2 and 56 , whereby their operating capacity would be diminished.
[0083] The physical form of pumping hot exhaust gas through an ejector pump 30 differs in a considerable and decisive characteristic from all other pump embodiments. A gaseous medium can be compacted in any case to a similar pressure independent of its temperature with a specific available propulsion jet technique.
[0084] In contrast, in the case of for instance piston compressors, turbo compressors etc. the effort of pumping increases proportionately to the increasing temperature respectively volume of the propellant.
[0085] The molecules of the propulsion jet leave the Laval-nozzle 22 in free flight to the suction tube 34 , where they collide only little by little with the molecules from the propellant in the mixing tube 35 , far away from the source nozzle 26 . It is not important at all if now a molecule hit in such a way is itself in a strong or weak Brownian molecular movement, namely if the propellant is hot or cold.
[0086] The process of compaction occurs advantageously only as pulse transmission. This pulse transmission between the propellant and the medium to be pumped makes it possible that a hot and widely expanded exhaust gas be transported in the same way as cold gas.
[0087] Using this pumping force of the ejector pump 30 it is possible to compact heated exhaust gas irrespectively of its temperature. Because the pumping is carried out as a pulse transmission only the mixing tube 35 must be lengthened to the same extent to which the volume of the gas to be pumped is increased compared to a cold gas. By this lengthening of the mixing tube 35 the collision probability of propelling molecules with hot molecules to be transported is equal to that with cold molecules to be transported.
[0088] FIG. 3 shows that the function of the exhaust gas turbine 38 can be adopted by a conventional combustion engine 58 for instance an internal combustion piston engine 58 . Because these engines 58 show functionally a mechanical compaction level, the function of the ejector pump 30 reduces to the pre-compacting the combustion air.
[0089] The ejector pump 30 replaces to such an extent the conventional turbocharger with the advantage that this doesn't show mobile parts and to the extent higher pre-compaction pressures can be produced. It is self evident that thereby the lifetime of the engine increases and the costs decrease compared to a conventional turbocharger. In the shown embodiment the feed water is pre-heated in the recuperator-heat exchanger 1 .
[0090] FIG. 4 shows a special embodiment of the representational invention: the bypass-accumulator 43 of mineral mass can be heated electrically by use of an external energy source. When required more or less driving gas which flows towards the burner 8 is conducted through this bypass-accumulator 43 controlled 44 . The gas mixture is thereby heated and saves fuel, to the same extent that it can absorb heat from the bypass-accumulator 43 .
[0091] The external energy source represents the breaking energy of the vehicle which produces electrical energy through the generator 46 coupled to the wheels 47 for heating 45 of the bypass-accumulator 43 . The other way around, during the driving operation these drive gears are driven by the internal combustion engine.
[0092] In reality a 50 kg heavy mineral bypass-accumulator 43 , which can be heated up to a temperature of 2000° C. (for instance magnesite), can absorb the entire breaking energy of a 30 ton truck on a decline of 500 m. This accumulated energy can be used again after passing the decline for the acceleration of the vehicle.
[0093] FIG. 4 shows also the embodiment of a recuperator-heat exchanger 1 , through which all possible fluid and gaseous media are conducted in separate heat exchangers. In that way there is a heat exchanger part available for each: for the exhaust gas 2 , for the combustion air 3 , for the feed water respectively drive steam 4 as well as for the fuel 5 .
[0094] FIG. 5 : Through the shown flattening of the aperture angle 27 of the divergent nozzle parts 24 of the Laval-nozzle 22 to <3° the Laval-nozzle can be extended with a multiple and to the same extend its heat exchange surface towards the driving steam can increase.
[0095] FIG. 6 : Through the shown distribution of the total driving stream of the driving gas to more accordingly diminished Laval-nozzles 22 , the total exchange surface also increases. The more small Laval-nozzles 22 are used in doing so, the bigger the effect of the enhancement of the heat exchanging surface will be.
[0096] FIG. 7 : This embodiment shows that the Laval-nozzles 22 can be used not only for transporting combustion air but also smoke gas from the smoke pipe 19 . The driving steam leaking from the driving steam outlets 26 flows together with the smoke gas to the suction chamber 33 of the injector 31 and is subsequently compacted after passing through the mixing tube 35 within the injector diffuser 37 from the downstream exhaust gas turbine 38 .
[0097] FIG. 8 : through the shown flattening 34 of the conventional round nozzle-sections of a Laval-nozzle on an expanded but the other way around diminished section 29 , the exchange surface also increases to a considerable extent.
[0098] The represented fissure of the interior surface of the smoke tube 19 or the burner 8 enhances the heat exchanging surface to about the same extent in which the surface opposite to a smooth surface of burner 8 or the smoke tube 19 is enhanced.
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The internal combustion engine includes a burner ( 8 ) which is continuously operated at overpressure, in an embodiment of this invention, a burner ( 13 ) is operated at atmospheric pressure. In each of these cases to this burner ( 8, 13 ) an exhaust gas turbine is connected downstream and to this a recuperator-heat exchanger ( 1 ) is connected downstream, which transfers residual heat from the exhaust gas to all gaseous and liquid media flowing into the internal combustion engine at the physically highest possible degree. The pre-heated combustion air or the smoke gas is compacted subsequently just by an ejector pump ( 30 ), without any mechanical compaction level. This succeeds by overheating the driving steam in a steam superheater ( 11, 21 ) with heat from the burners ( 8, 13 ) after having been heated in the heat exchanger ( 2 ) and subsequently by permanently renewing and superheating it during the isentropic expansion in the Laval-nozzle ( 22 ) by heat addition from the burner ( 8, 13 ). In further embodiments of the invention this is suitable as replacement for a conventional turbocharger and as an engine for a vehicle with recuperator use of breaking energy.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] U.S. Pat. Nos. 5,957,888 and 5,746,720 use common screw threads to change the length of the instruments, this is time consuming and perceived as difficult and complicated by the operating room surgical staff. The present invention uses a short rotational twist to unlock and lock and a push or pull telescopic action to set the device at the desired lengths.
BACKGROUND OF THE INVENTION
[0002] The present invention relates broadly to medical devices used during surgical procedures and more particularly to surgical procedures that require cannulas of multiple lengths due to patient abdominal body cavity wall thickness or tissue thickness.
BRIEF SUMMARY OF THE INVENTION
[0003] The present invention is comprised of two plastic molded resin or metal constructed components and can be of single use disposable or multi-use re-usable. It is inexpensive to manufacture and its ease of use will reduce training time required. Furthermore it will reduce stocking needs of the hospitals as compared to the current fixed length instrument counterparts.
[0004] Typically, in current devices the length of the cannula is a conduit allowing body cavity access through the body cavity abdominal wall for laparoscopic surgery is generally fixed at a specific length. These fixed length cannulas require the hospital to inventory cannulas of all commonly used lengths to meet the patient body abdominal body wall thickness or tissue thickness. The present invention allows the surgeon or operating room surgical staff to set the desired length with the one cannula relieving the hospital of excess inventory requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 Illustrates an outside view of the complete device, ready for use set at a mid length configuration.
[0006] FIG. 2 Illustrates an outside view of the complete device, ready for use set at a maximum length configuration.
[0007] FIG. 2 Illustrates an outside view of the complete device, ready for use set at a mid length configuration.
[0008] FIG. 4 Illustrates an outside view of the complete device, ready for use set at a shortest length configuration.
[0009] FIG. 5 Illustrates an exploded view of the device with reference numerals.
[0010] FIG. 6 Illustrates an outside view of the complete device, ready for use set at a mid length configuration with reference numerals.
[0011] FIG. 7 Illustrates a full length section view with reference numerals.
[0012] FIG. 8 Illustrates an assembled view with a mid sectional area showing the gas sealing detail.
[0013] FIG. 9 Illustrates section “B-B” showing the detail of the twist-lock feature.
[0014] FIG. 10 Illustrates an exploded view with two sectional areas defined.
[0015] FIG. 11 Illustrates section “A-A”.
[0016] FIG. 12 Illustrates a 90 degree rotated view of the twist-lock lug( 28 ) detail.
REFERENCE NUMERALS
[0017] 1 . Cannula Head.
[0018] 2 . Inner Body Tube.
[0019] 3 . Twist-Lock Receiver.
[0020] 4 . Gas Seal.
[0021] 5 . Bevel.
[0022] 6 . Outer Body Tube fascia anchoring threads.
[0023] 7 . Conical Taper.
[0024] 8 . Slots.
[0025] 9 . Outer Body Tube.
[0026] 10 . Trough.
[0027] 11 . Gas Seal Inner Bevel.
[0028] 12 . Expanding Inner Taper.
[0029] 13 . Gas Seal Bore.
[0030] 14 . Instrument Bore.
[0031] 15 . Section View Showing Gas Seal Area.
[0032] 16 . Lug Stop/Lock Wall.
[0033] 17 . Lug Stop Pocket.
[0034] 18 . Lug Detent.
[0035] 19 . Lug Detent Ramp.
[0036] 20 . (Omitted)
[0037] 21 . Lug Guide Wall/Stop.
[0038] 22 . Lug Section View.
[0039] 23 . Lug.
[0040] 24 . Lug Lead-In Taper.
[0041] 25 . Lug Entrance.
DETAILED DESCRIPTION OF THE INVENTION
[0042] 1. An outer body tube ( 9 ) that embodies a smooth tubular interior surface with a protruding alignment/locking lug ( 23 ). The bevel ( 5 ) provides for a smooth transition of outer body tube ( 9 ) and inner body tube ( 2 ) diameters reducing tissue trauma upon device removal from the body cavity abdominal wall. Generally made from polypropylene, polycarbonate, ABS or other plastic resins for disposable one-time use or Radel, Ultem or other autoclaveable plastic resins including metals allowing for user autoclaving sterilization methods.
[0043] 2. The inner body tube ( 2 ) slip fits within the outer body tube ( 9 ) and embodies a smooth, thin, flexible flared edge lip gas seal ( 4 ) this sealing lip is in light contact sufficient to provide a gas seal, creates and maintains the gas seal while allowing free extension and retraction of the two members via a lengthwise trough ( 10 ). Generally made from polypropylene, polycarbonate, ABS or other plastic resins for disposable one-time use or Radel, Ultem or other autoclaveable plastic resins including metals allowing for user autoclaving sterilization methods.
[0044] 3. Multiple slots or twist-lock receivers ( 3 ) intersecting perpendicular with the trough ( 10 ) include a sufficient funnel like lug entrance ( 25 ) for the lug ( 23 ) providing easy location and engagement for setting the desired length.
[0045] 4. A lug detent ( 18 ) is a smooth radius cam like detail for receiving and engaging the protruding alignment locking lug ( 23 ) located inside the bore of the outer body, provides for the short twist motion to engage the lug ( 23 ) detail by first contacting the lug detent ramp ( 19 ) that provides for the means to expand the outer body tube ( 9 ) and deflect the inner body tube ( 2 ) that in combination allows the lug ( 23 ) to traverse the apogee of the lug detent ( 18 ) and then falling into the lug pocket stop ( 17 ) thereby holding securely in position the two body members at the selected length.
[0046] 5. The gas seal ( 4 ) also comprises a conical taper located in the inside smooth diameter of the inner body tube ( 2 ) this conical taper creates the thin flared edged lip of the gas seal ( 4 ) also provides a smooth transition between the inner body tube ( 2 ) and the inside smooth bore of the outer body tube ( 9 ) thereby reducing the possibility of the surgical instruments used therethrough of catching or snagging onto.
[0047] 6. A conical taper ( 7 ) eases the tissue dilation force required to insert the cannula assembly through the abdominal body cavity wall.
[0048] 7. Eight multiple slots (more or less) about and through the conical taper ( 7 ) allow flexing for the removal of the molding core pin enabling this component to be injection molded.
[0049] 8. An inner taper ( 12 ) is the area that allows for the transition of the inside diameter of the outer body tube ( 9 ) to match the inner body tube ( 2 ) thereby reducing undesirable dimensional gapping of the surgical instruments outside diameters used therethrough and the inside diameter of the inner body tube ( 2 ).
[0050] 9. A lug twist-lock receiver ( 3 ) detail consists of a lug/stop wall ( 16 ) to abut the lug ( 23 ) firmly, limiting and indicating the selected position is secure. The lug/stop pocket ( 17 ) allows sufficient area to contain the lug ( 23 ) after it falls from the apogee of lug detent ( 18 ) detail.
[0051] 10. A trough ( 10 ) provides the linear guidance and telescopic movement for the lug ( 23 ) as the device is telescoped to the users desired length. The lug guide wall/stop provides for a linear smooth surface for the lug ( 23 ) when slight pressure is applied in a counterclockwise direction during the telescoping of the outer body tube ( 9 ). Perpendicular at various positions are the twist-lock receivers ( 3 ) for receiving the lug ( 23 ). The twist-lock receivers ( 3 ) have a generous, lug entrance ( 25 ) tapered or radius entry for the lug ( 23 ) allowing the surgeon or assistant ease of locating and engagement to the desired length position.
[0052] 11. A lug lead-in taper ( 24 ) is provided for device assembly of the outer body tube ( 9 ) onto the inner body tube ( 2 ).
[0053] The Adjustable Length Cannula is manufactured and shipped assembled ready for use.
[0054] The surgeon or operating room surgical nurse or surgical assistant can adjust the length of the device by grasping the outer body tube ( 9 ) with the distal end facing away from the user using one (left) hand and grasping the cannula head ( 1 ) with the other (right) hand. By rotating the cannula head ( 1 ) counterclockwise from the outer tube ( 2 ) until the lug ( 23 ) abuts the lug guide wall/stop ( 21 ) of the trough ( 10 ). The device is now able to be telescoped to the desired length suitable to the patients abdominal body cavity wall or tissue thickness. Upon selecting the suitable length position, as predetermined by the twist-lock receiver ( 3 ) locations, the user while still grasping the cannula head ( 1 ) rotates clockwise to engage the lug ( 23 ) into the twist-lock receiver ( 3 ) slight pressure is needed to pass the lug ( 23 ) over the detent ( 18 ) until the lug ( 23 ) drops into the lug stop pocket ( 17 ) and abuts with a felt click or vibration the lug stop/lock wall ( 16 ). The device length is now secured and ready for use.
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The Adjustable Length Cannula surgical instrument assembly may be provided with a valve seal assembly where the upper portion of the valve seal is rigidly mounted to the upper head end of the adjustable cannula body assembly. The lower portion of the adjustable cannula body is of two or more components that includes a gas seal that telescopes to multiple desired lengths by telescoping and securing in position with a short twist motion with a detent locking detail.
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RELATED APPLICATIONS
[0001] This application is the US National Stage under 35 USC 371 of PCT application PCT/EP2012/004888, filed on Nov. 27, 2012, which claims the benefit of the priority date of German application DE 10 2011 120 372.2, filed on Dec. 7, 2011. The content of the foregoing applications is incorporated herein by reference.
FIELD OF INVENTION
[0002] The invention relates to container processing, and in particular, to filling containers.
BACKGROUND
[0003] In the Trinox filling method, a probe-type tube that is open at both ends, sometimes called a “Trinox tube,” is used as a fill-level-determining element. The bottom end of the tube extends into the container, which is in a sealed position with the filler element.
[0004] To carry out the filling procedure, one begins by overfilling the container so that the fill level is above the desired fill level. As a result, the Trinox tube extends below the surface of the content. To reach the desired fill level, one applies a pressurized gas, sometimes referred to as a “Trinox gas,” to the container head space that is not occupied by the content. This forces content out of the container through the Trinox tube until the Trinox tube emerges from below the level of the content. At this point, the desired fill level is set.
[0005] A disadvantage of known methods is that the content ejected out of the container by of the Trinox tube is returned into the content vat. To the extent the ejected content has come in contact with a contaminated container, there is a risk that contaminated content will find its way into the content vat.
SUMMARY
[0006] The invention provides a way to avoid the risk that liquid content returned to the content vat will be contaminated.
[0007] In one aspect, the invention features a filler element that includes a housing, a channel formed therein, a valve in the channel, an opening downstream from the valve that dispenses content into a container when the valve is open, a tube for fill-level adjustment, a controlled gas channel, and a collection space. The tube, which adjusts a fill level of content in the container, projects past the dispensing opening and extends into an interior of the container during filling thereof. This tube connects to a collection space separated from a content vat from which the content comes through the channel. To adjust the desired fill level, a gas pressure is applied to the interior through the tube, thereby displacing excess content from the container. The controlled gas channel permits the gas to enter the container interior.
[0008] In another aspect, the invention features an apparatus for processing containers. Such an apparatus has a filler element for the filling of containers with liquid content. The filler element has a filler-element housing, a liquid channel formed in the filler element housing, a liquid valve in the liquid channel, a dispensing opening downstream from the liquid valve, with downstream being defined by a flow direction of the content, a tube for adjusting a desired fill level of content in the container, a controlled gas channel, and a collection space. The content is made available in a content vat from which content can flow through the liquid channel. The dispensing opening dispenses content into a particular container when the liquid valve is open. The tube has a first open end projecting past the dispensing opening and extending into an interior of the container during filling thereof. To adjust the desired fill level, a gas pressure is applied to the interior through the tube, thereby displacing excess content from the container. The controlled gas channel permits application of the gas into the container interior. The tube is connected to the collection space, which is separated from the content vat.
[0009] Some embodiments include a control valve that connects the tube to the collection space.
[0010] Other embodiments include a valve that connects the collection space to the content vat. This valve can be a stop valve, in some embodiments, or a switchover valve, in other embodiments.
[0011] Other embodiments include a pipe connected to the collection space for draining content. The collection space is connected to the pipe via a valve, which can be a stop valve or a switchover valve. Among these embodiments are those that further include an installation for processing the content, with the pipe being connected to the installation.
[0012] In some embodiments, collection space jointly serves a plurality of filler elements. Among these are embodiments in which the collection space is an annular channel.
[0013] Other embodiments include a rotary filling machine having a circulating rotor. In these embodiments, the filling element, together with a plurality of additional filling elements, is disposed on the circulating rotor.
[0014] In yet other embodiments, the tube is a trinox tube.
[0015] In another aspect, the invention features a method for filling a container with liquid content supplied from a content vat. Such a method includes extending a tube, for example, a trinox tube, into the container, upon completion of over-filling the container, passing gas through the tube to achieve a desired fill level of content by using gas pressure to force excess content out of a head space of the container, and causing content displaced by the gas pressure to be collected in a collection space separated from the content vat.
[0016] Some practices of the method include returning the content collected in the collection space to the content vat. Among these practices are those that include processing the content collected in the collection space prior to returning the content to the content vat.
[0017] Further developments, benefits and application possibilities of the invention arise also from the following description of examples of embodiments and from the figures. In this regard, all characteristics described and/or illustrated individually or in any combination are categorically the subject of the invention, regardless of their inclusion in the claims or reference to them. The content of the claims is also an integral part of the description.
[0018] As used herein, the word “containers” refers to cans, bottles, tubes, pouches, whether made of metal, glass and/or plastic, as well as other packaging means that are suitable for filling with liquid or viscous products.
[0019] As used herein, the term “fill-level-controlled filling” means a controlled filling of the containers such that, at the end of the particular filling process, they are filled with the liquid content up to a desired fill level.
[0020] As used herein, the term “fill-level-determining element” is an element, preferably a probe-type or tube-type element, that extends into the container during filling and with which the desired fill level is controlled and/or set.
[0021] As used herein, the words “basically” or “approximately” mean deviations from the exact value in each case by +/−−10%, and preferably by +/−5% and/or deviations in the form of changes not significant for function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and other features and advantages of the invention will be apparent from the following detailed description and the accompanying figures, in which:
[0023] FIGS. 1-3 show simplified representations of a filling element of a filling system or a filling machine of a rotary design for the fill-level-controlled filling of containers in the form of bottles with liquid content.
DETAILED DESCRIPTION
[0024] FIG. 1 shows a filler element 1 mounted on part of a rotary filling machine for the fill-level-controlled filling of containers, in the form of bottles 2 , with liquid content.
[0025] The rotary filling machine has a multiplicity of the same kind of filler elements 1 on the circumference of a rotor 3 that can be driven to rotate around a vertical machine axis. An annular vat 4 supplies liquid content for all the filler elements 1 of the filling machine jointly.
[0026] During the filling operation, the annular vat 4 is partially filled with liquid content. As a result, within the annular vat 4 , there exists a lower liquid space 4 . 1 and, above it, a gas space 4 . 2 . For pressure filling of bottles, a pressurized inert gas, for example CO 2 gas, occupies the gas space 4 . 2 .
[0027] Three annular channels 5 , 6 , 7 have different functions depending on the filling method. The first annular channel 5 supplies a pressurized Trinox gas, i.e. a pressurized inert gas, which is for example CO 2 or nitrogen. The second annular channel 6 supplies a pressurized compressed gas, i.e. a pressurized inert gas, for example, CO 2 gas. The third annular channel 7 supplies a vacuum or negative pressure.
[0028] The filler element 1 comprises a filler element housing 8 , in which a liquid channel 9 is formed. A product pipe 10 connects an upper part of the liquid channel 9 to the lower liquid space 4 . 1 of the annular vat 4 by a product pipe 10 . On the underside of housing 8 , the liquid channel 9 forms an annular dispensing opening 11 through which, during filling, the liquid content flows into the bottle 2 . The bottle 2 has its bottle mouth lying in a sealed position against the filler element. A centering cone 12 provides the sealin the area of the dispensing opening 11 . A container carrier or bottle plate 13 raises the bottle into a sealed position against the filler element 1 .
[0029] A liquid valve 14 with a valve body 15 is provided in the liquid channel 9 . The valve body 15 interacts with a valve surface in the liquid channel 9 . It is made on a gas tube 16 arranged to be coaxial with a vertical filler element axis FA, or on a section of this gas tube 16 that has a widened cross-section. The valve body 15 acts as a valve plunger.
[0030] The gas tube 16 protrudes through the dispensing opening 11 above the underside of the filler element 1 and thus extends, during the filling, into the relevant bottle 2 or into a head space thereof. For the controlled opening and closing of the liquid valve 14 , an actuation device 17 , which is pneumatic in the illustrated embodiment, acts on the gas tube 16 . The actuating device 17 is housed in an inner space of the housing 8 , where it is separated and sealed from the liquid channel 9 .
[0031] The filler element 1 has a probe-type tube 18 arranged to be coaxial with a filler element axis FA. The gas tube 16 encloses, but is spaced apart from, this probe-type tube 18 . The probe-type tube 18 , or Trinox tube 18 , is open at both ends thereof. During the filling operation, a lower open end 18 . 1 of the tube 18 extends into the top area of the head space of the bottle and projects over the lower open end of the gas tube 16 .
[0032] The Trinox tube 18 is fed through the filler element housing 8 . A top section forming an upper end 18 . 2 projects over the top of the housing 8 and is held on a support arm 19 or support ring of an adjustment device 20 . Axial movement of the Trinox tube 18 in the direction shown by the double arrow A sets the fill level to which the bottles 2 are each filled with liquid content.
[0033] A control valve 21 connects the upper end 18 . 2 of the
[0034] Trinox tube 18 to an annular channel 22 . The annular channel 22 is also common to all the filler elements 1 of the filling machine or the filling system. In the illustrated embodiment, the annular channel 22 serves as a content collection channel. The annular channel 22 , together with the control valve 21 , is provided on the support arm 19 .
[0035] A flexible pipe 23 connects the annular channel 22 to a preferably electrically-actuated switchover valve 24 . The switchover valve 24 selectively connects the annular channel 22 to the annular vat 4 . In doing so, the switchover valve 24 causes liquid content collected in the annular channel 22 to empty into either the content vat 4 or into a pipe 25 that leads to a content-processing installation.
[0036] The content-processing installation processes the content drained from the annular channel 22 during the emptying prior to returning it to the content vat 4 . Processing steps could include one or more of filtering, heating to a specified temperature, sterilizing, and carbonating. Following processing by the content-processing installation, the content is returned to the content vat 4 . Following these processing steps, the liquid content is fed to another use, for example returned to the content vat 4 .
[0037] The upper open end of the gas tube 16 , or a gas channel 27 formed between the inner surface of the gas tube 16 and the outer surface of the Trinox tube 18 , opens into a gas space 26 inside the housing 8 . In addition, various controlled gas paths with control valves 28 - 31 are provided in the housing 8 to connect the gas channel 27 to the annular channels 5 , 6 , 7 in a controlled manner as described in more detail below.
[0038] The filler element 1 thus makes it possible to pressure fill bottles 2 using the Trinox filling method. The filling operation starts with axially adjusting the tube 18 to set the desired fill-level. In particular, the lower open end 18 . 1 of the tube 18 defines the desired fill level (level N1) reached at the end of the filling process.
[0039] The liquid valve 14 and all the control valves 21 , 28 - 31 are initially closed. A bottle plate 13 raises the empty bottle against the filler element 1 and seals its bottle opening against the filler element 1 .
[0040] Next, the control valve 30 opens to create a connection between the annular channel 7 and the gas channel 27 connected to the inside of the bottle 2 . This evacuates the bottle 2 .
[0041] After evacuation, the control valve 30 is closed and the control valve 29 is opened. This connects the gas channel 27 to the annular channel 6 to pre-tension the inside of the bottle to the filling pressure with a pressurized inert gas. Before pre-tensioning the bottle, it is possible to purge the inside of the bottle with the inert gas one or more times. To carry this out, one simply carries out the activation sequence of the control valves 29 and 30 as described above as many times as desired.
[0042] After the pre-tensioning of the bottle 2 to the filling pressure, with the control valve 29 still open, the liquid valve 14 is opened. As a result, liquid content flows into the bottle through the annular dispensing opening 11 enclosing the gas tube 14 . The liquid content entering the bottle forces the inert gas out of the bottle and into the annular channel 6 through the gas channel 27 and the open control valve 29 . During this filling phase, the bottle 2 is deliberately overfilled to a level N2 above the level N1 of the desired fill level. Upon reaching the desired overfill level, liquid valve 14 closes to stop further flow of content into the bottle 2 .
[0043] With the bottle now overfilled, the control valve 28 is opened. This creates a connection between the annular channel 5 and the gas channel 27 . Pressurized Trinox gas from the annular channel 5 will then fill the head space in the bottle 2 . The control valve 21 is then opened so that the pressurized gas can force liquid content out of the inside of the bottle via the Trinox tube 18 into the annular channel 22 . This flow out the tube 18 ends once the the lower open end 18 . 1 of the Trinox tube 18 is no longer immersed in the contents. At this point, thus the desired fill level (level N1) will have been reached.
[0044] The filling process ends with closing the control valves 21 , 28 . With the liquid valve 14 still closed, for example by opening the valve 31 , a release or pre-release of the filled bottle 2 occurs. The bottle plate 13 then lowers the filled bottle from the filler element 1 .
[0045] It is clear that in particular the process steps before the actual filling phase can also be designed differently from the way described above.
[0046] With the filler element 1 or with the filling system having these filler elements, pressure filling is also possible.
[0047] In pressure filling, the Trinox tube 18 is used as a fill-level-determining gas return tube. At the end of the filling phase, inert gas forced out of the bottle is returned into the gas space 4 . 2 of the vat 4 . This is carried by closing control valves 28 - 31 , opening liquid valve 14 and control valve 21 , and causing the switchover valve 24 to connect the annular channel 22 and the gas space 4 . 2 . The inflow of the contents into the bottle 2 is automatically ended when the lower open end 18 . 1 of the Trinox tube 18 is immersed by the contents level of the contents that have entered the bottle 2 and a state of equilibrium has been reached between the level of the contents in the annular vat 4 and the content column formed in the Trinox tube 18 . The level of the lower open end 18 . 1 thus in turn determines the fill level (level N1) of the content in the particular bottle 2 .
[0048] FIG. 2 shows s a further embodiment, a filler element 1 a that differs from the filler element 1 in that the annular channel 22 is provided on the annular vat 4 and is connected firmly to the annular vat 4 by a pipe 32 . The switchover valve 24 and the pipe 25 are not provided. The filler element 1 a can carry out the same filling methods as the filler element 1 .
[0049] FIG. 3 shows an alternative filler element 1 b. This alternative embodiment is similar to the filler element 1 except that the annular channel 22 is likewise provided on the annular vat 4 and is connected to the control valve 21 by the flexible pipe 23 , and the pipe 25 is connected directly to the annular channel 22 . The filler element 1 b is suitable for Trinox filling methods with processing of the contents collected in the annular channel 22 .
[0050] The invention has been described above using examples of embodiments. It is clear that numerous modifications and variations are possible without thereby departing from the inventive idea underlying the invention.
[0051] Having described the invention, and a preferred embodiment thereof, what is claimed as new, and secured by Letters Patent is:
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A filler element includes a housing, a channel formed therein, a valve in the channel, an opening downstream from the valve that dispenses content into a container when the valve is open, a tube for fill-level adjustment, a controlled gas channel, and a collection space. The tube, which adjusts a fill level of content in the container, projects past the dispensing opening and extends into an interior of the container during filling thereof. This tube connects to a collection space separated from a content vat from which the content comes through the channel. To adjust the desired fill level, a gas pressure is applied to the interior through the tube, thereby displacing excess content from the container. The controlled gas channel permits the gas to enter the container interior.
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BACKGROUND OF THE INVENTION
The present invention relates generally to emergency escape apparatus for a building and more particularly to a motorized fire escape for high rise buildings.
In the past, there have been many deaths due to a lack of simple, effective fire escape system from tall high rise buildings such as hotels and modern apartment buildings. In case of fire, the occupants of these buildings are told to try to stay in their rooms or try to take the stairways down to the ground because while access to the roof might be easy there are no convenient ways of bringing people down from a highrise roof.
Various expedients have been used to rescue people from burning buildings. For the lower buildings, a safety net is sufficient or a ladder from a fire truck. However, for very tall buildings, the only rescue system available has been the limited carrying capability helicopters which in many instances were totally useless due to adverse weather conditions.
Another form of fire escape apparatus has used a rope with a means for allowing the person to brake himself while going down the rope. The disadvantage of this system is that there is no way for a person who is unconscious due to smoke inhalation to be lowered and some knowledge of mountaineering is required. Another disadvantage of this system is that once an occupant has reached the ground there is no way for returning the braking mechanism back to the roof for re-use.
SUMMARY OF INVENTION
The present invention provides fire escape apparatus which may even be used by an unconscious person.
The present invention further provides a system which may be easily expanded for multi-story buildings with no limitation as to the maximum height of the building.
The present invention further provides an inexpensive motorized fire escape.
The present invention further provides mechanism by which the operative part of the fire escape apparatus may be returned to the roof of the multi-purpose building for re-use.
Other advantages of the present invention will be apparent to those skilled in the art from a review of the following drawings and the description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the side view of the present invention taken along the line 1--1 of FIG. 2;
FIG. 2 is a top view of the present invention;
FIG. 3 is a cross-sectional view of the present invention taken along line 3--3 of FIG. 1;
FIG. 4 is a cross sectional view of the present invention taken along line 4--4 of FIG. 1;
FIG. 5 is a cross-sectional view of an alternate embodiment of the present invention taken along the line 5--5 of FIG. 6;
FIG. 6 is a front view of the alternate embodiment of the present invention;
FIG. 7 is a top view of a portion of the alternate embodiment; and
FIG. 8 is a side view of an operative portion of the alternate embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, therein is shown a cross-sectional view of the emergency escape apparatus 10 of the present invention. The building structure 12 has secured to it a plurality of support brackets 14.
The support brackets 14 are generally welded to a hollow member or tube 16. The tube 16 is open at both ends and is generally one story long for convenience although either shorter or longer lengths are possible. On the side of the tube away from the building there is provided a split 18 which runs the entire length of the tube 16. Disposed within the tube 16 is a plastic self-lubricated bushing, roller chain 20. As would be evident to those skilled in the art a plastic chain capable of supporting the necessary loads or a wire rope would be equally usable.
The chain 20 has secured thereon equi-distantly spaced, a plurality of ears 22 which are used to engage a member which will be described later. The chain 20 is driven by upper and lower sprockets 24 and 26, respectively, which may either be secured to the tube 16 or to the support brackets 14 for rotation therein. At the bottom portion of the tube 16, the open end is joined at joint 28 to another tube 16. At ground level for the building 12, the bottom-most tube 16 will be spaced a short distance above the ground.
At the top end of the tube 16, the open end is connected to an arcuate tube 30 at a joint 32. As would be evident to those skilled in the art, the joint 32 may be achieved merely by lining up the tubes, by welding, or by bolting a collar over the nonsplit portion.
The ears 22 extend into the split on tube 16. The ears 22 use the split as a guide.
The arcuate tube 30 is similar to the tube 16 in having a split 34 provided in the building distal wall. The arcuate tube 30 has disposed therein a chain 36 having ears 22 secured thereto.
The chain 36 is driven by a pair of sprockets 38 and 40. The sprocket 40 is driven by another sprocket (not shown in FIG. 1) which is connected to a sprocket 42 by a drive chain 44. The sprocket 42 is driven by a gear reducer equipped motor 46 which is secured to the building 12. A support bracket 48 supports the portion of the arcuate tube 30 which extends over building 12.
The drive from the motor 46 is transferred via the drive chain 44 to the chain 36 which in turn drives a sprocket arrangement on which an intermediate drive chain 50 is disposed. This intermediate drive chain 50 further drives the sprocket 24 and the chain 20. Similarly, between stories of the building 12 are other intermediate drive chains 50 which drive the other chains for each story. As would be evident, while at one point the motor 46 will be driving, at other points the drive will be acting via the speed reducer as an electronic brake while lowering many occupants.
Also shown in FIG. 1 is the emergency escape apparatus in use with an occupant 52 being supported by a harness 54 which is connected by a wire 56 to a plastic ball 58 disposed within the tube 16. Referring now to FIG. 2, therein is shown a top view of the arcuate tube 30. The tube 30 is generally Y-shaped with a branch 60 welded thereon. The split 34 extends down this branch. FIG. 1 is the section taken along the line 1--1 of this figure.
Referring now to FIG. 3, therein is shown a cross section of FIG. 1 taken along the line 3--3. FIG. 3 shows the ear 22 as a rectangular member. It should be noted that the ear 22 only takes up a portion of the tube since the ball 58 is being utilized as the member engaging with the ear 22. If a cylindrical member were to replace the ball 58, the tube 30 and the tube 16 could be made rectangular to match the cross section of such an engageable means.
Because the chain 36 must clear safety walls which are sometimes on the edge of building roofs, it is desirable that the chain conform to the arc of the underside of the tube 30. In order to accomplish this, each of the links of the chain 36 are provided with a pair of wings 62 which engage a pair of flanges 64 on the underside of the arcuate tube 30.
Referring now to FIG. 4, therein is shown a cross sectional view of one of the bracket areas showing the bracket 14 which may be angle irons bolted to the side of the building 12. The sprocket 24 is secured to a shaft 66 which is mounted in a pair of bearings 68 and 70 which are respectively secured to the support brackets 14 by bearing plates 72 and 74. Outwardly of the bearings 68 and 70 is an intermediate sprocket 76 to which the intermediate chains 50 are connected.
As would be evident to those skilled in the art, from the particular drive arrangement shown it is evident that the motor 46 may be located either at the top or bottom of the building. In the preferred embodiment the motor 46 is placed at the top of the building 12 where it will not be easily accessible to vandals and its drive capabilities are the most important. To avoid problems with power failure to the building, in the preferred embodiment, the power lines (not shown) to the motor 46 run from ground level and are secured to the outside of the tubes.
In operation during an emergency, the occupants of the building will be advised to escape either upwards or downwards. At the roof, an occupant 52 will be placed in a harness 54. The ball 58 will be inserted in the split 34 of the branch 60 to be moved into engagement with one of the ears 22 on the chain 36. Generally, the ears on the chain 36 are closer together than on the chain 20 and the drive sprockets slightly smaller to more slowly pick up the occupant 52. The branch 60 permits cuing of people to use the emergency escape apparatus 10.
When a ball 58 reaches the straight portion of arcuate tube 30 it will be picked up to lift the occupant 52 over any wall on the building 12. Once past the wall, the occupant 52 will drop a short distance of about 3 feet under the influence of gravity to an ear 22 on the chain 20 which is timed to be at the highest position for engagement when the ball 58 disengages from the ear 22 on the chain 36.
Once the occupant 52 is being supported by an ear 22 on the chain 20, the motor 46 becomes an electric brake and slowly lowers the occupant from one tube 16 to the other tube 16 until the occupant is brought down to the ground. At the bottom the ball drops out at the open end of the tube and the occupant 52 may either walk or be carried away.
As would be evident, a large number of people may be using the emergency escape apparatus 10 at any one time to escape from burning building.
Returning now to FIG. 5, therein is shown an alternate embodiment of the present invention which includes tubes for returning the ball 58 in the harness 54 back to the roof of the building 12 so as to allow re-use thereof. Generally, the return tubes parallel the lowering tubes and are positioned closer to the building 12 so as to make use of the upward movement of the chain. As shown in FIG. 5, upper and lower tubes 16 are paralleled by return tubes designated by the numeral 80. The return tubes 80 may be supported by the support brackets 14 which in this embodiment support the double sprockets 82 and 86 which may best be seen by reference to FIG. 6. Disposed between the returned tubes 80 is a holder designated by the numeral 88 which may best be seen by reference to FIG. 7. Generally, the holder 88 will be made from elastomer material which is deformable to allow ears 90 on the interior portion of the holder 88 to deform to let an object pass through the center of said holder.
As seen in FIG. 5, the double sprockets 82 and 86 are connected by an intermediate drive chain 92 which carries on it a plurality of ears 94 which are equi-distantly spaced on the intermediate drive chain 92.
Referring now to FIG. 8 therein is shown a ball 58 connected by a wire 56 to a harness 54. Connected to the wire 56 between the ball 58 and the harness 54 is a ball-shaped container 96 which is hinged at the connection to the wire 56 at the hinge 98. The two halves of the ball-shaped container are oversized to allow the ball 58 and the harness 54 and wire 56 to be rolled up and contained by the container 96 which will be held closed by a latch 100 integrally molded therein. When in its closed condition, the container 96 is of a ball-shaped configuration which fits within the inside diameter of the return tube 80.
In operation, an occupant 52 will be lowered by means of the tube 16 down to the ground at which point the occupant 52 will remove the harness 54 and roll the ball 58, the wire 56 and the harness 54 into configuration fit within the ball-shaped container 96. The two halves of the container 96 will then be closed and held in place by the latch 100.
The container 96 will then be inserted in the bottom of return tube 80 where, as the emergency escape apparatus continues to operate, an ear 22 will engage the container 96 and move it upwardly in the return tube 80. The container 96 will continue to be urged upwardly by the ear 22 until it is pushed past the holder 88 by deforming the ears 90. Once the container 96 is past the holder 88, the ears 90 will spring back in place and retain the container 96 until an ear 94 on the intermediate drive chain 92 can engage the container 96 and continue to move it upward into engagement with another holder 88 which will again hold the ball until another ear 22 on the higher chain 20 can engage the container 96 and carry it to the roof of the building structure 12 where it can be removed. The container 96 will be opened to allow the ball 58 to be inserted back in cue and to be reused again.
As would be evident to those skilled in the art, it would be possible to use the double sprocket arranged shown in FIG. 5 in the arrangement shown in FIG. 1. However, this would mean that the precise spacing between the ears would become more critical, and the emergency escape apparatus would have to be tailored to each building taking into account the differences in distance between the various floors at all levels of the building. It should also be noted that the exact ear arrangement used with the double sprocket arrangement shown in FIG. 5 will require precise location in order to prevent jamming of the ball-shaped containers 96 and the ball 58 in their various movements in the emergency escape apparatus 10.
As many alternate embodiments would be evident to those skilled in the art from the foregoing description, the description should be construed in an illustrative and not a limiting sense.
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A fire escape having a roller chain carried in a slotted vertically extending tube and driven to cause controlled downwardly movement in the tube. The roller chain carries ears which support molded plastic balls connected through the tube's slot to harnesses for escaping persons. The controlled movement of the chain allows even an unconscious person to be lowered from the top of a building safely to the ground.
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This application is a continuation of application Ser. No. 07/683,322, filed Apr. 10, 1991, now abandoned.
FIELD OF THE INVENTION
This invention relates to electronic component sockets, and more particularly to a socket for single in-line memory modules and like components.
BACKGROUND OF THE INVENTION
Electronic component sockets are known for mounting single in-line memory modules. A memory module generally comprises a circuit board having a plurality of electronic memory devices mounted thereon and having a linear array of contact pads along an edge of the circuit board. The circuit board is installed in the socket by insertion of the contact end of the board into a cooperative groove in the socket body containing an array of electrical contacts which are matable with the contact pads of the circuit board. The circuit board is rotated into engagement with a pair of latches which are disposed at respective ends of the socket body and operative to retain the circuit board within the socket body and the electrical contacts of the socket in mating engagement with the contact pads of the circuit board.
Memory module sockets and similar sockets in which a circuit board is inserted and rotated into a locked position are shown for example in U.S. Pat. Nos. 3,920,303; 4,128,289; 4,136,917; 4,575,172; 4,713,013; and 4,850,892.
Memory module sockets having plastic latches integrally formed with the socket body are shown in U.S. Pat. Nos. 4,850,891 and 4,850,892. Memory module sockets having metal latches are shown in U.S. Pat. Nos. 4,986,765 and 4,995,825. The metal latches disclosed therein are retained within cooperative latch receiving openings or pockets at respective ends of a socket body or housing. The size and configuration of the metal latches disposable within a cooperative opening are limited by the presence and necessity of the openings. Moreover, the internally mounted metal latches require elements to retain the latches within the mounting openings, such as a securing arm, as shown in U.S. Pat. No. 4,986,765, or an outwardly formed barb, as shown in U.S. Pat. No. 4,995,825. The necessity for the mounting opening or pocket also limits the strength and solidity of the socket body, because the socket body is deprived of structural integrity by the opening.
SUMMARY OF THE INVENTION
The invention provides a socket for substrates such as single in-line memory modules, circuit boards, and similar components which are inserted into and rotated into fixed position on the socket. The socket housing includes end portions having improved structural integrity for externally mounting cooperative latch elements. External mounting permits a greater variety of latch sizes and configurations to suit operational requirements.
The end portions of the socket housing include respective latch-receiving sections or members for externally mounting cooperative latches. The end portions may also contain abutment structures to prevent the latches, which are preferably made of resilient material such as metal, from bending when a memory module or like component is urged into latched position. The end portions may also provide a substantially nonresilient base on which to mount or form male keys and female keyways for side-by-side coupling or mounting of two or more component sockets of like configuration.
An exemplary latch comprises a mounting member such as a collar with a compliant C-section corresponding to the latch-receiving section or member on the socket housing, a detent for clasping a memory module, and a resilient section connected therebetween for biasing the detent against a memory module. The collar is mounted onto the cooperative area of the end portion, and the latch is thereby disposed exteriorly on the socket body.
DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a pictorial view of an electronic component socket of the invention with a circuit board secured thereon;
FIG. 2 is an exploded view showing a socket end portion, associated latch and circuit board of FIG. 1;
FIG. 3 is a perspective view of the housing socket end portion and associated latch of FIG. 2 in combination;
FIGS. 3a and 3b are perspective views of exemplary latches externally mounted upon end portions of coupled sockets;
FIG. 4 is a side view of two low-profile versions of the socket of FIG. 1 key-locked together;
FIG. 5 is an exploded view of an end portion and associated socket of FIG. 4;
FIG. 6 is a perspective view of a socket housing latch-mounting member in another embodiment of the invention;
FIG. 7 is a partial view of the latch mounting member of FIG. 6 and associated latch collar member;
FIG. 8 is a pictorial view of a socket in another exemplary embodiment of the invention;
FIG. 9 is an exploded view of the socket end portion and associated latch of FIG. 8; and
FIG. 10 and 11 are exploded views of socket end portions and associated latches in further embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is made to the drawings, wherein like numerals correspond throughout to like features. There are shown exemplary embodiments of an electronic component socket 10 of the invention configured for receiving a single in-line memory module (SIMM) and like components. The socket 10, mounted upon a substrate or circuit board 80, is shown retaining a memory module 70, circuit board, or like component in fixed position.
An exemplary socket 10, as shown in FIG. 1, is comprised of an insulative housing 18 having a substantially rigid and nonresilient first end portion 12 and second end portion 14. The insulative housing 18 is preferably formed from a suitable plastic material. A groove 17, located between end portions 12 and 14, intersects spaced-apart slots 16 located on the socket housing 18. As shown in FIG. 2, each slot 16 typically contains an electrical contact 13. The electrical contacts 13 correspond to electrical contacts 75 of the memory module 70 inserted into the groove 18 on the socket housing 18 and rotated into fixed position. End portions 12 and 14 contain latch-mounting sections or members 40 operative for external mounting of latches 30 having collar members 34. As illustrated in FIGS. 1 and 3 the latch 30 is mounted on the upstanding latch mounting section 40 such that the collar member 34 engages an alignment portion 41 of the end portion, which facilitates proper orientation of the latch 30. The socket housing latch-mounting sections or members 40 are preferably integrally formed out of the same insulative material as the housing 18. The locking members 25 include fingers 24 conformed for cooperative engagement with openings 23 on the memory module 70. When rotated in the groove 17 and latched against the locking member 25, the memory module 70 is rendered electrically communicative with the substrate or circuit board 80 upon which the socket 10 is mounted. For convenience of reference, a longitudinal axis is defined along the groove 17 and end portions 12 and 14, while a transverse axis is defined as being substantially orthogonal to the longitudinal axis and extending from the front to the back of the housing 18.
An exemplary end portion 12 of the socket 10 comprises a latch-mounting member or section 40 which is operative for mounting a cooperative latch member 30. Preferably, the latch-mounting section 40 contains opposing shoulders 41 and 43 to permit cooperative engagement with a latch collar member 34. The section 40 may be shaped as a protruding tower, post, mooring, pedestal or other exteriorly accessible structure for convenient latch mounting or removal. The latch-mounting section 40 may also have a variety of cross-sectional shapes to access a cooperatively shaped latch collar member 34, which may be press fit, snapped, clasped, or otherwise mounted thereon.
The end portion 12 includes at least one locking member 25 which prevents further rotation of the memory module 70 which has been inserted into the groove 17 then rotated into latched position. As seen in FIG. 2, the locking member 25 is conformed to provide a relief against which a latch 30 is resiliently disposed and to provide cooperative engagement with and between the memory module 70 and detent 32. The member 25 may be shaped as a vertical tower or arm containing a lateral protrusion or finger 24 operative to engage with a corresponding opening 23 (See FIG. 1) on the memory module 70. The locking member 25 further defines a groove or channel 27 conformed to cooperatively engage with an anti-stress tab 33 on the latch 30 so as to limit the movement or travel of the latch member 30 and to limit the stress placed upon the latch. A variety of locking member constructions, shapes, and sizes are possible depending upon the shape of the memory module or other substrate to be accommodated.
An abutment member 22 is located adjacent to the collar mounting member 40 to prevent bending or twisting of a latch 30 when a memory module 70 is urged into latching position against a locking member 25. The abutment member 22 has an upper portion spaced from the latch mounting member 40 so as to avoid interfering with latch installation or removal.
The end portion 12 also provides a solid foundation for posts 44 used in mounting the socket housing 18 onto a substrate 80, as well as for mounting a male key 50 and female keyway 52, elements which are known in the art.
An exemplary latch member 30, as shown in FIG. 2, is preferably formed from a unitary piece of resilient material, such as a continuous piece of metal. The latch includes a detent member 32 for clasping a memory module 70. The detent member 32 includes an anti-stress tab 33 conformed for cooperative engagement with a channel or groove 27 located in a housing socket locking member 25 to limit movement or bending of the latch 30. The latch also includes a collar member 34, which cooperatively mates with a collar-shaped latch-mounting member 40 of the socket housing 18 and preferably has a compliant C-shape section having opposing ends 35 to permit exterior mounting or press-fitting of the latch 30 onto the latch-receiving member 40. A resilient section 36 or arm, connecting the detent member 32 and collar member 34, biases the detent member 32 towards the locking member 25 of the housing and is preferably elongated and curved to provide the intended degree of resilience. The latch 30 and associated end portion 12 of FIG. 2 are shown in mated combination in FIG. 3.
FIG. 3a shows an exemplary embodiment of latches 30 exteriorly mounted on end portions 12 of socket housings 18 which have been coupled or ganged together by keys 50. The latch detent member 32 further comprises an elongated arm 32a operative to facilitate manual accessability to, and manipulation of, the detent member 32 at a distance from the portion of the detent member 32 which comes into clasping contact with a memory module or other substrate. The insertion and removal of memory modules or other inserted boards, as well as the insertion and removal of latches, are thereby facilitated, while the need to create access space by decoupling adjacent socket housings 18 or dismounting them from a common substrate is avoided.
FIG. 3b shows another exemplary embodiment of latches 30 having elongated arms 32a and further comprising tabs 32b operative to permit manipulation of the detent member 32 in a number of directions. The tabs 32b provide manual accessibility such that the detent member 32 may be pulled away from its latched position against the locking member 25, and such that the latch 30 may be vertically mounted upon or dismounted from the latch-receiving section or member 40. The invention thus provides a variety of exteriorly mounted latch configurations which, even where socket housings are coupled together in close proximity, readily permit manipulation of the detent member and facilitate insertion and removal of latches and substrates such as memory modules.
FIG. 4 shows two low-profile versions of the socket housings of FIG. 1 keylocked together at an angle on a common substrate 80. Other embodiments shown throughout herein mate similarly but assume an essentially vertical orientation when key-locked together. Substrate mounting posts 44 are attached at an angle to the end portions 12. The end portions 12 are connected together by male keys 50 mounted at the top of the end portion 12 and disposed within female keyways 52 located in the bottom of the housing 18. An exploded view of a socket end portion and associated latch are shown in FIG. 5.
FIG. 6 is an exploded view of an end portion 12 in a further exemplary embodiment of the invention. The latch mounting section or member 40 includes prongs 54 and 55 having detents 56 and 57 conformed for cooperatively receiving and locking a latch collar member. Numerous variations of the pronged retaining member principle are possible within the scope of the invention. The prongs 54 and 55, which are preferably integrally molded with the socket housing and of sufficient longation for purposes of providing resilience, contain head portions 58 and 59 conformed for receivably locking a latch collar member slipped downwards over the head portions 58 and 59 and locked against the socket housing 18 by detent-shaped clasps 56 and 57. Head portions 58 and 59 further include sloped surfaces 60 and 61 to permit bending of the prongs 54 and 55 towards an intermediate column 53 sufficient to allow slidable insertion of collar member 34. The intermediate column contains indentations 53a and 53b corresponding to and for accommodation of the opposing ends of latch collar member 34. As shown in FIG. 7, the latch collar member 34 is secured by detent-shaped clasps 56 and 57. The collar member 34 may be dismounted from the collar-mounting member or section 40 simply by pushing the prong head portions 58 and 59 towards each other.
Other end portion configurations and associated latches are within contemplation of the present invention. Alternative versions are shown in FIGS. 8 through 11. As shown in FIG. 8, the latch member 30 may be conformed so as to be exteriorly mounted at the extreme end of the socket housing 18, thereby conserving space. The resilient arm 36 of the latch 30 joins the top part of the collar member 34. As shown in FIG. 9, a heightened protrusion or raised section or structure 60 which is preferably molded integrally atop of the latch-mounting section or member 40 contains lateral upstanding portions 61 and 62 sized to allow disposition and flexure of the resilient arm 36 of the latch 30. In addition, an orientation or anti-overstress tab 64 on the latch 30, conformed for cooperative engagement with a tab guide 63, facilitates exterior mounting of the latch 30.
In further exemplary embodiments, orientation guides facilitate positioning of the latch exteriorly on the socket end portion. As shown in FIG. 10, a protruding circular post 72 on the socket end portion 12 is conformed for cooperative engagement with a circular guide opening 71 on the associated latch collar member 34; while in FIG. 11 a protruding elongated slot 82 is conformed for slidable mating with a correspondingly shaped guide slot 81 on the associated latch collar member 34. FIGS. 10 and 11 show collar receiving slots 73, disposed on the socket housing 18, corresponding to opposed ends 35 of the latch collar members 34. The collar members 34 contain ramped ends 35 operative to facilitate downward installation of the collar 30 and to engage with the corresponding slots 73.
It will be known to those skilled in the art that modifications of the invention can be practiced within the spirit of the invention. Accordingly, the scope of the invention is limited only by the scope of the claims.
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The invention provides a socket for substrates such as single in-line memory modules, circuit boards, and similar components which are inserted into and rotated into fixed position on the socket. The socket housing includes end portions having improved structural integrity for externally mounting cooperative latch elements. The external mounting permits a greater variety of latch sizes and configurations to suit operational requirements. An exemplary latch is preferably metal and comprises a mounting collar having a compliant C-section which corresponds to a latch-receiving section or member on the socket housing, a detent for clasping a memory module, and a resilient section connected therebetween for biasing the detent so that it clasps the memory module in fixed position in the socket. The latch collar is mounted onto the cooperative section of the socket end portion, and the latch is thereby disposed exteriorly on the socket body.
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The invention described herein may be manufactured and used by and for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
The field of the invention is that of ordnance and warhead construction. The present invention relates to fragmentary warhead construction and to the construction of discrete fragment warheads. In particular, the invention relates to a novel way of constructing warhead fragments within a fragmenting rod, wherein a plurality of fragment kill mechanisms may be incorporated within a single rod.
In the prior art, most missile fragmentation warheads either use a solid steel case filled with explosive (which is the conventional design) or consist of explosive surrounded by a thin shell with "discrete" fragments glued to the shell which is generally called the discrete fragment design. In either case the warhead is then mounted into the ordnance section where structural loads are carried by a surrounding shroud.
An example of the conventional steel case design is LaRocca, U.S. Pat. No. 3,799,054 filed Mar. 26, 1974. This reference teaches a warhead for controlling the fragmentation of explosive devices having a cylindrical metallic fragmentation casing, wrapped with metallic strips of heavy density to cause fragments to form. This type of construction is limited to ordnance which has a single type of fragment, as the fragments are formed by the metal case. Because the fragmenting section is also load bearing and/or structurally supporting, some fragment materials are precluded. Only those materials which are structurally strong can be used for load bearing elements, thus eliminating many materials that could be used for fragments. In addition, the steel case design either employs heavy materials like LaRocca, or involves complex machining of the warhead case to form the fragments.
An example of discrete fragment design is represented by Brumfield et al., U.S. Pat. No. 3,977,327 filed Aug. 31, 1976. The Brumfield et al. reference is typical of many fragmentation schemes which precut fragments and then must sandwich them between steel or aluminum cylinders to form the case or missile airframe. Construction of this type of warhead is tedious and labor intensive.
It is also extremely difficult to manually place all the fragments in the required matrix pattern with each fragment aligned to precisely form the desired pattern. It is conventional to twist and shake the heavy warhead case to coax each fragment into its proprietary physical position, but gaps and spaces inexorably remain. These irregularities degrade performance and attenuate lethality.
It is, of course, possible to mix fragments of differing material when the discrete fragments are loaded into the warhead. A problem with this design is the uncertainty involved in the fragment pattern, as the fragments are dispersed radially from the center of the warhead upon detonation and the different type fragments will be on different bearings and heights. Thus, a small target might fall within a sector of the fragment pattern containing only one type of fragment. This would preclude any synergistic effect expected from mixing fragment kill mechanisms.
To date, most missile fragmentation warheads either use the conventional to discrete design. Both designs have associated advantages and disadvantages. In the conventional design the case is notched or welded to produce the desired fragment break up. The advantages to this design are that it reliably produces uniform size fragments with high velocities, and it is easily produced. One disadvantage to this design is that fragmentation customization is not easily performed. It is inherently difficult (if not possible) to use fragments of different materials without a performance penalty. Also, changing the fragment size and geometry is not easily done. In contrast, the discrete fragment design allows for easy tailoring of the fragments as fragments of differing materials and geometries are easily utilized, however, this warhead is much more costly to produce as each fragment must be attached to the warhead.
A related application by Applicants, filed even date with this application entitled Fragmenting Notched Warhead Rod, Ser. No. 07/740,524, addresses the production difficulties inherent with discrete fragment warheads. These notched rods are inserted as a unit into a warhead case to form the fragment matrix. The rod is notched so that when it is subjected to an explosive load it will break into individual fragments. The fragment size can be adjusted by varying the distances between notches, the thickness of the rod, and the rod width. Various materials can be selected to form this notched rod without concern for the strength of the warhead case. While these notched warhead rods greatly reduce the labor and cost associated with discrete fragmenting warhead construction, the fragment pattern uncertainty discussed above remains. The fragmenting rods may be laterally stacked on the periphery of the warhead with an amelioration of the fragment uncertainty problem, but complete kill mechanism integration throughout all fragment pattern sectors seems unlikely.
The present invention is an improvement of the fragmenting warhead rods designed to overcome the problems associated with fragment pattern uncertainty by formulating each rod with a plurality of fragment materials so that each rod will fragment into individual fragments having more than one kill mechanism. This insures that any target impacted, even by a single fragment, would suffer more than one kill mechanism.
SUMMARY OF THE INVENTION
The present invention consists of a composite rod constructed of a plurality of fragment materials and then grooved to define individual fragment shapes. The grooves cause the rod to break into individual fragments upon detonation, resulting in each fragment carrying more than one fragment kill mechanism. Because these rods are not load bearing, various materials may be combined without concern for the strength of the warhead case.
Therefore, an object of the present invention is to teach a device that can form a customized fragment pattern having a plurality of kill mechanisms that is easy to manufacture.
It is also an object to teach a method of forming a fragmenting warhead, with each single fragment having a plurality of kill mechanisms, without regard for the load bearing strength or ductility of the material.
It is yet another object of the instant invention to provide a device for forming a discrete fragment warhead that minimizes irregularities in the fragment pattern while imparting multiple kill mechanisms in each fragment.
A further object is to teach a warhead design that exhibits advantages of discrete fragments and multiple kill mechanisms without the high labor and assembly costs extant in the prior art.
Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings which show an advantageous embodiment of the invention and wherein like numerals designate like parts in the several figures, and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a discrete fragment warhead containing the composite fragmenting rods of the present invention.
FIG. 2 is an isometric illustration of one of the fragmenting rods of the warhead of FIG. 1.
FIG. 3 is a side view illustration of one of the composite fragmenting rods of the warhead of FIG. 1 wherein each fragmenting section contains a liquid material.
FIG. 4A is a selected combination composite fragmenting rod of the present invention.
FIG. 4B is another selected combination composite fragmenting rod.
FIG. 4C is yet another selected combination composite fragmenting rod.
FIG. 4D is still another selected combination composite rod.
FIG. 4E is a final selected combination composite rod.
FIG. 5A is a selected possible geometric fragment shape for use with the fragmenting rods of FIG. 2 and FIG. 3.
FIG. 5B is another selected geometric fragment shape.
FIG. 5C is yet another geometric fragment shape selected for illustration for use with the fragmenting rods of FIG. 2 and FIG. 3.
FIG. 6 is a table of possible materials that might be used in constructing the rods of FIG. 2 and FIG. 3
DETAILED DESCRIPTION
Turning now to FIG. 1, a warhead 5 is shown comprised of an inner case 14 and outer case 16 sandwiching the composite fragmenting rods 10 of the present invention. The composite rods 10 illustrated in FIG. 1 are notched with grooves 12 to form individual composite fragments 13. Warhead 5 is a conventional dual wall warhead containing high explosives (HE), 22, known to those skilled in the art. A novel type of dual wall warhead wherein the inner wall 14 and outer wall 16 are comprised of composite materials is the subject of a separate application by Applicants entitled Filamentary Composite Dual Wall Discrete Fragment Warhead, filed even date with this application and bearing Ser. No. 07/740,522. The teachings of this related application, while considered nonessential to the claims appended hereto, provide a description of one of the many possible uses of Applicants' composite fragmenting rods.
On detonation of HE, 22, the rods 10 break into individual composite fragments 13 which have been designed to exhibit the desired mass, geometry and multiple target kill mechanisms.
FIG. 2 illustrates an individual composite rod 10 which is the preferred embodiment for use in the most common type fragmenting warheads. Therein, composite rod 10 is shaped to have an inner radius 24 which is machined to conform to the outside surface of the inner case wall 14 of a dual case warhead such as illustrated in FIG. 1. Likewise, rod 10 has an outer radius 26 conforming to the inner radius of the outer warhead case 16 so that the fragments 13 formed by many rods 10 fit sandwiched between the dual walls, 14 and 16, of a warhead. It is intuitive to one skilled in the art of warhead technology that the rods might be fixedly attached to either or both of the warhead's walls 14 and 16, and that a plurality of rods 10 might be affixed one to another to form a fragmentation panel or blanket.
Another conventional type warhead would omit outer case 16 on the warhead illustrated in FIG. 1 to form a single walled ordnance case. In this embodiment, rods 10 would have inner radius 24 affixed to the outside surface of the single case of the warhead. Likewise, the rods could be glued to the outside surface of a single case
It is important to note that rod 10 of FIG. 2 is comprised of two or more distinct materials 11 and 15. The materials are chosen for particular properties depending on the kill mechanism desired. For example, if the target were to be a fuel tank on a particular missile and lethality concerns dictated that both penetrating and incendiary fragments strike the target, material 11 could be tungsten, which is a known penetrating kill mechanism, and material 15 could be zirconium, which is a known incendiary.
FIG. 3 illustrates a composite fragmenting rod where each fragment section is comprised of both a solid 11 and a liquid 30 kill mechanism. In this embodiment, each segment of the composite notched rod 10 would be comprised of a solid kill mechanism 11 and would sealably contain a liquid material 30.
FIGS. 4A through 4E illustrate five of the innumerable combinations of materials and geometries possible with Applicants' composite fragmenting rods. FIGS. 4A, 4D and 4E illustrate combinations which might be used against hardened targets where rod 11 is comprised of a penetrating material and material 15 is either an incendiary or a vaporific material. FIG. 4B and 4C might be used against less robust targets and material 11 might be vaporific and material 15 incendiary. The possible combinations are endless and considered a design feature controlled by target parameters. It is considered within the scope of Applicants' invention to permute and juxtapose various fragment materials and geometries in whatever combination and pattern should present the best target kill mechanisms. It is also important to note that while only a combination of two materials have been chosen for illustration, three, four or more materials may be incorporated within the rods to obtain sophisticated results without departing from the scope of Applicants' invention.
While the rods chosen for illustration in FIG. 2 and FIG. 3 are notched with grooves 12 to form simple fragment patterns, it is important to note that more complex and/or irregular shaped grooves may be used to form any shape fragments desired.
FIGS. 5A, 5B and 5C illustrate only three of an infinite number of possible fragment shapes which might be formed in composite rod 10.
Composite rods 10 may be machined, extruded, pultruded, or constructed with a powder metallurgy process such as is disclosed in Hellner, et al., U.S. Pat. No. 4,592,283 filed Jun. 3, 1986. Thus, any fragment parameters may be obtained using rods 10 by selecting materials and changing geometric shape using construction techniques known to those of ordinary skill in the art.
FIG. 6 is a table juxtaposing various conventional fragment materials with the desired fragment kill mechanism. For instance, if a combination of penetration and incendiary effects are desired, then one of the materials in the penetration column could be combined with a material from the incendiary column to form a composite rod fragmenting into fragments, each having both properties. Likewise, a material combination would be chosen where at least one of the materials were vaporific if special effects were desired. The liquid materials may comprise any formula of many known to those in the warhead arts when the special kill mechanisms associated with liquids are desired. Examples of commonly known liquid kill mechanisms include mercury, napalm, gasoline, and virtually any reactive liquid material. In this case, the rods would be constructed from a solid material in table 6 chosen for its associated kill mechanism and a liquid would be sealably inserted therein using known construction techniques.
The materials listed in table 6 are illustrative only and any metal, metal alloy, composite or liquid that exhibits the characteristics desired in the fragment could be used and is considered within the scope of this invention.
Obviously, any permutation of materials and geometric positioning may be employed to obtain the precise design and kill mechanism desired and many modifications and variations of the present invention are possible in light of the above teachings without going outside the scope of Applicants' invention.
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A rod is constructed using two or more materials. It is notched so that w it is subject to an explosive load it will break into individual fragments of predetermined shape and size. Rod materials are selected so that a combination of two or more kill mechanisms can be included in a single fragment. If desired, the rod can be divided into segments that contain liquid compounds.
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TECHNICAL FIELD
[0001] The present invention relates to a fast maturation method of an oligonucleotide library, which aims to prepare a protein library.
BACKGROUND ART
[0002] When plural random amino acid sequences are introduced into one site of a protein, oligonucleotides synthesized at random are introduced into the gene of the protein. However, when an introduced sequence is synthesized completely at random (NNN sequence), a stop codon emerges at a ratio of about 1/21. In addition, when synthesized an oligonucleotide to be introduced is a long strand, an oligonucleotide having deleted or inserted bases is found in a proportion of a few percent. Since they markedly reduce the diversity of the resulting protein library, those oligonucleotides need to be removed during preparation of the oligonucleotide library.
[0003] As a method for removing such unnecessary oligonucleotides from a synthesized oligonucleotide library, a method utilizing antibiotic drug selection can be mentioned. For example, a random oligonucleotide library to be the maturation target is ligated to the 5′ terminus of a drug resistance gene such as β-lactamase, and introduced into a plasmid. Escherichia coli is transformed with this plasmid and applied to an agar plate containing the corresponding antibiotic. As a result, only Escherichia coli having an in-frame gene without a stop codon or a frame shift due to deletion or insertion of bases can grow as a colony on the plate, since such Escherichia coli can express a drug resistance protein. Therefore, by recovering a gene from such colonies, a maturated oligonucleotide library free of unnecessary oligonucleotides can be obtained.
[0004] However, this method has some problems. Firstly, it is difficult to form a large number of colonies by a general method, since the number of colonies of Escherichia coli varies depending on the ligation efficiency of oligonucleotide library to a vector and transformation efficiency of Escherichia coli . Secondly, to obtain a large number of colonies, the corresponding number of samples needs to be prepared, which requires a lot of efforts and time.
[0005] The period that the present inventors required to maturate an oligonucleotide library having 10 8 diversities by this method was about 1 week. When an oligonucleotide library encoding an antibody gene library wherein 6 CDRs (complementary-determining regions) of the antibody are randomized is prepared, oligonucleotide libraries encoding each of these 6 CDRs are sequentially maturated, and maturation of the whole oligonucleotide library encoding the antibody gene library requires about 6 weeks.
[0006] Furthermore, since the above-mentioned manipulation requires large amounts of expensive reagents (enzymes etc.), the method is extremely costly.
[0007] On the other hand, patent document 1 discloses a ribosome display. In addition, patent document 1, paragraph [0051], discloses mRNA having a sequence encoding a translation reaction elongation arrest sequence of Escherichia coli SecM at the downstream of a spacer sequence.
DOCUMENT LIST
Patent Document
[0000]
patent document 1: JP-A-2008-271903
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0009] The present invention aims to provide a production method of a maturated oligonucleotide library, which can conveniently produce many kinds of maturated oligonucleotide libraries at once in a short time at a low cost.
[0010] In addition, the present invention aims to provide an efficient maturation method of a random oligonucleotide library using a ribosome display of an in vitro selection system (JP-A-2008-271903).
Means of Solving the Problems
[0011] The present invention is based on the finding that, in maturation of a random oligonucleotide library, the in-frame ratio can be improved by adding an arrest sequence (e.g., SecM sequence) to the 3′ terminus of oligonucleotide, and maturation can be achieved extremely efficiently.
[0012] The first aspect of the present invention relates to a production method of a maturated oligonucleotide library. In this method, first, a tag sequence is added to the 5′ terminus of a maturation target oligonucleotide library and an arrest sequence (e.g., SecM sequence) is added to the 3′ terminus thereof to give a terminal-modified product of a maturation target oligonucleotide library (terminal-modified sequence product). The maturation target oligonucleotide library is a random oligonucleotide library. Examples of the random oligonucleotide library include an oligonucleotide library containing an NNS sequence. Examples of the NNS sequence include an NNS sequence containing a codon corresponding to 31 amino acids. When the maturation target oligonucleotide library is a completely random oligonucleotide library, a stop codon emerges at a rate of about 1/21. Therefore, the random oligonucleotide library is preferably free of a completely random sequence (NNN).
[0013] Then, a transcript of the terminal-modified sequence product is obtained by transcription thereof. Thereafter, the transcript is translated in vitro.
[0014] In the above-mentioned method, the tag sequence is exemplified by FLAG sequences. For example, the resultant product can be easily recovered by using beads on which an anti-FLAG antibody is immobilized.
[0015] In the above-mentioned method, it is preferable to translate a transcript in vitro by using a cell-free translation system. Since the treatment is completely performed in vitro, the maturation efficiency of the oligonucleotide library can be improved. Examples of the cell-free translation system include an Escherichia coli cell-free translation system. Preferred as a cell-free translation system is a reconstituted cell-free translation system, i.e., PURE system. A reconstituted cell-free protein synthesis system that has been developed by a group including the present inventor is a synthesis system consisting exclusively of specified factors involved in protein synthesis reaction, such as translation factors and ribosome.
[0016] Ribosome display is a method that includes forming an mRNA-ribosome-oligopeptide ternary complex (ribosome display complex) in in vitro translation system and selecting a protein encoding a polypeptide having a specific function. As mentioned above, the terminal-modified product of the present invention has an arrest sequence at the 3′ terminus of the maturation target oligonucleotide library. When an oligonucleotide constituting a random oligonucleotide library introduced into an in vitro translation system contains a stop codon, or when a frame shift exists due to the deletion or insertion of bases, normal translation up to the arrest sequence is not available during translation. Thus, translation of an oligonucleotide having a stop codon introduced therein or an oligonucleotide containing a frame shift fails to form a ternary complex of mRNA-ribosome-oligopeptide. Thus, only an in-frame oligonucleotide translated up to the arrest sequence can be selected by, for example, selecting such complex with an antibody to the introduced tag sequence.
Effect of the Invention
[0017] In the production method of the maturated oligonucleotide library of the present invention, the treatment is performed completely in vitro, and therefore, an oligonucleotide library having high diversity (e.g., not less than 10 11 -10 12 diversities) can be the target of selection.
[0018] The production method of a maturated oligonucleotide library of the present invention includes convenient and efficient operations, and therefore, for example, 8 kinds of maturation target oligonucleotide libraries individually formed can be simultaneously maturated in one day. This is a remarkable difference from conventional methods that require about 1 week for maturation of one kind of oligonucleotide library.
[0019] Furthermore, the production method of a maturated oligonucleotide library of the present invention can simultaneously achieve reduction of cost, since it does not require a large amount of expensive enzymes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 shows a random oligonucleotide library (NNS sequence) before and after maturation.
DESCRIPTION OF EMBODIMENTS
[0021] The first aspect of the present invention relates to a production method of a maturated oligonucleotide library. In this method, first, a tag sequence is added to the 5′ terminus of a maturation target oligonucleotide library and an arrest sequence (e.g., SecM sequence) is added to the 3′ terminus thereof to give a terminal-modified sequence product of a maturation target oligonucleotide library.
[0022] In the present specification, “maturation” refers to removing oligonucleotides containing a stop codon and a frame shift due to the deletion or insertion of bases from an oligonucleotide library. The “maturation target oligonucleotide library” means a mixture of oligonucleotides that can be maturated. The “random oligonucleotide library” means a mixture of oligonucleotides having various sequences as defined below. The “maturated oligonucleotide library” means a mixture of maturated oligonucleotides.
[0023] The maturation target oligonucleotide library is exemplified by a random oligonucleotide library. The random oligonucleotide library is exemplified by an oligonucleotide library containing an NNS sequence. NNS sequence is exemplified by an NNS sequence containing 31 amino acid codons. When the maturation target oligonucleotide library is a completely random oligonucleotide library, a stop codon emerges at a ratio of about 1/21. Therefore, a random oligonucleotide library is preferably free of a completely random sequence (NNN). Such random sequence (incomplete random sequence) is exemplified by NNK sequence, NNS sequence and NNY sequence. Here, N means any of adenine (A), guanine (G), cytosine (C) and thymine (T). K means any of guanine (G) and thymine (T). S means any of cytosine (C) and guanine (G). Y means any of cytosine (C) and thymine (T). In the present specification, the “NNK sequence” refers to an oligonucleotide sequence containing a plurality of “NNK” (i.e., “NNK”×m (m is an integer of 2 or more)) successively. In the present specification, “NNS sequence” refers to an oligonucleotide sequence containing a plurality of “NNS” (i.e., “NNS”×m (m is an integer of 2 or more)) successively. In the present specification, “NNY sequence” refers to an oligonucleotide sequence containing a plurality of “NNY” (i.e., “NNY”×m (m is an integer of 2 or more)) successively. In one embodiment, the random oligonucleotide library is an oligonucleotide library containing repeats of NNK sequence, NNS sequence or NNY sequence. The “oligonucleotide library containing repeats of NNK sequence, NNS sequence or NNY sequence” refers to an oligonucleotide containing a plurality of random sequences selected from NNK sequence, NNS sequence and NNY sequence in one oligonucleotide. In this case, a plurality of NNK sequence, NNS sequence or NNY sequence may be contained, or a plurality of mutually different random sequences may be contained so that both NNK sequence and NNS sequence are contained. The oligonucleotide constituting the random oligonucleotide library in the present specification has, for example, 3×n bases. Examples of n include not less than 5 and not more than 20, and not less than 7 and not more than 11. A specific example of n is 9. A method for synthesizing a random nucleotide library is known. Therefore, a random nucleotide library may be produced by a known method.
[0024] In the above-mentioned method, the tag sequence to be added to the 5′ terminus of the maturation target oligonucleotide library is exemplified by FLAG sequence. The tag sequence is not limited to FLAG sequence. Other example of the tag sequence is Myc sequence. An antibody that specifically binds to FLAG tag and Myc tag is already commercially available. Therefore, a protein fused with such tag can be easily labeled and purified using an antibody or a substance having an immobilized antibody. For example, when a ribosome display complex containing the maturated oligonucleotide library of the present invention has FLAG tag, the ribosome display complex can be easily recovered and purified using beads with an immobilized anti-FLAG antibody.
[0025] The arrest sequence is a sequence that stalls the translation on ribosome on the way. An arrest sequence derived from Escherichia coli is exemplified by SecM sequence (Nakatogawa and Ito (2002) Cell, vol. 108, p. 629-636) and TnaC sequence (Gong et al, (2002) Science, vol. 297, p. 1864-1867). In addition, an artificially synthesized arrest sequence for Escherichia coli is exemplified by the sequence reported by Tanner et al. (Tanner et al, (2009) J. Biol. Chem., vol. 284, p. 34809-34818). Furthermore, a eukaryote-derived arrest sequence is exemplified by uORF sequence (Hood et al, (2009) Annu. Rev. Microbiol, vol. 63, p. 385-409).
[0026] Then, a terminal-modified sequence product is transcribed to give a transcript. The transcription step is known in the field of biotechnology. Thus, the transcription step can be performed based on a known method.
[0027] Thereafter, the transcript is translated in vitro. This translation step is exemplified by translation of a transcript in vitro using a cell-free translation system. In this case, the maturation efficiency of oligonucleotide can be improved by performing the treatment completely in vitro. When a sequence derived from Escherichia coli is used as an arrest sequence, a preferable cell-free translation system is, for example, an Escherichia coli cell-free translation system. A preferable cell-free translation system is a reconstituted cell-free translation system, namely, PURE system (see, for example, “Shimizu Y, Inoue A, Tomari Y, Suzuki T, Yokogawa T, Nishikawa K, Ueda T (2001) Cell-free translation reconstituted with purified components. Nature Biotechnology 19, 751-755”).
[0028] PURE system is a cell-free translation system reconstituted with independently prepared factors necessary for translation. PURE system is almost free of contamination with nuclease and protease that decrease efficiency of ribosome display. Therefore, higher selection efficiency has been reported by using PURE system than a cell-free translation system of a cell extract type (Villemagne et al, (2006) J. Immunol. Methods, vol. 313, p. 140-148). On the other hand, many organisms are provided with a means to bypass translation stalling on ribosome that occurs during translation. In the case of Escherichia coli , for example, a reaction called trans-translation involving 10S-RNA (tmRNA) and SmpB protein occurs, and ribosome stalling is cancelled (Moore and Sauer (2007) Annu. Rev. Biochem., vol. 76, p. 101-124). A general cell-free translation system of a cell-extract type containing an intracellular component also includes such bypass component in the system. Therefore, the formation efficiency of ribosome display complex is considered to decrease when a cell-free translation system of a cell-extract type is used. In fact, it has been reported that the formation efficiency of ribosome display complex increases by adding an antisense sequence of 10S-RNA to a cell-free translation system of an Escherichia coli - extract system (Hanes et al, (1997) Proc. Natl. Acad. Sci. USA, vol. 94, p. 4937-4942). That is, in the present invention, a PURE system free of the bypass component explained above is an optimal cell-free translation system.
[0029] A cell-free translation system has an energy regeneration system and at least one amino acid. Energy regeneration system means factors involved in the regeneration of energy sources necessary for protein synthesis such as ATP, GTP and the like. Examples of substances of the energy regeneration system include enzymes involved in ATP regeneration (creatinine kinase, pyruvate kinase etc.), and substrates thereof (phosphocreatine, phosphoenolpyruvate etc.). A cell-free translation system contains at least one kind of amino acid, preferably naturally-occurring 20 kinds of amino acids. A cell-free translation system may further contain a non-natural amino acid. A cell-free translation system may contain, for example, buffers (e.g., HEPES-potassium, Tris-acetate etc.), various salts, surfactants, RNA polymerases (T7, T3, and SP6 RNA polymerases etc.), chaperone proteins (DnaJ, DnaK, GroE, GroEL, GroES, and HSP70 etc.), RNA (mRNA, tRNA etc.), protease inhibitors, or (ribo)nuclease inhibitors.
[0030] As explained above, preferable use of the present invention is a method of maturation of a random oligonucleotide library using ribosome display. Ribosome display is a method that includes forming an mRNA-ribosome-oligopeptide ternary complex in in vitro translation system and selecting a protein encoding a polypeptide having a specific function. As mentioned above, the terminal-modified sequence product of the present invention has an arrest sequence at the 3′ terminus of the maturation target oligonucleotide library. When an oligonucleotide constituting a random oligonucleotide library introduced into an in vitro translation system contains a stop codon, or when a frame shift exists due to the deletion or insertion of bases, normal translation up to the arrest sequence is not available during translation. Thus, translation of an oligonucleotide having a stop codon introduced therein or an oligonucleotide containing a frame shift fails to form a ternary complex of mRNA-ribosome-oligopeptide.
[0031] For example, only an in-frame oligonucleotide translated up to the arrest sequence can be selected by, for example, selecting such complex with an antibody to the introduced tag sequence.
[0032] The present invention is explained in more detail in the following by referring to Examples, which are not to be construed as limitative.
Example 1
Construction of Template
[0033] A maturation target random oligonucleotide library containing codons encoding 9 amino acids, which is added with a FLAG sequence at the 5′ terminus and added with a Myc sequence at the 3′ terminus, was prepared by DNA synthesis (SEQ ID NO: 1: ATGGACTATAAAGATGACGATGACAAAnnsnnsnnsnnsnnsnnsnnsnnsnnsGAGCAGAA GCTGATCTCTGAGGAGGATCTG). A 5′ UTR sequence comprising a T7 promoter and an SD sequence, which is added with a FLAG sequence at the 3′ terminus, was also prepared by DNA synthesis (SEQ ID NO: 2: gaaattaatacgactcactatagggagaccacaacggtttccctctagaaataattttgttt aactttaagaaggagatataccaatggactataaagatgacgatgacaaa). The partial sequence (220-326-position amino acid residues) of gene III of M13 phage was amplified by PCR with KOD Plus DNA Polymerase (manufactured by TOYOBO) (denaturation: 94° C., 15 seconds, annealing: 57° C., 30 seconds, extension: 68° C., 60 seconds, 25 cycles) using a phage genome derived from M13KO7 as a template and primer Myc-g3p (SEQ ID NO: 3: GAGCAGAAGCTGATCTCTGAGGAGGATCTGGAATATCAAGGCCAATCGTCTGAC) and primer g3p-SecMstop (SEQ ID NO: 4: CTCGAGTTATTCATTAGGTGAGGCGTTGAGGGCCAGCACGGATGCCTTGCGCCTGGCTTATC CAGACGGGCGTGCTGAATTTTGCGCCGGAAACGTCACCAATGAAAC), and purified with a purification column manufactured by Qiagen. A PCR reaction solution containing the three kinds of DNAs (5′ UTR, random oligonucleotide library and g3p, each 1 μmol), 5′ primer (SEQ ID NO: 5: gaaattaatacgactcactatagggagaccacaacggtttccctctag) (10 pmol), SecM stop sequence (SEQ ID NO: 6: ggattagttattcattaggtgaggcgttgagg) (10 pmol) and KOD Plus DNA polymerase was prepared, and subjected to 10 cycles of PCR reaction (denaturation: 94° C., 15 seconds, annealing: 57° C., 30 seconds, extension: 68° C., 60 seconds). After confirmation of a band containing three genes linked together by electrophoresis using 1% agarose gel, the band was excised and purified with a column manufactured by Qiagen to finally give a maturation target oligonucleotide library containing the random sequence.
In Vitro Transcription
[0034] The purified maturation target oligonucleotide library DNA (1 μg) was transcribed into mRNA with 20 μl of in vitro transcription kit (Ribomax™ Large Scale RNA Production System-T7, Promega), and purified with a column (RNeasy mini column, Qiagen).
[0035] In vitro translation using a cell-free translation system (construction of ribosome-Peptide-mRNA complex): a cell-free translation system (PURE system), which is a protein synthesis reaction reagent, was prepared according to the previous report (Shimizu et al. (2005) Methods, vol. 36, p. 299-304). To the prepared reaction solution (100 μl) was added maturation target oligonucleotide library mRNA (100 pmol), and the mixture was incubated at 37° C. for 30 min. An ice-cooled Wash buffer (50 mM Tris-OAc, pH 7.5, 150 mM NaCl, 50 mM Mg(OAc) 2 , 0.5% Tween 20, 10 μg/ml budding yeast ( Saccharomyces cereviseae ) total RNA (manufactured by Sigma)) (500 μL), a Blocking buffer (50 mM Tris-OAc, pH 7.5, 150 mM NaCl, 50 mM Mg(OAc) 2 , 0.5% Tween 20, 10 μg/ml budding yeast ( Saccharomyces cereviseae ) total RNA (manufactured by Sigma), and 5% SuperBlock (Pierce)) (500 μL) were added.
In Vitro Selection
[0036] A FLAG M2 carrier (50 μL slurry, manufactured by Sigma) which was blocked with 5% SuperBlock at 4° C. overnight in advance was washed twice with 500 μl of Wash buffer using MicroSpin (registered trade mark) column (manufactured by GE Healthcare), after which translation reaction solution was added to the recovered FLAG M2 carrier, and the mixture was stirred by rotation at 4° C. for 1 hr. The supernatant was discarded using MicroSpin (registered trademark) column (manufactured by GE Healthcare); 1 mL of Wash buffer was added to the recovered FLAG M2 carrier, and stirred by rotation at 4° C. for 5 min. After this process was repeated 20 times, 100 μl of Elution buffer (50 mM Tris-OAc, pH 7.5, 150 mM NaCl, 50 μg of FLAG peptide (Sigma)) was added to the recovered FLAG M2 carrier, and the mixture was allowed to stand at 4° C. for 15 minutes. Thus, the complex was separated from the FLAG M2 carrier. The supernatant was recovered with MicroSpin (registered trade mark) column (manufactured by GE Healthcare), and mRNA was recovered and purified with RNeasy Micro (manufactured by Qiagen).
RT-PCR
[0037] The recovered mRNA was processed into cDNA with Transcription High Fidelity cDNA Synthesis Kit (Roche), and subjected to a PCR reaction using KOD Plus DNA polymerase (denaturation: 94° C., 15 seconds; annealing: 57° C., 30 seconds; extension: 68° C., 60 seconds; 20 cycles). The primers used are shown below.
[0000]
reverse transcription reverse primer:
Myc-R (SEQ ID NO: 7:
CAGATCCTCCTCAGAGATCAGC)
PCR primer:
FLAG-F (SEQ ID NO: 8:
atggactataaagatgacgatgacaaa)
Myc-R (SEQ ID NO: 7:
CAGATCCTCCTCAGAGATCAGC)
Subcloning for DNA Sequence Analysis
[0038] DNA (100 ng) before and after selection were added with A at the 3′ terminus with rTaq DNA polymerase (manufactured by TOYOBO). Thereafter, subcloning was performed using a TOPO TA cloning kit (manufactured by Invitrogen). The subcloning was performed based on the explanation of this kit. Escherichia coli single colony after transformation (each 20 colonies) was cultured in 3 ml of LB medium, and plasmid was recovered from the amplified Escherichia coli and used for DNA sequence analysis.
Results and Discussion
[0039] FIG. 1 shows random oligonucleotide library (NNS sequence) before and after maturation.
[0040] As shown in FIG. 1 , as a result of the DNA sequence analysis before maturation, the appearance frequency of oligonucleotide containing stop codon (TAG) was 40% ( 8/20), deletion of base was 5% ( 1/20), insertion of base was 0% ( 0/20), and the appearance frequency of finally complete in-frame oligonucleotide was 55% ( 11/20). In addition, after maturation, appearance frequency of those containing stop codon, and deletion and insertion of bases was 0% ( 0/20), and all oligonucleotides were confirmed to be in-frame. These results show that the selection of in-frame oligonucleotide has been almost completely achieved by the present method, and the effectiveness of the present method has been verified.
[Sequence Listing Free Text]
[0041] SEQ ID NO: 1: oligonucleotide
[0000] n shows optional base.
s shows guanine or cytosine.
[0042] SEQ ID NO: 2: oligonucleotide comprising T7 promoter, SD sequence and initiation codon
[0043] SEQ ID NOs: 3-8: primer
INDUSTRIAL APPLICABILITY
[0044] The production method of a maturated oligonucleotide library of the present invention can be utilized in, for example, biochemical industry and protein drug industry.
[0045] This application is based on a patent application No. 2010-142470 filed in Japan (filing date: Jun. 23, 2010), the contents of which are incorporated in full herein.
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The present invention provides a method of producing a maturated oligonucleotide library, including a step of obtaining a terminal-modified product of a maturation target oligonucleotide library, including adding a tag sequence to the 5′ terminus of the maturation target oligonucleotide library and an arrest sequence, which stalls translation elongation on a ribosome, to the 3′ terminus of the maturation target oligonucleotide library, a step of transcribing the terminal-modified sequence product to give a transcript, and a step of in vitro translation for translating the transcript in vitro, wherein the maturation target oligonucleotide library is a random oligonucleotide library.
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RELATED APPLICATIONS
[0001] None
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention pertains to a method of producing a printed fabric and more particularly, a process in which one side of the fabric is first coated with dyestuff and then a coating is applied in a decorative pattern or motif that affects the manner in which the dyestuff adheres to the fabric so that when the fabric is washed, some of the dyestuff is removed from the fabric.
[0004] 2. Background of the Invention
[0005] There are many ways of producing decorative woven fabrics for clothing, furnishings and other uses. One popular way is to print patterns on fabrics. The most common fabric printing methods include silk screening and rotary printing. In many instances these methods are useful to produce printed fabrics with many different types of designs that have a high quality and are attractive esthetically.
[0006] However, these methods are not very effective in producing fabrics with very fine details. For example, designers and customers would like to have printed fabrics that have a knitted or so-called ‘Jacquard’ look. Neither the screening methods nor standard rotary printing methods are capable of producing fabric with patterns having sufficiently fine details to achieve this look.
SUMMARY OF THE INVENTION
[0007] Conventionally, a printed fabric is made by bleaching a raw fabric and applying dyestuff to one surface, using a silk screening, a rotating print roller, etc. The fabric is then heated to set the dyestuff, washed and then inspected.
[0008] In order to make a fabric with motifs that have finer details, in the present invention, the conventional dyestuff is used to coat one side of a fabric so that the side has a ground or base color. Next, coating is applied. The fabric is then padded and heated. The fabric is then washed. During washing, dyestuff in the areas of the fabric covered by the coating is removed leaving a visible pattern on the fabric that has a lighter shade then the ground color.
[0009] Preferably, the dyestuff and the coating are applied using a rotary print roller.
[0010] The amount of dyestuff removed from the fabric during washing is dependent on the concentration of an active ingredient in the coating. A bigger concentration of this active ingredient (for example PEG) results in more dyestuff being washed off leaving the motif with a lighter shade.
[0011] The resulting fabric has a motif that is more precise and has finer details then fabrics made with the prior art methods. More specifically, the coating and the resulting motif can be selected to provide the fabric with a unique and intricate pattern that gives the fabric a knitted or Jacquard look.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a flow chart of a conventional process for printing fabrics;
[0013] FIG. 2 shows a flow chart of process for printing fabrics in accordance with this invention;
[0014] FIGS. 3A-3D show a piece of fabric with a print applied in accordance with this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring first to FIG. 1 , conventionally, a fabric is printed using the following process. First (step 10 ) the fabric is woven to obtain a raw or in grey fabric. Next, the woven fabric is bleached (step 12 ) so that it has a uniform, preferably white, color. In step 14 dyestuff is selected that is compatible with the fibers of the bleached fabric and that can be used to dye the woven fabric to the desired color.
[0016] Next, in step 16 , the dyestuff is printed in a preselected pattern on the bleached fabric using either a silk screening technique or a rotary printer.
[0017] In step 18 the fabric is heated (and, optionally, pressed) to cause the dyestuff to adhere to the fabric fibers and to insure that the fabric is colorfast.
[0018] In step 20 , the fabric is washed to remove excess dyestuff and other matter. Finally, the fabric is tentered to set its physical dimensions (step 22 ) and then inspected (step 24 ).
[0019] As discussed above, a problem with this process is that it cannot be used to make a fabric with a print having fine details. For example, the process cannot be used to make a fabric having a print imitating the look of a knit material (the so-called Jacquard look).
[0020] The present invention is now described in conjunction with FIGS. 2 and 3 A- 3 D. The first three steps of the novel process are identical to the steps 10 - 14 in FIG. 1 , with the fabric being woven in step 10 and bleached in step 12 . FIG. 3A shows the bleached fabric 100 . In step 14 dyestuff matching is performed.
[0021] In step 16 the dyestuff is applied to one side of the bleached fabric 100 , preferably using a conventional rotary printing roller (not shown). The result is a base- or ground-color fabric 102 shown in FIG. 3B . This fabric has a uniform color with no distinctive design.
[0022] Next, in step 17 A a coating is applied to the base-color fabric, again preferably using a printing roller. However, the printing roller is provided with a pattern defining on the fabric a selected motif. A printing machine with a roller suitable for this purpose is the DR-9000 printing machine made by the Daiyang Machinery Company of the Republic of Korea.
[0023] Thus, the fabric 104 from step 17 A includes two different types of regions: region 104 A with the base-color formed by the dyestuff, and regions 104 B formed by the coating. It should be understood that in FIG. 3C (and 3 D), regions 104 B are shown as having a geometric elliptic shape for the sake of simplicity, however in actuality, these regions can have much more complicated shapes. The purpose of the coating is to inhibit or reduce the adherence of the dyestuff to the fabric fibers in the regions 104 B.
[0024] The coating forming regions 104 B may be composed of various materials and compositions. One preferred composition includes an aqueous PEG (polyethylene glycol) solution (available from Sanyo Chemical of Japan, Shell of the United States, etc.). A typical solution may consist of the following ingredients:
PEG-400 67.3% Petroleum 15% Urea 12% Sodium Chloride 3% Algin 2.5% Emulsifying agent 0.2 %
[0025] PEG-400 is an aqueous solution of PEG. The concentration of PEG in the PEG-400 aqueous solution may vary in accordance with the effects that are desired, as discussed below.
[0026] Importantly, the coating applied during step 17 A is not visible on the fabric and regions 104 B are shown in FIG. 3C only for illustrative purposes.
[0027] Once the coating is applied, in step 17 B a padding step is performed during which the fabric is padded and pressed using a pressure nip or other means to insure that the dyestuff and the coating stay on the fabric. Next, in step 17 C, the fabric is aged for about 40-50 minutes.
[0028] After aging, the standard process is resumed. In step 18 the fabric is heated to set the dyestuff. In step 20 the fabric is washed.
[0029] In the conventional process, the dyestuff is deposited on the fabric uniformly, and excess dyestuff is removed uniformly as well, during washing. Therefore, after printing, the appearance of the fabric remains unchanged. However, in the present invention, the presence of the coating changes the characteristics of the dyestuff and/or the fabric fibers. As a result, during washing a substantial amount of the dyestuff is removed from the regions 104 B and therefore these regions are about 10-20% lighter than the regions 104 A. In this manner, the pattern or motif defined by the coating during the printing step 17 A becomes clearly visible, as shown in FIG. 3D . Depending on several factors, such as the color and contents of the dyestuff, and the composition of the coating, the regions 104 B can be lighter by anywhere between 10-90% then the uncoated regions 104 A.
[0030] After washing, the fabric 106 is tentered in step 22 and then inspected in step 24 .
[0031] The resulting fabric has a pattern or motif that can have much finer details than the fabric obtained from conventional printing processes. Moreover, as discussed above, the difference in the shading between the ground color and the motif is easily but precisely controlled by changing the composition of the coating.
[0032] While the invention has been described with reference to several particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles of the invention. For example, instead other coating compositions may be used, such as a sodium formaldehyde foxilate rongalite-c available from Hunan ZhongCheng Chemicals Co. Ltd. of Hunan, China. In addition, the sequence of the steps can be changed. For example, the coating could be applied before the printing of the base color. Alternatively, the coating step may be repeated with different solutions, thereby generating fabrics with multiple shadings. Accordingly, the embodiments described in particular should be considered as exemplary, not limiting, with respect to the following claims.
[0033] While the invention has been described with reference to several particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles of the invention. Accordingly, the embodiments described in particular should be considered as exemplary, not limiting, with respect to the following claims.
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A raw fabric is bleached and coated with dyestuff in a base color. A coating, formed for example of an aqueous PEG solution, is also applied to portions of the fabric,. The fabric is heated and then washed causing some dyestuff from the coated fabric portions to be removed thereby leaving the respective portions of the fabric with a lighter shade. The coating is applied in a pattern, for example, a pattern that resembles or gives the fabric a Jacquard look.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application and invention relate to and claim priority to four co-pending provisional applications by the same inventors: U.S. Ser. Nos. 61/455,367, 61/461,413, 61/463,296 and 61/519,071 filed Oct. 19, 2010, Jan. 18, 2011, Feb. 14, 2011 and May 16, 2011 and entitled “Rapid Tank Response, Equipment and Methodology;” “A Point and Shoot System (including as previously filed,) An Ambush System and Method and a Hollow Point System and Method, all for Fighting Industrial Tank Hazards;” “Further Developments—Fixed System (Point and Shoot, Ambush and Hollow Point),” and “Fixed/Semi-Fixed Aerated Foam Systems for Industrial Tank Hazards,” respectively. The four co-pending applications are all herein and hereby incorporated by reference in their entirety to the extent permitted by law and regulation.
FIELD OF THE INVENTION
[0002] The field of invention includes fixed systems for fighting fire in industrial tanks including a wand with at least one laterally directed nozzle projecting aerated foam around interior tank wall portions plus a fixed centrally directed nozzle for projecting aerated foam. The invention also relates to a fixed system for fighting fire in large industrial tanks with a fixed roof.
BACKGROUND OF THE INVENTION
Industry Background
[0003] Williams Fire and Hazard Control, Inc. (Williams) has been a leader in the design, development, and production of specialty firefighting equipment and methodology for use on large industrial tank fires. A study published in a report by SP Fire Technology in 2004, written by Henry Persson and Anders Lonnermark, stated:
Despite the lack of large-scale tank fire tests in the last 15 to 20 years, significant improvements have been made regarding tank fire fighting using mobile equipment. The pioneers in this development have been Williams Fire & Hazard Control Inc. (WFHC) drawing attention to the need for solving the logistics during a fire and to use relevant tactics. By using large capacity monitors, large diameter hose and foam concentrate stored in bulk containers, the logistics become manageable. The use of large-scale monitors has also made it possible to achieve sufficiently high application rates in order to compensate for foam losses due to wind and thermal updraft. Williams have also introduced the “Footprint” technology where all the foam streams are aimed towards one single landing zone on the fuel surface, resulting in a very high local application rate making the foam spread more rapidly and efficiently. One of the main factors in achieving an efficient extinguishment, according to Williams, is the use of a high quality foam, suited for tank fire protection and until recently, they were primarily using 3M AFFF/ATC. Due to 3M's withdrawal from the foam business a similar foam type is now used, manufactured by Ansul. “Thunderstorm ATC.” In 1983, Williams extinguished a 45.7 m (150 ft) diameter gasoline tank in Chalmette, La. (“Tenneco fire”), which at that time was the largest tank ever extinguished using mobile equipment. A new record was set in 2001 when an 82.4 m diameter (270 ft) gasoline tank was extinguished in Norco, La. (“Orion fire”). The concept for tank fire fighting used by Williams has been shown to be successful in many other fires [35] and the concept has also been successfully used by other companies, e.g. during the Sunoco fire in Canada 1996.”
(Note: Thunderstorm™ foam concentrates are now developed and produced by Chemguard Inc.)
Historical Development
[0005] Historically, Williams has specialized in mobile equipment and methodology. “Fixed system” approaches to large tank fires, historically, have demonstrated limited success in the industry as well as high cost.
[0006] On the one hand, for “rim seal fires” (fire around the rim of a tank floating roof, around the roof seal,) traditional fixed system approaches place a large number of “foam chambers” or “foam pourers” around the perimeter of the storage tank, every 40 feet or every 80 feet depending upon whether the “foam dam” on the floating roof is 12″ or 24″ high. These devices drop or “pour” highly aerated fire fighting foam down the tank wall into the tank “periphery,” or area between the tank wall and the “foam dam” on the floating roof, by force of gravity. The cost for such system is high.
[0007] On the other hand, for “full surface liquid tank fires” in 100 foot plus diameter tanks, proven fixed systems have not existed. That is, to the inventor's best knowledge, no fixed system has put out a fully engaged full surface liquid tank fire in a 100 foot plus diameter tank.
Williams Fully Portable Systems
“Rim Seal Fire”
[0008] Before the “Daspit Tool,” Williams successfully used fully portable devices and methods to extinguish “rim seal fires,” using a two part attack. In the first phase of the Williams attack a fire fighter approached the tank and hung a portable device (foam wand with a non-reactive nozzle design) over the top edge of the tank proximate a platform or landing. The wand largely dispensed foam directly under the device, suppressing the fire in the immediate vicinity, over a 30 to 40 foot length. After a “beachhead” was established, a “beachhead” of 30 to 40 feet of tank rim with no flames under a landing, fire fighters mounted the tank wall using the ladder leading to the landing, and carried up handheld nozzles and hoses. (The gpm's of handheld nozzles are roughly limited to 60 gpm for a one person nozzle and a 125 gpm for a two person nozzle.) These nozzles were the primary fire extinguishing tools for the seal fire. Having gained access to the top of the tank wall through use of a foam wand, the fire fighters extinguished the “seal fire” by walking the “wind girder” around the tank wall, using the portable nozzles in a known manner.
Daspit Tool System
[0009] Subsequently, Williams developed a Daspit tool, a portable base for affixing a portable nozzle and monitor to the top of a tank rim or wall. With the Daspit tool, nozzles up to 2000 gpm could be attached to the top of a tank wall. Specifically again, on “a rim seal fire,” with this improved technique, a portable foam wand device was again used to dispense foam downward to establish a “beachhead” area. A fire fighter then carried a Daspit Tool™, (being a clamping device used to secure a temporary fire fighting monitor and nozzle to the top edge of a storage tank, or any other approved mounting location) and hose while climbing the ladder and attached the Tool to the tank rim above the beachhead. The monitor and nozzle were then pressurized with water/foam solution and directed by the fire fighter stationed at the landing to dispense foam inside the tank and shoot out fire located around the tank's perimeter. The entire attack could be set up and executed in a matter of minutes, after, of course, the responding fire fighters had arrived at the scene.
Full Surface Fire
[0010] In September of 2004 Williams was called to Cushing, Okla. to assist in the extinguishment of a “full surface” 117 foot diameter crude tank fire. The Williams team arrived with portable foam wands and with “Daspit Tools,” monitors and nozzles. (Again, “Daspit Tools” permit staging a monitor and nozzle on a tank wall rim. The “Daspit Tool” provides a base for a monitor and nozzle.) Williams first used portable foam wands to extinguish the fire around an area under a platform and ladder along the wall of the tank. Having gained “control” of that limited area, Williams personnel mounted the ladder of the burning tank to the platform, secured a Daspit Tool there and directed its monitor and nozzle to extinguish the full surface crude tank fire. Thus, Williams provided evidence that a portable foam wand and sufficiently large portable monitor and nozzle (rendered useable by virtue of the Daspit Tool base) could be effectively used to extinguish a “full surface tank fire”, at least of crude in at least a 117 foot diameter tank.
Williams Fixed Systems Development
[0011] Williams had long appreciated that a “fixed” system, performing appropriate tasks, would be faster and offer much lower risk of harm and danger to personnel. (Danger to personnel includes the clutter on a ladder provided by the hoses necessary to supply a portable monitor and a wand. Furthermore, if such hose were to break while it runs up the ladder, the personnel involved with the ladder and platform would be put in significant danger.)
[0012] A problem to solve, and a goal for Williams in industrial tank fire fighting, became to develop a cost-effective, reliable, fixed system for quickly and efficiently blanketing appropriate areas of a tank fire with foam, including not only the “periphery,” (which is the location of the “rim seal fire,”) but also a tank “full surface fire.” Such system, moreover, should perform satisfactorily for tanks of 200 and 300 and 400 feet diameter, and even greater, and include tanks with and/or without a fixed roof, and should not be prohibitively expensive.
[0013] The resulting Williams commercial embodiments, discussed below, were developed, tested and designed to solve these problems and meet these goals. The commercial embodiments were designed to protect: (1) floating roof only tanks against “rim seal fire” and vapor hazard; (2) floating roof only tanks against “rim seal fire” and full surface fire; and (3) fixed roof tanks against any surface hazard. The inventive systems are cost-effective and practical, for tank diameters from 100 feet to above 400 feet.
[0014] The instant inventors have demonstrated, in the development process, that the industry erred in certain prior assumptions regarding the proper expansion of foam needed for fixed systems, and regarding the capacity to throw or project and run an adequately expanded foam.
[0015] The instant inventors have demonstrated, with side by side testing, that “projecting” and “directionally discharging” an “aerated foam” (an expansion of between 2-to-1 and 8-to-1) from an aerated foam nozzle can produce a focused stream of at least 1100 gpm of aerated foam, with a significantly enhanced tight landing footprint, and with a surprising foam run, and including a surprising foam run speed and fire fighting effectiveness. The inventors have shown, with testing, that their aerated foam nozzles can reach a more extensive tank fire surface in a shorter period of time than can prior art “foam chambers.” The novel system can extinguish larger tanks with fewer units and is applicable not only to rim seal fires but also to full surface liquid tank fires, including of those of large tanks. The instant inventions, supported by test results, promise cost effective fixed systems to extinguish fires in tanks of diameters greater than 200 feet, greater than 300 feet, and greater than 400 feet. The instant fixed systems are designed to be attached along the tank outer wall, and to discharge into the tank from a point near a top tank wall portion, thereby enhancing the reliability as well as the cost effectiveness of the fixed system, in the event of a hazard.
Invention Development Stages
[0016] The instant invention proceeded in several stages. A first determination was made, based on experience and testing, to actively pursue outer tank wall mounted units discharging proximate the tank wall upper rim. (The inventors have experimented with “bubble-up” or so-called Type I systems but have not yet been able to successfully test a satisfactory, practical and cost effective bubble-up system. Pipe-inside-the-tank systems, based on extensive experience, were deemed impractical given the prevalence of floating roofs and the complications inherent therein. In regard to roof mounted systems, either fixed roof or floating roof or systems that “extend-over” the top of the liquid, experience again indicated far too high a likelihood that such a fixed system would be placed out of service by the very incident that causes the fire or hazard.)
[0017] A second determination, based on testing, was to preferably discharge aerated foam from an aeration chamber proximate to and upstream of the nozzle, the aerated foam preferably having at least a 2-to-1 to 8-to-1 expansion ratio. A 3-to-1 to 5-to-1 ratio was preferred. A tubular jet ambient air aeration chamber provided a reliable structure for the aeration, able to perform while enduring heat and stress. It was determined by testing that this aerated foam could be significantly projected, could produce a significant foam run, and could run quickly without losing fire fighting effectiveness.
[0018] Thirdly, the inventors created a nozzle that could significantly, directionally, “project” and/or “forcefully project” a proper aerated foam in a “substantially focused stream,” to land in a focused pattern, with an enhanced tight landing footprint, and again with significant foam run and effective fire extinguishment characteristics. A key to this stage was a stream shaper.
[0019] One general belief in the industry had been that “forcefully projecting” aerated foam destroyed the bubbles and resulted in poor foam quality and poor foam run. Prior art fixed systems with aerated foam chambers did not “forcefully project” aerated foam. Rather, for rim seal fires and/or small tanks, they poured or dropped by gravity highly aspirated foam down the inside walls of the tank. This resulted in a low gpm of discharge and a poor foam run.
[0020] The instant inventors demonstrated that, with the instant nozzles, the expectation of poor bubble quality and poor foam run for “projected” or “forcefully projected” aerated foam was misplaced. Use of a stream shaper may be instrumental in helping to secure the good results and enhanced landing footprint.
[0021] Testing has shown that a stream shaper can significantly enhance the integrity and focus of thrown footprints of aerated foam. Aerated foam discharged through a proper stream shaper has non-destructively landed at least dozens of feet away, in tightly focused footprints, and run surprisingly further and quicker than industry predictions, while maintaining the fire fighting effectiveness of the bubbles. A 2-to-1 to 8-to-1 expanded foam, preferably a 3-to-1 to 5-to-1 expanded foam, can be non-destructively landed in tight target areas to a greater extent and further away than industry expectations. The stream shaper is one key why the instant system can land foam at least 20 feet away in a tank “periphery” and run the foam greater than 100 feet further in the periphery. In preferred embodiments a footprint-enhancing stream shaper for an aerated foam nozzle has four or greater fins, each fin having a longitudinal dimension greater than a radial dimension. Preferably each fin has a longitudinal dimension greater than twice its radial dimension. Preferably also the stream shaper fins are installed in a tip of a nozzle such that the downstream end of the fins is approximately flush with the nozzle tip discharge orifice.
Terms
[0022] The following use of terms is helpful in discussing the structure and performance of the instant inventions as they developed.
[0023] The term “riser” is used to refer to any pipe or line or system of such, affixed to or near or adjacent to an outer tank wall, installed to provide water, water and foam concentrate and/or fire fighting fluid to a top portion of a large industrial storage tank. Although risers are shown herein as vertical pipes, they could be any shape, and in particular, they could be a combination of vertical and/or circular portions. E.g. one or more fluid distribution rings could be installed around a tank, connecting with vertical riser portions. A riser can come in sections, as illustrated herein.
[0024] A “tip” of a nozzle is a nozzle barrel portion terminating in a discharge orifice, frequently including a swedge-down portion to enhance discharge pressure.
[0025] A “fin” (also referred to in the art as a vane) directs fluid flow in a conduit.
[0026] A “stream shaper” provides fins or vanes extending in a nozzle or conduit. A fin radial dimension is the dimension measured radially from a center axis of a barrel or conduit out toward the barrel or conduit wall. A fin longitudinal dimension is the dimension of the fin measured longitudinally in a nozzle or conduit, along a nozzle or conduit longitudinal axis or in the upstream/downstream direction of flow.
[0027] A “deflector,” as used herein, provides an obstruction in a fluid conduit, directing a portion of fluid flowing therein toward a discharge orifice or port.
[0028] A tank “periphery” is an annular area on an top of a floating tank roof, between the tank wall and the floating roof “foam dam.” Foam dams are usually 24 inches high or 12 inches high. A “rim seal fire” is a fire in the “periphery.” (A full surface fire can ensue when a floating roof fails, e.g. sinks or tilts.)
[0029] An “aerated foam nozzle” or an “aerated foam projecting nozzle” will be used to indicate a nozzle that discharges foam created from a foaming concentrate that has passed through an ambient air aeration chamber located at, proximate to, and/or just prior to, a nozzle.
[0030] Two nozzles discharging “in roughly opposing directions” will be used to mean discharging in roughly opposite directions, within at least +/−15° of a median “directly opposite” directional axis. By one measure, thus, the included angle between two discharge axes of two nozzles discharging in roughly opposing directions, taken in the direction of discharge, will be between 180° and 150°.
[0031] A “substantially focused” stream indicates a discharge of foam where at least 60% of the foam remains within a 20 degree cone around a discharge axis during flight.
[0032] A “projecting” nozzle means a nozzle that, if set at 0° inclination to the horizon and at a supply pressure of 100 psi, and if a landing footprint is measured on a horizontal plane five feet below the discharge orifice, and when throwing aerated foam with an expansion of between 3/1 and 5/1, then the nozzle can land at least 50% of the aerated foam greater than 5 feet from the discharge orifice and can land some foam greater than 20 feet. “Projecting” thus means landing at least 50% of foam, aerated with an expansion of between 3-to-1 to 5-to-1, greater than 5 feet from the nozzle discharge orifice and landing significant foam greater than 20 feet, if discharged horizontally and measured on a plane five feet below the discharge orifice.
[0033] A “forcefully projecting” nozzle means a nozzle that, if set at 0° inclination to the horizon and at a supply pressure of 100 psi, and if a landing footprint is measured on a horizontal plane five feet below the discharge orifice, and when throwing aerated foam with an expansion of between 3/1 and 5/1, then the nozzle can land at least 50% of the aerated foam greater than 50 feet from the discharge orifice and can land some foam greater than 80 feet. “Forcefully projecting” thus means landing at least 50% of foam, aerated with an expansion of between 3-to-1 to 5-to-1, greater than 50 feet from the discharge orifice and landing some foam greater than 80 feet, if discharged horizontally and with a landing footprint measured on a horizontal plane 5 feet below the discharge orifice.
[0034] The concepts of “substantially focused” stream and “projecting” and “forcefully projecting” together with “aerated foam nozzle” help distinguish the instant inventive nozzle and wand systems from aspirated foam discharge devices of the prior art. Prior art discharges from traditional “foam chambers” or “foam pourers” are not “substantially focused” or “projecting.” On the other hand, the term “aerated foam nozzle” distinguishes the instant nozzles from master stream nozzles of the prior art, for instance, nozzles that throw a water/foam concentrate liquid mixture where essentially all aeration takes place significantly after leaving the nozzle structure rather than in an associated upstream or in-nozzle aeration chamber.
[0035] Given the surprisingly good foam run results with the instant nozzle design and aerated foam, the inventors tested “opposing nozzle” fixed units, referred to by the inventors as “wand heads” and “wands.” “Two nozzle” and “three nozzle” fixed units, or “wand heads” or “wands,” were tested, discharging roughly horizontally and primarily left and/or right, and optionally, “toward the center.” For insertion through existing openings in a wall of a “fixed roof” tank, a conduit with a single center pointing nozzle plus dual non-obtrusive side ports with interior deflectors was tested, the unit suitable for inserting into existing fixed roof tank wall flanged openings.
[0036] The “wand heads” are adapted to be supplied by “risers,” mounted on, proximate to or about outside tank wall portions, the “wand heads” to be secured so as to discharge just inside a top tank wall portion, for enhanced reliability. The “wand heads” preferably include a proximally located ambient air aeration chamber providing properly aerated foam for the nozzle(s). The aeration chambers are served by water/foam concentrate line(s) or pipe(s), again typically referred to as “risers.” A fixed wand head with two opposing nozzles preferably directs discharges roughly left and right, projecting aerated foam substantially horizontally and in roughly opposing directions. A fixed separate riser and fitting can be provided, especially proximate a tank ladder and landing platform, to supply and support an additional fixed nozzle or portable monitor and nozzle, which can project foam toward the center of the tank or otherwise around the tank. Preferably a “three nozzle” fixed unit for open floating roof tanks can be installed to discharge left, right and roughly toward the center. For fixed roof tanks, a single center pointing nozzle with two conduit-located deflection ports can be installed, the ports functioning as side nozzles. The unit can be inserted through flanged openings typically provided in existing fixed roof tanks. The single conduit nozzle plus two “deflector ports” can discharge left, right and toward the center of a tank with a fixed roof.
[0037] (The inventors further teach, for alcohol or the like liquids, possibly not discharging both left and right but alternately discharging all left or all right, to establish a swirl pattern run, and to further bank the discharge against the wall to minimize plunge.)
[0038] (Preferably in most embodiments a fourth smaller orifice will discharge a relatively small amount of aerated foam, say less than 150 gpm, directly down the tank wall to land and cover tank surface directly under the unit. Frequently this small fourth discharge port may not be mentioned herein, and in many cases it appears unnecessary. However, it will likely be included in commercial units out of caution.)
[0039] The instant system thus offers a cost effective solution to a costly and dangerous problem. Providing first responding fire fighters with a proper means for successful extinguishment of at least tank rim seal fires, and preferably also means for full surface vapor suppression and means for extinguishing full surface liquid tank fires, by strategically and permanently fixing a relatively few inexpensive components onto a tank, as well as providing supporting tools (monitors, nozzles, hose, and pumps,) should be paramount in considering how to best protect a hazard. Doing so ensures a good relationship with the first responders as well as provides a better solution to large tank hazards.
[0040] To recap and reflect on the development history, a Williams two stage “fully portable” attack for “rim seal fires,” and even for “full surface liquid tank fires,” has been successful. However, as required by the two stage “fully portable” attack, requiring humans to carry hoses up a tank ladder to the tank landing, and to charge the hoses around their feet in order to activate a primary system, presented a personnel risk that was not attractive. Unmanned or largely unmanned fixed systems presented a far more attractive personnel environment. However, any fixed or semi-fixed system must also approach the degree of reliability and flexibility and cost effectiveness as that provided by the two stage “portable” system.
[0041] A surprising discovery, that heightened the reliability, cost effectiveness and flexibility of the instant fixed systems, came with the testing of a landing footprint-enhanced, “aerated” foam nozzle “projecting” aerated foam. The aerated foam nozzle, with tight landing footprint-enhancement, tested to show that it could “throw” aerated foam significantly left and/or right while still landing a predominant portion of that foam in the narrow tank “periphery.” Further, the nozzle could throw or project aerated foam successfully for a significant distance, e.g. at least 20 feet, while landing the foam predominately in the periphery. And the momentum of the “throwing” or the projecting enabled the system to “run” foam, tests showed, a surprising distance, 120 feet both left and right of the nozzle, and to do so very quickly. As a result, a footprint-enhanced aerated foam nozzle could form a suitable cost effective primary fixed means for at least extinguishing rim seal fires. To compare with the Williams prior “portable system,” the prior portable foam wand was only used to establish a “beachhead” directly below the wand, which allowed humans to mount the tank wall at the wand position by the ladder and to put into place the primary fire extinguishing system, fed by hoses running up the ladder. To the contrary, with the instant novel fixed systems, a portable monitor and nozzle, if used, becomes secondary. A “fixed left and/or right wand” becomes the key element of the primary fire extinguishing system for the “rim seal fire.” A further fixed center pointing nozzle covers a full surface fire.
Discussion of Other Discovered Teachings
[0042] The problem of an effective practical reliable design for a fixed fire extinguishing system for tank fires, especially in tanks of diameter of greater than 100 feet and 200 feet, has existed for a long time. Search into existing solutions uncovered the following. Foam Chambers—For example, Blomquist U.S. Pat. No. 3,876,010
[0043] For floating roof seal fires, “foam chambers” or “foam pourers,” discussed above; dropping highly aspirated foam between a tank wall and a floater roof “foam dam” have been a traditional fixed fire fighting system solution. These systems are inadequate to attack a “full surface” fire in a >200 foot diameter tank and likely inadequate for >a 100 foot diameter tank. Their foam run is typically less than 50 feet, so that a large number of such chambers are required. Given the degree of expansion imparted to the foam, the foam run is slow and short and the gpm is limited. Applicant experimented with the common foam chambers to confirm that the run of their highly aspirated foam was only about 40-50 feet in each direction around the tank perimeter or periphery (e.g. in the area between tank wall and the “foam dam” on the floating roof.) And this 40-50 foot run was also relatively slow.
Saval and Knowsley
[0044] A “Saval” apparatus was noticed on the Internet and a similar Knowsley apparatus discovered. This apparatus type proposes two 45° down pointing nozzles, “discharging” left and right, stationed along the wall rim, (as well as a small directly downward discharge). The two 45° nozzles do not discharge “significantly horizontally” and no nozzle is proposed to discharge “toward the center” of the tank. Further Saval's nozzles appear to “bank” their discharges against the tank wall. The effect of banking could be to soften the impact of landing on the liquid and/or to direct more of the foam into the periphery and/or to heighten the aeration. However, one of skill in the art knows that the “banking” technique lessens the lateral force behind the foam, wastes projection energy and reduces foam run capability. Neither Saval nor Knowsley claim a novel or exceptional “foam run” capability. This implies that Saval's and Knowsley's foam run is in the same order as that of the traditional “foam chambers” and/or “foam pourers.” Uribe US Patent Publication No. US 2004/0140106
[0045] Uribe teaches a tank wall mounted fixed system nozzle with an aeration chamber. The degree of aeration is not mentioned. No stream shaper is disclosed. Uribe does not discharge right or left, but only toward the center, as with the Nihilator below. Uribe asserts that eventually his discharged foam will cover a whole tank surface. Since one of ordinary skill in the art knows that foam has a limited lifetime and a limited run, Uribe's statement implies that Uribe's tank is inherently of less diameter than 100 feet.
Nihilator
[0046] Reference to a Nihilator device was located, although the Nihilator appears to be no longer offered as a commercial product. One of ordinary skill might surmise that the Nihilator was not effective. The Nihilator is a center pointing nozzle apparently designed for a fixed roof tank and has an aeration chamber. The Nihilator discharges foam toward the center of the tank and suggests that it be used with traditional foam chambers.
Major Commercial Embodiments
[0047] The instant invention and its related embodiments have several major commercial embodiments. For ease of reference, the current major commercial embodiments are given graphic names.
Primary Target—Floating Roof but No Fixed Roof—Large Tanks
[0048] “Point and Shoot” (semi-fixed) System—Useful for:
Rim seal protection and fire fighting Full surface foam blanket when no fire exists, e.g. for sunken roof vapor suppression
Advantages
[0000]
Each wand can protect up to 240′ of seal rim circumference, as opposed to 40′ or 80′ with conventional foam chambers; therefore fewer wands are needed
Portable monitor and nozzle provides back-up redundancy and vapor suppression capability
Low costs, minimal installation
[0054] “Ambush” (fixed) System—Useful For:
Full surface protection, rim seal fire and fully engaged full surface liquid tank fire (floating roof sunk) Number of systems per tank depends on tank diameter (and product stored) System can be used to extinguish rim seal rim fires with center nozzle valved off so as not to overload a floating roof
Advantages
[0000]
Left/right/center (and possibly down-the-wall) streams can discharge and/or project aerated foam in 3 or 4 directions
System capable of discharging 1900 gpm from each assembly on the largest model
Each wand can protect up to 240′ of seal rim and up to 150′ toward the center
Requires significantly fewer wand installations than prior art
Primary Target
Fixed Roof, Large Tank
[0062] “Hollow Point” (fixed) System—Useful for:
Closed roof, full tank protection
Advantages
[0000]
Easy installation on existing tanks, through existing single 6″ flanged holes.
Each wand can protect up to 240′ of seal rim and up to 250′ toward the center
Incorporates a Teflon vapor seal to stop vapors from traveling down the tube and out aeration holes
Can project 2700 gpm of foam total, via forward and left/right and down streams
Requires significantly fewer wand installations than prior art
[0069] Again, success of the above embodiments may be based in part upon the development of a stream shaper affixed in the tip of the nozzles, which facilitates providing a projecting and forcefully projecting foam nozzle, as well as developing a properly aerated foam for the context.
The Major Commercial Systems and Methodologies
In Greater Detail
[0070] The invention, as introduced and discussed above, relates to various aspects and embodiments for fixed and semi-fixed systems and methods for extinguishing liquid tank fires in large industrial storage tanks. The invention covers tanks with and without fixed roofs and systems that are fixed or semi-fixed, and systems developed primarily for rim seal fires and for full surface liquid tank fires.
The Semi-Fixed System (for Rim Seal Fire and Vapor Protection)—Point and Shoot, Summarized
[0071] The Point and Shoot fixed wand and riser system is a semi-fixed system that can be used immediately for “rim seal fire” protection as well as for vapor suppression. The Point and Shoot fixed wand and riser system is predicated upon the successful rim-seal extinguishments made by Williams using fully portable equipment, as well as the subsequent Daspit Tool development. Given the further development of a proper aeration chamber and a stream shaped nozzle combination, aerated foam nozzle units, or “wands,” fixed to the wall of the tank become a cost-effective primary “rim seal fire” extinguishing means. A further fixed riser, for supplying fire fighting fluid to a portable monitor and nozzle, can provide redundancy in case of damage to the primary system as well as extra full surface vapor suppression capability. (And of course, further independent fixed risers with fixed center pointing nozzles offer a fully fixed full surface fire protection capability.)
[0072] Thus, the semi-fixed Point and Shoot wand and riser system and method provides safer and quicker extinguishment for rim seal fires, as well as a back-up for component disablement or vapor suppression. This minimal fixed wand and riser system requires only strategically permanently affixing a few inexpensive components directly onto a tank. As a consequence of a proper combination of a footprint-enhanced nozzle with a properly aerated foam, the left and right nozzles of a wand can be fixed 220 to 240 feet apart, (as opposed to 40 to 80 feet apart with prior art foam chamber systems.) Thus, the footprint enhanced aerated foam nozzle wand system can be staged as a primary fire extinguishing system for the “rim seal fire” while one or more risers, installed proximate a tank landing and ladder for the quick attachment of portable monitor/nozzles, can be regarded as redundant backup rim seal fire protection, in case of damage to the primary system, and as a capability to provide full surface vapor suppression if a floating roof partially or totally sinks. This semi-fixed system permits attacking a seal fire quickly with much less risk to personnel.
[0073] The semi-fixed elementary system, called the Point and Shoot System, has a recommended layout as follows:
[0000]
Number of Foam Wands for Full
Encirclement Seal Protection
240′ Coverage From Each-24″ Tall Foam Dam Required
at least 220′ coverage from each-12″ tall foam dam
Tank Diameter
No. of Foam Wands Required
0′-76′
1
77′-153′
2
154′-229′
3
230′-306′
4
307′-382′
5
383′-458′
6
Williams Fire and Hazard Control 1-800-231-4613
Note:
The number of prior art “foam chambers” which would be required to protect the above tank sizes is many multiples of the number of the instant novel “foam wands” required, due to the extended coverage of the instant “foam wands” (240′ vs. 80′ or 220′ vs. 80′).
[0074] The Point and Shoot semi-fixed system is particularly applicable for large tanks with no fixed roof for “rim seal fires” and full surface vapor suppression. A major advantage is low cost. The Point and Shoot system is characterized by a pair of aerated foam projecting nozzles attached together in a fixed “wand,” structured to discharge in roughly opposing directions and roughly horizontally. The aerated foam tank wand has been demonstrated to be able to land and run foam approximately 120 feet in each direction in the tank “periphery,” that is the space between the “foam dam” and the tank wall of a floating roof. See below test results. Preferably in addition to the fixed foam wands risers attached to or about the tank wall, at least one additional at least four inch riser is attached to the tank wall to be associated with the tank landing ladder system. The additional riser is structured to communicate fire fighting fluid from approximately the ground to approximately the top of the tank and is structured with a fitting at its end, proximate the top of the tank, the fitting suitable for attaching a portable (at least 150 gpm at 100 psi) monitor and nozzle.
The Fixed System for Floating, not Fixed, Roof—Including Full Surface Fire—Ambush Summarized
[0075] One new primary danger arises from the fact that industrial storage tanks for storing flammable liquids and hydrocarbon products are being constructed of ever greater diameters. Today 405 ′ diameter tanks, and greater, are being constructed. Large scale portable fire fighting nozzles, such as 10,000 gpm, 12,000 gpm or 14,000 gpm nozzles, capable of throwing fire extinguishing and hazard suppressing liquids (water and foam concentrate) over the top of the tank wall typically recite maximum ranges in the 400-500 foot range. Fire fighting foams from the large scale portable nozzles can be relied on to run, at best, approximately 100′. (Conservatively, the foam might only be reliably counted upon to run about 80 feet.) Thus, portable fire fighting nozzles effectively addressing a full surface, fully engaged flammable liquid tank fire in a 405′ diameter tank by throwing foam over the wall from an upwind location probably have to be staged within 100′ of a tank wall. Considerations of logistics as well as the existence of moats, buildings and other equipment and piping around the tanks, and especially considerations of heat and personnel safety, render extremely problematical any tactic requiring approaching a fully engaged full surface liquid tank fire in a 405′ diameter tank closer than 100′.
[0076] Further pressure for improvement comes from the fact that the value, to the tank owner, of a gallon of the product in the tank is also increasing dramatically. Owners of large tanks and of large tank products want the product and the tank to be protected from fire.
[0077] The above considerations incentivized the inventors to develop a fully fixed system, including one or more fixed center pointing nozzles plus an aerated foam wand, preferably a left and right discharging wand but possibly an all left or all right discharging wand. The system is known as the Ambush and provides a first defense for addressing fire and vapor hazards, including full surface liquid tank fires, in all tanks without a fixed roof, but especially in large diameter tanks.
[0078] The Ambush could be implemented in one fashion as a “fixed” Point and Shoot System. The Point and Shoot riser provided with a fitting for attaching a portable monitor and nozzle, located near the tank ladder and landing, could be provided instead with a permanently fixed center pointing nozzle, such as a master stream self-educting nozzle. The riser and nozzle could look and function much like the Hollow Point riser and nozzle, without however the lateral space constraints, the side ports and without the necessity of an aeration chamber. The adjustment of the nozzle could be fixed or set with respect to the tank size and other fixed wands such that the nozzle covers a relevant center portion of the tank surface with foam. No separate ambient air aeration chamber would be required, as known in the master stream fire fighting nozzle field. A separate fixed riser and nozzle need not be limited to being located near a tank ladder and landing. Only so many fixed center directed riser and nozzles need be included as will adequately cover the center portion of the tank surface with foam, in context.
[0079] An Ambush System provides a tailored design of three nozzle units, or wands, preferably with all nozzles using one or two proximate ambient air aeration chambers and all working off of one or two associated risers. These three nozzle units are designed to be installed as units around a tank.
[0080] The three nozzle, fixed, aerated foam wand system includes a set of fixed aerated foam nozzles. This set of nozzles, each referred to as a fixed “wand,” has left and/or right and over the top (toward the center) capability, all with enhanced landing footprints. Preferably the units of three nozzle wands are spaced around, and proximate to, the inner tank wall, each unit preferably providing two nozzles that discharge predominantly left and right, along inner tank wall portions, and a third nozzle that discharges toward the center. Preferably the “toward the center” nozzle discharges at least beyond an approximate 80′ annular ring of foam, anticipated to be created upon an open tank surface by the left and right discharging nozzles. (In some cases the three nozzle wand unit also provides a fourth small port or nozzle to discharge directly beneath the wand and on the inside of the tank wall.) Any disablement of a fixed wand due to a particular fire or hazard or incident can be supplemented by large portable nozzles staged on the ground, throwing foam over the tank wall, as is known in the art.
[0081] The perimeter of a 405′ tank runs approximately 1,250 feet. Testing shows that the instant novel fixed foam wands (Ambush System) should be able to direct foam to run at least 80′ to 90′ in each direction, preferably 120 feet, and to also run the foam 80 ′ or so inward toward the center of the tank. (Again, in addition, a small amount of foam may be discharged directly below the fixed foam wands.) These nozzles could cover the inner tank wall with a roughly 80′ wide annular foam ring, relatively quickly. A third nozzle attached to each fixed wand, preferably with its own aeration chamber, projects foam toward the center of the tank and at least toward the inside of the 80′ annular foam ring being established. Preferably, for a large tank, the third nozzle lands a footprint of foam with a footprint midpoint approximately 90 to 120 feet radially inward of the tank wall. The length of the landing footprint should preferably extend at least 20 to 30 feet forward and backward from the landing midpoint, along the discharge projection line. The landing footprint should preferably spread at least 15 to 20 feet laterally from the discharge projection line. Such a discharge of foam has been shown to be capable of running foam toward and through the center of a 405′ diameter tank. Taking the center projected foam together with the peripherally discharged foam, a total gpm of foam should be selected such that the surface of the tank would be covered with an adequately deep and lasting foam blanket. That is, the gpm of the wands and nozzles should take into account the desired and/or required application rate density for the tank surface.
[0082] This fixed three nozzle open system and methodology has an advantage of concentrating a foam blanket on portions of the tank liquid surface adjacent to the tank walls. The portions adjacent to the tank walls are important because the tank wall itself can retain significant heat. The tank wall typically needs the most cooling. For a 405 foot diameter tank, for instance, seven or eight large three nozzle fixed foam wands might be utilized, each large three nozzle foam wand discharging approximately 2,000 gpm of water/foam concentrate total from its nozzle cluster. In a preferred embodiment a nozzle discharging to the left and to the right might discharge approximately 700 gpm each. A nozzle directed toward the center might project approximately 500-900 gpm toward the center. A small port discharging immediately under the fixed wand might discharge approximately 100 gpm downward.
[0083] Again, to the extent that one or more fixed foam three nozzle wands are disabled by the fire or an explosion, large portable fire fighting nozzles can be staged on the ground and used to supplement the non-disabled portions of the fixed system.
[0084] In the three nozzle fixed aerated foam wand system the discharge orifices for the nozzles preferably contain fins, or stream shapers, to minimize the turbulence in the discharge of aerated foam out of the nozzles. Minimizing turbulence enhances the range and the run of the foam, and tightens the landing footprint.
[0085] One preferred three nozzle fixed aerated foam wand embodiment includes two aeration chambers. The aeration chamber(s) typically consist of tubular jets inserted inside of piping proximate a series of air intake ports, and the chamber is situated proximately upstream of the nozzle discharges. The jets, in a known manner, create a low pressure zone, sucking air in through the ports and mixing the water/foam concentrate with air to create an aerated foam for discharge. Bends incorporated in the conduit between an aeration chamber and a discharging nozzle may enhance the aeration of the foam. No bend may be included between an aeration chamber and a center projecting nozzle, however, to minimally aerate that foam in order to enhance foam throw and run. Discharge from that nozzle has a longer flight time in which to further aerate. Two aeration chambers enable tailoring the aeration more closely to the nozzle purpose.
[0086] Although the three nozzle system was initially designed to address the problem of a very large, fully engaged, full surface liquid tank fire (no fixed roof), such as a fire in an industrial tank having a diameter of 405 feet, the fixed three nozzles aerated foam wand system was quickly seen to have application to tanks of all diameter sizes, and in the situation of either a fully engaged fire or a rim seal fire or simply a need for vapor suppression. The large fixed wand is useful even if a floater remains in place and there is only a seal fire or a need for vapor suppression over the floater. A valve can be provided to eliminate foam discharged toward the center in the case of a rim seal fire.
Fixed Roof Fixed Nozzle System—Hollow Point Summarized
[0087] A fixed roof fixed nozzle wand system has been designed as a direct response to the issues faced by foam chambers when installed on a closed roof tank for the purpose of full surface protection. One wand of the instant fixed roof fixed nozzle system projects foam directly toward the center of the tank as well as left and right to protect near the inner tank walls. The wand unit preferably incorporates a Teflon vapor seal to prevent tank vapors from escaping the tank via the aeration holes in the wand system's supply piping.
[0088] In contrast with foam chambers that simply pour foam onto the surface from the circumference of a tank, such that the foam must run across the liquid surface using only gravity as its means of propulsion via the static head from the piled up foam near the tank wall, the instant fixed roof aerated foam wand discharge head projects foam out into the tank with significant velocity, to push the foam toward the center of the tank. From the same wand foam from interior left/right discharge ports is projected to protect the area near the tank walls.
[0089] As foam accumulates in the center, it will begin to flow outwards back toward the tank walls. The foam at the tank walls will meet and flow toward the center of the tank, closing the gap between the two.
[0090] Each fixed roof wand discharge head is preferably designed to flow 1000 gpm; 600 gpm is delivered through the center stream projecting toward the center of the tank with 200 gpm projecting left and right against the tank wall. This flow rate can be regulated by an internal jet just upstream of the aeration holes. Air is introduced to the stream at the aeration holes by the Venturi effect created by the internal jet. This aerates the foam before it leaves the wand to allow for aerated foam to land on the liquid surface. The ambient air aeration chamber is preferably intended to create a relatively low expansion foam compared to other devices, in order to maintain small bubble foam. This foam is best suited for quickly and effectively running across a liquid surface, thus providing a quick coverage and extinguishment of the tank. One main objective of the fixed roof wand system is to improve upon current methods of closed roof storage tank protection. The fixed roof wand system does so by projecting foam, rather than pouring foam, and by carefully engineered discharge tip sizes and designs coupled with an efficient ambient air aerator and favorable flow rates, stream shapers and stream straighteners.
[0091] One fixed roof wand system recommended layout, for example, is as follow:
[0000]
Number of Hollow Point Systems Required for
Full Surface Protection
1000 gpm Discharge from Each System
Tank Diameter
Discharge Heads Required
0′-103′
1
104′-146′
2
147′-178′
3
179′-206′
4
207′-221′
5
222′-242′
6
242′-262′
7
263′-280′
8
281′-297′
9
298′-313′
10
314′-316′
11
317′-330′
12
Williams Fire and Hazard Control 1-800-231-4613
Note:
The application densities used in the above calculations are based upon an escalating scale from .12 gpm/ft{circumflex over ( )}2 to .14 gpm/ft{circumflex over ( )}2. These numbers are based upon Williams experience with extinguishing large full surface storage tank fires.
Special Methodology—Alcohols
[0092] Alcohols and related liquids and polar solvents are known to attract water out of foam bubbles. Foam, therefore, is preferably landed “lightly” on alcohols or like fluids to minimize the depth of any plunge of the foam below the liquid surface. The inventors teach that a swirl pattern may be preferable for running foam landing on alcohol or the like liquids in the case of fire. Thus the inventors teach, for tanks of alcohol or related liquids or polar solvents, a method of banking discharged foam against inner tank walls prior to landing the foam on the liquid, and discharging the foam predominantly all left or all right, from a plurality of nozzles, to develop a swirl pattern run for the foam in the tank.
Aerated Foam
[0093] The preferred foam for producing the requisite aerated foam for the instant fixed systems is to use an ambient air aeration chamber located just upstream of the nozzles. It is known in the art to produce an aeration chamber just downstream of the nozzle discharge orifice gap. In this sense the word nozzle is used to reference the portion of the barrel that contains the gap, or the swedging down to the narrowest orifice, thereby recovering the greatest head pressure for discharge. Such nozzle discharge orifice gap can discharge into an aeration chamber where aerated foam is produced and is then discharged from the aeration chamber into the atmosphere. U.S. Pat. No. 5,848,752 to Kolacz, in particular FIG. 3 , illustrates this type of foam aeration nozzle. Also, U.S. Pat. No. 4,944,460 to Steingass illustrates this type of aeration foam nozzle. All things being equal, a separate aeration chamber upstream of the nozzle gap is preferred. However, one of skill in the art would recognize that such is not the only way to create aerated foam.
SUMMARY OF MAJOR COMMERCIAL EMBODIMENTS
[0094] The Point and Shoot system, at a minimum, includes installing a one or two nozzle aerated foam wand system, as a fixed system, preferably every 100′ to 240′ around the perimeter of a tank, which should be sufficient to extinguish tank “rim seal fires.”
[0095] A good reason for also installing at least one fixed riser proximate a landing, for releasably affixing a portable monitor and nozzle, together with the above one or two nozzle system, would be to provide redundancy and backup foam protection, in case some fixed system units were damaged due to an explosion, and to provide as well a full surface foam “blanket” for “vapor suppression” should a floating roof of the tank sink. Such a fixed monitor riser would have a fire department connection at the bottom of the tank and a monitor quick disconnect fitting at the top. During an event, if needed, a firefighter could carry a lightweight aluminum monitor and nozzle to the top of a tank and install the monitor on the riser pipe using the quick disconnect fitting (approximately 2 minute installation). From this vantage point, the fire fighter could directly apply foam to needed areas. This maximizes the effectiveness of the resources available to the firefighter. The danger and hazard from laying fire hoses up a ladder on the side of the tank to implement a portable system are avoided. Williams recommends installing a fixed monitor riser pipe at locations near landings of the tank. This fixed monitor riser pipe could also be used to apply foam if necessary to any exposed areas due to a “cocked” roof or in the event a foam wand head has been compromised due to an explosion. This elementary semi-fixed system minimizes initial capital investment for protection of a tank without a fixed roof, at least from a rim seal fire and a sunken roof, while providing a proven system that is easy to operate and to maintain. The equipment eliminates the need to drag multiple hoses up a tank's ladder which impedes firefighters from getting onto or off of the tank quickly.
[0096] The Ambush system is a fixed system particularly applicable for full surface liquid tank fires and/or rim seal fires, including in large tanks, again as above, preferably for tanks without a fixed roof. The Ambush system preferably includes three nozzle aerated foam wands, with two nozzles that discharge in roughly opposing directions and that can be oriented with respect to a tank to discharge roughly horizontally. The third nozzle projects in a direction roughly perpendicular to the discharge axis defined by the first two nozzles. When oriented with respect to the tank, the third nozzle projects roughly toward the center of the tank with an appropriate angle of inclination. The third nozzle is preferably structured to land aerated foam at least 100 feet distant. All three nozzles significantly directionally project aerated foam.
[0097] The Hollow Point system is a fixed system particularly applicable to hazards and fire in large tanks with a fixed roof, and preferably can be installed in and through existing upper tank wall openings. The Hollow Point system is characterized by a conduit ending in a nozzle tip, the conduit having two side discharge ports with associated, largely interior “deflectors.” The ports, conduit and nozzle are structured to pass through existing tank wall openings and to be oriented with the ports discharging in roughly opposing directions, roughly horizontally, and the nozzle tip discharging roughly toward the center. Both the nozzle and ports preferably discharge a substantially focused stream.
[0098] The heightened projection capability and foam run capability of each system described above results in the installation and servicing of significantly fewer units per tank than with previous fixed systems. The new systems can protect significantly larger tanks with less fixed equipment and in less time. A stream shaper installed in the tip of the nozzles contributes to the heightened projection capability of the nozzles, and together with the development of a properly aerated foam, produces a focused stream and optimized foam run.
Testing
[0099] As discussed above, the current accepted fixed system for protecting storage tanks comprises “foam chambers” (sometimes called “foam pourers.”) Fixed foam chambers have limitations, one main limitation being their method of applying foam to a seal area. Either because of (1) the degree of aeration produced by the foam chamber and/or (2) a perceived delicacy of the foam bubble and/or the (3) dispersed footprint discharged, the chamber is structured to only gently “pour” a greatly expanded foam down onto a tank's seal. The foam chamber pours; it does not throw or project. The foam chamber relies on gravity and the head created by the pile of foam to push the foam left and right of the foam chamber. This system severely limits the distance the foam can “run,” left and right of the foam chamber in the seal rim periphery area. This system requires a tank to have a large number of foam chambers spaced around the circumference, every 40 or 80 feet, depending upon whether the “foam dams” of the floating roof are 12″ or 24″. Many tanks are now greater than 300 foot diameter. Some are greater than 400 foot diameter. A 400 foot diameter tank with a 12″ foam dam would require about 23 traditional foam chambers to protect the periphery. The instant invention requires only about 6 units to protect the same periphery.
[0100] In contrast with the currently accepted fixed systems, Williams has developed an improved aerated foam nozzle system to discharge a proven effective foam surprisingly farther, many times farther, in both left and right directions, than traditional foam chambers. Tests show, below, that the instant system covers a larger area in less time with foam that effectively extinguishes fire. Further, a rim mounted nozzle has been also demonstrated that can run foam to the center of a 400 foot diameter tank.
[0101] In December of 2010 a “proof of concept” test was run at the Williams Fire and Hazard Control test facilities. The purpose of the test was to compare and contrast, by observation, two foam application devices flowing into a simulated tank “rim seal periphery area,” the ones between a tank wall and a floating roof “foam dam.”
[0102] The purpose of the test was to determine whether the relative foam flow performance of the novel Williams projecting foam wand could provide the anticipated benefits compared to a conventional “foam chamber.” Foam from both devices was discharged into a simulated floating roof “periphery,” the ones between a tank wall and a floating roof foam dam. For each device the foam traveled through this simulated wall/foam dam “periphery” to reach and extinguish a liquid hydrocarbon pan fire, which was simulating a storage tank floating roof “rim seal fire.” Flow rates and distances were recorded as elements of performance along with the delivered foam quality, foam expansion ratio and drain time.
[0103] The concept being tested was whether the foam applied through a high flow rate projecting foam wand would cover the distance in the seal area more rapidly and protect a larger segment of a floating roof seal along the periphery.
[0104] The observed test confirmed the concept. Foam from the projecting foam wand traveled 3 times the distance (120 feet versus 20 feet) in 25% less time (74 seconds versus 101 seconds from the chamber.) Both successfully extinguished a pan fire at their terminus. The novel foam wand applied foam more rapidly on the target area than the conventional foam chamber. In addition, the novel foam wand provided a gpm per square foot application rate 50% greater (0.6 versus 0.4 US gpm per square foot) than the foam chamber. Simulated periphery dimensions were 2 four inches wide and 2 four inches deep.
[0105] To summarize the test and the results, a novel aerated foam nozzle was set up on a mock seal area with a foam dam and flowed alongside a traditional foam chamber. The NFPA recognized maximum distance for a traditional foam chamber to cover is 80′ total, 40′ to the left and right, for a 24″ foam dam. The traditional foam chamber was able to cover this distance in 1 minute 40 seconds. The novel aerated foam nozzle was able to cover an area three times greater in significantly less time. The aerated foam nozzle covered an area of 240′ ( 120 ′ to the left and right) in 1 minute 14 seconds. It was shown that foam applied through the novel high flow rate wand projecting left and right would cover a foam dam seal area more rapidly, travel further per device, and protect a larger segment of floating roof seal along the periphery.
[0106] Further testing of a fixed Hollow Point wand, discussed above, showed that a roughly 80′×170′ pond of water (13,600 square feet) could be covered in foam with a Hollow Point wand in approximately 1 minute and 25 seconds. The furthest corner of the tank from the nozzle was 145′ away. That furthest corner received ample foam coverage. The speed, run and authority of the foam was surprising.
[0107] Testing of the center nozzle of the Ambush wand, discussed above, also indicated a capacity to achieve an approximately 150′ end range of a center nozzle landing footprint with the mid-point of the landing footprint at about 130′.
[0108] In August 2011 a full Ambush system was tested on a 277 foot diameter empty tank. Six three nozzle wand units were spaced around the periphery of the tank. The total flow per device was 1500 gpm giving a total system flow of 9,000 GPM. The measured footprint size of the center pointing nozzle was approximately 60 feet long by 20 feet wide with a mid-point range of approximately 90′ away from the nozzle. By observation, the total surface of the tank floor was covered with foam. Photographs show testers wading knee deep in foam toward the middle of the tank.
SUMMARY OF THE INVENTION
[0109] The invention addresses fixed fire fighting systems for large industrial tanks and preferably includes two connected nozzles, each structured to project aerated foam of between 100 gpm and 900 gpm in substantially focused streams and in roughly opposing directions. The two nozzles each preferably have a stream shaper in a tip portion of the nozzle with fins of a longitudinal dimension greater than a radial dimension and which terminate substantially flush with a nozzle tip solid bore discharge orifice. The two nozzles preferably are attached proximally downstream of and in fluid communication with at least one ambient air aeration chamber structured in combination with the two nozzles to produce aerated foam having an expansion of between 2-to-1 to 8-to-1. A third nozzle of the fixed system is preferably structured to discharge between 200 gpm and 900 gpm in a direction of within 30° of a perpendicular to the discharge axis defined by the two nozzles discharging in the roughly opposing directions.
[0110] The fixed system preferably includes at least one riser for communicating water and foam concentrate, attached to and in fluid communication with the two nozzles, and possibly the third nozzle. A first riser can be attached to two connected nozzles and a second riser can be attached to a third nozzle, or alternately all nozzles can be attached to a first riser. The second riser can be located proximate to the first riser, or not. A second ambient air aeration chamber may be associated with the third nozzle to produce aerated foam. Preferably the system includes a valve attached upstream of a second ambient air aeration chamber.
[0111] The invention addresses fixed fire fighting systems for large industrial tanks also preferably including at least one first aerated foam projecting nozzle, in fluid communication with and located proximate to and downstream of an ambient air aeration chamber. The nozzle and aeration chamber are preferably structured together for producing foam with an expansion of between 2-to-1 to 8-to-1. The nozzle preferably has a stream shaper in its tip and is affixed to the tank so as to discharge a substantially focused stream roughly horizontally along an upper inner tank wall portion. A centrally directed nozzle is preferably also affixed proximate the top tank wall, located and structured to discharge roughly toward the center of the tank.
[0112] The centrally directed nozzle may be in fluid communication with an aeration chamber located proximate to and upstream of the centrally directed nozzle. The centrally directed nozzle may have a stream shaper in its tip and be structured to produce foam in combination with the aeration chamber having an expansion of 2-to-1 to 8-to-1.
[0113] Preferably there are two aerated foam projecting nozzles affixed to the tank so as to discharge a substantially focused stream roughly horizontally and in roughly opposing directions. Preferably the aerated foam projecting nozzle or nozzles are structured to discharge between 100 gpm and 900 gpm. Preferably the aerated foam projecting nozzle or nozzles are attached to the tank and to a riser attached proximate the tank.
[0114] The invention also addresses fixed systems for fighting fire in large industrial tanks with a fixed roof, preferably including a first ambient air aeration chamber located upstream of, and fluid communication with, and proximate to, a fire fighting nozzle. The first ambient air aeration chamber is preferably structured to produce aerated foam. The fire fighting nozzle preferably includes at least one stream shaper located in a tip portion of the nozzle. The stream shaper preferably has fins with a longitudinal dimension greater than a radial dimension, and the fins preferably terminate substantially flush with a solid bore tip discharge orifice. At least two discharge ports are preferably located in a fluid conduit between the aeration chamber and the nozzle tip with each discharge port having a deflector portion located in the conduit proximate the port for deflecting fluid passing through the conduit out the port. A stream straightener is also preferably located upstream of and proximate the discharge ports. Stream straighteners (for locating upstream of a discharge orifice) are known in the art and can be purchased, for instance, from Elkhart Brass.
[0115] The invention also includes a fixed aerated foam fire fighting system for a tank with a fixed roof including a first ambient air aeration chamber located upstream of, and fluid communication with, and proximate to, a forcefully projecting fire fighting nozzle, forcefully projecting aerated foam in a substantially focused stream, with the aeration chamber structured to produce aerated foam. The invention includes at least two discharge ports in a fluid conduit between the aeration chamber and a nozzle tip, each port having a deflector portion located in the conduit proximate to the port to deflect fluid to the port. The invention preferably includes a stream straightener located upstream of and proximate the discharge ports. (Such mid-stream stream straighteners are known in the art.)
[0116] Preferably the ambient air aeration chamber is structured to produce aerated foam roughly horizontally with an expansion of between 2-to-1 to 8-to-1, and more preferably with an expansion of between 3-to-1 to 5-to-1.
[0117] Preferably the at least two discharge ports are structured to discharge aerated foam roughly horizontally in roughly opposing directions. Preferably the system includes an at least four inch riser structured for communicating fire fighting fluid outside of the tank wall and in fluid communication with the aeration chamber. Preferably a vapor membrane is located between the riser and the aeration chamber.
[0118] The invention also includes an aeration chamber structured to produce aerated foam with an expansion of between 2-to-1 to 8-to-1, and a fluid conduit attached between the aeration chamber and a nozzle tip. The nozzle is structured to forcefully project between 200 gpm and 1000 gpm, at 100 psi, of aerated foam with an expansion of between 2-to-1 to 8-to-1, in a substantially focused stream. The conduit includes a pair of substantially opposing discharge ports with interior deflector surfaces, the surfaces structured to deflect a portion of fire fighting fluid passing through the conduit toward the ports.
[0119] The invention also includes a fixed system fire fighting method for an industrial tank, including projecting aerated foam substantially horizontally along inner tank wall portions in an substantially focused stream from at least one aerated foam projecting nozzle. The method includes producing from the nozzle aerated foam having an expansion of between 2-to-1 to 8-to-1 and forcefully projecting foam from a center directed nozzle roughly toward the center of the tank, the center directed nozzle affixed proximate an inner tank wall portion. Preferably the invention includes projecting aerated foam substantially horizontally along inner tank wall portions from a first and second aerated foam projecting nozzle, roughly horizontally and in generally opposing directions.
[0120] The invention also includes a method for extinguishing fire in a fixed roof large industrial tank, including affixing a conduit, having an aerated foam, forcefully projecting nozzle at its distal end, through an opening at a top portion of a large industrial tank wall. The invention preferably includes forcefully projecting aerated foam, having an expansion of between 2-to-1 to 8-to-1, radially toward the center of the tank in a substantially focused stream and projecting aerated foam through two discharge ports on the side of the conduit, roughly horizontally and in roughly opposing directions, along interior side wall portions of the tank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0121] A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiments are considered in conjunction with the following drawings, in which:
[0122] FIG. 1 illustrates an embodiment of a fixed system having two aerated foam projecting nozzles discharging foam in opposing directions, roughly horizontally, along a top portion of a tank wall and having a third center projecting nozzle connected thereto, with the projecting nozzle and the pair of aerated foam projecting nozzles each having their own ambient air aeration chamber proximately upstream.
[0123] FIG. 2 is a cut-away view of the embodiment of FIG. 1 .
[0124] FIG. 3A indicates the embodiment of FIG. 1 including the attachment of the three nozzles to a single riser located proximate the outside tank wall of a tank.
[0125] FIG. 3B illustrates alternate embodiments for a fixed system with the aerated foam projecting nozzles projecting horizontally along the tank wall and including the center pointing nozzle. FIG. 3B illustrates that the center pointing nozzle can be attached to its own riser, independently of the riser for the pair of aerated foam projecting nozzles projecting horizontally along the inner tank wall.
[0126] FIGS. 4A-4D are drawings illustrating the embodiment of FIG. 3A in detail.
[0127] FIGS. 5A-5H are drawings of the “wand head” of FIG. 3A in detail, the wand head including nozzle wand head with a center pointing nozzle and a pair of left/right foam projecting inner wall nozzles.
[0128] FIG. 6 is relevant because of FIG. 3B . FIG. 3B presents an embodiment where the riser for the center pointing nozzle is separate from the riser for the two left/right directed nozzles. Hence, the center pointing nozzle can actually be located independently and separately from the left/right directed nozzles, using its own riser. Preferably a riser includes a riser top portion, a riser extension pipe and a riser inlet pipe, as illustrated in FIG. 6 .
[0129] FIG. 7 illustrates a foot rest kit to help support an independent riser, also attached by brackets to a tank wall.
[0130] FIG. 8 illustrates with drawings the embodiment of FIG. 6 for establishing a fixed riser proximate a tank wall, useful for attaching a center pointing nozzle.
[0131] FIG. 9 is a table correlating preferred flow rates for the left right pointing nozzle and the center pointing nozzle, referred to as “upper,” to tank diameters.
[0132] FIG. 10 illustrates planning for an arrangement of nozzles of the Ambush system, including the three fixed nozzle type, given a tank size.
[0133] FIG. 11 illustrates a proposed placement of three nozzle fixed wands to cover a fire in a 300 foot diameter tank.
[0134] FIG. 12 illustrates staging three nozzle wands around a 405 foot diameter tank, including gpms.
[0135] FIG. 13 illustrates staging three nozzle fixed wands around a 277 foot diameter tank, including flow per device, effective ranges and footprint size.
[0136] FIG. 14 illustrates a fixed nozzle wand for fitting into an existing opening of a tank with a fixed roof.
[0137] FIG. 15 is a partial cutaway of the nozzle of FIG. 14 .
[0138] FIG. 16 is a side view of the nozzle of FIG. 14 , showing the fixed nozzle wand installed through a tank wall.
[0139] FIG. 17 shows the embodiment of FIG. 14 together with a riser to form a full wand.
[0140] FIG. 18 shows the embodiment of FIG. 14 together with the riser to form a full wand attached to a tank wall.
[0141] FIG. 19 shows the embodiment of FIG. 14 together with the riser, attached to a tank wall and with an indication of further sourcing of water and foam concentrate.
[0142] FIG. 20 illustrates the number of fixed nozzle systems with dual side ports required for full surface protection of a fixed roof tank, by tank diameter.
[0143] The drawings are primarily illustrative. It would be understood that structure may have been simplified and details omitted in order to convey certain aspects of the invention. Scale may be sacrificed to clarity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0144] FIG. 1 illustrates a preferred embodiment of a wand head WH for a fixed fire fighting system for a large industrial tank. The wand head WH is indicated as installed proximate to the tank wall portion TW, in fact utilizing support panel SP for extra support. The nozzles AFPN and CPN of the wand head are located with respect of the tank to discharge just over the tank wall. The embodiment of FIG. 1 includes center pointing nozzle CPN and a pair of aerating foam projecting nozzles AFPN. The aerating foam projecting nozzles discharge substantially horizontally and in roughly opposing directions along an upper interior edge of the tank wall TW. The aerated foam projecting nozzles are shown with a tip portion TP and a stream shaper SS located in the tip having fins FN that terminate substantially flush with the discharge opening DO of the tip. Riser RS passes through the wind girder WG and furnishes water and foam concentrate to the embodiment of three nozzles. Each nozzle is shown with its own ambient air aeration chamber AAAC locating proximate to the nozzle and just upstream of the nozzle.
[0145] FIG. 2 is a partial cutaway of the embodiment of FIG. 1 . The ambient air aeration chambers can be shown to be of a tubular jets type having a tubular jets TJ within ports for drawing in air in a fashion known in the art. The embodiment of FIG. 1 is further illustrated in FIG. 3 showing a full riser RS coming from proximate the ground and rising to proximate the top of the tank wall TW. The riser passes through the wind girder WG.
[0146] FIG. 3B illustrates an alternate embodiment of the instant fixed system invention illustrated in FIG. 3A . In FIG. 3B the center pointing nozzle CPN, although nominally attached to the conduit of the pair of aerated foam projecting nozzles AFPN, has not only its separate ambient air aeration chamber AAAC 2 (from AAAC 1 ) but its separate riser RS 2 (from RS 1 .) Given the configuration of FIG. 3B , it is clear that the center pointing nozzle can actually be physically separated from the wand of the pair of aerated foam projecting nozzles. Each can have their own aeration chamber and each canhave their own riser.
[0147] It becomes further apparent that riser RS 2 not only need not be located next to riser one RS 1 , but the nozzle attached to the second riser could actually be any effective fire fighting nozzle for discharging foam to cover center portions of the tank. It may, but need not have, a proximate ambient air aeration chamber AAAC 2 . It could be a nozzle of the sort that relies upon aeration by virtue of substantial flight of the air.
[0148] FIGS. 4A-4D offer a drawing sheet showing particulars of the wand head of the embodiment of FIG. 1 . FIG. 4C illustrates by dashed lines the roughly horizontal direction and roughly opposing directions of the pair of aerated foam projecting nozzles.
[0149] FIGS. 5A-5G show further details of the wand head of the embodiment of FIG. 1 including drawing cutaways showing the tubular jet TJ in the aeration chamber AAAC, the stream shaper SS and the fins FN therein.
[0150] FIG. 6 illustrates three sections of a potentially free standing riser that might be used to separately locate a center pointing nozzle of any appropriate size and style. These riser portions, including a riser top portion RTP, a riser extension pipe REP and riser inlet pipe RIP, are intended to be joined together and provide a free standing riser for attaching (most likely) a center pointing nozzle. The center pointing nozzle could be fixedly attached, and as discussed previously, need not necessarily include an ambient air aeration chamber. FIG. 7 illustrates a riser foot rest RFR and a bracket BR both useful for securing a riser RS proximate a tank wall. FIGS. 8A-8G illustrates in further detail a riser RS and method and apparatus for securing a riser proximate and adjacent a tank wall, including brackets BR and riser footrest RFR.
[0151] FIG. 9 illustrates figuring a three nozzle fixed wand configuration into a system for tank sizes from 150 foot diameter to a 500 foot diameter. A proposed optimum flow both for the left and right pointing aerating projecting nozzles and for upper and center pointing nozzles is indicated.
[0152] FIG. 10 illustrates calculations that affect the type and number of fixed three nozzle wands required for a tank surface. FIG. 10 indicates that in the annular area, supplied with foam by the aerated foam protecting nozzles, an application rate of 0.10 gpm per square foot is recommended. For the open surface area of the middle of the tank, an application rate of at least 0.16 gpm per square foot is recommended.
[0153] FIG. 11 represents calculations for a fixed system of the instant invention for a 300 foot diameter tank. The tank is shown configured with seven fixed systems discharging left, right, and toward the center. Application rate densities are indicated. Total gpm for all devices is indicated as well as the gpm per three nozzle wand. A gpm against the wall indicated in FIG. 11 comes from a port in the conduit that discharges up to 150 gpm down under any wand as a safeguard.
[0154] FIG. 12 illustrates calculations for a 405 foot diameter tank where ten three nozzle wands are proposed each wand providing 1,300 gpm total against the inner wall and 600 gpm toward the center. FIG. 12 indicates a design of a fixed three nozzle aerated foam wand system for extinguishing a full surface liquid tank fire in a 405 foot diameter tank. Ten dispersing units are prescribed. Each unit is assumed to have three nozzles, one dispersing to the left, one to the right and one toward the center. All three nozzles disperse 600 gpm. In addition 100 gpm is dispersed downward against the wall. (This fourth direction may not be needed, or may be optional). The landing footprints for the ten nozzles discharging toward the center of the tank are predicted to project a footprint to land approximately 150 feet away from the tank wall. The foam should easily run an additional 55 feet or so toward the center, as well as return back toward the wall 30 feet or more to meet foam from the nozzles discharging left and right expanding toward the center of the tank from the walls. The drawing FIG. 12 in addition indicates a fallout region from the discharge path of the nozzles discharging toward the center of the tank. The fallout region supplies foam into mid-radial annular areas of the tank. The drawing indicates a capacity to blanket a 400 foot diameter tank with foam using ten fixed units.
[0155] An attached spreadsheet shows how the three nozzle fixed system can plan and provide a fixed system full surface fire protection for tank sizes from 100 foot diameter to 500 foot diameter.
[0000]
Ambush System
Total Flow
Required
Flow
Actual
Desired
Actual
Distance
to Achieve
Required
Flow
Number
Appli-
Appli-
Surface
Tank
Between
Desired
From Each
Actual
from each
Tank
of
cation
cation
Area of
Circum-
Devices
Application
Device
Total
device
Size
Devices
Density
Density
Tank
ference
(<180)
Density
(<Actual)
Flow
(GPM)
100
2
0.12
0.17
7850
314
157
942
471
1300
650
110
2
0.12
0.14
9499
345
173
1140
570
1300
650
120
3
0.12
0.17
11304
377
126
1356
452
1950
650
130
3
0.12
0.15
13267
408
136
1592
531
1950
650
140
3
0.12
0.13
15386
440
147
1846
615
1950
650
150
4
0.12
0.15
17663
471
118
2120
530
2600
650
160
4
0.12
0.13
20096
502
126
2412
603
2600
650
170
3
0.12
0.15
22687
534
178
2722
907
3300
1100
180
4
0.12
0.17
25434
565
141
3052
763
4400
1100
190
4
0.12
0.16
28339
597
149
3401
850
4400
1100
200
4
0.12
0.14
31400
628
157
3768
942
4400
1100
210
4
0.12
0.13
34619
659
165
4154
1039
4400
1100
220
5
0.12
0.14
37994
691
138
4559
912
5500
1100
230
5
0.12
0.13
41527
722
144
4983
997
5500
1100
240
5
0.13
0.17
45216
754
151
5878
1176
7500
1500
250
5
0.13
0.15
49063
785
157
6378
1276
7500
1500
260
5
0.13
0.14
53066
816
163
6899
1380
7500
1500
270
5
0.13
0.13
57227
848
170
7439
1488
7500
1500
280
6
0.13
0.15
81544
879
147
8001
1333
9000
1500
290
6
0.13
0.14
66019
911
152
8582
1430
9000
1500
300
7
0.13
0.15
70650
942
135
9185
1312
10500
1500
310
8
0.13
0.16
75439
973
122
9807
1226
12000
1500
320
6
0.14
0.14
80384
1005
167
11254
1876
11400
1900
330
7
0.14
0.16
85487
1038
148
11968
1710
13300
1900
340
7
0.14
0.15
90746
1068
153
12704
1815
13300
1900
350
8
0.14
0.16
96163
1099
137
13483
1683
15200
1900
360
9
0.15
0.17
101736
1130
126
15260
1696
17100
1900
370
8
0.15
0.16
107487
1162
145
16120
2015
16800
2100
380
9
0.15
0.17
113354
1193
133
17003
1889
18900
2100
390
9
0.15
0.16
119399
1225
136
17910
1990
18900
2100
400
10
0.15
0.17
125600
1256
126
18840
1884
21000
2100
410
10
0.15
0.16
131959
1287
129
19794
1979
21000
2100
420
9
0.16
0.18
138474
1319
147
22156
2462
24300
2700
430
10
0.16
0.19
145147
1350
135
23223
2322
27000
2700
440
10
0.16
0.18
151976
1382
138
24316
2432
27000
2700
450
11
0.16
0.19
158963
1413
128
25434
2312
29700
2700
460
12
0.16
0.20
166106
1444
120
26577
2215
32400
2700
470
13
0.16
0.20
173407
1476
114
27745
2134
35100
2700
480
13
0.16
0.19
180864
1507
116
28938
2226
35100
2700
490
14
0.16
0.20
188479
1539
110
30157
2154
37800
2700
500
15
0.16
0.21
196250
1570
105
31400
2093
40500
2700
Open Surface
Appli-
Total
Annular Area
Tank
Flow Breakdown (GPM)
Surface
Surface
cation
Upper
Surface
Total
Size
Left
Right
Upper
Wall
Diameter
Area
Density
Flow (GPM)
Area
Flow
100
300
300
0
50
0
0
0.00
0
7850
1300
110
300
300
0
50
0
0
0.00
0
9499
1300
120
300
300
0
50
0
0
0.00
0
11304
1950
130
300
300
0
50
0
0
0.00
0
13267
1950
140
300
300
0
50
0
0
0.00
0
15386
1950
150
300
300
0
50
0
0
0.00
0
17663
2600
160
300
300
0
50
0
0
0.00
0
20096
2600
170
400
400
200
100
10
79
7.64
600
22608
2700
180
400
400
200
100
20
314
2.55
800
25120
3600
190
400
400
200
100
30
707
1.13
800
27832
3600
200
400
400
200
100
40
1256
0.64
800
30144
3600
210
400
400
200
100
50
1963
0.41
800
32656
3600
220
400
400
200
100
60
2826
0.35
1000
35168
4500
230
400
400
200
100
70
3847
0.26
1000
37680
4500
240
500
500
400
100
80
5024
0.40
2000
40192
5500
250
500
500
400
100
90
6359
0.31
2000
42704
5500
260
500
500
400
100
100
7850
0.25
2000
45216
5500
270
500
500
400
100
110
9499
0.21
2000
47728
5500
280
500
500
400
100
120
11304
0.21
2400
50240
6600
290
500
500
400
100
130
13267
0.18
2400
52752
6600
300
500
500
400
100
140
15386
0.18
2800
55264
7700
310
500
500
400
100
150
17663
0.18
3200
57776
8800
320
600
600
600
100
160
20096
0.18
3600
60288
7800
330
600
600
600
100
170
22687
0.19
4200
62800
9100
340
600
600
600
100
180
25434
0.17
4200
65312
9100
350
600
600
600
100
190
28339
0.17
4800
67824
10400
360
600
600
600
100
200
31400
0.17
5400
70336
11700
370
600
600
800
100
210
34619
0.18
6400
72848
10400
380
600
600
800
100
220
37994
0.19
7200
75360
11700
390
600
600
800
100
230
41527
0.17
7200
77872
11700
400
600
600
800
100
240
45216
0.18
8000
80384
13000
410
600
600
800
100
250
49063
0.16
8000
82896
13000
420
800
800
1000
100
260
53066
0.17
9000
85408
15300
430
800
800
1000
100
270
57227
0.17
10000
87920
17000
440
800
800
1000
100
280
61544
0.16
10000
90432
17000
450
800
800
1000
100
290
66019
0.17
11000
92944
18700
460
800
800
1000
100
300
70650
0.17
12000
95456
20400
470
800
800
1000
100
310
75439
0.17
13000
97968
22100
480
800
800
1000
100
320
80384
0.16
13000
100480
22100
490
800
800
1000
100
330
85487
0.16
14000
102992
23800
500
800
800
1000
100
340
90746
0.17
15000
105504
25500
3″-5″
Open Surface
Annular Area
Foam
Seal
Area to Meet
Acceptable?
Equivalent
Tank
Application
Blanket
Seal
Area
1% foam
3% foam
0.16
Actual >=
Open
Size
Density
(minutes)
Area
Time
flow
flow
Requirement
Requirement
Surface
100
0.17
3.7
615
1.3
715
2145
0
YES
0
110
0.14
4.5
678
1.4
715
2145
0
YES
0
120
0.17
3.6
741
1.0
1073
3218
0
YES
0
130
0.15
4.2
804
1.1
1073
3218
0
YES
0
140
0.13
4.9
867
1.2
1073
3218
0
YES
0
150
0.15
4.2
929
1.0
1430
4290
0
YES
0
160
0.13
4.8
992
1.0
1430
4290
0
YES
0
170
0.12
4.3
1055
0.9
2145
6435
3750
YES
69
180
0.14
3.6
1118
0.7
2860
8580
5000
YES
80
190
0.13
4.0
1181
0.7
2860
8580
5000
YES
80
200
0.12
4.4
1243
0.8
2860
8580
5000
YES
80
210
0.11
4.9
1306
0.8
2860
8580
5000
YES
80
220
0.13
4.3
1369
0.7
3575
10725
6250
YES
89
230
0.12
4.7
1432
0.7
3575
10725
6250
YES
89
240
0.14
3.7
1495
0.5
4875
14625
12500
YES
126
250
0.13
4.1
1557
0.6
4875
14625
12500
YES
126
260
0.12
4.4
1620
0.6
4875
14625
12500
YES
126
270
0.12
4.7
1683
0.6
4875
14625
12500
YES
126
280
0.13
4.2
1746
0.5
5850
17550
15000
YES
138
290
0.13
4.5
1809
0.5
5850
17550
15000
YES
138
300
0.14
4.2
1871
0.5
6825
20475
17500
YES
149
310
0.15
3.9
1934
0.4
7800
23400
20000
YES
160
320
0.13
4.4
1997
0.5
7410
22230
22500
YES
169
330
0.14
4.0
2060
0.4
8645
25935
26250
YES
183
340
0.14
4.2
2123
0.4
8645
25935
26250
YES
183
350
0.15
3.9
2185
0.4
9880
29640
30000
YES
195
360
0.17
3.7
2248
0.3
11115
33345
33750
YES
207
370
0.14
4.0
2311
0.4
10920
32760
40000
YES
226
380
0.16
3.7
2374
0.3
12285
36855
45000
YES
239
390
0.15
3.9
2437
0.3
12285
36855
45000
YES
239
400
0.16
3.7
2499
0.3
13650
40950
50000
YES
252
410
0.16
3.9
2562
0.3
13650
40950
50000
YES
252
420
0.18
3.5
2625
0.3
15795
47385
56250
YES
268
430
0.19
3.3
2688
0.3
17550
52650
62500
YES
282
440
0.19
3.5
2751
0.3
17550
52650
62500
YES
282
450
0.20
3.3
2813
0.2
19305
57915
68750
YES
296
460
0.21
3.2
2876
0.2
21060
63180
75000
YES
309
470
0.23
3.1
2939
0.2
22815
68445
81250
YES
322
480
0.22
3.2
3002
0.2
22815
68445
81250
YES
322
490
0.23
3.1
3065
0.2
24570
73710
87500
YES
334
500
0.24
3.0
3127
0.2
26325
78975
93750
YES
346
[0156] FIG. 13 illustrates configuring 6 three nozzle fixed system wands to cover a 277 foot diameter tank. Each device would flow 1500 gpm giving a total system flow of 9000 gpm.
[0157] FIG. 14 illustrates a riser RS and nozzle system appropriate for retro-fitting a tank with a fixed roof. The nozzle is designed such that it can be inserted into an opening near the top of the side of the tank wall. A center pointing nozzle CPN is provided with a tip TP. A pair of ports P are provided on each side of the nozzle, each port having a deflector DF which deflects foam from the conduit out the ports. An ambient air aeration chamber AAAC is provided on top of a riser RS.
[0158] FIG. 15 is a partial cross section of the embodiment of FIG. 14 . It can be seen that a vapor seal VS is present between two flanges just above the jet nozzle TJ of the ambient air aeration chamber AAAC. The vapor seal is ruptured by a water stream when activating of the system. A better view of the deflectors DF proximate the ports P is given with the cutaway view, together with the location of the stream shaper SS and its fins FN in the tip TP of the center pointing nozzle CPN.
[0159] FIG. 16 affords a side view of the embodiment of FIG. 15 , showing the nozzle affixed through a flanged opening FO of the tank wall TW.
[0160] FIG. 17 affords a full wand view of the embodiment of FIG. 14 with the riser RS attached to the wand head and the wand carrying the center pointing nozzle CPN.
[0161] FIG. 18 illustrates again the nozzle embodiment of FIG. 14 installed through an opening FO of a tank wall TW of tank T. FIG. 18 also illustrates the riser RS bringing water foam concentrate from proximate the ground up to the nozzle located proximally a top portion of the tank wall.
[0162] FIG. 19 illustrates a further installation of the nozzle embodiment of FIG. 14 in a tank wall TW under a fixed roof FR and including riser RS.
[0163] FIG. 20 illustrates a computation of the required number of embodiments of a nozzle for a fixed roof in accordance with the embodiment of FIG. 14 , as per tank diameter. Each nozzle as per the embodiment of FIG. 14 is designed to discharge a 1000 gpm total.
[0164] The foregoing description of preferred embodiments of the invention is presented for purposes of illustration and description, and is not intended to be exhaustive or to limit the invention to the precise form or embodiment disclosed. The description was selected to best explain the principles of the invention and their practical application to enable others skilled in the art to best utilize the invention in various embodiments. Various modifications as are best suited to the particular use are contemplated. It is intended that the scope of the invention is not to be limited by the specification, but to be defined by the claims set forth below. Since the foregoing disclosure and description of the invention are illustrative and explanatory thereof, various changes in the size, shape, and materials, as well as in the details of the illustrated device may be made without departing from the spirit of the invention. The invention is claimed using terminology that depends upon a historic presumption that recitation of a single element covers one or more, and recitation of two elements covers two or more, and the like. Also, the drawings and illustration herein have not necessarily been produced to scale.
|
Fixed systems and method for extinguishing large scale industrial tank fires, with and without fixed roofs, and featuring aerated foam projecting nozzles and including fixed center directed nozzles. The invention includes two connected nozzles, which project aerated foam of between in substantially focused streams and in roughly opposing directions. The two nozzles have a stream shaper in a tip portion of the nozzle with fins which terminate substantially flush with a nozzle tip solid bore discharge orifice. The two nozzles preferably are attached proximally downstream of and in fluid communication with at least one ambient air aeration chamber structure in combination with the two nozzles to produce aerated foam. A third nozzle of the fixed system is structured to discharge in a direction of within 30° of a perpendicular to the discharge axis defined by the two nozzles discharging in the roughly opposing directions.
| 0
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FIELD OF THE INVENTION
The invention relates to an actuator for operating a valve, including: A drive component; a drive shaft, which is connectable with the valve; and a torque lock, which is connectable with the drive shaft.
BACKGROUND OF THE INVENTION
Torque locks are already known in the state of the art. Torque locks permit an unhindered rotational driving of a machine part—for example manually—in both directions of rotation, while reverse torques, i.e. those exerted by the driven part on the drive are blocked, as much as possible, in both senses of rotation, without an additional braking device being needed for such function. A torque lock, or load-torque lock, known from DE 85099971 U works according to the jamming rollers, or jamming wedge, principle. In such case, there is arranged within a closed, ring-shaped housing, a suitable cylindrical inner body, which is connected with the output part, thus the part to be driven, such that it cannot rotate relative thereto. The cylindrical inner body has on its periphery a recess, in which each jamming roller sits, pressed outwards by clamping springs. These prevent a rotation of the cylindrical inner body relative to the ring-shaped, outer housing. Arranged between the two jamming rolls is a strut-shaped driving part, which is e.g. a component of a hand wheel. If this driving part is rotated in one or the other direction, one of the two jamming rolls is released against the force of the pressing spring and the driven part can be adjusted. In such case, the second jamming roll then does not carry a load. Reverse torques from the driven part are, in contrast, blocked in both directions.
Rotary drives with torque locks using the jamming rollers principle are used, for example, for position securement on displacing drives for machine parts. Additionally, they serve e.g. for securing and manual adjustment of gate drives, for hatch and window securement, or for rebound protection in the case of control and shutoff butterfly valves. The disadvantage of the known torque locks based on the jamming rollers principle, or also the jamming wedge principle, is that these torque locks can exhibit a relatively critical blocking behavior. Additionally, a relatively high wear is experienced with them, since by the jamming, followed by releasing, of the jamming elements, the contacting parts are subjected to high frictional forces. Due to the wear or due to the slightest deformation of the materials, a continuing worsening of the blocking function can occur.
SUMMARY OF THE INVENTION
An object of the invention is to provide an actuator in which reverse torques from the valve are not transmitted to the drive component.
The object is solved by providing that the torque lock used in the case of the actuator of the invention has at least one essentially rotationally symmetric spring element arranged in a ring-shaped housing, with the torque lock being so constructed that a torque introduced via the drive component sets the drive shaft in rotation and that a torque introduced via the valve blocks the rotation of the drive shaft. Preferably, the spring element is so embodied, that the torque lock works extremely reliable throughout different torque ranges.
In an advantageous further development of the device of the invention, it is provided that the rotationally symmetric spring element is a wrap spring. A special embodiment provides especially that at least one entraining element is provided on the drive component, while at least one blocking piece is arranged on the output drive shaft. Furthermore, the two end regions of the wrap spring are so embodied and arranged that, in the case of an introduction of the torque via the drive component, the at least one entraining element so interacts with the two end regions of the wrap spring that the torque lock is unlocked and the drive shaft turns; in the case of an introduction of torque via the valve, in contrast, the at least one blocking piece so interacts with at least one of the two end regions of the wrap spring that the torque lock blocks. Preferably, the spring wire of the wrap spring has a square cross section. However, the cross section of the spring wire of the wrap spring can also be round. The load, or torque, introduction into the wrap spring occurs preferably via bent spring ends. The bent spring ends are optimized with reference to strength such that the torque lock works with a high degree of process stability.
In principle, the drive component can be any kind of drive. By way of example, a direct drive can be mentioned, which, for the actuator of the invention, must be so constructed that it produces a high torque at small rotational speeds. Furthermore, the drive component can be an electric motor, or an electric motor with a reduction transmission coupled therewith. Additionally, the drive component can be a separately operable, adjustment wheel, or a separately operable adjustment wheel with a reduction transmission coupled thereto. Preferably, the separately operable adjustment wheel is a hand wheel.
A preferred form of embodiment of the actuator of the invention provides a second reduction transmission, which is arranged between the valve and the torque lock. Especially a worm transmission is installed as the second reduction transmission. Worm transmissions are usually constructed such that they exhibit an intrinsic self-locking. It is true that this does reduce overall efficiency; however, the intrinsic self-locking can effectively prevent an accidental and undesired rotation of the drive shaft. As a result of the self-locking, the drive shaft moves only after a defined torque, which balances the self-locking, is exceeded. This points out a decided advantage of the actuator of the invention: Since the actuator has a torque lock, the intrinsic self-locking of the reduction transmission can be omitted. This embodiment of the actuator of the invention therefore exhibits an increased overall efficiency, compared with the known solution.
Advantageously, the torque lock used in the case of the actuator of the invention is embodied as an integral part of the drive component. However, an alternative form of embodiment provides that the torque lock is an independent function module, which is so embodied and constructed that it can be coupled to the drive shaft. This embodiment permits the retrofitting of any actuator with the torque lock of the invention.
BRIEF DESCRIPTION OF THE INVENTION
The invention will now be explained in greater detail on the basis of the drawings, the figures of which show as follows:
FIG. 1 a : a schematic drawing of a first embodiment of the actuator of the invention;
FIG. 1 b : a schematic drawing of a second embodiment of the actuator of the invention;
FIG. 2 : a model-like, exploded drawing of a preferred form of embodiment of the torque lock of the invention;
FIG. 3 : a longitudinal section through a preferred embodiment of the torque lock of the invention; and
FIG. 3 a : a cross section taken according to the cutting plane A-A of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 a and 1 b are schematic representations of alternate forms of embodiment of the invention. In the case of the form of embodiment shown in FIG. 1 a , the drive component 3 operates the valve 2 directly via the drive shaft 4 . Valve 2 is preferably an adjusting element 2 , e.g. a globe or gate valve, each with spindle and threaded bushing, a throttle valve or butterfly valve. Depending on the adjusting element 2 , the operating, or displacement process, which is introduced via the drive component 3 , is a rotary, or swinging or pivoting, movement. The drive component 3 is preferably a direct drive 11 . However, it is also possible to insert a first reduction transmission 20 after the electric motor. Of course, alternatively or additionally to the electric drive component 3 , also a separately operable adjustment wheel, e.g. a hand wheel, can be used for manual operation of the valve. The torque lock 5 is associated with the drive shaft 4 .
FIG. 1 b shows a schematic representation of a second embodiment of the actuator 1 of the invention. The form of embodiment shown in FIG. 1 b differs from that shown in FIG. 1 a by a second reduction transmission 12 , which is arranged between the torque lock 5 and the valve 2 at the torque lock output drive shaft 4 b . The reduction transmission 12 is preferably a worm transmission. Worm transmissions usually exhibit an intrinsic self-locking, which should suppress unintended rotations of the drive shaft 4 . This embodiment of an actuator 1 is especially advantageous, since, due to the interposed torque lock 5 , this intrinsic self-locking of the worm transmission 12 can be omitted, whereby the overall efficiency of the actuator 1 can be improved.
FIG. 2 presents a model-like, exploded representation of a preferred form of embodiment of the torque lock 5 of the invention. Essential components of the torque lock of the invention are the wrap spring 7 and a drive shaft divided in two parts, with an entraining mechanism 8 on the drive input side and a blocking mechanism 9 on the drive output side. An entraining element 8 is attached to the torque lock input drive shaft 4 a ; the blocking piece 9 is attached to the torque lock output drive shaft 4 b . The entraining element 8 has the form of a portion of a hollow cylinder. The two end regions 21 , 22 of the entraining element 8 lie against the insides of the spring ends 10 a , 10 b of the wrap spring 7 .
Wrap spring 7 is arranged in the blocking ring 6 . Preferably, the spring wire of the wrap spring 7 has a square cross section. However, the cross section of the spring wire of the wrap spring 7 can also be round.
Blocking piece 9 is, as already indicated, provided on the torque lock output drive shaft 4 b . Blocking piece 9 is composed of portions of cylindrical surfaces. The radial boundary surfaces form the end regions 23 , 24 of the blocking piece 9 . The first end region 23 , or the second end region 24 , acts, in the case of a torque introduction coming from the direction of the valve 2 , respectively, on the bent spring end 10 a , or on the bent spring end 10 b . The bent spring ends 10 a , 10 b are, moreover, optimized with respect to strength in a manner such that the torque lock 5 functions process stably in high degree.
As soon as the torque lock input drive shaft 4 a turns as a result of a torque introduction coming from the direction of the drive component 3 , the entraining element 8 drives, with the pertinent one of the end regions 21 , 22 , the wrap spring 7 via the inner side of the pertinent spring end 10 a , 10 b . This releases the wrap spring 7 from the blocking ring 6 , whereby a turning of the output drive shaft 4 is permitted.
If, in contrast, a reverse torque is introduced from the direction of the valve 2 via the torque lock output drive shaft 4 b , then, depending on the turning direction, either end region 23 or end region 24 of the blocking piece 9 presses on the outside of the pertinent spring end 10 a or 10 b . This causes the wrap spring to be pressed with amplified force against the blocking ring 6 . As a result of this pressing, a rotation of the drive shaft 4 is effectively prevented. As soon, in turn, an introduction of a torque occurs from the direction of the drive component 3 , the wrap spring 7 is again released from the blocking ring 6 , and the blocking action of the torque lock 5 is canceled.
FIG. 3 shows a detailed drawing of a longitudinal section through a preferred embodiment of the torque lock 5 of the invention. FIG. 3 a provides a cross section according to the cutting plane A-A of FIG. 3 . The torque lock 5 of the invention is arranged in a housing 13 with adapted flange 18 . The torque lock 5 is arranged on the drive shaft 4 .
Essential components of the torque lock 5 are the wrap spring 7 , which is positioned in the blocking ring 6 , the torque lock input drive shaft 4 a with the entraining element 8 , and the torque lock output drive shaft 4 b with the blocking piece 9 . Of course, the torque lock 5 could be designed such that the blocking ring 6 is part of the housing 13 . Spacers 19 a , 19 b serve to determine the axial position of the wrap spring 7 .
The torque lock 5 is mounted on the drive shaft 4 via bearings 15 a , 15 b , 15 c . In the illustrated case, the bearings 15 a , 15 b are ball bearings, while bearing 15 c is embodied as a needle bearing. Moreover, the torque lock 5 is sealed relative to the drive shaft 4 via the seals 14 a , 14 b , 14 c , which are preferably O-rings. The part of the housing 13 facing the drive component 3 (not separately shown in FIG. 3 ) is embodied as a flange in the illustrated case.
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Actuator for operating a valve, including: a drive component; a drive shaft, which is connectable with the valve; and a torque lock, which is connectable with the drive shaft The torque lock includes at least one essentially rotationally symmetric spring element arranged in a ring-shaped housing, and is so constructed that a torque introduced via the drive component causes the drive shaft to rotate, and a torque introduced via the valve blocks rotation of the drive shaft.
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[0001] This invention was made with Government support under Contract DE-AC0676RLO1830 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a method of storing data. In particular, but not exclusively, the present invention relates to storage of data as encoded DNA in living organisms.
BACKGROUND OF THE INVENTION
[0003] A data preservation problem looms large behind today's information superhighway. All current storage (e.g. paper, magnetic media, silicon chips) media require constant attention to maintain their information content. People or natural disasters can easily destroy all of them intentionally or accidentally. With the large amount of information generated by our society every day, it is time to think of a new generation of data memory.
[0004] The use of deoxyribonucleic acid (DNA) as a component of memory storage has been proposed for a number of reasons. For example, DNA as a memory medium is compact. One cubic centimeter of DNA in solution could store 10{circumflex over ( )}21 bits of information, whereas, a current conventional computer has a memory of at most 10{circumflex over ( )}14 bits. Also, most computers operate linearly, one block of data after another. Biochemical reactions are highly parallel in operation. That is a single biochemical operation can affect trillions of DNA strands in a test tube.
[0005] Heller et. al. (U.S. Pat. No. 5,787,032) describe the use of synthetic DNA polymers as an optical storage media for memory. Clelland et. al. reported in Nature (Vol. 399, Jun. 10, 1999, pp. 533-34 or www.nature.com) that encoding meaningful information as DNA sequences is possible. The authors conducted an experiment wherein an encoded DNA strand was hid behind a period (i.e., a dot) of a printed document. The document was then sealed and mailed to its owners using regular US Postal Service. The embedded message was successfully recovered in a lab environment. This work proved that a DNA strand can be a substitute for a piece of paper in terms of information storage. However, a naked DNA molecule can easily be destroyed when exposed to unfavorable environmental conditions such as excessive temperature or dessication/rehydration. Even nucleases in the environment may degrade the DNA molecules over time. Therefore, exploiting DNA as a memory medium would require an effective protective storage medium.
[0006] Establishing memory of stored information in a living organism can provide adequate protection for the encoded DNA strands. By providing a living host for the DNA—one that can tolerate the addition of “artificial” gene sequences and survive extreme environmental conditions. Perhaps more importantly, the host needs to be able to grow and multiply with the embedded information. Propagation of a host for memory embodied in DNA can allow for preservation and continuation of the stored memory, as well as protecting the integrity of the information contained in the memory. As well there is opportunity to utilize this capability to store purposeful information.
SUMMARY OF THE INVENTION
[0007] With a careful coding scheme and arrangement, applicants have invented a process to encode data or information as an artificial DNA strand and store it in a living host safely and permanently. The instant invention can be used to identify origins and protect R&D investments (i.e., DNA watermarking) such as agricultural products and rare animals. For example, the present invention allows for storage of data that comprises specific information about the host organism. The agricultural industry can use this invention to “label” crops. By storing various data regarding the particular plant, including origin, type, generation, etc., the agricultural industry can then rely on this information at a later date (e.g., when produce hits the market). It can also be used in environmental research to track generations of organisms and observe the ecological impact of pollutants. Today, there are microorganisms that can survive heavy radiation exposure, high temperatures, and many other extreme conditions. These hardy microorganisms can serve as memory hosts and protect the stored data or information. There are living organisms such as weeds and cockroaches that have existed on earth for hundreds of millions of years. These organisms are excellent candidates as well for preserving critical information for a future civilization.
[0008] Therefore, one embodiment of the present invention is a method of storing data in a living organism wherein at least one DNA sequence is encoded to represent data and incorporated into a living organism.
[0009] Another embodiment of the present invention is to provide sequences encoded to represent data with other sequences not specifically coded and incorporating them into a living organism for the purpose of memory storage.
[0010] Yet another embodiment of the present invention is to provide a method of storing programmed data into a living organism.
[0011] Still another embodiment of the present invention is to provide a memory storage system wherein DNA, encoded to represent data, is stored in a living organism.
[0012] Yet another embodiment of the present invention is to provide a method of storing editable data in a living organism.
[0013] Still another embodiment of the present invention is to provide a method of storing programmed data that responds to a stimulus into a living organism.
[0014] Yet another embodiment of the present invention is to provide a method of storing information that responds to a stimulus and reacts to specific encoded programming into a living organism.
[0015] Still another embodiment of the present invention is to provide a memory storage system wherein a living organism comprises at least one DNA sequence encoded to represent data, which is incorporated into the native DNA of a living organism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A more complete appreciation of the invention will be readily obtained by reference to the following Description and the accompanying drawings in which like numerals in different figures represent the same structures or elements, wherein:
[0017] [0017]FIG. 1 is a simplified schematic diagram of the process of present invention.
[0018] [0018]FIG. 2 is an illustration of a plasmid vector with encoded DNA inserted.
[0019] [0019]FIG. 3 is a graphical illustration of the encoded DNA sequence and the decoded message.
[0020] [0020]FIG. 4 shows an example of a DNA sequence of a song phrase.
DETAILED DESCRIPTION
[0021] The present invention comprises a method of storing data in a living organism, wherein at least one DNA sequence is encoded to represent data and is thereafter incorporated into the living organism. The method of the present invention comprises encoding DNA to represent specific data by selecting at least 2 of the four DNA nucleotide bases to represent specific text and arranging the nucleotide bases in a manner to represent the data. Encoding the DNA bases to represent specific data can be achieved in numerous and varied ways and the embodiments set forth herein are not meant to be exclusive, but rather exemplify the broader aspects inherent to the present invention.
[0022] The present invention comprises a method of storing data in a living organism by incorporating encoded DNA into a viable cell of said living organism. FIG. 1 shows a simplified schematic of one aspect of the present invention. Firstly, the data to be stored is encoded into a DNA sequence. The four-nucleotide bases associated with a DNA sequence are assembled to represent the specific data by correlation with a specific code. For example, three of the four basic nucleotide bases (Cytosine or C, Guanine or G, Thymine or T and Adenine or A) can be assigned to represent a text character. A string of DNA nucleotide bases can then be assembled to represent text information or data. Once the specific data has been encoded into a DNA sequence, it is then inserting into a vector that will provide as a “vehicle” for transport into a living organism. A vector is a DNA molecule originating from a virus, a plasmid, the cell of a higher organism or synthetically assembled, into which another DNA fragment of appropriate size can be integrated without loss of the vectors capacity for self-replication; vectors introduce foreign DNA into host cells, where it can be reproduced in large quantities. Vectors can be selected from the group consisting of plasmids, cosmids, and yeast artificial chromosomes, and recombinant molecules containing DNA sequences. The vector comprising the encoded DNA is then introduced into a viable cell of a living organism. It is understood by those skilled in the art that DNA bases can be incorporated into a living cell in different ways and the particular vectors used and specific methodology is dependant upon the type of host cell. Once the vector is inside the cell of the host living organism, it can reside and be stored indefinitely. The vector DNA, along with the encoded DNA will be regenerated and coexist with the hosts genomic DNA.
[0023] The stored data can than be retrieved by means currently know by those skilled in the art. Stored data can be retrieved by standard PCR amplification method as PCR product (DNA fragment). Standard DNA sequencing method such as the dideoxy termination method can then identify the stored information within the amplified PCR product. Alternatively, stored information within the PCR product can be determined by hybridization with a panel of known oligonucleotides. Once the data is retrieved, it is then encoded and the original message is obtained.
[0024] Another aspect of the invention is to encode the DNA to represent data that is programmed data. The programmed data can then be programmed to accomplish an activity, continue a communication process, and even respond to a stimulus that will then result in an action. For example, we can construct a gene fusion between a hydrogen-peroxide-inducible promoter with a lysozyme gene, which will kill the bacteria if we add hydrogen peroxide to the engineered bacteria. We can also construct gene fusion with a regulatory gene, which will trigger a cascade of genetic responses (in our case is information). Gene fusions technique is a very common technique that has been used in studying bacterial gene regulation such as the use of green fluorescent protein.
[0025] The living organism utilized in the present invention can be single-celled or multi-cellular, prokaryotic or eukaryotic. Although bacterial cells serve well as host organisms to demonstrate the present invention, it is understood that other living cells can be utilized as well.
[0026] Another aspect of the present invention is the storage of data in multicellular living organisms. This embodiment of the present invention can be achieved by incorporating at least one DNA sequence encoded to represent data into a germ cell; a precursor cell that gives rise to gametes that will then serve as specialized haploid cells (sperm or egg) in sexual reproduction, or stem cell; a relatively undifferentiated cell that will continue dividing indefinitely, throwing off (producing) daughter cells that will undergo terminal differentiation into particular cell types. The encoded DNA sequence will then propagate into a multicellular living organism. This embodiment of the invention is a memory storage system that takes advantage of multicellular organisms (e.g., insect, rodent) and serves to propagate the encoded DNA sequence in all daughter cells stemming from the original host stem cell.
[0027] The present invention comprises a memory storage system wherein a living organism comprises therein at least one DNA sequence encoded to represent data. The stored data resides in a living organism and remains there until recovery is desired. The data is then retrieved and decoded so as to enable communication. Like a computer memory device that can store data and programs, the present invention comprises the same or similar items in a DNA memory system. Unlike a computer compiled software program, a program in a DNA memory system can comprise a set of rules, options, or instructions that respond to specific circumstantial or environmental conditions. In other words, the living organism will detect stimuli condition as well as react according to the information or instructions encoded in the DNA sequence. The host cell of the living organism should not express the non-native encoded DNA (artificial to the genomic DNA of the organism) and cause destructive consequences such as toxic effects. It is desired to custom-design an encoded DNA sequence that will respond to specific events and cause the host cell of the living organism to react or change. Therefore, the present invention provides a unique nano-scaled event detection tool that will detect and respond to a plurality of stimuli based on the programming encoded into the DNA that is incorporated into a host cell of a living organism.
[0028] For a clear and concise understanding of the specification and claims, including the scope given to such terms, the following definitions are provided:
[0029] As used herein, the word ENCODE means to express given data or information by means of a code.
[0030] As used herein, the word DATA means Information of any form that is used for communication, analysis, and or reasoning in making decisions.
[0031] Cells to be used as a carrier of the encoded DNA needs to be made competent using standard methods and will uptake the encoded DNA molecules. This can be achieved by either chemical transformation or electroporation methods.
EXAMPLE 1
[0032] DNA Host Identification—Two well-understood bacteria, Escherichia coli ( E. coli ) and Deinococcus radiodurans ( D. radiodurans ), were utilized for our experiment. We selected E. coli and D. radiodurans because microorganisms, in general, grow very rapidly and the embedded information can be inherited rapidly and continuously. Deinococcus, survive extreme conditions such as ultraviolet, desiccation, partially vacuum environments, and ionizing radiation up to 1.6 million Rad (about 0.1% of the same radiation dose would be fatal to human beings). Some strains of Deinococcus can also tolerate high temperature. Although bacteria were chosen as preferred embodiments, it is understood that any living cell, whether single-celled or multicellular organism, can be used in the use of this invention.
[0033] Information Encoding—A (Adenine), C (Cytosine), G (Guanine), and T (Thymine) were used to assemble a DNA sequence information stream to represent data. Table 1 depicts the encoding key for a set of triplets—a DNA sequence with any 3 of the 4 basic units. It is recognized that other types and methods of coding information can be utilized and this example is not meant to be exclusive to this invention.
TABLE 1 DNA encoding table AAA-0 AAC-1 AAG-2 AAT-3 ACA-4 ACC-5 ACG-6 ACT-7 AGA-8 AGC-9 AGG-A AGT-B ATA-C ATC-D ATG-E ATT-F CAA-G CAC-H GAG-I CAT-J CCA-K CCC-M CCG-M CCT-N CGA-O CGC-P CGG-Q CGT-R CTA-S CTC-T CTG-U CTT-V GAA-W GAC-X GAG-Y GAT-Z GCA-SP GCC-: GCG-, GCT-- GGA-. GGC-! GGG-( GGT-) GTA-{grave over (+0 )} GTC-′ GTG-“ GTr-” TAA-? TAC-; TAG-/ TAT-[ TCA-] TCC- TCG- TCT TGA- TGC- TGG- TGT- TTA- TTG- TTG- TTT-
[0034] Unique DNA Searching—The entire genomic sequence of E. coli and D. radiodurans are known. A number of fixed-size sequences (20-base pairs) were identified. Several criteria were used to identify these set of 20-mers—1. these sequences do not exist in either Deinococcus radioduran or Escherchia coli genome; 2. the 20-mer will not have complimentary sequence with more than four bases at the 3′ end, e.g -AATT or -CCGG at 3′ end; 3. the GC content of the 20-mer will be in the range of 40 to 60%; 4. the 20-mer will have at least any two of TAG, TAA or TGA stop codons. Criteria 1 to 3 will provide unique tags for subsequent PCR retrieval of encoded DNA, while criterion 4 will prevent the formation of fusion proteins that may be detrimental to the host bacterium. These sequences ensure that no unnecessary mutations or damage to the bacteria result. The sequences will serve as sentinels to tag the beginning and end of the embedded messages—similar to the file header and footer in a magnetic tape—for later identification and retrieval. Of the 10 billion potential candidates in the bacterium Deinococcus, we found only 25 qualified sequences that are acceptable for our experiments. A brutal force computational analysis is used to compute this set of 20-mers. There is 4 20 combinations of 20-mers. All the 20-mers do not have GC content (% of G or C within the 20-mer) between 40 to 60% were eliminated, and then the 4.1 million 20-mer exist in Deinococcus radiodurans were eliminated. Finally, sequences with complementary 3′ end (-AATT,-TTAA,-GGCC,-CCGG,-ATAT,-TATA,-GCGC,-CGCG), SEQ ID.: 1 were eliminated. The remaining 20-mer was searched for the presence of stop codons. The sequences shown in Table 2 are the identified DNA sequences used to design oligonucleotides (oligos) used herein. Multiple stop codons (i.e., triplets such as TAA, TGA, and TAG) are present in many of the sequences. These codons discourage the host from “reading” the non-native DNA that has been encoded to represent data, and subsequently producing chimeric proteins that may be harmful to the bacteria.
TABLE 2 25 20-base Pair Sequences Utilzed Herein. SEQ ID NO.: 2 AAGGTAGGTAGGTTAGTTAG SEQ ID NO,: 3 AGGTTTGGTGGTATAGTTAG SEQ ID NO.: 4 ATAGGAQTGTGTGTAGTTAG SEQ ID NO.: 5 ATATTAGAGGGGGTAGTTAG SEQ ID NO.: 6 GGAGTAGTGTGTATAGTTAG SEQ ID NO.: 7 GGGAGTATGTAGTTAGTTAG SEQ ID NO.: 8 GGTTAGATGAGTGTAGTTAG SEQ ID NO.: 9 TAAGGGATGTGTGTAGTTAG SEQ ID NO.: 10 TAGAGGAGGGATATAGTTAG SEQ ID NO.: 11 TAGATGGGAGGTATAGTTAG SEQ ID NO.: 12 TAGGAGAGATGTGTAGTTAG SEQ ID NO.: 13 TATAGGGAGGGTATAGTTAG SEQ ID NO.: 14 TGTGGGATAGTGATAGTTAG SEQ ID NO.: 15 AGAGTAGTGAGGATAGTTAG SEQ ID NO.: 16 ATAAGTAGTGGGGTAGTTAG SEQ ID NO.: 17 ATGGGGTATGGATAGTTAG SEQ ID NO.: 18 ATGGGTGGATTGATAGTTAG SEQ ID NO.: 19 GGGAATAGAGTGTTAGTTAG SEQ ID NO.: 20 GGGATGATTGGTTTAGTTAG SEQ ID NO.: 21 GTATGGGAATGGTTAGTTAG SEQ ID NO.: 22 TAGAGAGAGTGTGTAGTTAG SEQ ID NO.: 23 TAGAGTGGTGTGTTAGTTAG SEQ ID NO.: 24 TAGATTGGATGGGTAGTTAG SEQ ID NO.: 25 TAGGGTTGGTAGTTAGTTAG SEQ ID NO.: 26 TATAGGGTAGGGTTAGTTAG
[0035] Laboratory Procedures and Results
[0036] Two 46-mer complementary oligos were created, each comprising two different 20-mer oligos connected by a 6-base pair long restriction enzyme site. The two 20-mer oligos were created from two different sequences listed in Table 2. The restriction enzyme site was to prepare for later encoded DNA fragment insertion. These two 46-mer long complementary oligos form a double stranded 46-base pair DNA fragment. The DNA fragment was then cloned into a recombinant plasmid as illustrated in FIG. 3 where two 20-mer long oligos 104 serve as “sentinels placed at the beginning and end of the inserted encoded DNA 102 , which was then incorporated into plasmid vector 100 . Because the two 20-mer oligos do not exist in the genome of the host, they served as identification markers for later message retrieval. The stop codons in these two oligos also help protect the message as well as the host from any potential damage. Table 3 shows the phrases considered for insertion, along with their respectively coded sequences. For this experiment, each phrase used (2, 3, 4, 5, 8,9,11) was inserted into a different single cell of D. radians . The present invention can be practiced such that all of the desired phrases are inserted into the same single cell or individual phase can be inserted into different cell. Two complimentary oligos (5′AGAGTAGTGAGGATAGTTAGAGATCTCTCTAATCACACACATCTCA3′, SEQ ID NO.: 27 and 5′TGAGATGTGTGTGATTAGAGAGATCTCTAACTATCCTCACTACTCT3′), SEQ ID NO.: 28 containing two arbitrarily chosen 20-mer tags (5′AGAGTAGTGAGGATAGTTAG3′, SEQ ID NO.: 29 5′TGAGATGTGTGTGATTAGAG3′), SEQ ID NO.: 30 arbitrarily selected from Table 2, were chemically synthesized. These two chemically synthesized oligos (46-mer) were allowed to anneal to each other to form a 46 bp DNA fragment, which was cloned into a cloning vector, pCR-blunt (InVitrogen Inc.). A BglII restriction enzyme site, AGATCT, was built in within 46 bp DNA fragment. As a result, encoded DNA message can be cloned into the BlgII site by standard cloning procedure, and the message can be retrieved with that pairs of tags or primer pairs present within the plasmid vector. (See FIG. 2)
TABLE 3 Stored Data Utilized Herein 1 A WORLD OF TEARS, 2 AND A GOLDEN SUN, 3 AND A SMILE MEANS 4 AND A WORLD OF FEARS, 5 AND THE OCEANS ARE WIDE, 6 FRIENDSHIP TO EVERYONE, 7 IT IS TIME WE'RE AWARE. 8 IT'S A SMALL SMALL WORLD. 9 IT'S A SMALL WORLD AFTER ALL, 10 IT'S A WORLD OF HOPES 11 IT'S A WORLD OF LAUGHTER, 12 IT'S SMALL SMALL WORLD. 13 THERE IS JUST ONE MOON 14 THERE'S SO MUCH THAT WE SHARE, 15 THOUGH THE MOUNTAINS ARE HIGH, SEQ ID NO.: 31 1 AACGCAAGGGCAGAACGACGTCCCATCGCACGAATTGCACTCATGAGGCGTCTAGCG SEQ ID NO.: 32 2 AAGGCAAGGCCTATCGCAAGGGCACAACGACCCATCATGCCTGCACTACTGCCTGCG SEQ ID NO.: 33 3 AATGCAAGGCCTATCGCAAGGGCACTACCGCAGCCCATGGCACCGATGAGGCCTCTA SEQ ID NO.: 34 4 ACAGCAAGGCCTATCGCAAGGGCAGAACGACGTCCCATCGCACGAATTGCAATTATGAGGCGTCTAGCG SEQ ID NO.: 35 5 ACCGCAAGGCCTATCGCACTCCACATGGCACGAATAATGAGGCCTCTAGCAAGGCGTATGGCAGAACAGATCATGGCG SEQ ID NO.: 36 6 ACGGCAATTCGTCAGATGCCTATCCTACACCAGCGCGCACTCCGAGCAATGCTTATGCGTGAGCGACCTATGGCG SEQ ID NO.: 37 7 ACTGCACAGCTCGCACAGCTAGCACTCCAGCCGATGGCAGAAATGGTCCGTATGGCAAGGGAAAGGCGTATGGGA SEQ ID NO.: 38 8 AGAGCACAGCTCGTCCTAGCAAGGGCACTACCGAGGCCCCCCGCACTACCGAGGCCCCCCGCAGAACGACGTCCCATCGGA SEQ ID NO.: 39 9 AGCGCACAGCTCGTCCTAGCAAGGGCACTACCGAGGCCCCCCGCAGAACGACGTCCCATCGCAAGGATTCTCATGCGTGCAAGGCCCCCCGCG SEQ ID NO.: 40 10 AACAAAGCACAGCTCGTCCTAGCAAGGGCAGAACGACGTCCCATCGCACGAATTGCACACCGACGCATGCTA SEQ ID NO.: 41 11 AACAACGCACAGCTCGTCCTAGCAAGGGCAGAACGACGTCCCATCGCACGAATPGCACCCAGGCTGCAACACCTCATGCGTGCG SEQ ID NO.: 42 12 AACAAGGCACAGCTCGTCCTAGCACTACCGAGGCCCCCCGCACTACCGAGGCCCCCCGCAGAACGACGTCCCATCGGA SEQ ID NO.: 44 13 AACAATGCACTCCACATGCGTATGGCACAGCTAGCACATCTGCTACTCGCACGACCTATGGCACCGCGACGACCT SEQ ID NO.: 45 14 AACACAGCACTCCACATGCGTATGGTCCTAGCACTACGAGCACCGCTGATACACGCACTCCACAGGCTCGCAGAAATGGCACTACACAGGCGTATGGCG SEQ ID NO.: 46 15 AACACCGCACTCCACCGACTGCAACACGCACTCCACATGGCACCGCGACTGCCTCTCAGGCAGCCTCTAGCAAGGCGTATGGCACACCAGCAACACGCG
[0037] The embedded DNA (Table 3) was then inserted into a plasmid vector 100 , shown in FIG. 3. The resultant vectors are then transferred into E. coli by electroporation (high-voltage shocks). It is recognized by one of ordinary skill in the art to transfer vectors by other means that may be more particularly suited for the specific host cell. For example, we have used pCRblunt for cloning most of the specifically designed oligos. As bacteria grow and divide, the recombinant plasmid vectors also replicate to produce an enormous number of copies of DNA plasmid vectors containing the encoded DNA. This produces multiple copies of the encoded DNA fragment, allowing storage and continuation of the stored data.
[0038] The stored data was then recovered by searching for the two 20-mer oligos (data markers) 104 (FIG. 3). The cells were harvested then lysed to obtain crude genomic DNA comprising the incorporated encoded DNA. With standard procedures, the encoded DNA was located and amplified with polymerase chain reaction (PCR) techniques. Specific primers (M13 reverse, TGAGCGGATAACAATTTCACACAG, SEQ ID NO.: 48 or M13 sequencing primer, GTTTTCCCCAGTCACGACGTTG), SEQ ID NO.: 49 or a pair of tag primers (FIG. 2) can be used to amplify the encoded DNA as PCR DNA fragment. (You might want to add some detail and technically bolster this KK) Once the encoded information was obtained, it was then decoded to reveal the original data (song phrases). FIG. 4 shows an example of a DNA sequence of a song phrase recovered and the decoded message revealed. We use a simple script to convert DNA sequence into words based on our assignment of each of the triplets. We have data from E. coli only although we have tried once with D. radiodurans but not successful yet.
[0039] Although the invention has been described with respect to specific preferred embodiments, many variations and modifications may become apparent to those skilled in the art. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.
1
46
1
32
DNA
Deinococcus radiodurans
1
aattttaagg ccccggatat tatagcgccg cg 32
2
20
DNA
Artificial Sequence
Synthesized Oligo A
2
aaggtaggta ggttagttag 20
3
20
DNA
Artificial Sequence
Synthesized Oligo B
3
aggtttggtg gtatagttag 20
4
20
DNA
Artificial Sequence
Synthesized Oligo C
4
ataggagtgt gtgtagttag 20
5
20
DNA
Artificial Sequence
Synthesized Oligo D
5
atattagagg gggtagttag 20
6
20
DNA
Artificial Sequence
Synthesized Oligo E
6
ggagtagtgt gtatagttag 20
7
20
DNA
Artificial Sequence
Synthesized Oligo F
7
gggagtatgt agttagttag 20
8
20
DNA
Artificial Sequence
Synthesized Oligo G
8
ggttagatga gtgtagttag 20
9
20
DNA
Artificial Sequence
Synthesized Oligo H
9
agagtagtga ggatagttag 20
10
20
DNA
Artificial Sequence
Synthesized Oligo I
10
ataagtagtg gggtagttag 20
11
20
DNA
Artificial Sequence
Synthesized Oligo J
11
ataggggtat ggatagttag 20
12
20
DNA
Artificial Sequence
Synthesized Oligo K
12
atgggtggat tgatagttag 20
13
20
DNA
Artificial Sequence
Synthesized Oligo L
13
gggaatagag tgttagttag 20
14
20
DNA
Artificial Sequence
Synthesized Oligo M
14
gggatgattg gtttagttag 20
15
20
DNA
Artificial Sequence
Synthesized Oligo N
15
gtatgggaat ggttagttag 20
16
20
DNA
Artificial Sequence
Synthesized Oligo O
16
taagggatgt gtgtagttag 20
17
20
DNA
Artificial Sequence
Synthesized Oligo P
17
tagaggaggg atatagttag 20
18
20
DNA
Artificial Sequence
Synthesized Oligo Q
18
tagatgggag gtatagttag 20
19
20
DNA
Artificial Sequence
Synthesized Olgo R
19
taggagagat gtgtagttag 20
20
20
DNA
Artificial Sequence
Synthesized Oligo S
20
tatagggagg gtatagttag 20
21
20
DNA
Artificial Sequence
Synthesized Oligo T
21
tgtgggatag tgatagttag 20
22
20
DNA
Artificial Sequence
Synthesized Oligo U
22
tagagtggtg tgttagttag 20
23
20
DNA
Artificial Sequence
Synthesized Oligo V
23
tagattggat gggtagttag 20
24
20
DNA
Artificial Sequence
Synthesized Oligo W
24
tagggttggt agttagttag 20
25
20
DNA
Artificial Sequence
Synthesized Oligo X
25
tatagggtag ggttagttag 20
26
46
DNA
Artificial Sequence
Complimentary Oligo A
26
agagtagtga ggatagttag agatctctct aatcacacac atctca 46
27
46
DNA
Artificial Sequence
Complimentary Oligo B
27
tgagatgtgt gtgattagag agatctctaa ctatcctcac tactct 46
28
20
DNA
Artificial Sequence
Arbitrary Chosen 20-mer Tag A
28
agagtagtga ggatagttag 20
29
20
DNA
Artificial Sequence
Arbitrary Chosen 20-mer Tag B
29
tgagatgtgt gtgattagag 20
30
57
DNA
Artificial Sequence
Line #1 Encoded Information
30
aacgcaaggg cagaacgacg tcccatcgca cgaattgcac tcatgaggcg tctagcg 57
31
57
DNA
Artificial Sequence
Line #2 Encoded Information
31
aaggcaaggc ctatcgcaag ggcacaacga cccatcatgc ctgcactact gcctgcg 57
32
57
DNA
Artificial Sequence
Line #3 Encoded Information
32
aatgcaaggc ctatcgcaag ggcactaccg cagcccatgg caccgatgag gcctcta 57
33
69
DNA
Artificial Sequence
Line #4 Encoded Information
33
acagcaaggc ctatcgcaag ggcagaacga cgtcccatcg cacgaattgc aattatgagg 60
cgtctagcg 69
34
78
DNA
Artificial Sequence
Line #5 Encoded Information
34
accgcaaggc ctatcgcact ccacatggca cgaataatga ggcctctagc aaggcgtatg 60
gcagaacaga tcatggcg 78
35
75
DNA
Artificial Sequence
Line #6 Encoded Information
35
acggcaattc gtcagatgcc tatcctacac cagcgcgcac tccgagcaat gcttatgcgt 60
gagcgaccta tggcg 75
36
75
DNA
Artificial Sequence
Line #7 Encoded Information
36
actgcacagc tcgcacagct agcactccag ccgatggcag aaatggtccg tatggcaagg 60
gaaaggcgta tggga 75
37
81
DNA
Artificial Sequence
Line #8 Encoded Information
37
agagcacagc tcgtcctagc aagggcacta ccgaggcccc ccgcactacc gaggcccccc 60
gcagaacgac gtcccatcgg a 81
38
93
DNA
Artificial Sequence
Line #9 Encoded Information
38
agcgcacagc tcgtcctagc aagggcacta ccgaggcccc ccgcagaacg acgtcccatc 60
gcaaggattc tcatgcgtgc aaggcccccc gcg 93
39
72
DNA
Artificial Sequence
Line #10 Encoded Information
39
aacaaagcac agctcgtcct agcaagggca gaacgacgtc ccatcgcacg aattgcacac 60
cgacgcatgc ta 72
40
84
DNA
Artificial Sequence
Line #11 Encoded Information
40
aacaacgcac agctcgtcct agcaagggca gaacgacgtc ccatcgcacg aattgcaccc 60
aggctgcaac acctcatgcg tgcg 84
41
78
DNA
Artificial Sequence
Line #12 Encoded Information
41
aacaaggcac agctcgtcct agcactaccg aggccccccg cactaccgag gccccccgca 60
gaacgacgtc ccatcgga 78
42
75
DNA
Artificial Sequence
Line #13 Encoded Information
42
aacaatgcac tccacatgcg tatggcacag ctagcacatc tgctactcgc acgacctatg 60
gcaccgcgac gacct 75
43
99
DNA
Artificial Sequence
Line # 14 Encoded Information
43
aacacagcac tccacatgcg tatggtccta gcactacgag caccgctgat acacgcactc 60
cacaggctcg cagaaatggc actacacagg cgtatggcg 99
44
99
DNA
Artificial Sequence
Line # 15 Encoded Information
44
aacaccgcac tccaccgact gcaacacgca ctccacatgg caccgcgact gcctctcagg 60
cagcctctag caaggcgtat ggcacaccag caacacgcg 99
45
24
DNA
Artificial Sequence
M13 Reverse Primer (PCR Amplification Primer)
45
tgagcggata acaatttcac acag 24
46
22
DNA
Artificial Sequence
M13 Sequence Primer (PCR Amplification Primer)
46
gttttcccca gtcacgacgt tg 22
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Current technologies allow the generation of artificial DNA molecules and/or the ability to alter the DNA sequences of existing DNA molecules. With a careful coding scheme and arrangement, it is possible to encode important information as an artificial DNA strand and store it in a living host safely and permanently. This inventive technology can be used to identify origins and protect R&D investments. It can also be used in environmental research to track generations of organisms and observe the ecological impact of pollutants. Today, there are microorganisms that can survive under extreme conditions. As well, it is advantageous to consider multicellular organisms as hosts for stored information. These living organisms can provide as memory housing and protection for stored data or information. The present invention provides well for data storage in a living organism wherein at least one DNA sequence is encoded to represent data and incorporated into a living organism.
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PRIORITY CLAIM
[0001] This application claims priority to pending European Application No. 11181138.6 filed on Sep. 13, 2011.
[0002] This application is a continuation of pending International Application No. PCT/EP2012/061504 filed on 15 Jun. 2012, and which was published as WO 2013/037522which designates the United States and claims priority from European Application No. 11181138.6 filed on Sep. 13, 2011.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates to a roller for heating a web of paper or fabric with a cylindrical roller shell, a front side and a rear side and a rotational axis. The cylindrical roller shell is heated by at least one heat source.
[0005] 2. Description of Relevant Art
[0006] In paper and fabric industry wet paper web or a wet fabric web, respectively, are transported through a drying section to remove excess water from the paper web or fabric web. In the drying section the web travels over heated drum dryers which are as well called rollers. The rollers are typically heated with steam. Such a roller is e.g. disclosed in the patent application DE 10 2005 043 734 A1. Supplying the rollers with steam is expensive and the humidity provided by the steam is difficult to handle in the drums. Further, it is difficult to provide a homogenous surface temperature of the roller. The humidity problem can be solved by using heated oil instead of steam, but the other shortcomings remain unresolved.
[0007] A different approach is disclosed in the US-patent publication 5,666,744: The wet paper web is transferred to a fabric conveyor sheet and travels though a drying unit. In the drying unit the wet paper web on the fabric sheet is exposed to infrared light emitted by infrared units positioned along the traveling path of the wet paper web. At the same time the moisture is removed by vacuum units positioned on the opposite site of fabric sheet from the infrared unit. This permits to combine heat drying and vacuum drying.
[0008] The international patent application published as WO 2010/020485 A1 suggests to dry a wet paper web by micro waves. The paper web crosses a gap between opposed rollers multiple times. In the gap the wet paper web is exposed to the micro waves. This method has the shortcoming that the paper web has to travel the gap multiple times and that it is difficult to provide an homogeneous micro wave intensity within the gap. Further, the gap must be perfectly shielded against leaking radiation.
[0009] U.S. Pat. No. 4,990,751 discloses an electrically heated roller for drying a paper web. The roller has an outer shell, having the form of a tube like hollow cylinder. In the cylinder is a second hollow cylinder. On the surface shell of the second hollow cylinder are parallel bars supporting strands in a ring like hollow space between the outer shell and the second hollow cylinder. An electric current is provided to the strands, to thereby produce heat. The heat is transferred to the outer shell as radiant heat.
[0010] DE 30 33 689 A1 discloses as well an electrically heated roller for drying a paper web with two concentrically arranged hollow cylinders. Between the inner and the outer cylinder is a compartment. In the compartment are electric heating pads, which are in thermal contact with the inner and the outer hollow cylinder. This arrangement of the heating pads provides a uniform heat distribution.
[0011] German Utility Patent DE 201 01 859 U1 discloses a further embodiment of an electrically heated drying roller. The drying roller has tube like hollow cylinder as roller shell. The cylinder has a couple of bores, being parallel to the cylinder axis. In each of the bores is a heater wire. Heat produced by applying a current through the heater wires is transferred as radiant heat to the hollow cylinder.
[0012] U.S. Pat. No. 4,158,128 discloses a heated roller for processing sheet material by applying a uniform load across the width of the sheet material. To this end the roller comprises a core and a shell of two coaxial pipes. The ends of the pipes are interconnected by a hermetic joint to thereby form a space between the pipes. A fluid for heating or cooling the roller circulates in the space. Alternatively the space may accommodate electrical heaters. The core of the roller has a middle section with a constant outer diameter that corresponds to the inner diameter the inner pipe thereby bearing the pipes, i.e. the inner pipe rests on the middle section of the core. At both sides of the middle section the outer diameter of the core is reduced and the pipes overlap the middle section.
[0013] EP 0 156 790 discloses as well a roller with a pipe like shell. The pipe like shell is supported by a hollow single shaft via hubs and heated by electrical heating elements. For providing a uniform heat distribution a low melting metal, low meting alloy or low melting salt is incorporated in roller.
[0014] DE 102 01 380 A1 discloses a roller with a roller shell. In the roller shell are bores parallel to the roller axis for accommodating electrical heating elements. The heating elements are each supported by fixtures in the respective bore such that the there is no direct contact between the roller shell and the heating elements, to thereby heat the roller only by radiant heat. For supporting the roller shell, the figures show a cylindrical single shaft supporting the roller shell over its full width.
[0015] DE 30 33 689 A1 discloses a heated roller having an inner pipe and as roller shell a coaxial outer pipe. Heating pads are arranged between the inner and the outer pipes. At both facing sides of the inner and outer pipes are discs being flanged to the pipes. Each disc has a shaft for supporting the discs and thereby the inner and outer pipes.
[0016] Although the cited documents disclose related art, the above summaries of the respective cited documents are not intended to be applicants admitted prior art, but rely on applicant's analysis of the cited documents.
SUMMARY OF THE INVENTION
[0017] The problem to be solved by the invention is to provide a simple and at the same time efficient drying station for a web of paper or fabric, subsequently briefly referred to as “web”.
[0018] The invention is based on the observation, that the electrically heated rollers of the prior art either require a lateral thermal contact to the roller drum or that the heat is transferred as radiant heat to the roller drum. In the first case, the heating elements are difficult to replace. In the second case the heat transfer between the heating elements and the roller drum is not efficient.
[0019] Solutions of the problem are described in the independent claims. The dependent claims relate to advantageous embodiments of the invention.
[0020] The roller of claim 1 comprises at least a cylindrical roller shell with a cylinder axis, a front side and a rear side. The cylinder axis is the rotational axis. The cylindrical roller shell comprises at least one, preferably multiple bores, which extend at least approximately parallel to the cylinder axis. The bores may be through holes, i.e., connect the two facing sides of the roller shell. In at least one of the bores is at least one, preferably replaceable, slab like heater cartridge. The heater cartridge has a surface that is in thermal contact with the bore's inner surface. The heater cartridge is preferably an encapsulated heating element, i.e. heat is provided by heating an encapsulating housing of the heating elements. The length of the cartridge may be shorter than the length of the bore, e.g. smaller ½, smaller ⅓, smaller ¼ or even less of the bore's length. Such heater cartridges are commercially available and can be replaced very quickly, thus the tooling time can be kept low. In the bore is preferably a liquid inorganic compound for example a solution comprising inorganic salts. When heating the heater cartridge, the solvent of the solution evaporates. The inner surface of the bore is thus coated with the inorganic salts. The inorganic salts provide for an at least almost perfect thermal contact between the heater cartridge and the inner surface of the bore. In addition the coating dramatically enhances the thermal conductivity of the bore.
[0021] Before inserting the liquid inorganic compound into the bore the bore is preferably evacuated. Subsequently an amount of the liquid inorganic compound is inserted in the bore and the bore is sealed. When heating the roller with the heater cartridges the solvent will change its phase and become a gas. The inorganic salts will remain evenly distributed at the inner surface of the bore and thus coat the bore. Preferably the drum is rotated while heated, to better distribute the inorganic salts and other possible constituents of the liquid inorganic compound. Examples for suited liquid inorganic compounds can be found e.g. in patents U.S. Pat. No. 6,132,823, U.S. Pat. No. 6,911,231, U.S. Pat. No. 6,916,430, U.S. Pat. No. 6,811,720 and the application US2005/0056807, which are incorporated by reference as if fully disclosed herein.
[0022] In a second embodiment the cylindrical roller shell surrounds an inner roller shell and forms thereby a ring like or at least one ring segment like hollow space between the cylindrical roller shell and the inner roller shell. In the hollow space between the cylindrical outer roller shell and the inner roller shell is at least one heat source, e.g. a replaceable mounted slab like heater cartridge. The heat source is thermally connected to at least one of the cylindrical roller shell and/or the inner roller shell. For thermally contacting the heating element, the heating element can be inserted into the hollow space, the hollow space can be evacuated and subsequently a liquid inorganic compound for example a solution of at least one inorganic salt can be inserted in the hollow space. Subsequently a predefined amount of a solution of at least one inorganic salt, for example one of the solutions disclosed in at least one of the patents U.S. Pat. No. 6,132,823, U.S. Pat. No. 6,911,231, U.S. Pat. No. 6,916,430, U.S. Pat. No. 6,811,720 and/or the application US2005/0056807, is filed in the bore. The pressure in the bore is still kept well below the ambient pressure. Now the roller is preferably rotated and the heating elements are switched on. The liquid inorganic compound is thereby evenly dispersed in the bore and at the same time evaporated, thus the inorganic salt coat the surface of the heater cartridge and at the same time inner surface of the hollow space, thereby thermally connecting the heating element and the roller shells.
[0023] Both constructions permit a light weight and however stable roller which can thus quickly be accelerated or stopped, due to its low moment of inertia. The heat sources can be almost freely arranged within the hollow space ore bores, respectively and thereby a uniform temperate on the roller's surface can be maintained. The hollow space can be coated like the bores with inorganic salts and may be evacuated to enhance the heat conductivity of the opposed surfaces of the hollow space, e.g. like it is described in the patents U.S. Pat. No. 6,132,823, U.S. Pat. No. 6,911,231, U.S. Pat. No. 6,916,430, U.S. Pat. No. 6,811,720 and the application US2005/0056807. This permits at least an almost perfect homogenous heat distribution.
[0024] More generally one may summarize the invention as providing a drying roller with at least one tube like roller shell. The roller has at least one recess or compartment, into which at least one heating element, e.g. a heater cartridge, is inserted. The heating element is thermally connected to the roller shell by coating of at least one inorganic salt. The method for thermally connecting the heating element to the roller shell may be summarized as follows: In a first step the recess is evacuated and a liquid inorganic compound, for example a solution of the at least one inorganic salt is inserted in the recess. Subsequently the roller is heated and preferably at the same time rotated. Thereby the liquid inorganic compound evenly distributes in the recess and is at the same time evaporated. Thus the inorganic salts remains as coating on the heating element and the inner surface of the recess.
[0025] In a preferred embodiment at least one heat source is at least one slab like electrical heater element, which is thermally connected to the at least one inner roller shell. This enables to arrange the heater elements preferably evenly spaced and circumferentially of the inner shell and thereby further enhance the heat distribution on the cylinder's surface. Such heater elements can be replaced very quickly, thus the tooling time can be kept low.
[0026] For example, in a preferred embodiment the heat source comprises multiples lab like electrical heater elements, being arranged in parallel to each other on the outer surface of the inner roller shell and in parallel to the rotational axis of the roller.
[0027] In a preferred embodiment the inner roller shell has at least one recess for the at least one heat source. This provides an optimized heat transfer between the heat source and the inner roller shell and as well a good heat transfer between the inner shell and the cylindrical roller shell due to a reduced average distance between the inner shell and the cylinder.
[0028] If the heat source is inserted from the front and/or rear side of the drum into the hollow space or the bore, respectively it can be efficiently supplied with energy, preferably electricity, and can be replaced quickly in case of failure.
[0029] The at least one of the roller shells is preferably reinforced by least one ring with an outer narrow side and an inner narrow side, wherein the outer narrow side statically contacts the inner side of the respective roller shell. This stabilizes the roller, without significant increase of weight.
[0030] The roller is further stabilized if the cylindrical roller shell and the inner roller shell are attached to disks at the front and the rear side of the roller.
[0031] In a preferred embodiment the roller has roller shaft, which supports at least one slip ring, the latter being electrically connected with the at least one heat source for supplying electric energy to the at least one heat source.
[0032] Preferably the roller shaft has two halves, each being shorter than the width of the roller, one of which is mounted at the facing sides, i.e. the front and the rear side, respectively, of the roller. For example, the shaft may be preferably statically mounted to the discs being attached to the cylindrical roller shell and the inner roller shell at the front and the rear side of the roller. Thus there may be a fixed connection between the cylindrical roller shell and the shaft's halves. This enable a simple support of the roller e.g. by standard bearings without significant increase of the moment of inertia of the roller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] In the following, the invention will be described by way of example, without limitation of the general inventive concept, on examples of embodiment and with reference to the drawings.
[0034] FIG. 1 shows a cross section of a roller.
[0035] FIG. 2 shows a detail of FIG. 1 .
[0036] FIG. 3 shows a view on the front side of the roller of FIG. 1
[0037] FIG. 4 shows a view of a disk to be mounted at the rear side of the roller of FIG. 1 .
[0038] FIG. 5 shows a further embodiment of a roller.
[0039] FIG. 6 shows a detail of FIG. 5
[0040] FIG. 7 shows cross sections A-A and B-B as indicated in FIG. 5 .
[0041] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The roller 1 in FIG. 1 has the shape of a hollow ring like cylinder with a cylinder surface 21 as rest for a paper web (not shown). Both facing sides of the hollow cylinder are at least essentially closed by a front disk 41 and rear disk 42 . The parallel disks 41 , 42 support a cylindrical roller shell 44 (cf. FIG. 1 ). The cylindrical roller shell 44 encloses an inner roller shell 46 . The inner roller shell 46 is spaced in a radial direction from the cylindrical roller shell 44 . The the inner roller shell 46 , the cylindrical roller shell 44 and the two disks 41 , 42 form a ring like hollow space 45 . The outer diameter of the hollow space 45 is defined by the inner surface of the cylindrical roller shell 44 . The inner diameter of the hollow space 45 is defined by the adjacent surface of the inner roller shell and is reduced by a step from the front to the rear, i.e. it has two sections with different diameters. The wider section permits insertion of casings 48 as compartments for electrical heater elements 60 . The electrical heater elements 60 are inserted from the front side and extend through the front disk 41 with their electrical connectors (cf. FIG. 2 , FIG. 3 ).
[0043] Preferably the surfaces enclosing the hollow space 45 is coated as disclosed in the patents U.S. Pat. No. 6,132,823, U.S. Pat. No. 6,911,231, U.S. Pat. No. 6,916,430, U.S. Pat. No. 6,811,720 and the application US2005/0056807, which are incorporated by reference as if fully disclosed herein. The coating fluid can be inserted into the hollow space 45 through a tube 76 . Subsequent to the coating process the hollow space is preferably evacuated as well via tube 76 . The tube 76 can as well be used for testing the structural integrity of the hollow space under extremely low and/or high pressures. Of course the tube 76 can be closed, e.g. by a bolt and/or a valve.
[0044] The inner roller shell is reinforced by rings like 52 with an outer narrow side and an inner narrow side, wherein the outer narrow side statically contacts the inner side of the inner roller shell 46 and thereby stabilizes the roller 1 without significant increase of weight and thus without significant moment of inertia. The difference d between the inner and the outer diameters of the rings 52 is smaller than ⅓ of the radius r of the cylindrical roller 44 , more preferably smaller than ¼ of the radius r of the cylindrical roller 44 .
[0045] From both disks 41 , 42 extends a half of a roller shaft 70 , flanged to the respective disk 41 , 42 , thereby enabling to bear the roller 1 in a supporting frame (not shown). A temperature sensor 80 extends from the front disk 41 into the hollow space 45 (cf. FIG. 3 ) and permits a control unit to maintain the temperature at a defined value or interval.
[0046] The rear disk 42 has an opening 74 to chamber 72 formed by the inner shell and the two disks 41 , 42 . The opening 74 ensures ventilation of the chamber 72 , in addition the chamber can easily be inspected (cf. FIG. 1 , 4 ).
[0047] The roller 1 in FIG. 5 has a roller drum of a tube like hollow cylindrical roller shell 44 with a cylinder axis 2 (c.f. FIG. 6 ). The outer cylinder surface is the roller surface 21 for supporting and heating a paper web. In the roller shell 44 are a couple of recesses 45 , which are in this example bores 45 . The recesses 45 extend at least approximately parallel to the cylinder axis 2 . Only small deviations from the axial direction of the cylinder axis should be tolerated. The difference in the distance of the recess 45 to the cylinder axis 2 at one facing side of the roller shell 44 to the respective distance at the opposite facing side of the roller shell 44 is preferably smaller than +/−0.1 mm. The bores 45 are through holes spanning from one facing side of the roller shell 44 to the opposite facing side of the roller shell 44 . One side of each of the bores 45 is closed by insertion of a slab like heater cartridge 60 , which seals the respective opening of the bore 45 . The heater cartridge is preferably fastened by bolts or any other releasable fastening means. In case of failure of a heater cartridge it can be replaced, by releasing the fastening means and retracting the heater cartridge. Subsequently a new one can be inserted in the bore 45 and fastened. The bore is closed at the opposite facing side of the roller shell by a cover plate 47 . The cover plate 47 supports an injection device 47 for evacuating the bore and subsequently filling a predefined amount of a liquid inorganic compound, e.g., an aqueous solution of at least one inorganic salt in the bore 45 . The distance between each bore depends on the diameter of the roller drum. The angle error should be kept small, preferably smaller than 0.1°.
[0048] The roller shell 44 has the form of a ring like hollow cylinder, and thus has a central trough hole 43 . The roller shell 44 is supported by two shafts 70 , being inserted into the through hole 43 , one from each facing side of the roller shell 44 . The outer diameter of the proximal end sections of shafts 70 fits to the inner diameter of the roller shaft 44 . The roller shell 44 may be fastened to the shafts 70 by bolts or by welding. The shafts 70 are each supported by a bearing assembly 50 , which may be mounted to a supporting frame. The heater cartridges 60 are connected via cables and a rotary joint 54 to a power supply.
[0049] For thermally connecting the heater cartridge with the roller shell 44 , the bore is in a first step evacuated, this means at least a part of the air in the closed bore is removed to obtain a lower than ambient pressure in the bore. Subsequently a predefined amount of a liquid inorganic compound, for example a solution of at least one inorganic salt, for example one of the liquid inorganic compounds disclosed in at least one of the patents U.S. Pat. No. 6,132,823, U.S. Pat. No. 6,911,231, U.S. Pat. No. 6,916,430, U.S. Pat. No. 6,811,720 and/or the application US2005/0056807, is filled in the bore. The pressure in the bore is still kept well below the ambient pressure. Now the roller shell 44 is preferably rotated and the heater cartridges are switched on. The liquid inorganic compound is thereby evenly dispersed in the bore and at the same time evaporated, thus the inorganic salt(s) coat the surface of the heater cartridge and at the same time the inner surface of the recesses 45 , thereby thermally connecting the heater cartridge and the roller shell 44 .
[0050] It will be appreciated to those skilled in the art having the benefit of this disclosure that this invention is believed to provide heated roller for heating a web of paper or fabric. Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.
LIST OF REFERENCE NUMERALS
[0000]
1 roller
2 cylinder axis
21 roller surface
41 disk
42 disk
43 central through hole of roller shell 44
44 cylindrical roller shell
45 hollow space/bore/recess
46 inner roller shell
47 cover plate
48 casing
49 injection device
52 ring
54 slipring/ rotary joint
60 heat source/electrical heater/heater cartridge
70 shaft
72 chamber
74 opening
76 tube
80 temperature sensor
90 solution/fluid/inorganic salts
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A heated roller for heating a paper web or fabric web with a cylindrical roller shell, a front side and a rear side permits a homogenous temperature on its surface if the cylindrical roller shell surrounds an inner roller shell thereby forming a ring like or at least one ring segment like hollow space between the cylindrical roller shell and the inner roller shell and if at least one heat source is inserted in the hollow space.
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This is a division of application Ser. No. 973,197, filed Dec. 26, 1978, which is a division of application Ser. No. 916,979, filed June 19, 1978, now U.S. Pat. No. 4,156,079, issued May 22, 1979.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,064,125, issued Dec. 20, 1977 to John Krapcho, discloses antiinflammatory compounds (and salts thereof) having the formula ##STR2## wherein R 1 ' is alkyl, cycloalkyl or aryl; R 2 ' is acyl; R 3 ' is alkylamino or dialkylamino; A 1 ' is a saturated bond or an alkylene group having 1 to 4 carbon atoms; and A 2 ' is an alkylene group having 2 to 5 carbon atoms.
RELATED APPLICATIONS
Several additional U.S. patent applications have been filed by John Krapcho which disclose compounds that are structurally related to the compounds which make up the invention hereinafter set forth. The applications are continuation-in-part applications of the application that matured into U.S. Pat. No. 4,064,125. The applications are Ser. No. 834,216, filed Sept. 21, 1977; Ser. No. 835,099, filed Sept. 21, 1977; and Ser. No. 835,462, filed Sept. 21, 1977.
These applicatitons disclose antiinflammatory compounds (and salts thereof) having the formula ##STR3## wherein R 1 " is alkyl, cycloalkyl or aryl; R 2 " is acyl or sulfonyl; R 3 " is alkylamino, dialkylamino or a nitrogen containing heterocyclic, A 1 " is a saturated bond or an alkylene group having 1 to 4 carbon atoms; and A 2 " is an alkylene group having 2 to 5 carbon atoms.
Other antiinflammatory compounds (and salts thereof) that are structurally related to the compounds which make up the invention hereinafter set forth are disclosed in two United States patent applications filed by John Krapcho and Chester F. Turk. The applications are Ser. No. 773,561, filed Mar. 2, 1977 and Ser. No. 897,476, filed Apr. 18, 1978 which is a division of the first application. These applications disclose antiinflammatory compounds (and salts thereof) having the structural formula ##STR4## wherein R 1 '" is alkoxycarbonyl, amido, or substituted amido; R 2 '" is acyl or sulfonyl; and R 3 '" is alkylamino, dialkylamino or a nitrogen containing heterocyclic group; A 1 '" is an alkylene group having 2 to 5 carbon atoms; and n is 1, 2 or 3.
BRIEF DESCRIPTION OF THE INVENTION
Compounds having the formula ##STR5## and the pharmaceutically acceptable salts thereof, have useful antiinflammatory activity. In formula I, and throughout the specification, the symbols are as defined below.
R 1 is alkyl, cycloalkyl or aryl; ##STR6## wherein Y is alkyl, cycloalkyl, aryl, arylalkyl, styryl, or styryl wherein the phenyl group is substituted with a halogen, alkyl, alkoxy, trifluoromethyl, nitro or amino group;
R 3 is alkylamino, dialkylamino or a nitrogen containing heterocyclic group selected from 1-pyrrolidinyl, 1-piperidinyl, 4-morpholinyl, 1-piperazinyl, and 4-alkyl-1-piperazinyl;
R 4 is alkoxy (methoxy is preferred);
A 1 is a saturated bond or an alkylene group having 1 to 4 carbon atoms; and
A 2 is an alkylene group having 2 to 5 carbon atoms.
The terms "alkyl" and "alkoxy", as used throughout the specification, whether by themselves or as part of larger groups, refer to groups having 1 to 6 carbon atoms.
The term "aryl", as used throughout the specification, whether by itself or as part of a larger group, refers to phenyl or phenyl substituted with a halogen, alkyl, alkoxy, trifluoromethyl, nitro, or amino group.
The term "halogen", as used throughout the specification, refers to fluorine, chlorine, bromine and iodine; chlorine and bromine are preferred.
The term "cycloalkyl", as used throughout the specification, refers to cycloalkyl groups having 3 to 7 carbon atoms.
The term "alkylene", as used throughout the specification, refers to a straight or branched chain, divalent, saturated hydrocarbon group.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention can be prepared using as starting materials a 2-hydroxybenzaldehyde having the formula ##STR7## and a compound having the formula
R.sub.3a --A.sub.2 --X (III)
wherein X is a halogen atom or other leaving group and R 3a is alkylbenzylamino, dialkylamino, or a nitrogen containing heterocyclic group.
Reaction of the two starting materials (formulas II and III) and a strong base, e.g., sodium hydride, sodium hydroxide, or the like, yields an intermediate having the formula ##STR8## The reaction can be run in an organic solvent, e.g., benzene, xylene, toluene, or the like; reaction conditions are not critical, but the reaction will preferably be run at an elevated temperature. In a preferred embodiment of this invention, the 2-hydroxybenzaldehyde of formula II is first treated with a strong base in a polar organic solvent, and subsequently reacted with a compound of formula III in an aromatic hydrocarbon solvent.
An intermediate of formula IV can be reacted with a primary amine having the formula
H.sub.2 N--A.sub.1 --R.sub.1 (V)
to yield the corresponding Schiff base having the formula ##STR9## The reaction can be run in an organic solvent, e.g., an aromatic hydrocarbon, and will preferably be run at the reflux temperature of the solvent.
Reduction of a compound of formula VI, using chemical or catalytic means, yields the corresponding intermediate having the formula ##STR10## The reaction can be run using gaseous hydrogen in the presence of a catalyst such as Raney nickel or palladium. Preferably, the reaction will be run using a chemical reducing agent such as sodium borohydride.
The Schiff bases of formula VI and the compounds of formula VII are novel compounds useful in the preparation of the antiinflammatory compounds of formula I; as such, they constitute a part of this invention.
The products of formula I, wherein R 3 is dialkylamino or a nitrogen containing heterocyclic group can be prepared by reacting the corresponding compound of formula VII with the appropriate acid or sulfonyl halide, preferably the acid or sulfonyl chloride (R 2 --Cl) or, when R 2 is acyl, an acid anhydride ((YCO) 2 O) can also be used. The reaction can be run in an organic solvent, e.g., a halogenated hydrocarbon such as chloroform.
The products of formula I, wherein R 3 is alkylamino can be prepared by first reacting the corresponding compound of formula VII wherein R 3a is alkylbenzylamino with an acid or sulfonyl halide or acid anhydride, as described above, to yield an intermediate having the formula ##STR11## Debenzylation of a compound of formula VIII using the well-known catalytic hydrogenation procedure yields the corresponding product of formula I.
Those products of formula I wherein the R 1 or R 2 group contains an amino substituent are preferably prepared by reduction of the corresponding nitro compound.
The pharmaceutically acceptable salts of the compounds of formula I are readily prepared using procedures well known in the art. Acid addition salts are specifically contemplated. Exemplary salts are the hydrohalides, sulfate, nitrate, phosphate, oxalate, tartrate, maleate, citrate, benzenesulfonate, and others.
The compounds of formula I, and the pharmaceutically acceptable salts thereof, can be used for the treatment of inflammation in mammalian species such as mice, dogs, cats, monkeys, etc. Joint tenderness and stiffness (in conditions such as rheumatoid arthritis) are relieved by the compounds of this invention. Formulation of the compounds can be carried out according to accepted pharmaceutical practice in oral dosage forms such as tablets, capsules, elixirs or powders, or in injectable form in a sterile vehicle. The compounds of this invention can be administered in amounts of about 0.1 to 2.0 grams per 70 kilograms of animal body weight per day, preferably about 0.1 to 1.0 gram per 70 kilograms of animal body weight per day.
The following examples are specific embodiments of this invention.
EXAMPLE 1
4-Chloro-N-[[5-methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methyl]-N-(2-phenylethyl)benzamide, hydrochloride salt (1:1)
A. 5-Methoxy-2-[3-(4-morpholinyl)propoxy]benzaldehyde
A stirred solution of 25 g of 2-hydroxy-5-methoxybenzaldehyde in 125 ml. of dimethylformamide is treated portionwise with 8.2 g of 50% sodium hydride (oil dispersion). The temperature is kept below 35° C. by means of an ice-water bath. When the addition is complete, the mixture is warmed to 70° C. and cooled to 25° C. This is followed by the addition of a solution of 36 g. of N-(3-chloropropyl)morpholine in 65 ml. of toluene. The mixture is stirred and heated at 100°-105° C. for 4 hours, cooled, poured into 300 ml. of ice-water and extracted with three 150 ml. portions of ether. The combined ether layers are then extracted with 40 ml. of cold 1:1 hydrochloric acid, followed by 20 ml of water. The aqueous phases are combined, layered over with 150 ml of ether, stirred and basified with 40 g. of potassium carbonate. The layers are separated and the aqueous phase is extracted with three 100 ml portions of ether. The combined ether layers are dried over magnesium sulfate. The solvent is removed on a rotary evaporator and the residue is distilled to give 34 g. of the title compound, boiling point 180°-185° C. at 0.1-0.2 mm of Hg.
B. 4-[3-[4-Methoxy-2-[[(2-phenylethyl9imino]methyl]phenoxy]propyl]morpholine
5-Methoxy-2-[3-(4-morpholinyl)propoxy]benzaldehyde (33.4 g) and 14.5 g of phenethylamine are refluxed in 120 ml of toluene for about 1 hour. After cooling to about 50° C., the solvent is removed using a rotary evaporator and the oily residue is distilled to give 42.1 g of the title compound, boiling point 240°-245° C. at 0.2-0.3 mm of Hg.
C. 4-[3-[4-Methoxy-2-[[(2-phenylethyl)amino]methyl]phenoxy]propyl]morpholine
A stirred solution of 4-[3-[4-methoxy-2-[[(2-phenylethyl)imino]methyl]phenoxy]propyl]morpholine (41.7 g) in 190 ml of methanol is reduced with 12.4 g of sodium borohydride (added portionwise). A cold water bath is used to maintain the temperature of the reaction mixture at 35° C. After 3 hours, the solvent is treated with water and the product is extracted two times with ether. The ether fractions are combined, treated with water, dried and concentrated to give 33.3 g of the title compound, boiling point 249°-254° C. at 0.3-0.4 mm of Hg.
D. 4-Chloro-N-[[5-methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methyl]-N-(2-phenylethyl)benzamide, hydrochloride
A solution of 16.0 g. of 4-[3-[4-methoxy-2-[[(2-phenylethyl)amino]methyl]phenoxy]propyl]morpholine in 50 ml. of chloroform is added dropwise (at 10°-15° C.) to a stirred solution of 7.7 g of p-chlorobenzoyl chloride in 150 ml. of chloroform. After the addition is completed, the solution is stirred at room temperature for 2 hours, heated at reflux for 1 hour, cooled and concentrated to give a glass-like residue. The residue is rubbed under ether, the evaporation repeated and the partly solid residue taken up in 100 ml of acetonitrile. On diluting to 650 ml with ether, seeding and rubbing, the crystalline hydrogen chloride salt separates. After cooling overnight, the product weighs 21.7 g, melting point 137°-139° C. Recrystallization from 50 ml of warm acetonitrile-50 ml of ether, yields 20.3 g of the title compound, melting point 138°-140° C.
EXAMPLE 2
4-Chloro-N-[[ 2-[3-(dimethylamino)propoxy]-5-methoxyphenyl]methyl]-N-(2-phenylethyl)benzamide, maleate salt (1:1)
A. 2-[3-(Dimethylamino)propoxy]-5-methoxybenzaldehyde
2-Hydroxy-5-methoxybenzaldehyde (31.2 g) in 170 ml of dimethylformamide is treated first with 10.1 g of 50% sodium hydride, then with 160 ml of a 2 N toluene solution of 3-dimethylaminopropyl chloride, following the procedure described in Example 1A, yielding 34.1 g of the title compound, boiling point 149°-155° C. at 0.2-0.3 mm of Hg.
B. N-[[2-[3-(Dimethylamino)propoxy]-5-methoxyphenyl]-methylene]benzeneethanamine
2-[3-(Dimethylamino)propoxy]-5-methoxybenzaldehyde (33.5 g) and 17.4 g of phenethylamine are reacted in 140 ml of toluene following the procedure described in Example 1B yielding 39.9 g of the title compound, boiling point 197°-202° C. at 0.2-0.3 mm of Hg.
C. N-[[2-[3-(Dimethylamino)propoxyl]-5-methoxyphenyl]-methyl]benzeneethanamine
N-[[2-[3-(Dimethylamino)propoxy]-5-methoxylphenyl]-methylene]benzeneethanamine (39.5 g) is reduced with 13.0 g of sodium borohydride in 200 ml of methanol following the procedure described in Example 1C yielding 29.7 g of the title compound, boiling point 205°-210° C. at 0.4-0.5 mm of Hg.
D. 4-Chloro-N-[[2-[3-(dimethylamino)propoxy]-5-methoxyphenyl]methyl]N-(2-phenylethyl)benzamide, maleate salt (1:1)
N-[[2-[3-(Dimethylamino)propoxy]-5-methoxyphenyl]methyl]benzeneethanamine (15 g) and 8.1 g of p-chlorobenzoyl chloride are reacted in 220 ml of chloroform following the procedure described in Example 1D. The syrupy residue from the chloroform evaporation does not crystallize. It is converted to the oily base using potassium carbonate and ether extractions. The oily base (17.3 g) and 4.2 g of maleic acid (the hydrochloride, hydrobromide, methanesulfonate, phosphate, citrate and succinate salts are oils or gums) are dissolved in 60 ml of warm acetonitrile and diluted to 400 ml with ether. On seeding and rubbing, the crystalline maleate salt separates. After 2 days in the cold, there is 21 g of product, melting point 110°-112° C. (sintering at 85° C.).
EXAMPLE 3
4-Chloro-N-[[4-methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methyl]-N-(2-phenylethyl)benzamide, methanesulfonate salt (1:1)
A. 4-Methoxy-2-[3-(4-morpholinyl)propoxy]benzaldehyde
2-Hydroxy-4-methoxybenzaldehyde (25 g) in 125 ml of dimethylformamide is treated first with 8.2 g of 50% sodium hydride, then with 36 g of N-(3-chloropropyl)morpholine dissolved in 65 ml of toluene, following the procedure described in Example 1A, yielding 30.2 g of the title compound, boiling point 190°-195° C. at 0.1-0.2 mm of Hg.
B. 4-[3-[5-Methoxy-2-[[(2-phenylethyl)imino]methyl]phenoxy]propyl]morpholine
4-Methoxy-2-[3-(4-morpholinyl)propoxy]benzaldehyde (29.7 g) and 13.0 g of phenethylamine are reacted in 110 ml of toluene following the procedure described in Example 1B, yielding 33.1 g of the title compound, boiling point 240°-245° C. at 0.1-0.2 mm of Hg.
C. 4-[3-[5-Methoxy-2-[[(2-phenylethyl)amino]methyl]phenoxy]propyl]morpholine
4-[3-[5-Methoxy-2-[[(2-phenylethyl)imino]methyl]phenoxy]propyl]morpholine (33 g) is reduced with 9.8 g of sodium borohydride in 150 ml of methanol following the procedure described in Example 1C, yielding 25.8 g of the title compound, boiling point 249°-254° C. at 0.3-0.4 mm of Hg.
D. 4-Chloro-N-[[4-methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methyl]-N-(2-phenylethyl)benzamide, methanesulfonate salt (1:1)
4-[3-[5-Methoxy-2-[[(2-phenylethyl)amino]methyl]phenoxy]propyl]morpholine (12 g) and 5.8 g of p-chlorobenzoyl chloride are reacted in 160 ml of chloroform following the procedure described in Example 1D. The foamy residue from the chloroform evaporation (triturated with ether and evaporation repeated) is taken up in 75 ml of acetonitrile and diluted to 400 ml with ether. On seeding and rubbing, the crystalline hydrochloride salt separates. After cooling for 3 days, the product weights 16.5 g, melting point, 95°-98° C. (foaming; sintering at 80° C.).
EXAMPLE 4
4-Chloro-N-[[3-methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methyl]-N-(2-phenylethyl)benzamide, maleate salt (1:1)
A. 3-Methoxy-2-[3-(4-morpholinyl)propoxy]benzaldehyde
o-Vanillin (30.4 g), dissolved in 160 ml of dimethylformamide, is treated with 9.6 g of 50% sodium hydride, then with 130 ml of 2 N N-(3-chloropropyl)morpholine in toluene following the procedure described in Example 1A, yielding 42.9 g of the title compound, boiling point 178°-183° C. at 0.2-0.3 mm of Hg.
B. N-[[3-Methoxy-2-2-[3-(4-morpholinyl)propoxy]phenyl]methylene]benzeneethanamine
3-Methoxy-2-[3-(4-morpholinyl)propoxy]benzaldehyde (42.5 g) and 18.5 g of phenethylamine are reacted in 150 ml of toluene following the procedure described in Example 1B, yielding 50.0 g of the title compound, boiling point 229°-234° C. at 0.2-0.3 mm of Hg.
C. N-[[3-Methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methyl]benzeneethanamine
N-[[3-Methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methylene]benzeneethanamine (49.7 g) is reduced with 14.8 g of sodium borohydride in 225 ml of methanol following the procedure described in Example 1C, yielding 40.2 g of the title compound, boiling point 0.2-0.3 mm of Hg.
D. 4-Chloro-N-[[3-methoxy-2-(4-morpholinyl)propoxy]phenyl]methyl-N-(2-phenylethyl)benzamide, maleate salt (1:1)
N-[[3-Methoxy-2-[3-(4-morpholinyl)propoxy]phenyl]methyl]benzeneethanamine (20 g) and 9.6 g of p-chlorobenzoyl chloride are reacted in 250 ml of chloroform, following the procedure described in Example 1D. The syrupy residue from the chloroform evaporation cannot be crystallized and it is converted to the oily base using potassium carbonate and ether extractions. The base (25.2 g) and 5.6 g of maleic acid (the hydrochloride, hydrobromide, methanesulfonate, phosphate, citrate and succinate salts are oils or gums) are dissolved in 80 ml of warm acetonitrile and diluted to 480 ml with ether. On seeding and rubbing, the crystalline maleate salt separates. After cooling for 2 days, the product weighs 28.3 g, melting point 140°-142° C. Following recrystallization from 50 ml of acetonitrile, the product weighs 25.4 g, melting point 141°-143° C.
EXAMPLES 5-10
Following the procedure of Example 1, but substituting the compound listed in column I for 2-hydroxy-5-methoxybenzaldehyde, the compound listed in column II for N-(3-chloropropyl)morpholine, the compound listed in column III for phenethylamine and the compound listed in column IV for p-chlorobenzoyl chloride, yields the compound listed in column V.
__________________________________________________________________________Column I Column II Column III Column IV Column V__________________________________________________________________________5. 2-hydroxy- N-(2-chloro- n-propylamine phenylacetyl N-[[3-methoxy-2-[2-(1- 3-methoxy- ethyl)pyrrolidine chloride pyrrolidinyl)ethoxy]phenyl]- benzaldehyde methyl]-N-(propyl)phenyl- acetamide6. 2-hydroxy- N-(3-chloro- cyclopropyl- cinnamoyl N-(cyclopropyl)-N-[[4- 4-ethoxy- propyl)piperidine amine chloride ethoxy-2-[3-(1-piperidinyl)- benzaldehyde propoxy]phenyl]methyl]-3- phenyl-2-propenamide7. 2-hydroxy- N-(4-chloro- benzylamine 3-(4-chloro- N-benzyl-3-(4-chlorophenyl)- 5-methoxy- butyl)piperazine phenyl)-2- N-[[5-methoxy-2-[4-(1- benzaldehyde propenoyl piperazinyl)butoxy]phenyl]- chloride methyl]-2-propenamide8. 2-hydroxy- 4-methyl-1-(5- isopropylamine cyclohexanoyl N-(isopropyl)-N-[[3-butoxy- 3-butoxy chloropentyl)- chloride 2-[5-(4-methyl-1-piperazinyl)- benzaldehyde piperazine pentoxy]phenyl]methyl]cyclo- hexanamide9. 2-hydroxy- N-(2-chloro- phenethylamine benzenesulfonyl N-[[4-methoxy-2-[2-(4- 4-methoxy- ethyl)morpholine chloride morpholinyl)ethoxy]phenyl]- benzaldehyde methyl]-N-(phenylethyl)- benzenesulfonamide10. 2-hydroxy- 3-dimethylamino- 4-methoxy- 3-(trifluoromethyl)- N-[[2-[3-dimethylamino)- 6-methoxy- propyl chloride aniline benzoyl chloride propoxy]-6-methoxyphenyl- benzaldehyde methyl]-N-(4-methoxy- phenyl)-3-(trifluoro- methyl)benzamide__________________________________________________________________________
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Compounds having the formula ##STR1## or a pharmaceutically acceptable salt thereof, wherein R 1 is alkyl, cycloalkyl or aryl; R 2 is acyl or sulfonyl; R 3 is alkylamino, dialkylamino or a nitrogen containing heterocyclic group; R 4 is alkoxy; A 1 is a saturated bond or an alkylene group having 1 to 4 carbon atoms; and A 2 is an alkylene group having 2 to 5 carbon atoms; have antiinflammatory activity.
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TECHNICAL FIELD
[0001] The present invention relates to methods and arrangements for checking connectivity and detecting connectivity failure of data transmission paths in a network, e.g. Ethernet broadcast network.
BACKGROUND
[0002] In certain network systems with high availability, it is also a requirement that the system shall be able to come over network failures. Failover mechanism is usually triggered by a connectivity detection mechanism which may be run either on data-link or on network layer. However, there can be a vast range of application scenarios where such mechanisms are demanded.
[0003] Existing solutions which can be used for detecting connectivity loss are, for example, IPv6 (Internet Protocol version 6) Neighbour Discovery, Internet Control Message Protocol (ICMP) Ping, Bidirectional Forwarding Detection and Ethernet OAM Connectivity Fault Management.
[0004] Some problems with the above existing solutions will hereafter be described.
[0005] The main disadvantage of the IPv6 Neighbour Discovery method is that, although it is getting more and more portion of the IP implementations, it is still not widely used. Moreover, it is a network layer mechanism, layer 3 (L3), in the Open Systems Interconnection (OSI) model scheme and it is possible that in some scenarios a suitable layer 2 (L2), data-link layer, solution is preferred. The method is described in reference [1], see reference list in the end of the Detailed Description section of this disclosure.
[0006] Internet Control Message Protocol, ICMP, Ping based detection is very simple and can be used with IPv4 (Internet Protocol version 4) protocol. The method uses a unique request/reply mechanism between connection endpoints. This has a drawback when multiple network elements are testing connectivity towards the same network element, putting a potentially huge processing load on that network element. If Quality of Service is used in the network, an ICMP packet often has the lowest priority traffic class and it is therefore dropped first if the network should be congested. Such an event usually only further escalates the problem the network is having. It is a network layer mechanism, Layer 3 in the OSI model.
[0007] Bidirectional Forwarding Detection, BFD, is a L3 detection mechanism that is mostly used in the routing world. Each supervised link requires a BFD supervision session on the top, which would need a tremendous amount of parallel sessions in case of certain scenarios where hosts are deployed very densely. Some systems have hardware and software limitation on the maximum number of possible BFD sessions at a time. Also, configuration wise it makes the system very difficult. Basically BFD has the same drawback as ICMP Ping. BFD was not designed to use for hosts checking connectivity. The method is described in reference [ 2 ], see reference list in the end of the Detailed Description section of this disclosure.
[0008] Ethernet OAM (Operations, Administration and Maintenance) Connectivity Fault Management, CFM, is a fault monitoring mechanism which uses the continuity check protocol. It is a L2, data-link layer, detection mechanism. This is a neighbor discovery and health check protocol which discovers and maintains adjacencies at a Virtual Local Area Network level or link level. The major disadvantage of this solution is that it can only detect faults on L1 and L2 but not higher layers (L3-L7) of the Open Systems Interconnection model scheme. The method is described in reference [ 3 ], see reference list.
[0009] However, the known connectivity detection mechanisms are dependent of the type of the network layer (L3) being used. Thus, there is a need for a sufficient and scalable data-link (L2) connectivity detection mechanism independent of the type of the network layer (L3) being used.
SUMMARY
[0010] One object of this disclosure is to provide a sufficient and scalable data-link connectivity detection mechanism independent of the type of the network layer (L3) being used.
[0011] According to a first aspect, an arrangement and embodiments thereof are provided and described, which are adapted for checking connectivity and detecting connectivity failure of data transmission paths between one or more first nodes and one or more second nodes in a data communications network. Each of said first nodes comprises an issuing device and each of said second nodes comprises a listening device. Said listening device comprises a receiving device, a storing means and checking means. The receiving device is configured to receive an Address Resolution Protocol, ARP, message periodically sent from one of said first nodes over a data transmission path. The storing means is configured to store the time instant when said ARP message was received as an entry of the latest received ARP message from the first node in a record comprising entries corresponding to one or more data paths to said one or more first nodes. The checking means is configured to detect connectivity failure by periodically checking said record for entries in relation to a predetermined threshold value, aging value, and to detect if one or more of said entries have exceeded said predetermined threshold value.
[0012] According to another aspect, an arrangement and embodiments thereof are provided and described, which are adapted for arrangement for checking connectivity and detecting connectivity failure of data transmission paths between one or more first nodes and one or more second nodes in an Ethernet broadcast network. The arrangement in the first node comprises an issuing device configured to transmit periodically an Address Resolution Protocol, ARP, message towards a second node.
[0013] Different embodiments of the arrangements are described and provided in the following detailed description and the dependent claims.
[0014] According to yet another aspect, a method and embodiments thereof are presented, which provides possibility to check connectivity and detect connectivity failure of data transmission paths between one or more first nodes and one or more second nodes in a data communication network. Said second node is configured to receive an Address Resolution Protocol, ARP, message periodically sent from one of said first nodes over a data path, and to store the time instant when said ARP message was received as an entry of the latest received ARP message from the first node in a record comprising entries corresponding to one or more data transmission paths to said one or more first nodes. It then detects connectivity failure by periodically checking said record for one or more entries in relation to a predetermined threshold value, aging value.
[0015] According to yet further one aspect, a method and embodiments thereof are presented, which enables checking of connectivity and detecting connectivity failure of data transmission paths between one or more first nodes and one or more second nodes in an Ethernet broadcast network. In the first node, the method comprises transmitting periodically an Address Resolution Protocol, ARP, message towards a second node.
[0016] Different embodiments of the methods are described and provided in the following detailed description and the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing, and other, objects, features and advantages of the present invention will be more readily understood upon reading the following detailed description in conjunction with the drawings in which:
[0018] FIGS. 1A and 1B are block diagrams of exemplary networks in which arrangements and methods described herein may be implemented;
[0019] FIGS. 2A and 2B are block diagrams of exemplary networks in which arrangements and methods described herein have been implemented;
[0020] FIG. 3 is a flowchart illustrating an embodiment of the method for enabling checking and detecting connectivity failure;
[0021] FIG. 4 is a flowchart illustrating an embodiment of the method for checking and detecting connectivity failure;
[0022] FIG. 5 is a flowchart illustrating an embodiment of the checking and detecting process.
DETAILED DESCRIPTION
[0023] In the following description, for purposes of explanation and not limitation, specific details are set forth, such as particular circuits, circuit components, techniques, etc. in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods, devices, and circuits are omitted so as not to obscure the description of the present invention with unnecessary detail.
[0024] FIGS. 1A and 1B are block diagrams illustrating two examples of data communications networks and systems 10 having a number of edge nodes. In the illustrated examples, the two networks may be different embodiments of Local Area Networks, LANs, configurations e.g. Ethernet broadcast domain. Both examples are simplified.
[0025] In FIGS. 1A and 1B , the exemplified embodiments of the systems and networks 10 comprise network nodes 12 which purpose is to interconnect the LAN 14 with data communications network using other standards, e.g. protocols, for transferring data than the LAN 14 . If the LAN is an Ethernet network and system, Ethernet frames are used for transferring incoming and outgoing data traffic. The connected network may be using Internet Protocol as standard, e.g. IPv4 or IPv6. Thus, the edge nodes may comprise equipment 16 , e.g. one or more gateways or routers for routing the data traffic to the correct addresses.
[0026] In the exemplified LANs 14 , the edge nodes 12 are connected to the subscriber nodes 18 via data paths 11 , which may comprise one or more links via a number of switches. Said links and switches are not illustrated as said elements are not essential for the understanding of the methods and arrangements to be described in this disclosure.
[0027] The exemplified LANs 14 comprise edge nodes 12 connected via data (transmission) paths 11 to one or more subscriber nodes 18 , which may connect one or more subscriber User Equipments, UEs, to the LAN. Different data communication products, e.g. office or home LAN routers, data computers, telecommunication equipments, e.g. Base Station Controllers, NodeB:s, eNB:s, and television sets, etc. are examples of different UEs that may be connected to said node 18 . Each subscriber node 18 comprises interface equipment 20 for connecting the user equipments with the data paths 11 over the LAN 14 .
[0028] The edge node equipment 16 and subscriber node equipment 20 may comprise elements and components for supporting detection of connectivity failure according to any of the known methods as described in the Background of this disclosure.
[0029] In FIG. 1A , three edge nodes 12 are interconnecting the subscriber node 18 to other networks (indicated by black double direction arrow) via data paths 11 . If a failure or breakdown of one of the edge nodes 18 is detected by the node 18 , the node 18 may be configured to direct the traffic originally designated to go via said non-operating node to one of the other nodes 12 still working.
[0030] A network and system as described above may be a High Availability, HA, system, which is often used in connection with telecommunication technologies.
[0031] In FIG. 1B , the illustrated example comprises a High Availability system, in which two subscriber nodes 18 are included. Each of said subscriber nodes 18 are connected to a separate data path 11 , which connects a subscriber node 18 to an edge node 12 . Said edge node 12 , data path 11 and subscriber node constitute a blade. In the illustrated example, one Ethernet Broadcast domain 14 comprises a blade. However, both blades may be incorporated in the same Ethernet Broadcast domain 14 .
[0032] The HA system applies a failover mechanism that moves traffic from one blade to the other. The failover mechanism is triggered if the HA system detects loss of connectivity. In case of loss of connectivity over the data path in one of the blades, both ingress and egress data traffic over said non-operating data path of the HA system is moved by the overlaying failover mechanism to the other working blade.
[0033] In the following, methods and arrangements for checking connectivity and detecting connectivity failure of data transmission paths between one or more nodes in Ethernet broadcast networks, e.g. as discussed above and illustrated in FIGS. 1A and 1B .
[0034] FIGS. 2A and 2B are illustrating two examples of embodiments of a data communications network, e.g. Ethernet broadcast networks, wherein methods and arrangements for checking connectivity and detecting connectivity failure of data transmission paths.
[0035] The network configuration in FIG. 2A corresponds to the network configuration illustrated in FIG. 1A and described above. In the similar way, the network configuration in FIG. 2B corresponds to the network configuration illustrated in FIG. 1B and described above. The arrangement 100 for checking connectivity and detecting connectivity failure of data transmission paths is adapted to be implemented in the first and second nodes. In the following description, for purpose of generalization, the edge nodes 12 in FIGS. 1A and 1B are denoted first nodes 112 and the subscriber nodes are denoted second nodes 118 . The data paths 11 in FIGS. 1A and 1B corresponds to the data paths 110 in FIGS. 2A and 2B . The Ethernet broadcast domains 14 in FIGS. 1A and 1B corresponds to the Ethernet broadcast domains 114 in FIGS. 2A and 2B .
[0036] The first nodes 112 comprise an issuing device 116 besides other elements and components, e.g. gateway functionality, router functionality, etc., necessary for the functionality of a first node. Said other elements and components are not illustrated only for the purpose of avoiding details unnecessary for the understanding of the operation of the methods and arrangement.
[0037] According to one example of an embodiment of the arrangement 100 for checking connectivity and detecting connectivity failure of data transmission paths between one or more first nodes 112 and one or more second nodes 118 in an Ethernet broadcast network 114 , the first nodes 112 comprises an issuing device 116 configured to transmit periodically an Address Resolution Protocol, ARP, message towards a second node 118 . The ARP message may be a Gratuitous ARP, GARP, message comprising a Sender's Protocol Address, SPA, field and a Target Protocol Address, TPA, field, wherein the issuing device 116 is configured to set the Sender's Protocol Address, i.e. the protocol address of the first node, into the TPA field, i.e. TPA=SPA. As the GARP message is periodically transmitted, it is denoted Periodic ARP, PGARP. The time period between two sent PGARP messages towards a certain second node 118 may be denoted message interval or message issuing interval. Further, the issuing device 116 is configured to generate and transmit Ethernet Address Resolution Protocol, ARP, request messages. ARP messages are described in more detail in reference [ 4 ], see reference list in the end of the Detailed Description section of this disclosure.
[0038] For example, two user equipments, computers A and B, are in an office, connected to each other on the office local area network by Ethernet cables and network switches, with no intervening gateways or routers. Computer A wants to send a packet to B. Through other means, it determines that B's IP address is 192.168.0.55. In order to send the message, it also needs to know B's MAC address. First, A uses a cached ARP table to look up 192.168.0.55 for any existing records of B's MAC address (00:eb:24:b2:05:ac). If the MAC address is found, it sends the IP packet on the link layer, L2, to address 00:eb:24:b2:05:ac via the local network cabling. If the cache did not produce a result for 192.168.0.55, A has to send a broadcast ARP message (destination ff:ff:ff:ff:ff:ff) requesting an answer for 192.168.0.55. B responds with its MAC address (00:eb:24:b2:05:ac). B may insert an entry for A into its own ARP table for future use. The response information is cached in A's ARP table and the message can now be sent.
[0039] Ethernet ARP messages may also be used as an announcement protocol. This is useful for updating other hosts' mapping of a hardware address when the sender's IP address or MAC address has changed. Such an announcement, also called a gratuitous ARP message, is usually broadcast as an ARP request containing the sender's protocol address (SPA) in the target field (TPA=SPA), with the target hardware address (THA) set to zero. An alternative is to broadcast an ARP reply with the sender's hardware and protocol addresses (SHA and SPA) duplicated in the target fields (TPA=SPA, THA=SHA).
[0040] An ARP announcement is not intended to solicit a reply; instead it updates any cached entries in the ARP tables of other hosts that receive the packet. The operation code may indicate a request or a reply because the ARP standard specifies that the operation code is only processed after the ARP table has been updated from the address fields.
[0041] Many operating systems perform gratuitous ARP during startup. That helps to resolve problems which would otherwise occur if, for example, a network card was recently changed (changing the IP-address-to-MAC-address mapping) and other hosts still have the old mapping in their ARP caches.
[0042] Gratuitous ARP is also used by some interface drivers to provide load balancing for incoming traffic. In a team of network cards, it is used to announce a different MAC address within the team that should receive incoming packets.
[0043] The proposed connectivity check mechanism applies periodically sent Ethernet ARP request messages being sent to ff:ff:ff:ff:ff:ff hardware (MAC) broadcast address with the source hardware (MAC) address of the sender device. Sender Protocol Address (SPA) and Target Protocol Address (TPA) are both set to the L3 protocol address of the machine issuing the ARP request message. In case IPv4 is applied as a L3 protocol, then SPA and TPA both equal to the IP address of the first node comprising the issuing device.
[0044] These ARP message types are often referred to as Gratuitous ARP messages.
[0045] According to arrangements and methods described hereafter, Periodical Gratuitous ARP messages (PGARP) are sent over the Ethernet broadcast domain periodically with a pre-defined time interval. Time interval shall be tuned to the system's requirements and characteristics. PGARP messages are sent by the first nodes 112 . PGARP message interval shall be set to the same value in the whole broadcast domain.
[0046] Each network node in a Ethernet broadcast domain system maintain an ARP table which reflects live connections at any given time on L2 towards all applied L3 addresses used as next hops in the system.
[0047] With PGARP messages the first nodes announce that links towards the second nodes 118 are alive.
[0048] The second nodes 118 , which may be considered as the receiving hosts, comprise a number of components and elements for handling an ARP message and other elements and components necessary for the functionality of a second node. Other elements and components are not illustrated only for the purpose of avoiding details unnecessary for the understanding of the operation of the methods and arrangement.
[0049] According to the illustrated examples of embodiments, each second node 118 is provided with a listening device 120 . The listening device 120 comprises a receiving device 122 configured to receive an ARP message periodically sent from one of said first nodes 112 over a data transmission path 110 and storing means 124 configured to store the time instant when said ARP message was received as an entry of the latest received ARP message from the first node 118 in a record 134 comprising entries corresponding to one or more data paths 110 to said one or more first nodes 112 . The listening device 120 also comprises at least one timer 132 . The timer 132 is started or restarted and runs for a predetermined time period, herein denoted aging value. When said time period has run out, timer expires, and the connectivity check is performed. The timer automatically starts again after each ended period. It should be noted that in some embodiments there may different timers for different entries, e.g. one timer for one group of entries corresponding to a group of data transmission paths and additional timers for other data paths in the Ethernet broadcast domain. The listening device is further provided with checking means 126 configured to detect connectivity failure by periodically checking said record 134 for entries in relation to a predetermined threshold value, aging value, and to detect if one or more of said entries have exceeded said predetermined threshold value.
[0050] The checking means 126 is further configured to notify a service entity 128 if a connectivity failure has been detected. Said service entity may be incorporated in the listening device 120 , but in some embodiments the listening device 120 is connected to the service entity being placed outside the listening device.
[0051] The service entity 128 is configured to send a notification message as an alert and/or alarm message to a subscriber connected to the second node and/or a responsible party, e.g. the responsible operator or maintenance system of the Ethernet LAN, to inform about the connectivity failure of a data transmission path. The responsible party may then take care of the failing path and/or redirect the data packet traffic to a data path which is still up and working. The message may be sent to a maintenance node comprising an application which is triggered by the received message to repair the failing data path. By means of a failover mechanism, the service entity 128 may direct data transmission over a data path 110 to another of said first nodes 112 for which connectivity failure has not been detected.
[0052] The listening device 120 and its components and elements described above are controlled by a controller 130 . The listening device 120 may either comprise the controller 130 or be controlled by a separate controller 130 .
[0053] Embodiments of the issuing device 116 and the listening device 120 may be implemented in digital electronically circuitry, or in computer hardware, firmware, software, or in combinations of them. Embodiments may be implemented in a computer program product tangibly embodied in a machine readable storage device for execution by a programmable processor; and method steps may be performed by the programmable processor, such as the controller 130 , executing a program of instructions to perform functions of the invention by operating on input data and generating output.
[0054] Embodiments may advantageously be implemented in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program may be implemented in a high-level procedural or object-oriented programming language or in assembly or machine language if desired; and in any case, the language may be a compiled or interpreted language.
[0055] Generally, the controller 130 will receive instructions and data from a read-only memory and/or a random access memory. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing may be supplemented by, or incorporated in, specially designed ASICs (Application Specific Integrated Circuits).
[0056] The issuing device 116 and listening device 120 are configured to support a method and embodiments thereof for checking connectivity and detecting connectivity failure of data transmission paths. How the different components and elements of the issuing device and listening device operate and cooperate for supporting said method and embodiments thereof is described in more detail with reference to FIGS. 3 , 4 and 5 hereafter.
[0057] FIG. 3 is a flowchart illustrating of the method for enabling checking connectivity and detecting connectivity failure of data transmission paths between one or more first nodes and one or more second nodes in an Ethernet broadcast network. The first node is therefore configured to:
[0058] S 100 :—Transmitting periodically an Address Resolution Protocol, ARP, message towards a second node. The ARP message is generated and transmitted periodically by means of the issuing device 116 . Further, the Address Resolution Protocol, ARP, message is preferably a Periodic Gratuitous ARP message comprising a Sender's Protocol Address, SPA, field and a Target Protocol Address, TPA, field. The issuing device is further configured to set the Sender's Protocol Address, i.e. the protocol address of the first node, into the TPA field, thus resulting in that TPA=SPA, i.e. both fields comprises the same address.
[0059] FIG. 4 is a flowchart illustrating an example of the method in a second node.
[0060] The Ethernet broadcast network comprises one or more first nodes, each of said first nodes comprises an issuing device, and one or more second nodes, each of said second nodes comprises a listening device. According to the method, the listening device 120 is configured to:
[0061] S 210 :—Receive an ARP message periodically sent from one of said first nodes over a data path. The issuing device 116 is configured to generate and transmit Periodical Gratuitous ARP messages, PGARP, over a data transmission path over the Ethernet broadcast domain periodically with a pre-defined time interval towards the second node 118 , which may be a subscriber host. The predetermined time interval, denoted message interval, shall be tuned to the system's requirements and characteristics. PGARP messages are sent by the first nodes 112 . PGARP message interval shall be set to the same value in the whole broadcast domain. The PGARP message is usually broadcast as an ARP request containing the sender's protocol address (SPA) in the target field (TPA=SPA), with the target hardware address (THA) set to zero.
[0062] The listening device 120 comprises a receiving device 122 configured to receive each ARP message periodically sent. The issuing device 116 is also configured to send ARP request messages, which the receiving 122 device also is able to receive and handle as stated in the standard document [ 4 ], see reference list.
[0063] The method further comprises:
[0000] S 220 :—Store the time instant when said ARP message was received as an entry of the latest received ARP message from the first node in a record comprising entries corresponding to one or more data transmission paths to said one or more first nodes. The listening device 118 is therefore provided with storing means 124 , which is configured to store the time instant when said ARP message was received as an entry of the latest received ARP message from the first node 118 in a record 134 . Said record 134 may comprise entries corresponding to one or more data paths 110 to said one or more first nodes 112 . Said record may be a standard Address Resolution Protocol, ARP, table that has been modified to store even time instants of received ARP messages. The ARP table stores the peer MAC addresses to which the ARP messages are addressed.
[0064] The method further comprises:
[0065] S 230 :—Detect connectivity failure by periodically checking said record for one or more entries in relation to a predetermined threshold value, aging value. The listening device 118 is further provided with checking means 126 configured to detect connectivity failure by periodically checking said record for entries in relation to a predetermined threshold value, denoted aging value, and to detect if one or more of said entries have exceeded said predetermined threshold value. The aging value may preferably be set to a multiple of the message interval. The checking means 126 may further be configured to notify a service entity 128 if a connectivity failure has been detected. Said service entity may be incorporated in the listening device 120 , but in some embodiments the listening device 120 is connected to the service entity being placed outside the listening device.
[0066] The service entity 128 may be configured to send a notification message as an alert and/or alarm message to a subscriber connected to the second node and/or a responsible party, e.g. the responsible operator of the Ethernet LAN, to inform about the connectivity failure of a data transmission path. The responsible party may then take care of the failing path and/or redirect the data packet traffic to a data path which is still up and working. The message may be sent to a maintenance node comprising an application which is triggered by the received message to repair the failing data path. The service entity 128 may also have been configured to direct data transmission over a data path 110 to another of said first nodes 112 for which connectivity failure has not been detected by means of a failover mechanism.
[0067] In the following, the checking and detecting process is described in more detail with reference to FIG. 5 .
[0068] FIG. 5 is a flowchart of an embodiment of the checking and detecting process S 230 . The checking and detection mechanism is illustrated for a given monitored first node, e.g. edge node or issuing host node, 112 . For each first node 112 in the network the same mechanism shall be applied, but the aging value can differ between different second nodes 118 , e.g. subscriber hosts.
[0069] Said process starts with the step of starting the timer in the checking means 126 that checks the record of entries in the record 134 , e.g. the ARP table:
[0070] S 232 :—Start timer. The timer 132 of the listening device 120 is started or restarted and runs for a predetermined time period, herein denoted aging value. When said time period has run out, timer expires, S 234 , the connectivity check is performed. The timer automatically restarts after each expiration of a time period;
[0071] S 234 :—Timer expires. The timer 132 runs for a predetermined time, which is the interval set between two successive checks performed by the checking means 126 . During this interval, a number of PGARP messages are periodically received from each one of the first nodes connected to the second node. The number of PGARP messages received during the threshold value interval depends on the (PGARP) message (issuing) interval. The threshold value can be unique per each second node 118 in the domain, but it is preferably a multiple of the PGARP message interval. The time instant for each received message is stored and thereby updating the entry of a data path corresponding to the first node from which the PGARP message was received. If connectivity of one data path is lost, the entry of said data path and first node will after a while exceed the aging value as the time instant for said entry will not be updated;
[0072] S 235 : Checking record for one or more entries in relation to a predetermined threshold value, aging value. The checking means 126 in the second nodes periodically checks their ARP tables 134 , to see if the timer 132 for entries in the record, or ARP (cache) tables 134 , indicates a time longer than the pre-defined threshold value, Aging Value, has passed since last a message was received from that specific first node;
[0073] S 236 : Connectivity failure detected? If the checking means does not detect any entries having time values that exceed the threshold value, i.e. aging value, the condition in S 236 is not fulfilled, No, the checking and detecting process and mechanism restarts the timer, S 232 . If, however, the checking means 126 does detect one or more entries having time values that exceed the threshold value, i.e. aging value, the condition in S 236 is fulfilled, Yes, the checking means 126 is configured to notify a service entity 128 if a connectivity failure has been detected;
[0074] S 238 : Failure notified? As the checking and detecting process runs on without stop, and if the detected connectivity failure has not been taken care of, a notification will be sent from the checking means 126 for each loop of the process. The service entity may therefore have been configured to only accept the first connectivity failure notification for a certain data path and first node. Thus, service entity is configured to check if the connectivity failure has already been notified, or not. If the condition is fulfilled, yes, the timer is restarted, S 232 , without the sending of any new notification message. The service entity may store a sent message, and the storage is checked if it contains a message corresponding to the current notification. If said condition is not fulfilled, a notification message is sent in S 240 ;
[0075] S 240 : Notify connectivity failure. The service entity 128 is configured to generate and send a notification message as an alert and/or alarm message to a subscriber connected to the second node and/or a responsible party, e.g. the responsible operator or management system of the Ethernet LAN, to inform about the connectivity failure of a data transmission path. The responsible party may then take care of the failing path and/or redirect the data packet traffic to a data path which is still up and working. The message may be sent to a maintenance node comprising an application which is triggered by the received message to repair the failing data path. The service entity 128 could also have been configured to direct data transmission over a data path 110 to another of said first nodes 112 for which connectivity failure has not been detected by means of a failover mechanism. The timer or timers are restarted, S 232 , after the service device 128 has been trigged by the checking device.
[0076] The above described examples and embodiments of the arrangement and method for checking connectivity and detecting connectivity failure of data transmission paths have a number of advantages:
Fast detection mechanism for failures in the physical layer (L1), data-link layer (L2) and data network layer (L3); Works on L2; Scalable according to system's requirements; Suitable when Ethernet Operation, Administration and Maintenance functionality is not possible to be used (e.g. with a Base Station Control, eNB, etc) and L2 mechanism is preferred; Suitable if IPv6 Neighbor Discovery is not available; Suitable if BFD is not desired due to huge blade systems where BFD requires tremendous amount of supervision sessions; Easy enhancement of existing implementations already in place; Each second node, i.e. subscriber host, can decide when to trigger the failover mechanism. The first nodes, i.e. edge nodes, can use the same configuration regardless the configuration of the second nodes; Compared to ICMP Ping based supervision method, the new solution uses less IP addresses and subnets, e.g. in a Base Station Control, eNB, etc.; The solution provides less complexity to implement than the other solutions.
[0087] A number of embodiments have been described. It will be understood that various modifications may be made without departing from the scope of this disclosure. Therefore, other implementations are within the scope of the following claims.
REFERENCE LIST
[0000]
[1] Neighbor Discovery for IP version 6 (IPv6), IETF RFC 4861
[2] Bidirectional Forwarding Detection (BFD), IETF RFC 5880
[3] IEEE 802.1ag—Connectivity Fault Management
[4] An Ethernet Address Resolution Protocol, IETF RFC 826
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A method is presented for connectivity checking and detection of connectivity failure, based on a modified Ethernet ARP address resolution mechanism to detect broken connectivity on physical, data-link and network layer between a first and a second node. The detection mechanism uses Periodical Gratuitous ARP messages (PGARP). PGARP messages are sent by a first node, the sender host or Issuer. On the other side of a data path is a second node, receiver host or Listener configured to detect lost connectivity by means of missing PGARP messages. The process on the Listener then informs subscribing services, host local, or remote, about the state of the connectivity.
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[0001] This application claims priority from provisional patent applications 60/330,934 filed on Nov. 2, 2001, No. 60/294,573 filed on Jun. 1, 2001, and No. 60/290,650 filed on May 15, 2002.
FIELD OF THE INVENTION
[0002] The present invention is directed to a silt fence system, and in particular, to a system that employs flexible yet long-lasting fence stakes.
BACKGROUND ART
[0003] In the prior art, it is mandatory in most jurisdictions to use erosion control measures at construction sites. In many instances, hay bales, filters over drain openings, or the like are used to control erosion. Another popular technique is the erection of silt fences around a perimeter of a particular site. These fences include a fabric material that is water permeable, but resistant to the passage of fine dirt or soils, sediment, and the like. The principal use of these types of fences is to control the erosion of the land under construction, and prevent soil from entering the public drainage system.
[0004] One significant problem with silt fences is the inability of these structures to handle excessive forces created by the combination of soil and water accumulating at the fence line. The fence material is usually stapled to wooden stakes that are pounded in the ground. In many instances, the wooden stakes are not strong enough or are too rigid to withstand the large hydraulic forces created by the soil and/or water. Thus, the stakes often times break, thus compromising the integrity of the silt fencing.
[0005] Another problem with these prior art fence systems is a lack of longevity for the wooden stakes. In many fence installations, the stakes rot due to the moist conditions well before the construction job is completed. This is particularly burdensome in construction sites that may be in existence for more than one or two years. With the degradation of the wooden stakes, the silt fence system must be continually repaired, and such repair increases the cost of the construction both in terms of manpower costs to repair the fence, material costs for the stakes themselves, and lost time towards completing the construction. In addition, builders can be subjected to fines or other penalties from the localities for local erosion control ordinance violations, and these types of penalties can be particularly onerous to the builder.
[0006] As such, a need has developed to provide improved silt fencing for erosion control. In response to this need, the present invention provides a silt fence system that employs flexible fence stakes that are capable of withstanding heavy loads without breaking. In addition, the fence stakes have increased service lives so that replacement of the stakes is minimal during the construction period.
SUMMARY OF THE INVENTION
[0007] It is a first object of the present invention to provide an improved silt fence system.
[0008] Another object of the invention is to provide a silt fence system that employs stakes that have a rubber or rubber material core for flexibility, and an outer casing or coating of a plastic or polymeric material for both rigidity or strength and longevity.
[0009] Still another object of the invention is a method of installing the improved silt fence system in place of systems employing wooden stakes.
[0010] Other objects and advantages of the present invention will become apparent as a description thereof proceeds.
[0011] The invention is an improvement in silt fence systems that employ a fabric material and a plurality of stakes, wherein the fabric material is secured to the stakes to define an erosion control barrier at a construction site. The improvement comprises in one embodiment that each stake have a core of a flexible material and an outer casing of a plastic or polymeric material.
[0012] The invention also entails a method of installing a silt fence at a construction site by providing a silt fence fabric material, and a plurality of fence stakes, wherein each fence stake further comprising a core of a flexible material and an outer casing of a plastic or polymeric material. At least a portion of each stake is inserted into the ground, and the stakes are in spaced apart intervals defining an erosion barrier line; the silt fence fabric material to attached to the stakes.
[0013] The system and method can include means for attaching the fence to the stakes, said means including (1) fasteners sized to fit within openings in the stakes, (2) staples, and (3) snaps molded to the stakes to fit within openings in the stakes.
[0014] The stakes can be square in cross section and the fence can have a reinforcing band running along its length. The fence can have a flap at a bottom edge thereof, with the flap adapted to rest on a ground surface. The flap can have a plurality of openings to attach the flap to the ground surface using stakes, pins or other fasteners. The stake outer casing can be molded or extruded onto the flexible core and the flexible material can be a rubber material. The polymeric material can be PVC piping.
[0015] In another embodiment, each stake has a core segment of at least a cement or cement-like material and an outer casing of a plastic or polymeric material. The method for installing this stake parallels the method described above for the stake with a flexible core. The core can include a granular material, and more preferably, a granular material that is disposed between segments of the cement or the cement-like material. The invention also relates to the stakes of the silt fence system as well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Reference is now made to the drawings of the invention wherein:
[0017] [0017]FIG. 1 is a perspective view of one embodiment of a stake of the invention;
[0018] [0018]FIG. 2 is a cross-sectional view along the line II-II of FIG. 1;
[0019] [0019]FIG. 3 is a cross-sectional view of an alternative stake configuration; and
[0020] [0020]FIG. 4 is a perspective view of one embodiment of the silt fence system of the invention;
[0021] [0021]FIG. 5 is a sectional view of one mode of attachment of the fence to the stake of FIG. 4;
[0022] [0022]FIGS. 6 and 7 are sectional views of alternative modes of attachments; and
[0023] FIGS. 8 - 12 show various views of another embodiment of the inventive stake.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present invention offers significant advantages in the field of erosion control, particularly erosion control through the use of silt fences. The invention involves a silt fence system wherein the fence stakes have a flexible core made from a rubber or rubber-like material, and an outer casing or core made from a plastic or polymeric material. The flexible core allows the stakes to flex when subjected to heavy loads from soil and water against the fence fabric material. The plastic outer core provides strength to support the loads, and longevity in resisting the affects of the elements, e.g., humidity, sunlight, abrasion, etc., over time.
[0025] Referring now to FIGS. 1 - 7 , one embodiment of the silt fence system of the invention is designated by reference numeral 10 (FIG. 4), and includes a silt fence 1 , and a pair of fence stakes 3 . While only a pair of stakes 3 are shown, it should be understood that the system could involve a number of stakes.
[0026] In FIG. 1, each stake 3 is depicted with a square cross section, but as explained below, other surface configurations can be employed. The stake 3 has a striking end 5 and a pointed opposite end 7 . The stake 3 also includes an inner core 9 and an outer casing or layer 11 (FIG. 2). The core 9 is made of a flexible material such as a rubber material or the like. The outer casing is shown with openings 12 to facilitate attachment of the silt fence as discussed below. As also explained below, other types of attachments can be utilized.
[0027] The dimensions of the stake, either in terms of a side dimension, or a diameter, can vary depending on the intended application. For example, in areas where high loads are anticipated, e.g., at the bottom of a slope or the like, the stakes can have a heavier duty construction such that the dimensions would be larger. In lighter duty applications, the dimensions can be smaller since the forces from soil/water would be less. The casing thickness could vary as well depending on the particular application. A thicker casing could be used where more strength is needed, and a thinner casing could be employed in applications where less forces may be present. Similarly, the dimension of the core could change depending on the application, a larger core could be employed where more flexibility is needed.
[0028] A preferred dimensional range for a square stake would be between about one-half inch square to 2.5 inches square, with a more preferred size of about 2 inches square. The casing dimensions could vary using thin dimensions, e.g., up to {fraction (1/4)} inch, to up to an inch or more in thicker uses.
[0029] [0029]FIG. 3 shows an alternative stake construction wherein the core 9 ′ is circular with an annular outer casing 11 ′.
[0030] [0030]FIG. 4 shows the system 10 with a portion of a silt fence 13 . The fence 13 has a flap 15 , preferably about 6 inches in width, designed to rest on the ground surface 17 when installed on the stakes 3 . The flap 15 can have openings 19 , e.g., grommets or the like, to allow the flap to be pinned or staked to the ground with pins 21 for additional resistance against loads applied to the fence and stakes. Of course, openings other than grommets can be employed to assist in keeping the flap down. Further yet, the flap 15 could be made without openings if desired.
[0031] The silt fence 13 can also have a band 23 of reinforcement running along its length, such as nylon or the like. The band can be sewn onto the fence fabric to provide the reinforcement, or be made an integral part thereof. Preferably as shown in FIG. 4, the band is at or near the bottom of the fence to provide maximum resistance against forces from soil and/or water.
[0032] The silt fence material itself is well known in the art of erosion control, and a further explanation is not necessary for understanding of the invention. Examples of silt fences are disclosed in U.S. Pat. No. 5,108,224, herein incorporated by reference.
[0033] The core of the stake can be any number of flexible materials such as rubber or rubber-like material. Similarly, the outer casing can be any number of plastic or polymeric materials, such as polyethylene, polyvinyl chloride, polypropylene, or the like. A preferred material for the core is an EDPM rubber material for flexibility, with the outer core/casing being made of polyvinyl chloride for both strength and resistance to the environment.
[0034] The stakes can vary in height, e.g., 1 to 5 feet, and also vary in cross sectional shape or configuration. For example, besides the stakes depicted with square cross sections, stakes could employ oval, circular, octagonal, or just about any polygonal shape. Further, the outer surface of the outer casing could have one configuration with the cross sectional shape of the inner core having another shape. For example, the outer surface could be square in cross section with the inner core being circular in cross section.
[0035] In one mode, the outer casing can be formed on the inner core, e.g., by extrusion, by dipping, by spraying, by molding, by extrusion, or the like. In another mode, the outer casing could be a pre-formed article, e.g., a sleeve that is snugly fit over the inner flexible core. Preferably, the casing is molded to the core.
[0036] The method of use entails first inserting each stake into the ground in spaced apart intervals. Insertion can be done using a hammer or the like and directing the pointed edge of the stake towards the ground. The silt fence is then attached to the stakes, with the flap folded toward the side intended to catch the soil. The flap can then be secured to the ground surface using the pins 21 .
[0037] To attach the fence to the stakes in one mode, as shown in FIG. 5, a tack 31 could be employed to fit within a complementary sized opening 33 in the outer casing 11 . Tacks 31 would be pressed through the fence material 13 and into the openings 33 to secure the fence in place. Alternatively, the fence material 13 could be stapled using staples 35 as shown in FIG. 6.
[0038] [0038]FIG. 7 shows an embodiment wherein plastic snaps 37 could be molded into the outer casing 11 and used to secure the fence 13 . In this mode, the stakes would be end stakes to allow for attachment of the end edge 39 of the fence 13 to the stake, as opposed to stakes used in the middle of the fence as shown in FIG. 4. It should be understood that the mode of attachment can vary from that disclosed and other attachments can be utilized to secure the fence to the stakes, e.g., other type fasteners or snaps and the like. Another example would be an elongated member having a number of protrusions, each protrusion aligned to fit within the spaced apart openings 12 in the stake, see FIG. 4.
[0039] Although not shown, the stake end 5 could have a reinforced layer to better withstand the impact from driving the stake into the ground. Examples of reinforced layers include a fiber-reinforced plastic to resist impact, a plastic which is more flexible or forgiving than the outer casing 11 to better absorb impact, or even a flexible material such as the core material or like materials.
[0040] While the stake is preferably used as a support for silt fence systems, it can be used in other applications such as supporting landscape items such as trees, bushes and the like, or other items or articles such as signs, or the like. The stakes could also be used with twine, rope, etc., to surround areas to limit access thereto.
[0041] Another aspect of the invention involves a stake that is made of polymer piping and a core of a rigid material such as a cement. Referring to FIG. 8, the piping is designated by reference numeral 41 , and it is preferably PVC piping. The piping has an inside passageway 43 . Referring to FIG. 9, the passageway is filled with a cement 45 , preferably a quick-setting cement, thus forming the stake 40 . Since the cement is exothermic, the setting action helps form a bond between the inner wall of the PVC piping and the cement.
[0042] The cement can occupy the entire passageway length, or a portion thereof. In a preferred mode as shown in FIG. 10, sand 47 can be situated between two segments of cement 45 . In this way, the piping flexibility is enhanced over its length, and its overall weight is reduced. In yet another mode as shown in FIG. 11, the cement 45 could occupy a lower portion of the piping with the sand 47 occupying an upper portion. The one end of the piping with the sand 47 could have a cap 49 to contain the sand 47 occupying the one end of the piping 41 .
[0043] In yet another mode as shown in FIG. 12, one end 51 of the piping 41 ′ can be tapered to facilitate driving the piping into the ground.
[0044] It should be understood that the embodiments of FIGS. 8 - 12 could be substituted for the other stakes with the silt fencing, methods of attachment, and methods of use as described above for FIGS. 1 - 7 .
[0045] In summary, silt fence stake system embodiment comprises a plurality of silt fence stakes and a length of slit fence, the stakes attached to the length of silt fence at intervals to create a silt barrier. Each stake further comprises a length of polymer piping, preferably PVC piping, wherein at least a portion of an inner passageway of the piping has a rigid material such as a cement therein. Preferably, the rigid material is inserted into the passageway, and then the stake is installed with the fence. The inner passageway can be filled entirely with the cement or a mixture of cement and another material that provides flexibility such as a sand or the like.
[0046] The piping can be attached to the silt fence and can be driven into the ground in any conventional manner. While PVC and quick-setting cement are exemplified, other polymers could be used for the piping, and other materials could be used as the rigid material insert other than cements, e.g. other setting compositions that would add rigidity to the piping. The polymer piping affords protection against the elements with the cement providing rigidity against hydraulic forces.
[0047] A preferred way of attachment of the silt fence to the stakes is through the use of hook and loop fasteners.
[0048] As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfills each and every one of the objects of the present invention as set forth above and provides new and improved silt fence system and method of use.
[0049] Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims.
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A silt fence system employs silt fencing that is supported along the fence length with stakes. The stakes have a polymer or plastic outer casing, and either a flexible core or a core segment of rigid material such as cement. The outer casing provides resistance to the elements and the flexible material provides the give to handle hydraulic forces with breaking of the stake, as is the case when wooden stakes are used. The system employs the rigid core stakes in situations where hydraulic forces are large enough that the combination of the plastic outer casing and flexible core is insufficient to maintain stake position.
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RELATED APPLICATION INFORMATION
[0001] This application claims priority to provisional application Ser. No. 61/026,194 filed on Feb. 5, 2008, incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] This disclosure relates to positioning blocks for securing voltage carrying members, and more particularly, to a positioning block configured to connect to riser bus bars to maintain a position of the riser bus bars and gaps therebetween.
[0004] 2. Description of the Related Art
[0005] Meter modules include a plurality of externally visible power consumption meters. The meter modules electrically connect with an electric power distribution system by an electric busway system riser. The busway system riser includes separate vertically extending bus conductors, one for each phase within a multi-phase power distribution system along with a neutral bus conductor. Connected to these bus conductors are riser bus bars or bus bars. During the assembly or installation of a busway meter module apparatus, the bus bars may move increasing the risk of coming into contact with adjacent riser bars of different polarities.
[0006] In conventional systems, the riser bars were connected to meter socket assemblies and straps in an assembly-fixture. The assembly fixture with the riser bars and meter socket assemblies were then transported and installed into a final assembly of the busway system. This method is cumbersome and leaves the possibility of shifting or undesired movement of the bus bars during transport and installation.
SUMMARY OF THE INVENTION
[0007] A positioning block and method for spacing riser bus bars includes an insulating material body forming recesses along a longitudinal axis of the block, each recess for receiving an electric riser bus bar therein. A binding feature is formed adjacent to at least one wall of the recesses for securing the riser bus bar within the recess. A locator feature is formed between the walls of each recess for aligning the riser bus bar within the recess.
[0008] Another positioning block for spacing riser bus bars includes an insulating material body forming recesses along a longitudinal axis of the block, each recess for receiving an electric riser bus bar therein. A pair of opposing binding features is formed adjacent to opposing walls of the recesses for securing the riser bus bar within the recess. A locator feature is formed between the walls of each recess for aligning the riser bus bar within the recess.
[0009] A method for securing riser bus bars includes providing a positioning block having an insulating material body forming recesses along a longitudinal axis of the block, a pair of opposing binding features formed adjacent to opposing walls of the recesses and a locator feature formed between the walls of each recess; aligning the positioning block on one or more riser bus bars by employing the locator feature to receive an electric riser bus bar within the recesses; and securing the positioning block on the riser bus bars by employing the binding features to secure the riser bus bars within the recesses.
[0010] These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0011] This disclosure will present in detail the following description of preferred embodiments with reference to the following figures wherein:
[0012] FIG. 1 is a perspective view of an electrical enclosure with a cover removed having a meter stack fabricated therein also with a cover removed;
[0013] FIG. 2 is a perspective view of the electrical enclosure of FIG. 1 with a close up view of riser bus bars;
[0014] FIG. 3 is a perspective view of a positioning block in accordance with one illustrative embodiment;
[0015] FIG. 4 is a perspective view showing a positional block being installed on riser bus bars in accordance with the present principles;
[0016] FIG. 5 is a perspective view showing a sub-assembly formed by using two positional blocks on riser bus bars in accordance with the present principles;
[0017] FIG. 6 is a magnified view of detail 5 shown in FIG. 5 showing a positional block attached to the riser bus bars in accordance with the present principles; and
[0018] FIG. 7 is a perspective view of the positioning block at a reverse angle showing recesses or openings where access to snap stems permits the removal of the positional block after its installation in accordance with one illustrative embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] The present invention provides a way of positioning, stabilizing and insulating single or three phase vertical bus sockets. A positioning block in accordance with the present principles is employed to fasten together two or more vertical bus bars keeping them properly spaced electrically as well as providing a way to keep the bus bars assembled as a unit while attaching them to meter socket positions in a cabinet or meter unit.
[0020] The positioning block in accordance with the present principles gap the single or 3 phase vertical bus bars that distribute electrical current to individual meter sockets in a modular metering unit. The positioning bar serves as a support structure/fixture preventing the bus bars from coming into contact with one another as well as providing a way of keeping the bus assembly intact while installing the riser bus bars in the meter stack assembly.
[0021] The present invention will be described in terms of a meter module assembly but should not be construed as limited to the illustrative example and may be employed with other electrical assemblies of other devices where a temporary assembly of parts is needed.
[0022] 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 well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
[0023] Referring now in specific detail to the drawings in which like reference numerals identify similar or identical elements throughout the several views, and initially to FIG. 1 , a partially assembled meter module assembly or enclosure 10 includes three (or four or more) electrically insulated bus bar conductors or riser bus bars 12 for a power system. The meter assembly 10 includes a meter stack enclosure 18 . Both the meter module assembly 10 and the meter stack enclosure 18 are depicted with their respective covers removed to show internal details. The bus bar conductors 12 each carry a separate current phase of a three-phase electrical power distribution system. The meter module assembly 10 , when assembled is configured to receive a plurality of meters (not shown) on meter sockets 14 .
[0024] The riser bus bars 12 are installed in the meter stack enclosure 18 and may be bolted or otherwise mounted therein. Since each riser bus bar 12 is installed separately tolerances and misalignments could build up and cause the assembly to function outside of specifications. Since the electrical components may be carrying high voltages and currents providing a predetermined and safe gab/spacing between the riser bus bars 12 is an important consideration.
[0025] Referring to FIG. 2 , a closer view of the meter stack enclosure 18 is shown to more clearly show the riser bus bars 12 therein. The riser bars 12 are disposed vertically in the enclosure 18 . Each riser bar 12 preferably includes at least one through hole 20 formed therein. The through hole 20 in each riser bus bar 12 is preferably provided at a same corresponding location on the riser bar 12 such that at assembly time a set of through holes line up horizontally across the riser bus bars 12 . This could be altered to provide a hole pattern as needed based upon the type or design of a position bar as described hereinafter.
[0026] Referring to FIG. 3 , a positioning block 100 is provided in accordance with the present principles. Block 100 may include an insulating material, and preferably includes a dimensionally stable insulating material. For example, block 100 may include XYRON 540V (commercially available from ASAHI™) or NORYL SE1-X (commercially available for GENERAL ELECTRIC™). In one illustrative example, block 100 includes body dimensions of, e.g., 8 in.×0.750 in.×1.2 in. Other dimensions are also contemplated and acceptable depending on preference and application.
[0027] Block 100 includes a plurality of recesses 102 . These recesses 102 are spaced apart by a predetermined or set amount to provide a fixed gap between riser bars 12 ( FIG. 2 ) when assembled. In one embodiment, regions 104 provide a spacing of 0.750 inches between riser bars 12 . Other gap distances may also be employed. Binding snaps 106 are formed at or near walls of the recesses 102 . Binding snaps 106 are designed and configured such that when riser bus 12 is fastened to the block 100 , an angular feature 108 of the snap 106 will flex and spread to capture a broader area of the bus bar surface. The snaps 106 will flex using snap stems 134 . When the snaps 106 recover, the riser bus 12 will be captured and secured by the block 100 . Locator pins 110 are provided protruding from a surface 112 . The locator pins 110 fit into through holes 20 ( FIG. 2 ) of riser bars 12 .
[0028] Other snaps or binding designs are also contemplated. In one such embodiment, a single binding on one wall of a recess 102 may be employed along with an opposing wall of that recess to secure the riser bar 12 (e.g., only one binding is employed). In other embodiments, other mechanical elements such as screws, cams, clips or the like may be employed to secure the riser bars 12 in recesses 102 .
[0029] Referring to FIGS. 4 , 5 and 6 , during assembly, the riser bars 12 are aligned with the snaps 106 and locator pins 110 of the positioning block 100 . The positioning block 100 is forced toward the riser bars 12 into the recesses 102 , preferably one at a time. The riser bar 12 is forced into the recess 102 so that the locator pins 110 pass through the through hole 20 . The locator pins 110 of block 100 are aligned with holes 20 in the riser bus bars 12 ( FIG. 4 ). The snaps 106 are spread apart from each other for that recess 102 as the block 100 is pushed downward in the direction of arrow “A” ( FIG. 4 ).
[0030] The binding snaps 106 expand outward until a width of the bus bar 12 clears snap points of the snaps 106 . The snaps 106 then spring inwardly capturing the bus bar 12 in place ( FIGS. 5 and 6 ). As the riser bar 12 moves further into the recess 102 , the snaps 106 recover to capture the riser bar 12 in the recess 102 keeping the riser bar 12 securely in position. To release the riser bar 12 , the snaps 106 simply need to be spread apart and the positioning block pulled away from the riser bar 12 .
[0031] To ensure a proper gap along the riser bars 12 , multiple positioning blocks 100 may be installed along the length of the riser bars 12 . In one embodiment, an assembly 130 as depicted in FIG. 5 may be assembled and moved to be placed within an enclosure. Since the positioning blocks 100 secure the riser bars 12 in all directions, subassembly 130 can be moved and installed as a unit. Alternately, subassembly 130 may be assembled within an enclosure one component at a time (e.g., first riser bars 12 followed by positioning blocks 100 ). The positioning blocks 100 permit easier assembly of subsequently assembled components such as meter sockets 14 ( FIG. 1 ), straps and meters.
[0032] The block 100 maintains a designed distance between the individual bus bars 12 preventing them from being allowed to be pulled or pushed too close to one another to cause an electrical short spacing issue during operation. It should be understood that while locating features such as locator pins 110 are illustratively depicted in the FIGS., other indexing mechanisms may be employed such as slots or tabs. Further, instead of or in addition to the binding features depicted, e.g., snaps 106 , other securing mechanisms may be employed. For example, magnetic components, epoxies, clips etc. may be employed to secure the positioning block 100 to riser bars 12 .
[0033] Referring to FIG. 7 , an illustrative example is shown for a back side of the positioning block 100 . In this embodiment, snap stems 134 are accessible from the reverse side of the block 100 . Access to the snap stems 134 is provided within openings or recesses 136 . If a positioning block should need to be removed from a riser bar assembly, a technician or mechanic could insert a screw driver or other wedge tool into the recess 136 to disengage the snap 106 from the riser bar 12 being secured by the snap 106 . In one embodiment, a tool having a wedge or wedges corresponding to each recess 136 may be employed to concurrently release all of the snaps 106 and free the positioning block 100 from the riser bars 12 .
[0034] The positioning block 100 facilitates at least three main functions. 1) The block 100 permits assembly of the riser bus bars as a single unit so that other components can be easily assembled thereto during manufacture. 2) The block 100 helps to maintain the proper through-air spacing between components of opposite polarity after the riser bus bars 12 are assembled to the block 100 . 3) The block 100 maintains the position of the riser-bus assembly during any removal or replacement of components in the field. The block 100 is easily installed without any additional mechanical fastening means.
[0035] Having described preferred embodiments for riser bar positioning block (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments of the invention disclosed which are within the scope and spirit of the invention as outlined by the appended claims. Having thus described the invention with the details and particularity required by the patent laws, what is claimed and desired protected by Letters patent is set forth in the appended claims.
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A positioning block and method for spacing riser bus bars includes an insulating material body forming recesses along a longitudinal axis of the block, each recess for receiving an electric riser bus bar therein. A binding feature is formed adjacent to at least one wall of the recesses for securing the riser bus bar within the recess. A locator feature is formed between the walls of each recess for aligning the riser bus bar within the recess.
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RELATED APPLICATION
[0001] This application claims the benefit of Korean Application No. 2000-46938, filed Aug. 14, 2000, the disclosure of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to semiconductor devices, and more particularly, to duty cycle correction circuits.
BACKGROUND OF THE INVENTION
[0003] Recently, the speed of semiconductor memory devices, for example, dynamic random access memories (DRAMs), has increased to improve the performance of existing systems. However, increasing demand for improved systems may require DRAMs that can process even more data at even higher speeds. Accordingly, synchronous dynamic random access memories (SDRAMs) that operate in synchronization with system clocks have been developed for a high-speed operation, thus significantly increasing data transmission speeds.
[0004] There are limitations on the amount of data that may be input to and/or output from a memory device per clock cycle of a system clock. To address these limitations, dual data rate (DDR) SDRAMs have been recently developed in order to further increase the transmission speed of data. DDR SDRAMS input and/or output data in synchronization with both the rising edge and the falling edge of a clock.
[0005] Reliable data transmission is possible when the duty cycle of a clock signal is equivalent at 50%, which is ideal, in a DDR SDRAM or a direct rambus dynamic random access memory (RDRAM). Thus, when a signal having a duty cycle that is not equivalent, i.e. greater than or less than 50%, is provided as an input, the signal typically does not perform very well as an input signal. Duty cycle correction circuits have been developed to address this problem.
[0006] A block diagram of a conventional duty cycle correction circuit is illustrated in FIG. 1. A duty cycle correction circuit includes a duty cycle corrector 10 and a detection circuit 13 . The duty cycle corrector 10 generates a pair of complementary input signals IN and INB, from which distortion is typically removed, in response to first and second complementary clock signals CLK and CLKB, having distortion resulting from nonequivalent duty cycles. The detection circuit 13 feeds back first and second detection signals DETECT and DETECTB obtained by detecting distortion in the duty cycles of the complementary pair of input signals IN and INB of the correction circuit 10 in response to the pair of complementary input signals IN and INB.
[0007] Now referring to FIG. 2, a circuit diagram of a conventional detection circuit 13 of FIG. 1 will be discussed. When mismatching exists among diode-connected loads M 1 and M 4 , cross-coupled loads M 2 and M 3 , source coupled pairs M 5 and M 6 , and/or the respective transistors in the detection circuit 13 , increased distortion may occur in the duty cycles of the pair of complementary input signals IN and INB due to mismatching of the respective transistors, even though less distortion is present in the duty cycles of the complementary pair of clock signals CLK and CLKB.
SUMMARY OF THE INVENTION
[0008] Semiconductor devices according to embodiments of the present invention include a duty cycle correction circuit having a duty cycle corrector and a detection circuit. The duty cycle corrector generates a first input signal having a second duty cycle with a higher degree of equivalence than the first duty cycle in response to a first detection signal and a first control signal having a first duty cycle. The detection circuit generates the first detection signal in response to the first input signal. The detection circuit includes a current source having first and second current sources and a bias circuit that is electrically coupled to the first and second current sources and controls a bias of the first and the second current sources responsive to the first input signal.
[0009] In some embodiments of the present invention, the duty cycle corrector further generates a second input signal having a fourth duty cycle with a higher degree of equivalence than the third duty cycle in response to a second detection signal and a second control signal having a third duty cycle. The detection circuit, in other embodiments of the present invention, further generates the second detection signal in response to the second input signal.
[0010] In further embodiments of the present invention, the duty cycle correction circuit includes a load matching circuit that is electrically coupled to the first and second current sources and matches a load of the bias circuit in response to the second input signal.
[0011] In still further embodiments of the present invention, the first control signal is a true clock signal and the second control signal is a complementary clock signal. Furthermore, the first and second input signals are complementary signals and the first and second detection signals are complementary signals.
[0012] In some embodiments of the present invention, the duty cycle correction circuit further includes a first output driver circuit that pulls the first detection signal up or down in response to the first input signal and a second output driver circuit that pulls a second detection signal up or down in response to a second input signal. The current generated by the current source is supplied to the first output driver circuit, the second output driver circuit and the bias circuit responsive to a bias voltage. The bias voltage may be a voltage at a first node during a period and is calculated according to the equation V NODB +V NODC −VDD−GND. V NODB is the voltage at a second node, V NODC is the voltage at a third node, VDD is a source voltage, and GND is a ground voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram illustrating a conventional duty cycle correction circuit;
[0014] [0014]FIG. 2 is a circuit diagram illustrating a conventional detection circuit of FIG. 1; and
[0015] [0015]FIG. 3 is a circuit diagram illustrating a detection circuit according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Signal lines and signal thereon may be referred to by the same reference names. Like numbers refer to like elements throughout.
[0017] Now referring to FIG. 3, a circuit diagram of a detection circuit 13 A according to embodiments of the present invention will be discussed. It will be understood that the detection circuit 13 A receives a pair of complementary input signals IN and INB that are generated by a duty cycle corrector, for example, duty cycle corrector 10 , in response to a pair of complementary clock signals CLK and CLKB. It will be further understood that although the inputs of the duty cycle corrector are described herein as a complementary pair of clock signals, the present invention is not limited to this configuration. For example, the inputs to the duty cycle corrector may be a complementary pair of control signals CNTL and CNTLB. The detection circuit 13 A includes a first output driver 31 , a bias circuit 33 , a current source 35 , a second output driver 39 , and a load matching circuit 37 .
[0018] The first output driver 31 pulls a first detection signal DETECT up or down in response to a complementary input signal INB. The first output driver 31 may include a PMOS transistor M 3 and an NMOS transistor M 1 that are electrically connected as illustrated in FIG. 3. In particular, the drains of transistors M 3 and M 1 are connected together and the complementary input signal INB is applied to the gates of transistors M 3 and M 1 . Furthermore, the first detection signal DETECT is connected to the drain of the PMOS transistor M 3 and a first capacitor C 1 may be electrically connected between the first detection signal line DETECT and ground GND.
[0019] The second output driver 39 pulls a second detection signal DETECTB up or down in response to an input signal IN. The second output driver 39 may include a PMOS transistor M 4 and an NMOS transistor M 2 that are electrically connected as illustrated in FIG. 3. In particular, the drains of transistors M 4 and M 2 are connected together and the input signal IN is applied to the gates of transistors M 4 and M 2 . Furthermore, the second detection signal DETECTB is electrically connected to the drain of the PMOS transistor M 4 and a second capacitor C 2 may be electrically connected between the second detection signal line DETECTB and ground GND.
[0020] The current source 35 steers current to the first output driver 31 , the second output driver 39 , and the bias circuit 33 , in response to a bias voltage. The bias voltage is the voltage of a node NODA. The current source 35 may include first and second current source transistors, PMOS transistor M 11 and NMOS transistor M 9 , respectively. First and second current source transistors M 11 and M 9 are electrically connected as illustrated in FIG. 3.
[0021] The detection circuit 13 A according to embodiments of the present invention has a structure, in which the source coupled pair of the NMOS transistors M 1 and M 2 and the source coupled pair of the PMOS transistors M 3 and M 4 are stacked. The current steering capability of the source coupled pairs is used in the structure to steer current to one side of the detection circuit 13 A. Thus, the degree of deterioration of the characteristics of a transistor in the detection circuit 13 A due to mismatching of the processes of the transistors M 1 and M 2 and/or M 3 and M 4 used for the source coupled pairs may be reduced.
[0022] When the bias of the first and second current source transistors M 9 and M 11 , which operate as the current source 35 , is provided from outside of the duty cycle detection circuit the level of the first or second detection signal DETECT or DETECTB, which are a complementary pair of detection signals, is saturated to the source voltage VDD or the ground voltage GND. This is called the common mode problem. Accordingly, embodiments of the present invention include a self-bias circuit located within the detection circuit 13 A in order to reduce the distortion introduced by the common mode problem.
[0023] A self-bias circuit 33 according to embodiments of the present invention includes a PMOS transistor M 7 and an NMOS transistor M 5 that are electrically connected as illustrated in FIG. 3. In particular, the drains of transistor the PMOS transistor M 7 and NMOS transistor M 5 are electrically connected together and the complementary input signal INB is applied to the gates of transistor the PMOS transistor M 7 and the NMOS transistor M 5 . The NMOS transistor M 5 and the PMOS transistor M 7 , which operate as the self-bias circuit 33 , dynamically determine the bias of the NMOS transistor M 9 and the PMOS transistor M 11 of the current source 35 according to the complementary input signal INB. Since the bias circuit 33 does not need to operate at high speed, the ratio of the width to the length (W/L) may be small.
[0024] A load matching circuit 37 is provided to compensate for the mismatch of load caused by adding the self-bias circuit 33 to the detection circuit 13 A. The load matching circuit 37 includes a PMOS transistor M 8 , an NMOS transistor M 6 , a PMOS transistor M 12 and an NMOS transistor M 10 that are electrically connected as illustrated in FIG. 3. The characteristics of the NMOS transistor M 6 may be similar to the characteristics of the NMOS transistor M 5 of the self-bias circuit 33 . Similarly, the characteristics of the PMOS transistor M 8 may be similar to the characteristics of the PMOS transistor M 7 of the self-bias circuit 33 . Furthermore, the characteristics of the NMOS transistor M 10 may be similar to the characteristics of the NMOS transistor M 9 and the characteristics the PMOS transistor M 12 may be similar to the characteristics of the PMOS transistor M 11 of the current source 35 .
[0025] The operation of the detection circuit 13 A according to embodiments of the present invention will now be described. Since the input signal IN and the complementary input signal INB are a pair of complementary input signals, operations will only be discussed with respect to the complementary input signal INB.
[0026] When the complementary input signal INB is at the supply voltage VDD, transistors M 1 and M 5 are turned on and transistors M 3 and M 7 are turned off. This causes transistor M 5 to sink current from the first node NODA in an amount that is proportional to the difference between the source voltage VDD and the voltage V NODC of the third node NODC, i e. VDD-V NODC . On the other hand, when the complementary input signal INB is at the ground voltage GND, transistors M 1 and M 5 are turned off and transistors M 3 and M 7 are turned on. This causes transistor M 7 to supply current to the first node NODA in an amount that is proportionate to the difference between the ground GND and the voltage V NODB of the second node NODB, i.e V NODB -GND.
[0027] Accordingly, net current, which is proportional to the equation:
T INB-H ×( V NODC. −VDD )+ T INB-L ×( V NODB. −GND ) (1)
[0028] where T INB-H equals a period that the complementary input signal INB is at a logic high level and where T INB-L equals a period that the complementary input signal INB is at a logic low level, is supplied to the first node NODA every period. When the duty cycle correction circuit 10 is in a steady state, the duty cycle is corrected, i.e. the duty cycle is equivalent. Therefore, the period that the complementary input signal is at the logic high level is equal to the period that the complementary input signal is at the logic low level. Accordingly, a net current, which is proportionate to V NODB +V NODC −VDD−GND, is supplied to the first node NODA every period. The amount of the net current is positive when the values of V NODB and V NODC are high. Accordingly, when the values of V NODB and V NODC are high, the voltage of the first node NODA increases. Similarly, the amount of the net current is negative when the values of V NODB and V NODC are low, thus reducing the voltage of the first node NODA.
[0029] If the current through current source transistor M 11 is larger than the current through current source transistor M 9 , the voltages V NODB and V NODC of nodes NODB and NODC, respectively, increase. Accordingly, the current through current source transistor M 11 is reduced and the current through current source transistor M 9 increases. However, when the current through current source transistor M 11 is smaller than the current through current source transistor M 9 , the voltages V NODB and V NODC of nodes NODB and NODC, respectively, are reduced. Accordingly, the current through current source transistor M 11 increases and the current through current source transistor M 9 is reduced. As a result, the detection circuit 13 A operates such that the amount of the current through transistor M 11 is typically the same as the amount of the current through transistor M 9 , thus reducing distortion caused by mismatched transistors and providing an equivalent duty cycle.
[0030] As described above, a duty cycle correction circuit according to embodiments of the present invention may reduce the deterioration of the performance of the detection circuit caused by mismatched transistors and makes it is possible to correctly detect the duty cycle of the complementary input signals. In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.
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Semiconductor devices according to the present invention include a duty cycle correction circuit having a duty cycle corrector and a detection circuit. The duty cycle corrector generates a first input signal having a second duty cycle with a higher degree of equivalence than the first duty cycle in response to a first detection signal and a first control signal having a first duty cycle. The detection circuit generates the first detection signal in response to the first input signal. The detection circuit includes a current source having first and second current sources and a bias circuit that is electrically coupled to the first and second current sources and controls a bias of the first and the second current sources responsive to the first input signal.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to interfacing and communication among trading partners.
[0003] 2. Related Art
[0004] Today's competitive business climate encourages businesses to forge trading partnerships with other businesses. However, finding a trading partner and interfacing with that trading partner in a cooperative and meaningful way is not easy. When using electronic data systems, there is generally a very high level of coordination required. The methods, processes, and systems used by one business entity might turn out to be incompatible with another business entity with whom they wish to collaborate.
[0005] In some cases one trading partner may convert its business systems, so as to use the same methods, processes, and business systems used by another trading partner. While this approach generally achieves the goal of interfacing electronic business systems, it is subject to several drawbacks. First, it can often frustrate business practices at the human level. Second, it can require educating employees in a new business system, thus creating an additional expense.
[0006] Systems integration can be quite complex at the information systems level. Machine to machine and human to machine interaction can be frustrated by lack of common communications protocols and data formats. While buying new equipment is an option, it involves a substantial added expense, as well as involving the substantial added expense of education of employees in the use of the new equipment.
[0007] Accordingly, it would be desirable to provide a technique for allowing trading partnerships to be forged within an electronic communications framework, while allowing each trading partner to retain its unique business methods and processes without compromise of business to business interactions.
SUMMARY OF THE INVENTION
[0008] The invention provides a method for business to business communication among trading partners that use differing business rules and processes. Generally, a trading partner is a company, however, it can be an individual or other entity. A trading partner server maintains a directory of trading partners and a business profile associated with each of those trading partners. The business profile includes information regarding attributes descriptive of the trading partner. Attributes includes information regarding rules and processes used by the trading partner, so other potential trading partners can decide if they would like to collaborate with that trading partner. The trading partner server uses information in each trading partner's profile to provide an interface capable of seamless communication between two trading partners regardless of their data systems, rules for doing business, or their business processes.
[0009] When one trading partner would like to communicate with another trading partner (such as, for example, to form a trading partner alliance), the first trading partner contacts the trading partner server and requests information regarding the second trading partner. The first trading partner notes the second trading partner's attributes, which might include an appropriate method for first contact. Generally, a first contact is a notice of interest from the first trading partner to the second. The second trading partner may accept or reject the proposed contact.
[0010] One trading partner may require that communications it receives use its preferred protocol as designated in its profile. In the event this is not possible, the trading partner server can act as a translator between the two trading partners. Likewise the trading partner server can translate from one set of business practices to another. Examples include: if trading partner A uses gallons on its invoices while trading partner B uses liters, or if trading partner A uses Y2K format dates on its invoices and trading partner B does not. This allows each trading partner to maintain its unique business practices and processes.
[0011] The trading partner server not only provides a machine to machine interface but also a machine to human interface. A human being (using a basic technological interface such as text-based email) can interact with a trading partner using machine interface on the trading partner's terms by way of the translation capability of the trading partner server.
[0012] The invention provides for updating a trading partner's profile at the trading partner server directory, so that when a trading partner changes a business processes or interfaces it does not have to notify every other trading partner. In that event, the trading partner updates the information in the directory at the trading partner server, whereupon that information is applied automatically to all subsequent communication involving the trading partner.
[0013] The invention also allows “legal to legal” communications (that is, binding legal agreements) to be executed substantially automatically, so that new trading partner alliances can be forged relatively efficiently. More informal agreements, such as those not intended to be non-legally binding, or proposals for interaction, can be handled similarly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows a block diagram of a system for business to business collaborative viral adoption.
[0015] FIG. 2 shows a block diagram of a trading partner server and collaborative devices in a method for business to business collaborative viral adoption.
[0016] FIG. 3 shows a process flow diagram of a method for business to business collaborative viral adoption.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] In the following description, a preferred embodiment of the invention is described with regard to preferred process steps and data structures. Those skilled in the art would recognize after perusal of this application that embodiments of the invention can be implemented using one or more general purpose processors or special purpose processors or other circuits adapted to particular process steps and data structures described herein, and that implementation of the process steps and data structures described herein would not require undue experimentation or further invention.
[0000] Lexicography
[0018] The following terms refer or relate to aspects of the invention as described below. The descriptions of general meanings of these terms are not intended to be limiting, only illustrative.
EDI—Electronic Data Interchange is a standard format for exchanging business data. The standard is ANSI X 12 and it was developed by the Data Interchange Standards Association. ANSI X 12 is either closely coordinated with or is being merged with an international standard, EDIFACT. An EDI message contains a string of data elements, each of which represents a singular fact, such as a price, product model number, and so forth, separated by delimiter. The entire string is called a data segment. One or more data segments framed by a header and trailer form a transaction set, which is the EDI unit of transmission (equivalent to a message). A transaction set often consists of what would usually be contained in a typical business document or form. The parties who exchange EDI transmissions are referred to as trading partners. ERP—Enterprise Resource Planning, a business management system that integrates all facets of the business, including planning, manufacturing, sales, and marketing. As the ERP methodology has become more popular, software applications have emerged to help business managers implement ERP. RosettaNet—A non-profit organization (www.rosettanet.org) that seeks to implement standards for supply-chain (manager-supplier) transactions on the Internet. Created in Winter 1998, the group includes companies like American Express, Microsoft, Netscape, and IBM, and is working to standardize labels for elements like product descriptions, part numbers, pricing data, and inventory status. The group hopes to implement many of its goals through XML, a mark-up language that lets programmers classify information with tags. WSDL—The Web Services Description Language (WSDL) is an XML-based language used to describe the services a business offers and to provide a way for individuals and other businesses to access those services electronically. WSDL is the cornerstone of the Universal Description, Discovery, and Integration (UDDI) initiative spearheaded by Microsoft, IBM, and Ariba. UDDI is an XML-based registry for businesses worldwide, which enables businesses to list themselves and their services on the Internet. WSDL is the language used to do this.
[0024] As noted above, these descriptions of general meanings of these terms are not intended to be limiting, only illustrative. Other and further applications of the invention, including extensions of these terms and concepts, would be clear to those of ordinary skill in the art after perusing this application. These other and further applications are part of the scope and spirit of the invention, and would be clear to those of ordinary skill in the art, without further invention or undue experimentation.
[0000] System Elements
[0025] FIG. 1 shows a block diagram of a system for business to business collaborative viral adoption.
[0026] A system 100 includes a trading partner server 110 , a plurality of machine collaborators 120 each associated with a machine trading partner 121 , at least one human collaborator 130 associated with a human trading partner 131 , and a communication network 140 .
[0027] The trading partner server 110 includes a machine interface 112 , a human interface 114 , a directory 116 , a processor, a main memory, and software for executing instructions (not shown, but understood by one skilled in the art). This software preferably includes software for operating the trading partner server 110 consistent with the methods and techniques described and explained further herein.
[0028] The machine interface 112 includes software capable of interfacing at least one of the machine collaborators 120 with any other one of the machine collaborators 120 .
[0029] The human interface 114 includes software capable of interfacing a human collaborator 130 with at least one of the machine collaborators 120 .
[0030] The directory 116 includes a set of trading partner profiles 118 . A trading partner profile 118 is maintained for each known machine collaborators 120 and for human collaborators 130 . Each trading partner profile 118 preferably includes the trading partner's preferred method of communication, business processes, business rules, and any other information relating to the business (such as for example, a list of trading partner preferences not found in its business processes or business rules).
[0031] The trading partner preferences portion of the trading partner profile 118 includes additional information about the trading partner that other trading partners might find useful in determining whether an alliance should be attempted. Any one or combination of the following could be included: a mission statement, company goal, history of the entity, references to its other trading partners, financial statements, personnel briefs. The trading partner preferences portion is limited only by what the creating trading partner entity wishes to include.
[0032] The directory 116 publishes (that is, provides to each trading partner requesting that information) the processes that each trading partner supports. A set of translation engines included in the machine interface 112 and the human interface 114 are responsive to the business rules maintained in the directory 116 . Information to record in the directory 116 (such as its preferred set of business rules) is provided on its own behalf by each trading partner. The business rules define how each trading partner will communicate with any other trading partner.
[0033] A human collaborator 130 may list as the preferred method of communication plain text messages in a particular format. A machine collaborator 120 may list EDI as the preferred method for communication. Other secondary protocols can also be listed, and a facility at the trading partner server is enabled for allowing negotiation of what protocol will be used. In a preferred embodiment, secondary protocols might include: Java, JavaScript, HTTP (Hypertext Transfer Protocol), and FTP (File Transfer Protocol).
[0034] When two trading partners each list different preferred protocols that the other does not support, the trading partner server 110 can recommend a protocol that both entities support by comparing each entity's trading partner profile 118 . Alternatively, the trading partner entities can communicate using a common basic protocol (such as Internet email) and negotiate through a written dialog a protocol to be used for further communication.
[0035] The machine collaborator 120 includes a processor, a main memory, and software for executing instructions (not shown, but understood by one skilled in the art). This software preferably includes software capable of operating the machine collaborator 120 consistent with the invention and further explained herein.
[0036] The machine trading partner 122 refers to one or more persons associated with a business entity running the machine collaborator 120 .
[0037] The human collaborator 130 includes a processor, a main memory, and software for executing instructions (not shown, but understood by one skilled in the art). This software preferably includes browser and other software capable of operating the machine collaborator 120 consistent with the invention and further explained herein.
[0038] The human trading partner 132 refers to one or more persons that use the human collaborator 130 .
[0039] The communication network 140 includes at least a portion of a communication network, such as a LAN, a WAN, the Internet, an intranet, an extranet, a virtual private network, a virtual switched network, or some combination thereof. In a preferred embodiment, the communication network 140 includes a packet switched network such as the Internet, as well as (in addition to or instead of) the communication networks just noted, or any other set of communication networks that enable the elements described herein to perform the functions described herein.
[0040] The communication link 142 operates to couple each machine collaborator 120 , human collaborator 130 , and the trading partner server 110 to the communications network 140 .
[0041] The term trading partner(s) is used herein to refer generically to both a machine collaborator 120 and a human collaborator 130 .
[0000] Trading Partner Server
[0042] FIG. 2 shows a block diagram of a trading partner server and collaborative devices in a method for business to business collaborative viral adoption.
[0043] The trading partner server 110 is the primary controller for the system 100 . Trading partners contact the trading partner server 110 and browse trading partner profiles 118 in the directory 116 for trading partners that interest them and to see if there is a process match.
[0044] New trading partners are required to register at the trading partner server by entering all the information necessary to create a trading partner profile 118 . Entering the trading partner profile 118 may be accomplished through the use of web forms or similar means.
[0045] Already-registered trading partners may edit or delete their trading partner profile 118 on the trading partner server 110 . Once a trading partner updates a trading partner profile 118 , the trading partner server 110 makes its updated trading partner profile 118 available to current and prospective trading partners. Thus, no other information exchange or retooling is necessary to change a trading partner profile 118 . Communication is processed as before, with the trading partner server 110 taking care of any issues relating to communication protocol, business process, and business rules, leaving the individual trading partners free to concentrate on their respective business enterprises.
[0046] When a first trading partner has found a second trading partner it is interested in collaborating with, the first trading partner registers its interest in the second trading partner. This interest is either accepted or rejected by the second trading partner.
[0047] Once two trading partners have agreed that they have an interest in each other, they can proceed with formalizing the relationship. Legal to legal (L2L) communications can proceed through the trading partner server 110 . Documents such as non-disclosure agreements can be handled electronically as can all other workflow product.
[0048] The collaborative aspect of day-to-day communication between trading partners (either machine collaborator or human collaborator) is accomplished through the trading partner server 110 . The trading partner server 110 provides ongoing translation of each trading partner's business processes into each other trading partner's business processes, and it enforces the business rules specified by each trading partner.
[0000] Business Process Translation
[0049] Business process translation between two machine collaborators 120 is accomplished by the machine interface 112 . For example, if one machine collaborator 120 will only accept data in EDI format and another will only accept data in WSDL, the machine interface can provide the translation. As data is received at the trading partner server 110 , the destination machine trading partner 122 is looked up in the directory 116 . The incoming data is converted to the format acceptable to the destination machine trading partner 122 (as specified by the destination machine trading partner 122 ), so that conducting business with an external trading partner is as easy as dealing with internal departments using the local computer system.
[0050] Business process translation between a machine collaborator 120 and a human collaborator is accomplished by the machine interface 112 and the human interface 114 .
[0051] For one example, if a relatively large company (for example, “MegaKorp”) requires all its purchase orders to be electronically sent and acknowledged using their (relatively expensive) invoicing system regardless of the size of the transaction, those relatively small companies (for example, “Petro's Pizza”), which has an Internet connection with email but not the relatively expensive invoicing system, would not be able to become a supplier to MegaKorp. By registering at the trading partner server 110 and becoming a human trading partner 132 , Petro's Pizza can thus do business with MegaKorp on MegaKorp's terms, but without investing in the relatively expensive invoicing system.
[0052] In this example, a purchase order from MegaKorp would arrive at the trading partner server 110 through the machine interface 112 . Petro's Pizza would be found in the directory 116 along with their associated business processes and rules, and the purchase order would be formatted as an email since Petro's Pizza has only that capability. The email would then be sent to Petro's Pizza via the human interface 114 , and Petro's Pizza would respond through the human interface 114 . The response to MegaKorp from Petro's Pizza would be received at the trading partner server 110 from the human interface 114 . MegaKorp would be located in the directory 116 along with their associated business processes and rules, and the response would be formatted accordingly and sent to MegaKorp via the machine interface 112 .
[0000] Enforcing Business Rules
[0053] As previously mentioned, the directory entry for each trading partner includes not only the preferred formats for data but also the rules that apply for doing business with other trading partners. Using the previous example of Petro's Pizza and MegaKorp, MegaKorp's purchase order process (as specified in the directory 116 ) might stipulate that an initial purchase order requires a cost estimate response before a final purchase order is sent, which itself requires a confirmation. The system enforces these rules and provides the conduit for fulfilling them.
[0054] To continue with the example, when the initial purchase order is received at Petro's Pizza, the human trading partner 132 at Petro's Pizza would be informed in the email that a cost estimate is required. When the final purchase order is received following a cost estimate by Petro's Pizza, a confirmation would be requested from Petro's Pizza. Implementation and enforcement of many business rules can be automated in full or in part by the trading partner server 110 . In the example case of Petro's Pizza, the confirmation could be as simple as the human trading partner 132 activating a hypertext link to send the appropriately formatted response to MegaKorp indication confirmation of their order.
[0055] Petro's Pizza is given as an example of the translation process and enforcement of business rules; it is intended to be exemplary and not limiting. The number of business processes and rules that can be incorporated into the system is limitless, and the invention may be used to support ERP and supply-chain management such as RosettaNet.
[0000] System Operation
[0056] FIG. 3 shows a process flow diagram of a method for business to business collaborative viral adoption. The method 300 is performed by the system 100 . Although the method 300 is described serially, the steps of the method 300 can be performed by separate elements in conjunction or in parallel, whether asynchronously, in a pipelined manner, or otherwise. There is no particular requirement that the method 300 be performed in the same order in which this description lists the steps, except were so indicated.
[0057] At a flow point 310 , the trading partner server 110 is ready to process incoming requests for collaborative contact.
[0058] At a step 312 , a trading partner (either a human trading partner 132 or machine trading partner 122 ) contacts the trading partner server 110 and establishes their identity. Establishing identity can include the use of passwords or other authentication techniques.
[0059] At a step 314 , the trading partner queries the directory 116 for other trading partners that interest them. The information available on other trading partners is limited to what those potential trading partners wish to make available. The available information may be a short introduction or a full-blown company dossier.
[0060] At a step 316 , the trading partner registers interest in another trading partner they have found in the directory 116 .
[0061] At a step 318 , the second trading partner either accepts or rejects the first trading partner's interest. If the interest is rejected, the process flow may continue at step 310 or the process may be terminated.
[0062] At a step 320 , negotiation of contact parameters is accomplished. This includes business processes, business rules, legal agreements, fees, and other operational procedures to be followed. The legal to legal portion can include non-disclosure agreements, which can be executed electronically. The electronic nature of the agreement means it may be passed to others when higher authority is required.
[0063] At a step 322 , dialog between the trading partners is expedited with the trading partner server 110 providing the business to business translation and enforcement of business rules, so that each trading partner can retain their individual identity yet benefit from a business symbiosis.
[0064] The process may be repeated starting at step 310 .
[0000] Generality of the Invention
[0065] The invention has applicability and generality to other aspects of business to business communication and collaboration between business entities.
[0000] Alternative Embodiments
[0066] Although preferred embodiments are disclosed herein, many variations are possible which remain within the concept, scope, and spirit of the invention, and these variations would become clear to those skilled in the art after perusal of this application.
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The invention provides a method for business to business communication among trading partners that use differing business rules and processes. A trading partner server provides a center for communication between the trading partners enforcing the business rules and enabling the trading partners to communicate effectively. Legally binding and non-legally binding agreements necessary to support a business discourse are handled electronically through the trading partner server.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a continuation-in-part of application Ser. No. 14/450,285, filed 3 Aug. 2014.
FIELD OF THE INVENTION
[0002] The disclosure relates generally to an offshore platform employing multiple legs of piling and piling guide sleeve annulus subject to being filled with grout after piles have been driven.
BACKGROUND OF THE INVENTION
[0003] In an offshore platform installation, a grout seal is typically utilized to seal the annulus between a pile sleeve inner surface and a pile outer surface and against a high column of concrete during the grout hardening period. FIG. 1 illustrates a deepwater offshore platform with extended legs from water surface to sea floor and a plurality of skirt pile sleeves for housing piles. As shown in FIG. 1 , an offshore platform deck 1 is supported by a jacket 2 extended from water surface 6 to sea floor 5 . A plurality of pile sleeves 4 are attached to the bottom of the extended legs to house a plurality of piles 3 , which are driven into sea floor 5 to provide the anchoring to the platform.
[0004] A grout seal is usually located at the bottom of a skirt pile sleeve 4 near sea floor. The seal has to be rugged and highly reliable because any seal failure such as grout leaking could cause the connection failure between a pile sleeve and a pile. Consequently, it could result in the foundation failure of the platform.
[0005] Existing Grout Seals for Offshore Structures
[0006] In general, there two types of grout seals for pilings in offshore jacket installation: 1) an active grout seal type such as an inflatable packer, and 2) a passive grout seal type such as a CRUX grout seal or a mechanical grout seal.
[0007] Inflatable Packer
[0008] Inflatable packer was introduced to offshore industry in 1970′s and it has been widely utilized in offshore platform fields. Today, inflatable packers still occupy a very large percentage of grout seal market, especially in deepwater platform applications. Inflatable packer is an active assembly which requires a control system above water surface to activate the seal by injecting air or water to form a sealing function. FIG. 2 is an ISO cross section view of a typical inflatable packer used as a grout seal. As an active seal, the seal element is in a retracted position without making contact between the seal outer surface and a pile prior to pile lowering and inserting. As shown in FIG. 2 , an inflatable packer element 8 is fixed to the inner wall of a sleeve 4 in a non-inflated condition; an injection tubing 7 is attached at the outer wall of the sleeve 4 . To prevent mud at sea floor to pollute grout during pile driving, a mud wiper 9 is usually installed below the packer element 8 .
[0009] In installing an offshore jacket, common practice utilizing an inflatable packer is to fabricate the jacket on land with jacket leg members and with inflatable packers installed at the bottom of skirt sleeves as grout seals. The jacket is then towed to an installation site for installation. U.S. Pat. No. 3,468,132 to Harris, issued on Sep. 23, 1969, describes a traditional inflatable packer assembly. Until today, this type of active grout seal is still widely used in offshore jacket installation applications.
[0010] An inflatable packer is composed of three subsystems in addition to the packer assembly located at the bottom of a pile sleeve: a power subsystem and a high pressure air/water injection subsystem and a piping subsystem. There are two major disadvantages for using an inflatable packer assembly as a grout seal: 1) the assembly is very expensive in terms of yard installation, yard testing and field operation; 2) the assembly is very complicated which could have potential damages in each of the three subsystems during jacket site installation. U.S. Pat. No. 4,279,546 to Harris, issued on Jul. 21, 1981, describes some of these potential damages for an inflatable packer during field operations.
[0011] Passive Seals
[0012] A typical passive seal is CRUX annular seal, as described in British Pat. No. GB2194006 to Philip et al., issued on Feb. 24, 1988. The seal assembly has an outer head portion attached at the sleeve inner wall and a bulbous ring functioning as a seal element. FIG. 4 illustrates a CRUX annular seal element 19 prior to piling activities. As shown, a guide shim 16 is attached to the inner wall of sleeve 4 . An outer head portion 18 is fixed to the sleeve 4 inner wall with an inside cavity 17 . A bulbous ring 20 with a fiber core forms the sealing function. The inner diameter of the bulbous ring 20 is less than the outer diameter of a pile so that the deformed ring produces compression force against the pile outer surface to form a sealing function when a pile is driven through the ring. FIG. 5 is a partial cross-section view of a CRUX annular seal when a pile 3 is driven through and a column of grout 13 is poured between the pile 3 and pile sleeve 4 . As shown in FIG. 5 , the bulbous ring 20 is deformed and the annular seal element 19 is bended against the pile 3 outer surface, which has several levels of shear keys 21 , to form a seal for a poured column of grout 13 .
[0013] A passive seal is significantly less expensive than an inflatable packer. However, the common concerns for this type of seals are the protection and the reliability of the seals during offshore pile installation activities such as pile inserting and pile driving. The pile bottom outer edge could function as a knife to damage the resilient section between the bulbous ring 20 and the outer head portion 18 due to dynamic heave motions of a pile during pile lowering and inserting.
[0014] A traditional mechanical grout seal is also a passive seal. A traditional mechanical grout seal is usually only used for shallow water applications because it could not take potential dynamic loading from shear keys which are commonly welded both on the pile top outer surface and on the sleeve inner wall of a deepwater platform for increasing the concrete bonding strength between the sleeve and the pile. A mechanical seal is composed of an annular rubber tubular wall with multiple equally spaced steel bars passing through the rubber tubular wall. These steel bars are bonded and fixed with the rubber tubular wall through a vulcanization process. The bottom of the tubular wall is fixed at the sleeve inner wall and each steel bar top passes through a steel ring which is fixed at the sleeve inner wall. As a result, each steel bar top should be able to slide up and down inside the corresponding steel ring.
[0015] FIG. 3 is an ISO cut-off section view of a typical mechanical seal with a driven pile and a column of grout poured in the annulus between a pile and pile sleeve above the seal. As shown in FIG. 3 , a mechanical seal element 15 , which has an annular inner diameter less than the outer diameter of the pile 3 , is attached to the inner wall of the sleeve 4 . A plurality of steel bars 11 are through and bonded with the resilient seal element 15 and slides upward through the rings 12 which are fixed at the sleeve 4 inner wall. The seal element 15 forms a seal for the poured column of grout 13 between the pile 3 outer surface and the inner surface of the sleeve 4 during pile 3 grouting. A plurality of tapered guide shims 16 are placed above the seal element 15 . The seal element 15 also prevents the mud 14 pollution during pile 3 driving.
OBJECTIVES AND SUMMARY OF THE INVENTION
[0016] The principal objective of the disclosure is to provide a passive grout seal that is rugged and resilient, more specifically, to provide a rugged means for anchoring the seal to the sleeve inner wall, to provide a sufficient compression force against the pile outer surface in order to provide a sealing function against a high column of grout above the seal, and to provide a passive grout seal that is resilient during the sealing action for accepting a limited pile offset from the sleeve axial center induced during pile driving.
[0017] Another important objective of the disclosure is to provide a protection means for the resilient part of the assembly from physical damages especially during the pile lowering and driving activities.
[0018] A still further important objective of the disclosure is to utilize the seal height and the density difference between grout and seawater to produce an increased compression force at pile outer surface along with the seal height and water depth, to further increase the grout sealing capacity.
[0019] Another objective of the disclosure is that the introduced grout seal is a passive one without any expensive power system and any associated piping/control subsystems. The seal should be automatically activated when a pile passes through the seal.
[0020] A further objective of the disclosure is that the introduced grout seal is able to allow the sleeve to have an upward relative sliding against the pile after a pile is driven, due to the requirement of a potential leveling operation.
[0021] A grout seal assembly for sealing an annulus between a pile outer surface and a sleeve inner surface is disclosed. The grout seal assembly is made up with three portions: an upper portion of the assembly is composed of a plurality of spaced hanging strips fixed at the sleeve inner wall surface, the upper portion allows fluid passing into the annulus below; a middle portion of the assembly is composed of an annular tube, made of resilient materials and bonded together with the hanging strips from the upper portion, the middle portion has a cone section on the top of a tubular section; and a bottom portion of the assembly is composed of a tube section extended from the middle section and is fixed to the sleeve inner wall to form a sealed annulus between the sleeve inner surface and the tube outer surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The drawings described herein are for illustrating purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. For further understanding of the nature and objects of this disclosure reference should be made to the following description, taken in conjunction with the accompanying drawings in which like parts are given like reference materials, and wherein:
[0023] FIG. 1 is an elevation view of a deepwater offshore platform with extended legs from water surface to sea floor and with a plurality of skirt pile sleeves for housing piles;
[0024] FIG. 2 is an ISO cross section view of a typical inflatable packer used as a grout seal with a mud wiper below;
[0025] FIG. 3 is an ISO cut-off section view of a typical mechanical seal with a driven pile and a column of grout poured in the annulus between the pile and the pile sleeve above the seal;
[0026] FIG. 4 is an enlarged partial cross-section view of a CRUX annular seal without a driven pile;
[0027] FIG. 5 is an enlarged partial cross-section view of a CRUX annular seal with a driven pile and a column of grout poured between the pile and pile sleeve;
[0028] FIG. 6A is an enlarged partial cross-section view of a grout seal disclosed herein with non-welded connections at the top and a flange connection at the sleeve bottom in accordance with one embodiment;
[0029] FIG. 6B is an enlarged partial A - A cross-section view of the grout seal shown in FIG. 6A with pre-installed fixings to anchor each strip top to the sleeve inner wall in accordance with one embodiment;
[0030] FIG. 7 is an enlarged partial cross-section view of the grout seal shown in FIG. 6A with a driven pile, without pile offsetting to one side, and a column of grout poured in the annulus between the pile and the pile sleeve in accordance with one embodiment;
[0031] FIG. 8 is an enlarged cross-section view of a grout seal disclosed herein with a driven pile offsetting to one side and a column of grout poured in the annulus between the pile and the pile sleeve in accordance with one embodiment;
[0032] FIG. 9 is an enlarged partial cross-section view of a grout seal disclosed herein with welded connections at the top and an annular welded connection near the sleeve bottom to form a sealing function accordance with one embodiment;
[0033] FIG. 10 is an enlarged cross-section view of the grout seal shown in FIG. 9 without a driven pile offsetting to one side and with a column of grout poured in the annulus between the pile and the pile sleeve;
[0034] FIG. 11A is an enlarged partial cross-section view of a grout seal disclosed herein with a planar ring plate below the installed annular resilient tube, an annular pad, a plurality of stiff plates below the ring plate, an annular bandage tube bonded on the outer surface of the annular resilient tube at the lower part of the resilient tube. The seal assembly has welded connections at the top and an annular welded connection between a doubler and the sleeve inner wall surface near the sleeve bottom to perform a sealing function in accordance with one embodiment;
[0035] FIG. 11B is an enlarged cross-section view of the grout seal shown in FIG. 11A without a driven pile offsetting to one side and with a column of grout poured in a sealed annulus between the pile outer surface and the pile sleeve inner surface. Rows of shear keys are omitted for clarity;
[0036] FIG. 11C is an enlarged partial cross-section view of the grout seal shown in FIG. 11A with a maximum driven pile offsetting to one side to cause a minimum gap width at the same side between the pile outer surface and the inner edge of the planar ring plate, and with a column of grout poured in a sealed annulus between the pile outer surface and the pile sleeve inner surface. Rows of shear keys are omitted for clarity;
[0037] FIG. 11D is an enlarged partial cross-section view of the grout seal shown in FIG. 11A with a maximum driven pile offsetting to one side to cause a maximum gap width at another side between the pile outer surface and the inner edge of the planar ring plate, and with a column of grout poured in a sealed annulus between the pile outer surface and the pile sleeve inner surface. Rows of shear keys are omitted for clarity.
[0038] FIG. 12A is an enlarged partial cross-section view of the grout seal disclosed herein with a cone shape ring plate below the installed annular resilient tube, a plurality of stiff plates below the cone shape ring plate, an annular bandage tube bonded on the outer surface of the annular resilient tube at the lower part of the resilient tube. The seal assembly has welded connections at the top of the assembly and an annular welded connection between a doubler and the sleeve inner wall surface near the sleeve bottom to perform a sealing function for the assembly in accordance with one embodiment;
[0039] FIG. 12B is an enlarged cross-section view of the grout seal shown in FIG. 12A without a driven pile offsetting to one side to cause equal widths at both sides between the pile outer surface and the inner edge of the cone shape ring plate and with a column of grout poured in a sealed annulus between the pile outer surface and the pile sleeve inner surface. Rows of shear keys are omitted for clarity;
[0040] FIG. 12C is an enlarged partial cross-section view of the grout seal shown in FIG. 12A with a maximum driven pile offsetting to one side to cause a minimum gap width between the pile and the inner edge of the cone shape ring plate, and with a column of grout poured in a sealed annulus between the pile outer surface and the pile sleeve inner surface. Rows of shear keys are omitted for clarity;
[0041] FIG. 12D is an enlarged partial cross-section view of the grout seal shown in FIG. 12A with a maximum driven pile offsetting to one side to cause a maximum gap width at the other side between the pile and the inner edge of the cone shape ring plate, and with a column of grout poured in a sealed annulus between the pile outer surface and the pile sleeve inner surface. Rows of shear keys are omitted for clarity;
[0042] FIG. 12E is an enlarged cross-section view of the grout seal shown in FIG. 12A with a maximum driven pile offsetting toward one side to cause a minimum gap width, at the same time, forming a maximum gap width at another side between the pile outer surface and the inner edge of the cone shape ring plate, and with a column of grout poured in a sealed annulus between the pile outer surface and the pile sleeve inner surface. The annular bandage tube wall thickness plus the bonded annular resilient tube section wall thickness together is at least equal to the half width of the formed maximum gap. Rows of shear keys are omitted for clarity.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0043] Before explaining the disclosed apparatus in detail, it is to be understood that the system and method is not limited to the particular embodiments and that it can be practiced or carried out in various ways.
[0044] In accordance with one embodiment of the present disclosure, the main body of the annular grout seal is composed of three different sections: an upper section, a middle section and a bottom section.
[0045] The upper section of the seal is composed of 8 to 16 equally spaced resilient strips around the sleeve inner wall. The tops of the strips are fixed to the sleeve inner wall. The bottoms of the strips are bonded with the middle section through a vulcanization process. Each resilient strip is made of several layers of steel nets bonded with elastomer materials through the same vulcanization process. In a preferred embodiment, the strips are strong enough to take the potential vertical dynamic loading induced by pile lowering and inserting actions and to take other potential dynamic forces inside the sleeves such as vortex induced force during a jacket launch and vibration forces during pile driving. These strips are also made to be strong enough against the potential cutting and scraping forces induced by the sharpness of the pile bottom outer edge and pile rough outer surface. Under this configuration, there are many designed holes between each pair of strips to let the grout pass through the top section and fill the vacant room below during grouting operation. One advantage of these hanging rubber strip configuration is easy to accept a pile offset inside the sleeve during pile inserting and pile driving operations.
[0046] The middle section of the seal is a resilient tube, with a cone section on top of a tubular section. The top end of the cone section has an inner diameter greater than the corresponding pile outer diameter. The resilient tube is made of several layers of fiber nets bonded with elastomer materials together through the same vulcanization process described above. The inner diameter of the tubular section is less than the diameter of the corresponding pile. In a preferred embodiment, the tubular section has a constant inner diameter and a smooth inner surface, with a height of at least one foot (305 mm). This height requirement is designed to suit the typical one foot vertical spacing of shear keys at pile top outer surface; this will allow the tubular section encounter at least one level of shear keys at the pile top outer surface to further enhance the sealing capacity of the seal assembly . The inner smooth surface of the tubular section helps to reduce the friction force during pile driving operation, while the pile outer surface is sliding through the seal, or while a leveling operation is needed.
[0047] The bottom section of the seal is also a resilient tube made of the same material as the middle section. Diameter of the bottom section varies through the height of the section. The top of the bottom section is an extension of the bottom of the middle section. The bottom of the bottom section is fixed at the sleeve inner wall or at the sleeve bottom by a flange, to form a sealed room for a grout column. As the height of the grout column increases inside the annulus, the grout induced horizontal compression force increases accordingly against the pile outer surface through the middle and the bottom tubes.
[0048] FIG. 6A illustrates one embodiment of the grout seal. As shown in FIG. 6A , the grout seal has a plurality of bulbous ring section 22 placed below a tapered guide shim 16 which is fixed to the inner wall of the sleeve 4 . Each bulbous ring section 22 is connected to the top of a hanging strip 24 . In some embodiments, there may be as many as sixteen strips 24 for a grout seal. A tubular section plate 23 is placed just below each bulbous ring section 22 . The tubular section plate 23 pushes the strip 24 firmly against the inner wall of the sleeve 4 so that the bulbous ring section 22 may not move downwardly. Both sides of each tubular section plate 23 are extended and fixed at the sleeve 4 inner wall with a pair of pre-installed fixings 27 at the wall surface, as shown in FIG. 6B . One exemplary pre-installed fixing is angles plus bottom plates at these angle bottoms. These fixings 27 provide an anchoring means to sleeve 4 wall for the tubular section plate 23 and for the strip 24 . These strips 24 are extended downwardly and placed in front of an annular resilient tube 25 . The annular resilient tube 25 has a cone section 25 A on top of a tubular section 25 B with a constant inner diameter and a smooth inner surface. The bottom of the annular resilient tube 25 has a flange connection 26 at the bottom of sleeve 4 to form a seal for a grout column. The strips 24 and the cone section 25 A of the annular resilient tube 25 are bonded together through a vulcanization process. In a preferred embodiment, the connections of seal top strips 24 to the sleeve inner wall, and the connections at the seal bottom to sleeve inner wall, are designed to be strong enough to allow the grout seal to take relative sliding motion (both upward and downward) between the pile 3 and the pile sleeve 4 during a potential leveling operation.
[0049] Referring now to FIG. 7 , the grout seal in FIG. 6A is activated with a pile 3 driven and without any pile offset. Grout 13 passes through the holes between strips 24 to fill the annulus room below to form a grout column. Shear keys 21 at the pile 3 outer surface make contact with strips 24 and/or annular resilient tube 25 to enhance the sealing capacity. Shear keys are wrapped by these strips and/or resilient tube. Because the density of grout 13 is greater than that of seawater, the fluid pressure of grout 13 at the column bottom near the flange 26 is much greater than the surrounding seawater pressure at the same water depth. The weight of the grout column forces the resilient tube 25 to be extended downwardly and bended. As a result, the fluid pressure induced by the grout 13 column should provide an increasing horizontal compression force against pile 3 outer surface through the annular resilient tube 25 .
[0050] The total sealing capacity from the grout seal disclosed herein comes from three areas:
[0051] 1) The constant diameter of the annular resilient tube 25 should have a tubular section with its diameter smaller than the pile 3 outer diameter. As the pile 3 passing through the seal assembly, the annular resilient tube 25 inner diameter should be enlarged to produce a compression force against the pile 3 outer surface;
[0052] 2) The wrapped shear keys 21 by these strips 24 and/or the tubular of the annular resilient tube 25 should further enlarge the tubular diameter of the annular resilient tube 25 to produce an increased compression force against the pile 3 outer surface;
[0053] 3) The high column of grout 13 at the seal bottom should provide an increasing horizontal fluid pressure against pile 3 outer surface through the bottom portion of the annular resilient tube 25 to create an additional sealing force of the invented seal.
[0054] Referring to FIG. 8 , when a driven pile 3 has a large offset inside a sleeve 4 , the basic sealing capacity of the grout seal should have little change. As shown in FIG. 8 , the hanging strips 24 should be easy to compensate the pile 3 offsets at the top of the seal. At the bottom of the seal, the side with a narrower annulus should have a more downwardly extended annular resilient tube 25 , more than the other side. However, the sealing capacity should maintain the same for the whole seal.
[0055] The sealing capacity of the grout seal disclosed herein is independent of the pile 3 offset because of the following three facts: 1) The compression force caused by the annular resilient tube 25 inner diameter is independent of the pile 3 offset; 2) The increased compression force against the outer pile 3 surface due to the wrapping up the shear keys 21 is independent of the pile 3 offset; and 3) The increasing horizontal fluid pressure force against pile 3 outer surface is independent of the narrowness of the annulus and it only depends on the height of the grout 13 column.
[0056] In accordance with another embodiment, the grout seal assembly may be installed inside an independent steel-can. The steel-can may then be welded to the bottom of the sleeve 4 , or it may be directly installed inside the sleeve inner wall near the bottom.
[0057] The connection at the top of each strip 24 to the inner wall of sleeve 4 may be a welded connection or a non-welded connection. In the case of non-welded connections, a part of a bulbous ring section 22 may be added to the top of the strip 24 and a section of a tubular section plate may be utilized combined with some pre-welded fixings to keep the bulbous ring section 22 to the wall.
[0058] Welded connections may be also applied to both the top connections and the bottom connections of the seal. In accordance to one embodiment, at the top of each strip 24 , a section of the strip may be pre-connected to the outer surface of a doubler plate 28 through a vulcanization process. Welding is then applied at the both sides of the doubler plate 34 to fix the top of each strip 24 to the sleeve inner wall. The same method may be also applied to the bottom section. A part of the seal bottom resilient tube 25 may be pre-connected with an annular doubler 34 surface through a vulcanization process and then the annular doubler 34 may be welded around the sleeve inner wall at the top and the bottom to form a sealed annulus. One advantage of this configuration is to reduce the annulus dimension and the size of the tapered guide shims 16 . Another advantage is to place the grout seal directly inside most sleeve 4 designs without attaching an extra can as a traditional inflatable packer does.
[0059] FIG. 9 illustrates an embodiment of the grout seal with welded connections at both the top and the bottom of the seal. A doubler plate 28 for each strip 24 is welded to the inner wall of sleeve 4 at both horizontal sides. A section of each strip 24 top surface is then anchored to a corresponding doubler plate 28 with a bonding surface 30 through a vulcanization process. One section of the bottom annular resilient tube 25 may also be anchored to an annular doubler 34 with a bonding surface 30 through a vulcanization process. The annular doubler 34 is welded at the top and at the bottom to the sleeve 4 inner wall.
[0060] Referring now to FIG. 10 , the grout seal illustrated in FIG. 9 is activated with a pile 3 driven and without any pile offset. Grout 13 passes through the holes between strips 24 to fill the annulus room below to form a grout 13 column. Some shear keys 21 at the pile 3 outer surface make contacts and wrapped with strips 24 and/or annular resilient tube 25 to enhance the sealing capacity of the seal. Because the density of grout 13 is greater than that of seawater, the fluid pressure of grout 13 at the column bottom is much greater than the surrounding seawater pressure. As a result, the fluid pressure induced by the grout 13 column should provide a horizontal compression force against pile 3 outer surface through the annular resilient tube 25 .
[0061] However, the annular resilient tube 25 in FIG. 10 would be subject to a large amount of downward pulling force during a grout 13 pouring operation due to a build-up grout 13 column inside the sealed annulus between a sleeve 4 inner wall surface and a driven pile 3 outer surface. As the grout 13 column gets higher and higher (up to 80 feet or more), the pulling down force, which induces stress inside the annular resilient tube 25 wall, becomes increasingly greater. In order to overcome this high stress, the annular resilient tube 25 wall thickness has to be increased accordingly. This increased thickness of the wall will cause the increase both in the tube 25 wall stiffness for bending and in the total weight of the tube 25 . The increase in both aspects will create difficulties for handling and site installation of the assembly.
[0062] One improvement method disclosed herein is to add one annular ring structure, which has anchoring means at the inner surface of the sleeve 4 and below the installed resilient tube 25 . The annular ring structure, with its inner diameter of a central circular opening larger than the outer diameter of the pile 3 , is designed to avoid interference during pile 3 inserting. In this configuration, the majority of the grout column weight during grout pouring will be taken by this annular ring structure and the overall wall thicknesses of the annular resilient tube 25 can be kept thin as a whole. To maintain a thin wall of the tube 25 will bring the following two benefits:
1) Total weight reduction in the annular resilient tube 25 and resultant direct cost savings for the whole system; and 2) Reduced elongation/bending stiffness and the total weight of the tube shall make it convenient and easy for handling, transportation and site installation of the assembly.
[0065] However, this improvement could cause one drawback during the application of the system. Even though the majority of the planar area between the sleeve 4 inner surface and the pile 3 outer surface is blocked by this annular ring structure, there is still an open annular gap between the inner edge of the annular ring structure and the pile 3 outer surface. During grout pouring, the gravity load from the high grout 13 column will force a section of the tube 25 wall at the open annular gap location to bulge out downward and the wall thickness at the bulged section to become thinner due to the pressure loading. The thinner the tube wall, the larger the bulge, especially when the gap is wide. As the size of a bulged tube wall becomes large, the inner bending stress inside the wall will be increased and this could cause a local structural failure at the wall of the bulged tube 25 section, thus inducing grout 13 leakage.
[0066] To overcome this drawback, another improvement is then introduced. Because this is a local structural failure issue, a localized annular bandage tube 25 C is added and bonded at the outer surface of the annular resilient tube 25 , located at the lower part of the resilient tube 25 . The primary objective of adding this bandage tube is to reduce both bulge size and bending stress inside the tube 25 wall in order to avoid a local structural failure during grout 13 pouring. In addition, the increased local wall thickness and the reduced bulge size of the tube 25 will help a section of the tube 25 to be plunged into the annular open gap and to perform a grout sealing function with the aid of the grout 13 column induced pressure force acting at the bandage tube 25 C upper surface.
[0067] The thickness and the stiffness of the selected bandage tube 25 C wall will depend on the designed grout column height during grout pouring. In one embodiment, the annular resilient tube 25 is composed of multiple layers of polyester or Aramid fiber nets bonded together with elastomeric materials through a vulcanization process to increase the compacity against a high grout 13 column. In another embodiment, the bandage tube 25 C wall is composed of multiple layers of steel nets bonded together with elastomeric materials through a vulcanization process. These steel nets shall increase the bending stiffness of the annular bandage tube and shall reduce the size of the bulge at the annular gap to help seal the annular gap with the aid of the grout 13 column induced pressure force acting at the bandage tube 25 C upper surface. Because this is only a local reinforcement action, the total increased weight of this bandage tube shall be very limited.
[0068] Because the basic function of the annular ring structure is for structural support purpose only and it does not have the sealing requirement, the whole annular ring structure can be fabricated into several sections for easy handling, transportation and final assembly during site installation.
[0069] In accordance with one embodiment of the present disclosure, the grout seal assembly comprises: 1) an annular ring structure 36 or 37 which is fixed at a sleeve 4 inner wall surface below the installed annular resilient tube 25 ; and 2) an annular bandage tube 25 C bonded at the outer surface of the annular resilient tube 25 and located at the lower part of the resilient tube 25 as shown in FIGS. 11A and 12A .
[0070] Two options for the annular ring structure:
[0071] 1) As shown in FIG. 11A , the annular ring structure 36 comprises a planar ring plate 36 B fixed at the sleeve 4 inner wall surface below the installed annular resilient tube 25 with an inner diameter 40 of the central circular opening larger than the outer diameter of a pile 3 ; an annular pad 36 A with a triangle cross section located at the annular corner between sleeve 4 vertical inner wall surface and the planar ring plate 36 B, a plurality of evenly spaced stiff plates 36 C below the planar ring plate 36 B to connect the planar ring plate 36 B and the sleeve 4 inner wall surface together ; or
[0072] 2) Alternatively, as shown in FIG. 12A , the annular ring structure 37 comprises a cone shape annular ring plate 37 A fixed at the sleeve 4 inner wall surface below the installed annular resilient tube 25 , with an inner diameter 40 of the central circular opening larger than the outer diameter of a pile 3 , a plurality of evenly spaced stiff plates 37 B below the cone shape ring plate 37 A to connect the cone shape ring plate 37 A and the sleeve 4 inner wall surface together.
[0073] The latter option provides a smoother curvature and less internal bending stress for a bulged section of the tube 25 under the same annular gap size and under the same grout 13 column height during grout 13 pouring, compared to the first option.
[0074] In one embodiment, an annular bandage tube 25 C is composed of the same materials as the annular resilient tube 25 with multiple layers of polyester or Aramid fiber nets bonded together with elastomeric materials through a vulcanization process, with the tube 25 C height 38 larger than the maximum annular gap width 35 between the pile 3 outer surface and the annular ring structure inner edge 39 of the annular ring structure 36 or 37 . The annular bandage tube 25 C is added and bonded at the outer surface of the annular resilient tube 25 , located at the lower part of the resilient tube 25 , to function as a localized structural reinforcement for the tube 25 and as a sealing tool by partially plunging a section of the tube 25 , including the bandage tube 25 C, into the annular gap 41 during grout 13 pouring, with the aid of the grout 13 column induced pressure force acting at the bandage tube 25 C upper surface. The exact location and the height 38 of the bandage tube 25 C at the outer surface of resilient tube 25 shall be determined by calculations and testing for different applications to ensure that this reinforced tube section 25 C shall cover all potential bulged sections of the tube 25 over the annular gap 41 under all possible pile 3 offsetting configurations.
[0075] FIG. 11A illustrates one embodiment of the grout seal assembly in the present disclosure. As shown in FIG. 11A , a planar annular ring plate 36 B is placed below the installed annular resilient tube 25 , with smooth and rounded corners at its inner annular edge 39 for the protection of a bulged tube 25 section during grout 13 pouring, and an annular pad 36 A at the annular corner between the planar ring plate 36 B outer edge and the sleeve 4 vertical inner wall surface. In one embodiment, the annular pad 36 A, with a triangle cross section, may be made of non-metal materials such as rubbers or plastic materials fixed to the planar ring plate 36 B upper surface. The planar ring plate 36 B and the annular pad 36 A may be fabricated into multiple sections for easy handling, transportation and site installation of the assembly. The purpose of using the annular pad 36 A at the annular corner is to reduce the curvature of the annular resilient tube 25 at the annular corner during grout 13 pouring. An annular bandage tube 25 C is added and bonded at the outer surface of the annular resilient tube 25 , located at the lower part of the resilient tube 25 . A plurality of evenly spaced stiff plates 36 C below the planar ring plate 36 B are used to connect the planar ring plate 36 B and the sleeve 4 inner wall surface together.
[0076] Referring now to FIG. 11B , the grout seal assembly illustrated in FIG. 11A is activated with a driven pile 3 , without any pile 3 offset and with an annular gap 41 between the pile 3 outer surface and the annular ring structure inner edge 39 of the planar ring plate 36 B which has the inner diameter 40 of a central circular opening larger than the outer diameter of the pile 3 . Grout 13 passes through the holes between strips 24 to fill the sealed annulus room below and to form a grout 13 column. The resilient tube 25 bottom is pulled downward by the gravity load of the grout 13 column and the bottom portion of the tube 25 makes full contact at the upper surface of the planar ring plate 36 B, the pile 3 outer surface and the sleeve 4 inner surface. The annular gap 41 is fully covered by a bulged section of the annular resilient tube 25 with the annular bandage tube 25 C on top.
[0077] Referring now to FIG. 11C , the grout seal assembly illustrated in FIG. 11A is activated with a driven pile 3 and with a maximum pile 3 offset at one side to cause a minimum gap width 42 at the same side between the pile 3 outer surface and the annular ring structure inner edge 39 of the planar annular ring 36 B. Grout 13 passes through the holes between strips 24 to fill the sealed annulus room below and to form a grout 13 column. The resilient tube bottom 25 is pulled downward due to the gravity load of the grout 13 column and the bottom portion of the tube 25 makes full contact at the upper surface of the planar ring plate 36 B, the pile 3 outer surfaces and the sleeve 4 inner surface. Little bulging of the tube 25 is formed at the minimum gap width 42 .
[0078] Referring now to FIG. 11D , the grout seal assembly illustrated in FIG. 11A is activated with a driven pile 3 and with a maximum pile 3 offset at one side to cause a maximum gap width 35 at another side between the pile 3 outer surface and the inner edge 39 of the planar annular ring 36 B. Grout 13 passes through the holes between strips 24 to fill the annulus room below and to form a grout 13 column. The resilient tube bottom 25 is pulled downward by the gravity load of the grout 13 column and the bottom of the tube 25 makes full contact at the upper surface of the planar ring plate 36 B, the pile 3 outer surface and the sleeve 4 inner surface. A maximum bulged section of the tube 25 is formed over the gap 35 with a plunged action into the maximum annular gap 35 , which is the distance between the pile 3 outer surface and the inner edge 39 of the planar annular ring 36 B, to perform a grout 13 sealing function and with the annular bandage tube 25 C on top.
[0079] FIG. 12A illustrates another embodiment of the grout seal assembly in the present disclosure. As shown in FIG. 12A , a cone shape ring plate 37 A, with smooth and rounded corners at its inner annular edge 39 for the protection of the tube 25 during bulging, is placed below the installed annular resilient tube 25 . The cone shape ring plate 37 A can be divided into multiple sections for easy handling, easy transportation and easy site installation. An annular bandage tube 25 C is added and bonded at the outer surface of the annular resilient tube 25 , located at the lower part of the resilient tube 25 . A plurality of evenly spaced stiff plates 37 B below the cone shape ring plate 37 A are used to connect the cone shape ring plate 37 A and the sleeve 4 inner wall surface together.
[0080] Referring now to FIG. 12B , the grout seal assembly illustrated in FIG. 12A is activated with a driven pile 3 and without any pile 3 offset to have an annular gap 41 between the pile 3 outer surface and the inner edge 39 of the cone shape ring plate 37 A which has the inner diameter 40 of a central circular opening larger than the outer diameter of the pile 3 . Grout 13 passes through the holes between strips 24 to fill the annulus room below to form a grout 13 column. The resilient tube 25 bottom is pulled downward by the gravity load of the formed grout 13 column and the bottom portion of the tube 25 shall make full contacts at the upper surface of the cone shape ring plate 37 A, the vertical surfaces of the pile 3 outer surface and the sleeve 4 inner surface. The annular gap 41 is fully covered by a bulged section of the annular resilient tube 25 with the annular bandage tube 25 C on top.
[0081] Referring now to FIG. 12C , the grout seal assembly illustrated in FIG. 12A is activated with a driven pile 3 and a maximum pile 3 offset at one side and to cause a minimum gap width 42 at the same side between the pile 3 outer surface and the inner edge 39 of the cone shape ring plate 37 A. Grout 13 passes through the holes between strips 24 to fill the annulus room below to form a grout 13 column. The resilient tube 25 bottom is pulled downward by the weight of the grout 13 column and the bottom of the tube 25 makes full contacts at the upper surface of the planar ring plate 37 A, the pile 3 outer surface and the sleeve 4 inner surface. Little bulging of the tube 25 is formed at the minimum gap 42 .
[0082] Referring now to FIG. 12D , the grout seal assembly illustrated in FIG. 12A is activated with a driven pile 3 and with a maximum pile 3 offset at one side to cause a maximum gap width 35 at the other side between the pile 3 outer surface and the cone shape ring plate 37 A inner edge 39 . Grout 13 passes through the holes between strips 24 to fill the sealed annulus room below and to form a grout 13 column. The resilient tube 25 bottom is pulled downward by the gravity load of the grout 13 column and the bottom of the tube 25 makes full contact at the upper surface of the cone shape ring plate 37 A, the pile 3 outer surface and the sleeve 4 inner surface. A maximum bulged section of the tube 25 is formed over the maximum annular gap 35 with a plunged action into the gap 35 to form a grout 13 sealing function and with the annular bandage tube 25 C on top.
[0083] In one embodiment, as illustrated in FIG. 12E , the annular bandage tube 25 C wall thickness plus the bonded annular resilient tube 25 section wall thickness together is equal or larger than the half width of the maximum annular gap 35 , which is the distance between the pile 3 outer surface and the inner edge 39 of the cone shape ring plate 37 A. Under this configuration, especially with the application with the cone shape ring plate 37 A, the plunged tube 25 section with the combined wall thicknesses of the annular resilient tube 25 section and the annular bandage tube 25 C together will function as an annular plug to provide a total block to the maximum annular gap 35 with the aid of the grout 13 column induced pressure force acting at the bandage tube 25 C upper surface.
[0084] Although a preferred embodiment of a grout seal assembly in accordance with the present invention have been described herein, respectively, those skilled in the art will recognized that various substitutions and modifications may be made to the specific features described without departing from the scope and spirit of the invention as recited in the appended claims.
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A passive annular grout seal assembly is disclosed for sealing an annular opening between a driven pile and a skirt pile sleeve for an offshore platform. The annular seals are located at the bottom of the pile sleeves near sea floor and automatically activated when piles are inserted and driven through the pile sleeves without any active operational procedure during offshore piling. The seal configuration fully utilizes the seal height, the grout column height and the density difference between grout and sea water to produce enhanced sealing capacity against the column of grout above.
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BACKGROUND OF THE INVENTION
Printing control circuits have been developed but these have shortcomings which affect their usefulness as regard accurate and consistent printing of characters. These devices have employed a light comb arrangement to determine the position of the printed output. In the case of a matrix type character print-out a synchronized pulsed light beam together with a fixed comb-like member having a plurality of apertures is utilized together with a photodetector on the print head to determine the actual position of said print head. Such output positional information is then utilized to control the speed of said print head in order to achieve consistent character printing. Magnetic output detection means have also been utilized to determine the actual position of the print head.
SUMMARY OF THE INVENTION
It is therefore, an object of this invention to provide an improved printing control circuit.
Another object of this invention is to provide a printing control circuit which achieves constant character width impressions on a print medium.
A further object of this invention is to provide a printing control circuit which automatically compensates for frequency change in the line voltage to provide printing of characters which are all of the same width.
A still further object of this invention is to provide a printing control circuit which can be utilized for either 50 or 60 Hz line operation without the necessity of changing motors or gear trains.
These and other objects of the present invention are accomplished in the illustrative embodiment by providing a phase-lock loop circuit which utilizes at least two frequency dividers. The phase-lock loop includes a phase detector which has as one of its inputs the standard line voltage at either 60 or 50Hz. This same voltage is supplied to a a.c. synchronous motor which horizontally drives a print head in a print carriage. The output of the phase detector is coupled to a voltage controlled oscillator through a low pass filter. The voltage output from the voltage controlled oscillator has its frequency divided down by a first frequency divider to provide a timing signal to a character generator and control circuit which has fed to it input data signals. Such character generator and control circuit in turn drive a matrix print head. This same output is further divided down in the loop by a second frequency divider whose output is coupled to said phase detector. This phase detector compares the input line voltages frequency and phase with the output voltage from said second frequency divider to generate any phase error therebetween, thereby automatically varying the frequency of the timing signals as a function of the frequency of the line voltage.
BRIEF DESCRIPTION OF THE DRAWING
The invention is illustrated by the sole FIGURE in the drawing which is a simplified functional block diagram of the circuit incorporating the features of this invention.
DESCRIPTION OF THE INVENTION
Referring to the sole FIGURE, which is a simplified functional block diagram of the invention, a voltage source 1, referred to as V-INPUT, which may be the line voltage, 120 volts a.c. at 60 Hz, is coupled over line A to one input of a phase detector circuit 3 as well as to the input of a a.c. synchronous motor 5, over line B. The output from the phase detector 3, is coupled over line C to the input of a low pass filter 7 whose output is coupled over line D to the input of a voltage controlled oscillator 9. The voltage controlled oscillator 9 provides a local reference signal, 30,000 Hz in the preferred embodiment, having a frequency which is variable over a range on either side of the nominal frequency of the component of the input signal to which the loop is to lock, preferably at 30,000 Hz. The output signal from the phase detector 3 is fed to a low pass filter 7 which eliminates all signal components except for the voltage controlled oscillator correction voltage. The phase detector 3 provides an output signal which is a function of the frequency and/or phase difference between its two inputs. The output of the voltage controlled oscillator 9 is coupled over line E to a frequency divider comprising a first frequency divider 11, which in the preferred embodiment provides a division by 50, and whose output F is coupled to a second frequency divider 13, which in the preferred embodiment provides a division by 10. The resulting output from the second frequency divider 13 is coupled over line G to the second input of said phase detector 3. The output from the first frequency divider 11 is also coupled over line F to the input of a character generator and control circuit 15 and provides timing signals of the appropriate frequency, in this embodiment 600 Hz at line F. The character generator and control circuit 15, converts the input data signals coupled over line H into output signals in a form suitable to energize an output printing device, in the preferred embodiment a conventional solenoid driven matrix printer 17, which is shown as a "5 high" matrix printer. This matrix printer 17 is conventionally mounted in the carriage mechanism of a printer unit (not shown) and is driven horizontally by the synchronous motor 5.
In operation if the input signal applied over line A is zero, or some value far from 60 Hz, such as 54 Hz, and the output frequency of the voltage controlled oscillator 9 is 30,000 Hz in the absence of any control voltage, then the error signal applied to the second input to the phase detector at line G will be 60 Hz. The phase error output over line C of the phase detector 3 will result in a 6 Hz phase error signal passed through the low pass filter 7 to the input of the voltage controlled oscillator 9. This error signal will tend to drive the voltage controlled oscillator 9 to 27,000 Hz. However, if the V input voltage is 60 Hz, but out of phase with the error signal over line G, the voltage at the output of the low pass filter will be a d.c. value of a magnitude proportional to the phase difference. Such voltage applied to the input of the voltage controlled oscillator 9 will tend to shift the oscillators frequency to thereby decrease the phase error reducing it oward zero whereby the voltage controlled oscillator will be phase-locked to the 60 Hz V-INPUT line voltage. If the frequency of the line voltage tends to change for any reason, an error signal will be developed in the loop to counteract the change. In both cases, where the frequency of the line voltage changes or where there is a difference in phase between the line voltage and the error signal, the frequency of the voltage controlled oscillator will vary as a function thereof thereby automatically producing timing signals whose frequency is proportionally changed. For example, if the line frequency increases the speed of the synchronous motor 5 and therefore the print head 7 will increase. At the same time the frequency of the timing signals applied to the character generator and control circuit 15 will increase thereby providing constant width printed characters.
In order to simply utilize said circuit in countries which have a 50 Hz line frequency it is only necessary to replace the first frequency divider 11 by one that divides by 60 instead of 50 while still providing the same 600 Hz timing signal. Such a system can be best utilized where there exists a similar whole number relationship between line frequency (50 or 60 Hz), controlled oscillator frequency, and desired frequency of timing pulses.
Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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A phase-locked loop circuit for use in a printer which automatically compensates for speed changes in the print head due to changes in line frequency to maintain consistent character width print impressions.
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FIELD OF THE INVENTION
[0001] The invention relates to an anti-pinch system for a closure system associated with an aperture of a motor vehicle. More specifically, the invention relates to an anti-pinch system for an aperture of a motor vehicle wherein the anti-pinch system differentiates a number of zones.
DESCRIPTION OF THE RELATED ART
[0002] Motor vehicles typically have anti-pinch systems associated with powered closure assemblies used to selectively open and close an aperture. By way of example only, an aperture of a motor vehicle is found within a door or side and the closure panel associated therewith is a window and its associated control mechanism. A non-exhaustive list of closure assemblies includes door windows, sliding doors, liftgates, deck-lids, sunroofs and the like.
[0003] The anti-pinch systems associated with these closure assemblies typically sense the presence of a foreign object in the path of the closure panel by using characteristics such as motor current or a feedback device, such as a Hall effect sensor, position sensors, tachometer and the like. These feedback devices sense an abnormal characteristic in the parameter being sensed relative to the normal or unobstructed operating characteristic of the closure panel.
[0004] U.S. Pat. No. 6,051,945, issued to Furukawa on Apr. 18, 2000, discloses an anti-pinch assembly for a closure panel. A processor controls a motor that moves the windowpane between its open and closed positions. A Hall effect sensing device is positioned such that it can sense the velocity of the output shaft of the motor. To measure velocity, the Hall effect sensors are disposed around the shaft of the motor. A magnet is secured to the shaft and provides the magnetic field required sensed by the Hall effect sensors. Once the velocity of the shaft is measured, acceleration is derived and the force is calculated using the mass of the windowpane. This system requires the use of multiple sensors and calculations to determine the presence of an object.
[0005] Simple detection of obstructions based on motor speed or electrical current passing through the motor are inadequate due to the normally varying characteristics of these parameters through the full range of motion for the closure panel.
SUMMARY OF THE INVENTION
[0006] The disadvantages of the prior art may be overcome by providing an anti-pinch assembly that prevents objects from getting caught by a closure panel of a motor vehicle by providing an anti-pinch system having multiple zones of varying sensitivity.
[0007] According to one aspect of the invention, there is provided an anti-pinch assembly is used for a closure panel supported by the motor vehicle. The closure panel is movable between an open position and a closed position., A controller is operably connected to the closure panel for controlling the operation of the closure panel. A position sensor is connected to the controller for indicating the position of the closure panel as the closure panel moves between the open and closed positions. A capacitive sensor is mounted on the frame of the vehicle and connected to the controller for providing an output signal to the controller indicative of the presence of a foreign object in the path of the closure panel. The controller varies the function of the capacitive sensor through a plurality of threshold levels as a function of the position of the closure panel as indicated by the position indicator. In a critical zone of travel, namely, travel of the closure panel nearing the closed position, the capacitive sensor can be utilized in either a contact mode or a non-contact mode or a combination of both.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Advantages of the invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0009] FIG. 1 is a schematic of one embodiment of the invention;
[0010] FIG. 2 is a side view of an aperture in a door of a motor vehicle incorporating one embodiment of the invention;
[0011] FIG. 3 is a schematic view of the driving circuit for the invention of FIG. 1 ;
[0012] FIG. 4 is a cross section of a portion of an aperture and a window pane disposed adjacent a graphic representation of zones; and
[0013] FIG. 5 is a cross section of graph of an aperture and a windowpane incorporating adhesive based sensor strips.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to the Figures, an anti-pinch assembly is generally indicated at 10 . The anti-pinch assembly 10 is used in conjunction with a closure panel assembly. The closure panel assembly includes of a closure panel 12 , defining a leading edge 13 , and its operating system, discussed subsequently. The closure panel 12 travels along a path between open and closed positions. The anti-pinch assembly 10 prevents the closure panel 12 from pinching or crushing an obstruction or object (not shown) that may be extending through an aperture 14 of a motor vehicle 16 (both shown in FIG. 2 ) when the closure panel 12 nears the closed position. It should be appreciated by those skilled in the art that the closure panel 12 may be any motorized or automated structure that moves between an open position and a closed position. By way of example, a non-exhaustive list of closure panels 12 include windowpanes, doors, liftgates, sunroofs and the like. Apertures include window frames, door openings, sunroof openings and the like. For purposes of simplicity, the remainder of this disclosure will focus on the windowpane and window frame combination.
[0015] The anti-pinch assembly 10 includes a controller 18 . The controller 18 is electrically connected, directly or indirectly, to a power source 20 . A conductor 22 graphically represents this connection. The power source 20 is preferably the power source 20 for the motor vehicle 16 . The power source 20 may be a battery, a generator or any other electricity generating device or combination thereof.
[0016] A motor 24 receives electricity through a conductor 26 that, directly or indirectly, operatively extends between the power source 20 and the motor 24 . The motor 24 rotates a shaft 28 operatively connected to the closure panel 12 in a conventional manner. The operative connection transforms the rotational energy into mechanical energy. More specifically, the electric output of the motor 24 into an opening and closing movement of the closure panel 12 . The motor 24 optionally may be provided with separate motor controller. Operation of the motor 24 is effected by the motor controller.
[0017] A position sensor 30 is disposed adjacent the motor 24 . The position sensor 30 identifies the position of the shaft 28 of the motor 24 and generates a position signal. By identifying the position of the shaft 28 upon receipt of the position signal, the controller 18 determines with specificity the position of the leading edge 13 of the closure panel, i.e., the windowpane 12 . As the shaft 28 rotates, the position sensor 30 identifies where along the rotation the shaft 28 is as well as how many rotations the shaft 28 has executed. The degree of accuracy of the position sensor 30 is a variable that will depend on the specific design.
[0018] In one embodiment, the position sensor 30 is a Hall effect sensor that utilizes a single magnet (not shown) that is secured to the shaft 28 . The magnet rotates with the shaft 28 and its magnetic field affects the position sensor 30 as it passes thereby.
[0019] In an alternative embodiment, the position sensor is a Hall effect sensor that is secured to a portion of the mechanism (not shown) that moves the windowpane between the open and closed positions. The position sensor 30 could be secured to a drive screw, glass run channel or some other portion of the mechanism that moves proportionally to the windowpane or closure panel 12 .
[0020] A capacitive sensor 32 is mounted relative to the window frame in a spaced relation and electrically connected to the controller 18 .
[0021] The capacitive sensor 32 is capable of determining changes in magnetic fields in the surrounding space due to the introduction of an object that has a dielectric that is different than that of the surrounding space. The capacitive sensor 32 can be tuned to detect smaller changes in the surrounding space, i.e., when an object is extending through the window frame 40 but not touching the window frame 40 , referred to as a non-contact mode. The capacitive sensor 32 detects changes in the surrounding space defined by the aperture 14 by measuring the capacitance of the capacitive sensor 32 , discussed subsequently. Changes occur prior to the immediate closing of the closure panel 12 and when an object extends therethrough. An object extending through the aperture 14 will disrupt the dielectric fields being measured by the capacitive sensor 32 and the sensor 32 will responsively generate an output signal relative thereto.
[0022] The capacitive sensor 32 may also be used in a second mode, i.e., a contact mode. In the contact mode, the sensitivity of the capacitive sensor 32 is reduced. Therefore, a change in the dielectric field surrounding the capacitive sensor 32 triggers the anti-pinch assembly 10 only when the capacitive sensor 32 is moved by the object when it actually contacts the sensor 32 or the sealing system 37 that houses the sensor 32 . The sensitivity of the sensor 32 is reduced so that the leading edge 13 of the closure panel 12 does not trigger the anti-pinch assembly 10 , which would result in the closure panel 12 failing to reach its closed position ever.
[0023] Referring to FIG. 4 , the capacitive sensor 32 is molded into a flexible, and/or low durometer compound, in a range of less than 40-50 Shore. The compound is flexible and configured as the sealing system 37 of the aperture 14 . Flexibility of the sealing system 37 can also be controlled by the cross-sectional configuration, including controlling thickness of the arm and walls supporting the capacitive sensor. In the embodiment shown in FIG. 4 , the capacitive sensor 32 is molded directly into the sealing system 37 .
[0024] Referring to FIG. 5 , wherein like primed numerals represent similar elements in an alternative embodiment, the capacitive sensor 32 ′ may be added as an aftermarket item by using adhesive 39 to attach the capacitive sensor 32 ′ to the sealing system 37 ′.
[0025] Referring to FIG. 2 , a door 36 of a motor vehicle 16 is shown. The door 36 defines the aperture 14 (a window frame in this case) as an opening extending between a base 38 of the door 36 and around a window frame 40 having a forward boundary 42 , an upper boundary 44 and a rearward boundary 46 . The capacitive sensor 32 extends along the forward 42 and upper 44 boundaries. The capacitive sensor 32 is designed to measure the electromagnetic field directly therebelow within the aperture 14 .
[0026] The capacitive sensor 32 is preferably a long conductor that extends out from and along a window frame 40 at a predetermined distance from the window frame 40 . The predetermined distance creates a specific capacitance for the capacitive sensor 32 because the capacitive sensor 32 uses the window frame 40 as ground. Any changes in the distance between the capacitive sensor 32 and the window frame 40 changes the capacitance in a manner far greater than when an object extends through the window frame 40 but does not touch the capacitive sensor 32 . This change in capacitance is monitored by the controller 18 . If an object, regardless of its dielectric constant, contacts the capacitive sensor 32 enough to flex it out of its position, the change is detected by the controller 18 , which will subsequently stop and/or reverse the closure of the window.
[0027] The controller 18 includes a threshold generator 33 that generates a threshold value for the capacitive sensor 32 . This threshold determines in which zone the anti-pinch assembly 10 is operating. The threshold is a value of a dielectric that the capacitive sensor 32 can detect. The threshold generator 33 includes a pulse generator 34 and a threshold capacitor 35 . The threshold capacitor 35 is connected in parallel with the capacitive sensor 32 and is approximately 1000 times the capacitance of the capacitive sensor 32 . The pulse generator 34 generates a regular pulse train of less than 5 volts, preferably 3-5 volts at a frequency of about 12 Mhz (200-500 ns per pulse), which signal is applied to the capacitive sensor 32 . Since the capacitive sensor 32 is small in comparison with the threshold capacitor 35 , the capacitive sensor 32 will become fully charged quickly. Once charged, the pulse train is reflected back to the threshold capacitor 35 thereby charging it in a stepped manner, graphically represented at 39 , until the threshold capacitor 35 is fully charged. A counter 137 counts the number of pulses required to fully charge the threshold capacitor 35 and the count is placed in a floating memory. The capacitors 32 , 35 are then discharged or reset and the process is re-started.
[0028] The count can be averaged over time so that the effects of weather and other extrinsic conditions can be factored out. A comparator 45 compares the counts of successive counts.
[0029] The determination of the presence of an obstacle is performed by monitoring the count. A measured signal is generated based on the monitored count. Any obstacle, whether it be a body part or otherwise, extending into the window aperture 14 or contacting the seal 44 will affect the dielectric constant of the field. The number of pulses required to fully charge the threshold capacitor 35 will increase should an object be present, resulting in an increased measured signal. If the change between a predetermined number of successive counts deviates or increases beyond a first predetermined threshold signal or count, the controller 18 determines that an object has extended through the window frame 40 or has moved the capacitive sensor 32 by touching or moving the sealing system 37 .
[0030] When detection of an obstacle is made, the controller 18 then changes the motor signal being sent to the motor 24 . The new motor control signal directs the motor 24 to either stop the closure panel 12 from moving or to reverse the direction in which the shaft 28 is rotating, retracting the closure panel 12 . If the closure panel 12 is returned to its open position, the controller 18 normalizes the motor control signal and allows the motor 24 to operate according to normal operation. If the closure panel 12 remains in the same position, the anti-pinch assembly 10 will not allow the closure panel 12 to continue to its closed position until after the compare value is eliminated.
[0031] As noted previously, the motor may be provided with a separate motor controller having a position sensor. Thus, the motor controller will provide a position signal to the controller 18 and the controller 18 will send a motor control signal back to the motor controller.
[0032] Referring to FIG. 4 , a graphic representation of multiple zones is generally shown at 56 . The graph 56 shows each zone 58 , 60 , 62 as a function of position or location of the leading edge 13 of the windowpane 12 . Each different zone 58 , 60 , 62 is contiguous with the next such that the leading edge 13 of the windowpane 12 can never in a position where controller 18 is not monitoring the capacitance of the capacitive sensor 32 . Each of the zones 59 , 60 , 62 is a graphic representation for each of a plurality of threshold values above which the count must reach before the anti-pinch assembly 10 stops or reverses the windowpane 12 .
[0033] In the lower or primary zone 58 , the controller 18 increases the sensitivity of the capacitive sensor 32 to allow it to detect the presence of an object even when the object is low enough to avoid physically moving the capacitive sensor 32 .
[0034] In the secondary zone 60 , usually about 4 mm separating the upper edge 13 of the windowpane 12 from the sensor 32 , the controller 18 decreases the sensitivity of the capacitive sensor 32 . The position sensor 30 generates the position signal and the controller 18 responsively determines when the windowpane 12 enters the secondary zone 60 .
[0035] In this zone of operation, the ability to detect an object is reduced. In other words, the controller 18 applies a second predetermined threshold that has a magnitude and/or duration greater than the first predetermined threshold.
[0036] The reduction in sensitivity allows the windowpane 12 to approach the capacitive sensor 32 without the controller 18 misidentifying the windowpane 12 as an object that might be pinched between the windowpane 12 and the window frame 40 . As may be appreciated by those skilled in the art, a decrease of sensitivity still allows the capacitive sensor 32 to detect an object contacting it. Therefore, should an object remain in the path of the windowpane 12 as the upper edge 13 approaches the sealing system 37 , the controller 18 will still be able to detect it and stop or retract the windowpane 12 .
[0037] In the optional third or upper zone 62 of operation, the controller 18 deactivates the capacitive sensor 32 . This allows the windowpane 12 to enter the sealing system 37 to properly seal against thereto. The capacitive sensor 32 is deactivated because, depending on the sealing system 37 ; the capacitive sensor 32 may move upon entry. If it were still active, it would inhibit the closing of the window or aperture 14 . Upon the windowpane 12 being retracted, the controller 18 reverts to the reduced sensitivity mode (intermediate zone 60 ) and, subsequently, the higher sensitivity mode (lower zone 58 ). The anti-pinch assembly 10 will remain active until the windowpane 12 is returned to its closed position abutting the sealing system 37 .
[0038] The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.
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An anti-pinch assembly is used for a closure panel supported by the motor vehicle. The closure panel is movable between an open position and a closed position. A controller is operably connected to the closure panel for controlling the operation of the closure panel. A position sensor is connected to the controller for indicating the position of the closure panel as the closure panel moves between the open and closed positions. A capacitive sensor is mounted on the frame of the vehicle and connected to the controller for providing an output signal to the controller indicative of the presence of a foreign object in the path of the closure panel. The controller varies the function of the capacitive sensor through a plurality of threshold levels as a function of the position of the closure panel as indicated by the position indicator. In a critical zone of travel, namely, travel of the closure panel nearing the closed position, the capacitive sensor can be utilized in either a contact mode or a non-contact mode or a combination of both.
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RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/222,616, filed Jul. 2, 2009, which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to a solid bowl centrifuge for separating solids from a liquid, for different applications, such as in a waste water treatment facility. In particular, the invention relates to a weir and choke plate assembly for a solid bowl centrifuge.
Conventional solid bowl centrifuges typically are embodied as helical conveyor centrifuges having a screw within a bowl. The screw and bowl are coaxial and rotate independently of each other. The screw rotates to transport solids in a liquid solids mixture to a solids discharge end of the centrifuge. The rotations of the screw conveyor and the bowl apply a centrifugal force causing the liquid and solids in the bowl to form an annular ring having an outer surface against the wall of the bowl and an inner cylindrical ring surface (the “pond level”) that surrounds a gas filled void at the center of the centrifuge.
Solids in the rotating bowl tend to settle radially outward on the bowl wall and are moved by the screw to the solids discharge end of the centrifuge. The clarified liquid, also referred to as centrate, is radially inward and flows to a liquid discharge at a head wall which is at an end of the centrifuge opposite to the solids discharge end.
Weir assemblies are attached to the head wall of the centrifuge. The weir assembly typically includes a passage for the discharge of liquid centrate from the bowl of the centrifuge. The conventional weir assembly is adjustable to regulate the level of the liquid in the bowl. For example, German Patent Publication DE 1 183 023 discloses a weir assembly having two concentric ring-disks forming a V-shaped drain opening that is radially adjusted during operation of the centrifuge to regulate the liquid level in the centrifuge bowl. Other adjustable weir assemblies and weir aperture geometries are disclosed in DE 1 452 260. Similarly, DE 39 21 327 discloses weir elements for weir assemblies formed of flaps, slides and wedges arranged adjacent drain openings in the head wall of a centrifuge. These weir elements rotate with the bowl of the centrifuge and are adjusted radially by a set collar. The pond level of the liquid centrate in the centrifuge bowl, as well as the quantity of the centrate being drained, is regulated by adjusting the radial position of the set collar.
DE 102004019368 discloses a solid bowl centrifuge with an adjustable weir system having adjacent weir plates in which the inner weir plate rotates with bowl and the outer weir plate is fixed. The outer weir plate does move in a small set-wise rotational movement that allows for an adjustment of the effective gap between the outer and inner weir plates. The adjusting mechanism for the outer weir plate is eccentrically mounted with respect to the rotating centrifuge. The centrate flows through the gap between weir plates.
DE 43 20 265 discloses a solid bowl centrifuge with an adjustable weir having a non-rotating choke plate, also referred to as a throttle plate. The choke plate is axially displaced, arranged outside of the bowl, and is adjacent a rotating liquid drain openings in the bowl. The choke plate is in a plane parallel to the drainage cross sections for the liquid and of the liquid pond level in the bowl of the centrifuge. As the gap between the choke plate and drain openings decreases, the liquid drainage flow resistance increases and the liquid pond level in the centrifuge increases by extending radially inward during centrifuge operation.
DE 102 03 652.7 discloses a weir discharge with a rotating weir plate and a non-rotating choke plate that creates a liquid centrate discharge opening in which at least one nozzle is assigned to an outlet for discharging clarified liquid from the drum. Energy may be saved depending on the relative angle of the nozzles. Another energy savings concept for a weir is disclosed by WO2004035221.
U.S. Patent Application Publication US2004/0058796 discloses a weir discharge system where the centrate is directed outwards through a non-rotating annular cup with at least one opening that is connected to the centrifuge housing. The position of the annular cup can be adjusted during operation and thereby the centrate flow and liquid pond level are controlled.
DE 37 28 901 C1 discloses a centrate discharge system having inner and outer rotating weir plates between which is a fixed gap opening. The inner weir plate has a larger inner diameter than does the outer weir plate. The fixed gap between the weir plates creates a flow path for the centrate. After the gap is closed by a flange, the liquid level rises until the centrate flows over the edge of the outer weir.
U.S. Pat. No. 5,169,377 discloses a weir discharge system in which the liquid outflow is regulated by an annular discharge gap between rotating ring-weir plates. The outer ring weir plate moves axially to change the size of the gap between the ring and a circular discharge opening.
A weir and choke plate assembly should provide one or more of an easy adjustment of the liquid pond level in the centrifuge, a relatively low torsion moment to drive the assembly, a gas seal to isolate the gas filled void in the centrifuge from ambient atmosphere, and a decanting function in which the liquid level in the centrifuge is periodically raised to a radially inward drain opening.
BRIEF DESCRIPTION OF THE INVENTION
A solid bowl centrifuge has been developed having a variably adjustable weir choke and plate assembly. By axially adjusting the choke plate, the liquid pond level in the centrifuge bowl may be regulated in an operationally reliable manner. The centrate discharges from the centrifuge head in a radially outward direction through a radial gap between a weir plate and a choke plate. The opening of the gap is directed radially outwards.
The weir and choke plates rotate at the same rotational speed as the bowl. Because the plates rotate together, the total torsion moment applied to the plates is lower as compared to the torsion moments applied to a weir plate and choke plate that rotate at different speeds. Due to the lower torsion moment, reduced energy is required to drive a centrifuge having weir and choke plates that rotate at the same speeds.
The adjusting device for varying the level of the liquid in the centrifuge bowl comprises an open radial gap defined by a distance between the parallel opposing ring faces of the weir plate and choke plate. The width can be varied between total closure up to a distance where the centrate does not contact the choke plate.
The gap between the weir and choke plates creates a flow resistance that increases as the axial distance of the gap decreases. As the gap closes and the flow resistance increases, the pressure of the liquid increases to raise the level of the liquid in the bowl. As the gap increases, the level of the liquid in the bowl drops until the flow is dictated by a natural crest height over the weir plate.
The weir and choke plate assembly disclosed herein may allow for a periodic separate discharge of accumulated top layered fractions of the centrate without significant interference in the operation of the centrifuge. The choke plate may include apertures to allow an outflow of the centrate if the regular flow through the radial gap is too low or blocked. The flow through the apertures in the choke plate and the flow through the gap can be combined or separated in the discharge casing.
Moreover, the top layer of the liquid in the centrifuge may be decanted periodically by reducing the radial gap to raise the liquid level and eventually an overflow of the centrate through the apertures in the choke plate.
A centrifuge has been developed for separating solid-liquid mixtures comprising: a rotating bowl having a head wall with at least one drain opening for clarified liquid, said bowl having a rotational axis; a weir plate fixed to the head wall of the bowl and rotating with bowl, wherein the weir plate is aligned with the at least one drain opening; a choke plate coupled to and rotating with the rotating bowl, the choke plate having surface axially aligned with the drain opening or the weir plate, wherein said choke plate is movable axially with respect to the head wall, and a gap between the drain opening or the weir plate, wherein the gap has a radially inward inlet receiving the clarified liquid from the bowl and a radially outward outlet for discharging the clarified liquid from the bowl.
A method for clarifying liquid in a liquid and solid mixture has been developed using a solid bowl centrifuge having a rotating bowl, a choke plate and a weir plate, the method comprising: feeding the liquid and solid mixture into the bowl; forming the liquid and solid mixture in the bowl into an annulus having an inner annular liquid surface by rotating the bowl; draining clarified liquid from the liquid and solid mixing by draining a radially inward portion of the annulus through an opening in the head wall and over a radially inward edge of the weir plate fixed to and rotating with the head wall, and forming a gap between the choke plate and the head wall or weir plate, wherein the gap extends in a generally radial direction and includes a radially inward inlet to receive the clarified liquid and a radially outward outlet to discharge the clarified liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a solid bowl helical conveyor centrifuge, shown in partial cross-section.
FIG. 2 is a perspective view of the outer surface of a head wall of a bowl of the centrifuge, weir plates attached to the head wall and weir plates attached to a collar.
FIG. 3 is a cross-sectional view of an upper-half of head wall of the bowl, choke plate, weir plate and associated mechanism for axially moving the weir plate.
FIG. 4 is a cross-sectional view of a first weir and choke plate assembly having an upper-half of the choke plate outside of the head wall and weir plate showing their relative relationship and the centrate gap between the plates.
FIG. 5 is a part perspective and part cross-sectional view of an alternative weir and choke plate assembly in which the choke plate is inside of the head wall.
FIG. 6 is a front view of a choke plate for the weir and choke plate assembly shown in FIG. 5 .
FIG. 7 shows another embodiment of the weir and choke plate assembly shown in FIGS. 5 and 6 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side view of a conventional solid bowl centrifuge 10 . A rotating inner screw assembly 14 transports solids along the length of a bowl 12 . The bowl 12 rotates to centrifugally displace a liquid solid mixture 13 radially outward against the bowl that surrounds the screw. The bowl 12 may be a drum, basket or other generally annular container and they are collectively referred to herein as a “bowl.” A housing 11 of the centrifuge encloses and supports the bowl 12 and screw 14 assembly.
A mixture of solids and liquid 13 is typically held in a holding pool and enters an axial inlet 34 of a feed pipe 32 that discharges the mixture to a distributor 38 at a center portion of the bowl. The distributor 38 discharges the liquid and solids mixture 13 in a central portion of the channel 20 . The liquid and solids mixture flows through the feed pipe 32 and to a generally conical distributor 38 that rotates with the screw body 16 . The distributor has radially outward openings through which the liquid and solids mixture pass through the screw body 16 and enter a center portion of the channel 20 .
Once in the rotating bowl, the mixture 13 forms an annular ring shape bounded an inside surface of the rotating bowl. The solids tend to settle radially outward against inside surface the rotating bowl. The radially inward portion of the mixture 13 is clarified liquid, which is referred to as centrate.
A screw assembly 14 coaxial to the bowl and within the bowl moves the solids to a solids discharge casing 22 at one end of the bowl. The opposite end of the centrifuge includes a head wall 60 of the centrifuge. The screw assembly 14 has a cylindrical screw body 16 and a screw blade 18 forming a helix around the screw body. Turning the screw blade 18 moves the solids to the end of the bowl having the discharge casing 22 .
The liquid solid mixture 13 forms an annulus in the bowl with a cylindrical inner liquid surface 15 facing a gas filled annular void 21 between the mixture and a cylindrical body of the screw. The annular liquid surface level 15 is referred to as the “pond level”. The pond level 15 , in a radial direction, is generally uniform in the channel. An annular channel 20 between the inside surface of the bowl 12 and a cylindrical screw body 16 defines a passage for the liquid and solids mixture 13 in the centrifuge 10 . A gas filled void 21 forms in a region of the channel between the pond level of the mixture 13 and the outer surface of the cylindrical screw body 16 .
The screw body 16 and bowl 12 are separately rotatably driven by, for example, a motor 24 and a generator 26 , respectively. Rotation of the bowl imparts centrifugal forces that cause the liquid and solids mixture to move radially outward in the channel 20 and form an annular ring in the channel 20 . The liquid passes through openings and over edges in the screw blade 18 to ensure that the pond level 15 remains uniform through the channel.
The bowl and optionally, the screw body may taper 27 radially inward between the distributor 38 and the discharge casing 22 . As the solids material move along the tapered 27 portion of the bowl, the solids are moved radially inward and beyond the liquid surface level in the channel. Once the solids have moved in the channel beyond the liquid surface level, the solids are separated from the liquid and can be discharged through the discharge casing 22 .
A novel assembly of weir plates and choke plates has been developed for a solid bowl helical conveyor centrifuge. FIG. 2 is a perspective view of the outer surface of a head wall 60 of a bowl of the centrifuge, weir plates 28 attached to the head wall and choke plates 44 attached to a collar 76 . FIG. 3 shows, in cross-section, a side view of an end portion of the solid bowl helical conveyor centrifuge and particularly shows a portion of the head wall 60 , centrate discharge casing 36 , the weir plate 28 and the choke plate 44 . The choke plate moves axially with respect to the rotational axis 52 of the screw and bowl. FIG. 4 shows in cross-section a side view of the weir plate 28 and choke plate 44 . A centrate discharge casing 36 provides a housing over the outside of the head wall 60 and for the weir and choke plate assembly.
As shown in FIG. 2 , the weir plates 28 may be attached, e.g., bolted, to the outer surface of the head wall. The weir plates 28 may include a flat bracket 29 and a U-shaped channel 31 which forms a short flow passage 43 ( FIG. 3 ) axially between the head wall and the choke plate. The U-shaped channel 31 may be welded to the bracket 29 of the weir plate 28 . A head wall plate 49 extends axially from the outer surface of the bowl head wall 60 and faces in a radial direction an open end of the U-shaped channel 31 of the weir plate 28 .
The weir plates 28 are mounted to the head wall 60 adjacent and partially covering drain openings 50 in the wall. The drain openings 50 are generally arranged in an annular array on the head wall. Each drain opening may be at different angular positions on the headwall. All of the drain openings may be at common radial distances from the axis of the head wall.
Each weir plate 28 covers a radially outer portion of a drain opening 50 to define a radially outer edge of a centrate flow passage 43 through the opening 50 in the head wall. The choke plates 44 are each aligned with and adjacent one of the weir plates. In each weir plate, the U-shaped channel 31 has an axial end 58 ( FIG. 4 ) opposite to a flat surface 56 on the corresponding choke plate 44 .
Centrate flows 51 radially through a gap 54 between the axial end 58 of the U-shaped channel 31 of the weir plate and the flat surface 56 on the choke plate. These surfaces of the weir and choke plates forming the gap 54 may extend radially for a sufficient distance, e.g., 1 mm to 25 mm, to form a radially extending centrate flow passage 51 through the gap 54 . The radial length of the gap 54 is sufficient to cause the centrate to flow 51 radially through the gap.
The desired pond level 15 in the bowl is indicated by the dotted line 53 shown on the choke plate in FIG. 2 . The actual pond level of the centrate liquid 15 is shown in FIG. 3 . The centrate in the bowl is radially outward of the pond level 15 . From the pond, centrate liquid flows 51 through the drain opening 50 and the U-shaped channel 31 towards the choke plate 44 and turns radially outward to flow out a gap 54 between the axial end 58 of the U-shaped channel 31 and a face 56 of the choke plate 44 .
A gas filled void 21 in the bowl is radially inward of the pond level 15 . Gases may escape through a gap between the head wall plate and U-shaped channel 31 of the weir plate 28 .
The radial position of the weir plates 28 on the head wall may be adjusted by means of parallel and generally radial slots 46 in the weir plate bracket 29 . These slots receive the bolts holding the weir plate to the head wall. Each weir plate bracket 29 may be marked with gradations 47 that are aligned with a reference circle 48 marked on the head wall. By aligning the proper gradation marking 47 to the reference circle 48 for each of the weir plates, the radial position of each of the weir plates on the head wall may be precisely positioned at a uniform radial distance from the axis of the bowl.
As shown in FIGS. 3 and 4 , the discharge clarified liquid, e.g., “centrate”, flows through the channel 20 in the bowl towards the head wall 60 and through drain openings 50 arranged annularly in the head wall 60 . These openings 50 are preferably arranged in a circle on the head wall, wherein the circle of openings is centered on the rotational axis of the bowl.
The gap (G) 54 between the weir plate 28 and choke plate 44 defines a passage for the centrate flowing to the discharge casing 36 . The flow 51 of centrate is generally axially as the centrate moves through the channel 20 and into the opening 50 of the head wall. Because of centrifugal force, the flow 51 quickly turns radially outward as the centrate flows over the edge of the channel 31 on the weir plate 44 and enters the gap 54 between the weir plate and the choke plate. The centrate flows 51 radial outward through the gap 54 and into the centrate discharge casing 36 .
The choke plates 44 are mounted on the shaft 64 ( FIG. 3 ) of the bowl or screw conveyor. The choke plate includes a collar 77 that engages the shaft. An upper surface of the collar supports a ball bearing assembly 66 , which provides an engagement between the choke plate and a non-rotating axial adjustment mechanism 75 . This adjustment mechanism 75 is supported by a pillow box bearing 70 mounted on the shaft 64 . The choke plate adjustment mechanism includes a turning wheel 72 for manual or automated adjustment of the gap 54 . The turning wheel 72 causes a helically threaded ring 74 of the adjustment mechanism to move the ball bearing assembly 66 axially and thereby axially move the choke plate. The choke plate may include labyrinth seals 78 that engage the axial adjustment mechanism 75 and the head wall 60 . A sealing gasket may extend annularly in the labyrinth seal 102 .
By adjustment of the turning wheel 72 , the width of the gap 54 may be varied between total closure in which substantially no centrate flows out through the weir plate to a gap width in which the centrate does not fill the gap and thus does not impinge on the choke plate.
The choke plates 44 arranged adjacent to the outside of the head wall may include an annular array of discharge openings 45 positioned radially inwardly of the gap 54 . These openings 45 provide centrate discharge in the event the gap becomes clogged or the gap unduly restricts the discharge of centrate. If the pond level 15 increases radially inward because of excessive liquid and solid mixture 13 in the centrifuge, the discharge openings 45 allow the centrate to flow into the centrate discharge casing. Instead of openings 45 in the choke plates, lowering the U-shaped side walls of channel 31 , also allow the centrate to discharge into the centrate discharge casing.
The centrifuge may be operated in a decanting mode. In this mode, the gap 54 is narrowed by axially advancing the choke plate towards the weir plate or, towards the head wall if the choke plate(s) is inside of the head wall. With the gap narrowed or closed, the pond level 15 in the centrifuge rises radially inward. With the gap narrowed or closed, the centrate flows through optional openings 45 in the choke plate or overflows the side walls of the U-shaped channels 31 that extend from the choke plate. The centrate flows through the openings 45 or over the channel side walls and into the centrate discharge casing 36 . By allowing the pond level to rise, the decanting mode provides greater separation of solids from the liquid and the resulting centrate may have less solids than the centrate that would have otherwise flowed through the gap 54 .
The decanting mode may be performed periodically or a regular cycle or when the operator of the centrifuge desires to reduce the solids content in the centrate. The decanting mode may also be performed when the operator of the centrifuge desires to reduce the floating solids or foam in the centrifuge which, of course, results in a periodically higher solid or foam content in the centrate which may be treated differently downstream of the centrate casing.
FIG. 5 is a part perspective and part cross-sectional view of an alternative weir and choke plate assembly 80 in which the choke plates 92 are inside of the head wall 84 of the bowl 86 of a solid bowl helical conveyor centrifuge. FIG. 6 is a front view of a choke plate collar 88 which supports arms 90 that are attached to the choke plates 82 . The arms extend through openings 93 in the head wall 84 . The weir and choke plate assembly 80 functions to control the pond liquid surface level 15 , control the flow of centrate out of the bowl, and seal the gas in the gas filled void 21 in the bowl from ambient air outside of the centrifuge. Gas sealing is helpful to prevent or minimize oxygenation of the liquid solid mixture 13 in the bowl. The choke plate 92 is preferably an annular plate or an annular array of plates having an inside diameter 89 that is slightly greater than an outside diameter of the hub 104 for the screw conveyor. A sealing ring 91 provides a seal between the inner rim of the choke plate 92 and the hub 104 of the screw conveyor. If the choke plate does not serve as a gas seal the sealing ring 91 may be omitted and the choke plate 92 may be equipped with openings 106 (illustrated by dotted lines in the choke plate 92 in FIG. 7 ) that serve the same purpose as the openings 45 in the choke plate shown in FIG. 4 .
The choke plate 92 may be an annular plate forming a ring or an annular array of plates each aligned with one of the openings 93 in the head wall. The choke plate(s) has a front surface 92 that conforms to an inside surface of the head wall 84 . The openings 93 allow centrate to flow from the bowl to a discharge casing or channel. The choke plate 92 is attached, e.g., bolted, to an arm 90 extending axially between the plate and the choke plate collar. The arm 92 extends through the opening 93 in the head wall. The choke weir and choke plate assembly 80 includes an annular array of choke plates 82 each adjacent one of the openings 93 . Each choke plate is attached by an arm 90 to the choke plate collar in a centrate casing (see 36 in FIGS. 1 and 3 ).
The choke plate 92 may be advanced axially (see arrow 95 ) to define the width of a gap 96 between the front surface 92 of the choke plate and the inside surface of the head wall at the rim of the opening 92 in the head wall. The gap 96 has a radial length of preferably 1 mm to 25 mm which corresponds to the overlap between the front surface of the choke plate and the inside surface of the head wall. Adjacent the radial gap 96 is an axial gap 103 between the outer rim of the choke plate and the inner wall of the bowl. The gaps 96 and 103 form a restriction to the centrate flowing (see arrows in FIG. 7 ) from the bowl to the centrate discharge casing 36 .
The choke plate 92 is advanced axially by an operator moving the choke plate collar 88 axially with respect to the shaft of the bowl or screw conveyor. The choke plate 92 may attach to shaft with a pillow box bearing ( 70 in FIG. 3 ) and may be moved axially by an axial adjustment mechanism ( 75 in FIG. 3 ). The mechanisms for axially moving the choke plate shown in FIG. 3 may be also applied to the choke plate 82 .
The weir plates 94 mounted to the head wall 84 may be generally rectangular plates having an inside surface conforming to an outer surface of the head wall adjacent to an opening 93 in the head wall. The weir plates 94 may be bolted to the head wall 84 and adjusted radially with respect to the head wall in a manner similar to the weir plate bracket 29 shown in FIG. 2 .
FIG. 7 shows the embodiment of the weir and choke plate assembly shown in FIGS. 5 and 6 in which the assembly substantially isolates the gases in the void in the bowl from the ambient air outside of the centrifuge. The annular choke plate 82 generally prevents ambient air from mixing with the gases in the void in the bowl. A seal 91 between the inner rim of the choke plate and the hub 104 of the screw conveyor prevents gas passage between the void 21 and ambient air.
The solid bowl centrifuges disclosed herein have a rotating bowl having an end region with drain openings for clarified liquid. The drain openings are aligned with a weir plate and choke plate assembly that provides an adjustable radial gap for varying a level of the liquid in the centrifuge bowl during operation of the centrifuge. The weir and choke plate assembly has opposing parallel plates rotating together with the centrifuge bowl.
The choke plate may be arranged inside the bowl to face an inner surface of the head wall or outside the bowl to face an outer edge of a weir plate. The choke plate may include radially inward openings through which centrate may flow during a decanting function.
The choke plate may alternatively be used to seal the gas filled void in the centrifuge against the out atmosphere. The centrate exits solely through the radial gap. The centrate in the gap forms an effective gas seal between the gas filled void 21 in the centrifuge and ambient air. The gas filled void is radially inward of the liquid annular ring formed by the spinning bowl.
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.
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A centrifuge for separating solid-liquid mixtures including: a rotating bowl having a head wall with at least one drain opening for clarified liquid, said bowl having a rotational axis; a weir plate fixed to the head wall of the bowl and rotating with bowl, wherein the weir plate is aligned with the at least one drain opening; a choke plate coupled to and rotating with the rotating bowl, the choke plate having surface axially aligned with the drain opening or the weir plate, wherein said choke plate is movable axially with respect to the head wall, and a gap having between the drain opening or the weir plate, wherein the gap has a radially inward inlet receiving the clarified liquid from the bowl and a radially outward outlet for discharging the clarified liquid from the bowl.
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BACKGROUND OF THE INVENTION
Crystalline para-oriented aromatic polyamide fiber, such as poly(p-phenylene terephthalamide) have been spun from concentrated sulfuric acid solution. While crystallinity is desired for many uses, there are applications where noncrystalline polymers and highly oriented fibers and films of amorphous oriented aromatic polyamides permit processing, modification or properties not attainable with crystalline products. Stable, highly amorphous character is not usually easy to achieve in condensation polymers and often the result is a high degree of solvent sensitivity and lack of dimensional stability at elevated temperatures.
Essentially amorphous aromatic polyterephthalamides are described in Macromolecules 1985, v. 18, pp 1058-1068 and J. Poly. Sci. Part A: Polymer Chem. V 25, 1249-1271 (1987). The noncoplanar conformation of certain of the polyamides disclosed in these publications is said to enhance solubility. The authors refer to solubility in amide solvents, such as tetramethylurea (TMU) even without LiCl, a known solubility promoter. Omission of the salt results in a cost-saving but more importantly, avoids the need for salt elimination by washing with water and drying. However, the particular soluble polyterephthalamide mentioned cannot be spun from sulfuric acid solution because the aromatic --CF 3 group is unstable therein and is converted to --CO 2 H and beyond. The present invention provides new aromatic homopolyterephthalamides and homo-2,6-naphthalamides that overcome such deficiencies and certain copolymers thereof, as well as fibers and films of the polymers.
SUMMARY OF THE INVENTION
The present invention is directed to a new family of amorphous high molecular weight para-oriented aromatic homopolyamides that are soluble in dimethylacetamide (DMAc) and N-methylpyrrolidone (NMP) even in the absence of metal salts. The polymers have an inherent viscosity of at least 1.0 and encompass the homopolymers. ##STR1## and copolymers thereof in which up to 92.5 mol %, preferably u to 50 mol %, of the diamino moiety is replaced by ##STR2##
DETAILED DESCRIPTION OF THE INVENTION
The key monomer for polymers of the invention, is 2,2'-dibromo-5,5'-dimethoxy-[1,1'-biphenyl]-4,4'-diamine. This diamine is disclosed in Chem. and Industry, 1935, p. 213. To form the homopolymer, this diamine is reacted with terephthaloyl chloride or 2,6-naphthoyl chloride. High molecular weight polymer, inherent viscosity (η inh ) of at least 1.0 is prepared by this method. One may obtain fluid solutions of the polymer in DMAc or NMP, without metal salts. As polymer inherent viscosity increases above about 4, stronger solvents such as sulfuric acid are employed to obtain fluid solutions. Gel formation in the organic medium may occur as the polymer concentration increases, but these gels may be fluidized on heating.
Polymerization of terephthaloyl chloride with 2,2'-dibromo-5,5'-dimethoxy-[1,1'-biphenyl]-4,4'-diamine to yield high molecular weight polymer (inherent viscosity up to about 10) may be carried out under standard conditions in a solvent such as NMP or DMAc. The reactants combine in substantially stoichiometric proportions to yield the polymer in solution. Calcium chloride, lithium chloride and the like are not required to achieve dissolution. The dopes may be converted directly to fibers, films or fibrids without any intermediate step of redissolving the polyamide in strong acid such as sulfuric acid. Achievement of high molecular weight as well as solubility is quite surprising since the polyamide from the analogous 5,5'-dimethoxy-[1,1'-biphenyl]-4,4'-diamine and terephthaloyl chloride precipitates out of solution at low molecular weight (inherent viscosity=1.33) as shown in Comparative Example A.
The polymers of the invention may be oriented by drawing but remain non-crystalline. The amorphous nature of the polymer makes it possible to modify properties by use of additives which can penetrate the macromolecular structure quite homogeneously. This is not possible with highly crystalline structures present in fibers or films of poly(p-phenylene terephthalamide).
Fibers and films of polymers of the invention cannot be redissolved in organic solvents once formed and dried and thus are resistant to shrinkage or other deleterious effects of organic solvents. Conventionally, polymers must be crystallized to achieve such resistance.
The polymers of the invention are flame resistant. If desired, however, flame retarding additives such as Sb 2 O 3 may be incorporated.
Measurements
Inherent viscosity, η inh , is defined by the following equation: ##EQU1## where η rel is the relative viscosity and C is the concentration in grams of polymer per deciliter of solvent, typically 0.5g in 100 ml. (Thus, the units for inherent viscosity are dl/g.) The relative viscosity, η rel , is determined by dividing the flow time of the dilute solution in a capillary viscometer by the flow time for the pure solvent. The flow times are determined at 30° C. The solvents employed are the NMP or DMAc reaction medium prior to polymer precipitation or sulfuric acid on precipitated polymer.
TGA
Thermal Gravemetric Analysis (TGA) measurements were made on the Du Pont 2100 Thermal Analyzer using the Model 951 TGA attachment. Samples weighing 5 to 15 mg were run at 20° C./min up to 600° C. plotting weight loss vs. temperature.
Tensile
Tensile measurements were made on single filaments following the test procedure found in ASTM D 2101-82 The filaments were conditioned at 21° C. (70° F.) and 65 percent relative humidity and tested on a conventional tensile tester using flat clamps with rubber facing and a 2.5 cm (1") gauge length at a 10%/min strain rate (for low elongation, 0-8%). T is tenacity at break in gpd, M is the initial modulus in gpd and E is the break elongation in %. The 0.64 cm (0.25 inch) wide film strips were tested in an analogous manner.
Procedure For Determination Of The Fiber X-ray Orientation Angle
A bundle of filaments about 0.5 mm in diameter is wrapped on a sample holder with care to keep the filaments essentially parallel. The filaments in the filled sample holder are exposed to an X-ray beam produced by a Philips X-ray generator (Model 12045B) operated at 40 kv and 40 ma using a copper long fine-focus diffraction tube (Model PW 2273/20) and a nickel beta-filter.
The diffraction pattern from the sample filaments is recorded on Kodak DEF Diagnostic Direct Exposure X-ray film (Catalogue Number 154-2463), in a Warhus pinhole camera. Collimators in the camera are 0.64 mm in diameter. The exposure is continued for about fifteen to thirty minutes (or generally long enough so that the diffraction feature to be measured is recorded at an Optical Density of ˜1.0).
A digitized image of the diffraction pattern is recorded with a video camera. Transmitted intensities are calibrated using black and white references, and gray level is converted into optical density. A data array equivalent to an azimuthal trace through the selected equatorial peaks (or, in the case of non-crystalline material, through the oriented amorphous scattering maxima) is created by interpolation from the digital image data file; the array is constructed so that one data point equals one-third of one degree in arc.
The Orientation Angle is taken to be the arc length in degrees at the half-maximum optical density (angle subtending points of 50 percent of maximum density) of the equatorial peaks, corrected for background. This is computed from the number of data points between the half-height points on each side of the peak (with interpolation being used, this is not an integral number). Both peaks are measured and the Orientation Angle is taken as the average of the two measurements.
Crystallinity Index
Crystallinity Index for fibers of poly(p-phenylene terephthalamide) and related polymers are derived from X-ray diffractograms of the fiber materials. The diffraction pattern of poly-p-phenylene terephthalamide is characterized by the X-ray peaks occurring at about 20° and 23° (2 Θ). As crystallinity increases, the relative overlap of these peaks decreases as the intensity of the crystalline peaks increases. The Crystallinity Index of poly-p-phenylene terephthalamide is defined as the ratio of the difference between the intensity values of the peak at about 23° and the minimum of the valley at about 22° to the peak intensity at about 23°, expressed as percent. It is an empirical value and must not be interpreted as percent crystallinity.
X-ray diffraction patterns of yarn samples are obtained with an X-ray diffractometer (Philips Electronic Instruments; ct. no. PW1075/00) in reflection mode. Intensity data are measured with a rate meter and recorded either on a strip-chart or by a computerized data collection-reduction system. The diffraction patterns were obtained using the instrumental settings:
Scanning Speed 1°, 20 per minute;
Time Constant 2;
Scan Range 6° to 38°, 2 Θ and
Pulse Height Analyzer, "Differential".
The Crystallinity Index is calculated from the following formula: ##EQU2## where A=Peak at about 23°,
C=Minimum of valley at about 22°, and
D=Baseline at about 23°.
EXAMPLES
The following examples, except for Comparative Example A, are illustrative of the invention and are not to be construed as limiting.
EXAMPLE 1
A solution of 12.48 g 2,2'-dibromo-5,5'-dimethoxy-[1,1-biphenyl]-4,4'-diamine (0.031 mole) dissolved in 283.5 g NMP (275 ml) was cooled to 5°-10° C. 6.27 g terephthaloyl chloride (0.031 mole) was added to the well-stirred solution. It rapidly dissolved and viscosity of the solution increased during 20 min to ultimately provide a stiff gel. After standing 15 hr at 21° C., a specimen of this 5.5% gel was diluted to 0.5% solids for inherent viscosity measurement: η inh =9.8 in NMP. A polymer specimen, precipitated into water, gave η inh =7.9 in 100% sulfuric acid.
Satisfactory results can be anticipated if 2,6naphthoyl chloride is employed in place of terephthaloyl chloride in this example.
COMPARATIVE EXAMPLE A
To a solution of 14.39 g dianisidine (0.059 mole; 95% purity) in 378 g NMP (367 ml) containing 9.05 g, anhydrous CaCl 2 (0.082 mole), cooled to 5°-10° C., was added 11.88 g terephthaloyl chloride (0.059 mole). Within a few minutes the initially clear solution opacified as precipitate formed and viscosity failed to increase. Analysis of supernatant liquid after standing 1 hour showed it to consist of NMP and CaCl 2 , but no polymer. The precipitated polymer had a η inh of 1.33 measured in sulfuric acid.
EXAMPLE 2
15.5 g 2,2'-dibromo-5,5'-dimethoxy-[1,1'-biphenyl]-4,4'-diamine (0.0375 mole) was dissolved in 169 ml N-methylpyrrolidone (174 g) containing 5.8 g dissolved anhydrous CaCl 2 (0.053 mole) and the solution cooled to 5°-10° C. 7.61 g terephthaloyl chloride (0.0375 mole) was added to the stirred solution which became extremely viscous after several minutes and remained isotropic as indicated by its clarity. To improve fluidity, the solutions were diluted from 10.0% polymer solids to 6.2% by addition of solvent. HCl formed in the polymerization was neutralized by reaction with 2.06 g anhydrous calcium oxide (0.0375 mole). Polymer η inh was 3.62 measured in 100% sulfuric acid. Films were cast on glass plates, dried at 100° C. under vacuum, soaked in water to extract CaCl 2 for 2 hr/25° C. and 1 hr/60° C., then dried at 100° C. They were cut into 0.64 cm (0.25 inch) wide strips and drawn 1.75X over a 2 inch hot plate at 300° C. Wide angle X-ray analysis showed that the films were non-crystalline before and after hot stretching but in the latter case, an orientation angle of 23° had developed. Tenacity and modulus had increased from 0.9/28 to 2.6/72 gpd. Thermogravimetric analysis (TGA) showed that weight loss became significant above 350° C.
Examples 3, 4 and 5 which follow, describe preparation of copolymer from terephthaloyl chloride (or alternately 2,6-naphthoyl chloride) and a combination of two diamines, 1,4-phenylene diamine and 2,2'-dibromo5,5'-dimethoxy-[1,1'-biphenyl]-4,4'-diamine, said reacting diamines being in the molar proportions of 92.5/7.5 respectively in Ex 3, 80/20 in Ex 4 and 50/50 in Ex 5.
EXAMPLE 3
A solution of 46.07 g 1,4-phenylene diamine (0.427 mole) and 12.97 g 2,2'-dibromo-5,5'-dimethoxy[ 1,1'-biphenyl]-4,4'-diamine (0.0346 mole) in 1095 ml NMP (1128 g) containing 71.0 g anhydrous CaCl 2 (0.65 mole) was cooled to 5° C. and treated with 93.62 g terephthaloyl chloride (0.461 mole) to form a gel or crumb. This was precipitated by water in a blender, filtered, washed, dried to give 117 g copolymer with an inherent viscosity of 3.65 measured in sulfuric acid. The polymer was dissolved in 100% sulfuric acid to form a spin dope of 19% (w/w) solids. This dope, held in a reservoir at 70° C., was heated to 80° C. during extrusion through a 10-hole spinneret (0.002 inch per hole diameter), with a back pressure of 200 psi, through a short air-gap into a cocurrent of cold water. Yarn was wound up at 100 ypm. The inherent viscosity of the yarn polymer was 3.32 measured in sulfuric acid. The as-spun fibers had a bent stress-strain curve, indicative of imperfect orientation, and average T/E/Mi=14.3 gpd/5.4%/435 gpd. X-ray analysis showed negligible crystallinity but an orientation angle of 18°. By heating the fibers for a few seconds under tension at 350°-500° C., there was a distinct improvement in properties. Thus after treatment at 500° C., T/E/Mi were 20.3/2.8/730 with orientation angle of 12°. The stress-strain curve now indicated slight strain-hardening. The crystallinity index was 33.
Comparable results can be expected by replacement of terephthoyl chloride with an equimolar amount of 2,6-naphthoyl chloride.
EXAMPLE 4
A copolymer with an η inh of 5.25 in sulfuric acid was prepared by the same procedure as in Example 3 in which terephthoyl chloride was used. A solution at 16.5% solids in 100% sulfuric acid at 80° C. was excessively viscous for spinning. Lower inherent viscosity copolymer (η inn =3.60) at 16% solids in sulfuric acid had suitable viscosity for spinning. At 80° C. it was extruded through a 20-hole spinneret (0.003 inch diameter holes) through a small air-gap into water at 2° C. and wound up at 100 ypm. As-spun fibers had average T/E/Mi/dpf=9.8/6.5/283/3.8 (best values 12.3/7.9/326/3.3); the stress-strain curve showed a distinct knee; η inh was 3.54 in 100% H 2 SO 4 ; density was 1.484 g/cc. X-rays showed no crystallinity and an orientation angle of about 26°. Tensioned heat-treatment at 350° C. to 450° C. failed to develop significant crystallinity although orientation improved. Heat treatment at 400° C. gave fibers with T/E/Mi=12.2/3.7/400 (best values 13.6/2.4/490), with considerable straightening of the stress-strain curve, and orientation angle of 14°.
EXAMPLE 5
This copolymer was prepared by the procedure of Ex. 3 as a gel at 5.5% solids in NMP/CaCl, and had an inherent viscosity of 6.18 in 96% sulfuric acid.
EXAMPLE 6
A copolymer was prepared from terephthaloyl chloride, chloro-1,4-phenylene diamine and 2,2'-dibromo-5,5'-dimethoxy-[1,1'-biphenyl]-4,4'-diamine (with the diamines in a ratio of 30/70 mole %, respectively) by a procedure similar to Ex. 3 except the solvent was DMAc. At the conclusion of the polymerization, the copolymer at 5.8% solids in DMAC/CaCl 2 was still in solution which was clear and viscous. The inherent viscosity of the copolymer was 6.94 (in DMAc). White fibers were obtained by dry spinning.
A copolymer analogous to that obtained in this example would result by use of 2,6-naphthoyl chloride as the dicarboxylic acid reactant.
EXAMPLE 7
To a solution in 273 ml NMP (282 g) containing 4.17 g 3,4'-oxydianiline (0.021 mole) and 8.42 g 2,2'-dibromo- 5,5'-dimethoxy[1,1'-biphenyl]-4,4'-diamine (0.021 mole), cooled to 5°-10° C., was added 8.46 g terephthaloyl chloride (0.042 mole), with stirring. Solution viscosity increased to an estimated 1500-2000 poises. 2.33 g anhydrous CaO (0.0417 mole) was mixed in. (The inherent viscosity of the copolymer was 3.36 measured in NMP.)
Films were cast on glass plates using a 0.04 inch wide doctor knife, dried at 80° C. overnight, soaked in water several days to extract CaCl 2 , dried at 100° C., and cut into 0.64 cm (0.25 inch) wide strips. These were stretched over a hot plate at various temperatures and tensile properties measured (highest tenacity in parentheses).
______________________________________DrawTemp. Draw T(T).sub.max E Mi(°C.) Ratio (gpd) (%) (gpd) Denier______________________________________0 As cast 0.6(0.8) 15 21 4200350 4.0X 6.4(7.5) 4.8 170 1033375 4.5X 5.0(7.1) 2.8 187 863400 5.5X 4.6(5.8) 2.9 208 716525 5.75X 4.6(5.4) 2.6 217 612______________________________________
X-rays showed that drawing at 375° C. gave an amorphous material with orientation angle of 36°. Density of as-cast film (1.452±0.05%) did not significantly change on drawing, e.g., 1.456±0.06% at 475° C.
Use of an equimolar quantity of 2,6-naphthoyl chloride in place of terephthaloyl chloride can be expected to yield comparable results.
EXAMPLE 8
This copolymer was prepared, at 6% solids, in the same way as in Example 7, to give a clear gel. In this example the same reacting diamines were present in 20/80 molar proportions, the 3,4'-oxydianiline being the minor component. The polymer η inh in NMP was 5.82. The gel was fluidized by heating.
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Amorphous para-oriented aromatic homo- and co-polyamides are prepared from terephthaloyl chloride or 2,6-naphthoyl chloride and 2,2'-dibromo-5,5'-dimethoxy-[1,1'-biphenyl]-4,4'-diamine with up to 92.5 mol % of certain other diamines.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 09/755,728, filed Jan. 5, 2001 now abandoned, which claims the benefit of U.S. Provisional Patent Application Ser. Nos. 60/174,459 and 60/174,584 both filed Jan. 5, 2000.
FIELD OF THE INVENTION
This invention relates to magnetic recording heads for use with magnetic recording media. More specifically, the invention relates to the structure and method of manufacturing for a coil within such a recording head.
BACKGROUND OF THE INVENTION
Recording heads for use with magnetic recording media typically include a pair of magnetically coupled poles, consisting of a main write pole and an opposing pole. The main pole may have a significantly smaller surface area on its bottom surface than the opposing pole. A coil is located adjacent to the main pole for inducing a magnetic field in the main pole. Magnetic recording media used with such recording heads typically includes a recording layer having alternating magnetically hard tracks and nonmagnetized transitions. If perpendicular recording is desired, a magnetically soft lower layer will typically be located adjacent to the recording layer, opposite the recording head.
The recording density is inversely proportional to the width of the magnetically hard recording tracks. Trackwidth is primarily determined by the width of the main write pole, which is limited by the various manufacturing processes used to produce such poles. Additionally, the efficiency of the coil structure in inducing magnetic flux within the poles affects the performance of the recording head.
Therefore, there is a need for an improved recording head having a main pole that can be manufactured to narrow widths. Additionally, there is a need for a recording head having a coil structure maximizing the efficiency of inducing magnetic flux in the poles.
SUMMARY OF THE INVENTION
The invention is a recording head for use with magnetic recording media, and an improved method of manufacturing such a head. Although not limited to such use, such a recording head is particularly useful for fixed or hard drives for computers.
Recording heads made in accordance with this invention include a read portion and a write portion. The write portion may be of either perpendicular or longitudinal configuration. A typical perpendicular recording head includes a main pole, an opposing pole magnetically coupled to the main pole, and an electrically conductive coil adjacent to the main pole. The bottom of the opposing pole will typically have a surface area greatly exceeding the surface area of the main pole's tip. Likewise, a typical longitudinal recording head includes a pair of poles, with a coil adjacent to one pole. Unlike a perpendicular recording head, a longitudinal recording head will typically use poles having bottom surfaces with substantially equal areas. In either case, electrical current flowing through the coil creates a flux through the main pole. The direction of the flux may be reversed by reversing the direction of current flow through the coil. In some preferred embodiments, the opposing pole of the perpendicular head (or the first pole of the longitudinal head) can also form one of two substantially identical shields for the read element, located between these two shields. The read element will preferably be either a GMR read element or a spin valve.
The write structure of the present recording head uses only inorganic insulators, for example, alumina, which may be vacuum deposited. The use of inorganic insulators also prevents the necessity of using a hard bake process, as would be necessary to cure an organic insulator. Such hard bake processes will degrade a typical GMR read sensor. Additionally, such processes cause expansion and contraction of the various components of the recording head, thereby possibly causing cracking due to the resulting stresses. Additionally, the present recording head places the writing pole on a very flat surface, thereby facilitating greater control of the spinning process used to deposit the photoresist for defining the main pole. Depositing such photoresist in a more controlled manner, providing a more uniform thickness of photoresist, permits the write pole to be plated or deposited in a manner dimensioned and configured to conform to submicron track widths.
A preferred method of manufacturing a recording head of the present invention begins with a read sensor deposited between a pair of shields, with the entire structure deposited on a substrate in the conventional manner. The read sensor may preferably be a GMR read element or a spin valve. After chemical-mechanical polishing the surface of the combined shield and opposing write pole, the write gap (preferably alumina) is deposited on top of this shield. Next, photoresist shielding is deposited on top of the opposing pole/shield and write gap, leaving exposed the area where the coil will be deposited. Next, the coil (preferably copper) is deposited on the write gap. If desired, the photoresist shielding may be removed at this point, and replaced with photoresist shielding defining a slightly larger opening around the coil. Insulation (preferably alumina) is then deposited on top of the coil, with the larger opening in the photoresist ensuring that all surfaces of the coil are covered. The photoresist shielding is then removed, and the main write pole is deposited on top of the insulation and write gap, with the top portion of the write pole magnetically coupled to the opposing pole/shield.
An alternative method of manufacturing the recording head also begins with chemical-mechanical polishing of the surface of the opposing write pole, which also forms one of the two shields for the read sensor. A layer of material forming the insulation is deposited on this surface, followed by the material forming the coil, which is in turn followed by material forming the opposite layer of insulation. Photoresist shielding is then applied to the second layer of insulation, over that portion of the insulation and coil which will remain part of the final recording head. The undesired portions of the coil and insulation material are then ion milled away, with the ion milling conducted at an angle so that the remaining portion is tapered, with the widest portion adjacent to the opposing pole. The photoresist shielding is then removed, and the write gap is deposited on top of the second layer of insulation, coil, and shield/opposing write pole. The main write pole is then deposited on top of the write gap, and magnetically coupled to the top of the opposing write pole/shield.
A typical magnetic recording medium includes a first layer having a plurality of magnetically permeable tracks separated by nonmagnetized transitions. The tracks are further subdivided into sectors. If perpendicular recording is desired, the magnetic recording medium will include a magnetically permeable lower level. The lower level is magnetically soft relative to the tracks.
The recording head is separated from the magnetic recording medium by a distance known as the flying height. The magnetic recording medium is moved past the recording head so that the recording head follows the tracks of the magnetic recording medium, with the main pole oriented parallel to the tracks and perpendicular to the trackwidth. Current is passed through the coil to create magnetic flux within the main pole. The flux will cause the magnetic fields in the tracks to align with the magnetic flux of the main pole (in the case of perpendicular recording) or the write gap (in the case of longitudinal recording). Changing the direction of electric current changes the direction of the flux created by the recording head and therefore the magnetic fields within the magnetic recording medium. A binary “zero” is recorded by maintaining a constant direction of magnetic flux through the main pole, and a binary “one” is recorded by changing the direction of magnetic flux through the main pole.
It is therefore an aspect of the present invention to provide a recording head wherein all insulating materials are inorganic.
It is another aspect of the present invention to avoid the necessity of using a hard bake process in manufacturing a recording head.
It is another aspect of the present invention to provide a recording head wherein the read element is protected from damage caused by heat during manufacturing.
It is another aspect of the present invention to provide a recording head free from thermally induced stresses.
It is a further aspect of the present invention to provide a recording head with a coil having an efficient flux path.
It is another aspect of the present invention to provide a recording head wherein the surface upon which the main write pole is deposited is kept flat, thereby permitting uniform deposition of narrower write poles.
These and other aspects of the present invention will become more apparent through the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a typical hard disc drive for a computer for which the present invention may be used, illustrating the disc drive with its upper housing portion removed.
FIG. 2 is a partially sectioned, partially schematic, isometric view of an embodiment of a recording head according to the present invention.
FIG. 3 is a cross-sectional side view of a recording head according to the present invention.
FIG. 4 is a bottom view of a recording head according to the present invention.
FIG. 5 is a cross-sectional side view of a substrate, shields and read element for a recording head according to the present invention.
FIG. 6 is a cross-sectional side view of a substrate, shields, read elements and write gap for a recording head according to the present invention.
FIG. 7 is a cross-sectional side view of a substrate, shields, read element, and write gap for a recording head according to the present invention, after application of photoresist.
FIG. 8 is a cross-sectional side view of a substrate, shields, read elements, write gap, and deposited coil material for a recording head according to the present invention.
FIG. 9 is a cross-sectional side view of a shields, write gap, and deposited coil material for a recording head according to the present invention.
FIG. 10 is a cross-sectional side view of a substrate, shields, read elements, write gap, and coil of a recording head of the present invention, after removal of photoresist shielding.
FIG. 11 is a cross-sectional side view of a substrate, shields, read element, write gap, and coil of a recording head of the present invention, after application of photoresist shielding.
FIG. 12 is a cross-sectional side view of a substrate, shields, read sensor, coil, and deposited insulation material for a recording head according to the present invention.
FIG. 13 is a cross-sectional side view of a substrate, shields, read element, write gap, coil and insulation for a recording head according to the present invention, after removal of the photoresist shielding.
FIG. 14 is a cross-sectional side view of an alternative embodiment of a recording head according to the present invention.
FIG. 15 is a cross-sectional side view of a substrate, shields, and read element for an alternative recording head according to the present invention.
FIG. 16 is a cross-sectional side view of a substrate, shields, read element, coil, and coil insulation for an alternative recording head according to the present invention.
FIG. 17 is a cross-sectional side view of a substrate, shields, read element, coil and coil insulation for an alternative recording head according to the present invention, after application of photoresist shielding.
FIG. 18 is a cross-sectional side view of a substrate, shields, read element, coil, and insulation for an alternative recording head of the present invention, following removal of unnecessary coil and insulation material.
FIG. 19 is a cross-sectional side view of a substrate, shields, read element, coil, and insulation for an alternative recording head according to the present invention, after removal of the photoresist shielding.
FIG. 20 is a cross-sectional side view of a substrate, shields, read element, coil, insulation, and write gap for an alternative recording head according to the present invention.
Like reference numbers denote like elements throughout the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention are recording heads for use with magnetic recording media, which may be configured for longitudinal or perpendicular recording. Although not limited to such use, such a recording head is particularly useful for fixed or hard drives for computers. As used herein, recording head is defined as a head adapted for read and/or write operations, although the present invention is specifically directed towards the write portion of the recording head.
The invention will most commonly be used within a fixed disc drive 10 for computers, one of which is illustrated in FIG. 1 . The fixed disc drive 10 includes a housing 12 (with the upper portion removed and the lower portion visible in this view for maximum clarity) dimensioned and configured to contain and locate the various components of the disc drive 10 . The disc drive 10 includes a spindle motor 14 for rotating at least one magnetic storage medium 16 within the housing, in this case a magnetic disc. At least one arm 18 is contained within the housing 12 , with each arm 18 having a first end 20 with a recording head or slider 22 , and a second end 24 pivotally mounted to a bearing 26 . An actuator motor 28 , such as a movable coil DC motor, is located at the arm's second end 24 , pivoting the arm 18 to position the head 22 over a desired sector of the disc 16 . The actuator motor 28 is regulated by a controller which is not shown and which is well known.
Referring to FIGS. 2 , 3 , 4 , and 14 , the features of the recording head 22 are illustrated. The recording head 22 includes means for concentrating magnetic flux onto a small surface area of the magnetic recording media, here a magnetically permeable main pole 30 , oriented substantially perpendicular to the magnetic recording medium 16 , and having a tip 32 . The tip 32 includes a bottom surface 34 . The top 36 of the main pole 30 is preferably magnetically coupled to an opposing pole 38 , possibly through a joint 40 . The opposing pole 38 includes a bottom surface 42 . If perpendicular recording is desired, then the bottom surface 42 will have a surface area significantly larger than the surface area of the bottom surface 34 of the main pole 30 . If longitudinal recording is desired, then the bottom surfaces 34 and 42 may have substantially identical areas. An electrically conductive coil 44 is located adjacent to the main pole 30 , and is dimensioned and configured to induce a magnetic flux in the main pole 30 . The coil 44 is surrounded by insulation 46 , which in the present invention is made from inorganic material. A preferred and suggested material for the insulation 46 is alumina.
Located adjacent to opposing pole 38 , opposite the main pole 30 and coil 44 , is a read element 48 . The read element 48 is preferably a GMR read element or spin valve, operating in conjunction with electrical contacts 50 located on opposing sides of the read element 48 . If the read element 48 is a GMR read element, a permanent magnet 52 may be located above the read element 48 . The read element 48 is located between a pair of opposing shields. In some preferred embodiments, the opposing pole 38 may form one of the two magnetic shields. The other shield 58 is located on the opposite side of the read element 48 . The entire recording head 22 is built up on a surface 54 of a substrate 56 .
One alternative method of making a recording head according to the present invention is illustrated in FIGS. 5-13 . As illustrated in FIG. 5 , the method begins by providing a substrate 56 upon which the read element 48 and its associated shields 38 and 58 have already been deposited. The surface 60 of shield/pole 38 is chemical-mechanical polished to ensure that it is flat. The write gap 62 , which forms a part of the insulation 46 , is deposited on the surface 60 of pole 38 . A preferred material for the write gap is alumina. A first photoresist shield 64 is applied over the write gap 62 , as illustrated in FIG. 7 , thereby defining the eventual size and location of the coil 44 . The material forming the coil, preferably copper, is deposited as illustrated in FIGS. 8 and 9 . This material may be deposited either perpendicular to the write gap 62 , or at an angle to the write gap 62 , to produce an appropriately dimensioned and configured coil 44 within the gap 66 defined by the photoresist 64 . At this point, the first photoresist 64 may be removed as illustrated in FIG. 10 , for replacement with a second photoresist shield 68 defining an opening 70 larger than the opening 66 in the first photoresist 64 (FIG. 11 ), or the original photoresist 64 may simply be left in place. Referring to FIG. 12 , a layer of insulation material 72 is deposited over the coil 44 and photoresist 64 or 68 . The photoresist 64 or 68 is removed as illustrated in FIG. 13 . The use of these deposition procedures has now defined a surface 74 having a very flat surface area. Referring back to FIG. 3 , the write pole 30 is deposited on top of the surface 74 . The flat surface 74 permits the photoresist that will ultimately define the width of the write pole 30 to be spinned into place in a more controlled manner, thereby permitting a small write pole to be produced without compromising the pole's magnetic properties.
An alternative procedure for making a write pole of the present invention is illustrated in FIGS. 14-20 . As before, the process begins by providing a substrate 56 having a read element 48 and its associated shields 38 and 58 secured to the substrate surface 54 . The surface 60 is chemical-mechanical polished to ensure that it is flat. These components are illustrated in FIG. 15 . Referring to FIG. 16 , a first layer of insulation 76 (preferably alumina) is deposited on the surface 60 , followed by the material forming the coil 44 (preferably copper), and a second layer of insulation 78 . A photoresist shield 80 is then deposited over the second layer of insulation 78 , thereby protecting those portions of the insulation layers 76 and 78 that will remain, and that portion of the coil 44 that will remain. The photoresist 80 has also thereby defined the excess material 82 to be removed in subsequent steps. This excess material 82 is removed as illustrated in FIG. 18. A preferred method of removing the excess material 82 is by ion milling, which may be performed at an angle. Preferably, the angle is selected so that the remaining coil and insulation assembly 98 is tapered, with the area of the surface 84 , adjacent to the photoresist (and eventually the main pole 30 ) being smaller than the area of the surface 86 adjacent to the shield and opposing pole 38 . The arrows B indicate a preferred direction for the milling process. Photoresist 80 may then be removed as illustrated in FIG. 19 , and write gap 62 may be deposited as illustrated in FIG. 20 . These deposition processes define a surface 88 on the write gap 62 , with the surface 88 preferably having flat surface topology. Referring back to FIG. 14 , the flat surface 88 permits the photoresist that will ultimately define the width of the write pole 30 to be spinned into place in a more controlled manner, thereby permitting a small write pole to be produced without compromising the pole's magnetic properties.
Referring back to FIG. 2 , a magnetic storage medium 16 , here a magnetic disc, for use with a perpendicular recording head 22 is illustrated. The disc 16 includes a recording layer 90 having a plurality of magnetically permeable tracks 92 , which are divided into sectors. Each sector has several different magnetic fields within the magnetically permeable material (not shown and well understood). The tracks 92 are separated by nonmagnetized transitions 94 . If perpendicular recording is desired, then the disc 16 also includes a magnetically permeable lower layer 96 , which is magnetically soft relative to the tracks 92 . In use, the disc 16 will be separated from the tip 32 of the main pole 30 by a flying height A. The flying height A is sufficiently small so that a high concentration of flux from the main pole 30 will pass through the track 92 , but sufficiently large to prevent damage to disc 16 from contact with the recording head 22 .
Recording is accomplished by rotating the disc 16 relative to the recording head 22 so that the recording head 22 is located above the appropriate sectors of the tracks 92 . As recording progresses, the disc 16 will move past the recording head 22 . Current will be supplied to the coil 44 , thereby inducing a magnetic field within the main pole 30 . As a portion of the sector of the track 92 passes under the main pole 30 , the orientation of its magnetic field will correspond to the orientation of the magnetic field of the main pole 30 in the case of perpendicular recording, or the orientation of the magnetic field within the write gap in the case of longitudinal recording. As the main pole passes over the disc 16 , the direction of current passing through the coil 44 will remain constant when a binary “0” is being recorded, thereby creating consistent orientation of the magnetic fields within the track 92 . The current passing through the coil 44 will reverse directions when a binary “1” is being recorded, thereby changing the orientation of a magnetic field within the track 92 .
The recording density possible with a perpendicular recording head is primarily dependent upon the main pole's width C. The width C required is determined by the precision with which the deposition or plating process used to deposit the write pole 30 can be accomplished. This precision is affected by the flatness of either surface 74 or surface 88 , upon which the write pole 30 will be plated. It is well known in the art that a photoresist will be used to define the area upon which the main pole 30 will be plated or sputtered, and that this photoresist is applied by a spinning process with the photoresist in liquid form. The spinning process can be controlled more precisely if applied to a flat surface. Therefore, maximizing the flatness of the surface area 72 or 88 minimizes the area upon which the write pole 30 must be deposited to ensure that the proper magnetic properties are present, thereby minimizing the width C of the write pole and maximizing recording density.
Additionally, because all electrically insulating materials used within a recording head 22 of the present invention are inorganic, and preferably vacuum deposited, a thermally efficient, low stress structure results. The hard bake process is typically used to cure organic insulators are avoided, freeing the read sensor from degradation caused by these processes. Additionally, the hard bake process causes the components of the recording head 22 to expand and contract, resulting in thermal stresses and possibly cracks.
The present invention has the additional advantage of keeping the path for the magnetic field around the coil 44 as simple as possible. The distance from the bottom surface 34 to the top of the coil may be less than 2 microns.
While a specific embodiment of the invention has been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
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A recording head for use with magnetic recording media has an improved structure, made by a simplified manufacturing process. The electrically insulating materials within the recording head are inorganic. The insulating materials are vacuum deposited, with no need to use a hard bake process that would be required for use of organic insulators. In one embodiment, the write gap is first masked, and then the coil is deposited on the write gap. A slightly larger area is then exposed within the mask, permitting insulation to be deposited over the coil. In a second embodiment, the coil and associated insulation are deposited and then milled to have a tapered configuration. This recording head also places the writing pole on a very flat surface, thereby allowing plated or deposited films to be easily manufactured to correspond to narrow track widths.
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BACKGROUND OF THE INVENTION
Technical Field
The present invention relates in general, to the preservation of organs, tissues and cells during storage and transport and, in particular, to a method of maintaining organs, tissues and cells in a viable state prior to transplantation, and to a composition suitable for use in such a method.
Background Information
Ischemia, a localized tissue hypoxia resulting from partial or complete loss of blood circulation, ensues rapidly upon death of an organism. In designing a protocol for storing a tissue prior to transplantation, the susceptibility of the particular tissue to ischemia must be considered. One factor that influences the rate at which ischemia produces cellular injury, and subsequently cell death, is temperature. Kidneys, for example must be procured immediately after cessation of donor heartbeat, and can be stored for only 1-3 days at 0°-4° C., using current technology. The exact time is dependant upon whether or not continuous perfusion is employed. This is in contrast with bone marrow, which can tolerate at least 12 hours of warm ischemia post mortem and 3 days of cold ischemia at 0°-4° C.
In order to extend the period for which particular cells, tissues and organs can be maintained in a state which will permit subsequent successful transplantation into a recipient host, new methods must be developed. One such method is provided by the present invention.
SUMMARY OF THE INVENTION
It is a general object of the invention to provide a method of maintaining cells, tissues and organs in a viable state.
It is a specific object of the invention to provide a method of storing cells, tissues and organs at refrigerated temperatures prior to transplantation.
It is another object of the present invention to provide a tissue storage solution that permits storage of cells, tissues and organs at refrigerated temperatures for periods of time longer than is possible using present clinically accepted solutions.
Further objects and advantages of the present invention will be clear from a reading of the description that follows.
The present invention relates to a method of delaying the detrimental effects of ischemia on organ, tissue and cell viability, and to a storage solution suitable for use in such a method.
In one embodiment, the present invention relates to a method of storage comprising the steps of:
i) contacting a cell, tissue or organ to be stored with a solution comprising transferrin and selenium; and
ii) maintaining the cell, tissue or organ in contact with the solution at a sub-ambient temperature in a non-frozen state.
In another embodiment, the present invention relates to a storage solution comprising insulin, transferrin, hydrocortisone, selenium and a Goodes buffer, for example, 4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid (HEPES).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1: Comparison of six cold storage solutions using canine anterior cruciate ligament-derived fibroblasts in vitro.
FIG. 2: Cold ischemia study using hydrocortisone, insulin, transferrin and selenium-containing storage solution and Euro-Collins storage solution.
FIG. 3: Effects of hydrocortisone, insulin, transferrin and selenium removal on cell survival at 4° C.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method of storing cells, tissues and organs, and to a storage solution suitable for use in such a method. The present storage method is such that viability of the material is maintained. Maintenance of viability permits subsequent successful transplantation of the stored material into a recipient host.
In the present method, material to be stored is placed in contact with a storage solution comprising transferrin and selenium, advantageously at concentrations in the ranges of 2.5 μg/ml to 10 μg/ml and 2.5 ng/ml to 7.5 ng/ml, respectively. In a preferred embodiment, insulin and hydrocortisone are also present in the storage solution, advantageously at concentrations in the ranges of 2.5 μg/ml to 7.5 μg/ml and 25 ng/ml to 40 ng/ml, respectively. In a most preferred embodiment, a Goodes buffer, for example HEPES, is also present in the solution at a concentration in the range of 10 mM to 30 mM (corresponding to 2.92-8.85 g/l in the case of HEPES). The inclusion of a Goodes buffer in the storage solution is particularly advantageous where storage for more than two days is required. For shorter storage periods, other pharmaceutically acceptable buffers, for example, a bicarbonate buffer, can be used.
The above-described components of the tissue storage solution of the present invention can be present, for example, in a medium capable of supporting cellular metabolism in vitro at 37° C. or the components can be present in a buffered physiological salt solution that is incapable of supporting cellular metabolism at 37° C. Such salt solutions can include a carbohydrate source (for example, glucose).
In the present method, cell viability is maintained by storing the cells, tissues or organs in the above-described solution at sub-ambient temperatures, in a non-frozen state. Advantageously, temperatures in the range of -4° to 4° C. are used.
Materials suitable for storage according to the present method include, but are not limited to, heart, kidney, lung, liver, cornea, pancreas, skin, blood vessels, tendons, ligaments, bone, bone marrow, endocrine and exocrine glands, gametes, ova, nerves, gastrointestinal tract, ureter, bladder, or structures or cellular components derived from any of the above. Where intact organs are to be stored, such organs are flushed with the above-described solution prior to storage.
The following non-limiting Examples further describe the present invention.
EXAMPLE 1
Comparison of Six Storage Solutions
Confluent cultures of canine anterior cruciate ligament(ACL)-derived fibroblasts were placed, for five days at 0°-4° C., in: physiological saline (0.9% (w/v) NaCl) (designated NaCl); 2) a culture medium containing fetal calf serum (Dulbecco's Modified Eagle Medium plus 10% v/v fetal calf serum) (designated PS); 3) a buffered physiological salt solution (0.10 g/l CaCl 2 (anhydrous), 0.20 g/l KCl, 0.20 g/l KH 2 PO 4 , 0.10 g/l MgCl 2 .6H 2 O, 8.00 g/l NaCl, and 2.16 g/l Na 2 HPO 4 .H 2 O) (designated DPBS); 4) Hanks Balanced Salt Solution as in Table I without hydrocortisone, insulin, transferrin and selenium and containing 15 mM HEPES instead of 25 mM (designated H); 5) the solution of Table I (designated HITS); or 6) the solution of Table I plus chondroitin sulfate (25 g/l) and sucrose (47.922 g/l) (designated HITS.).
At the end of this period, the solutions were removed from the cultures, the cells were washed, and placed in contact with fresh serum-free culture medium. After 2 hrs. of incubation in the serum-free medium, the cells were labeled with tritiated glycine at 37° C. in a 5% CO 2 and air incubator using a technique adopted from that detailed below in Example 2. The relative protein incorporation between the experimental groups is an indication of the level of cellular viability.
TABLE I______________________________________ g/l______________________________________CaCl.sub.2 (anhydrous) 0.14KCl 0.40KH.sub.2 PO.sub.4 0.06MgCl.sub.2.6H.sub.2 O 0.10MgSO.sub.4.7H.sub.2 O 0.10NaCl 8.00NaHCO.sub.3 0.35Na.sub.2 HPO.sub.4.7H.sub.2 O 0.09D-Glucose 1.00Phenol Red 0.01Hepes 4.425Transferrin 0.005Insulin 0.005Selenium 0.000005Hydrocortisone 0.000036______________________________________
The results shown in FIG. 1 clearly indicate the superiority of the solution of the present invention (that given in Table I) over the others tested. (C=control--no storage at 0°-4° C.; storage medium=Dulbecco's Modified Eagle Medium plus 10% v/v fetal calf serum.
EXAMPLE 2
Comparison of Hydrocortisone, Insulin, Transferrin and Selenium-Containing Storage Solution and Euro-Collins Storage Solution
Bisected human heart valve leaflets were placed in either the solution described in Table I or Euro-Collins solution at 4° C. for 1-5 days. (Euro-Collins=KH 2 PO 4 (2.05 g/l), KHPO 4 (7.40 g/l), KCl (1.12 g/l), NaCO 3 (0.84 g/l), and glucose (38.5 g/l).) After cold storage, the leaflets were washed and placed in tritiated glycine and incorporation of the isotope into protein was determine after 48 hrs of incubation using the following protocol:
Tritiated Labelling of Tissue
Day 1--Make up a 16 μCi/ml H-glycine solution in serum free Dulbecco's Modified Eagle Medium (DMEM). Cut tissue up into small pieces and place in a 5 ml snap-cap tube. Add 0.5 ml of the H-glycine to each tube. Incubate for 48 hours at 37° C.
Day 2 - Decant medium from the tubes and wash tissue quickly twice with phosphate buffered saline (PBS). Add PBS and let sit for 30 minutes. Remove PBS and add more PBS. Incubate overnight at 4° C.
Day 3--Decant PBS off of tissue and place tissue into 15×100 mm glass tubes. Wash for 15 minutes in alcohol, then wash for 15 minutes with ether. Remove ether and allow the tissue to dry for at least one hour. Weigh and record weight of tissue from each tube. Place all tissue into clean 12×75 mm glass tubes.
Add 200 μl H 2 O to each tube and let rehydrate for 30 minutes to 1 hour.
Add 500 μl 1M NaOH to each tube and place tubes in a heating block at 60° C. Allow 60 minutes incubation for valve tissue.
Pipette samples into microtubes and sonicate twice for 20 seconds each time Centrifuge in microfuge for 2 minutes.
Apply 100 μl of each sample to glass fiber filter discs. Allow to dry for at least one hour. Move filter discs to glass scintillation vials and add 2 ml ice cold 10% trichloroacetic acid (TCA) to each vial. Refrigerate for 30 minutes minimum. Remove TCA and wash four times with 3 ml ice cold alcohol. Then wash twice with 3 ml ice cold ether. Allow filter discs to dry for at least one hour. Add 130 μl H 2 O to each filter disc. Add 1 ml Protosol to each vial. Vortex vigorously. Add 10 ml scintillation fluid and 100 μl glacial acetic acid. Transfer vials into racks, place racks in counter and allow to dark adapt for 30 minutes before counting. Count each vial for 5 minutes.
The results are summarized in FIG. 2. A total of 27 comparisons were done after 1-5 days of incubation. In 23 out of the 27 comparisons, the solution described in Table I was clearly superior. In only one instance did the Euro-Collins solution support protein synthesis levels greater than the solution described in Table I. In three cases, the numbers were similar.
These results demonstrate a highly significant maintenance of cellular viability by the storage solution of the present invention, relative to the current clinically accepted alternative.
EXAMPLE 3
Effects of Removal of Hydrocortisone, Insulin, Transferrin and Selenium on Cell Storage at 4° C.
Human kidney-derived proximal tubule cells were plated on bovine type I collagen/fetal calf serum-coated Costar 24 well plates and placed in either complete solution (C) (see Table II) or in the solution shown in Table I from which either one or all of the following had been removed: hydrocortisone (H), insulin (I), transferrin (T), or selenium (S). The plates were then placed in a refrigerator at 4° C. for 72 hours. Viability was assayed by the neutral red spectrophotometric assay described below in Example 4.
TABLE II______________________________________Complex culture medium used for testing HITS components.COMPONENTS mg/L______________________________________INORGANIC SALTS: VitaminsCaCl.sub.2 (anhyd.) 100 Biotin 0.00365CaCl.sub.2.2H.sub.2 O 22 D-Capantothenate 2.24CuSO.sub.4.5H.sub.2 O 0.001245 Choline chloride 8.98FeSO.sub.4 :7H.sub.2 O 0.417 Folic acid 2.65KCl 311.8 i-Inositol 12.60MgCl.sub.2.6H.sub.2 O 61 Niacinamide 2.0185MgSO.sub.4.7H.sub.2 O 100 Pyridoxine HCl 0.031NaCl 6999.5 Riboflavin 0.219NaHCO3 2438 Thiamine HCl 2.17Na.sub.2 HPO.sub.4.7H.sub.2 O 134 Vitamin B.sub.12 0.68ZnSO.sub.4.7H.sub.2 O 0.4315 Pyridoxal HCl 2.0Fe(NO.sub.3).sub.3.9H.sub.2 O 0.05NaH.sub.2 PO.sub.4.H.sub.2 O 62.5OTHER COMPONENTSD-Glucose 1401Hypoxanthine 2.05Linoleic acid 0.042Lipoic acid 0.105Phenol red 8.1Putrescine 2HC1 0.0805Sodium pyruvate 110Thymidine 0.365AMINO ACIDS:L-Alanine 4.45L-Arginine HCl 147.5L-Asparagine.H.sub.2 O 7.505L-Aspartic acid 6.65L-Cysteine 24L-Cysteine HCl.H.sub.2 O 17.56L-Glutamic acid 7.35L-Glutamine 365Glycine 18.75L-Histidine HC1.H.sub.2 O 31.48L-Isoleucine 54.47L-Leucine 59.05L-Lysine HCl 91.25L-Methionine 17.24L-Phenylalanine 35.48L-Proline 17.25L-Serine 26.25L-Threonine 53.45L-Tryptophan 9.02L-Tyrosine 38.70L-Tyrosine(disodium salt) --L-Valine 52.85______________________________________
Data shown in FIG. 3 are expressed as the mean survival ±1 S.E. of 4-6 experiments in percent of 37° C. controls.
EXAMPLE 4
Influence of Divalent Cations (Ca +2 and Mg +3 ) on Cell Viability in the Presence of HEPES and Bicarbonate Buffers.
In order to access the effects of HEPES and bicarbonate buffers on the viability of cells stored in the absence of divalent cations, human proximal tubule cells were plated on bovine type 1 collagen/fetal calf serum coated Costar 24 well plates and placed in the solutions indicated below in Table III (which solutions are based on that shown in Table I) for 24, 48, or 72 hours under cold (4° C.) ischemic conditions. N=4 for each solution in each of the four experiments performed. All data is expressed in Table III as a percent survival compared to a 37° C. control as assessed by the neutral red spectrophotometric assay described as follows:
Neutral Red Assay
Highest quality Neutral Red dye was obtained from Aldrich Chemical Co. (Milwaukee, Wis.). A 0.5% solution was prepared in tris-buffered saline (TBS). A ten fold concentrated TBS stock was prepared as follows: to 1.0 liter of distilled deionized water was added 24.2 g Trizma 7.7 (Sigma Chemical Co., St. Louis, Mo.), 68.0 g NaCl, 2.0 g KCl, 2.0 g MgCl 2 .6H 2 O, and 1.0 g CaCl 2 (anhydrous). The saline was then filter sterilized using a 0.22 μ nitrocellulose filter. The saline stock was diluted to 1 X using distilled deionized water. To prepare the Neutral Red solution, 0.5g Neutral Red was added to 100 ml 1X TBS solution, care being taken to minimize the light exposure of this photosensitive dye. The dye solution was filtered using Whatman No. 42 paper just prior to use.
Kidney tubule cells were gently washed 4X with TBS which had been warmed to 37° C. Following suction removal of the last saline wash, 0.5 ml of 0.5% Neutral Red in TBS warmed to 37° C. was added to each well. The plates were then floated in a covered 37° C. water bath for 30 min to allow maximum dye uptake. The unabsorbed Neutral Red solution was then aspirated off and the cells were washed 4X with cold TBS at 4° C. The dye was extracted with cold 50% ethanol at 4° C. for 15 min. A 0.15 ml aliquot was then drawn from each well and placed in the wells of Costar 96-well flat-bottom plates. Controls consisted of 50% ethanol blanks and 1X TBS blanks. Samples were read using a 450 nm filter on a Titertek Multiskan ELISA plate reader. Three rows of serial dye dilutions in 50% ethanol were used to generate a concentration curve.
TABLE III______________________________________BUFFER CATIONS DAY 1 DAY 2 DAY 3______________________________________HEPES Ca, Mg 74% 61% 41%HEPES Ca 98% 93% 80%HEPES Mg 76% 60% 44%HEPES NONE 100% 97% 88%HCO.sub.3.sup.- Ca, Mg 79% 65% 45%HCO.sub.3.sup.- Ca 97% 89% 52%HCO.sub.3.sup.- Mg 80% 64% 48%HCO.sub.3.sup.- NONE 99% 92% 59%______________________________________ Ca.sup.2+ = CaCl.sub.2 (anhydrous) (0.14 g/l) Mg.sup.2+ = MgCl.sub.2.6H.sub.2 O [0.10 g/l] and MgSO.sub.4.7H.sub.2 O [0.10 g/l]- HEPES = 5.66 g/l (20 mM) HCO.sub.3.sup.- = NaHCO.sub.3 [0.35 g/l]-
These results clearly demonstrate the superiority of HEPES buffer in the absence of magnesium or both calcium and magnesium after 3 days of storage.
The foregoing invention has been described in some detail for purposes of clarity and understanding. It will be clear to one skilled in the art from a reading of the present disclosure that various changes can be made in form and detail without departing from the true scope of the invention.
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The present invention relates to a method of maintaining viability of a cell, tissue or organ. The method involves maintaining the cell, tissue or organ in contact with a storage solution comprising transferrin and selenium at a subambient temperature in a non-frozen state. The invention further relates to a storage solution suitable for use in the above-described method. In one embodiment, the solution comprises insulin, transferrin, hydrocortisone, selenium and 4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid.
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The invention herein described was made in the course of work under a contract or subcontract thereunder with the Department of the Army.
FIELD OF THE INVENTION
This invention relates to a method of transmission control, and more particularly, to a method of controlling transmission upshifts to minimize turbine flare.
BACKGROUND OF THE INVENTION
Generally, a motor vehicle automatic transmission includes a number of gear elements coupling its input and output shafts, and a related number of torque establishing devices such as clutches and brakes which are selectively engageable to activate certain gear elements for establishing a desired speed ratio between the input and output shafts. The brake can be of the band type or disk type; engineering personnel in the automotive art refer to disc type brakes in transmissions as "clutches" or "reaction clutches". As used herein, the terms "clutches" and "torque transmitting devices" will be used to refer to brakes as well as clutches. The input shaft is connected to the vehicle engine through a fluid coupling, such as a torque converter, and the output shaft is connected directly to the vehicle wheels.
In the type of transmission involved in this invention, the clutches are fluid operated, and each develops torque capacity in relation to the fluid pressure in its apply chamber once such apply chamber has been filled. Shifting from one forward speed ratio to another involves releasing the pressure supplied to an off-going clutch associated with the current speed ratio while initiating the supply of fluid pressure to an on-coming clutch associated with the desired speed ratio. Shifts performed in this manner are termed clutch-to-clutch shifts and require precise timing in order to achieve high quality shifting.
The present invention is directed to upshifting the transmission from a current speed ratio to a desired speed ratio which is numerically lower than the current ratio, the speed ratio being defined as the transmission input speed divided by the transmission output speed. Thus, an upshift involves a pulldown or reduction of the input speed.
The quality of an upshift depends on the cooperative operation of several functions, such as pressure changes and the timing of control events. One of the measures of upshift quality is turbine flare. Turbine flare during an upshift occurs when one or both of the following conditions are satisfied:
a) The on-coming clutch is underfilled when the off-going clutch is released. In this case, the turbine flare starts when the off-going clutch starts to slip, and the amount of such slip is indicative of the degree of flare.
b) The initial on-coming clutch pressure after the fill period is too low. In this case, the on-coming clutch does not have the required torque capacity to hold the turbine speed or pull it down, and the turbine flare starts during the transition from off-going clutch to on-coming clutch.
Typically, an upshift control, whether open loop or closed loop, is designed to manage the smooth transfer of torque from one clutch to the other within a given time period. If the time period expires, full pressure is applied to the on-coming clutch. If the on-coming clutch does not already have a reasonably high pressure, the sudden application of high pressure can have the effect of a shock as a result of a undesirably rapid change of axle torque. Uncontrolled turbine flare leads to such a condition.
SUMMARY OF THE INVENTION
This invention is directed to an improved upshift control which identifies and minimizes turbine flare during upshift by controlling on-coming clutch pressure. The slip speed across the off-going clutch is the primary variable used to determine the flare and correct the on-coming clutch pressure.
In the course of an upshift, the pressure on both the on-coming clutch and the off-going clutch are varied under computer control which develops pressure command signals for both clutches. In particular, the off-going clutch pressure is progressively decreased to effect clutch release, while the on-coming clutch is applied. The on-coming pressure includes a fill pressure for filling the respective apply chamber and a subsequent apply pressure which progressively increases to engage the on-coming clutch.
A control responsive to slip is used to calculate a compensation term which adjusts the oncoming pressure command signal to attenuate flare, should it occur. The turbine speed and the output speed of the transmission are monitored throughout the shift and the value of the off-going clutch slip is periodically calculated. The change of slip between consecutive slip calculations is used as a measure of rate of change of slip speed, or slip rate.
When the slip is positive and the slip rate is also positive but relatively small, a term proportional to slip is produced and an integral term is also produced by accumulating slip rate values in consecutive program loops. The proportional and the integral terms are added to produce the compensation term. When the flare reduces in speed in response to the compensation term, the slip rate becomes negative. At this point, a negative integral term is combined with the other terms in the compensation term to thereby reduce the compensation signal and avoid an over-correction. As a result of the compensation, the flare is attenuated and the on-coming clutch capacity increases gradually at a rate sufficient to assume the full input torque before a time-out period expires.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a transmission, including a computer-based control unit for carrying out the control of this invention.
FIGS. 2, 3, 4 and 5 are flow diagrams representative of computer program instructions executed by the computer-based controller of FIG. 1 in carrying out the shift control of the transmission.
FIG. 6, parts (a) through (f), is a graphical illustration of transmission parameters experienced during a number of consecutive upshifts including turbine and output speeds, the commanded and actual clutch pressures, output torque, off-going clutch slip and flare compensation.
DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to FIG. 1, the reference numeral 10 generally designates a motor vehicle drive train, including a throttled internal combustion engine 12, a fluidic torque converter 14 comprising a pump 16 and a turbine 18, a multiple speed fluid operated power transmission 20 schematically represented by two speed ranges SR1 and SR2 controlled by clutches C1 and C2, respectively. Gear shifts are accomplished by selectively engaging and disengaging the clutches C1 and C2.
The transmission depicted here is representative of well known transmissions having several forward ranges, say six ranges, for example, and therefore having a larger number of clutches and speed ratios. The two ratio model, however, is used to illustrate the principal of the anti-flare upshift control. It is assumed then, that initially, the clutch C1 is fully applied and the speed ratio SR1 is functioning. The ratio SR2 is a lower ratio than SR1 and an upshift is effected by releasing clutch C1 and applying clutch C2.
The engine 12 is connected to the torque converter 14 via shaft 22, the torque converter 14 is connected to the transmission 20 via shaft 24, and the transmission 20 has an output shaft 26 coupled to a pair of drive wheels through a final drive gearset (not shown). The speed and torque relationships between the engine 12 and the drive wheels of the vehicle are controlled by the fluid operated clutches C1 and C2.
The clutches C1 and C2, as well as the torque converter 14, are supplied by a pressure regulated hydraulic pressure source 30. The clutches are coupled to the source 30 via solenoid control valves 32 which determine the admission or discharge of fluid to the clutches and the clutch pressure. The operation of pressure source 30 and the solenoid operated control valves 32 is controlled by a computer-based control unit 34 via lines 35 in response to various input signals representative of system parameters. Such inputs include, among others, a torque converter output shaft speed signal Nt on line 36, a transmission output shaft speed signal No on line 38, a system supply voltage signal Vb on line 40 and an operator range selector position signal on line 42. The input signals No and Nt are obtained with conventional electrical transducers such as magnetic speed pickups 44.
Internally, the control unit 34 comprises a number of conventional devices including a microcomputer with internal clock and memory, an input/output device (I/O) and an array of drivers. A driver is dedicated to each solenoid control valve 32. The driver outputs are used to energize the respective solenoid control valves. The driver currents determine the hydraulic pressure supplied by the solenoid control valves, with a low current yielding a low pressure and a high current yielding a high pressure for a normally closed valve. Accordingly, the computer control, when properly programmed, is effective to manage the clutch pressures to effect an upshift from SR1 to SR2 by controllably releasing the pressure in the off-going clutch C1 and applying pressure to the on-coming clutch C2.
FIGS. 2 through 5 are flow diagrams representative of computer program instructions, executed by the computer-based control unit 34 of FIG. 1 in carrying out the shift control technique of this invention. In the description of the flow diagrams the functional explanation marked with numerals in angle brackets, <nn>, refers to blocks bearing that number.
FIG. 2 represents an executive or main loop program which directs the sequential execution of various subroutines. Initialization <50> designates a series of instructions executed at the initiation of each period of vehicle operation for setting the various timers, registers and variable values of control unit 34 to predetermined initial values. Thereafter, the blocks 52 to 60 are sequentially and repeatedly executed as indicated by the flow diagram lines at a rate which, typically, may be 20 msec per loop.
After initialization, the various input signal values are read and conditioned for use by the microcomputer <52>. The input signals are tested for integrity and the system operation is monitored to diagnose any operational problems <54>. For this purpose it is sometimes desirable to utilize more transducers, e.g., clutch pressure sensors, to check the operation of various system elements. Then any problems are analyzed and solutions to overcome or otherwise deal with them are developed <56>.
After shift scheduling determines that a certain shift should occur <57>, the clutch control block 58 analyzes the various system input signals, develops pressure command signals for operation of each clutch and includes a routine for upshift on-coming clutch control. Then the command signals are conditioned to effect the solenoid drive currents to carry out the pressure commands for specific shift operations <60>, and the required control signals are outputted to the drivers for the solenoid operated control valves 32.
In FIG. 3, the routine for upshift on-coming clutch control 58' is shown. The general approach for on-coming clutch control is to first quickly fill the clutch by commanding a high pressure for a brief fill time, and then, starting at a lower pressure, by increasing the pressure at some ramp rate. If the shift has just been initiated <62>, timers counters and parameters are initialized including anti-flare logic parameters <64>. Typically, only a limited time, say 1.5 sec is permitted for shift completion; if the time expires <66>, a rapid clutch pressure increase is commanded <68>. Once the maximum commanded pressure has been attained <70>, the maximum pressure is commanded and an end-of-shift flag is set <72> and the routine is completed.
If the shift has not timed out <66>, the anti-flare logic is applied <74> to develop, when appropriate, additional pressure command values to increase the on-coming clutch pressure before time-out. If the shift is still in the fill phase <76>, the fill phase commands are executed to obtain the fill phase pressure <78> and the on-coming clutch pressure is commanded to be the fill phase pressure plus compensation pressure mandated by the anti-flare logic <80>. When the shift phase is no longer in the fill phase <76>, the open loop on-coming clutch control routine is executed <82>.
The open loop on-coming clutch control routine 82 is shown in FIG. 4. Clutch base pressure is calculated as a function of engine torque <84>, the torque being supplied from an engine controller, not shown, or being determined from a table of torque as a function of engine speed and throttle position. If the diagnostic routine 54 does not indicate a slip problem and the on-coming clutch slip is near synchronization <86>, the maximum pressure is commanded and the end-of-shift flag is set <88>; otherwise a counter is incremented <90> and the command clutch pressure is calculated as the base pressure, plus the product of the counter value and a constant, plus the anti-flare logic pressure <92>. If the maximum pressure has been reached <94>, the program goes to block 88; otherwise the routine exits.
The anti-flare logic routine 74 generates a compensation pressure value P which, when added to the fill pressure or the open loop pressure for the on-coming clutch, should be sufficient to stem the on-coming clutch slip which allows flare. The value P includes a term P p proportional to slip S and, depending on the rate of slip, a positive integral term P ui and a negative integral term P di . The pressure component terms are set to zero at the shift initiation by the block 64 and new values for the terms are calculated during the shift as a function of the slip S. The slip S will have been calculated in the diagnostic block 54 as S=Nt-No*SR1 which is the difference between the turbine speed and the product of the output speed and the current speed ratio.
FIG. 5 shows the anti-flare logic routine 74. If the diagnostic routine 54 indicates a problem with the slip value, the anti-flare logic is not used <100>. Also, if the slip S is not above a threshold speed C1, say 25 rpm, the pressure compensation calculation is bypassed <102>. When slip is above the threshold C1, the rate of slip DELTAS is calculated as the change in slip since the previous program loop or DELTAS=S new -S last <104>. If DELTAS is above a threshold C2 <106>, a trial proportional term is first calculated as P x =K p *S where K p is a calibrated gain factor such as 0.2 <108>.
To select the maximum value of the trial proportional term, as it is calculated in successive loops, it is determined whether P p is less than P x <110>, and if so P p is set equal to P x <112>. In most cases of positive DELTAS, the term P p is sufficient for pressure compensation, but where the turbine speed is near the engine governed speed and DELTAS is small, the proportional term alone does not provide sufficient correction and a more robust compensation is desirable. Accordingly, if DELTAS is less than a threshold C3, say 5 rpm <114>, an integral term P ui is calculated as P ui =P ui +K u *DELTAS where K u is a gain constant such as 0.1 <116>. This term is particularly effective when the turbine flare begins near the governed speed. When the on-coming pressure becomes sufficient to start reducing flare, DELTAS is no longer positive <106> and new values of P p and P ui are not generated but the last calculated value is retained.
If the turbine flare occurs due to an underfill condition, the proportional term and integral term for positive slip difference effectively reduces the fill time by increasing the commanding pressure. However, when the clutch is filled, the resulting pressure might be more than the desired pressure for turbine pull down, resulting in a shift shock. To offset a pressure which becomes too high, the routine assesses whether DELTAS becomes more negative than a threshold C4, such as 25 rpm <118>. If so, a negative integral term P di is calculated as P di =P di +K d *DELTAS <120>. Pdi is effective to suitably reduce the compensation pressure value P. The final step in the anti-flare logic is to sum the proportional and integral terms to calculate the pressure value P <122>. The value P is added to the commanded on-coming clutch pressure in all phases of the shift, as indicated at <80> and <92>.
FIG. 6, graphs a-f, illustrate transmission shift parameters generated during an anti-flare logic simulation for a six speed ratio transmission. The graphs cover a 2-3 shift, a 3-4 shift and a 4-5 shift performed in rapid sequence, covering the time period of 3.7 seconds to 7.2 seconds of the test.
Graph (a) shows the turbine speed Nt and the transmission output speed No over the sequence of shifts. Graph (b) shows the commanded on-coming clutch pressure P c , the actual on-coming pressure P on , and the off-going clutch pressure P off during each shift. The line identified as P on in one shift becomes P off in the next shift. The transmission output torque is displayed in graph (c). Torque oscillations occurring between shifts are a consequence of mismatch between turbine and output accelerations. The off-going clutch slip S is shown in two graphs, (d) and (e). In graph (d), the slip is shown over its whole range, both positive and negative, and in graph e only the positive values of slip are shown and are scaled for better visibility. The graph (f) shows the compensation pressure P and its components as calculated by the anti-flare logic.
During the 2-3 shift, the slip S, as shown in graph (e), does not reach the threshold C1 (25 rpm) so that no compensation pressure P is calculated. It is apparent from graph (b) that the off-going pressure P off is ramped down to gradually release the off-going clutch, and the commanded pressure P c as developed by the on-coming clutch control logic 58' causes the actual on-coming clutch pressure P on to increase at a steady rate. When the maximum pressure P m is commanded the on-coming pressure P on ramps up at a higher rate. In this illustration, the next shift begins before the full clutch pressure is attained.
During the 3-4 shift, the commanded fill pressure P f is clearly shown. This shift does cause the slip to exceed the threshold C1. At that time, the proportional term P p is immediately generated, as shown in graph (f) and the integral term P ui is built up in steps. When the slip S starts to decrease the anti-flare terms remain constant. The rate of slip decrease is not sufficient to trigger the calculation of a negative integral term. The effect of the calculated pressure P is reflected in the commanded pressure P c at point A and in the actual pressure P on which then increases in slope, thereby heading off a significant pressure deficiency when the maximum pressure is commanded. The calculated value P and its components are reset to zero at the beginning of the 4-5 shift.
During the 4-5 shift the anti-flare logic is again invoked due to the large slip S. The value P p is increased in several stages and is the dominant term in the pressure value P because of the large slip value. The integral term is not immediately calculated because, at first, DELTAS is greater than the threshold C3; when the integral value P ui is calculated it does not become large. When the slip declines at a sufficient rate, the negative integral term P di is calculated. In this instance, it too is small and has only little effect on the total compensation pressure P. In other circumstances, however, the negative integral term can become very important in correctly adjusting the on-coming clutch pressure.
It will thus be seen that the anti-flare logic is able to compensate for low on-coming clutch pressure which results in slip of the on-coming clutch and turbine flare to assure a shift free of excessive shock upon timing out of the shift.
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In a computer-based control, pressure is progressively decreased in an off-going clutch for gradual release while pressure is progressively increased in an on-coming clutch. Positive off-going clutch slip and the rate of slip change are monitored to detect the onset of turbine flare. A control calculates a compensation pressure which is added to the on-coming clutch pressure to reduce the slip and thus the flare. The control calculates a term proportional to slip and an integral term when the slip and slip rate are positive. When the slip rate goes negative, the control calculates a negative integral term. All the calculated terms are combined to produce the compensation pressure value.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a non-provisional application of U.S. Provisional Application No. 61/802/806, filed Mar. 18, 2013, entitled: LIQUID NITROGEN & CARBON DIOXIDE THERMO VANES COLD TRAP EXCHANGER AND, and claims the filing priority and benefit of the provisional application, the disclosure of which is incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] This invention is to clean up the atmosphere and improve natural cycling for plant life.
[0003] A number of refrigerants and processes being used for refrigeration systems contribute pollution to the atmosphere. The present cryogenic process eliminates the release of Freon and other gases that are harmful to air and natural photon cycling.
[0004] After cooling with liquid nitrogen, the liquid nitrogen is transformed to a gas and the heat exchanger process is complete. This releases only pure nitrogen to the atmosphere. Nitrogen is clean and it accelerates nitrogen fixation for natural growth of nature's plants.
[0005] This invention relates to a liquid nitrogen thermo vane heat exchanger that is particularly well suited for refrigerated transportation storage containers.
[0006] Refrigerated trucks and other refrigerated transportation containers typically use conventional refrigerating systems operated by diesel engines. In such systems, a compressor operated by the diesel engine compresses a gaseous refrigerant until it is transformed into a liquid. The pressure on the liquid is then released through an expansion valve, and the refrigerant is passed through a heat exchanger, and this absorbs heat and chills the heat exchanger coils, thus cooling the container. While this system is in use widely, there are a number of drawbacks with this system.
[0007] Diesel engines are noisy, dirty and require fuel and need repairs from time to time. They also produce undesirable gaseous emissions. The refrigerating units themselves typically use fluro-chemical type compounds, which are an undesirable pollutant when released occasionally into the atmosphere. At present, no safety alarms are needed for this condition. The newest version uses a process known as Thermo Cycling. The process turns on or off the cooling unit when specific temperatures are reached. This process allows the food container atmosphere to maintain temperatures as low as 20 degrees. This process, along with the practice of running the devices at a higher average temperature, are methods employed to save on fuel costs, without losing safety of food.
[0008] A number of refrigerants and processes can be used for refrigeration systems. Liquid nitrogen is one such refrigerant. Liquid nitrogen vaporizes at a much lower temperature than the currently used gaseous refrigerant and thus provides a much colder refrigerant than the conventional gaseous refrigerant when released through a heat exchanger. Liquid nitrogen is available in pressurized containers and can be released through a thermo vane heat exchanger and then can provide power for gas turbines before being released to the atmosphere. Since nitrogen is a major component of air, the release of nitrogen poses no pollution threat.
[0009] It is an object of the present invention to provide a liquid nitrogen refrigeration system having improved and controlled cooling characteristics which is also useful in cold traps for a food processor.
SUMMARY OF THE INVENTION
[0010] A liquid nitrogen thermo vane heat exchanger comprises a vertical array of alternating vaporization chambers and pressure control chambers connected together in series. The vaporization chambers each have a plurality of thermo vanes mounted in exterior loops along the exterior of the chamber. The thermo vane tubes provide a controlled rate of vaporization of the liquid nitrogen and an increased exterior surface area to facilitate refrigeration.
[0011] In the present invention, the liquid nitrogen vane cooling exchanger comprises a plurality of separate heat exchanger chambers in the form of flat blades mounted in a vertically spaced relationship in a rack. The chambers having thermo vanes on the exterior are alternately positioned with adjacent chambers which are designed with deflector blades in the various chambers.
[0012] The thermo vanes are an important feature of the present invention. They provide a controlled rate of vaporization of the nitrogen while at the same time providing the equivalent of a cooling surface on the heat exchanger to provide added exterior surface area for improving the cooling capacity of the cold trap. Because of the small designed flat surface, liquid nitrogen in the thermo vane tubes cannot flash or boil turbulently in the tubes. Instead, the vanes have a controlling effect on liquid nitrogen that controls the vaporization of the liquid nitrogen. When the nitrogen can vaporize in thermo vanes by the process of film boiling under other conditions as well, when nitrogen vaporizes in thermo vanes by the process of film boiling, a thicker than normal layer of vapor or gas is formed at the wall of the vanes and this insulates the liquid nitrogen from the much warmer wall of the surface. This slows the vaporization rate of the nitrogen. At the same time, the vapor adjacent the walls flows in a laminar flow pattern to the outlet of the thermo vanes and then into the larger interior of the heat exchanger. The laminar flow improves the refrigeration effectiveness of the cold trap. In short, the thermo vanes provide an effective way of controlled vaporization of an otherwise very volatile liquid.
[0013] These and other features and advantages of the present invention are described below in connection with a detailed description of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a perspective view of a liquid nitrogen capillary heat exchanger constructed in accordance with the present invention.
[0015] FIG. 2 is a front elevational view of the capillary heat exchanger.
[0016] FIG. 3 is an end view of one of the chambers taken along lines 3 - 3 of FIG. 2 .
[0017] FIG. 4 is a perspective view showing a cooling tube with capillary tubes employing the capillary tube covering fins of the present invention, with only one representation capillary tube set and cover being shown.
[0018] FIG. 5 , consisting of FIGS. 5 a 5 b and 5 c are schematic diagrams of alternate embodiments of the capillary tube heat exchange of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The basic construction of the heat exchanger of the present invention is similar to the heat exchanger disclosed in applicant's U.S. Pat. No. 5,582,015, which is incorporated herein by reference and described below.
[0020] Referring to the drawings and more particularly FIG. 1 , a heat exchanger 10 in which the present invention is employed comprises a series of heat exchanger chambers 12 , 14 spaced vertically apart in alternating arrangement in a support rack 16 . Support rack 16 comprises a pair of spaced vertical support members 18 positioned at each end of the rack and interconnected by cross-members 20 and longitudinal members 21 . A base 22 is connected at the bottom of the support members and extends outwardly from each side thereof in order to provide support for the rack.
[0021] Chambers 12 and 14 are substantially the same in construction, with the exception that chambers 12 have a series of capillary tubes 24 and 26 spaced along the longitudinal length of each chamber. Chambers 12 desirably are copper pipes 28 having a four and one-half inch O.D. and a wall thickness of ¼ inches. The pipes in the preferred embodiment are about 56 inches long. Caps 30 are removably fitted on the ends of the pipes by welded ends on the pipes and on the interior of the caps or by such suitable fasteners. A pressure tight fit is essential. The pipes are mounted in the rack with the end caps 30 resting on cross-members 20 of the rack and with flexible metal bands 32 extending from the cross-member one side of the cap over the top of each cap and then down into attachment with the cross-member on the other side of the cap. The bands are held in place by removable fasteners.
[0022] While the pipes for chambers 12 and 14 are substantially the same, with the exception of the capillary tubes 32 , for convention, the pipe for chamber 12 will be referred to as pipe 28 and the pipe for chamber 14 will be referred to as pipe 29 .
[0023] Referring to the construction of chamber 12 , pipe 28 includes a series of small openings one-quarter inch in diameter at four separate angularly spaced locations at each of 51 axial positions along the pipe, with each series of openings preferably being spaced axially apart by a distance of one inch. The first three inches at each end of the pipe has no openings. As shown in FIG. 3 , the openings in pipe 28 comprise a horizontal opening 36 at the left hand side of the pipe, an opening 38 positioned downwardly therefrom by an angle of 45 degrees, an opening 40 positioned downwardly form opening 36 a distance of 78 degrees, and an opening 42 positioned upwardly to the right from a vertical position by a distance of 35 degrees. Capillary tubes 24 and 26 , which are about nine inches long, form elongated loops as shown and are fitted and welded into these openings. Each capillary tube is formed of copper and preferably has a one-quarter inch O.D. and a one-sixteenth ( 1/16) inch I.D. The capillary tubes extend all the way through the walls of the pipes so that the interior of the capillary tubes is in communication with the interior of the pipes. All chambers 12 are of substantially the same construction.
[0024] Pipes 29 have no capillary tubes attached to the outside thereof but can be filled with a heat transmissive particulate material, preferably copper filings 31 . The copper filings improve the heat transfer in the interior of the pipe and also serve to slow down the flow of refrigerant through the pipe so as to maximize heat transferring the interior of the pipe and also serve to slow down the flow of refrigerant through the pipe so as to maximize heat transfer. It is desirable to have the flow of refrigerant through the system be slow enough that the amount of heat that the refrigerant can absorb from the exterior environment is maximized and the back pressure caused by vaporization is controlled.
[0025] As shown in FIG. 2 , all of the chambers are connected in series, starting from the first chamber at the bottom of the rack (the numbers of the chambers and tubes in serial order from bottom to the top being indicated in parenthesis after the number of the chamber or tube) to the last chamber or ninth chamber at the top of the rack. Pipe 28 ( 1 ) has an inlet 44 at the left hand end ( FIG. 2 ), which is connected through an inlet orifice valve 46 to a conduit 48 leading upwardly thorough relief valve 49 to a suitable source of liquid nitrogen, which is maintained under pressure in a conventional pressurized tank 51 of the type that can be purchased commercially from any number of vendors. The right hand end of pipe 2891 ) is connected through openings in the end cap to a larger pipe 50 and a smaller pipe 52 leading upwardly to corresponding openings in the right hand end cap of pipe 29 ( 2 ). Pipe 50 has a three-quarter inch O.D. and pipe 52 has a one-quarter inch O.D. As shown in FIG. 2 , the level of liquid nitrogen 54 in pipe 28 ( 1 ) covers the bottom of the pipe and does not fill the entire pipe. And inlet 56 of pipe 50 extends inwardly into the interior of pipe 28 ( 1 ) and then downwardly under the surface of the liquid nitrogen 11 in the pipe, so that pipe 50 will be filled with liquid. The smaller pipe 52 is in communication with the vapor portion of the interior of pipe 28 ( 1 ) and conveys vapor into the next adjacent pipe. Pipe 52 enters the end cape of pipe 29 ( 2 ) in an opening 33 on the left hand side of the end cap on the horizontal axis, while pipe 50 enters the pipe at an opening 35 at the axis ( FIG. 4 ).
[0026] On the left hand side of pipe 29 ( 2 ), a large pipe 58 corresponding with pipe 50 exits pipe 29 ( 2 ) and extends upwardly to the left hand end of 29 ( 3 ), with the pipe exiting from the axis of the pipe and entering in the axis of the next adjacent pipe. A smaller pipe 60 exits from an opening 62 on the right hand side of the end cap at the horizontal axis and extends upwardly into an opening 64 in the upper portion of the end cap on the vertical axis.
[0027] All of the pipes in the heat exchanger are connected in the same way, so that liquid nitrogen enters the heat exchanger in the left hand end of the lowermost pipe for level control, extends backwardly and forwardly through each of the pipes as it moves upwardly through the heat exchanger, and then exits from an outlet opening 66 at the right hand end of the uppermost pipe 2999 ). The movement of the liquid and the gas through the heat exchangers is caused by the vapor pressure of nitrogen as it evaporates in the system.
[0028] Pressure gauges 70 ( 1 )- 70 ( 9 ) are mounted on the respective pipes 28 or 29 ( 1 )-( 9 ) in order to monitor the pressure in each of the pipes. Since back pressure is a critical factor in this system, it is important to maintain proper pressure in each of the pipes. In addition, a pressure valve 72 is connected to outlet 66 of the heat exchanger. This sets the threshold pressure for release of nitrogen.
[0029] The desired pressures in each of the pipes, as indicated by the pressure gauges and the pressure at the outlet pressure valve 72 are set forth in the following table.
[0000]
70(1)
24.7 psig
70(2)
23.2 psig
70(3)
22.9 psig
70(4)
21.4 psig
70(5)
21.3 psig
70(6)
15.1 psig
70(7)
12.9 psig
70(8)
7.5 psig
70(9)
5.2 psig
[0030] In addition to the inclusion of copper filings in tubes 29 , it is desirable to include a desiccant to remove moisture from the gas. An aluminum silicate gel, which has the appearance of small pellets works fine for this purpose.
[0031] The tubes 28 do not have the desiccant or copper filings in them but instead are provided with the capillary tubes on the exterior portions of them. The capillary tubes are extremely important features of the present invention. They provide a controlled rate of vaporization of the nitrogen while at the same time providing added exterior surface area for improving the cooling capacity of the heat exchanger. Because of the small diameter of the capillary tubes, liquid nitrogen in the capillary tubes cannot flash or boil turbulently in the tubes. Instead, the capillary tubes have a controlling effect on liquid nitrogen that controls the vaporization of the liquid nitrogen. The nitrogen vaporizes in the capillary tube by a phenomenon known as film boiling. While liquid nitrogen vaporizes by film boiling under other conditions as well, when nitrogen vaporizes in a capillary tube by the process of film boiling, a thicker than normal layer of vapor or gas is formed at the wall of the capillary tube, thus insulating the liquid nitrogen from the much warmer wall of the capillary tube. This slows the vaporization rate of the nitrogen. At the same time, the vapor adjacent the walls flows in a laminar flow pattern to the outlet of the capillary tube and then into the larger interior of the pipe. The laminar flow improves the refrigerating effectiveness of the heat exchanger. In short, the capillary tubes provide an effective way of controlled vaporization of an otherwise very volatile liquid.
[0032] In accordance with the present invention, the construction of the foregoing capillary tube heat exchanger is modified to give the heat exchanger substantially enhanced heat transfer characteristics. In the present invention, the capillary tube loops 24 and 26 are covered with hollow covers or fins 100 , shown in FIGS. 4 and 5 . Each fin 100 is formed of a heat transmissive material, such as a metal. Copper or other metal with good heat transmission properties is desirable. A somewhat elastic material can be desirable. Fin 100 is a flat, hollow member having spaced sides 104 and 106 and edges 108 joining the sides. The sides may have a rounded outer contour to conform with the rounded outer contours of the capillary tube loops being encased. As shown, a single fin desirably covers both capillary tube loops located at approximately the same axial position on the cooling tube. Separate fins could be used for each loop, but a single fin provides a larger heat transfer surface and is therefore preferred. The fins may be formed of a flexible material that can be deflected somewhat in order to fit the fins over the capillary tube loops.
[0033] The dimensions of the fins corresponds with the dimensions of the capillary tube loops. Desirably, the fins are shaped and the interior sides are spaced apart by a distance sufficient to permit the fin to be inserted over the capillary tube loops with the fin being in at least loose general contact with the loops when installed.
[0034] When the fins are thus installed and in contact with the capillary tubes, the area of the effective cooling surface provided by the capillary tubes is dramatically increased without losing any of the benefits achieved by the narrow size of the capillary tubes. With the construction of the present invention, the effective area of the cooling surface can be increased by as much as 88%. This can result in dramatically decreased cooling tubes for a refrigerator truck. In the refrigerated truck industry, it is desired to be able to drop the refrigerative temperature to −20 degrees in twenty minutes. In one test, a cooling system without cooling fins was able to reduce the temperature only to −18 degrees in this time. With the fins, the temperature was reduced to as low as −40 degrees. While these results are merely exemplary of limited testing, they do reflect that the cooling fins provide a significant improvement in the cooling capabilities of a nitrogen refrigeration system in a truck cooler.
[0035] Heat Exchanger Specifications. The specification of a heat exchange construction in accordance with the present invention are as follows.
[0000]
Height
94″
Width
72″
Depth
72.5″ for thermo vanes, the entire length of trailer
Weight (empty)
750 lbs.
Weight (operational)
785 lbs.
BTU's (in operation)
48,000
Operation pressure
20-30 psi (gauged)
Static Pressure
0
Barometric Pressure
1009 HPA
Humidity
Varies with product
Temp. Control Range
−30° to +170° F.
Dew Point
Varies with product
Material
Copper and Stainless Steel
Gs Type
Liquid Nitrogen
[0036] A fuel tank for storage and supply of liquid Nitrogen can have the following specifications:
[0000]
Overall Length
75″
Diameter
26′
Capacity
100 gal.
Operating Pressure
20-30 psi (gauged)
Static Pressure
20-30 psi (gauged)
Weight (empty)
405 lbs.
Weight (full)
1195 lbs.
[0037] One advantage to the use of this cryogenic process for refrigerating vehicles is that gas turbines are running off the exhaust of the fuel source and generating electric power to run electric strip heaters when heat is required for vehicle trailers or storage. As well as the turbines that run the fans of the circulation systems and are released to the atmosphere with 100% heat recovery as well the exhaust from the fans that give cooling efficiency of 100%. Using cooling fins attached to thermo vanes cryogenic activity and heat transfer that is more efficient than existing cooling devices.
[0038] The outlet of thermo vane collectors support the pneumatic supply for control valves and temperatures controls, with 15 psig regulator before exit of system.
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A cold trap heat exchanger with a horizontal and vertical arrangement of vaporization chambers, with vibration pads for vehicle use. Vaporization pipes each have a series of thermo vanes mounted on horizontal arranged pipes. This fluid controls the vaporization of the liquid fluid and surface area causing a liquid film on surface area varies of both tubes and pipes to occur, and this increases the facilitate refrigeration. The pneumatic chambers are filled with liquid N 2 . These gases are controlled through regulated orifice for back pressure on gas turbines used to move atmosphere circuits across cold trap tubes and veins and flow through vanes for cooling control of designed areas and chambers in cooling application that may be required for cooling.
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BACKGROUND OF THE INVENTION
The invention relates to suspended ceiling structures and, in particular, to a system for converting conventional T-grid for lay-in tiles to a snap-up panel construction.
PRIOR ART
Conventional suspended ceilings comprise a rectangular metal grid and lay-in tiles. Typically, the metal grid members have an inverted tee configuration and the tiles or panels are supported on the upper faces of the tee flanges. Situations arise where it is desirable to change the ceiling surface for various purposes such as to present a new appearance or look, or to conceal a soiled or otherwise damaged ceiling. The traditional approach to renewing the ceiling is to replace the tiles and either refurbish the lower visible faces of the grid tees or replace them. These approaches can be expensive considering the cost of new materials and installation labor, as well as the cost of handling and disposal of the old materials. Still further, replacement of existing ceiling tiles with new tiles does not yield a completely new “look” but, rather, only a renewed appearance.
U.S. Pat. Nos. 4,696,142 and 6,467,228 illustrate “snap-up” ceiling panels of a type used with the present invention.
SUMMARY OF THE INVENTION
The invention provides a system for resurfacing existing suspended ceilings that utilizes the original grid for support and allows the original tiles to remain in place. The disclosed resurfacing system provides a mounting clip with gripping elements that engage the existing grid and support elements that mate with peripheral portions of new ceiling panels. The mounting clip, in the illustrated embodiment, is configured to snap onto the flange of a standard tee or grid member and, more specifically, is configured to be installed at an intersection of the tee grid members such that it grips the adjacent flange areas at all four grid member extensions from the intersection.
As disclosed, moreover, the preferred clip is arranged to be manually installed without tools by simply twisting or rotating it about the center of the intersection, causing it to simultaneously grip onto all four grid extensions. A number of features allow the clip to be accurately positioned and readily snapped into place even where previously installed ceiling panels remain in place. The clip can beneficially be made by injection molding a suitable plastic material so as to achieve the resilience to enable it to reliably snap into the installed position. Moreover, the clip can be modified by cutting it with a hand shear or snips, without shattering or splitting, to fit areas where the grid members intersect walls, light fixtures, air vents, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a suspended ceiling system, viewed from above, illustrating a conventional tee grid, lay-in tiles, an adaptor clip of the invention at the intersections of the grid tees, and snap-up panels supported on the tee grid by the adaptor clips;
FIG. 2 is a perspective top view of the adaptor clip of the invention;
FIG. 3 is a bottom perspective view of the adaptor clip of the invention;
FIG. 4 is a bottom view of the adaptor clip;
FIG. 5 is a side view of the adaptor clip;
FIG. 6 is a top plan view of the adaptor clip;
FIG. 7 is a cross-section of the adaptor clip taken along the lines 7 - 7 indicated in FIG. 6 ;
FIG. 8 is a cross-section of the adaptor clip taken along the lines 8 - 8 indicated in FIG. 6 ;
FIG. 9 is a cross-sectional view of the adaptor clip taken along the lines 9 - 9 indicated in FIG. 4 , but shown upright;
FIG. 10 is a fragmentary cross-sectional view of the adaptor clip taken along the lines 10 - 10 indicated in FIG. 6 ; and
FIG. 11 is a fragmentary cross-sectional view of the ceiling installation taken along the staggered plane indicated by the lines 11 - 11 in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a suspended ceiling system 10 embodying the invention. The system includes a rectangular grid 11 formed of conventional main and cross tees 12 . The rectangular grid 11 in the illustrated case forms square modules that are 2 foot by 2 foot, but it will be understood that the invention is applicable to other rectangular grid patterns such as the common 2 foot by 4 foot module. The cross tees or cross runners 12 intersect the main tees or main runners at regularly spaced locations along the lengths of the main tees and are coupled together with end connections of known construction. As is customary, the tees or runners have the general cross section of an inverted tee with a vertical stem or web 13 ( FIG. 11 ) and a horizontal flange 14 at the lower edge of the stem. The flange 14 has symmetrical portions 16 each extending horizontally away from the stem 13 . The width of the flange 14 of a common type of tee is nominally 15/16″. At a regular tee intersection, four tee sections or portions extend horizontally outwardly from a theoretical center of the intersection. Typically, the sections of a main tee extend in opposite directions along one line and the sections of two cross tees extend in opposite directions along a line perpendicular to the line of the main tee.
Conventional ceiling tiles or panels 15 usually have acoustic and fire retardant properties and are normally supported on the grid tees 12 by resting in direct contact on the upper faces of the flange portions 16 .
A plurality of clips or adaptors 17 , installed on the tees or runners 12 at strategic locations, most typically at their intersections, are arranged to enable new ceiling panels 18 to be attached and supported on the grid 11 while, typically, previously installed tiles 15 remain on the grid 11 . The illustrated clip 17 is a one piece injection molded body having a cruciform shape in plan view formed by four identical arms or sections 19 . The major areas of the sections 19 are generally co-planar. The clip 17 can be formed of a suitable thermoplastic material such as a glass filled polybutylene tetra phthalate. This and like material has sufficient resilience to allow the clip to be installed and removed more than one time.
An upper face of the clip 17 has gripping elements 21 formed to interengage with the flange portions 16 of the grid tees 12 and a lower face of the clip has support elements 22 formed to mate with perimeter portions 23 of the ceiling panels 18 . Each of the four arms or sections 19 of a clip body has a gripping element 21 arranged to engage and couple with a separate one of the four tee parts or sections of the grid 11 that comprise an intersection. The gripping or mounting element 21 as shown most clearly in FIG. 8 , is L-shaped in cross-section with a short vertical leg 26 supporting a second cantilevered longer leg 27 . The second or major leg 27 extends above an upper surface 28 of its respective body section 19 a distance about equal to and, preferably, slightly less than the thickness of the tee flange 14 to which it is to be mounted. A lower face of the horizontal leg 27 , distal from the short vertical leg 26 , is beveled at 29 and, proximal to the vertical leg 26 the lower surface is recessed at 31 vertically above the lowermost zone of the distal beveled part 29 . A notch 32 at the juncture of the short vertical leg 26 and the planar section of the main body of the respective clip arm or section 19 enables the gripping or mounting element 21 to be manually broken off with thumb pressure for special applications or installations where it might otherwise interfere with a structure on which the clip 17 is to be mounted. The horizontal longer leg 27 of the gripping or mounting element 21 extends horizontally to a plane that is short of the center line of the arm or section 19 so that as discussed below, when properly installed on a grid tee flange 14 , it does not interfere with the tee stem or web 13 .
The perimeter of the clip 17 is reinforced and thereby stiffened by a downwardly extending flange 36 . When the clip 17 is properly installed on the grid tees 12 , central and outlying portions of the upper surface 28 are arranged to abut the lower face of the grid tee flanges 14 . Centering rib formations 37 shown, for example, in FIGS. 2 , 6 , and 7 , extend upwardly from the planar upper surface 28 and are symmetrically disposed on opposite sides of a center line of the respective clip arm 19 . The ribs 37 each include a laterally outwardly facing inclined ramp surface 38 and a laterally inward facing alignment surface 39 having a relatively small tilt or draft of, for example, about 5 degrees.
Panel supporting elements or members 22 extend downwardly from the plane of the main body. The support elements 22 are symmetrically spaced on opposite sides of the center of the arms or sections 19 . One of the support elements 22 , on the side of the section 19 carrying the respective gripping element 21 is interrupted in the area of the gripping element such that it is in two parts spaced along the length of the respective section 19 . Each support element 22 has an L-shaped section (e.g. FIG. 7 ) with a generally vertical leg 41 depending from the body proper of the associated section 19 and a horizontal flange or leg 42 extending from the vertical leg 41 . The support elements 22 are stiffened by gussets 45 . The gap between the support elements 22 is accompanied with a rectangular notch 44 in the main body of the section 19 . The notch 44 permits the clip 17 to be molded with simple tooling that releases the clip with straight molding press platen opening motion without secondary slide action.
Holes 46 molded in the clip body adjacent the outward ends of the sections 19 and near the center of the body are provided to receive optional fasteners such as screws for fixing the clip 17 to a suspended grid or associated ceiling fixtures. The holes 46 are reinforced by concentric small annular flanges 47 . A square hole 48 at the geometric center of the clip and notches 49 at the distal ends of the sections or arms 19 have corners lying on the center line of the respective sections. The corners of the hole 48 and notches 49 can be used as sights to align the clip 17 with a grid on which it is being installed or a chalk line or a laser beam, for example.
The clip 17 is manually installed, typically without tools, at an intersection of grid tees 12 from below the grid 11 by horizontally aligning its center with the imaginary center of the intersection while the top face 28 of the clip is held in contact with the lower faces of the grid tees and the sections 19 are deliberately held out of angular alignment, slightly counter-clockwise when viewed from below, with the lines of the grid tees.
The gripping elements 21 , extending slightly above the plane of the main area of the clip body, raise the overlying tiles 15 that are carried on the respective grid tees 12 . The clip 17 is rotated about its center on a vertical axis causing the gripping elements 21 to slide over portions 16 of the grid tee flanges 14 . The beveled areas 29 smoothly cam the gripping elements 21 over respective tee flange portions 16 . An audible click will be heard and resistance to further rotation will occur when the tee flanges 14 snap into the pocket formed between the opposing ribs 37 on each clip section 19 . This snapping action is produced by the spring-like resilience of the gripping elements 21 and to some extent the resilience of the flanges 14 themselves. The tilt of each pair of alignment surfaces 39 tends to wedge the respective tee flange 14 into a snug and aligned fit there between. Once a flange 14 snaps between the surfaces 39 , the force to remove a clip is greater than that required to install it. The location of the alignment surfaces 39 , distal from the center of the clip 17 maximizes their position holding capacity. Fine adjustment of the clip position can be assisted by reference to the sights formed by the notches 49 and center hole 48 , and any selected reference lines or marks.
In a typical application, clips 17 are installed on all of the grid tee intersections of an existing suspended ceiling. At the perimeter of the ceiling and other interruptions or terminations of the grid, such as at lighting and air duct fixtures, the clip 17 may be suitably field cut or otherwise modified to provide support elements 22 at these locations. Fasteners installed through the holes 46 of the modified clips can be anchored in corresponding areas of the overlying grid flanges 14 or other structure to maintain the modified clip in position.
With reference to FIGS. 1 and 11 , the clips 17 enable new ceiling panels 18 to be installed on the grid 11 where, if desires, an earlier installation of ceiling tiles or panels 15 remain in place. It may be desirable to renew the appearance of a ceiling installation in which the ceiling panels and/or grid has been soiled with airborne dust and grime or otherwise become shopworn. U.S. Pat. Nos. 4,696,142 and 6,467,228 disclose types of ceiling panels that are compatible with the clip 17 . The panels 18 , typically formed of sheet metal, have peripheral vertically extending flanges 52 . The panels 51 are proportioned so that the flanges 52 have re-entrant surface portions 53 that snap over the upper surfaces of the upturned edges 43 of the horizontal flanges 42 of the support elements 22 . Normally, both the panel flanges 52 and the support elements 22 can be imparted with some relative resilience to permit this snapping action. Alternatively, a panel 18 or the support elements 22 can be designed to be the primary resilient element for this snapping action.
It will be understood that rectangular panels, other than the illustrated square panels 18 , can be mounted on the clips 17 . The clips 17 can be installed on less than all of the intersections of the grid tees 12 and can be installed on the grid tees between intersections. Thus, for example, 2 foot by 2 foot panels 18 can be installed on a 2 foot by 4 foot grid and, 2 foot by 4 foot panels can be installed on 2 foot by 2 foot grid patterns. Mounting the clips 17 at locations on an existing grid at locations other than intersections allows for re-squaring an out of square existing grid. The clips 17 can be installed along any grid tee 12 where additional panel support may be beneficial, for example, near the perimeter to support cut panels.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the lair scope of the teaching contained in this disclosure. For example, the clip can be made of metal by blanking and forming, spot welding parts together, or casting. The invention is, therefore, not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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An adaptor clip, for converting a standard tee grid ceiling to a snap-up panel system, comprising an injection-molded plastic body that includes gripping elements for engaging the tops of the flanges of the tee grid and support elements for mating with the upstanding peripheral flanges of the snap-up panels. The clip is arranged to be quickly and easily installed without tools by simply positioning it against the lower faces of intersecting tee grid members so that its center underlies the center of the intersection and rotating it about a vertical axis.
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FIELD OF THE INVENTION
The present invention relates to the field of diesel engines and more particularly to the control of the injection in such engine types.
It is well-known to associate with an engine one or more detectors intended to measure several parameters so as to better control the running thereof. These detectors can be pressure detectors allowing to measure the pressure within the chambers and outside, temperature detectors, injection needle lift detectors, etc.
It is also well-known to perform, by means of a computer, predetermined adjustments on an engine by transferring the information provided by the detectors to stored standard configurations. These standard configurations are referred to as "maps" by specialists. For this process to be effective, many detectors have to be used and complex charts of standard configurations relating to very diverse running conditions have to be "mapped".
Furthermore, fuel injection is a decisive operation in the running cycle of engines. This is the reason why many studies have focused on injection improvement via notably more effective control.
Injection control becomes a particularly delicate operation when high pressures, sometimes above 1200 bars, are required for injection into the cylinders. The most recently developed injectors work at such pressures, for example in direct-injection diesel engines.
Under such conditions, it is difficult to provide proper control of the quantity of fuel injected. It is notably difficult to provide a good distribution of the fuel in each of the cylinders. This distribution does not only condition the total fuel consumption, the combustion quality and therefore the pollution generated, but it also influences the driving convenience.
BACKGROUND OF THE INVENTION
The well-known methods allowing to improve the injection distribution cylinder by cylinder are based on a correction of the engine torque via analysis of the instantaneous crankshaft rotating speed taken in each cylinder. Document Toyota SAE 930 873 describes such a method.
The problem is even more acute when small fuel quantities are to be controlled, such as for example small fuel injections taking place before the main injection in direct-injection diesel engines. These pre-injections are referred to as "pilot injections" by specialists and will be thus called in the text hereafter.
These small injections allow to improve the combustion noise of the pollutant emissions.
Document FR-2,704,023 describes a way of controlling this injection type from quasi-zero pilot injections until detectable pre-injection values are obtained.
SUMMARY OF THE INVENTION
According to the invention, injection control can thus be achieved via control of the pilot injection and/or of the main injection into at least one of the engine cylinders, in real time, in a different and advantageous way.
In other words, the object of the invention is to control the quantity of fuel injected into a diesel engine.
The main stages of the invention can consist in:
(a) determining the pressure variation within at least one cylinder around a specific time of the engine cycle, for two successive cycles having different injection characteristics;
(b) deducing therefrom the difference between the quantity of fuel actually injected into said cylinder and a theoretical quantity of fuel;
(c) adjusting the injection parameters so as to balance in real time the quantity of fuel actually injected with the quantity of fuel to be theoretically injected.
According to the invention, the process is preferably implemented during stabilized running of the engine.
The process according to the invention can be implemented independently for each cylinder of the engine.
According to one of the embodiments of the invention, the process is implemented for one cylinder and the other cylinders are adjusted in the same way.
More precisely, the absolute value of the pressure variation between a cycle having a fuel pre-injection prior to the main injection and a cycle having only a main fuel injection is determined.
The quantity of pre-injected fuel is advantageously adjusted.
A computer is preferably used to implement the process, said computer allowing real-time adjustment of the quantity of fuel injected.
According to one of the aspects of the invention, stage (b) is carried out by means of data stored in said computer.
Furthermore, according to the invention, stage (c) is carried out by means of data stored in said computer by possibly using a correction self-adjustment process.
According to the invention, the quantity of mainly injected fuel can also be adjusted. This can be achieved by means of a relation stored in the computer between adjustment of the pre-injected quantity and that of the mainly injected quantity.
Said pressure variation is advantageously determined around the combustion top dead center.
According to an embodiment example of the invention, the process can be implemented with an injection system called "common rail"; an injection system comprising one pump injector per cylinder can also be used.
The process according to the invention also requires definition of particular times of the cycle such as, for example, the main injection start control time β; the time α o must preferably be contained in a given range.
Furthermore, if the pressure variation (.increment.P) is zero, the signal (T 1 ) relative to the quantity of pre-injected fuel is modified.
Besides, the present invention aims to modify the signal relative to the quantity of mainly injected fuel, which follows an adjustment of the injection parameters. The modified signal thus depends on the signal relative to the quantity of pre-injected fuel, on the signal linked with the quantity of mainly injected fuel and on the injection pressure.
A preferred application of the invention relates to direct-injection diesel engines.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features, advantages and details of the invention will be clear from reading the description hereafter, given by way of non limitative examples, with reference to the accompanying drawings wherein:
FIG. 1 relates to curves showing the cylinder pressures for cycles having different injection characteristics, around a given time of the engine cycle;
FIG. 2 is a curve defining the relation between the pressure variation according to FIG. 1 and the pilot quantity of fuel injected;
FIG. 3 illustrates an example of signals controlling the injection system, such as those delivered by the computer, according to the invention;
FIG. 4 illustrates the quantities injected with the control signals of FIG. 3, and
FIGS. 5A and 5B show control signals for two different working instances.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows experimental curves giving a relation between the cylinder pressure and the crankshaft angle. Curves A and B relate to different injection characteristics. In fact curve A relates to the pressure in a cylinder where a pilot injection takes place prior to the main injection, whereas curve B illustrates the pressure in a cylinder without pilot injection. A pressure variation .increment.P can be seen between the two curves, this variation having a maximum value here around 360° crankshaft angle for the combustion top dead center. Around this characteristic point (α o ), there is a good repeatability of the pressure variation for each injection type. Curves A and B are thus advantageously exploited to determine notably the pressure variation .increment.P around a given crankshaft angle (α o ).
This data is then used as input data of a curve such as that shown in FIG. 2.
This quasi-linear curve establishes the relation between the pressure variation .increment.P defined above and the quantity Q 1 of pilot-injected fuel, for a given speed and load. .increment.P being known, the quantity Q 1 of injected fuel is deduced from this curve.
A single curve is shown in FIG. 2, but actually a pencil of curves which correspond each to a given speed and load can be exploited.
The curves of FIG. 2 are calculation charts stored in an associated computer. As explained hereafter, the latter will allow to control permanently and to calculate in real time the quantity of pilot-injected fuel and/or the total quantity of fuel injected into at least one cylinder of the engine.
FIGS. 3 and 4 illustrate the implementation of an embodiment of the invention with an injection system known as "common rail".
FIG. 3 shows the control signal delivered by the computer and obtained for two successive combustion cycles C 1 and C 2 in a cylinder. This signal represents the control time at a predetermined time of the cycle, for a given cylinder. Cycle C 1 comprises control of a pilot injection that is activated by slot T 1 , followed by a main injection control corresponding to slot T 2 . A pressure P 1 which is a function of α o =P 1 (α 0 ) can be associated with this cycle. Cycle C 2 comprises no pilot injection, therefore only a slot T 2 of the signal appears. A corresponding pressure P 2 (α o ) is measured. It can be noted that, according to this embodiment of the invention, a pressure detector is thus necessary for each cylinder.
The pressure difference .increment.P=P 2 (α o )-P 1 (α o ) can thus be quantified and the process according to the invention can be implemented so as to obtain the quantity of fuel injected: Q 1 as represented in FIG. 4.
The relation existing between T i 1 and Q i 1 can thus be determined for each cylinder (i).
It is then possible to correct T i 1 for a later cycle in order to adjust the quantity Q i 1 of fuel injected during the pilot injection to cylinder (i).
Moreover, this information obtained for cylinder (i) can be used to correct T i 2 which is the main quantity of fuel to be injected into this cylinder.
In fact: ##EQU1##
The values T 1 (base) and T 2 (base) are stored in the computer, in the form of maps, as a function of the load and/or the position of the pedal and of the engine speed.
Furthermore, the function relating δT i 2 to δT i 1 is previously determined by any means known in the art. This function is also preprogrammed in the computer:
δT.sup.i.sub.2 =f(δT.sup.i.sub.1).
The present invention thus allows to correct not only the control time T i 1 by means of a quasi-instantaneous real-time calculation, but also the control time T i 2 for a given cylinder (i).
The controlled quantities really injected can be adjusted to the preprogrammed quantities.
The embodiment of the invention that has just been described requires one pressure detector per cylinder so as to be able to adjust the quantity injected for each cylinder individually, by implementing the process separately in each cylinder.
The advantage of this solution lies in the precision and in the reliability of the adjustment which notably takes account of the wear and/or of the fouling specific to each injector.
Without departing from the scope of the present invention, a single pressure detector can be used and the same adjustment can be performed while considering that the various cylinders and injectors are identical and therefore work quite similarly.
As mentioned above, the injection system can be a system known as "common rail" where the injection pressure is common to all the cylinders.
However, without departing from the scope of the invention, the injection system can comprise one pump injector per cylinder. The signals are then processed as mentioned above.
A characteristic element of the invention concerns the start (or phasing) of the main fuel injection. This time is the control time of signal T 2 (or T' 2 ).
Besides, another important element for implementing the process according to the invention is the selection of the crankshaft angle α o at which the pressures P 1 and P 2 are measured. The example of FIG. 1 was obtained for α o =360°, the combustion top dead center. More generally, α o must be selected prior to any energy release due to the main injection and after the end of the energy release linked with the pilot injection. It must be selected at a time of the cycle when the repeatability of the pressure curves P 1 and P 2 is good.
In cases where the difference .increment.P between pressures P 1 and P 2 is below a threshold (Σ), for example because T 1 is not significant enough, the pilot injection control system is increased stepwise until a pressure difference .increment.P above threshold (Σ) is obtained in order to be able to implement the process described above.
As described above, the process according to the invention can be implemented when there is at least one cycle having a pilot injection followed by a main injection. This succession can be associated with the normal running of the engine. FIG. 5A illustrates the corresponding injection control signals. In this instance, a cycle (C 2 ) having only a main injection thus has to be created according to the invention between two cycles (C 1 , C 3 ) corresponding to the normal running.
In order that this modification does not cause too great a work variation between two cycles, it will be attempted for example to balance the injected quantities. To that effect, signal T 2 relative to the single main injection will be modified to T' 2 .
The modification can be advantageously preprogrammed in the computer in the form of a preprogrammed function T' 2 =f(T 1 , T 2 , P inj ). Thus, according to signals T 1 and T 2 and to injection pressure P inj , a particular value will be assigned to T' 2 .
Conversely, the normal running may not be provided with a pilot injection, as illustrated in FIG. 5B where a normal cycle basically comprises a single (main) fuel injection. Introduction of a cycle with pilot injection can thus vary the work provided at each cycle. In order to minimize this work variation and to obtain good driving convenience, signal T' 2 is applied in the modified cycle (C 2 ). Signal T' 2 can be a preprogrammed value as mentioned above: T' 2 =f(T 1 , T 2 , P inj ).
It should however be underlined that, in this instance, the fact that no pilot injection is provided under normal running conditions does not mean that the control signal T 1 corresponding to the pilot injection is zero as in FIG. 5B. Signal T 1 may exist but it is then such that it does not lead to a pilot injection.
It will also generally be attempted to balance the quantities injected between the two cycles having different injection characteristics, so as to have Q 1 +Q 2 =k constant.
More generally, the invention requiring in any case a modification of the normal running, said modification is preprogrammed in the computer in order to decrease the work variation resulting from the normal running modification.
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A process for controlling the quantity of fuel injected into a diesel engine comprising at least one cylinder includes the steps of determining the pressure variation (.increment.P) within at least one cylinder around a specific time of the engine cycle, for two successive cycles (C 1 , C 2 ) having different injection characteristics; deducing therefrom the difference between the quantity of fuel actually injected into the cylinder and a theoretical quantity of fuel; and adjusting the injection parameters so as to balance in real time the quantity of fuel actually injected with the quantity of fuel that is to be theoretically injected. The process is preferably implemented during stabilized running of the engine.
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TECHNICAL FIELD
The present invention relates isolation of anti-idiotypic antibody 1A7 raised against anti-GD2mAb 14G2a and its use for the treatment and detection of melanoma and small cell carcinoma.
BACKGROUND
Monoclonal antibody to the human ganglioside GD 2 antigen, and to other melanoma and small cell lung carcinomas are known. For example, U.S. Pat. No. 4,675,287 to Reisfeld et al. discloses a monoclonal antibody to the human ganglioside GD 2 antigen. This antibody is reactive with melanoma and oat cell lung carcinoma cells. This monoclonal antibody is tolerated by the human immune system and thus human immune system does not remove this antibody by immunoactive mechanisms. International Patent Publication WO 8600909 to Reisfeld, R. A. et al is directed to a "Monoclonal antibody directed to human ganglioside GD 2 ." This patent is the international patent publication related to U.S. Pat. No. 4,675,287 to Reisfeld et al. described above. More specifically, the publication discloses a non-human, mammalian monoclonal receptor produced by a hybridoma formed by fusion of cells from a myeloma cell line and lymphocytes that produce antibodies that react with ganglioside GD 2 from a mammal immunized with a ganglioside GD 2 -containing immunogen is disclosed.
U.S. Pat. No. 4,693,966 to Houghton et al. discloses human monoclonal antibodies from lymphocytes of patients with malignant melanoma. The monoclonal antibodies of Houghton et al. specifically bind to antigens found on surfaces of renal, lung and breast cancer cells. The antibody also detects the cytoplasmic antigen expressed by cells of neuroectodermal origin, such as melanoma cells.
U.S. Pat. No. 4,965,498 to Yamasaki et al. discloses a monoclonal antibody specific to a sugar chain containing an N-glycolylneuramine acid and has the ability to bind to at least N-glycolyl GM 2 ganglioside. Page 1, lines 55-56 acknowledges that monoclonal antibodies against human melanoma which react with glycolipids such as GD 2 ganglioside are known.
U.S. Pat. No. 5,305,559 to Nicolson et al. is directed to methods and compositions for the identification of metastatic human tumors. Monoclonal antibodies of this patent react with human tumor cells and are prepared against a 580 kilodalton glycoprotein antigen gp580. Antibodies are specific for lung metastasis from breast tissue and are not reactive with melanoma tumors.
U.S. Pat. No. 5,091,177 to Hellstrom et al. issued is directed to monoclonal antibodies which define a glycolipid antigen associated with human non-small cell lung carcinomas. Activity with melanoma cells is not disclosed. The monoclonal antibody has an IgG2 isotope.
U.S. Pat. No. 5,134,075 to Hellstrom et al. discloses a monoclonal antibody which binds strongly to a protein antigen associated with human tumors, including lung tumors as well as melanomas and sarcomas. The monoclonal antibody is of the subclass IgG2a.
U.S. Pat. No. 5,240,833 to Nudelman et al. discloses monoclonal antibodies that bind to tumor-associated gangliosides. The monoclonal antibodies have selected preferential reactivity to melanomas, neuroblastomas and adenocarcinomas. They are anti-ganglioside antibodies with specific isotopes such as IgG3 and IgG2a.
U.S. Pat. No. 5,242,824 to Hellstrom et al. discloses novel monoclonal antibodies reactive with a glycolipid cell membrane antigen on the surface of human carcinomas. Monoclonal antibodies react with carcinomas of the lung, ovary and colon. They show no detectable reactivity with melanoma cells.
U.S. Pat. No. 5,270,202 to Raychaudhuri discloses a novel anti-idiotypic antibody IMelpg2 which is specific for melanoma cells. It can be used for the diagnosis and treatment of melanoma tumors.
U.S. Pat. No. 5,208,146 to Irie discloses murine monoclonal anti-idiotype antibodies raised against human monoclonal anti-ganglioside antibody known as L612. The monoclonal antibody is specific for melanoma cells.
U.S. Pat. No. 4,904,596 to Hakomori discloses a hybridoma cell line and monoclonal antibody to fucoganglioside, 6B, which is present in human colonic adenocarcinoma and lung carcinoma cells.
U.S. Pat. No. 5,009,995 to Albino et al. discloses monoclonal antibodies recognized by gp130 antigen of human cells. The monoclonal antibodies are useful in the detection of the gp130 antigen and human cells, including melanoma cells, which contain the antigen.
U.S. Pat. No. 4,918,164 to Hellstrom et al. discloses anti-idiotypic antibodies for immunization against tumor, for inhibition of immune suppression mediated by suppressor T cells or suppressor factors expressing an anti-idiotype against tumors bearing the oncofetal antigen. Monoclonal antibody recognizes a human melanoma associated GD3 ganglioside antigen.
Journal of Immunology, Volume 150, 142A, 1993 discloses an abstract of Chatterjee et al. entitled "Syngeneic Monoclonal Anti-IdiotypeAntibodies Against a Monoclonal Antibody to Human Melanoma-Associated Antigen." The abstract generally discloses that the 1A7 antibody was isolated, but does not disclose a method of obtaining it or provide any of its particular properties or uses.
Patent No. EP 280209 is directed to "Monoclonal antibodies against melanoma-associated antigens, hybridoma cell lines producing these antibodies, and uses of the monoclonal antibodies". This patent to Thurin et al. discloses hybridomas producing antibodies against ganglioside antigens GD 2 and GD 3 which are non-reactive with other ganglioside antigens.
None of the patents nor literature recognize an anti-idiotypic monoclonal antibody specific for melanoma and small cell carcinoma cells which is not tolerated by the human immune system.
Neuroblastomas are highly malignant tumors occurring during infancy and early childhood. Except for Wilms' tumor, they are the most common retroperitoneal tumors in children. Neuroblastomas arise most commonly in the adrenal medulla, but they may also develop in other sympathetic ganglia within the thorax or abdomen. These tumors metastasize early with wide spread involvement of lymph nodes, liver, bone, lung and marrow. The prognosis is often good when the tumor is diagnosed prior to obvious metastasis, but with metastasis, prognosis is poor despite the extensive use of radical surgery, deep X-ray therapy, and chemotherapeutic agents.
Several antigenic determinants have recently been detected on neuroblastoma cells with monoclonal antibodies (Mabs). See Seeger, Ann. Intern. Med., 97, 873 (1982); Wikstrand et al., Cancer Res., 42, 267(1982); Wikstrand et al., J. Neuroimmunlogy, 3, 43 (1982); Eisenbarth et al., Proc. Nat'l Acad. Sci. (USA), 76, 4913 (1979); Liao et al., Eur. J. Immunol., 11, 450 (1981); Seeger et al., Cancer Res., 4, 2714 (1981); Kennett et al., Advances in Neuroblastoma Research, p. 209, Raven Press, New York (Evans ed.) (1980); Seeger et al., J. Immunol., 128, 983 (1982); Kemshead et al., Pediatr. Res., 15, 1282 (1981).
A panel of such antibodies has been reported to be helpful in the differential diagnosis of neuroblastoma and lymphoblastic disorders, Kemshead et al., Pediatr. Res., supra; Kemshead et al., Lancet, 12 (1983). In these same studies, antibodies were used either in immunoperoxidase assays with tumor tissue sections or in direct immunofluorescence assays to detect tumor cells in bone marrow aspirates.
The effective use of Mabs directed to any tumor-associated antigens as diagnostic reagents depends on the quantity, expression and chemical nature of the corresponding antigen. In this regard, Mabs directed to tumor-associated gangliosides have been useful in defining antigens associated with melanoma, neuroblastoma, colon carcinoma, and adenocarcinoma, Hakomori et al., J. Natl. Cancer Inst., 71,231 (1983). One of these antibodies was reported to detect a ganglioside antigen shed into the serum of patients with colon carcinomas, Koprowski et al., Science, 212, 53 (1981). Some of the above neuroblastoma-associated antigens are present in fetal neural tissues whereas others are expressed by both fetal and adult neural tissues. Seeger, Ann. Intern. Med., supra.
Most of the monoclonal antibodies utilized to detect the neuroblastoma-associated antigens are not restricted in their reactivity to neuroectodermal tumors like melanoma and glioma but also recognize common antigens on other malignancies such as a variety of sarcomas and leukemias, Seeger, Ann. Intern. Med., supra. In addition, only some of the antigenic structures on neuroblastoma cells recognized by monoclonal antibodies have been partially characterized by immunochemical means. Thus, a monoclonal antibody designated Mab 390 was reported to react with an antigenic determinant of human Thy-1 that had a molecular weight of 25,000 daltons. Seeger et al., J. Immunol., supra.
Another Mab, designated A2 B5, was reported to recognize a GD2 ganglioside on neurons, Eisenbarth et al., Proc. Nat'l Acad. Sci. (USA), supra. A human monoclonal antibody produced in vitro by a lymphoblast cell line from a melanoma patient was also reported to react with a GD 2 ganglioside present on neuroectoderm-derived tumors, Cahan et al., Proc. Nat'l Acad. Sci. (USA), 79, 7629 (1982).
From a biological point of view, gangliosides are of considerable interest since they have been implicated in a variety of cellular functions, including cell-cell adhesion and communication, as well as cell-substrate interactions, Hakomori et al., J. Nat'l Cancer Inst., supra. Recent studies have emphasized the importance of gangliosides for tumor growth regulation by demonstrating differences in ganglioside composition among cells expressing various degrees of tumorigenicity, Itaya et al., Proc. Nat'l Acad. Sci. (USA), 73, 1568 (1976). Consequently, the use of monoclonal antibodies directed to ganglioside determinants aids in further delineating the role of gangliosides in these processes.
Most of the monoclonal antibodies directed against neuroblastoma-associated antigens that have been reported thus far, Wikstrand et al., Cancer Res., supra; Wikstrand et al., J. Neuro-immunology, supra; Eisenbarth et al., Proc Nat'l Acad. Sci. (USA), supra, recognize a common antigenic determinant on fetal tissues, especially fetal brain, as well as on adult brain and other neural tissues. In addition, cross-reactions of such antibodies have also been reported with normal kidney, fibroblasts, myoblasts, and thymocytes, Seeger et al., Cancer Res., supra, and Seeger et al., J. Immunol., supra, with islet cells, Eisenbarth et al., Proc. Nat'l Acad. Sci. (USA), supra, and with spleen cells, Wikstrand et al., Cancer Res., supra.
Furthermore, some of the monoclonal antibodies reported in the literature are not only restricted in their reactivity to neuroectodermal tumors, such as neuroblastoma, melanoma and glioma, but also show binding to some forms of leukemia, osteogenic sarcoma, rhabdomyosarcoma, leiomyosarcoma and even to carcinomas of the lung and breast, Seeger, Ann. Intern. Med., supra.
A monospecific human monoclonal antibody, (anti-OFA I-2), produced in vitro by a lymphoblast cell line that originated from a melanoma patient was reported to detect a GD2 ganglioside on human melanoma, glioma and neuroblastoma cells, while reportedly not reacting with a variety of cell lines derived from carcinomas and from different lymphoid tumors, Cahan et al., Proc. Nat'l Acad. Sci. (USA), supra, and Irie et al., Proc. Nat'l Acad. Sci. (USA), 79, 5666 (1982). However, problems have arisen when such a human monoclonal antibody is used for immunoperoxidase assays of human tissues in that the anti-human secondary antibody required for such assays causes a large amount of non-specific background reactivity.
Heterogeneity of neuroblastomas with regard to cell surface antigenic expression has been reported in Seeger, Ann. Intern. Med., supra; Kemshead et al., Pediatr. Res., supra; Kemshead et al., Int. J. Cancer, 27, 447(1981); and, Kemshead et al., Proc. Am. Assoc. Cancer Res., 2, 399 (1981). As discussed in these publications, Mab A2 B5 failed to react with some human neuroblastoma lines tested, and quantitative differences in antigenic expression were observed between different cell cultures. Analysis of tumor cells in heavily infiltrated bone marrow aspirates indicated that only 70 percent of the samples reacted with A2 B5, suggesting that the heterogeneity seen in the expression of antigen on cell lines is paralleled in fresh tumor material, Kemshead et al., Int. J. Cancer, supra.
Thus there is a need in the art for new methods of detecting and treating melanoma and small cell carcinoma. The present invention overcomes the deficiencies of the prior art by providing an anti-idiotypic antibody 1A7 raised against anti-GD2mAb 14G2a, which is not tolerated by the human immune system, and thus may be used as a vaccine to stimulate the immune system. This property of the present monoclonal antibody makes it ideal for a new immuno-therapeutic approach to cancer.
Disclosure of the Invention
It is an object of the present invention to provide an anti-idiotype monoclonal antibody 1A7, which is the internal image of the GD2 ganglioside antigen which is highly expressed on malignant melanoma cell and small cell carcinoma cells.
It is another object of the invention to provide an antibody which generates an active immunity to GD2 antigen which is highly expressed on malignant melanoma cell and small cell carcinoma cells.
A further object of the invention is to provide a pharmaceutical composition comprising anti-idiotype monoclonal antibody 1A7, and a pharmaceutically acceptably carrier.
A still further object of the invention provides a method of treatment of metastatic melanoma and small cell lung cancer comprising administering a pharmaceutically effective amount of a pharmaceutical composition of the invention to a patient in need of treatment.
In a preferred embodiment the method may be administered to a patient who has had disease removed by surgery, radiation or chemotherapy and remains at high risk for recurrence of metastatic melanoma and small cell lung cancer.
Another object of the invention is to provide a 1A7 monoclonal antibody which can be used as a substitute for GD2 antigen in all biochemical and serological assays, such as a monoclonal antibody probe. The 1A7 monoclonal antibody probe may be incorporated into a test kit in accordance with the present invention, such as a diagnostic test kit.
The above and other objects of the invention will become readily apparent to those of skill in the relevant art from the following detailed description and figures, wherein only the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode of carrying out the invention. As is readily recognized the invention is capable of modifications within the skill of the relevant art without departing from the spirit and scope of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows the binding of purified Ab3 to Ab2 1A7 on the plate by sandwich radioimmunoassay.
FIG. 2 demonstrates the inhibition of Ab1-Ab2 binding by monkey Ab3 or vice-versa (Ab2-Ab3 binding inhibition) which shows that Ab1 and Ab2 share idiotopes and Ab3 is true anti-anti-idiotypic in nature.
FIG. 3 shows the inhibition of binding of 125I labelled 14G2a antibody to GD2 positive melanoma cell line M21/P6 in presence of different concentrations of Ab1 and Ab3. Parallel inhibition curves were obtained using either purified Ab1 or Ab3 form monkey sera. This suggests that Ab1and Ab3 bind to the same epitope on GD2.
FIG. 3A shows the inhibition of binding of 125 I-labelled 14G2a antibody to purified GD2 on the plate by Ab1 and Ab3.
FIG. 4 shows the binding of Ab1 and Ab3 to different gangliosides on the plate by ELISA assay. 250 ng of GD2 and other gangliosides were coated per well of 96-well microtiter plates, blocked and incubated with different concentrations of purified Ab1 and Ab3. The bound antibody was detected using anti-Human-Ig-alkaline phosphatase labelled reagent and substrate. The O.D. value obtained after 2 hr. using 1.5 micrograms of different antibodies per well were plotted. At this concentration, there was only reactivity with GD2.
FIG. 5 shows the ELISA results confirmed by dot blot analysis.
STATEMENT OF DEPOSIT
A deposit of the hybridoma producing the 1A7 monoclonal antibody was made prior to the filing date of the above-identified patent application under the terms of the Budapest Treaty with the American Type Culture Collection, Parklawn Drive, Rockville, Md., USA, Accession No. HB-11786.
During the pendency of this application, access to the deposit will (a) be forwarded to one determined by the Commissioner to be entitled thereto;
(b) all restrictions imposed by the depositor on the availability to the public of the deposited material will be irrevocably removed upon the granting of the patent,
(c) the deposit will be maintained for a period of at least thirty years or at least five years after the most recent request for the furnishings of a sample of the deposited material; and
(d) the deposit will be replaced should it become necessary due to inviability, contamination or loss of capability to function in the manner described in the specification.
DESCRIPTION OF THE INVENTION
Anti-idiotype monoclonal antibody 1A7, is the internal image of a GD 2 ganglioside antigen which is expressed on malignant melanoma cells and on small cell carcinoma cells. The anti-idiotype antibody 1A7, raised against a known anti-GD 2 antibody (14G2a), mimics GD2 antigen. However, it is not tolerated by the human immune system. This property of the present monoclonal anti-idiotype antibody makes it ideal for a new immuno-therapeutic approach to cancer.
Discussion below represents the results of immunization and treatment of monkeys with anti-Id 1A7 (isotype IgGl-k) which mimics GD2. Murine monoclonal anti-Id 1A7 was raised against anti-GD2 mAb 14G2a (isotype IgG2a-k) obtained from Scripps Research Institute, La Jolla. In previous studies of the inventors, small animals, such as mice and rabbits, were immunized three to four times bi-weekly with anti-Id 1A7 coupled to KLH and mixed with Freund's Adjuvant. The production of anti-GD2 antibodies were induced in the animals.
A murine monoclonal antibody mAB (IgG2ak) which binds to the ganglioside GD2 in human melanoma, neuroblastoma, glioma and sarcoma has been used to generate monoclonal antibodies (Ab2) in BALB/c mice. The culture supernatants from primary fusion cells were initially screened by a sandwich radioimmunoassay using Id as antigen.
Several Ab2 hybridomas were obtained that reacted with the immunizing Id of 14G2a (Ab1) and did not react with any isotype or allotype matched control immunoglobulins. Three of the mAb2s reacted with the antigen binding site (paratope), since they inhibited the binding between 125 I-labelled 14G2a and the target melanoma cell line M21/P6. One of these clones 1AI-1A7 is used to raise anti-anti-idiotype antibodies (Ab3) in rabbits. Polyclonal rabbit A3 sera competed with Ab1 for binding to M21/P6 cell lines available from Scripps Institute, La Jolla, Calif., and inhibited the binding of radiolabelled Ab1 to Ab2.
The anti-idiotype monoclonal antibody to the anti-GD2 antibody (designated 14G2a) is designated 1A7. This anti-Idiotype antibody is, therefore, the internal image of the GD2 ganglioside antigen which is highly expressed on malignant melanoma cell and small cell carcinoma cells.
The anti-idiotype antibody mimics the GD2 ganglioside antigen. The present inventors have determined in mice, rabbits and monkeys, all acceptable experimental animal models, that when the anti-idiotype antibody is injected intracutaneously into these animals that they develop an anti-anti-idiotype antibody that is like anti-GD2 and mimics the original anti-GD2 (14G2a).
A pair of male and female cynomolgus monkeys were immunized with 2 mg of 1A7 (intact IgG1) mixed with 100 μg QS-21 (Cambridge Biotech), 3 to 4 times. Sera obtained from monkeys 2 weeks after 3rd and 4th immunizations were analyzed.
Anti-anti-Id(Ab3) antibody from monkey sera was purified first by adsorption and then elution from affinity column 1A7-sepharose 4B and then by passing through a negative affinity column of mouse IgG-sepharose 4B. The flow through material has been used as "purified" Ab3 and compared with the reactivity of Ab1 (14G2a) in different assays. 2.6 mg of purified Ab3 was recovered from 10 ml of sera (i.e. about 260 micrograms Ab3 per ml of serum) from monkey #PRO 685 and #PRO 778.
This anti-idiotype antibody can be used to treat patients with malignant melanoma and small cell lung cancer to generate an active immunity to the GD2 antigen which is highly expressed on their tumor cells. These patients are not capable in vivo of generating the active immunity to GD2, but by using the anti-idiotype as a surrogate antigen, they are able to overcome tolerance to this antigen and generate an active immunity to GD2 antigen.
These new anti-idiotype antibodies represent a new immunotherapeutic approach to cancer. The antibodies may be used for the treatment and therapy of metastatic melanoma and small cell lung cancer. The antibodies may also be used as a prevention for recurrent disease in patients who have had disease removed by surgery, radiation or chemotherapy and who remain at high risk for recurrence.
Production of Ab2 (1A7)
The murine mAb 14G2a is an anti-GD2 antibody that mediates antibody-dependent cytotoxicity and complement mediated lysis of neuroblastoma and melanoma cell lines in vitro. Murine monoclonal antibody 14G2a (Ab1) was used to immunize syngeneic BALB/c mice for the production of anti-idiotype antibody (Ab2). Six to eight weeks old female BALB/c mice were immunized four times over a period of two months. The first injection was given i.p. and other injections i.p. and s.c., respectively. Mice were bled from time to time and sera were checked for anti-idiotype activity by radioimmuno assay using 14G2a and MC10 (iso-allotype match control antibody) as plate coats. Three days before the fusion, mice were boosted intravenously with 14G2a in PBS.
Fusion
Fusion was done essentially following the method of Oi and Herzenberg, by using HAT sensitive mouse myeloma cell line P3-653 as a fusion partner and 50% PEG. The hybrids were selected by using HAT media. After screening for positive wells, the cells were cloned twice by limited dilution.
Selection of anti-Idiotype antibody (Ab2)
Initial screening of the hybridoma was done by sandwich RIA using 14G2a and MC10 at a concentration of 500 ng per well as plate coats. After overnight incubation at 4° C., the plates were non-specifically blocked with 1% BSA in PBS for 1.5 hrs. Thereafter, 100 μl of undiluted hybridoma culture supernatant were incubated for 2 hrs. at room temp. After washing with PBS, the plates were incubated with 125 I-labeled 14G2a for 1.5 hrs. at room temp. with shaking.
Radioimmuno assay (RIA)
Additional characterization of Ab2 was done by RIA. For the direct binding assay between Ab1 and Ab2, purified Ab1 was used to coat plate (500 ng/well) and the binding of radiolabeled Ab2 to Ab1 was tested in the presence of different Ab1, Ab2 or several control mouse myeloma proteins.
Anti-Idiotype assay
To determine whether Ab2 recognizes the paratope of Ab1, the following inhibition assays were done. Target tumor cells (M21/P6) which contain GD2 antigen as a cell surface constituent, were grown as confluent monolayer in 96-well tissue culture plates. The binding of radiolabeled Abl to cultured cells was tested for inhibition in the presence of different Ab2 culture supernatant and also purified Ab2 preparation.
Inhibition assay
Percent inhibition of the assay was calculated according to the formula: ##EQU1## in which R t is the average cpm of the experimental well with inhibitors, R C is the average background cpm and R MAX is the average maximum binding without any inhibitors.
Purification of Ab2
To get enough purified Ab2, ascites of Ab2 (1A7) hybridomas was prepared by injecting individual pristane primed BALB/c mice intraperitoneally with 2×10 6 to 1×10 7 viable hybrid cells. The IgG1 fraction was isolated from ascites by chromatography on a Protein A-Sepharose CL 4B column. The purity of the isolated IgG1 was checked by SDS-PAGE.
Induction of anti-anti-idiotype antibodies (Ab3) by anti-Idiotype monoclonal antibody 1A7:
Immunization of mice
Eight weeks old BALB/c mice (5 in each group) were immunized with 100 μg of 1A7 coupled with KLH using glutaraldehyde to increase the immunogenicity in the syngeneic mice. A total of 100 μg of Ab2 -KLH were injected i.p. with Freund's complete adjuvant. Two weeks later the mice were injected i.p. and s.c. with the same antigen dose mixed with incomplete Freund's adjuvant. After 2 weeks rest, animals were boosted similarly at biweekly intervals. For serum antibody measurement, mice were bled every 8-10 days after the last injection. The sera were assayed for anti-1A7 activity by sandwich radioimmuno assay, using 500 ng of 1A7 per well as plate coat and anti-GD2 activity by ELISA and FACS analysis.
Immunization of rabbits
Adult New Zealand white rabbits were injected s.c. with 500 μg of purified Ab2-coupled to KLH, mixed with complete Freund's adjuvant at day 0. Rabbits were boosted at biweekly intervals with 500 μg of KLH coupled Ab2 mixed with incomplete Freund's adjuvant. Rabbits were bled 7 days after the last injection and the sera were checked for anti-Ab2 activity as well as anti GD2 activity.
Immunization of monkeys
Cynomolgus monkeys (two per group, 2-4 kg weight) received four intramascular injections of purified Ab2 (2 mg) mixed with 100 μg of QS 21 as adjuvant. Control monkeys were immunized with unrelated Ab2, 11D10 mixed with QS 21 in the similar way. All injections were given at 2-week intervals. Monkeys were bled 10 days after each immunization.
Purification of Ab3
Ab3 from immunized monkey sera was purified using 1A7-Sepharose 4B as chromatography column. Bound protein to the column was eluted by glycine-HCl, pH 2.7 and dialyzed against PBS. The dialyzed protein was then passed through a mouse Ig coupled to Sepharose 4B column until it was completely depleted of anti-isotypic and anti-allotypic antibodies to murine Ig.
Characterization of Ab3 Sandwich Assay
To check whether Ab3 can bind to Ab2, sandwich assay was done. Briefly, 250 ng of Ab2 was coated in 96-well plates. After non-specific blocking with 1% BSA in PBS, 50 μl of different concentration of purified Ab3 from two monkeys sera was added and incubated for 2 hrs. at room temperature. After washing 125 I-labeled Ab2 was added and incubated for 1.5 hrs. After washing, bound radioactivity was measured.
Cell binding inhibition assay
To determine whether Ab3 competes with Ab1 for binding to i) human melanoma cell line M21/P6 or to ii) Ab2, the binding of radiolabeled 14G2a to M21/P6 cells or to Ab2 was tested for inhibition in the presence of different dilutions of Ab3 and Abl preparations. Percent inhibition of the assays were calculated according to the formula described above.
ELISA
To measure anti-GD2 reactivity in the serum of immunized mice, rabbit and monkeys, purified GD2 (250 ng/well) was adsorbed to 96-well plates. After blocking wells with 1% BSA in PBS, test serum and Abl were diluted in same buffer and added to wells and incubated overnight at room temp. After washing, the bound antibodies were detected using alkaline phosphatase labeled anti-mouse, anti-rabbit or anti-human Ig reagents as second antibodies.
In another experiment, different purified gangliosides (250 ng/well) were coated in 96-well plates. After blocking, 50 μl of different dilutions of monkey Ab3 and Ab1 were added to wells and incubated for 4 hrs. at room temp. Plates were washed and bound antibodies were detected using alkaline phosphatase-conjugated anti human Ig as second antibodies.
Dot Blot
Reactivity of immunized sera and purified Ab3 for anti-GD2 antibodies against various gangliosides was also measured by immunoblotting. Purified gangliosides (2 μg each of GM3, GM2, GM1, GD3, GD2 and GT1b) were spotted on strips of PVDF cellulose membrane at 1 cm intervals. After blocking with 3% BSA in PBS, the strips were incubated with purified Ab3 or Ab1 (10 μg ml) overnight at room temp. After washing, the strips were incubated with alkaline phosphatase conjugated second antibody (1:1000 dilution) for 2 hrs. at room temp. The strips were washed and developed with NBT and BCIP reagents (Bio Rad).
Binding of Ab3 to M21/P6 cells was also independently analyzed by flow cytometry. Target cells M21/P6 or control cells MOLT-4 (5×10 5 in PBS supplemented with 0.2% BSA) were incubated with different dilutions of Ab3 and Ab1 for 2 hrs. with gentle shaking at 4° C. After washing with PBS, the staining was done with FITC labeled second antibody and analyzed on a FACScan flow cytometer.
DETAILED DESCRIPTION OF THE FIGURES
FIG. 1 shows a Sandwich assay: 250 ng of 1A7 (Ab2) was coated in 96-well plate. After blocking, 50 μl of different concentration of PRO #685 or PRO #778 (Ab3) was added and incubated 2 h at room temp with shaking. After washing, 90000 cpm of radiolabeled 1A7 was added to each well and incubated 1.5 h at room temp. The plate was washed and bound radioactivity was measured.
FIG. 2 shows an inhibition assay: 500 ng of 1A7 (Ab2) or 14G2a (Ab1) was coated in 96-well plate. After blocking, 50 μl of different concentrations of PRO #685 (Ab3) along with 50 μl of radiolabeled 14G2a or 1A7 (90000 cpm) were added to each well. After 1.5 h incubation, plates were washed and bound radioactivity was counted.
FIG. 3 shows a cell binding inhibition assay: 2×10 6 M21/P6 cells were incubated with different concentration of PRO #685, PRO #778 Ab3 and 14G2a in presence of 90000 cpm of radiolabeled 14G2a for 2 hr with shaking. After washing, radioactivity bound to the cell pellet was counted.
In FIG. 3A, 250 ng of GD2 was coated per well in 96 well plate. Different concentrations of Ab3 and Abl along with 90,000 cpm of ( 125 I-labeled) 14G2a were added. Incubated 2 hrs at room temperature with shaking, washed and counted. Percent inhibition was calculated and plotted against concentration of Ab1 and Ab3 used.
FIG. 4 shows an ELISA assay: 250 ng of different gangliosides were coated in 96-well plate. After blocking, 50 μl of different concentration of PRO #685 (Ab3) and 14G2a (Ab1) were added and incubated 4 h at room temp. Bound antibody was detected using alkaline phosphatase conjugated second antibody.
FIG. 5 shows a Dot Blot assay. 2 μg of different gangliosides were coated on PVDF cellulose membrane strips and after blocking strips were incubated with either PRO #685 (Ab3) or PRO #778 (Ab3) or 14G2a (Ab1) or an unrelated monkey Ab3 which was raised against an unrelated Ab2, 11D10 and PBS-BSA control, each antibody used as 10 μg/ml, 5 ml of total solution. The incubation was done for 4 hrs at room temp. with shaking. After washing, the strips were incubated with alkaline-phosphatase labeled 2nd antibody (1:1000 dil) for 2 hrs. at r.t., washed and developed.
Pharmaceutical Formulation
Further, the 1A7 monoclonal antibody of the present invention is useful in pharmaceutical compositions for systemic administration to humans and animals in unit dosage forms, sterile parenteral solutions or suspensions, sterile non-parenteral solutions or suspensions oral solutions or suspensions, oil in water or water in oil emulsions and the like, containing suitable quantities of an active ingredient. Formulations for parenteral and nonparenteral drug delivery are known in the art as set forth in Remington's Pharmaceutical Sciences, 18th Ed., Mack Publishing (1989) incorporated herein by reference in its entirety.
The compounds are useful in pharmaceutical compositions (wt %) of the active ingredient with a carrier or vehicle in the composition in about 1 to 20% and preferably about 5 to 15%.
The above 1A7 monoclonal antibody can be present alone or in combination form with pharmaceutical carriers. The pharmaceutical carriers acceptable for the purpose of this invention are the art known carriers that do not adversely affect the drug, the host, or the material comprising the drug delivery device. Suitable pharmaceutical carriers include sterile water; saline, dextrose; dextrose in water or saline; and the like.
The effective dosage for mammals may vary due to such factors as age, weight, activity level or condition of the subject being treated. Typically, an effective dosage of a compound according to the present invention is about 2mg per injection in humans. A preferred dosage is 100 μg of Ab2-KLH (KLH=keyhole limpet hemocyanin) when injected i.p. with Freund's complete adjuvant in small animals. A more preferred dosage range is 0.001 mg to 10 mg of 1A7 (intact IgG1) mixed with QS-21 (Cambridge Biotech) in monkeys.
Probe
The 1A7 anti-idiotype monoclonal antibody according to invention may be labeled and used as a probe for the detection of melanoma or small cell carcinoma. The probes may be incorporated into a diagnostic test kit including a detectable label or marker for the probe.
Diagnostic Kit
The diagnostic kit may further comprise, where necessary, other components of the signal-producing system, including agents for reducing background interference, control reagents or an apparatus or container for conducting the test.
Examples of imaging reagents that can be used include, but are not limited to, radiolabels such as 131I, 111In, 123I, 99mTc, 32P, 125I, 3H, and 14C, fluorescent labels such as fluorescein and rhodamine, and chemiluminescers, such as luciferin. Other labels known to those of skill in the art are set forth in U.S. Pat. No. 4,366,241 and are incorporated herein by reference. The monoclonal antibody can be labeled with such reagents using techniques known in the art. For example, see Wensel and Meares, Radioimmunoimaging and Radioimmunotherapy, Esevier, New York (1983), for techniques relating to the radiolabeling of proteins. (See also, Sambrook, M. J., Fritsch, E. F. & Maniatis, T. (1989) Molecular Cloning: A Laboratory Manual (Cold Spring Harbor Lab., Cold Spring Harbor, N.Y., section 10, incorporated herein by reference in its entirety).
The purpose of the above description and examples is to illustrate some embodiments of the present invention without implying any limitation. It will be apparent to those of skill in the art that various modifications and variations may be made to the composition and method of the present invention without departing from the spirit or scope of the invention. All patents and publications cited herein are incorporated by reference in their entireties.
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The present invention relates isolation of anti-idiotypic antibody 1A7 raised against anti-GD2 mAb 14G2a and its use for the treatment of melanoma and small cell carcinoma. The antibody may be used as a substitute for isolated purified GD2 antigen in any appropriate application.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention is related to load management and control for power utilities and, more particularly, is directed to a method and apparatus for permitting an electric utility to selectively control distribution of its power to a plurality of customer loads.
2. Description Of The Prior Art
Most electrical power utilities in the United States must construct their power generating plants with sufficient capacity to meet the total customer power demand at any given point in time. This means that although maximum or peak power demands may occur only relatively infrequently, when compared with the average power demand, the utility must nevertheless have the power generating capacity to meet the peak demand. Many utilities therefore either pay for or charge their customers in accordance with peak power demands rather than average or actual power consumed. If the peak power demand periods can therefore be minimized or controlled, savings to the customer and utility will be effected.
The foregoing situation has lead to the development of load management systems for use by electric power utilities which permit them to control peak demands on the power generating equipment by turning off and on various customer loads during various times. Various types of customer loads which can be regulated in this manner to control and minimize peak power demand include, for example, electric hot water heaters, air conditioning compressors, electric space heaters, and the like.
One type of load management control technique is known as the ripple tone injection method. In such a system, audio frequency pulses are coded by control function and are impressed directly onto the utility's power lines. Receivers located at the customer loads respond to the coded pulses to effect the desired command function.
It is known to provide electromechanical ripple control transmitters, consisting of a motor/alternator set operating through thyristor static switches, to apply the pulse coding to the power lines. It has also recently been proposed to utilize static frequency converters, consisting of a static inverter and suitable coupling network, for a ripple control transmitter. See, for example, "Pulse Coded Inverter For Utility Load Management System", Galloway and Berman, IAS 1977 Annual, pages 149 through 155.
Known U.S. Pat. Nos. which relate to power load management include: 3,359,551; 3,886,332; 3,972,470; 4,064,485; 4,075,699; and 4,130,874.
In U.S. Pat. No. 3,359,551, for example, a system is disclosed for controlling the operation of a power distribution network in which signals are transmitted over power lines to a plurality of receivers which perform electrical circuit connections and disconnections in response to the received signals. In this system, the signals contain address and command information so that one of a plurality of receivers are selected in response to the address portion and a predetermined function is performed in response to the command portion. The transmitter at a selected location employs derivatives of these signals to produce predetermined sequences of relatively high frequency carrier bursts to be fed to the power lines for distribution to tuned receivers at the other end of the line.
In U.S. Pat. No. 4,075,699, a power monitoring and load shedding system is described which includes power consumption metering for entering overall power consumption into a central processing unit. Circuitry is provided for the central processing unit to turn local and remote loads on and off in accordance with stored energy consumption projecting and load shedding algorithms.
While each of the prior art systems appear useful in a given context, a practical, centralized load management control system for electric utilities must be cost effective in order that the savings resulting from load management outweighs the cost to the utility and the consumer of the load management system. It is toward achieving this broad objective that the present invention is advanced.
OBJECTS OF THE INVENTION
It is therefore a primary object of the present invention to provide a load management system for electric power utilities which is cost effective, reliable, easy to operate and maintain, and is modular in construction so as to be adaptable for controlling a wide range of customer loads.
Another object of the present invention is to provide a method and apparatus for permitting an electric power utility to directly or indirectly control customer loads, either automatically or manually, in accordance with pre-established control commands which may be varied or updated as the utility deems necessary.
A further object of the present invention is to provide a load management system for electric power utilities which utilizes a central control that provides an emergency load shedding control capability that allows the utility to maintain essential customer loads while dropping less essential loads for brief time periods to maintain system integrity.
A further object of the present invention is to provide an electric power utility with the capability of load management at minimum cost by utilizing proven components combined in a novel manner to provide the central operator of the system with updated status and alarm information concerning any of the substation units in order that corrective action can be taken.
A still further object of the present invention is to provide a load management system for electric power utilities which utilizes standard telephone line data links between the master station and the substation units, and the power distribution lines as a communication link between the substation units and the load-controlling receivers.
An additional object of the present invention is to provide a load management system for electric power utilities which permits system parameters to be fed back to the master control station from the substations to provide instantaneous updating of operating parameters which can be taken into account in load management decisions.
A still further object of the present invention is to provide a method of managing customer loads which incorporates reliability checks and communications integrity to insure proper operation.
SUMMARY OF THE INVENTION
The foregoing and other objects of the invention are attained in accordance with one aspect of the present invention through the provision of a system for permitting an electric power utility to control the distribution of its power along its power lines from a substation to a plurality of customer loads, which comprises a master control station including first programmable digital data processor means and input/output devices under the control of an operator for generating master control signals, at least one substation injection unit located at the substation and in communication with the master control station and operating under the control of second programmable digital data processor means for injecting in response to certain of the master control signals pulse code signals onto the power lines, and a plurality of remote receiver units each connected to a particular load device and to the power lines for receiving the pulse code signals, each of the remote receiver units responsive to one of the pulse code signals for connecting or disconnecting its load from the power lines.
The substation injection unit more particularly comprises means for converting the frequency of a standard three-phase power line voltage signal generated at the substation to a preselected frequency desired for the pulse code signals, means responsive to the second data processor means for controlling the output of the frequency converting means to generate said pulse code signals, and means for injecting the pulse code signals onto the power lines for transmission to the remote receiver units.
In accordance with more specific aspects of the present invention, the frequency converting means comprises three-phase rectifier means including a plurality of conduction controlled solid state devices under the control of the second data processor means for receiving the three-phase power line voltage signal and for developing a DC voltage signal of a predetermined level, and three-phase inverter means including a plurality of conduction controlled solid state devices also under the control of the second data processor means for receiving the DC voltage signal from the rectifier means and for converting same to the pulse code signal at the preselected frequency. The second data processor means includes means for controlling communications between the master control station and the substation injection unit.
In accordance with other aspects of the present invention, the injecting means comprises transformer means whose primary is connected to receive said pulse code signals for transforming the relatively low voltage and current thereof to a higher voltage for injection onto the power lines, and tuned circuit means connected to the secondary of the transformer means and tuned to the preselected frequency for passing the pulse code signals to the power output bus of the substation. The system further includes input power contactor means connected in series with the rectifier means for connecting and disconnecting same to the three-phase power line voltage signal, output power contactor means connected in series with the inverter means for connecting and disconnecting same to the power lines, and power breaker means connected in series with the input and output power contactor means and including a shunt trip circuit responsive to fault conditions for tripping the power breaker means and opening the input and output power contactor means. The system further includes means for sensing the fault conditions, including means for sensing overtemperature of the solid state devices in the inverter means, means for sensing excessive shift of the neutral line of the power lines, means for sensing overcurrent in the output of the rectifier means, and means for sensing short circuits across the DC bus of the inverter means.
In accordance with another aspect of the present invention, the substation injection unit further comprises means connected to the power lines for detecting each pulse in the pulse code signals, and means in the second data processor means for determining whether the outputs of the pulse detecting means consist of a properly shaped and timed pulse. The substation injection unit may further include analog input means for connecting one or more analog inputs at the substation indicative of one or more system parameters for transmission to the master control station, and discrete input means for connecting one or more discrete inputs at the substation indicative of one or more system parameters for transmission to the master control station.
The means for controlling the output of the frequency converting means more particularly comprises means for controlling the firing time of the solid state devices in the three-phase rectifier means to select one of a plurality of output voltage levels as the predetermined level, and means for controlling the firing time and sequence of the solid state devices in the three-phase inverter means to establish an idle mode and an inject mode for the inverter means, the idle mode corresponding to the absence of a pulse in the pulse code signals, while the inject mode corresponds to the presence of a pulse in the pulse code signal at the preselected frequency.
The means for controlling the firing time of the solid state devices in the three-phase rectifier means includes means for receiving the three-phase voltage waveforms from the power line, means for determining when each of the voltage waveforms is greater than the other two waveforms and for providing output signals thereupon, and means responsive to said output signals of said determining means for turning on and off the gates of the solid state devices in the rectifier means. Also provided are means connected to the second data processor means for receiving an indication of the desired output voltage level of the rectifier means, and time delay means connected to the determining means and the voltage level receiving means for delaying the output of the determining means for a period of time in accordance with the desired output voltage level.
The means for controlling the firing time and sequence of the solid state devices in the three-phase inverter means comprises first means responsive to a mode select address signal from the second data processor means for selecting either the idle mode or the inject mode, second means responsive to the first means for generating register output timing signals, and register means responsive to the first and second means for providing gate signals in a predetermined order to the solid state devices in the three-phase rectifier means.
The master control station preferably includes means for polling each of the substation injection units to obtain information pertaining to its status, possible alarm conditions, and analog or discrete data generated at the respective substation, means for transmitting and receiving serial binary block messages to and from each of the substation injection units, the block messages including substation injection unit address data, substation injection unit function commands and the data signals, and means for prioritizing and executing group control commands to be sent to the substation injection units.
In accordance with another aspect of the present invention, there is provided a method for permitting an electric power utility to regulate a plurality of customer loads which comprises the steps of arranging the customer loads into individually controllable load control groups, establishing first, second and third types of control lists, each of the lists including at least one group control command for causing one of the load control groups to be turned on or off, actuating the first type of control list upon command to execute its group commands once, actuating the second type of control list upon command to execute its group control commands cyclically and repetitively, and actuating the third type of control list upon command to execute its group control commands cyclically and repetitively while taking into account the power demand on the utility. The method includes the step of dynamically adjusting the on and off times of the loads in those of said control groups belonging to the third type of control list by monitoring the utility's system power demand and lengthening the off times of the loads in those of the control groups in the third type of control list as the power demand increases. As an alternative to real time monitoring of the system demand, a load profile table may established which is indicative of the anticipated total power demand at predetermined intervals of time, the on and off times of the loads in those of the control groups belonging to the third type of control list being adjusted by comparing the actual time with the load profile table. The method also contemplates the steps of periodically scanning each of the control lists to determine whether it should be activated or deactivated, periodically checking each of the group control commands in those of the lists that are activated to determine whether the command should be carried out, and generating data signals for those of the activated group commands when it is time to carry out the command.
In accordance with yet another aspect of the present invention, there is provided, in a system for controlling power distribution from a plurality of utility substations to a plurality of loads wherein a master control station under the control of an operator is in two-way communication with a plurality of microprocessor controlled substation injection units located respectively at the plurality of substations, a method of injecting a pulse code signal representing the desired control command onto the utility's power lines for transmission to receivers located at the loads comprising the steps of transmitting a first binary injection message representing a desired control command from the master control station to each of the plurality of substation injection units in turn, transmitting a second binary injection message representing the desired control command received in the previous step from each of the substation injection units in turn to the master control station, vertifying at the master control station that the second binary message is the same as the first binary message, transmitting a binary commence keying command signal from the master control station to all of the substation injection units simultaneously, generating a pulse code signal representing the first binary injection message at each of the substation injection units previously verified, and injecting the pulse code signals onto the utility's power lines for transmission to a plurality of coded receiver units remotely located at the loads to effect the desired control command. The method further contemplates the steps of positioning a special receiver unit in each of the substation injection units for receiving, on a pulse-by-pulse basis, the pulse code signal injected on the power lines, storing the outputs of each of the receiver units in its respective substation injection unit until the full pulse code signal has been injected, and transmitting the stored outputs from each substation injection unit to the master control station in turn to verify that the desired control command has been effected.
BRIEF DESCRIPTION OF THE DRAWINGS
Various objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood with reference to the following detailed description of the present invention when considered in connection with the accompanying drawings, in which:
FIG. 1 is an overall block diagram of a preferred embodiment of the system of the present invention;
FIG. 2 illustrates the communication message format from the master control station to a substation injection unit;
FIG. 3 illustrates the communication message format from a substation injection unit to the master control station;
FIG. 4 is a block diagram illustrating a preferred embodiment of a remote receiver unit;
FIG. 5 illustrates the format of the pulse code signals injected by the substation injection unit for transmission to the remote receiver units;
FIG. 6 is an overall block diagram of a preferred embodiment of a substation injection unit;
FIG. 7 is a block diagram illustrating certain components of a status and input/output board in the substation injection unit;
FIG. 8 is another block diagram illustrating the components of a pulse accumulator positioned in the substation injection unit;
FIG. 9 is a block diagram of a rectifier controller of the substation injection unit;
FIG. 10 is a block diagram of an inverter controller of the substation injection unit;
FIG. 11 is a block diagram illustrating the software components of the master control station;
FIG. 12a+b is a flow chart of the programs utilized in the master control station;
FIG. 13a-d is a flow chart of the programs utilized in the substation injection unit microprocessor; and
FIG. 14 is a graph which illustrates a typical load profile table utilized in the master control station.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Table of Contents
I. General System Description
A. Master Control Station (MCS)
B. Substation Injection Unit (SIU)
C. Communications Between MSC And SIU
D. Remote Receiver Unit (RRU)
II. Load Management Strategy
III. MCS Software
IV. Substation Injection Unit
A. Overall Block Diagram
B. Rectifier Controller
C. Inverter Controller
D. SIU Software
I. General System Description
Referring first to FIG. 1, there is illustrated a block diagram of a preferred embodiment of the load control system of the present invention. A master control station MSC is in two-way communication with a plurality of substation injection units SIU over voice grade telephone lines. Any of a number of substation injection units SIU may be employed, one at each substation of the utility, depending upon the number of loads and areas desired to be controlled. Sixteen such substation injection units SIU are illustrated by way of example.
Each of the substation injection units SIU is, in turn, connected through the power lines of the electric company to a plurality of remote receiver units RRU (up to 200,000 in the example) which, in turn, are each connected to control the on and off times of a controlled device CD which may comprise, for example, an electric hot water heater, air conditioning compressor, or the like.
A. Master Control Station (MCS)
The master control station MCS preferably comprises a microprocessor-based computer terminal, such as the Hewlett-Packard Model 9835A which, together with special internal programming and desired input/output devices, serves as an operator interface and as the originator/coordinator of all control instructions to the substation injection units SIU and the remote receiver units RRU. The master control station MCS may generate hard copy reports, archival records, activity files of control actions, operator interchanges, and may display system alarm information. The operator of the master control station MCS may interrogate the system files, adjust automatic control schedules and perform manual control action, in a manner to be described in greater detail hereinafter.
Communication between the master control stations MCS and each substation injection unit SIU is over voice grade telephone lines utilizing standard baud rate asynchronous FSK modems. This requires a modem connected at the output of the MCS and at each input to an SIU. The message packets between the master control station MCS and each substation injection unit SIU are fixed length strings of binary characters to be described in greater detail hereinafter.
B. Substation Injection Unit (SIU)
Each substation injection unit SIU consists broadly of three sections: a controller C, a frequency changer FC and an injection network IN. The controller C converts command and control messages from the master control station MCS into command signals for firing the solid state conduction controlled rectifying devices for the rectifier and inverter of the frequency changer FC. The controller C also responds to requests from the master control station MCS for alarm, status and data information. A special receiver is positioned in the substation injection unit SIU which is monitored by the controller C to provide information pertaining to the power line injection signal, amplitude and pulse position. The monitored information is sent to the master control station MCS on request in order to permit vertification of the accuracy of the pulse code pattern transmitted by the substation injection unit SIU.
The frequency changer FC of the substation injection unit SIU comprises a 60 Hertz-to-injection frequency converter which rectifies the incoming power line's three-phase 60 Hertz signal to form a DC voltage of a controllable magnitude, which is then fed to a static inverter that is turned on and off under direction of the controller C to form the pulse code signal which becomes the pulse code injection message that is transmitted to the remote receiver unit RRU on the power lines of the utility.
The injection network IN comprises a set of passive circuit elements that provides a basic insulation level and a low impedance path from the frequency changer FC to the power line for the pulse code injection message while at the same time providing a high impedance path to block the 60 Hertz power line energy.
C. Communications Between MCS and SIU
Referring now to FIG. 2, there is illustrated the preferred message format for communications from the master control station MCS to a substation injection unit SIU. The block of data consists of nine characters of eight bits each. The first character is a frame sync character which preferrable comprises an ASCII start of text character. Following frame sync is an eight bit character which defines a particular substation injection unit SIU. The next character defines the particular function that the master control station MCS wishes the substation injection unit SIU to perform, in accordance with Table 1 below:
TABLE 1______________________________________MCS/SIU MESSAGE INTERCHANGENo. Type Command To SIU SIU Response______________________________________1. B Set New Injection Injection Code Code Received2. A Commence SIU Keying- None All SIUs3. B Clear Command Register Status and Command SIU #N Registers4. B Report Status and Status and Command Command Registers Registers5. B Report Last Injection Last Injection Code Code Sent6. B Report Status and Data Status and Data for for Measurement Point Measurement Point7. C Execute-SIU #N Status and Command Registers8. B Set Injection Power Injection Power Level Level Received______________________________________
Following the SIU function block are five eight bit data characters for defining, for example, the forty bit pulse code desired to be injected onto the power lines. At the end of the message block is a frame sync character which preferably comprises an ASCII end of text character.
Transmission of the blocks of characters illustrated in FIG. 2 from the master control station MCS onto the telephone lines are received by all substation injection units concurrently. While most transmissions are addressed to only one SIU, some may be addressed to all SIUs. Only an addressed SIU will respond to a command from the MCS. The format of the communication transmissions from the SIU to the MCS illustrated in FIG. 3 and is seen to essentially correspond with the MCS to SIU communication format illustrated in FIG. 2. In FIG. 3, each transmission from an SIU to the MCS is preceded by a line settle period of approximately 200 milliseconds, while there is a 50 millisecond delay between the end of each SIU transmission and the start of the next MCS command transmission. Each of the characters illustrated in FIGS. 2 and 3 have a start, stop and optional parity bit. The overall message consists of a frame sync character, an SIU address character read from an internal constants register (rather than being a reflection of the in-bound station address from the MCS), an SIU function character, and five data characters followed by an end of text character as the frame sync. The carrier on and off intevals correspond to the times that the modem carrier of the SIU is turned on and off.
Table 1 above illustrates exemplary SIU function commands forwarded from the master control station MCS to the substation injection units SIU. These messages are encoded in the "SIU FUNCTION" block of FIG. 2. There are three general types of messages exchanged between the master control station MCS and the substation injection units SIU. Type A messages are recognized by all substation injection units. There are no SIU responses to the MCS for Type A messages since the SIUs are tied to a common party line and their responses would be mutually interfering. Type B messages are directed to a single SIU. Although the outbound message from the master control station MCS is monitored and passed through the initial stages of processing and decoding by all SIUs, only the single SIU that has a station address match with a station address code contained in the incoming message will continue the processing. Further, for Type B messages, the MCS receives a response from the addressed substation injection unit SIU. Type C messages consist of an order execution command directed to one substation injection unit SIU. This message enables execution of whatever command has been previously established in a software implemented command register in the addressed substation injection unit SIU. In other words, the contents of the command register in the addressed substation injection unit SIU has been previously established by a Type A or Type B message.
The message interchange between the master control station MCS and the substation injection unit SIU is based upon a setup-verify-execute sequence of commands. Message Nos. 1, 3 and 8 in Table 1 are setup commands. The substation injection unit SIU will store the received setup command in an internal software implemented command register. It will also set an internal command pending flag which will remain set for approximately 20 seconds. The substation injection unit SIU will respond to the setup command by sending back to the MCS the contents of its command register which will be a replica of the actual message received. The MCS will compare the SIU response to the original message sent to insure that the SIU is setup correctly. If it is not, there will be three more attempts to set up the SIU correctly. If these attempts fail, the addressed SIU will be marked off-line and designated as "removed from service". If the addressed SIU was set up correctly, the MCS will go to the next SIU and try to set it up, as may be required.
After all of the desired SIU's have been set up and verified, the MCS will send one of the execute commands which consist of Message Nos. 2 or 7 in Table 1. If the execute command is received by the SIU's while the command pending flag is set, the command that was setup will be implemented. If the command pending flag is not set when the execute command is received, the SIU will ignore it and do nothing. Such a condition will be detected by the master control station MCS when it examines the SIU status during routine polling.
Message Nos. 4, 5 and 6 request the status of a particular substation injection unit SIU. Not being setup commands, Message Nos. 4, 5 and 6 do not require an execute command before the addressed SIU will respond. That is, the MCS will request the status and the addressed SIU will respond with the desired status information. Message Nos. 4, 5 and 6 are transmitted twice, and after each transmission, the addressed SIU responds. This enhances system security and insures that the master control station MCS has the correct status information. Following is a discussion of each of the message numbers in Table 1.
Message No. 1 is a command to one substation injection unit SIU to load its software implemented injection register with a specific 40 pulse code signal to be injected under local SIU timing control commencing with the reception of Message No. 2. The SIU response to Message No. 1 is the actual injection code that the SIU received which will be compared in the MCS to the injection code that was sent to insure that the set up message was correctly received by the addressed SIU. Each SIU will be set up in turn until all on-line SIUs have been loaded with the injection code and verified. The MCS will then send Message No. 2 which will initiate the transmission of the 40 pulse code injection message. The controller in the SIU will respond to the 40 pulse code injection message to control the on and off timing of each individual pulse.
Message No. 3 is a command to clear the command register in a particular SIU. The SIU will respond with its status and the contents of its command register. The MCS will check the response to insure that the command was correctly received at the SIU. If it was, the MCS will send Message No. 7 to clear the command register in the addressed SIU. This command will be used on a selective basis to cancel a pending control order.
Message No. 4 is a command to a particular SIU to report its status and the contents of its command register. The SIU response is a message containing the status information read from the SIU status register and the contents of the SIU command register. The status report includes several on/off type of conditions or presence/absence type of conditions that are then interpreted by the MCS as alarm or status information. Items of this nature include overtemperature of the rectifier, overtemperature of the inverter, overtemperature of the cabinet interior, inlet voltage out of range, and the like.
Message No. 5 is a command to a specific SIU to report the last 40 pulse code pattern that was injected by the addressed SIU. The latter responds with a binary encoded translation of the 40 pulse code pattern read from a special injection monitor receiver connected within the SIU.
Message No. 6 is a command to a specific SIU to report its status and the current value for an analog measurement point. There may be one or a plurality of such analog measurement points located within the SIU, which will be described in greater detail hereinafter. In response to this command, the addressed SIU will read the measurement point, digitize its value, and send the representation back to the MCS.
Message No. 7 is an execute command which directs an SIU to execute a previously stored command, other than pulse code injection messages which are executed by Message No. 2. Message No. 7 is an execute command address to only one SIU, and the response is a report by the addressed SIU of its status and the contents of its command register.
Message No. 8 is a command to a selected SIU to set a new injection power level. The response to this command is the status and contents of the command register for the addressed SIU. The response will be compared to the original message that was sent to insure that the SIU is set up correctly. If it is, Message No. 7 will be sent to implement the new injection power level. Message No. 8 is used to dynamically adjust the injection power level for the best overall system performance and will be set based upon, among other things, the number of SIUs that are on-line versus the number of SIUs that are on the system.
D. Remote Receiver Unit
Illustrated in FIG. 5 is a preferred format for the pulse code signal transmitted by the substation injection units SIU to the remote receiver units RRU. The control messages are encoded into start, preselect, and execute pulses. The timing of each preselect and execute pulse with respect to the start pulse is precisely controlled. The preferred code includes 41 pulses: the start pulse, which is command to all control messages, numbered 0; seven preselect pulses numbered 5, 10, 15, 20, 25, 30 and 35; and 28 execute pulses numbered 6 through 9, 11 through 14, 16 through 19, 21 through 24, 26 through 29, 31 through 34, and 36 through 39. Every control message consists of a start pulse followed by a preselect pulse, followed by an execute pulse. The total preselect-execute pulse combinations in the preferred embodiment is 112, which allows 112 independent control functions, or 56 simultaneous control functions with one control message transmission. As may be appreciated from FIG. 5, the start pulse is a sync pulse of approximately 0.833 second duration followed by a 2.29 seconds rest period. Although one pulse string may contain several interleaved control commands, in typical applications only a few pulses will be active in any one pulse string. Since the start pulse activates all remote receiver units RRU, each pulse code message or string is separated by an inactive period of approximately 94 seconds to allow any falsely started RRUs to run to their reset position.
FIG. 4 illustrates a block diagram of a preferred embodiment of a remote receiver unit RRU which may comprise, for example, a Sangamo Weston Model 100 receiver. From the power line, the pulse code signal is first received by a frequency selector element 11 that discriminates between a valid control signal and all other parasitic frequencies which may exist on the power lines. Valid frequency signals are passed by frequency selector 11 to a decoder/selector 13 which discriminates between all of the pulses in a particular pulse code so that the particular remote receiver unit RRU acts only on the pulses that the receiver has been coded to recognize. When a proper pulse code signal is decoded by decoder/signal 13, the latter controls a contact block 15 which comprises a set of controlled output contacts for switched loads 17 and 19 which are capable of being activated simultaneously or independently. Both contacts in contact block 15 are preferably single pole, and the operating mechanism allows for positive latching so that different control messages are required to change the contact state from "ON" to "OFF", and vice versa. The absence of a control message or a power failure will not change the state of a latched contact.
In a preferred embodiment, the decoder/selector 13 comprises an electromechanical timing chain which monitors the presence or absence of a pulse in each of the 40 possible positions. When the proper combination of positions or slots have been filled, the output contact 15 is opened or closed. Each remote receiver unit is precoded so that it responds to one and only one pulse code signal; therefore, the switched loads 17 and 19 must be of the same class, for example, electric hot water heaters. In order to control, for example, an air conditioning compressor in the same location, a separately encoded remote receiver unit RRU must be connected thereto receive the pulse code signal.
II. Load Management Strategy
In the best mode presently contemplated for carrying out the present invention, with the 40 pulse injection code signal and remote receivers described above, there are 56 independently operable sets of contacts (on/off pairs) or load control groups. Each contact can control a separate type of load, such as electric hot water heaters, air conditioner compressors, street lights, or the like. Therefore, the operational programs for the master control station MCS has 56 predefined load control groups. Each group can be commanded to turn on (the contact in the receiver will close) or to turn off (the contact in the receiver will open). By turning the load groups on and off at the appropriate times, a desired load management strategy can be implemented. The system operator determines which group to turn on and off and when they should be turned on and off to best control the system load. The program in the master control station will implement the strategy which is set up by the operator.
The control commands that turn the load control groups on and off are linked together by the operator to form control lists. There may be, for example, 20 independent control lists, each containing one or more control commands, which are grouped into the lists according to different characteristics that enable management of various types of loads.
The management strategy of the present invention defines three different types of control lists, referred to hereinafter as Type 1, 2 and 3. Type 1 control lists are of a single pass nature. That is, when the type 1 list is activated, the group control commands in the list are transmitted at a predetermined time from the time the list is activated. When the end of a type 1 list is reached, the control sequence is finished and the list is deactivated. Type 1 control lists are typically used for emergency load shedding or other manually initiated, one shot, preplanned sequential control activity.
Type 2 control lists have a cyclic and repetitive nature. When a type 2 control list is activated, the group control commands in the list are sent in a predetermined order. When the end of the list is reached, the program goes back to the beginning of the list to start over. This cyclic action continues until the list is deactivated by an external event or by operator intervention. A type 2 control list is typically utilized for cycling hot water heaters, air conditioners, or street lights.
Type 3 control lists are characterized by a variable duty cycle. Type 3 lists can dynamically adjust the amount of time a controlled load is allowed to be on, depending upon the demand on the electrical network. As the demand on the network increases, the time the loads are allowed to be on decreases, thereby reducing the total demand. The group-off commands for a type 3 control list are evenly spaced over the duration of the cycle. When it is time to turn the next load control group off, the program calculates a new on-to-off ratio based upon the current value of one or more system parameters such as total demand. The new ratio is used to determine the length of time this group will be left off. The off time interval is subject to minimum and maximum limits established by the operator. The program will turn such a group off at the time specified in the list and then turn it back on after the calculated off time interval has elapsed.
The control lists may be initiated by a manual operator action, by an operator-entered load curve, by a discrete input received from the substation injection unit SIU or by a combination of analog inputs from the substation injection unit SIU. The control lists may be load dependent or load independent, and may run on particular days of the week, weekends, holidays or any desired combination of same.
III. MCS Software
The software program for the master control station MCS consists of three basic functional portions. The first portion, which may be referred to as the operator interchange module, handles the interaction between the system and the operator including control of the keyboard and generation of displays on the CRT. The second portion, known as the load profile module, monitors the control lists by periodically, for example, once a minute, checking to see whether any of the lists should be started or stopped, or if a group control command should be sent to a substation injection unit SIU. The third portion of the program, known as the line protocol module (which runs most of the time), handles the communications between the master control station MCS and the substation injection units SIU. Between injections of group control commands, the master control station MCS routinely polls each substation injection unit SIU for status information and telemetry data. It also checks each substation injection unit SIU for eight internal status conditions and monitors the status of eight customer discrete inputs and one analog input. Between the polling of each substation injection unit SIU, the MSC updates the display that is currently on the CRT.
Referring now to FIG. 11, a block diagram illustrates the software interaction of the various modules with various hardware which together comprise the master control station MCS. The operator interchange module is indicated by reference numeral 400 and handles the operator inputs from keyboard 404 while generating a display on CRT 402. While being the largest module in the system, it runs on a very low priority. The inputting of parameters through keyboard 404 or the generation of displays for CRT 402 is accomplished through the use of a System Menu which is a list of items that will direct the computer to the area the operator would like to manipulate. The program is preferably written so that data entry is operator oriented, that is, the computer asks a question by displaying it on the CRT 402 and the operator supplies the answer by typing it in through the keyboard 404. Each operator entry is checked for correctness and appropriateness at the time it is entered to ensure the security and integrity of the system. A printer 416 may be connected as an output device to provide a hard copy of the CRT display, if desired.
A real time clock 418 plugs into the programmable computer that forms the master control station MCS in order to provide a real time reference for interrupting the system periodically to perform certain functions. For example, certain software functions are implemented once a minute, certain functions are implemented once every five seconds, and the like.
The data base for the operator interchange module 400 is formed by a control list and command assignment table 406, SIU tables 408 and system status files 410. As the names of the blocks imply, they contain the tables and files that other modules manipulate and provide means with which the other modules can communicate information. The tables 406 and 408 and files 410 together may be referred to as the system files module and information is stored therein pertaining to the substation injection units (SIU), the analog and discrete inputs, the control lists, the group elements, the CRT displays and the like.
Another program known as the initialization module and indicated in FIG. 11 by reference numeral 414 is run immediately after the program tape is loaded into the computer in order to establish the data base. Initialization module 414 initializes the hardware interfaces connected directly to the computer. This program is normally run only once per program load, and is connected to a tape drive 412 which stores the operator-entered information in the event of a temporary power outage.
The load profile module is indicated by reference numeral 420 and handles activation, running and deactivation of the control lists. Module 420 also manipulates the analog and the discrete inputs as read from analog and discrete input tables 424, as well as information stored in a load profile table 422. Load profile module 420 calculates and controls the type 3 control list off-time intervals. Module 420 is run periodically, e.g., once a minute, based upon timing information received from real time clock 418. Control list information to load profile module 420 is fed from control list table 406. Module 420 goes through each list in turn: if the list is disabled, it will go on to the next list; if the list has been enabled by the operator, module 420 will check the various parameters to see if activation or deactivation of the control list is called for. Module 420 then exaines the group control commands within those lists that are activated and, if there is a time match, module 420 takes the group control command information and places it on a command stack 426 which acts as a buffer area for the line protocol module 428 for subsequent transmission to the substation injection units.
As explained above, for a type 3 control list, the load profile module 420 calculates a new on-to-off ratio at the beginning of each cycle based upon the current value of certain system parameters, which typically include total system demand. Such information may be obtained by load profile table 420 from information previously stored in the analog and discrete input tables 424, which information is obtained from either analog inputs and/or discrete inputs located at the substation injection units SIU. Alternatively, in the event the particular system installation is not provided with analog or discrete inputs, type 3 lists can still be controlled by information previously stored in load profile table 422 which, in essence, is a tabular listing of the anticipated megawatt demand on an hourly basis. The load profile table 422 can be updated by the operator via operator interchange module 400 at any time.
Whether utilizing the load profile table 422 or the analog and discrete input tables 424, the on-to-off time ratio is related to the desired system parameter of the utility by a graph such as that illustrated in FIG. 14. The off-time interval is indicated on the Y-axis and is directly related, over a limited range, to the network demand in megawatts on the X-axis. For each type 3 control list, the operator enters the demand at which he wants the control list to become active (the activate point) and the demand at which the group in the list would be turned off for the maximum off-time interval (the maximum off point). The off-time interval may be calculated by the equation: ##EQU1## for values of X that are greater than or equal to the activate point. The value Y will be rounded off to the closest integer and will be used as the off-time interval subject to two conditions: first, the minumum off-time interval is the cycle duration divided by the number of load control groups in the list and must be at least, for example, four minutes long; and, second, the maximum off-time interval is less than or equal to the limit defined by the operator. Otherwise, the off-time interval can vary by one minute increments as the load varies.
For values of X that are greater than the maximum off point, the off-time interval will be fixed at the upper limit defined by the operator. When the value of X has dropped so that it is between the deactivate point and the activate point, the off-time interval will remain at the minimum off-time interval. When the value of X falls below the deactivate point, the program will send commands to turn on all load control groups in the list and then deactivate the list.
As stated above, for any group control command for which a time match is determined in load profile module 420, the latter transfers the command to the command stack 426. If at any time there is insufficient room on command stack 426 for the load profile module 420 to put on a group control command, the operator will be notified by an alarm message, and the module 420 will try to place the group control command on the stack 426 again after a one minute delay.
The purpose of the line protocol module 428 is to process group control commands on the command stack 426, transmit messages to and receive messages from the substation injection units, poll the substation injection units for status conditions, retrieve substation injection unit analog and discrete inputs, and maintain communications and injection error statistics.
When the line protocol module 428 runs, which may be, for example, once every five seconds, it will first check the command stack 426. If there are no group control commands on stack 426, the line protocol module 428 will begin a polling sequence in which all substation injection units (SIU) will be requested to report their status and analog and discrete inputs, one SIU at a time. The received data will be used to update the system files 410. Further, the SIU status indicators will be checked for any changes or alarm conditions. If an alarm condition is detected, an alarm status flag will be set so that an alarm display will be generated by the operator interchange module 400. Any new analog or discrete inputs will be fed to the analog and discrete input tables 424 from line protocol module 428. If any of the analog or discrete inputs have changed and represent an alarm condition, an alarm status flag will be set. When the polling of each SIU is complete, line protocol module 428 will return to check the command stack 426 once again.
If there is one or more group control commands on stack 426, line protocol module 428 will try to combine the 40 pulse code injection messages. If the commands cannot be combined, the module 428 will send them in order of the priority of the control list from which the commands came. Transmission of the pulse code injection messages follows the setup-verify-execute sequence described hereinabove. That is, the pulse code injection message is first set up in each substation injection unit and verified, one at a time. After verification, a commence keying command is sent twice to all substation injection units for communications verification. The commence keying command initiates the pulse code injection process at the substation injection units which takes, in the preferred embodiment, approximately 94 seconds to complete plus a 94 second false start time, for a total of from two to three minutes per injection. An interface module 430, known as an RS-232, is disposed between the line protocol module 428 and a modem 431 which converts commands from the computer into signals for transmission on the telephone lines by the modem. After injection has been completed, the line protocol module 428 obtains the injection code from a special receiver in each substation injection unit that monitors the pulse code signals going onto the power lines. The received code from the special receiver in each SIU must match the pulse code signal transmitted, or an injection error is noted for that SIU. If an injection error is noted, the same message is re-injected. If two consecutive errors are noted, the particular SIU is disabled and an alarm indication is given to the operator.
After an injection message is set up by the line protocol module 428, the latter will update the status of the load control groups involved in the particular message. This is done so that the operator interchange module 400 can periodically write the current control list and group status on the system tape 412. The line protocol module 428 will also deliver to an archival tape module 440 the load control group commands involved in this message so that the archival tape module 440 can write the commands on a separate tape drive unit 442 for archival storage purposes.
The line protocol module 428 also maintains the communication and injection error statistics. Several sections of the line protocol module 428 function like I/O drivers. All communications line messages are handled by the message as opposed to by the character (a message comprises several characters). This allows the line protocol module 428 to stop running until the transfer of the entire message is completed so that other program modules are able to run while the line protocol module 428 is stopped. However, when message transfer is complete, the RS 232 interface 430 interrupts the MCS to initiate running of the line protocol module 428 once again. The latter will then check the received message for errors, update the SIU status, analog and discrete files, and the like. It stops running when another message transfer begins to allow the previously interrupted module to continue. The real time clock 418 together with the interface 430 restarts the line protocol module 428 in the event the message transfer is incomplete.
The MCS analog and discrete input module 432 is optional and is required only when there may be analog or discrete inputs connected directly to the MCS. When module 432 runs, it works together with the analog and discrete input interface tables 424 to bring in the current values of the inputs. It will then update the analog and discrete files in the system files 410 in the same manner as the line protocol module 428 does with the SIU analog and discrete inputs. Reference numeral 434 indicates a standard interface bus utilized with the module 432.
The SCADA module 436 is also optional and comprises a supervisory control and data acquisition system, which is a higher level computer that can control the MCS. A command interface 438 may be required for SCADA module 436.
The system software is illustrated in flow chart form in FIG. 12. In the flow chart of FIG. 12, reference numeral 414 refers again to the initialization module wherein the data base is established, initialized and updated from the previously stored information on tape drive 412. Further, in the initialization module 414, the difference between the current time and the time the last record was written on the system status files 410 is determined. If greater than a predetermined time interval, the operator is asked to enter the new date and time, and the last known list and group status are displayed. The main program is then loaded from the tape drive 412, and the display loop DL is entered.
In the display loop DL, if an alarm condition is indicated the alarm display is generated. If no alarm condition is present, the requested display is generated, and the program moves on to the clock interrupt cycle A.
In the clock interrupt routine A, the current date and time are obtained from the real time clock. If the latter has changed to the next minute, the program loops to the load profile module 420. If not, clock interrupt A checks to see if it is time to go to the line protocol module 428. This may be determined, for example, by a five second internal counter which is decremented to zero.
As pointed out above, the line protocol module 428 is run once every five seconds, and is therefore the highest priority routine in the program. The line protocol module 428 first tests to see if it is time to check an in-progress injection. If it is, the program loops to routine C which first obtains the last injection code from each substation injection unit. This information is obtained from the special receiver in each SIU. A comparison is then made between the received SIU injection codes and those transmitted to determine if there are any errors. If so, an injection error is indicated. If there are no errors, the group control command that made up the injection is removed from the command stack 426. The status tape file is then updated with the current list and group status whereafter the time is set for the next injection (approximately 94 seconds later), and the five second counter is reset to establish a new time for checking the line protocol module 428.
If it is not time to check an in-progress injection, the line protocol module 428 checks to see if it is time to start a new injection. If so, the program loops to routine B where there is first a test to see if there are any injection errors. If there are none, routine B checks the command stack 426 to see if it is empty, that is, to see whether or not there are any group control commands awaiting transmission. If not, the line protocol module 428 polls the injection substation unit, updates the analog, discrete and internal status files from the polling response, and resets the five second counter in clock interrupt A.
If there is one or more group control commands on the command stack 426, routine B first eliminates any duplicate group control commands, obtains the preselect code of the oldest command, looks for other group control commands with the same preselect code, and combines commands with the same preselect. The injection message is then generated and sent to each substation injection unit that is on-line and enabled. Routine B then verifies the injection message, and upon verification, sends the commence keying command to all SIUs. Thereafter, routine B sets the time for checking this injection (approximately 94 seconds later) and sets a new time to check the line protocol module 428.
Referring back to the clock interrupt routine A, if a minute change has gone by, the program cycles to the load profile module 420 wherein the first action taken to to determine the source of the list. If the list source is a Manual Key on the keyboard, the program cycles to routine E to determine if the particular control list is active. If it is not, the rest of the control lists are checked and the cycle returns to the load profile module 420. If the particular control list indicated by the Manual Key is active, the program cycles to routine J which is an "activate" routine common to all lists found active. In routine J, the first determination is the days that this particular list is allowed to run, and the type of day that today is, that is, whether today is a weekday, Saturday, Sunday or holiday. It is then determined whether this particular list is allowed to run today. If it is not, the rest of the control lists are checked and the routine returns to the load profile module 420. If the list is allowed to run today, the list is then checked to see whether it is already active, and, if it is not, the list is set active and the program cycles to routine F. If the list is active, the current time is obtained, and, if the list is a type 3 list, the new off-time interval is calculated. Each group control command in the list is then checked for a time match. For each time match found, the corresponding group control command is placed on the command stack to await transmission via the line protocol module 428. If the list is a type 3 list, the time is adjusted to turn the group back on or off. The remaining group control commands in this list are similarly checked, after which the rest of the control lists are checked.
Routine F is also the routine which is enabled if the list source is from the Dump, Reduce or Restore Keys on the keyboard. The lists assigned to the Dump, Reduce and Restore Keys are normally used for emergency situations only, and therefore have priority over other load management functions in the system. Within these three manually-initiated actions, the Dump list has priority over the Reduce list and the Restore list, while the Reduce list has priority over the Restore list. All lower priority lists are disabled when one of these lists is initiated by pressing the corresponding key. Further, all entries that are currently on the command stack are removed.
Returning to module 420, if the list source is the load profile table, the program cycles to routine G wherein values are obtained from the load profile table for this hour and for the next hour. The values are then linearly interpolated to obtain a value for the present minute. If this value is greater than or equal to the activate value for this list, the program cycles to the activate routine J. If the interpolated value is less than the deactivated value for this particular list, the program cycles to the "deactivate" routine K.
In routine K, if the list is currently active, all of the ON group control commands in the list are placed on the command stack, and the list is then set inactive.
Referring back to routine G, if the interpolated value is greater than the deactivate value but less than the activate value, the program cycles to routine F which was explained above.
If the list source on load profile module 420 is a discrete input from the substation injection unit, the program cycles to routine H wherein the contact number for this list and its current status is obtained. If the status of the contact number is correct to activate the list, the program cycles to routine J. On the other hand, if the status is correct to deactivate the list, the program cycles to routine K. Otherwise, the program cycles to routine F where the group control commands are tested for a time match and placed upon the command stack.
If the list source in the load profile module 420 is from an analog input, the program cycles to routine I wherein an analog input number is obtained for the list along with its current value for all analog inputs. The appropriate value is then calculated (average, summation or RMS), and the value is tested to see if it is greater than or equal to the activate value, or if it is less than the deactivate value. If the former is true, activate routine J is enabled, and if the latter is true, deactivate routine K is enabled. If the value is between the activate and deactivate points, routine F is enabled.
Not shown in FIG. 12 are the Menu Key routines which permit the operator to select a display indicator or enter system parameters according to the system menu, as well as the Keyboard Interrupt routine which allows input from the keyboard.
IV. Substation Injection Unit
A. Overall Block Diagram
Referring now to FIG. 6, there is illustrated a functional block diagram of a preferred embodiment of a substation injection unit in accordance with the present invention. Power is fed to the substation injection unit from the main power bus 42 of the power utility's substation, which is of the 15 kilovolt class. Bus 42 also transmits the utility's power to the remote receiver units RRU. A power supply for the substation injection unit is indicated by reference numeral 10 and supplies, for example, 60 Hertz, 240 volt, 36 amp, three-phase three wire power to a line terminal board 12 to which the interconnect cables for the interior of the substation injection unit are connected. From board 12, power is fed through a power circuit breaker 14 which has a shunt trip input 71 that is activated in a manner which will be described in greater detail hereinafter. Three-phase power is fed along line 25 from power breaker 14 to a 60 Hertz power input contactor 16. Contactor 16 connects the incoming power to a rectifier 20 under the control of control relay circuit 18, in a manner which will be described in greater detail hereinafter.
Rectifier circuit 20 comprises a standard SCR phase-controlled rectifier bridge under the control of a rectifier controller 68 in a manner to be described in greater detail below. Rectifier 20 acts to change the incoming three-phase AC power into a DC level at its output of approximately 325 volts. It should be noted, however, that the DC voltage level output of rectifier 20 may be adjusted to deliver one of a number of suitable output DC voltages by means of adjusting the firing angle of the silicon-controlled rectifiers (SCRs).
The DC output from rectifier 20 is then fed to an LC output filter 22 that smooths the AC ripple on the DC voltage. Also noted in box 22 is an inverter fault detector which basically detects what is known as a shoot-through condition in an inverter 24 that creates a short on the DC bus. The fault detector in block 22 acts to provide an alternate path for any surges in order to prevent the rectifiers in the inverter from being burnt out. Shoot-through conditions are also noted in the rectifier controller 68, in a manner which will be described more fully below.
Also positioned in block 22 is an overcurrent sensor which simply senses excess current on the DC line and, upon such detection, acts to disable the SCRs in rectifier 20 to prevent damage thereto.
Reference numeral 24 indicates a three-phase static inverter which is preferably of the form known in the art as a McMurray inverter. Inverter 24 converts the incoming DC voltage and current to AC voltage and current at a frequency which corresponds to the desired preselected pulse code frequency. By way of example, the pulse code frequency may be selected to be 340 Hertz. The presence or absence of a particular pulse in the 340 Hertz output of inverter 24 depends upon inputs received from inverter controller 46 which basically turns on and off the SCRs in inverter 24 in accordance with the specific pulse code signal desired for a particular injection message.
Inverter 24 operates in one of three modes under the control of inverter controller 46. One mode may be denoted the OFF mode wherein none of the SCRs in inverter 24 are conducting. Another mode may be described as the INJECT mode wherein the SCRs of inverter 24 are being turned on and off in a specific sequence to create a pulse code pattern at 340 Hertz that corresponds to the desired injection message communicated to inverter controller 46 by microprocessor 66, in a manner which will be described in greater detail hereinafter. A third mode may be denoted the IDLE mode and corresponds to those periods of time when no output pulse is present in the pulse code train. During IDLE, the lower three SCRs in the SCR bridge of inverter 24 are conducting which in conjunction with the feedback diodes provides a continuous short circuit on the primary of an injection transformer 30 to serve as a trap circuit for the 60 Hertz feedback current. The inverter 24 is sized to handle the combined current requirements of the ripple or injection frequency current and the desired amount of 60 Hertz backfeed current. The SCRs in inverter 24 operate under forced commutation as controlled by inverter controller 46.
From the inverter 24, the pulse code signal is fed through a power output contactor 28 which is under the control of control relay circuit 18, as is power input contactor 16. When the main power breaker 14 opens, power is removed from input and output contactors 16 and 28, respectively, via control relay circuits 18 to immediately isolate the SCRs in rectifier 20 and inverter 24 against damage. The status of input and output contactors 16 and 28 is fed to a system status board 64, as will be described in greater detail hereinafter.
The coded injection message from output contactor 28 is fed to the primary of an injection transformer 30 which performs two functions. Firstly, transformer 30 isolates the pulse code generator (consisting of rectifier 20 and inverter 24) from the power line 42. Transformer 30 also has its secondary connected to deliver the 340 Hertz alternating current signal to the injection inductors 32 and injection capacitors 34. Inductors 32 and capacitors 34 are tuned to provide a series circuit resonant at the desired pulse code frequency of 340 Hertz. Surge protection arc gaps 36 are connected across the injection inductors 32 and the transformer winding to the neutral to provide surge protection when the injection inductor 32 and capacitors 34 are connected to the substation bus 42. That is, a surge current can create an overvoltage on the inductors 32 and the arc gaps 36 are used to limit that voltage.
The substation injection unit runs with an isolated neutral; however, it is desirable to limit its relationship to the system neutral, and this function is performed by a neutral shift arc gap 38. That is, if the system neutral or the substation neutral shift too far with respect to one another, the neutral shift arc gap 38 will fire to hold them in a fixed voltage relationship.
From the inductors 32 and the capacitors 34, the 340 Hertz pulse code signal is applied through disconnect devices 40 which may be, for example, simple disconnect switches or a mechanized switch utilized to switch capacitor banks on and off the line. From there, the pulse code signal is applied to the substation bus 42 to be sent to the remote receiver units along the power lines.
The output from power output contactor 28 is also fed through current transformers 44 to a neutral shift detector 48 which acts to indicate when the power system neutral has shifted sufficiently to cause improper operation of the substation injection unit. Such a shift can be caused by, for example, a line-to-neutral or line-to-line fault which, if not cleared sufficiently rapidly, causes neutral shift detector 48 to function to disconnect the substation injection unit from the power line via system status board 64, control relay circuits 18, power breaker 14 and contactors 16 and 28.
Reference numeral 50 indicates generally the control logic for controlling the function and operation of the circuits described hereinabove in the substation injection unit. Single phase power is fed from terminal board 12 into a trip breaker 52 and then through an electromagnetic interference filter 54 which eliminates some of the transients and higher harmonics being supplied to a transformer 56. Transformer 56 steps down the voltage level to one usable by direct current power supply 58 which may be, for example, approximately 120 volts. Power supply 58 supplies direct current power to the control and communications module 60.
When the substation injection unit is transmitting a pulse code signal through the substation bus 42, part of that signal is fed back through the customer's power supply 10 down through terminal board 12, trip breaker 52 and may be detected by a pulse detector 62. Pulse detector 62 preferably comprises a modified remote receiver unit which is designed to detect, on a pulse-by-pulse basis, the pulse code signal impressed upon the power lines. Pulse detector 62 is set forth in greater detail in copending U.S. application Ser. No. 53,252, filed June 29, 1979, assigned to the same assignee as the present invention, said application being expressly incorporated herein by reference. The output of pulse detector 62 is fed to the system status and I/O board 64 in the control and communications module 60. With respect to this information, system status board 64 is used to confirm that the ripple tone or pulse code signal is being applied to the system.
The heart of the control and communications module 60 is a microprocessor 66 which may, for example, comprise a Motorola 6800 chip. The microprocessor 66, which can be denoted as a communications controller, performs several functions. For example, the pulses from the pulse detector 62 are fed to microprocessor 66 through system status board 64 for counting, storing, and transmission back to the MCS for comparison with the desired injection message sent to the substation injection unit by the master control station. This information is transmitted via a modem 74 that is connected to the telephone lines that are connected to the modem in the master control station. The microprocessor 66 stores the pulses received from pulse detector 62, on a pulse-by-pulse basis, and then transmits the complete 40 pulse code message back to the master control station where verification is made.
One function of the system status and I/O board 64 is to link and isolate the low level electronics portion of the control logic section 50 from the nominal higher voltage circuits in the substation injection unit. A block diagram of the system status and I/O board 64 is illustrated in FIG. 7 in combination with the microprocessor 66. The inputs to microprocessor 66 are received by the board 64 through a high voltage interface circuit 100 which converts the nominal 220 volt inputs to 5 volt logic level. In a preferred embodiment, seven such inputs are provided through high voltage interface 100. As explained above, one of the inputs is from pulse detector 62. A second input is from the neutral shift detector 48. Another pair of inputs are provided from two relays in control relay circuit 18, while yet another pair of inputs are provided from temperature detectors 24a to be described below. From the high voltage interface 100, the low level logic signals are fed to a latch 102 having a chip enable input 101. Chip enable input 101 to latch 102 is provided by an address decoder 104 which receives a 16 bit address signal from the microprocessor 66. When the right address is detected in decoder 104, the chip enable output 101 goes high to latch the data through latch 102 to be delivered to the input of the microprocessor 66 via an 8 bit data bus.
Outputs are transmitted from the microprocessor 66 in a similar fashion. That is, a 16 bit address bus feeds an address to an address decoder 106 which, upon detection of a proper address, causes a chip enable output 107 to go high to actuate latch 108 to receive the eight bits of data from microprocessor 66 to be sent to the desired output. For example, when it is desired to open or close the input contactors 16 and the output contactors 28, an appropriate address and data is sent from the microprocessor 66 through the output latch 108 to deliver the control signals to the control relay circuits 18.
Microprocessor 66 communicates with rectifier controller 68 and inverter controller 46 in a similar manner utilizing, of course, different address codes on its output address bus to address the particular controller desired.
Referring back to FIG. 6, it is seen that three-phase power is supplied to rectifier controller and gate generator 68 via line 69. The three-phase, 60 Hertz supply to rectifier controller 68 along with output voltage level commands from microprocessor 66 allows the controller 68 to establish a predetermined voltage level which must appear on the SCRs before they can be fired. This information provides a reference point for controlling the firing time of the SCRs of the rectifier. The firing time determines the level of output power. The master control station permits selection through microprocessor 66 of one of a plurality of desired output voltages for rectifier 20 which may comprise, for example, a high, medium and low voltage. The firing time that the SCRs in rectifier 20 are fired depends upon the selected output voltage level and is controlled by rectifier controller 68, in a manner to be described in greater detail hereinafter.
Reference numeral 24a indicates a pair of temperature rise detectors located in the inverter 24. One of the detectors is positioned adjacent the SCRs to detect an initial threshold of temperature. Upon reaching the initial threshold, a signal is transmitted to system status board 64 in control module 60 where it is transmitted back to the master control station through the microprocessor 66 to indicate that the maximum operating temperature of the substation injection unit has been reached. This permits corrective action to be taken at the master control station. The other temperature detector operates at a higher temperature threshold. When the high threshold is reached, a signal is sent directly to the control relay circuits 18 to operate the shunt trip via line 71 in power breaker 14 to immediately disable input contactor 16 and output contactor 28 to isolate the substation injection unit and render same incapable of further transmission. This signal is also transmitted through the control relay circuit 18 to the microprocessor 66 via line 65 and thereafter to the master control station to indicate an alarm condition. Line 65 consists of four lines between system status board 64 and control relay circuits 18. Control relay circuits 18 comprise a pair of relays to operate input and output power contactors 16 and 28, respectively. Further, the status of contactors 16 and 28 is periodically polled and reported to the master control station through system status board 64 and microprocessor 66.
A transformer 70 is connected to receive power from filter 64 and changes the line voltage to a desired level to operate a pulse gate power supply 72 which provides DC power for rectifier 20 and inverter 24.
Reference numeral 76 in control and communication module 60 refers to optional boards which may be provided in the substation injection unit to monitor analog or discrete data for feeding back system parameters to the master control station. For example, one analog input may be a direct current signal proportional to the system load which can be utilized in the load management system for the type 3 control lists. Alternatively, the demand information can be, for example, the inputs from kilowatt-hour meters where the input is dry contact closures on the lines which are attached to switch on the meters. The rate at which the switching operations occur are indicative of demand, and the total number of contact closures is proportional to the kilowatt-hours consumed. Referring to FIG. 8, meters A and B each have a pair of dry contacts which close every time the meter turns to produce a pulse from the high voltage interfaces 140 and 150. The outputs from high voltage interfaces 140 and 150 are fed to a pair of timers which may be located, for example, in a timing chip 160 (such as Motorola's 6840). Timer 1 in the chip 160 is loaded with a number from microprocessor 66, which, for example, is equivalent to five minutes. A 60 Hertz clock signal causes timer 1 to decrement. At the end of five minutes, the microprocessor 66 reads the present count in timer 2 and subtracts it from the previous count, which is equal to the total number of pulses in that time interval which is loaded into a RAM location 170. The same operation is performed with timer 3. The numbers are fed to a stack of memory locations in RAM 170, and, when an hour has elapsed, and the master control station calls for an analog value, the microprocessor 66 sums everything in the two RAM stacks and sends it to the master control station which then calculates the demand per hour.
B. Rectifier Controller
There is shown in FIG. 9 a functional block diagram of the rectifier controller. Further details of the rectifier controller are set forth in copending U.S. application Ser. No. 54,025, filed July 2, 1979, assigned to the same assignee as the present invention, said application being expressly incorporated herein by reference. The rectifier controller utilizes voltage sensors 110 to detect the more positive voltages by comparing the instantaneous magnitude of phase voltages A, B and C from the three-phase power grid. The phases of the three voltages must be rotating positively from A to B to C. The voltage sensors 110 produce outputs whenever one line is positive with respect to another line with which it is compared. The voltage sensors are connected to the SCR enabling logic 112 in order to determine the firing order of the SCRs.
The same information required for determining the firing order is fed to a dwell start detector 130. The dwell start detector is responsive to the outputs of voltage sensors 110 to produce an output whenever any two of the three-phase voltages are equal.
A delay register 122 is responsive to the dwell start detector 130 output and to time delay information from a decoder and counter 120 which receives output voltage signals from the microprocessor. If the time delay received from decoder 120 is zero, then the delay register 122 will immediately enable logic 112. When this condition exists, the rectifier will produce a full power output. The reason for this is that, in this event, the SCR enabling logic 112 will be time controlled only by the voltage sensors 110 since there is no dwell time delay. As the length of the time delay increases from zero, the firing of the SCRs will be delayed by the output from delay register 122.
The decoder and counter 120 also provides an input to a mode register 124. This mode register 124 is responsive to a mode command from the microprocessor through decoder 120 to deliver an appropriate signal to SCR enabling logic that is used to initiate and terminate operation of the rectifier controller upon command from the microprocessor or when there are other rectifier controller malfunctions.
During normal operation, the rectifier controller operates in response to commands from the microprocessor which are received by the decoder and counter 120 and in response to the three-phase voltages which are sensed by the voltage sensors 110. The commands from the delay register 122, the voltage sensors 110, and the mode register 124 under normal operation will permit firing of the rectifier SCRs by enabling logic 112.
Connected to the output of the SCR enabling logic 112 are gate pulse generators 114 which are utilized to generate bursts of high frequency pulses which may be, for example, on the order of 50 kilohertz. These pulses are then applied to gate amplifiers 116 which are used to increase the power level and to drive the rectifier SCRs 118. The rectifier SCRs have isolation transformers associated with their gates. These isolation transformers use the 50 kilohertz gate pulse generators 114 to provide the necessary gate control signal.
The rectifier controller also has associated with it additional means for controlling the SCR enabling logic 112 which are responsive to conditions on the DC bus. These means are an overcurrent sensor 128 and a shoot-through detector 132.
The overcurrent sensor 128 is placed in the direct current bus and senses a high direct current for sustained periods of time. This sensor may be, for example, a thermally responsive switch which closes to apply a signal to the mode control register 124 which will produce a disabling signal which is received by the SCR enabling logic 112.
In order to provide for rapid control of the rectifier direct current output voltage when a shoot-through occurs in the SCRs associated with the inverter circuitry, there is provided a shoot-through detector 132. A "shoot-through" is the undesirable condition which may occur in the inverter circuit when two series connected SCRs operating on the same voltage phase are simultaneously placed in conduction which produces a short circuit on the direct current bus. The shoot-through detector 132 responds to this short circuit condition on the direct current bus and produces a signal responsive to the short circuit condition. The shoot-through detector 132 is connected to the SCR enabling logic 112. When such a shoot-through condition is sensed, the SCR enabling logic 112 immediately disables the rectifier SCR gates, and thereby prevents any further power from being applied to the direct current bus during the period of the shoot-through condition. The SCR enabling logic 112 maintains the gates in their "off" condition for a predetermined period of time. This provides time for the inverter to recover from its undesirable shoot-through condition.
Shoot-through conditions may occur randomly in inverter circuits. The shoot-through detector 132 and the SCR enabling logic 112 permit the rectifier to be protected against damage from such random conditions. If the shoot-through condition becomes persistent and repetitive, there may be a serious fault associated with the inverter circuit's rectifiers. In order to determine if such serious and continuous shoot-through conditions are present, there is provided a shoot-through counter 126. The shoot-through counter 126 counts the number of shoot-through detections within a given time interval. When a predetermined number of shoot-throughs is detected within the predetermined period, the shoot-through counter 126 produces a shut down signal which is received by SCR enabling logic 112. The SCR enabling logic 112 will then permanently shut down the SCR gates until a microprocessor-initiated or manually initiated command is received to clear the fault and restart the rectifier. The shoot-through counter 126 also provides fault data supplied to the microprocessor which is used to control the rectifier controller as well as the inverter.
C. Inverter Controller
Referring to FIG. 10, information pertaining to the desired mode of operator of the inverter is received from the substation injection unit microprocessor along an address bus B by an address page recognition ROM 202 and a mode select register 204. The mode select register 204 provides a two bit output which represents one of the four possible modes of operation of the inverter. The four modes of operation are CRASH (output 00), OFF (output 01), IDLE (output 10), and INJECT (output 11). In the CRASH mode, the inverter SCRs are shut down in response to detection of a fault condition. In OFF, the SCRs are all turned off momentarily. The IDLE mode corresponds to the absence of a pulse in the pulse code signal that forms the injection message, while the INJECT mode corresponds to the presence of a pulse in the pulse code signal.
The initial timing of the inverter controller output signals is achieved through a mode control register 206. The mode control register 206 is clocked by a timing signal referred to as the load mode register signal received from a timing register 240, and is enabled by signals from an enable mode change register 230, to be explained more fully below. A second enabling input is applied to mode control register 206 from an OR gate 231 which is responsive to a back feed 60 Hertz signal obtained either from the power lines or from the rectifier controller of the substation injection unit, as will be explained in greater detail hereinafter.
Upon receipt of the two enabling inputs and the load mode register signal, mode control register 206 receives the two bit code from the mode select register 204 and delivers same to its two line output which forms a portion of an address for an eight bit address bus that feeds a plurality of read-only-memories (ROMs) 208, 210, 212, 214 and 216. ROMs 208 through 216 can be denoted as a next table ROM 208, a next line ROM 210, enable next mode change and next main SCR ROMs 212 and 214 and a next commutate SCR ROM 216.
Associated respectively with each of the ROMs 208 through 216 are output registers 218, 220, 222, 224 and 226 which can be denoted as a table register 218, a line register 220, main SCR registers 222 and 224 and commutate SCR register 226. An enable mode change register 230 is also connected to receive an output from ROM 212.
The addresses for next table ROM 208, next line ROM 210, enable next mode change and next main valve ROM 212, next main valve ROM 214 and next commutate SCR ROM 216 are generated in response to the initial two bit address from the mode control register 206, and further in response to timing signals received from timing registers 240 and 242. The address bus for providing information to the ROMs 208 through 216 includes eight bits of address. Two of the eight address bits are supplied by the mode control register 206. The remaining six bits are generated by next table and next line ROMs 208 and 210. The register 218 and 220 receive the information from ROMs 208 and 210 when they are clocked by advance table signals which are generated by timing register 242. The information in next table ROM 208 is the next table information and comprises two of the address bits which are applied to all of the ROMs 208, 210, 212, 214 and 216. The ROM 210 contains the next line address information in the form of the remaining four bits for the address bus.
The eight bit address to ROMs 208, 210, 212, 214 and 216 consists of the information on two lines from the mode control register 206, the information on two lines from table register 218, and the information on four lines which come from the line register 220. The address on the address bus is changed when a first timing signal, the advance table signal, is received from timing register 242. The advance table signal is applied to the clock terminals of table register 218 and line register 220. When these registers are clocked, the next table information from ROM 208 and the next line information from ROM 210 will be latched in and set as the table and line information for six of the eight bits of the address bus. As the address bus information changes, the output of next table ROM 208 and next line ROM 210 will advance to the next address of the ROMs which contains information at the location addressed by the address bus pertaining to the next desired address. In this manner, whenever the clock terminals of the table register 218 and the line register 220 are clocked, the address on the eight bit address bus will change to the next desired address. It is through the continuous clocking of the table register 218 and the line register 220 that the address information for ROMs 208, 210, 212, 214 and 216 is continuously changed for cycling the firing control information for the inverter valves.
The ROMs 212, 214 and 216 with their associated output registers 222, 224 and 226 operate in a similar manner. The information appearing on the outputs of ROMs 212, 214 and 216 is the next-to-be-used firing information for the main SCRs and commutate SCRs of the inverter.
When the next main SCR ROM 212 is addressed, there appears on its output bus three bits for indicating the next desired firing state of inverter SCRs 6, 4 and 2. Similarly, when the next main SCR ROM 214 is addressed, it produces on its output three bits for indicating the next desired firing state for inverter SCRs 5, 3 and 1.
The main SCR register 222 receives the three bits of information from next main SCR ROM 212 when a timing signal is received on the load main SCR register line which is generated by timing register 240. Similarly, the main SCR register 224 which controls SCRs 5, 3 and 1 is also clocked by the load main SCR register timing signal from controller timing register 240.
All of the commutate SCR firing controls are generated by next commutate SCR ROM 216 which also responds to the address bus information. Next commutate SCR ROM 216 has as outputs three bits which are received by commutate SCR register 226. The commutate SCR register 226 preferably comprises a 3 by 8 decoder for decoding the three bit output from next commutate SCR ROM 216 to create six commutate SCR firing signals (only six of the eight output bits are used). The commutate SCR register 226 has as a clock input the fire commutate SCR timing signal which is received from timing register 240.
In order to clock the mode control register 206, the table register 218, the line register 220, the main SCR register 222, the main SCR register 224, and the commutate SCR register 226, it is necessary to generate timing signals which are appropriately spaced in time to control the desired sequence of events. The timing of the events determines the output frequency of the inverter.
The apparatus for generating the necessary timing signals is also shown in FIG. 10. A 6fo signal (where fo=the desired pulse code frequency) is applied to the clock input of a run sequence flip-flop 200. The run sequence flip-flop 200 is triggered on the positive zero-crossing of the 6fo signal and produces an output to a sequence clock in the form of a NAND gate 228. The other input to NAND gate 228 is a one microsecond clock pulse. The output of NAND gate 228 is a sequence clock signal which is a burst of one microsecond clock pulses for a period of time determined by the run sequence flip-flop 200. The output of NAND gate 228 is fed to a timing sequence counter 232 at its clock terminal. The timing sequence counter 232 and a companion timing sequence counter 234 count the one microsecond clock pulses within the run sequence which are received from NAND gate 228. The output of timing sequence counters 232 and 234 is an eight bit address code which is used to address a timing sequence ROM 236 and a timing sequence ROM 238.
As signals are generated by the timing sequence counters 232 and 234, the data in the memory addresses of the timing sequence ROMs 236 and 238 are read out, one address each microsecond. The address code from the timing sequence counters 232 and 234 changes upon each clock input received from the NAND gate or sequence clock 228.
The data outputs from the timing sequence ROMs 236 and 238 are fed respectively to timing registers 240 and 242. There are four bits of data fed from timing sequence ROM 236 to timing register 240 and four bits from timing sequence ROM 238 to timing register 242. The clock signal for timing registers 240 and 242 comprises the one microsecond clock input. The outputs of the timing registers 240 and 242 are precisely timed pulses in accordance with the one microsecond clock, and in accordance with the timing sequence ROM address chosen by the timing sequence counters 232 and 234.
One output from the timing register 242 comprises a sequence terminate signal. The sequence terminate signal is applied to a reset sequence circuit 230 which preferably comprises a one-shot flip-flop. The output of the one-shot 230 is then applied to reset the timing sequence counters 232 and 234, and also to clear the run sequence flip-flop 200. The application of this pulse to the run sequence flip-flop 200 terminates the sequence until the next positive going 6fo signal is observed.
The five timing signals from the timing registers 240 and 242 are denoted the load mode register signal, the load main SCRs register signal, the advance table signal, the fire commutate SCR signal, and the sequence terminate signal, and are all controlled by the information loaded in the timing sequence ROMs 236 and 238. Only five of the eight potential output lines from ROMs 236 and 238 contain information which is used in the run sequence. These five lines are used to advance the table and line, load the main SCR registers, fire the commutator SCRs, load the mode register, and to terminate the sequence.
The termination of the sequence occurs after about 73 microseconds which is a relatively short period of time when compared to the time required for completion of one 6fo cycle. In the preferred embodiment, the pulse code output frequency fo is 340 Hertz. Therefore, the 6fo frequency is 2,040 Hertz. The time for one 6fo cycle is therefore approximately 490 microseconds. It therefore can be seen that the complete timing sequence occurs during the initial 73 microsecond portion of each 6fo signal. The outputs on the various timing lines to the inverter controller registers do not change until the next 6fo cycle is initiated over 400 microseconds later.
The load mode register timing signal is generated by timing register 240, and is applied to the mode control register 206 as the last pulse of the series of timing sequence pulses which control the cycling of the inverter controller. It is through this pulse that a new address is applied to ROMs 208 through 216 in response to a mode change address received by the mode select register 204. The load mode register clock pulse is the final timing pulse of the timing sequence. Therefore, a change in the information in the mode control register 206 will not effect the firing of the SCRs of the inverter until the next 6fo interval begins, and the next advance table timing signal is output from timing sequence ROM 238.
The enable mode change register 230 is responsive to the enable next mode change portion of the next main SCR ROM 212. The enable next mode change output is a one bit output which occurs at the end of each 6fo interval. The enable mode change register 230 is responsive to the load main SCR register timing signal from timing register 240 as is the main SCR register portion of register 222. The output of the enable mode change register 230 is then fed to the mode control register 206 to enable the mode control register at the end of each 6fo interval, or at the end of each 340 Hertz signal.
At the beginning of the INJECT mode, it is necessary to inject the pulse code signal at the proper point in the 60 Hertz voltage of the substation bus to prevent injection transformer saturation. This point is determined experimentally and is set by adjustment of the back feed window delay circuit 232.
The second enabling input for the mode control register 206 is received from the back feed window delay circuit 232 which receives the 60 Hertz signal representative of the line voltage. A back feed window delay circuit 232 and a one-shot window width circuit 233 provide one of the three inputs to an OR gate 231.
The two bit output from mode select register 204 is connected to inverters 234 and 235 so that the output of inverters 234 and 235 is a logical "0" when the mode select register outputs a signal representing the INJECT mode, which is a "11" input to the inverters 234 and 235. The OR gate 231 acts as a disabling gate for the mode control register 206. When the input to the OR gate 231 is "0" on all three lines, the output of the OR gate 231 will be a logical "1", which disables the mode control register 206. At all other times, when a "1" appears on any one of the three input lines to OR gate 231, the output of OR gate 231 will enable the mode control register 206. In this manner, the only possible time that the mode control register is disabled is during the INJECT mode when the output of inverters 234 and 235 are logical "0"s.
The back feed window delay circuit 232 has as an input a point on the 60 Hertz three-phase lines. The back feed window delay 232 is a one-shot with an adjustable time constant which will delay its output a predetermined period of time which is selectable in accordance with equipment operation. The back feed window delay may be on the order of, for example, one to five milliseconds. The delayed output from the back feed window delay 232 is then fed to a one-shot flip-flop 233 which has a predetermined width or time which is slightly greater than the time required for one 340 Hertz cycle. This time may be set to, for example, four milliseconds. The output of the one-shot 233 will be a logical "0" until the window from circuit 232 is seen. When the window is present, the one-shot 233 output will be a logical "1" which will allow the mode control register 206 to be enabled. When the output of the one-shot 233 is a "0" during INJECT, the mode control register 206 will be disabled by virtue of the fact that there are three "0"s on the inputs to OR gate 231.
The width of the window or the time period of four milliseconds for the one-shot 233 must be greater than the time interval between one enable mode change command from register 230 and the next. Since the enable mode change commands from register 230 occur only once in each 340 Hertz cycle, then the time period for the one-shot 233 must be slightly greater than the time for one 340 Hertz cycle.
Outputs of main SCR registers 222 and 224 are each connected to a gate pulse generator (not shown) which may each comprise, for example, 50 kilohertz oscillators. The outputs from the gate pulse generators are then applied to gate amplifiers or integrated circuit drivers (not shown). The outputs from the gate amplifiers are then applied to the inputs of the main SCR inverter SCRs through isolation transformers.
The commutate SCR register 226 has as an input one microsecond timing signals which are generated when the fire commutate SCR signal from timing register 240 clocks commutate SCR register 226. Since the output from register 226 output is at a high frequency, it is not necessary to utilize a 50 kilohertz oscillator as was used in the driving circuitry for the main SCR SCRs. Therefore, the outputs of commutate SCR register 226 are fed directly through transistor amplifiers and isolation transformers to the gates of the commutating SCRs of the inverter.
Further details of the inverter controller 46 are set forth in copending U.S. application Ser. No. 54,024 filed July 2, 1979, assigned to the same assignee as the present invention, said application being expressly incorporated herein by reference.
D. Substation Injection Unit Software
FIG. 13 illustrates the flow chart of the software program for the microprocessor 66 located in each substation injection unit. The program includes three major routines, each of which is broken into smaller parts to maximize the efficiency of the microprocessor. The three major routines are the INPUT routine where communications are being received at the substation injection unit, the OUTPUT routine where the substation injection unit is outputting information to the master control station, and the INJECT routine where the substation injection unit is involved in injecting the selected pulse code signal onto the substation's power lines. The INPUT and OUTPUT routines each take approximately 440 milliseconds to run, while the INJECT routine runs for approximately 90 seconds. The INPUT routine is broken into three routines designated as IN-1, IN-2 and IN-3, the OUTPUT routine is broken into five routines designated as OUT-1, OUT-2, OUT-3, OUT-4 and OUT-5, while the INJECT routine is broken into eleven routines designated as INJ-1 through INJ-11. Three internal pointers, one for the input, one for the output and one for the injection routines, are set by various steps in the routines in order to loop to other routines in proper sequence. The pointers utilized may be summarized as follows:
______________________________________INPUT POINTER0 OUTPUT1 IN-12 IN-23 IN-3OUTPUT POINTER0 INJECT1 OUT-12 OUT-23 OUT-34 OUT-45 OUT-5INJECTION POINTER0 MAIN1 INJ-12 INJ-23 INJ-34 INJ-45 INJ-56 INJ-67 INJ-78 INJ-89 INJ-9 10 INJ-10 11 INJ-11______________________________________
Each substation injection unit is provided with a manually operable switch having three positions: off, auto and manual. In the auto position, it indicates that the substation injection unit is communicating with the master control station and will inject whatever injection message is received and verified by the master. In the manual position, it indicates that the substation injection unit will communicate with the master, but will not automatically inject.
In the POWER UP initialization routine, all of the RAM locations are tested to see if there are any failures. If not, the timers are initialized, the rectifier and inverter are both turned off, values are read in from the CONSTANTS ROM, the input pointer is set equal to 1 to ready the substation injection unit for receiving an input message, and the output and injection pointers are set equal to zero.
The MAIN routine initially sets a watchdog timer which makes sure that the software program starts from the beginning. After testing to make sure the mode switch is either in auto or manual, the program receives the input pointer and goes to the proper subroutine established by the pointer. In a similar fashion, the INJECT and OUTPUT routines obtain the injection and output pointers, respectively, and then loop to the routine established by the respective pointers.
Referring first to routine IN-1, it first looks to see if a carrier detect flag has been received. The carrier detect flag is a signal from the modem of the substation injection unit which indicates that the master control station is trying to communicate with the substation injection unit. If the carrier detect is up, the routine looks to see if a character has been received. If so, it then checks to to see if there is a framing, parity or overrun error. If not, the routine checks to see if the character is an STX which would indicate the beginning of a transmission from the master control station. If so, a buffer is initialized and the input pointer is set to number 2.
Routine IN-2 first checks to see if a carrier detect is still up, and then to see if a character has been received and if there are any errors in the character. If the carrier detect is not up or there is an error detected, the routine goes to routine IN-1A, which is an abort input routine wherein the input pointer is set to number 1 and the program then loops to the INJECT routine. If there is no error, the character is saved in the buffer until it is full. Then the last character is checked to see if it is an ETX to denote the end of the message from the master control station. If so, the routine then checks to see if this particular message is directed to this particular substation injection unit. If it is not, the routine looks to see if it is a commence keying command which is directed to all substation injection units and, if it is, it directs the program to the KEYING routine. If the message is directed to this particular substation injection unit, the input pointer is set to number 3.
In routine IN-3, the command is decoded and is checked to see if it valid. If it is, the program loops to the proper routine to handle the decoded command.
The OUTPUT routines are similar. Routine OUT-1 first checks to see if a carrier detect is up, and, if it is, the program loops to the INJECT routine. If it is not, the routine raises a request to send flag, which is a signal to its modem that it desires to communicate with the master control station. The output pointer is then set to number 2.
In routine OUT-2, the substation injection unit checks to see if a clear-to-send flag is up, which is a response from its modem that the lines are clear for communication to the master control station. When this flag is received, a timer is set for a 250 millisecond delay, and the output pointer is set to number 3.
In routine OUT-3, the 250 millisecond delay is checked to see if it is over, and, if it is, a piece of hardware known as the ACIA is checked to see if it is ready for a character. If it is, a character is output, and, if all characters have not been sent, the program loops back to OUT-4 to repeat the outputting of a character. After all characters have been output, a 30 millisecond delay is set and the output pointer is set to number 5.
In routine OUT-5, the 30 millisecond delay is checked to see if it is finished, and, if it is, the request to send flag is dropped, the output pointer is set equal to zero and the input pointer is set equal to one. The last two settings cycle the program back to the INPUT routines.
Prior to injection of a pulse code signal, a commence keying command must have been received during INPUT routine IN-2. At that point, the program loops to the KEYING routine which first checks to see if the previously set timeout has expired. The timeout control is a preselected time period, for example, 20 seconds, after which a commence keying command will no longer be valid to commence keying of a previously set up and verified injection message. If the timeout has expired, the program loops to routine K1 where the injection pointer is set equal to zero, the input pointer is set equal to 1, and the program loops to MAIN.
If the timeout has not expired, the KEYING routine checks to see if the last command sent was a "set injection code" command. If not, the program loops back to MAIN. If the last command was a "set injection code", the program checks to see if the mode switch is in auto and, upon determining that it is, the start up rectifier voltage is set, the power contactors are closed, and a 100 millisecond delay is established. The injection pointer is set to 1, which indicates that the substation injection unit is ready for an injection, and the input pointer is also set to one.
The eleven INJECT routines will now be explained. In INJ-1, the program first determines whether the delay set has timed out; if it has, it checks to see if the contactor is closed. If the contactors are not closed, a contactor error is set and the routine loops to ABTINJ, or abort injection. In routine ABTINJ, the contactors are opened, a 100 millisecond delay is established, the injection pointer is set equal to 9, and the program loops back to MAIN.
If the contactor is closed, INJ-1 then turns on the rectifier, sets a 50 millisecond delay, and sets the injection pointer equal to 2.
In INJ-2, if the 50 millisecond delay is finished, the inverter is turned to its IDLE mode, whereafter a 50 millisecond delay is established and the injection pointer is set equal to 3.
When this 50 millisecond delay is finished, INJ-3 closes the injection contactors, sets a 100 millisecond delay, and sets the injection pointer equal to 4.
When this delay is finished, INJ-4 checks to see if the injection contactor has closed. If it has, it checks the shoot-through counter to see if it has counted more than three shoot-throughs for this particular pulse. If so, a pulse code generator error is set and the injection is aborted. If not, a pulse timer is started and the injection pointer is set to 5.
In INJ-5, a timer count is obtained from a counter which is being decremented by a 60 Hertz clock. A table of numbers are stored that correspond to time and indicates when each of the 41 pulses in the pulse code should be sent. The first step in INJ-5 is to check to see whether the current timer count is proper by comparing it with the table count. If it is, the pulse indication is obtained from an internal buffer set up by a set injection code message in the substation injection unit and is checked to see if there should be a pulse in that position. If there should not, the injection pointer is set to 7 and the program cycles to MAIN. If there should in fact be a pulse in the position indicated, the shoot-through counter is cleared, the inverter is set to INJECT whereupon generation of a 340 Hertz pulse is initiated. A 50 millisecond delay is then set, and the injection pointer is set equal to 6.
In routine INJ-6, if the 50 millisecond delay has expired, the power level from the rectifier is changed to its preselected or full value. This is achieved through the rectifier controller, as explained above. Therefore, when the inverter controller initially goes to INJECT in INJ-5, it provides a low voltage level on the output of the rectifiers, after which in INJ-6 the output voltage of the rectifier is raised to its nominal desired value. This is known as a "soft start". The injection pointer is then set to 7.
In routine INJ-7, the program first looks to see if the pulse has been completed. If it has, the information obtained from the special receiver or pulse generator is examined to see if there was or was not a pulse. The output of the rectifier is then set back to the minimum power level, a 50 millisecond delay is set, and the injection pointer is set equal to 8.
If the delay is finished in INJ-8, the inverter is set to IDLE which stops the injection of the 340 Hertz pulse. The routine then checks to see if the shoot-through counter is greater than three for this particular phase. If it is, a pulse code generator error is set and the injection is aborted. If it is not, the contents of the shoot-through counter is added to the previous count, and the total is checked to see if it is greater than or equal to 8. This loop allows three shoot-throughs per pulse and a total of eight shoot-throughs on all pulses output during a single injection. The program then checks to see if the last pulse in the train has been sent. If it has, this injection cycle is over and the program loops to the abort injection routine ABTINJ. If the last pulse has not been sent, the injection pointer is set to 5 to check the next pulse.
Routine INJ-9 comes into play when an injection is aborted under the ABTINJ routine. The INJ-9 routine first checks to see if the 100 millisecond delay has expired. If it has, it checks to see if the contactor has been opened as requested in the ABTINJ routine. If it has not been opened, a contactor error is indicated. In any event, the inverter is turned to its OFF mode, a 50 millisecond time delay is set, and the injection pointer is set to 10.
In routine INJ-10, when the 50 millisecond time delay has expired, the power contactor in the main breaker is opened, another 100 millisecond time delay is set, and the injection pointer is set to 11.
In INJ-11, after the 100 millisecond delay has expired, the program checks to see if the power contactor has in fact opened. If it has not, contactor error is indicated. In any event, the injection pointer is then set to zero and the program loops back to MAIN.
Recall that in routine IN-3, the decoded command, after validation, is enabled by going to the routine that handles the particular command. These commands can include a polling command, a set injection code command or a report injection code command.
If a polling command is is decoded, the master control station has requested certain information from the substation injection unit. Several conditions are checked in the routine POLLING COMMAND. Upon detection of a positive condition, a flag or bit is set to indicate the detected condition. As is apparent from the flow chart, the following conditions are checked: whether the substation injection unit mode switch is in its manual position; whether any SCRs are overtemperature; whether the cabinet is overtemperature; whether there is neutral shift error; whether there is a contactor error; and whether there is a pulse code generator error. After the status conditions are checked, and the appropriate flags or bits are set, the routine starts an analog conversion, inputs any new analog values, obtains the external discrete inputs, and generates a polling response, then looping to the message transmit or MESXMT routine.
In the MESXMT routine, the substation injection address is set, the output pointer is set equal to one, and the input pointer is set equal to zero, whereupon the substation injection unit is ready to transmit to the master control station.
If the decoded command is to set the injection code, the program loops to the SET INJECTION CODE routine. The injection code received from the master control station is saved in a buffer. Next, a response message is generated using the received injection code, and a one minute timeout is set. The program then loops to MESXMT to transmit the message back to the master control station for verification.
If the decoded command is to report the injection code, the program loops to the REPORT INJECTION CODE routine. First, the injection code read from the special substation injection unit receiver or pulse generator is obtained, and a response message is generated. The program then loops to MESXMT to transmit the message back to the master control station.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A method and apparatus which permits a power utility to have direct control of customers loads (CD) with a view toward facilitating enablement of a load management philosophy which includes peak shaving and load deferral. A master control station (MCS), which comprises a programmable microprocessor-based central controller, is in two-way communication with a plurality of substation injection units (SIU), one of each of which is positioned at a separate substation of the power utility. Each substation injection unit (SIU), under the control of its own microprocessor, responds to master control signals from the master control station (MCS) to inject a pulse code signal onto the power lines of the utility. The system includes a plurality of remote receiver units (RRU) which are positioned at and connected to control the on and off times of customer loads (CD). Each remote receiver unit (RRU) is preset to respond to particular pulse code signals from the substation injection units (SIU) to carry out the desired command functions, which can be implemented either automatically or manually on a fixed or dynamic-cycle basis as the need arises. The system utilizes a command signal and pulse code signal verification technique to insure system integrity and reliability.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is the U.S. national stage application of International Application No. PCT/CN2014/082573, filed on Jul. 21, 2014. The above-identified patent application is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to coalbed gas extracting, in particular to methods and devices for extracting coalbed gas from an inclined well shaft which contains also water, coal dust and sand.
BACKGROUND
[0003] Coalbed gas is a self-generating and self-preserving unconventional natural gas in coalbeds. There are 74 countries in the world that are endowed with coalbed gas resources, while China boasts coalbed gas reserve up to 36.8 trillion cubic meters, ranking No. 3 in the world; China has exploitable coalbed gas resources of about 10 trillion cubic meters. Nowadays, values of such unconventional resource has been recognized; the exploration and utilization of coalbed gas resources have been gradually progressing all over the world.
[0004] In the extraction process of coalbed gas, a large amount of coalbed water contained in coalbeds may cause excessively high pressure at the bottom of the coalbed gas well, so that the coalbed gas cannot flow into the well shaft. Therefore, it is required to discharge the coalbed water so as to reduce the pressure at the bottom of the coalbed gas well. In this way, the coalbed gas is able to continuously flow into the well shaft due to a pressure difference generated thereby. In addition, the production characteristics of coalbed gas requires that the coalbed water be stably drained with a reasonable drainage and extraction strength. Due to various restrictions such as topographic conditions, investment scale and national land policies, the drilling mode of multi-well cluster (multiple wells drilled in a well site) is increasingly adopted. As determined by this specific drilling mode, the vast majority of coalbed gas wells have inclined shafts. Combined with a shallow burial depth of coalbed that dictates a small hole curvature radius of the coalbed gas well, the following problems are resulted in the drainage and extraction process of coalbed water.
[0005] Firstly, the coal gas well is greatly sloped and having a small hole curvature radius. Even the existing vertical wells have such problems as serious hole deviation and high rate of overall angle change. The commonly used sucker-rod pumps (e.g., tubing pumps and screw pumps) thus suffer from serous abrasion of rods and tubes, resulting in high consumption of rod and tube materials as well as frequent workover operations.
[0006] Secondly, the output coalbed water contains coal dust and fracturing sand (this is because all the coal gas wells are put to production after fracturing). This leads to frequent faults (such as corrosion of rods, pipes and pumps, pump blocking and stuck pumps) in the existing coalbed water lifting devices (e.g., tubing pumps, screw pumps and electrical submersible pumps), which cause frequent workover operations.
[0007] Thirdly, most of the coal gas wells have a water yield less than the minimal discharge capacity requirement of electrical submersible pumps, and therefore do not comply with the well selection criteria of electrical submersible pumps.
[0008] Fourthly, although the operating conditions of sand discharge and oil extraction methods are relatively similar to the technical requirements for coalbed gas extraction through drainage of water and coal dust, the methods have yet to be applied in the field of coalbed gas extraction through water and coal dust drainage. Necessary modifications and improvements are to be made to the technical structure of the well shaft as well as to the methods themselves before they can be applied to coalbed gas extraction through water and coal dust drainage.
[0009] To sum up, the conventional coalbed water lifting technology employed nowadays would cause frequent workover operations on coalbed gas wells, significantly increasing the production cost of coalbed gas extraction. In addition, the frequent workover operations on coal gas wells may most easily cause damage to the reservoir bed and directly affect the extraction performance of coalbed gas.
SUMMARY
[0010] The following summary is illustrative only and is not intended to be limiting in any way. That is, the following summary is provided to introduce concepts, highlights, benefits and advantages of the novel and non-obvious techniques described herein. Select implementations are further described below in the detailed description. Thus, the following summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter.
[0011] Implementations of the present disclosure relate to a method for extracting coalbed gas through a water and coal dust drainage, which is so designed that the water and coal dust contained in the coalbed can be sufficiently sucked into a hydraulic jet pump and then discharged to the surface of the ground.
[0012] The implementations further relate to a device for realizing the method described above.
[0013] The implementations include: a method for extracting coalbed gas through a water and coal dust drainage. The method involves providing a power fluid into a downhole power fluid pipe in a well shaft via a wellhead device. The wellhead device is provided with a flow channel system such that the power fluid is transported into a hydraulic jet pump disposed inside a pump cylinder connected with the downhole power fluid pipe. Accordingly, the hydraulic jet pump starts to work to suck a formation fluid into the hydraulic jet pump through a suction inlet at a lower part of the hydraulic jet pump.
[0014] The method also involves forming a mixed fluid by mixing the formation fluid with the power fluid.
[0015] The method further involves transporting the mixed fluid upwards to ground, wherein the mixed fluid contains coal dust. The mixed fluid is transported by a downhole mixed fluid pipe in the well shaft, and the downhole mixed fluid pipe has a small flow channel cross section such that the mixed fluid containing the coal dust flows upward through the wellhead device to the ground at a flow rate higher than a sedimentation rate of the coal dust. Accordingly, a sedimentation of the coal dust is prevented. Also, the pump cylinder reaches a lower boundary of a coalbed, which prevents the coal dust from burying the coalbed.
[0016] The method still involves collecting the coalbed gas by a ground gas collecting device. The coalbed gas reaches the ground through an annular space inside a shaft casing.
[0017] In addition, a device for extracting coalbed gas through a water and coal dust drainage according to the present disclosure is realized in the following manner. This device is provided with a wellhead device having a flow channel system. This device is also provided with a power fluid inlet on the wellhead device connected with a downhole power fluid pipe in a shaft casing through the flow channel system in the wellhead device. This device is also provided with a mixed fluid outlet on the wellhead device connected with a downhole mixed fluid pipe in a shaft through the flow channel system in the wellhead device. This device is also provided with a hydraulic jet pump connected with the downhole power fluid pipe and the downhole mixed fluid pipe. The hydraulic jet pump includes a pump cylinder configured to be placed at a lower boundary of a coalbed.
[0018] When the method for extracting coalbed gas through water and coal dust drainage as well as the device thereof are adopted, the power fluid enters the hydraulic jet pump through the wellhead device and the downhole power fluid pipe. This enables the hydraulic jet pump to operate. The hydraulic jet pump sucks in formation fluid that contains both water and coal dust, and mixes the formation fluid with the power fluid to form a mixed fluid. The mixed fluid is transported upwards to the well head through a downhole mixed fluid pipe and discharged to the ground, completing the drainage and extraction of the coalbed water that contains coal dust. With the discharge of the coalbed water, the bottom-hole pressure of the coalbed gas well (i.e., the pressure at the bottom of the well at the working fluid level) is gradually decreased. When the bottom-hole pressure (at the working fluid level) of the coalbed gas well has dropped to a certain extent, the coalbed gas enters the well shaft under the action of the produced differential pressure. Since the density of the coalbed gas is much less than the density of the coalbed water, the coalbed gas thus moves upwards along an annular space inside the shaft casing and enters the ground gas collecting device through a gas well casing valve. The pump cylinder of the hydraulic jet pump is located at the lower boundary of the coalbed, which prevents the coal dust from burying the coalbed. Since no packer is provided under the well shaft, it is feasible to timely detect and record data such as the casing-head pressure and the working fluid level of the gas well. The speed of water drainage can be reasonably controlled by adjusting technical parameters of the downhole hydraulic jet pump and the pressure of the power fluid, so as to meet the requirement for drainage and extraction of the coalbed water. Furthermore, there is no moving components under the shaft, so there is no issue of sucker rod side-abrasion. Therefore, through the adoption of this method and the device thereof, the drainage and extraction process of coalbed water containing coal dust is simplified, the production cost significantly reduced, and the overall benefits of extracting the coalbed gas enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic diagram of an embodiment of a device for extracting coalbed gas through water and coal dust drainage according to the present disclosure.
[0020] FIG. 2 is a structure diagram of a hydraulic jet pump in a power fluid positive circulation mode in a device for extracting coalbed gas through water and coal dust drainage according to the present disclosure.
[0021] FIG. 3 is a structure diagram of a hydraulic jet pump in a power fluid reverse circulation mode in a device for extracting coalbed gas through water and coal dust drainage according to the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The present disclosure is described in detail with reference to the attached figures.
[0023] As shown in the attached figures, a device for extracting coalbed gas through water and coal dust drainage according to the present disclosure is realized in following manner. This device is provided with wellhead device 12 having a flow channel system. Power fluid inlet 2 on the wellhead device is connected with downhole power fluid pipe 7 in shaft casing 5 through the flow channel system in the wellhead device. Mixed fluid outlet 3 on the wellhead device is connected with downhole mixed fluid pipe 6 in the well shaft through the flow channel system in the wellhead device. The downhole power fluid pipe and the downhole mixed fluid pipe are connected with hydraulic jet pump 9 . Pump cylinder 10 of the hydraulic jet pump is located at the lower boundary of coalbed.
[0024] The operating principle of this device is described in view of a positive circulation of the power fluid, as follows. The power fluid of high pressure drives the downhole hydraulic jet pump to work. The flow channel of the downhole mixed pipe has a small cross section area, so that the mixed fluid containing coal dust flows upward to the ground through mixed fluid outlet 3 on the wellhead device at a flow rate much higher than the sedimentation rate of cost dust. As the coalbed water containing coal dust is discharged with control, the coalbed gas is able to continuously flow into the well shaft. Subsequently, under the action of downhole flow pressure at the bottom of the well, the coalbed gas moves along an annular space between shaft casing 5 and downhole power fluid pipe 7 , through casing valve 4 of the wellhead device, and eventually reaches the ground and flows onwards.
[0025] The upward sending of the mixed fluid containing coal dust is completed by the flow channel of the downhole mixed fluid pipe in the well shaft. The flow channel of the downhole mixed fluid pipe has a cross-section area less than a cross-section area of the flow channel of the downhole power fluid pipe, such that the mixed fluid containing coal dust flows upwards at a flow rate much greater than a sedimentation rate of coal dust.
[0026] Referring to FIGS. 1 and 3 , a device for extracting coalbed gas through water and coal dust drainage according to the present disclosure is described in view of a reverse circulation of the power fluid, as follows. This device is provided with wellhead device 12 having a flow channel system. Power fluid inlet 2 on the wellhead device is connected with downhole power fluid pipe 7 in shaft casing 5 through the flow channel system in the wellhead device. Mixed fluid outlet 3 on the wellhead device is connected with downhole mixed fluid pipe 6 in the well shaft through the flow channel system in the wellhead device. The downhole power fluid pipe and the downhole mixed fluid pipe are connected with hydraulic jet pump 9 . Suction inlet 10 of the downhole hydraulic jet pump is located at the lower boundary of coalbed. The power fluid of high pressure drives the downhole hydraulic jet pump to work. Through an optimized design of the flow channel cross-section area of the downhole mixed fluid pipe, along with a reasonable allocation of the quantity of the power fluid, the mixed fluid containing coal dust is configured to flow upwards at a flow rate much greater than the sedimentation rate of oil reservoir coal dust, thus able to reach the ground through mixed fluid outlet 3 on the wellhead device. As the coalbed water containing coal dust is discharged with control, the coalbed gas is able to continuously flow into the well shaft. Subsequently, under the action of downhole flow pressure at the bottom of the well, the coalbed gas moves along an annular space between shaft casing 5 and downhole power fluid pipe 7 , through casing valve 4 of the wellhead device, and eventually reaches the ground and flows onwards. The undermost end of the well shaft is an artificial well bottom 11 .
[0027] When the pump core of the hydraulic jet pump is transported to the downhole, the pulling-running tool 1 on the wellhead device can be used to send the pump core down the downhole power fluid pipe, and the power fluid is then used to send the pump core to the operating position in the pump cylinder.
[0028] When it is necessary to move the pump core of the hydraulic jet pump out of the downhole and to the ground, power fluid can be injected into the mixed fluid outlet so that the flow direction of the power fluid is opposite to that of the normal operating. This way, the hydraulic jet pump can be sent upwards along the downhole power fluid pipe to the pulling-running tool on the well head, so as to be taken out.
[0029] As the coalbed water is being discharged, the bottom-hole pressure of the coalbed gas well gradually decreases, which enables the coalbed gas to flow into the well shaft along cracks in the coalbed and then subsequently reach a gas collective device located on the ground through the annular space inside the shaft casing.
[0030] The high pressure power fluid required by the downhole hydraulic jet pump is provided by a ground power fluid pump. The coalbed water output by the coalbed gas well can be adopted as the power fluid and can be put into cycle use after a simple sedimentation process. The coalbed water output by various coalbeds 8 in the coalbed gas well is discharged to the ground and then enters the water collecting system.
[0031] As shown in FIG. 2 , first O-ring A 1 is used for the sealing between the power fluid and the output fluid. Second O-ring B 1 is used for the sealing between the output fluid and the mixed fluid. First pump core seat C 1 is used to support the hydraulic jet pump core. The power fluid enters the hydraulic jet pump through flow channel D 1 of the first power fluid pump core, and the mixed fluid flows out from mixed fluid outlet E 1 . First nozzle 6 . 1 is provided in the pump core of the hydraulic jet pump, first throat pipe 6 . 2 is provided under the first nozzle, and first check valve 6 . 3 is mounted in first formation fluid inlet F 1 at a lower part of the pump body.
[0032] As shown in FIG. 3 , third O-ring A 2 is used for sealing between the power fluid and the output fluid. Fourth O-ring B 2 is used for the sealing between the power fluid and the output fluid. Second pump core seat C 2 is used to support the hydraulic jet pump core. The power fluid enters the hydraulic jet pump through flow channel E 2 of the second power fluid pump core, and the mixed fluid flows out from mixed fluid outlet D 2 . Second nozzle 8 . 1 is provided in the pump core of the hydraulic jet pump, second throat pipe 8 . 2 is provided under the second nozzle, and second check valve 8 . 3 is mounted in second formation fluid inlet F 2 at a lower part of the pump body.
Additional Notes
[0033] The herein-described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely examples, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled”, to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable”, to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interacting and/or logically interactable components.
[0034] Further, with respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[0035] Moreover, it will be understood by those skilled in the art that, in general, terms used herein, and especially in the appended claims, e.g., bodies of the appended claims, are generally intended as “open” terms, e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc. It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to implementations containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an,” e.g., “a” and/or “an” should be interpreted to mean “at least one” or “one or more;” the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number, e.g., the bare recitation of “two recitations,” without other modifiers, means at least two recitations, or two or more recitations. Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention, e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc. In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention, e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc. It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0036] From the foregoing, it will be appreciated that various implementations of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope and spirit of the present disclosure. Accordingly, the various implementations disclosed herein are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
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A method for extracting coalbed gas. A wellhead device delivers power fluid into a downhole power fluid pipe in a well shaft, and conveys the fluid to a pump in a pump cylinder connected with the downhole power fluid pipe. The pump sucks in formation fluid via a suction inlet, mixes the fluid with the power fluid to produce a mixed fluid, and conveys the mixed fluid to ground surface. The mixed fluid containing coal dust travels at a flow rate greater than a sedimentation rate of the coal dust, passes though the wellhead device, and flows to the ground surface, thereby preventing a sedimentation of the coal dust. The suction inlet of the pump reaches a lower boundary of a coalbed so as to prevent coal dust from burying the coalbed, and the coalbed gas automatically shoots through an annular space of a well shaft casing.
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BACKGROUND OF THE INVENTION
The invention relates to a louvre window clip, and more particularly, to a louvre window clip assembly that is capable of replacing a louvre window support piece without having to remove an entire louvre window frame.
Louvre windows are glass window blades extending in parallel across a window frame. Louvre window clips are secured to the window frame and used to hold the glass blades of the louvre window in place. Each end of the glass window blade is supported in a glass receiving groove on a front side of the louvre clip. The back side of the louvre window clips are connected to an opening and closing mechanism attached to the frame member of the louvre window. The mechanism allows the louvre window clips to rotate to open and close the glass blades in unison.
A common type of louvered window utilized today, for example U.S. Pat. No. 2,770,853, involves a metallic frame member which is received in a window opening of a building structure. The frame, on one side, contains an actuating mechanism to effect movement of the glass blades between the closed overlapping position and the partially rotated open position. The actuating mechanism may consist of a pair of parallel flattened rod members extending vertically along the metallic frame member at one side of the window. The rod members may be affixed to a crank or lever mechanism, as shown in U.S. Pat. No. 2,726,426, capable of moving them in opposite longitudinal directions. For various reasons, including safety, it is desired that these mechanisms be enclosed within the frame such that when the frame is mounted in the window opening, there is no easy access to the operating mechanism except for access to the crank or louvered lever on the inside. The individual glass panes, have their ends carried in louver clips. At least one louvre clip for each pane is then operatively affixed to the moving rods so that upon reverse longitudinal movement of the rods, the clip is caused to undergo a rotational movement. The louvre clips are positioned on the exterior of the frame member and are connected through openings in the frame member to the actuating mechanism.
While it has been known to make louvre clips in a single piece structure having a portion extending through the openings in the frame member for fixture to the rods, the attachments to the rod normally must be made from the interior side of the frame member by means such as rivets or bolts extending through the rods into the louvre clip portion projecting into the interior of the frame. In the event that such assemblies are to be shipped broken down for ease of transport, this has generally meant that the louvre clips must be affixed to the frame member's segment when shipped and that they must be secured against a rotation to minimize the potential for damage to the clips in shipment and storage.
Generally, the glass blades have been supported in metal clips, resulting in a glass-to-metal abutment. In order to provide more resilient means for holding the glass in place, plastic clips have been developed. However, due to inclement conditions and/or usage, the clip may break, crack, or chip. Thus, the damaged louvre window clip must be replaced by a new one.
Such single piece clips have the disadvantage that if the clip becomes broken, a replacement can only be effectuated by obtaining access to the interior of the frame member. After the frame is seated in the window opening, clip replacement in such cases may require extensive disassembly of the entire louvre window.
While it has been known to manufacture the clip and operating mechanism connection in two pieces, normally such two piece assemblies are joined together by screws or the like internally of the frame; again requiring disassembly of the frame in order to replace the clip.
If the glass receiving portion of the louvre window clip is damaged or broken, the entire frame member of the window frame must be removed in order to remove the damaged clip. This process may require the removal of all the glass window panes from their respective louvre clips in order to remove the frame member of the window frame. The frame member must then be removed to access the interior wall of the frame member. Access to the interior wall of the frame member is necessary to disengage the damaged louvre window clip from the frame member and replace the damaged louvre window clip with a new one. After the damaged louvre clip has been replaced, the frame member is then reinserted into the window frame and each and every glass pane is inserted into its respective louvre window clip. This process takes an extreme amount of time.
It is generally desired that the clip be firmly affixed to the frame member so that the clip will not fall away from the frame member in the event that the glass pane is not in place or is removed or broken. For this reason, internal attachments have an advantage in that they secure the clip semipermanently to the frame. Nevertheless, since it is possible for clips themselves to become broken, chipped, damaged or otherwise inoperative, it is desirable to be able to replace clips periodically. It would be an advance to be able to make such a replacement without having to disassemble the frame or obtain access to the interior of the frame. It would also be desirable to be able to preassemble the frame with the operating mechanism but without the Louvre clips attached since this would provide for a more secure and compact shipment and greater ease of storage. This is particularly true since frequently it may be desired to provide the ultimate customer with clips of a different color or finish to match a desired decor.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a louvre window clip assembly for use with a window frame member that is replaceable from the exterior side of the frame member.
It is a further object of the invention to provide a louvre window clip assembly that may be replaced without having to disassemble the frame member or obtain access to the interior of the frame.
It is a further object of the invention to preassemble the frame member with the operating mechanism but without the louvre clips attached.
It is a further object of the invention to provide a louvre window clip assembly that is rotatably securable to the frame member.
It is a further object of the invention to provide a louvre window clip assembly which reduces the time required to replace a damaged louvre window clip.
It is a further object of the invention to provide a louvre window clip assembly that may be replaced without having to remove the plurality of louvre window clips attached in parallel to the damaged louvre window clip.
The invention includes a hub and clip assembly in which the clip is fastened to the hub so that the clip is positioned on the exterior of a window frame and the hub is positioned on the interior of the window frame. The clip and the hub are cooperatively shaped in order to properly fasten to one another. The clip is secured to the hub so that the clip and the hub simultaneously rotate about an axis that is perpendicular to the frame. The clip is capable of being removed from the hub without having to access the interior of the window frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear view of the clip section of the invention.
FIG. 2 is a front view of the hub section of the invention.
FIG. 3 is a side view of the hub.
FIG. 4 is a perspective rear view of the hub.
FIG. 5 is a perspective exploded view of the installation of the invention in a frame member.
FIG. 6 is a perspective view of the assembled invention.
FIG. 7 is a perspective view of the clip section and a glass pane.
FIG. 8 is a sectional view of the invention with the frame member.
FIG. 9 is a perspective view of multiple embodiments working in unison.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The louvre clip of the present invention consists of two component parts as shown in FIGS. 1 and 2. A molded plastic clip portion 10 carries a louvre window glass pane 11 (see FIG. 5) and is received on an exterior of a frame member 12 (FIG. 5). An interior hub portion 20 is primarily received interior of the frame member 12 and has a connecting portion 22 which projects through the frame member 20 and indexes with the clip portion 10 to connect the hub portion 12 and the clip portion 10 together.
FIG. 1 illustrates a backside 24 of the clip portion 10 of the present invention. A front side 26 (see FIG. 7) of the clip portion 10 is designed to receive the glass louvre window pane 11 in a glass receiving groove 28. The backside 24 of the clip portion 10 has an inner diameter 30 and an outer diameter 32. A mounting hole 34 is positioned in the center of the clip 10 and aligned with the glass receiving groove 28 on the front side 26 of the clip 10. The backside 24 of the clip portion 10 also has an engagement section 40 (shown in FIG. 1 as a U-shaped groove). The engagement section 40 is designed to receive the connecting portion 22 of the hub 20.
FIGS. 2, 3 and 4 illustrate various views of the hub 20. The hub 20 is generally disc-shaped having an interior section 42 with an enlarged diameter 44. The interior section 42 has a back face 46 with two projecting members 48 and 50 as connectors for cooperating with an operating mechanism 52 (as shown in FIG. 5). A front side 60 of the hub 20 has a smaller diameter section 62 that is adapted to project through the frame member 12. The front side 60 of the hub 20 cooperatively engages with the backside 24 of the clip portion 10 via the connecting portion 22 or other cooperatively aligned engagement. The hub 20 also has a mounting hole 64 located in the center of the hub 20. The mounting hole 64 of the hub 20 cooperatively aligns with the mounting hole 34 of the clip section 10 to accept a screw mounting (not shown). The connecting portion 22, shown here as a tongue, projects beyond an outer diameter 62 of the front side 60 of the hub 20 so that it may be slidably mounted into the groove 40 of the clip section 10.
FIG. 5 illustrates the installation of an embodiment of the invention onto the frame member 12. The frame member 12 is provided with a plurality of spaced apart generally circular openings 70. Each of the openings 70 has diametrically opposed recesses 72, 74 for receiving the tangs 72a, 74a of the tongue 22. The smaller diameter section 62 of the hub 20 is designed to be received in the circular opening 70 and to be rotatable with respect thereto. The enlarged diameter portion 44 has a diameter larger than the opening 70 whereby the hub 20 cannot be projected completely through the opening 70 in the frame 12 from the interior.
The connecting portion of tongue 22 projects above the reduced diameter section 62 on the exterior portion thereof and extends beyond the diameter 22 such that the hub 20 can only be inserted into the opening 70 when the connecting portion 22 is aligned with the recesses 72, 74. Thereafter, rotation of the hub 20 will entrap the metal of the frame member 12 between the projections of the ends of the connecting portion 62 in the enlarged diameter section 44 to retain the hub 20 in position in the frame 12. The location of the recesses 72, 74 is chosen with respect to the operating rotation of the hub 20, determined by the movement of the operating mechanism 52, consisting of hub control bars 80, 82, such that the bosses 72, 74 lie in an angular position not encountered by normal rotation of the hub 20 during opening and closing of the louvre window blades. In this manner, once the hub 20 is inserted into the frame member 12 and the bars 80 and 82 are connected to the hub 20 via the split connectors 48, 50, the hubs 20 will not be rotatable to a position permitting withdrawal of the hubs 20 from the frame member 12 during normal operation.
After the hub 20 is secured to the frame member 12 via the operating bars 48, 50, the U-shaped groove 40 on the clip section 10, slidably engages with the connecting portion 22 of the hub 20 forming the louvre window clip assembly 84 (further shown in FIG. 6). When the clip section 10 engages with the hub 20 the mounting holes 34 and 64 should be aligned. A mounting screw 86 or other mounting device, secures the clip section 10 to the hub 20. The louvre glass window pane 11 may then be installed into the glass receiving groove 28 on the front side 26 of the clip section 10. Once the glass window pane 11 is installed, the mounting screw 86 is no longer accessible unless the glass pane 11 is removed. This provides a security measure.
FIG. 6 shows the assembled invention 84. The hub 20 and the clip section 10 are engaged to form one louvre window clip assembly 84. The diameter 44 of the hub 20 is less than the inner diameter 30 of the clip section 10. This permits the hub 20 to uniformly fit within the clip section 10. An advantage of this uniform design is to protect against inclement weather conditions such as rain and wind.
FIG. 7 is a perspective front view of the clip section 10. A louvre window glass pane 11 is received by the glass receiving groove 28 of the clip section 10. The receiving groove 28 can be adapted to accommodate various materials other than glass. These materials include, but are not limited to, wood and vinyl slats of varying widths. The width of the receiving groove 28 may even be greater than the outer diameter 32 of the clip section 10 in order to accommodate the slats. Two edges 92, 94 of the clip section 10 are adapted to prevent the glass window pane 11 from sliding out of the glass receiving groove 28.
FIG. 8 is a side view of the invention 84 and the window frame member 12. The hub 20 has been inserted through the frame member 12. The clip section 10 is cooperatively engaged with the hub 20 and the mounting screw 86 has been inserted. The two projecting members 48 and 50 are cooperatively aligned with the operating mechanism 52 on the interior of the frame member 12. The glass window pane 1 1 is inserted into the clip section 10.
FIG. 9 shows a plurality of louvre window clip assemblies 84 installed in a window frame member 12. The plurality of louvre window clip assemblies 84 operate in unison via the operating mechanism 52. The operating bars 80 and 82 move in opposite direction to one another when activated. This movement provides a rotational torque causing the window clip assemblies 84 to rotate approximately ninety (90) degrees so that the glass window panes 11 completely open and close. As the louvre window clip assemblies 84 are closed they lock into place.
The present invention is subject to many variations, modifications and changes in detail. It is intended that all matter described throughout the specification and shown in the accompanying drawings be considered illustrative only. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
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A louvre window clip assembly that is used with a window frame. The clip assembly includes a clip, that is capable of receiving a glass window pane, and a hub. The hub and clip are engaged so that the clip is removable from the exterior of the window frame without having to access the interior of the window frame.
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FIELD OF THE INVENTION
The invention relates to a sewing machine comprising a needle bar jogging frame in which a needle bar, which is drivable with a reciprocating motion in a longitudinal direction of the needle bar, is mounted, which frame is mounted in a head of the sewing machine by means of a link joint and which is drivable with a swinging motion in a jogging plane coinciding with a workpiece feed direction.
BACKGROUND OF THE INVENTION
Sewing machines of this type are also referred to as needle feed sewing machines. In addition to being provided with needle feed, they can also be provided with a so-called upper feeding device for the workpiece or workpieces to be sewn.
A sewing machine is known from U.S. Pat. No. 2,292,257, wherein the upper area of a jogging frame is mounted by means of a link which is displaceable with a reciprocating motion by means of a crank mechanism approximately in the workpiece feed direction. This makes it possible for the needle to run essentially perpendicular to the workpiece when stitching into the material to be sewn. A disadvantage in this case is that a special drive is required for the mentioned crank mechanism, and that a straight-line motion of the needle can only be achieved in theory with a specific stitch length because the geometry of the crank mechanism for displacing the jogging frame in the jogging plane is invariable. Therefore, a distinct straight-line motion, i.e. displacement of the needle parallel to itself, is not achieved in the case of different stitch lengths. Furthermore, it is impossible to use such a mechanism in sewing machines in which the sewing direction for producing lock stitches can be reversed.
Because of the previously described disadvantages sewing machines having a jogging frame which can be driven with a swinging motion about a link joint have therefore gained a much greater acceptance in practice. With such a sewing machine of the defined type, which is known from U.S. Pat. No. 4,616,586, the swing drive of the jogging frame is effected by way of a needle bar feed shaft which can be driven with a swinging motion and is connected to the jogging frame via a chain of articulated levers. In addition, the jogging frame also bears a presser foot of an upper feeding device, which foot can be driven with a swinging motion together with the needle bar. As a result of the needle bar and needle being pivoted about the swivel axis of the fixed link, the needle undergoes, when stitching into the workpiece to be sewn, a bending load resulting in an increase in needle wear. A further disadvantage is that, as a result of its change in inclination during needle feed, i.e. during feed of the workpiece with the needle having stitched therein, the needle displaces the workpieces, to be sewn together, relative to one another, which can result in the two workpieces, to be sewn together, no longer being flush with one another at the end of a seam.
A zigzag-stitch machine is known from U.S. Pat. No. 3,313,258, wherein a needle bar jogging frame can be moved with a translational reciprocating motion at right angles to the sewing direction, i.e. at right angles to the workpiece feed direction, to produce the zigzag stitch. For this purpose the jogging frame is mounted on a sliding bar. Guidance of a needle bar jogging frame in such a manner in a needle feed direction, i.e. in the workpiece feed direction, is impossible.
SUMMARY OF THE INVENTION
It is an object of the invention to create a sewing machine of the type as defined, wherein, irrespective of the stitch length and of the sewing direction the needle bar is guided and displaced always parallel to itself. It is a further object of the invention to provide such a sewing machine with a simple construction.
This object is solved in accordance with the invention by the features that the jogging frame is a first member of a parallel four-bar linkage, the jogging frame being pivotably connected, at one end, to the link joint via a guide lever which is connected to the jogging frame by means of a link joint and serves as a second member, and the jogging frame being pivotably connected, at the other end, to a bearing fixed in the head serving as a fourth member via a lever which is articulated on the jogging frame by means of a link serving as a third member, and the guide lever and the lever having identical lengths and being arranged parallel to one another.
The design of the jogging frame bearing and guiding means in the form of a parallel linkage results in the needle bar and needle always being moved or displaced parallel to itself in the jogging plane of the jogging frame, irrespective of the stitch length and irrespective of whether the sewing direction is forward or backward to produce lock stitches. A drive of this type can be created in a very simple manner. It is therefore space-saving, robust and simple.
The drive of a jogging frame mounted in the manner according to the invention may be embodied in a particularly simple manner when the lever is connected to a swing drive. When the lever is rigidly connected to a needle bar feed shaft which is drivable with a swinging motion and which, being flush with the fixed bearing of the lever, is connected to the latter, the swinging movement is introduced via the link joint so that, in addition to fulfilling its guiding function, a member of the linkage at the same time fulfills a driving function.
Further advantages and features of the invention will become apparent from the ensuing description of an exemplary embodiment, taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a partially broken away side view of a sewing machine;
FIG. 2 shows a view of the head of the sewing machine with the cover removed, in the direction of arrow II in FIG. 1;
FIG. 3 shows a partial side view of the head of the sewing machine in the direction of arrow III in FIG. 2, in a view partially broken away and cut through different planes;
FIG. 4 shows a partial horizontal section through the head of the sewing machine along the line IV--IV in FIG. 2; and
FIGS. 5a to 5c show diagrammatic views of the jogging frame of the sewing machine in different swing positions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A sewing machine 1 has in the usual manner a base plate 2 and an arm 3 which, at one end, is connected to the base plate via a standard 4 and, at the other end, ends in a head 5. Rotatably mounted in the arm 3 is an arm shaft 6 on which a handwheel 7 is secured on the side of the standard 4 and outside the latter. In the region of the head 5 the arm shaft 6 is provided with a crank 8 which has a crank pin 9 for the pivotable location of a connecting rod 10. The free end of the connecting rod 10 remote from the crank pin 9 is pivotably connected to a needle bar connecting stud 11 which is secured on a vertically arranged needle bar 13 by means of a set screw 12. The crank 8, together with the crank pin 9, the connecting rod 10 and the connecting stud 11, forms a needle bar crank mechanism. At its lower end the needle bar 13 supports a needle 14.
The needle bar 13 is mounted so as to be movable in its longitudinal direction in a jogging frame 15. For this purpose the jogging frame 15 has an upper needle bar bearing 16 situated above the needle bar connecting stud 11 and a lower needle bar bearing 17 situated below the connecting stud 11.
The jogging frame 15 is mounted pivotably relative to the head 5 or arm 3 by means of a guide lever 18 on one side--the right hand side in FIG. 2. For this purpose this guide lever 18 is articulated on the jogging frame 15 by means of a link joint 19 and, at its other--upper--free end, is articulated so as to be freely pivotable on the head 5 of the arm 3 by means of a link joint 20. The tilt axes 21, 22 of the link joints 19, 20 and thus of the guide lever 18 and, in this respect, also of the jogging frame 15 run parallel to the arm shaft 6.
On its other side--the left hand side in FIG. 2--the jogging frame 15 is connected to a needle bar feed shaft 24 by means of a lever 23. For this purpose this lever 23 is rigidly mounted on the shaft 24. Its lower free end is pivotably connected to the jogging frame 15 by means of a link joint 25. The axis of rotation 26 of this link joint 25 and the shaft 24 also extend parallel to the arm shaft 6.
The drive of this needle bar feed shaft 24 mounted in the arm 3 is derived from the arm shaft 6. For this purpose an eccentric drive 27, which drives the needle bar feed shaft 24 via a tie rod 28 and a lever connected thereto via a hinge joint 29, is attached to the arm shaft 6. For this purpose the lever 30 is rigidly connected to the shaft 24. Because of this design, the jogging frame 15 and thus the needle bar 13 mounted in this frame are driven synchronously to create the reciprocating motion of the needle bar 13.
A slide bearing 31 for receiving a presser foot bar 32 which is movable parallel to the needle bar 13 is formed in the lower area of the jogging frame 15, adjacent to the lower needle bar bearing 17. A presser foot 33 is attached to the lower end of this bar 32. This presser foot 33 has an opening 34 to allow passage of the needle 14. The underside of the movable presser foot 33 is provided with profiling (not shown), for example in the form of teeth. The needle 14 and the movable presser foot 33 are arranged symmetrically with respect to one another in their jogging plane which is predetermined by the swinging motion of the jogging frame 15, this jogging plane being indicated by an arrow 35 in FIG. 2.
Mounted in the head 5 is another presser foot bar 36 in a bearing bushing 37 which is rigidly mounted in the head 5 so that the presser foot bar 36 can only move in its longitudinal direction; it is therefore referred to as the stationary presser foot bar 36. Attached to the lower end of the stationary presser foot bar 36 is a presser foot 38 having two webs 39 which, between them, receive with play the lower area 40 of the movable presser foot 33, which area is provided with the opening 34 and profiling.
At its upper end situated only slightly above its slide bearing 31, the presser foot bar 32 which is slidably mounted in and is movable with the jogging frame 15 is provided with a lug 41 to which an articulated lever 42 is linked, the other end of this lever being in turn articulated on an angle lever 43. A bearing block 44 on which the angle lever 43 is in turn pivotably mounted is secured on the stationary presser foot bar 36.
Symmetrically with respect to the lower area of the presser foot 33 which is movable with the jogging frame 15, there is provided in the base plate 2 a lower feed dog 45 which projects through a recess 46 in a throat plate 47 attached to the base plate 2. The feed dog 45 is attached in the conventional manner to a beam 48 which is moved, in the known manner, with a reciprocating and up- and down motion by a feed mechanism (not shown in detail) so that the feed dog 45 executes an actually approximately elliptical movement, which is usually referred to as a quadrangular movement, during operation of the sewing machine. The needle 14 cooperates with a hook 49, which is arranged in the base plate 2 below the throat plate 47, to produce a seam in a workpiece 50 which is shown by a dot-dash line in FIG. 2.
The lower area 40 of the presser foot 33 which can be driven with a swinging motion is associated with the feed dog 45, the workpiece 50 being received between these two parts. On the other hand, the webs 39 of the non-swingable presser foot 38 only come into contact with the throat plate 47 or the workpiece 50 lying thereon.
The presser foot 33 mounted in the jogging frame 15 is set on the lower feed dog 45 and holds the workpiece 50 firmly on the latter when the jogging frame 15 executes a swinging movement with the needle 14 having stitched into the workpiece. During this phase of movement the non-swingable presser foot 38 is lifted clear of the workpiece 50. If, on the other hand, the needle 14 has not stitched into the workpiece 50, the presser foot 33 is also lifted clear of the work-piece 50. On the other hand, the workpiece 50 is then retained firmly, i.e. generally rigidly, relative to the throat plate 47 by the presser foot 38 which has been lowered on to the workpiece. The drive of the two presser foot bars 32 and 36 with their presser feet 33 and 38 is in the present case of no importance and is known. In this connection reference is made specifically to U.S. Pat. No. 4,616,586.
The hook 49 is driven via a shaft 51 which is mounted in the base plate and can be driven by the arm shaft 6 with the aid of a timing belt drive 52. The drive of the feed mechanism (not shown) for the lower feed dog 45 is also derived from this source.
As shown particularly in FIGS. 5a to 5c, the guide lever 18 and the lever 23 are always arranged parallel to one another. The length 1 18 of the guide lever 18 between the tilt axes 21, 22 of the link joints 19, 20 is therefore identical to the length 1 23 of the lever 23 between the axis of rotation 26 of the link joint 25 and the axis of rotation 54 of the needle bar feed shaft 24 which, inter alia, is mounted rigidly in a bearing 55 in the head 5. Moreover, the distance a between the axis of rotation 54 of the shaft 24 and the tilt axis 22 of the fixed link joint 20 is identical to the distance b of the axis of rotation 26 of the link joint 25 from the tilt axis 21 of the link joint 19. It follows from these two conditions 1 23 =1 18 and a=b and from the condition that the axes 54 and 22 are arranged rigidly in the head 5 of the arm 3, that the guide lever 18, the lever 23 and the jogging frame 15 can be moved only parallel to themselves. The needle bar 13, together with the needle 14, is therefore moved by the drive via the needle bar feed shaft 24 always parallel to itself in the direction of arrow 35 or in the opposite direction thereto. FIG. 5a shows the jogging frame 15 in a neutral center position. FIG. 5b shows the frame in a position which is swung out in the direction of arrow 35, i.e. in the workpiece feed direction, that is at the end of a stitching action by the needle into the workpiece. On the other hand, FIG. 5c shows it in a position swung back in the direction of arrow 35, i.e. in the workpiece feed direction, that is at the end of a stitching action by the needle into the workpiece. On the other hand, FIG. 5c shows it in a position swung back in the direction of arrow 35, i.e. before the needle 14 stitches or when it begins to stitch into a workpiece 50.
It is evident from the preceding that the jogging plane of the jogging frame 15, which plane is indicated by the arrow 35, lies in the workpiece feed direction, and therefore this direction is also indicated by arrow 35.
It is advantageous if the two fixed axes 54 and 22 and thus also the two tilt axes 21 and 26 associated with the jogging frame 15 are respectively situated at approximately the same level, i.e. if the connecting line 56 between the two fixed axes 54 and 21 and the intermediate longitudinal axis 57 of the needle bar 13 along which the needle bar 13 and 14 are displaced form between them an angle c which is as near as possible to 90°. This means in other words that four axes 21, 22, 26, 54 define an approximate rectangle.
The jogging frame 15 can obviously be driven using adjustable variable swing-out distances, i.e. for different stitch lengths. The corresponding adjusting means are known, for example, from U.S. Pat. No. 4,616,586.
For the sake of completeness it should also be added that the head 5 is closed by means of a screw-on or screw-off cover 53. In the region of its upper needle bar bearing 16 the jogging frame 15 has a projection 58 extending into a recess 59 in the head 5. In the region of the lower needle bar bearing 17 the jogging frame 15 is situated in a recess 60 in the head 5, through which recess the frame projects downwardly. The recesses 59, 60 are each sealed on the outside by the cover 53. In its axial extension in the area of the two recesses 59, 60, the jogging frame 15 is dimensioned in such a way that it is guided so as to be movable in its jogging plane between the bottom of each corresponding recess 59 or 60, on the one hand, and the cover 53, on the other hand, but is guided largely free from play in the direction of axes 21, 22, 26, 54.
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In a sewing machine having a needle bar jogging frame in which a needle bar which can be driven with a reciprocating motion in its longitudinal direction is mounted, the jogging frame is in the form of a member of a parallel four-bar linkage. For this purpose the frame is mounted by way of a guide lever and a lever so as to be movable parallel to itself in the heat of the sewing machine. The lever and the guide lever are designed equal in length and arranged parallel to one another. This development creates a simply constructed jogging frame so that the needle bar and thus also the needle are always moved or displaced parallel to themselves in the jogging plane of the jogging frame, irrespective of the stitch length and irrespective of whether the sewing direction is forward or backward to produce lock stitches.
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TECHNICAL FIELD
This document discusses automated software engineering systems and methods, and more particularly, features relating to test case management.
BACKGROUND
Modern software applications and systems can be extremely complex, and may contain thousands or millions of lines of interrelated code spread across numerous files. Modern programs are also more interdependent than ever on other programs. That is because internet-based and other networked or otherwise connected systems continue to supplant stand-alone applications. Such networked applications may depend on many other programs to pass them appropriate data in order to run properly and without errors. Complex software systems carry with them a great risk of errors, such as so-called bugs.
Software generally is subjected to a number of iterative revisions as it moves from conception to initial launch (e.g., in alpha or beta test), and then through to commercial release. The process of identifying and tracking problems in software code as it goes through this process is generally referenced as quality assurance (QA), and entire departments may be devoted to such a function. One way that QA engineers attempt to identify problems in software for later eradication is by running a so-called “test case” by which software is run to see if its operates correctly and without errors.
A written test case can include a description of the functionality to be tested (taken, e.g., from the requirements for the software, or from “use cases,” such as specific examples of how the software is intended to be used), and the expected output of the case, so that the functionality of the software can be verified as working correctly. The engineer may then run the software to check its operation against the expected operation. As a simple example, an engineer may test a piece of software for adding two numbers together by running the software using two exemplary numbers, and checking whether the output matches the output that is expected. As a more realistic example, an engineer may place information into a database that is to be accessed by a program, and then may query the database using the software program to see if the appropriate data is returned and presented.
Each version of compiled and tested software is often referenced as a “build” of the software. Test cases generally need to be run for every build. A collection of related test cases is often referenced as a test suite.
Generally, QA engineers can use a test case management system during testing to help them plan testing, run the tests or test cases, and report the results of the testing. For the plan, the system may create trackable and loggable test cases to test one or more functionalities of an application, and to associate test cases with a particular bug or feature. For the run, the system may determine a sequence of test cases that need to be run, and may pass through the test cases and log the results of the testing in a database. For the reporting, the system may find information about test cases that were run on a specific “build” of the software, and may track progress of software during the QA cycle. The reporting may also report on code coverage, along with load and performance statistics and test progress, among other things.
SUMMARY
This document describes systems and methods that may be employed to permit more flexibility in the tracking and management of test cases. A system serving as an interface may be provided to permit interaction with one or more test case management systems by using various forms of mobile devices and mobile communications. In one implementation, the system may serve as a central system located between the test case management system or systems and the mobile devices. On one side, the system may include a number of interface modules directed to each of a number of different test case management systems, so as to receive test case information from such systems, and to present control commands to the systems. On the other side, the system may include a number of interface modules directed to each of a number of mobile communication mechanisms or systems, such as e-mail, text messaging, and mobile web access. The system may also contain information for a profile for each of various users of the system, so as to communicate with each user in an appropriate manner. For example, some users may prefer to receive a telephone call when a test case is completed or has an error, or may prefer to instead (or in addition) receive an e-mail containing information about the test and/or a link to a web page containing more detailed information about the test, and an ability to interact with the test.
In one implementation, a method of managing a software test case is disclosed. The method comprises receiving a message about a test case from a test case management system, associating the message with a mobile device, and translating the message and transmitting the translated message to the mobile device. The message may be received through an application programming interface (API). The message may also be associated with the mobile device by applying a user associated with the test case in the test case management system to a database that correlates users to mobile device identifiers. The translated message may be transmitted as a text message, and as an e-mail message containing a hyperlink associated with the test case.
In some aspects, the method further comprises receiving from the mobile device a request from the hyperlink and transmitting mobile web-based data in response. Also, the web-based data may comprise data in format elected from the group consisting of WML, xHTML, iMode, and XML. In addition, the method may include receiving from the mobile device a request for information about the test case and requesting information from the test case management system in response to the request.
In another implementation, a computer-implemented system is disclosed. The system comprises a first interface configured to receive testing information from one or more test case managers, a message translator that translates the testing information into one or more mobile messaging formats, and a second interface configured to transmit translated testing information to one or more types of mobile devices. The system may further comprise a user database that correlates test case user identifiers with mobile device identifiers. The first interface may include an application programming interface (API), and the interface may comprise a plug-in module for the application programming interface. In addition, the second interface may include an application programming interface (API), and may include a text messaging module or an e-mail module. Moreover, the message translator may be further adapted to convert queries from the one or more types of mobile devices to commands for the one or more test case managers.
In yet another implementation, a computer-implemented system is disclosed that comprises a first interface configured to receive testing information from one or more test case managers, a second interface configured to transmit translated testing information to one or more types of mobile devices, and means for converting information between the first interface and the second interface.
The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a conceptual diagram showing an example of a test case system.
FIG. 2 is a schematic diagram showing an example of a test case system that provides for remote monitoring and control.
FIG. 3 is a schematic diagram showing an example of a test case administrator system for remote monitoring and control of test case execution.
FIG. 4A is a swim lane diagram showing an example of a process performed by a test case system.
FIG. 4B is a swim lane diagram showing an example of a process performed by a test case system.
FIG. 5 is an example of a graphical user interface showing mobile registration information for a test case management system.
FIG. 6A is an example of a mobile device showing test case information from text messaging.
FIG. 6B is an example of a mobile device showing test case information using a markup language.
FIG. 7 shows an example of a generic computer device and a generic mobile computer device.
Like reference symbols in the various drawings indicate like elements,
DETAILED DESCRIPTION
In general, a test case management system includes a test case manager, a code database, one or more test cases, and one or more programming consoles. Programmers at the programming consoles produce source code that is stored and tracked in the source code database. The test case manager accesses the code, and determines which code should be tested to help ensure that the code is operable and bug-free. The test case manager retrieves data from the source code database and outputs testing information used to perform the test cases. The test case manager may be a commercial software application, such as Mercury TestDirector available from Mercury (www.mercury.com), ApTest Manager available from Applied Testing and Technology Incorporated (www.aptest.com), QaTraq available from Traq Software Limited (www.testmanagement.com), or TestLog available from PassMark Software Party Limited (www.passmark.com).
The source code database includes files that contain the programming, or source code, of a software application or applications. Programmers at programming consoles may create, delete, and/or update the files within the code database. The consoles may include, for example, personal desktop computers, laptop computers, or workstations running an appropriate operating system such as Microsoft Windows in its various forms, Apple's Mac OS, UNIX, Solaris, or Linux. The consoles may also operate an appropriate programming environment with programming tools, to assist the programmers in the process of creating, locating, and maintaining their code.
In some implementations, the code database may be managed by a revision control system (RCS), such as the commercially available RCS Perforce (www.perforce.com), though the particular type of RCS system is not critical. Such a system may be configured to track changes made to files in the code database. As a result, a programmer or a computerized system may be able to determine what changes have been made to the code from one version to another, and by whom the changes were made. In addition, the system may permit for reconstruction of the code at various points by tracking “deltas” between various versions of the code.
The testing information generated by the test case manager may indicate software test cases to be executed. For example, the report may include a list of files that were changed in order to ensure that the goal of a testing cycle is met, e.g., that the software is operated to a sufficient extent so as to conclude that a particular bug is not present or has been successfully removed from the code. The test case or test cases may also take certain input variables, which may be stored separately from the programming code, but in a location accessible to the operating application. For example, where the application is a search program, the data may include one or more exemplary search requests and a relatively large sample of responsive data. In such a situation, the test cases may involve the application of a variety of the search terms to one or more parts of the application.
Where multiple test cases are required, and particular data about the test cases is also to be referenced, the combination of information may be referenced as a test suite. The testing information may be in the form of such test suites, in that the test case manager may draw from various data sources, and not just the code database, change lists, and features, to generate the testing information.
The testing information may consist simply of information needed to operate a test case, such as identifiers for, or pointers to, files to be compiled and/or run, and data for inputting to the software (and perhaps data to which outputs should be compared, along with URLs). The testing information may also contain additional information, either as part of a single file or a group of related files. For example, the testing information may include an introduction that includes a unique identifier for the test case/suite, an identifier for the owner or creator of the test case/suite, a version of the test case/suite represented by the report, a description of the reason for the test case/suite (e.g., for later reference, similar to comments in source code), and a description of the requirement to be tested by the test case (e.g., operation of a certain portion of the software without errors).
In addition, the testing information or test cases in the testing information may contain a detailed written procedure for an engineer to conduct testing, or which describes what the automated test actually does during the test. The testing information may include preconditions or dependencies for a particular test case that are to be met before performing the test case. The preconditions may include, for example, another test case or some other action to be performed. The testing information may contain verification information describing an expected outcome of a test case.
FIG. 1 is a conceptual diagram showing an example of a test case system 100 . In general, the system 100 is conceptualized as a form of factory for running test cases on computer code, in which the operation of the factory can be controlled from a control console 112 . In addition, to provide more freedom to QA engineers and to permit shorter turn-around times for testing, the system 100 may additionally be provided with an interface 116 to the outside world, so that the system 100 may communicate information about test cases and receive commands for controlling test cases, from various mobile devices such as mobile device 114 . As a result, a QA engineer may, in appropriate circumstances, be notified immediately about problems or other occurrences with his or her test case, and may immediately address the problem to get the test case back on track, and thereby shorten turn-around times. For example, the engineer may be eating lunch on another part of a corporate campus when a test case hangs up, and may be notified on his or her mobile telephone about the problem, and may then change certain variables to get the test case restarted.
In FIG. 1 , a number of test cases in a queue 102 wait to be performed. Test cases move conceptually along a conveyor 104 as they are performed. For example, a test case 106 may be moved from the queue 102 to the conveyor 104 as it is performed, by a quality assurance (QA) engineer. Alternatively, the test case 106 may be performed automatically by the test case system 100 . Information regarding the results of performing the test case 106 is placed in a reports repository 108 . In certain implementations, only the results of successful test cases are placed in the reports repository 108 . Test cases that generate an error or an exception are recorded or stored in an exceptions repository 110 . One or more of the exceptions may be placed back in the queue 102 and performed again over the conveyor 104 , such as after a QA engineer has revised the parameters for the test, or the code to be tested has been revised. For example, a change may be made to the test case or the item tested by the test case, which may yield a new result when performed again.
A control console 112 represents test case management software operating on an appropriately provisioned computer. As described above, test case management software may recommend test cases to be performed, control the performing of test cases, and track the results of performing the test cases. The control console 112 may send reports to or be controlled by a mobile device 114 . The mobile device 114 may be, for example, a cell phone, a smartphone, a personal digital assistant, or a notebook computer. The control console 112 is shown as a single master control for illustration, but may be one of numerous workstations or mobile devices used by QA engineers in a department.
The mobile device 114 allows a QA engineer to monitor output from, or issue controls to, the control console 112 from a remote location, such as a restaurant, movie theatre, or the QA engineers home. For example, a particular test case may take more than one work day to complete. The QA engineer may receive notification regarding the outcome of the test case or a suite of test cases at home after the test cases have completed. Alternatively, a QA engineer may be away from a testing area where a test case is performed, such as in a department meeting. When the test case completes, the QA engineer may be notified and may take appropriate action, such as by issuing a control to the control console 112 to perform the test case again or to perform a subsequent test. In another example, a person other than the QA engineer is alternatively or additionally notified, such as a supervisor of the QA engineer or a project manager. The supervisor/project manager may, for example, have other duties in addition to monitoring the outcome of the test case. The supervisor/project manager may be notified of the outcome of the test case or send controls to the control console 112 while performing other duties in a location other than the testing area, such as the supervisor/project manager's office. The supervisor/project manager may be provided with information about a test case only if the QA engineer associated with the test case does not respond in a predetermined time period after being notified, or only if a particularly important test case provides an exception, or a number of test cases fail and more systemic problems with the test case system are indicated. Also, QA engineers or others may be provided with various statistical reports about the test case system at mobile devices.
An interface 116 provides communication between the control console 112 and the mobile device 114 . Particularly, the interface 116 may translate information sent from the control console 112 to the mobile device 114 into a format accepted by the mobile device 114 . For example, the interface 116 may translate the report 108 into a Short Message Service (SMS) text message for presentation using a mobile device such as a text-enabled cell phone. Such translation may involving comparing the report to a template to parse out the most relevant information in the report and to forward such information to the mobile device 114 , such as information about the start and stop times of the test, a summary of the test results, and an indication of whether the test performed successfully or not. Alternatively, the interface 116 may translate the report 108 into a format such as HyperText Markup Language (HTML), compact HTML (c-HTML), Extensible HyperText Markup Language (XHTML), or Wireless Markup Language (WML) for presentation using a mobile device, such as a smartphone or personal digital assistant (PDA). In addition, the interface 116 may translate controls received from the mobile device 114 , such as a control in an HTML form format, into a format accepted by the control console 112 , such as a call to an application program interface (API).
The form of application on the mobile device 114 may take a number of forms. For example, it may simply be native applications on the device 114 , such as text-messaging or a basic web browser, and may be communicated with by conventional techniques for such applications, such as by the provision of simple web pages. Also, a web browser may be communicated with in a more active manner, such as by using AJAX or similar techniques, and one or more browser plug-ins may be provided to further extend the functionality of the browser with respect to a test case system. The device 114 may also be provided with one or more stand-alone web applications running independent of any particular other application of native applications on the device 114 .
FIG. 2 is a schematic diagram showing an example of a test case system 200 that provides for remote monitoring and control. The system 200 includes a test case administrator 202 containing plug-ins modules 204 a - d that provide communication to mobile devices 206 a - d , respectively. In addition, the test case administrator 202 contains plug-ins modules 208 a - d that provide communication to test case management systems 210 a - d , respectively.
For example, using the plug-in module 208 a , the test case administrator 202 receives a message from the test case management system 210 a . The test case management system 210 a may be, for example, a commercially available test case management system having various capabilities. Using the plug-in module 204 a , the test case administrator 202 converts messages from test case management system 210 a into a format supported by the mobile device 206 a . The test case administrator 202 transmits the converted message to the mobile device 206 a.
In another example, the test case administrator 202 may receive a message from the mobile device 206 b using the plug-in module 204 b . Using the plug-in module 208 b , the test case administrator 202 converts the message into a format supported by the test case management system 210 b . The test case administrator 202 then transmits the converted message to the test case management system 210 b.
In general, to simplify the task of managing communications between test case management systems 210 a - 210 d and mobile devices 206 a - 206 c , test case administrator 202 may make all conversions to or from a common, generic format. Thus, for example, if additional modules are to be added to the system 200 , they can be written to perform a single transformation to or from a particular test case management system or mobile device communication format, and need not be written to convert communications to all the possible types of devices or systems that may appear on the other side of system 200 .
A new type of mobile device or test case management system may thus be added to the test case system 200 by creating a plug-in module for the mobile device or test case management system. In certain implementations, plug-in modules communicate with the test case administrator 202 using an API. For example, a mobile device provider or test case management system provider may provide a plug-in to be installed in the test case administrator 202 that uses the API to enable communication with the mobile device or test case management system. The API may be published by the maker of the test case administrator 202 , which explains the various parameters by which third parties may develop plug in modules so that they properly interact with the test case administrator 202 . In appropriate implementations, plug-ins may be provided on both the mobile device side of the system 200 and on the test-case management side of the system 200 to provide maximum flexibility.
The mobile devices 206 a - d may communicate with the test case administrator 202 using wireless networks, such as a local area wireless network (e.g., WiFi), a wide area broadband wireless network (e.g., WiMAX), a cellular network (e.g., GSM, GPRS, CDMA2000, iDEN, Mobitex, EV-DO, or UMTS), a satellite network, a microwave network, or a proprietary network. In certain implementations, the wireless network may include or be in communication with the Internet.
The test case administrator 202 may include or be in communication with a control terminal 212 . The control terminal 212 is a computer device, such as a desktop computer, and may also be connected to and/or include a server on which test case administrator 202 runs. The control terminal 212 allows a user to manage the test case administrator 202 with respect to the user's test cases. For example, the user may input notification information, such as an SMS handle or an e-mail address of the user. Alternatively, notification information may be retrieved from a database, such as a login system that stores user information. The control terminal 212 may be the same computer or computers that are also used to operate particular test case management systems 210 a - 210 d , such as when a QA engineer first uses his or her computer to establish parameters for being notified remotely by test case system 200 , and then uses his or her computer to set up and operate test cases in one of test case management systems 210 a - 210 d.
A user may be associated with a particular test case, indicating, for example, whether the user will receive notifications regarding the status of the test case. The test case administrator 202 receives the status of one or more test cases from one or more of the test case management systems 210 a - d . The status may indicate, for example, whether the test case completed, started, or stalled. The test case administrator 202 outputs the test case status in an SMS text message to one or more mobile devices associated with the test case. The SMS message may also include reports containing an analysis of test case results or a log of errors generated by one or more test cases. In addition, user permissions may be associated with a test case, for example, to allow the remote user to view the status of the test case or to send commands regarding the test case.
The test case administrator 202 may receive commands from one or more of the mobile devices 206 a - d . For example, the test case administrator 202 may accept SMS text message commands from the mobile devices 206 a - d that control the operation of one or more of the test case management systems 210 a - d . The SMS commands may be selected from a lexicon of commands, such as “start,” “stop,” “repeat,” “status,” and “report,” where each command is followed by an identifier of a test case and/or a test case management system. “Start” may indicate that a particular test case be initiated. “Stop” may indicate that a particular test case be stopped. “Repeat” may indicate that a particular test case be repeated a particular number of times. “Status” and “report” may request that the status or an analysis, respectively, of a particular test case be sent to the requesting mobile device.
The test case administrator 202 may parse incoming commands such as by breaking a command, e.g., “status,” from a test case identifier, e.g., “Bobs_new_case” or “case1234.” The parsed-out information may then be applied to particular fields associated with inputs to a test case management system running the particular test case. Such a transformation may occur via a generic data structure that includes a number of “least common denominator” fields for test case management. For example, certain values, such as test case names or identifiers, may be common across all or almost all test cases, and may thus be given a defined field in the generic data structure. Each of modules 204 a - 204 d and 208 a - 208 d may then be programmed to correspond the relevant field in its respective format with the common field in the generic data structure. In addition, the generic data structure may also include fields where less than all components use the field.
Moreover, the generic data structure may include one or more wild card fields that can carry various forms of data depending on the systems with which interaction takes place, and the modules 204 a - d and 208 a - d may be authored to transfer information to a particular one of the fields. Thus, for example, a user may understand that, for one test case management system, a third parameter in a message (after the command and the test case identifier) may have one effect, while for another test case management system, the third parameter may have a different effect.
In certain implementations, and particularly where one or more of the mobile devices 206 a - d include a web browser application, the test case administrator 202 may provide a graphical user interface (GUI) to the mobile devices 206 a - d . The GUI may provide a menu of commands associated with the test cases as well as lists of information associated with the test cases, such as the status of the test cases and estimated times for the initiation of the test cases. Also, a stand alone application on devices 206 a - 6 may also provided similar or extended GUI functionality.
In certain implementations, one or more of the mobile devices 206 a - d may include a test case client application that accesses the test case administrator 202 . The test case client application may provide a GUI to a user to view information received from the test case administrator 202 or to send commands to the test case administrator 202 regarding the test cases. The test case client application may store test case information in the mobile device, allowing the user to retrieve and/or review the information at a later time. Moreover, the mobile device may include programming code such as JavaScript code that makes requests of the test case system 200 , such as using AJAX-related techniques, to manage the device and avoid the need for full page deliveries from test case system 200 .
In addition, the mobile device may be docked (e.g., via physical dock, Bluetooth, or Irma) with a computer device, such as a desktop computer, in order to synchronize test case information in the computer with test case information in the mobile device. For example, the test case client application or another application in the mobile device may synchronize estimated test case completion times from the test case administrator 202 with a clock within the mobile device. The mobile device may use the estimated completion times to determine when to retrieve the status of test cases from the test case administrator 202 (using a “pull” approach). Alternatively or in addition, the mobile device may periodically retrieve test case status information from the test case administrator 202 . The synchronized information may also include lists of commands for particular test cases so that a user need not later enter various parameters for the commands, but may instead invoke a script or other mechanism for making command entry easier.
FIG. 3 is a schematic diagram showing an example of a test case system 300 for remote monitoring and control of test case execution. The test case system 300 includes a test case administrator 302 that provides communication between one or more test case management systems and one or more mobile devices. The test case administrator 202 includes interfaces 304 , 306 that provide communication to mobile device plug-in modules 308 a - b and test case management system plug-in modules 310 a - d , respectively. The mobile plug-in modules 308 a - b provide access to SMS-enabled devices and custom mobile clients, respectively (though other modules could also, or alternatively, be selected). For example, mobile client plug-in modules may provide access to mobile clients using media, such as e-mail, HTML, xHTML, c-HTML, and WML. The test case management system plug-in modules 310 a - d provide access to TestLog, ApTest, QaTraq, and TestDirector test case management systems, respectively, and may interoperate with APIs relating to those systems in addition to APIs associated with the test case administrator 302 .
A communication module 312 processes messages that pass through the interfaces 304 , 306 . A request handler 314 receives commands from mobile devices through interface 304 and passes the requests to the communication module 312 . The communication module 312 processes the requests and sends responses to the mobile devices using a response formatter 316 . For example, the responses may include information about the status of a test case in response to a “status” command, about the success or failure of a test, or about the confirmation of a change made to a test case.
The response formatter 316 formats the response (e.g, in an SMS, HTML, xHTML, c-HTML, or WML format) and sends the response to the mobile device through interface 304 . A test data receiver 318 receives test data (e.g., test case status or test case analysis) from test case management systems through interface 306 . The communication module forwards the test data to a requesting mobile device and/or mobile devices associated with the test case. The communication module 312 also forwards commands from mobile devices to a control module 320 . The control module 320 forwards the command to the associated test case management system through interface 306 . The request handler 314 , message formatter 316 , test data receiver 318 , and control module 320 may also be incorporated, for example, in the communication module 312 , or the interfaces 304 , 306 .
The test case administrator 302 also includes a user database 322 , a test database 324 , and a log database 326 . The user database 322 stores information regarding users of the test case system 300 , such as user identifiers and mobile device contact information associated with each user. In certain implementations, a user may have more than one associated mobile device and the user database 322 may include an ordered list of mobile devices used to contact the user. For example, a user may elect to receive an e-mail first and then an SMS message after a predetermined period of time, to reduce charges incurred by the SMS messages. In such an example, the user may often be at their PDA having e-mail capability, but may at times be only around a less-capable cellular telephone that has only text-messaging capabilities. As such, the user may be allowed to “cascade” their communication styles to meet their particular needs.
The test database 324 stores test case information. For example, the test database 324 may store user identifiers associated with each test case. Also, the test database 324 may store information particular to the command structure for a certain test case management system, so as to provide for accurate translation of communications between various mobile devices and a particular test case management system. In certain implementations, test case information may be retrieved from a test case management system.
The log database 326 stores a record of messages sent and received by the test case administrator 302 . For example, the log database 326 may include the message content and the time that the message was received or sent. In certain implementations, the log database 326 includes information linking one message to another message, a user, a mobile device, a test case management system, and/or a test case. For example, the log database 326 may include information that links a test case status message to a status request message, a mobile device that sent the status request, a test case management system that sent the status response, the test case associated with the status, and the user making the request. Each entry in a log may include one or more fields corresponding to each relevant aspect of a possible log entry, such as those just mentioned. A control terminal 328 allows test case administrator users to review recorded messages in the log database 326 , and to input user information into the user database 322 and test case information into the test database 324 .
FIGS. 4A and 4B are swim lane diagrams showing examples of processes 400 and 450 , respectively, that may be performed by a mobile device, a test case administrator, and a test case management system in a test case system. The processes 400 and 450 may be performed, for example, by a system such as the systems 100 , 200 , or 300 . For clarity of presentation, the description that follows uses the systems 100 , 200 , and 300 as the basis of examples for describing the process 400 and 450 . However, another system, or combination of systems, may be used to perform the processes 400 and 450 . In addition, the processes 400 and 450 are exemplary only. Other processes, including processes that add to, subtract from, combine, or break apart, the actions shown in processes 400 and 450 , may also be employed.
Referring to FIG. 4A , the process 400 may be performed by a mobile device, a test case administrator, and a test case management system in a test case system when executing a scheduled test case. The process 400 begins with receiving ( 402 ) test case parameters. The test case parameters may define the operation of a particular test case, such as the values typically entered by a QA engineer seeking to run a test case. For example, the parameters may include a name of the test case, various input variables for the test case, locations for code and data for the test case, and an identifier for the QA engineer. The test case administrator 302 may retrieve test case information from the test database 324 , as well as associated user information from the user database 322 .
The process 400 triggers the test case and notifies a mobile device client at action 404 . The triggering may occur upon receipt of the test case parameters, at a preset scheduled time (such as a time selected or scheduled by a QA engineer), or at another time, such as when previous test cases in a queue have been run or when adequate bandwidth exists in the testing system. For example, the test case administrator 302 may notify a mobile device, such as the mobile device 206 a , using the user information retrieved from the user database 322 . The test case administrator 302 may trigger the test case by sending a command to a test case management system associated with the test case, such as test case management system 210 a , using the test case management system plug-in 310 a . Alternatively, the test case management system may trigger the test case and may report such activity to the test case administrator.
The process 400 then displays ( 406 ) the test case initiation notification. For example, the mobile device 206 a may receive and present an SMS message from the test case administrator 302 indicating the initiation of the test case. Various forms of notifications may be assigned varying values of importance by a system or by particular users. For example, notifications of exceptions or completed test cases may be given a higher level of importance than notifications that a test case has been initiated. Particular users may then choose to be notified only about activities that exceed a certain level, so that, for example, a particular user may choose not to be notified about the initiation of a test case but may wish to hear about the completion of a test case. The user may also change their assigned alert level from time to time.
The test case management system then begins to perform the test case ( 408 ). For example, the test case management system 210 a may receive the command from the test case administrator 302 indicating the test case to begin. Performance of the test case may occur in a conventional manner, such as by obtaining from a test case database code for running the test case and input parameters for the test case. The test case management system then performs the test case.
In the exemplary process 400 , the test case management system receives an exception when performing the test case ( 410 ). The exception indicates an error or failure during the execution of the test case. For example, the test case management system 210 a may determine that the software under test may not be in a state required by the test case before the test case may be performed, or the test case management system 210 a may receive an unexpected output at a particular step of the test case. In addition, the code under test may “hang up” or otherwise create an error.
The process 400 then reports the received exception ( 412 ). The reporting may occur via standard messaging mechanisms that may be obtained via an application programming interface, or through interception of information that would normally be sent to a standard output device. In a like manner, the exception may be recorded in a file or in an entry in a more extensive file. For example, the test case management system 210 a may generate a report including the exception or a list of exceptions and/or conditions that lead to the exception, such as the state of the software under test. The test case management system 210 a then transmits the report to the test case administrator 302 .
The exception report is then received by the test case administrator and reformatted to a format used by the mobile device client. Such reformatting may initially involving parsing and changing the format of data received from the test case management system to a generic format, and then changing the generically formatted data to a format for the mobile device. For example, the test case administrator 302 may receive the exception report, and the message formatter 316 may format the report or relevant portions of the report (e.g., the report name and a field identifying whether the test ran successfully or not) into an SMS message. The test case administrator then 302 transmits the report to the mobile device 206 a.
The mobile device then displays the exception report or the portion of the report forwarded by the test case administrator ( 416 ). For example, the mobile device 206 a may receive and present the SMS message from the test case administrator 302 . The SMS message may, in addition to or instead of containing information about the test status, include data for obtaining additional test case information by other mechanisms. For example, a URL may be sent to the mobile device, and the user may then supply the URL to a web browser application, to be shown a web page containing additional detail about the test case.
After receiving the report information, the mobile device may transmit a command back to the test case administrator. For example, after reviewing the report information, a user may input a command, such as a “start” command, to the mobile device 206 a indicating that the test should be performed again. The mobile device 206 a may then transmit the command to the test case administrator 302 .
The test case administrator then interprets/checks the command and creates an action associated with the command ( 420 ). For example, the request handler 314 of test case administrator 302 may interpret the command received from the mobile device 206 a and check the validity of the command. The request handler 314 may determine that a parameter is missing from the command, such as the identifier for the test case to be started.
The test case administrator then sends an error message to the mobile device ( 422 ). For example, the test case administrator 302 may send an SMS message to the mobile device 206 a indicating the syntax error in the command, or another form of error. The sent message may also contain information, such as a URL, for allowing the user to easily address the problem.
The mobile device displays ( 424 ) the error message. For example, the mobile device 206 a receives and presents the SMS message from the test case administrator 302 . Alternatively, the message may be sent as an e-mail message to an address associated with the user of the mobile device, and the e-mail may include a URL and hyperlink for selection by a user, among other information. In general, e-mail notification may carry more information than can SMS text messaging notification.
The user of the mobile device then reformulates and transmits a new command ( 426 ). The command may be similar to the user's first command, but corrected in some manner. For example, a user may input the command again using the mobile device 206 a , or the mobile device 206 a may correct the syntax of the command. The mobile device 206 a sends the reformulated command to the test case administrator 302 once the new command as been received.
The test case administrator then interprets/checks the new command, and creates an action associated with the command ( 428 ). The creation of the action may involve parsing and interpreting the new command, and applying certain elements of the command to a test case management system. For example, the request handler 314 may pass the command to the communication module 312 after interpreting and checking the command. The communication module 312 passes the command to the control module 320 . The control module 320 creates an action associated with the command and transmits the action request to the test case management system 210 a.
The test case manager then begins and/or continues the test case ( 430 ). Such continued operation of a test case may then continue until, for example, the test case ends or another exception occurs. For example, the “start” command may indicate that the test case management system 210 a is to restart the test case.
The process 400 then ends ( 432 ) the test case. For example, the test case management system 210 a may wait a predetermined amount of time or wait for a particular output from the software under test before ending the test case.
Once the test ends, the test case management system generates a signal or stores a value representative of the completion of the test case ( 434 ). For example, the test case management system 210 a may report the results of the test case, such as the output of the software under test and the time at which the test case completed. The test case management system 210 a may then transmit the report or certain information from the report to the test case administrator 302 .
The test case administrator receives the test case report information and reformats the test case report information to a format used by the mobile device client ( 436 ), in manners like those discussed above. For example, the test case administrator 302 may receive the test case report and the message formatter 316 may format the report (or portions of the report) into an SMS message. The test case administrator 302 transmits the report to the mobile device 206 a.
The mobile device displays the test case report information ( 438 ) and the process 400 ends. For example, the mobile device 206 a may receive and present to the user the SMS message from the test case administrator 302 .
Referring to FIG. 4B , the process 450 may be performed by a mobile device, a test case administrator, and a test case management system when performing a test case initiated by a user of the mobile device. In general, process 450 shows the initiation of a test from a remote mobile device, followed by a request from for the remote mobile device for report information relating to the test case.
The process 450 begins with when a user of the mobile device sends a start message to the test case administrator ( 452 ). The command may be entered, for example, by the user selecting a control on an xHTML web page labeled “start,” and linked to a test case management system. For example, the mobile device 206 a may receive an input from a user indicting that a particular test case is to be started. The mobile device 206 a then transmits a start command to the test case administrator 302 .
The test case administrator then checks credentials associated with the message ( 454 ). The credentials may include various mechanisms for ensuring that only authorized users may interact with the system, such as user name and password pairs. For example, the request handler 314 may verify that the command was received from an SMS address associated with the test case. In addition, the command may include a user name and/or password that the request handler 314 may compare to a stored user name and/or password in the user database 322 .
The test case administrator them identifies a test case associated with the message ( 456 ). For example, the message syntax may include a test case identifier after the command name. The request hander 314 may interpret the test case identifier included in the message from the mobile device 206 a , and may check a database for a more complete identifier for the test case (e.g., the user can entered a shortened proxy for the full test case name).
The test case administrator then triggers the test case and notifies the mobile device client ( 458 ). Such action may involve the sending of simultaneous or near simultaneous messages from the test case administrator to the mobile device and to the appropriate test case management system. The test case administrator may initially perform look-ups for addressing information, i.e., to determine which test case management system to trigger when there are multiple systems. For example, the test case administrator 302 may notify a mobile device, such as the mobile device 206 a , using the user information retrieved from the user database 322 . The test case administrator 302 may trigger the test case by sending a command to a test case management system associated with the test case, such as test case management system 210 a , using the test case management system plug-in 310 a.
The test case management system then begins to perform the test case ( 460 ). The performance of the test case may proceed in a conventional manner until further communications with the mobile device are required. For example, the test case management system 210 a may receive the command from the test case administrator 302 indicating the test case to begin. The test case management system 210 a gathers the appropriate data (e.g., code) and other parameters and performs the test case. Upon receiving a message from the test case administrator, the mobile device will also display a test case initiation notification ( 462 ). For example, the mobile device 206 a may receive and present an SMS message from the test case administrator 302 indicating the initiation of the test case.
The user of the mobile device then sends a report query ( 464 ). For example, the mobile device 206 a may send a request to the test case administrator 302 for a report indicating the status of the test case. Such a request may occur after the user has received an indication that a test case has completed, or may occur when a user has not received an expected notification and wants to know what is happening with the test case.
The test case administrator again checks credentials associated with the report query ( 466 ), in a manner similar to that discussed above. For example, the request handler 314 may verify that the report request was received from an SMS address associated with the test case. In addition, the report request may include a user name and/or password that the request handler 314 may compare to a stored user name and/or password in the user database 322 .
The test case administrator then converts the query to a reporting command ( 468 ). The conversion may include an initial conversion to a generic format, followed by a conversion to a format consistent with the particular test case management system on which the test case has run or is running. For example, the control module 320 may convert the report request to a command, such as an API call, to a plug-in that communicates with the test case management system 210 a.
The test case administrator then submits the reporting command ( 470 ). For example, the control module 320 transmits the reporting command to the test case management system 210 a through interface 306 . The test case management system then runs the report ( 472 ), and transmits data relating to the report back to the test case administrator ( 474 ). Such transmission may also occur by the test case management system saving the report to a predetermined location, followed by the test case administrator accessing the report.
The test case administrator receives the test case report and reformats the test case report to a format used by the mobile device client ( 476 ). The reformatting may include rearranging the data, removing certain data, or combining date so as to match the particular communication abilities of the mobile device. For example, the test case administrator 302 may receive the test case report and the message formatter 316 may format the report in an SMS message. Where the reporting is via SMS, for example, much of the information from a full report may be removed, and a relatively short summary of the test case status may be provided.
The test case administrator then transmits the report data to the mobile device ( 478 ), which then displays the report data (which may include a full report or a subset of data from a full report).
FIG. 5 is an example of a graphical user interface (GUI) 600 showing mobile registration information for a test case management system. In general, the GUI 600 shows information that a user such as a QA engineer may enter in setting up an account with a test case administrator so that the test case administrator knows how to address the user when the user is at a mobile device. For example, a user at the control terminal 328 may input one or more mobile device addresses associated with a particular user using the GUI 600 . The GUI 600 is displayed in a web browser application. The GUI 600 shows a web page 602 provided by a test case administrator, such as the test case administrator 302 .
The web page 602 includes input controls 604 and 606 that allow a user to input an SMS address and an e-mail address, respectively, of mobile devices associated with a particular user. The web page 602 also includes selection controls 608 and 610 that allow a user to apply or cancel, respectively, inputs made in the input controls 604 and 606 . The SMS address and the e-mail address may be used, for example, by the test case administrator 302 to send notifications to the user regarding test cases associated with the user. Though not shown, the user may also enter scheduling information to control when mobile notification is enabled. For example, the user may enter a work schedule (e.g., 7 a.m. to noon, and 1 p.m. to 6 p.m.) during which communications are not sent to their mobile device, and for which communications are sent to the mobile device during other hours.
FIG. 6A is an example of a mobile device 700 showing test case information from text messaging. The mobile device 700 includes a display 702 capable of presenting SMS text messages, such as a message indicating the status of a test case. The basic message here shows that a test case named Pluto, having a test set number 4, was executed on Dec. 1, 2006 at 45 seconds after 5 p.m. by a technician named Johnny Johnson. The test threw exceptions relating to the test set that was executed, and was determined to have failed. This may indicate that there was a problem with the test case code or the test environment in which the code was run, or may indicate that there is a potential bug in the system. The exceptions may be indicated by a description, a name, or a code—here, A1 and A2 (which the QA engineer may have memorized or may have access to in an exceptions index).
The test environment may include the details of the machines on which the test was run (e.g., Windows vs. Mac, Intel vs. G4, RAM, etc.), and each configuration may be given a name—here, Jiggy. One or more links may be provided to each piece of information in the report. For example, a click-to-call link may be provided to Johnny Johnson's desk telephone so that the recipient of the message may easily call him to discuss the test. Likewise, links (e.g., hyperlinks) may be provided to each of the exceptions, so that the recipient may easily download more information about the particular exception, so as to make decisions about follow up testing.
FIG. 6B is an example of a mobile device 750 showing test case information. The exemplary display shows a summary view for a particular user, showing controls for obtaining additional information about a number of test reports that the user is about to run, is running, or has recently run.
The mobile device 750 includes a display 752 capable of displaying markup language, such as HTML, xHTML, c-HTML, or WML. In certain implementations, the display 752 may present graphical elements or images. Here, the display 752 presents a report of the status of a list of test cases. In general, the display provides an example of an overview screen for a particular QA engineer, with information about all or most of the engineer's outstanding testing program being shown. Selection of one of the test cases may produce an output like that shown in FIG. 6A . Stop light symbols indicate whether active test cases are in progress, paused, or stopped due to an exception. The status of test cases in progress may be retrieved. The display 752 also includes a list of queued test cases and their estimated start times. In addition, reports may be retrieved for completed test cases. A user may make inputs to select report and/or status retrieval controls using input devices, such as a scroll wheel, voice recognition, a stylus and touch screen, or a keypad.
FIG. 7 is a block diagram of computing devices 700 , 750 that may be used to implement the systems and methods described in this document, as either a client or as a server or plurality of servers. Computing device 700 is intended to represent various forms of digital computers, such as laptops, desktops, workstations, personal digital assistants, servers, blade servers, mainframes, and other appropriate computers. Computing device 750 is intended to represent various forms of mobile devices, such as personal digital assistants, cellular telephones, smartphones, and other similar computing devices. The components shown here, their connections and relationships, and their functions, are meant to be exemplary only, and are not meant to limit implementations of the inventions described and/or claimed in this document.
Computing device 700 includes a processor 702 , memory 704 , a storage device 706 , a high-speed interface 708 connecting to memory 704 and high-speed expansion ports 710 , and a low speed interface 712 connecting to low speed bus 714 and storage device 706 . Each of the components 702 , 704 , 706 , 708 , 710 , and 712 , are interconnected using various busses, and may be mounted on a common motherboard or in other manners as appropriate. The processor 702 can process instructions for execution within the computing device 700 , including instructions stored in the memory 704 or on the storage device 706 to display graphical information for a GUI on an external input/output device, such as display 716 coupled to high speed interface 708 . In other implementations, multiple processors and/or multiple buses may be used, as appropriate, along with multiple memories and types of memory. Also, multiple computing devices 700 may be connected, with each device providing portions of the necessary operations (e.g., as a server bank, a group of blade servers, or a multi-processor system).
The memory 704 stores information within the computing device 700 . In one implementation, the memory 704 is a volatile memory unit or units. In another implementation, the memory 704 is a non-volatile memory unit or units. The memory 704 may also be another form of computer-readable medium, such as a magnetic or optical disk.
The storage device 706 is capable of providing mass storage for the computing device 700 . In one implementation, the storage device 706 may be or contain a computer-readable medium, such as a floppy disk device, a hard disk device, an optical disk device, or a tape device, a flash memory or other similar solid state memory device, or an array of devices, including devices in a storage area network or other configurations. A computer program product can be tangibly embodied in an information carrier. The computer program product may also contain instructions that, when executed, perform one or more methods, such as those described above. The information carrier is a computer- or machine-readable medium, such as the memory 704 , the storage device 706 , memory on processor 702 , or a propagated signal.
The high speed controller 708 manages bandwidth-intensive operations for the computing device 700 , while the low speed controller 712 manages lower bandwidth-intensive operations. Such allocation of functions is exemplary only. In one implementation, the high-speed controller 708 is coupled to memory 704 , display 716 (e.g., through a graphics processor or accelerator), and to high-speed expansion ports 710 , which may accept various expansion cards (not shown). In the implementation, low-speed controller 712 is coupled to storage device 706 and low-speed expansion port 714 . The low-speed expansion port, which may include various communication ports (e.g., USB, Bluetooth, Ethernet, wireless Ethernet) may be coupled to one or more input/output devices, such as a keyboard, a pointing device, a scanner, or a networking device such as a switch or router, e.g., through a network adapter.
The computing device 700 may be implemented in a number of different forms, as shown in the figure. For example, it may be implemented as a standard server 720 , or multiple times in a group of such servers. It may also be implemented as part of a rack server system 724 . In addition, it may be implemented in a personal computer such as a laptop computer 722 . Alternatively, components from computing device 700 may be combined with other components in a mobile device (not shown), such as device 750 . Each of such devices may contain one or more of computing device 700 , 750 , and an entire system may be made up of multiple computing devices 700 , 750 communicating with each other.
Computing device 750 includes a processor 752 , memory 764 , an input/output device such as a display 754 , a communication interface 766 , and a transceiver 768 , among other components. The device 750 may also be provided with a storage device, such as a microdrive or other device, to provide additional storage. Each of the components 750 , 752 , 764 , 754 , 766 , and 768 , are interconnected using various buses, and several of the components may be mounted on a common motherboard or in other manners as appropriate.
The processor 752 can execute instructions within the computing device 750 , including instructions stored in the memory 764 . The processor may be implemented as a chipset of chips that include separate and multiple analog and digital processors. The processor may provide, for example, for coordination of the other components of the device 750 , such as control of user interfaces, applications run by device 750 , and wireless communication by device 750 .
Processor 752 may communicate with a user through control interface 758 and display interface 756 coupled to a display 754 . The display 754 may be, for example, a TFT (Thin-Film-Transistor Liquid Crystal Display) display or an OLED (Organic Light Emitting Diode) display, or other appropriate display technology. The display interface 756 may comprise appropriate circuitry for driving the display 754 to present graphical and other information to a user. The control interface 758 may receive commands from a user and convert them for submission to the processor 752 . In addition, an external interface 762 may be provide in communication with processor 752 , so as to enable near area communication of device 750 with other devices. External interface 762 may provide, for example, for wired communication in some implementations, or for wireless communication in other implementations, and multiple interfaces may also be used.
The memory 764 stores information within the computing device 750 . The memory 764 can be implemented as one or more of a computer-readable medium or media, a volatile memory unit or units, or a non-volatile memory unit or units. Expansion memory 774 may also be provided and connected to device 750 through expansion interface 772 , which may include, for example, a SIMM (Single In Line Memory Module) card interface. Such expansion memory 774 may provide extra storage space for device 750 , or may also store applications or other information for device 750 . Specifically, expansion memory 774 may include instructions to carry out or supplement the processes described above, and may include secure information also. Thus, for example, expansion memory 774 may be provide as a security module for device 750 , and may be programmed with instructions that permit secure use of device 750 . In addition, secure applications may be provided via the SIMM cards, along with additional information, such as placing identifying information on the SIMM card in a non-hackable manner.
The memory may include, for example, flash memory and/or NVRAM memory, as discussed below. In one implementation, a computer program product is tangibly embodied in an information carrier. The computer program product contains instructions that, when executed, perform one or more methods, such as those described above. The information carrier is a computer- or machine-readable medium, such as the memory 764 , expansion memory 774 , memory on processor 752 , or a propagated signal that may be received, for example, over transceiver 768 or external interface 762 .
Device 750 may communicate wirelessly through communication interface 766 , which may include digital signal processing circuitry where necessary. Communication interface 766 may provide for communications under various modes or protocols, such as GSM voice calls, SMS, EMS, or MMS messaging, CDMA, TDMA, PDC, WCDMA, CDMA2000, or GPRS, among others. Such communication may occur, for example, through radio-frequency transceiver 768 . In addition, short-range communication may occur, such as using a Bluetooth, WiFi, or other such transceiver (not shown). In addition, GPS (Global Positioning System) receiver module 770 may provide additional navigation- and location-related wireless data to device 750 , which may be used as appropriate by applications running on device 750 .
Device 750 may also communicate audibly using audio codec 760 , which may receive spoken information from a user and convert it to usable digital information. Audio codec 760 may likewise generate audible sound for a user, such as through a speaker, e.g., in a handset of device 750 . Such sound may include sound from voice telephone calls, may include recorded sound (e.g., voice messages, music files, etc.) and may also include sound generated by applications operating on device 750 .
The computing device 750 may be implemented in a number of different forms, as shown in the figure. For example, it may be implemented as a cellular telephone 780 . It may also be implemented as part of a smartphone 782 , personal digital assistant, or other similar mobile device.
Various implementations of the systems and techniques described here can be realized in digital electronic circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.
These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms “machine-readable medium” “computer-readable medium” refers to any computer program product, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor.
To provide for interaction with a user, the systems and techniques described here can be implemented on a computer having a display device (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor) for displaying information to the user and a keyboard and a pointing device (e.g., a mouse or a trackball) by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form, including acoustic, speech, or tactile input.
The systems and techniques described here can be implemented in a computing system that includes a back end component (e.g., as a data server), or that includes a middleware component (e.g., an application server), or that includes a front end component (e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the systems and techniques described here), or any combination of such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication (e.g., a communication network). Examples of communication networks include a local area network (“LAN”), a wide area network (“WAN”), and the Internet.
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made. For example, various forms of the flows shown above may be used, with steps re-ordered, added, or removed. Also, although several applications of the payment systems and methods have been described, it should be recognized that numerous other applications are contemplated. Accordingly, other embodiments are within the scope of the following claims.
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A method of managing a software test case includes receiving a message about a test case from a test case management system, associating the message with a mobile device, and translating the message and transmitting the translated message to the mobile device.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present disclosure relates generally to methods for assessing the status of a transplanted liver in a recipient in order to determine the presence or absence of rejection of transplanted liver. In particular, in several embodiments methods are disclosed for generating and implementing a specifically designed treatment regime to resolve rejection of the transplanted liver, based specifically on an individual patient's rejection symptoms.
[0003] 2. Description of Related Art
[0004] Organ transplantation, moving an organ from a donor site to a recipient site (either from a first to a second subject or from a first to a second location on a patient's own body) has been practiced in medicine for many centuries, with the first documented successful transplants occurring regularly in the early 1900's. Transplants are performed in order to replace the recipient's damaged or absent organ. While more recently, regenerative medicine and cell therapy has been focused on use of cells to treat damaged or diseased tissues, transplant of entire organs is still commonplace.
[0005] Worldwide, the kidneys are the most commonly transplanted organs, followed closely by the liver and then the heart. The cornea and bones and/or tendons (e.g., musculoskeletal grafts) are the most commonly transplanted tissues, transplanted tenfold more than whole organs. Other transplants include lungs, pancreas, intestine, thymus, skin, heart valves, and veins. While generally controllable, transplants still pose the risk of rejection of the transplanted organ or tissue by the recipient. Diagnosis of rejection is typically via study of clinical data, such as patient signs and symptoms, as well as laboratory data such as tissue biopsy.
SUMMARY
[0006] Despite the advances in organ transplantation, there remains the possibility of infection of the transplanted organ and/or rejection of the organ by the recipient. Improvement in the long-term success of organ transplants, can be facilitated by early detection and treatment of infection or rejection, which are described herein. In several embodiments, there are provided methods of treating the liver of a subject, comprising obtaining a biological sample from the liver (such as bile), ordering a test of the (sample (e.g., bile), obtaining the results of the test, evaluating the results to determine the status (e.g., health and/or function) of the liver of the subject. In several embodiments, the test is configured to identify the status of the liver of the subject as other than being in a recovery phase from acute rejection. In some embodiments, the test comprises isolating components from the sample (e.g., bile), liberating RNA from the isolated components, contacting the liberated RNA with a reverse transcriptase to generate complementary DNA (cDNA), and contacting the cDNA with sense and antisense primers that are specific for markers of liver condition and a DNA polymerase in order to generate amplified DNA, followed by detecting the amount of expression of the markers of liver condition.
[0007] In some embodiments, there is provided a method of determining the status of a liver of a subject, comprising: obtaining bile collected from the liver, isolating one or more biological components (e.g., vesicles, exosomes, microvesicles, or the like) from the bile by passing the bile through a filter (e.g., a membrane or plurality of membranes) configured to capture one or more of the biological components, detecting expression of at least one marker of liver condition, and identifying the status of the liver of the subject. In some embodiments, the detecting step further comprises the steps of isolating RNA from the collected bile, contacting RNA from the collected bile with a reverse transcriptase in order to generate complementary DNA (cDNA), and contacting the cDNA with sense and antisense primers that are specific for one of the markers of liver condition and a DNA polymerase to generate amplified DNA.
[0008] In other embodiments a method of determining the status of a liver comprises: obtaining bile collected from the liver, isolating one or more biological component from the bile by passing the bile through a membrane configured to capture one or more of the biological components, detecting expression of at least one marker of liver condition, and identifying status of the liver of the subject. In some embodiments, the detecting step further comprises the steps of isolating RNA from the collected bile, contacting RNA from the collected bile with a reverse transcriptase to generation complementary DNA (cDNA), and contacting said cDNA with sense and antisense primers that are specific for the marker of liver condition.
[0009] In some embodiments, a method of directing treatment of the liver of a subject is provided that comprises: receiving bile collected from the liver of the subject, detecting expression of at least one marker of liver condition, identifying the status of the liver of the subject, and informing a physician that it would be appropriate to treat the subject if the subject as indicated by the identified status of the liver. In some embodiments, detecting expression is performed by a method comprising: isolating one or more biological components from the bile, liberating RNA from the isolated biological components, contacting the liberated RNA with a reverse transcriptase to generate complementary DNA (cDNA), and contacting the cDNA with sense and antisense primers that are specific for each of the markers of liver condition and a DNA polymerase in order to generate amplified DNA.
[0010] In some embodiments, there is provided a method of identifying the status of a liver of a subject after a liver transplant, comprising: obtaining bile collected from the liver, isolating one or more biological components from the bile, liberating RNA from the isolated biological components, contacting the liberated RNA with a reverse transcriptase to generate complementary DNA (cDNA), detecting expression of at least one marker of liver condition by a computerized method, and using a computer to identify the status of the liver of the subject. In some embodiments, detecting expression by a computerized method comprises the steps of: contacting the cDNA with sense and antisense primers that are specific for each of the markers of liver condition and a DNA polymerase to generate a reaction mixture; exposing the reaction mixture to a thermal cycle.
[0011] In some embodiments, a method of identifying the status of a liver of a subject is provided that comprises: obtaining bile collected from the liver of the subject, isolating one or more biological components from the bile, detecting expression of at least one marker of liver condition, and identifying the status of the liver of the subject. In some embodiments, the detecting expression step is performed by a method comprising: liberating RNA from the isolated membrane particles, exosomes, exosome-like vesicles, and/or microvesicles; contacting the liberated RNA with a reverse transcriptase to generate complementary DNA (cDNA); and contacting the cDNA with sense and antisense primers that are specific for each of the markers of liver condition and a DNA polymerase in order to generate amplified DNA.
[0012] In some embodiments, the methods comprise collection of bile (or another liver-associated biological sample) from the liver of the subject after a liver transplant. In some embodiments, the methods herein are performed and bile is collected form the liver of the subject after liver surgery. In other embodiments, bile is collected prior to a liver transplant or liver surgery. In some embodiments, the methods herein may be performed by collected bile from an individual with a healthy liver. In other embodiments, the individual's liver may be diseased or otherwise unhealthy. In some instance, the methods described herein may be performed on a foreign transplanted liver.
[0013] In some embodiments, components isolated from the bile are one or more of membrane particles, exosomes, exosome-like vesicles, and microvesicles. In other embodiments, components isolated from the bile may be any biological component that comprises RNA or DNA.
[0014] In some embodiments, isolating the biological components of interest from the bile comprises filtering the bile. In some embodiments, filtering the bile will trap one or more of membrane particles, exosomes, exosome-like vesicles, and microvesicles on a filter. In some embodiments, the filter comprises material to capture components that are about 1.6 microns or greater in diameter. In several embodiments, a plurality of filters are used to capture vesicles within a particularly preferred range of sizes (e.g., diameters). For example, in several embodiments, filters are used to capture vesicles having a diameter of from about 0.2 microns to about 1.6 microns in diameter, including about 0.2 microns to about 0.4 microns, about 0.4 microns to about 0.6 microns, about 0.6 microns to about 0.8 microns, about 0.8 microns to about 1.0 microns, about 1.0 microns to about 1.2 microns, about 1.2 to about 1.4 microns, about 1.4 microns to about 1.6 microns (and any size in between those listed).
[0015] In some embodiments, the filter (or filters) comprises glass-like material, non-glass-like material, or a combination thereof. In some embodiments, the bile is passed through multiple filters to isolate the biological component of interest. In other embodiments, isolating biological components comprises diluting the bile. In other embodiments, centrifugation may be used to isolate the biological components of interest. In some embodiments, multiple isolation techniques may be employed (e.g., combinations of filtration selection and/or density centrifugation). In some embodiments, the bile is separated into one or more samples after the isolating step.
[0016] In some embodiments, a filter device is used to isolate biological components of interest. In some embodiments, the device comprises: a first body having an inlet, an outlet, and an interior volume between the inlet and the outlet; a second body having an inlet, an outlet, an interior volume between the inlet and the outlet, a filter material positioned within the interior volume of the second body and in fluid communication with the first body; and a receiving vessel having an inlet, a closed end opposite the inlet and interior cavity. In some embodiments, the first body and the second body are reversibly connected by an interaction of the inlet of the second body with the outlet of the first body. In some embodiments, the interior cavity of the receiving vessel is dimensioned to reversibly enclose both the first and the second body and to receive bile after it is passed from the interior volume of the first body, through the filter material, through the interior cavity of the second body and out of the outlet of the second body. In some embodiments, the isolating step comprises placing at least a portion of the bile in such a device, and applying a force to the device to cause bile to pass through the device to the receiving vessel and capture the biological component of interest. In some embodiments, applying the force comprises centrifugation of the device. In other embodiments, applying the force comprises application of positive pressure to the device. In other embodiments, applying the force comprises application of vacuum pressure to the device.
[0017] In some embodiments, liberating the RNA from the biological component of interest comprises lysing the membrane particles, exosomes, exosome-like vesicles, and/or microvesicles with a lysis buffer. In other embodiments, centrifugation may be employed. In some embodiments, the liberating is performed while the membrane particles, exosomes, exosome-like vesicles, microvesicles and/or other components of interest are immobilized on a filter. In some embodiments, the membrane particles, exosomes, exosome-like vesicles, microvesicles and/or other components of interest are isolated or otherwise separated from other components of the bile (and/or from one another—e.g., vesicles separated from exosomes).
[0018] In some embodiments, the chosen markers of liver condition indicate that a liver is healthy. In other embodiments, the chosen markers of liver condition indicate that a liver is unhealthy or diseased (e.g., as compared to a prior evaluation of the liver of a particular subject, or as compared to the general population/accepted clinical norms), or that a transplanted liver is being rejected. For example, certain markers of liver condition may indicate that a transplanted liver is in an early stage of acute rejection or early stage of acute infection; in acute rejection or acute infection; in sustained rejection or sustained infection; or in recovery.
[0019] In some embodiments, certain families of markers may indicate the status of the liver. For example the status of a liver may be determined as in an early stage of acute rejection or early stage of acute infection when one or more of macrophage-derived mRNAs, IL8, and chemokine mRNAs is detected. In some embodiments, the status of a liver may be determined as in acute rejection or acute infection when one or more of cytotoxic T-cell derived mRNAs (TNF − FasL, IFNG, GZB), or leukocyte-specific mRNAs (CD16, DEFA3) is detected. In additional embodiments, the status of a liver may be determined as in a recovery phase from acute rejection or acute infection when one or more of regulatory T-cell derived or anti-inflammatory cytokine mRNAs (IL10, TGFB, CTLA4, PD-1, FOXP3 is detected. In some embodiments, the status of a liver may be determined to be in sustained rejection or sustained infection when one or more of Th1-(IL2), Th2-(IL4) derived mRNAs or GMCSF is detected. In some embodiments, the methods herein are performed by selecting a marker from each of these families of markers and detecting the expression of each of the selected markers in order to determine the status of the liver.
[0020] In some embodiments, markers are selected from the group consisting of IL1B, IL6, IL8, TNF-alpha, FasL, IFNG, granzyme B, CD16, DEFA3, IL10, TGF beta, CTLA4, PD-1, FOXP3, IL2, IL4 and GMCSF. In some embodiments the status of a liver may be determined as in an early stage of acute rejection or early stage of acute infection when one or more of IL1B, IL6, and IL8 is detected. In some embodiments, the status of a liver may be determined as in acute rejection or acute infection when one or more of TNF-alpha, FasL, IFNG, granzyme B, CD16, and DEFA3 is detected. In some embodiments, the status of a liver may be determined as in a recovery phase from acute rejection when one or more of IL10, TGF-beta, CTLA4, PD-1 and FOXP3 is detected. In some embodiments, the status of a liver may be determined as in sustained rejection or sustained infection when one or more of IL2, IL4 and GMCSF is detected. In some embodiments, the methods herein are performed by selecting a marker from each of these families of markers and detecting the expression of each of the selected markers in order to determine the status of the liver. In some embodiments, none of
[0021] In some embodiments, the methods further comprise informing a physician that treatment of the subject is appropriate if the subject is not in the recovery phase from acute rejection. In some embodiments, the physician is advised to treat the subject when none of the markers of the recovery phase of acute rejection or infection, including IL10, TGF-beta, CTLA4, PD-1 or FOXP3, are detected. In some embodiments, IL1B, IL6, or IL8 is detected and rejection is not considered to be clinically relevant. In some embodiments, a physician is advised not to treat a subject when rejection is not considered to be clinically relevant. However, in other instances, both markers of the recovery phase of acute rejection or infection and markers of another form of rejection or infection may be detected. In some embodiments, advising a physician to treat the subject may be appropriate based on these results. In some embodiments, IL1B, IL6, or IL8 is detected and rejection is not considered to be clinically relevant. In some embodiments, a subject is treated with administration of antibiotic therapy (alone or in combination with other immune-boosting therapy) in response to this scenario. In some embodiments, both markers of early stage of acute rejection or early stage of acute infection and markers of acute rejection or acute infection are detected. In other embodiments, both markers of early stage of acute rejection or early stage of acute infection and markers of sustained rejection or sustained infection are detected. In other embodiments, both markers of acute rejection or acute infection and markers of sustained rejection or sustained infection are detected. In some embodiments, markers of early rejection or infection, acute rejection or infection, and sustained rejection or infection are all detected. In several such embodiments, additional tests are used to further determine if and how a patient should be treated. However, in some embodiments, the absolute change of one category of markers as compared to another (optionally normalized to a control) allow a determination of if and how a patient should be treated. For example, if the change in expression (e.g., an increase) of markers of sustained infection is greater than those for acute infection, a medical provider may deem it appropriate to treat the subject for sustained infection. In some embodiments, a plurality of samples is taken over time, so that a determination can be made as to whether a subject is progressing from a state of acute to sustained infection or, alternatively from a state of sustained infection to a healthier state.
[0022] In some embodiments, treating comprises a treatment selected from the group of removal of transplanted tissue, re-transplant, immunosuppressive therapy, antibody-based or antibiotic treatments, blood transfusions, or bone marrow transplant.
[0023] In some embodiments, the RNA liberated from the biological components of interest comprises poly(A)+ RNA.
[0024] In some embodiments, after amplified DNA is generated, it is exposed to a probe complementary to a portion of one of the markers of liver condition.
[0025] In some embodiments, the test of the bile or the identified liver status is corroborated with a histological evaluation of a biopsy of the liver. In other embodiments, the test of the bile or the identified liver status further comprises comparing the expression of the markers of liver condition in the subject to the expression of the markers of liver condition in a control sample.
[0026] In some embodiments, a computerized method is used to complete one or more of the steps. In some embodiments, the computerized method comprises exposing a reaction mixture comprising isolated RNA and/or prepared cDNA, a polymerase and gene-specific primers to a thermal cycle. In some embodiments, the thermal cycle is generated by a computer configured to control the temperature time, and cycle number to which the reaction mixture is exposed. In other embodiments, the computer controls only the time or only the temperature for the reaction mixture and an individual controls on or more additional variables. In some embodiments, a computer is used that is configured to receive data from the detecting step and to implement a program that detects the number of thermal cycles required for the marker of liver condition to reach a pre-defined amplification threshold in order to identify the status of the liver. In still additional embodiments, the entire testing and detection process is automated.
[0027] For example, in some embodiments, RNA is isolated by a fully automated method, e.g., methods controlled by a computer processor and associated automated machinery. In one embodiment a biological sample, such as a bile sample, is collected and loaded into a receiving vessel that is placed into a sample processing unit. A user enters information into a data input receiver, such information related to sample identity, the sample quantity, and/or specific patient characteristics. The user can then implement an RNA isolation protocol, for which the computer is configured to access an algorithm and perform associated functions to process the bile sample in order to isolate biological components, such as vesicles, and subsequently processed the vesicles to liberate RNA. In further embodiments, the computer implemented program can quantify the amount of RNA isolated and/or evaluate and purity. In such embodiments, should the quantity and/or purity surpass a minimum threshold, the RNA can be further processed, in an automated fashion, to generate complementary DNA (cDNA). cDNna can then be generated using established methods, such as for example, binding of a poly-A RNA tail to an oligo dT molecule and subsequent extension using an RNA polymerase.
[0028] Depending on the embodiment, the cDNA can be divided into individual subsamples, some being stored for later analysis and some being analyzed immediately. Analysis, in some embodiments comprises mixing a known quantity of the cDNA with a salt-based buffer, a DNA polymerase, and at least one gene specific primer to generate a reaction mixture. The cDNA can then be amplified using a predetermined thermal cycle program that the computer system is configured to implement. This thermal cycle, could optionally be controlled manually as well. After amplification (e.g., real-time PCR,), the computer system can assess the number of cycles required for a gene of interest (e.g. a marker of liver specific function) to surpass a particular threshold of expression. A data analysis processor can then use this assessment to calculate the amount of the gene of interest present in the original sample, and by comparison either to a different patient sample, a known control, or a combination thereof, expression level of the gene of interest can be calculated. A data output processor can provide this information, either electronically in another acceptable format, to a test facility and/or directly to a medical care provider. Based on this determination, the medical care provider can then determine if and how to treat a particular patient based on the assessment of the status of the liver post-transplant.
[0029] In several embodiments, there are provided methods for determining the status (e.g., the level of function and/or health) of a liver of subject. In several embodiments, the status is determined shortly after a liver transplant, or a liver surgery (or other treatment). For example, in several embodiments, there is provided a method of identifying the status of a liver of a subject after a liver transplant, comprising (I) obtaining bile collected the liver of the subject after the liver transplant, (II) isolating one or more of membrane particles, exosomes, exosome-like vesicles, and microvesicles from said bile, (III) detecting expression of at least one marker of liver condition from each of the following groups of markers: (a) IL1B, IL6 and IL8, (b) TNF-alpha, FasL, IFNG, granzyme B, CD16, DEFA3, and PRG2, (c) IL10, TGF beta, CTLA4, PD-1 and FOXP3, and (d) IL2, IL4 and GMCSF by a method comprising (i) liberating RNA from the isolated membrane particles, exosomes, exosome-like vesicles, and/or microvesicles, (ii) contacting the liberated RNA with a reverse transcriptase to generate complementary DNA (cDNA), and (iii) contacting said cDNA with sense and antisense primers that are specific for each of the markers of liver condition and a DNA polymerase in order to generate amplified DNA; and (IV) identifying status of the liver of the subject as (a) in an early stage of acute rejection or early stage of acute infection when one or more of IL1B, IL6, and IL8 is detected, (b) in acute rejection when one or more of TNF-alpha, FasL, IFNG, granzyme B, CD16, and DEFA3 is detected, (c) in a recovery phase from acute rejection when one or more of IL10, TGF-beta, CTLA4, PD-1 and FOXP3 is detected, or (d) in sustained rejection when one or more of IL2, IL4 and GMCSF is detected.
[0030] In several embodiments, there is provided a method of determining the status of a liver of a subject after a liver transplant, comprising obtaining bile collected from the liver, isolating one or more of membrane particles, exosomes, exosome-like vesicles, and microvesicles from said bile by passing said bile through a membrane configured to capture one or more of said membrane particles, exosomes, exosome-like vesicles, and microvesicles, detecting expression of at least one marker of liver condition selected from the group consisting of IL1B, IL6, IL8, TNF-alpha, FasL, IFNG, granzyme B, CD16, DEFA3, IL10, TGF beta, CTLA4, PD-1, FOXP3, IL2, IL4 and GMCSF by a method comprising, (i) isolating RNA from the collected bile, (ii) contacting RNA from the collected bile with a reverse transcriptase in order to generate complementary DNA (cDNA), and (iii) contacting said cDNA with sense and antisense primers that are specific for one of IL1B, IL6, IL8, TNF-alpha, FasL, IFNG, granzyme B, CD16, DEFA3, IL10, TGF beta, CTLA4, PD-1, FOXP3, IL2, IL4 and GMCSF and a DNA polymerase to generate amplified DNA, and identifying status of the liver of the subject as: (a) in an early stage of acute rejection or early stage of acute infection when one or more of IL1B, IL6, and IL8 is detected, (b) in acute rejection when one or more of TNF-alpha, FasL, IFNG, granzyme B, CD16, and DEFA3 is detected, (c) in a recovery phase from acute rejection when one or more of IL10, TGF-beta, CTLA4, PD-1 and FOXP3 is detected, or (d) in sustained rejection when one or more of IL2, IL4 and GMCSF is detected.
[0031] Additionally, there are provided methods of determining the status of a liver of a subject after a liver surgery, comprising: obtaining bile collected from the liver, isolating one or more of membrane particles, exosomes, exosome-like vesicles, and microvesicles from said bile by passing said bile through a membrane configured to capture one or more of said membrane particles, exosomes, exosome-like vesicles, and microvesicles, detecting expression of at least one marker of liver condition by a method comprising: (i) isolating RNA from the collected bile; (ii) contacting RNA from the collected bile with a reverse transcriptase to generation complementary DNA (cDNA); and (iii) contacting said cDNA with sense and antisense primers that are specific for said marker of liver condition, and identifying status of the liver of the subject as: (a) in an early stage of acute rejection or early stage of acute infection when one or more of macrophage-derived mRNAs, IL8, and chemokine mRNAs is detected, (b) in acute rejection when one or more of cytotoxic T-cell derived mRNAs (TNF alpha, FasL, IFNG, GZB), or leukocyte-specific mRNAs (CD16, DEFA3) is detected, (c) in a recovery phase from acute rejection when one or more of when regulatory T-cell derived or anti-inflammatory cytokine mRNAs (IL10, TGFB, CTLA4, PD-1, FOXP3 is detected, or (d) in sustained rejection when one or more of Th1-(IL2), Th2-(IL4) derived mRNAs or GMCSF is detected. [0007] In several embodiments, the isolating comprises filtering said bile. In some embodiments, the isolating comprises diluting and filtering said bile. In several embodiments, the filtration traps one or more of membrane particles, exosomes, exosome-like vesicles, and microvesicles on the filter. In this manner, several samples of bile can be processed sequentially, if there is a dilute vesicular concentration in each of the samples. Advantageously, this allows for a many-fold concentration of captured membrane particles. However, in several embodiments, a single sample allows for capture of a sufficient amount of membrane particles to enable a full analysis of the status of the subject's liver.
[0032] Additionally, in several embodiments, the isolating comprises placing at least a portion of said bile into a device comprising a first body having an inlet, an outlet, and an interior volume between the inlet and the outlet, a second body having an inlet, an outlet, an interior volume between the inlet and the outlet, a filter material positioned within the interior volume of the second body, and in fluid communication with said first body, wherein the first body and the second body are reversibly connected by an interaction of the inlet of the second body with the outlet of the first body, and a receiving vessel having an inlet, a closed end opposite the inlet and interior cavity, wherein the interior cavity of the receiving vessel is dimensioned to reversibly enclose both the first and the second body and to receive the bile after it is passed from the interior volume of the first body, through the filter material, through the interior cavity of the second body and out of the outlet of the second body; and centrifuging said device to cause said bile to pass through the device to the receiving vessel and capture said membrane particles, exosomes, exosome-like vesicles, and/or microvesicles on said filter material.
[0033] In several embodiments, the liberating comprises lysing said membrane particles, exosomes, exosome-like vesicles, and/or microvesicles. In some embodiments, the lysing is performed while said membrane particles, exosomes, exosome-like vesicles, and/or microvesicles are trapped on said filter.
[0034] In several embodiments, the RNA comprises poly(A)+ RNA. In several embodiments, the generated amplified DNA is exposed to a probe complementary to a portion of one of said markers of liver condition.
[0035] As an optional step, several embodiments, further comprise corroborating the identified liver status with histological evaluation of a biopsy of said liver. Moreover, in several embodiments, the methods further comprise treating the patient according to the outcome of the methods. For example, in several embodiments, the subject is treated according to whether the status of the subject's liver is identified as in a stage of early acute rejection, in acute rejection, in a recover phase, or in sustained rejection. Thus, in several embodiments, not only can the status of the subject's be determined in a timely and accurate fashion, but an appropriate treatment regimen can be prepared and/or implemented.
[0036] The methods summarized above and set forth in further detail below describe certain actions taken by a practitioner; however, it should be understood that they can also include the instruction of those actions by another party. Thus, actions such as “administering a treatment to a subject after determining the subject is suffering from liver transplant rejection” include “instructing the administration of a treatment to a subject after determining the subject is suffering from liver transplant rejection.”
BRIEF DESCRIPTION OF THE FIGURES
[0037] FIG. 1 depicts a process flow scheme used to capture exosomes (or other membrane-bound bodies) and process the nucleic acids in a sample in order to assess gene expression.
[0038] FIG. 2 is a cross-section view of one embodiment of a capture device as disclosed herein.
[0039] FIG. 3 is a cross-section view of one embodiment of a first hollow body as disclosed herein.
[0040] FIG. 4 is a cross-section view of one embodiment of a second hollow body as disclosed herein.
[0041] FIG. 5 is a cross-section view of an additional embodiment of a second hollow body as disclosed herein.
[0042] FIG. 6 is a cross-section view of microvesicle capture system as disclosed herein.
[0043] FIG. 7 depicts a timeline of rejection and recovery in a liver transplant subject and various diagnostic parameters that were evaluated.
[0044] FIGS. 8A-8B depicts hematoxylin and eosin staining of liver tissue sections that demonstrate infiltration of immune cells, indicative of transplant rejection.
[0045] FIGS. 9A-9Q depict gene expression analysis of a variety of markers of immune function that were isolated from bile samples from post-transplant patients.
DETAILED DESCRIPTION
[0046] With nearly 120,000 men, women, and children awaiting organ or tissue transplants in the United States, some of them requiring a second (or greater) transplant, the need for successful long-term transplants is paramount. As transplants have become much more common in the last several decades, preparation and post-transplant medical care has become more sophisticated and led to improved transplant success rates.
[0047] Transplants, however, still run the risk of various clinical problems, such as rejection, infection, relapse of original disease, drug toxicity, etc. Early diagnosis and differential diagnosis are critically important for the timing of treatment as well as the choice of appropriate drugs or drug combinations. Although various clinical parameters are available to initially identify rejection, such as, for example, fever, leukocytosis, elevation of CRP, serum biochemical parameters, etc., these are not specific enough to identify the nature of the problem. Biopsy is frequently carried out for definite diagnosis, but it is invasive and is not applicable routinely. Thus, there is a clear demand for better diagnostic procedures and treatment methods, which are provided in several embodiments of the methods disclosed herein.
Transplant and Rejection
[0048] Organ and tissue transplant, while not mainstream in the medical field, has become much more prominent as techniques for controlling complications with respect to transplant surgery, or post-surgery, have improved. Transplants may consist of transplantation of organs (e.g., an entire organ). Alternatively, transplants may comprise transplantation of a tissue, in other words a portion of an organ such as, for example, muscle, tendon, connective tissue, or skin. Organs that are transplanted include, but are not limited to, kidney, heart, liver, lungs etc. Tissues that are transplanted include, but are not limited to, muscle, tendon, connective tissue, skin, eyes, and/or cells. Depending on the embodiment, transplantation may be in one of several forms. For example tissue transplantation is often autologous (donor and recipient are same individual). Organ transplantation, on the other hand, is often allogeneic (donor and recipient are different individuals). However, depending on the embodiment disclosed herein, transplantation of organs or tissues may be autologous or allogeneic. In additional embodiments, xenogeneic transplants occur. Instill additional embodiments, syngeneic transplants occur. In some embodiments the methods disclosed herein are used to evaluate the post-transplants status of an individual having received an ABO incompatible transplant. Such transplants enable the use of organs for donation regardless of AB blood type, though they are typically limited to infant recipients. Regardless of the type of transplant has occurred, the methods disclosed herein are useful for assessing the condition of the recipient post-transplant and identifying (i) the presence of transplant rejection, (ii) the source or sources of the rejection, and (iii) the likely most efficacious treatment regime to address the rejection.
[0049] A variety of different mechanisms may come into play post-transplant that lead to rejection of a transplanted organ by the recipient. Organ or tissue rejection is an immune response that involves both the cellular immune pathway and humoral immune pathways. Cellular immunity is mediated by killer T cells which induce apoptosis of target cells, in this case, the cells of the transplanted organ. Humoral immunity is mediated by activated B cells that secrete antibody molecules that are directed against the transplanted tissue. In some cases rejection also involves the innate immune response. Depending on the type of transplant (e.g., the tissue involved), various rejection mechanisms may come into play. However, advantageously, the methods disclosed herein allow evaluation of the post-transplant status of the transplanted organ or tissue based on, for example, analysis of expression of organ or tissue-function related markers, such as, for example mRNA.
[0050] Post-transplant, donor dendritic cells (the primary antigen presenting cells) are released from the donor tissue or organ and move to and present in the recipient's lymphoid tissue (such as their lymph nodes). In this presentation, the dendritic cells present the donors “self peptides” to the recipient lymphocytes these lymphocytes (e.g. T cells, such as helper T cells and/or killer T cells, and B cells) enact specific immunity. This specific immunity then results in the immune responses that are directed specifically at the donor “self peptides”, thus raising immune responses to, and eventually rejection of, the donated tissue or organ.
[0051] Cellular immunity is a result of killer T cells (also known as cytotoxic T lymphocytes) having CD8 surface receptors that interact with the major histocompatibility complex class I molecules on transplant tissue from a donor. The MHC class I molecules display the donor's “self peptides”. After this interaction with the with the MHC class I molecules of the transplanted tissue (via the T cell receptor a.k.a. TCR) the killer T cells can then recognize their matching epitopes and trigger apoptosis of that target cell (or cells) thereby resulting in a reduced function or complete rejection of the transplanted organ or tissue.
[0052] Often times, a transplant recipient may have been exposed previously to an antigen that leads to specific immunity. This can occur for example if there were a blood type mismatch during a previous blood transfusion, such as a transfusion during the organ transplantation. Upon a subsequent exposure to the foreign antigens, pre-existing cross-reactive antibodies can be induced to cause inflammation and destruction of transplanted tissue.
Types of Rejection
[0053] As discussed above, depending on the organ or tissue transplanted certain particular types of rejection are more common than others. Hyperacute rejection, as suggested by the nomenclature, is a rapid response that occurs within minutes or hours of transplant and can lead to systemic inflammatory responses against the transplanted tissue. Most often, hyperacute rejection is the result of some pre-existing humoral immunity, the transplant serving as a subsequent exposure to nonself antigens. Hyperacute rejection is most often treated by removal of the transplanted tissue.
[0054] Acute rejection, with varying degrees of severity, occurs, in essence, in almost all transplants. Acute rejection is tied to the formation of cellular immunity against the transplanted tissue or organ. It typically occurs within 6 to 10 days of transplant, with risk of acute rejection being highest typically in the first 3 to 4 months. However, acute rejection can occur even after longer elapsed times. Acute rejection is most often recognized in highly vascularized tissues that are transplanted, such as, for example, the liver or the kidney. While acute rejection can be recognized and fairly promptly treated, which leads to prevention or reduction in risk of organ failure, recurrent episodes of acute rejection can lead to chronic rejection.
[0055] Chronic rejection refers to the long-term loss of function in transplanted organ. In some instances this occurs via fibrosis of the transplanted tissue blood vessels, and subsequent loss of adequate blood and/or oxygen flow to the tissue. Chronic rejection is typified by initial infiltration of lymphocytes which can lead to epithelial cell injury, followed by inflammatory lesions, and potential recruitment of fibroblasts which lead to the formation of scar tissue. Scar tissue, in many organs, obstructs function and/or blood flow which can lead to failure of the transplanted organ and/or further inflammatory or immune responses against the transplanted organ.
[0056] Depending on the type of rejection, the methods by which the rejection is diagnosed may vary. For example hyperacute rejection is often noticed and treated in a very short term. Diagnosis of acute and often chronic rejection, relies on clinical data, such as for example, patient symptoms or physical exams. More often than not, however, laboratory data, such as, for example, tissue biopsies and subsequent histochemical or pathological analysis, are used in diagnosing tissue or organ rejection. For example, a tissue biopsy may be evaluated for histological signs of rejection. These may include, but are not limited to, evidence of infiltration of T cells (and/or other cells such as eosinophils or neutrophils). Also indicative of rejection are structural changes to the transplanted tissue anatomy that suggest insufficient blood or nutrient supply, and/or damage due to host immune response. Also, injury to blood vessels, such as that caused by pro-inflammatory reactions, may be indicative of tissue rejection. However, tissue biopsy may be limited, depending on, for example, the health status of a recipient, the potential invasiveness of the biopsy (e.g., depending on what tissue or organ was transplanted).
Diagnostic Tests
[0057] Currently, many diagnostic tests are performed on a biological fluid sample (e.g., blood, urine, etc.) extracted from a patient for the diagnosis or prognosis of disease. The diagnosis or prognosis may be derived from identification of a biomarker or a biochemical pattern that is not present in healthy patients or is altered from a previously obtained patient sample. In several embodiments, the diagnostic tests rely on the presence of known and well characterized biomarkers in the fluid sample (e.g., electrolytes, urea, creatinine, glucose, plasma proteins such as albumins, immunoglobulins and the like, biological compounds such as thiamin, riboflavin, niacin, vitamin B6, folic acid, vitamin D, biotin, or iron). In several embodiments, the diagnostic tests are directed to detection of specific biomarkers (e.g., cell surface proteins) that are unique to diseased cells. In several embodiments, diagnostic tests are designed to detect or identify disease states through the isolation and amplification of nucleic acids, in order to study expression levels of certain disease-associated genes. For example, in several embodiments the methods disclosed herein evaluate the change in expression level of certain markers associated with liver function and/or liver health in order to assess the status of a liver transplant patient (e.g., presence or absence of rejection of the transplanted liver, and severity of the same). In several embodiments, these diagnostic tests employ a file sample isolated or obtained from the recipient of a liver transplant.
[0058] Often, use of bodily fluids to isolate or detect biomarkers significantly dilutes a biomarker and results in readouts that lack the requisite sensitivity. Additionally, most biomarkers are produced in low or even moderate amounts in tissues other than the diseased tissue, such as normal tissues. Thus, as described in more detail below, in several embodiments devices are used that enable the concentration of a target nucleic acid (or other biomarker) from a fluid sample such as for example, a bile sample obtained from a liver transplant recipient.
Vesicle-Associated RNA
[0059] As discussed in more detail below, several embodiments of the methods disclosed herein are based on the identification of specific nucleic acids that are markers of disease or injury to the liver. In particular, several embodiments of the methods employ what is generally considered a medical waste material, e.g., bile. Advantageously, in several embodiments, the methods disclosed herein provide a higher degree of sensitivity than alternative diagnostic assays disclosed above. While several embodiments disclosed herein are directed to the isolation of RNA associated with vesicles present in patient bile samples, in several embodiments, RNA (and the associated markers) that are normally found in blood or plasma are isolated from bile samples. In some embodiments, these markers are present in the bile due to damage or disease of the liver, or for example, rejection of a transplanted liver, and are indicative of one or more of the function, rejection status, and general health of the liver.
[0060] In several embodiments disclosed herein, there are provided methods for the capture of RNA from a sample of patient body fluid and subsequent analysis of that RNA for disease and/or tissue specific markers. In several embodiments, the method comprises isolation of vesicles associated with RNA from a patient bile sample (though in other embodiments, vesicles used for assessing the status of the liver can be obtained from plasma, serum, cerebrospinal fluid, sputum, saliva, mucus, tears etc.).
[0061] As described below, in some embodiments, the nucleic acids are vesicle-associated. In some embodiments, the nucleic acids detected are indicative of liver status post-transplant (or, in some embodiments, another aspect of liver disease and/or function). In several embodiments, the markers are not normally present in the bile of subject (e.g., their presences is indicative of a transplant rejection). In other embodiments, the marker may normally be present, but is expressed at elevated (or reduced) levels. In some embodiments, the detection of the nucleic acids is associated with severity and/or progression of transplant rejection. In some embodiments, bile is collected and nucleic acids are evaluated over time (e.g., to monitor a patient's response to anti-rejection therapy or progression of rejection).
[0062] According to various embodiments, various methods to quantify RNA are used, including Northern blot analysis, RNAse protection assay, PCR, RT-PCR, real-time RT-PCR, RNA sequencing, nucleic acid sequence-based amplification, branched-DNA amplification, ELISA, mass spectrometry, CHIP-sequencing, and DNA or RNA microarray analysis.
[0063] RNA (and other nucleic acids) are typically within the intracellular environment. However, certain nucleic acids exist extracellularly. For example, in several embodiments, the methods involve collection and analysis of naked extracellular nucleic acids (e.g., naked RNA) from the bile. This is advantageous in several embodiments because, typically, the extracellular environment that comprises substantial quantities of RNAses leads to rapid degradation of the nucleic acids.
[0064] In several embodiments, nucleic acids are associated with extracellular vesicles. In several embodiments, diagnosis and characterization of liver transplant rejection is performed by detection and quantification of specific RNA species from RNA-containing vesicles isolated from patient samples (e.g., bile). In one embodiment, such vesicles are trapped on a filter, thereby allowing RNA extraction from the vesicles. In additional embodiments, centrifugation is used to collect the vesicles.
[0065] Nucleic acids can be associated with one or more different types of membrane particles (ranging in size from 50-80 nm), exosomes (ranging in size from 50-100 nm), exosome-like vesicles (ranging in size from 20-50 nm), and microvesicles (ranging in size from 100-1000nm). In several embodiments, these vesicles are isolated and/or concentrated, thereby preserving vesicle associated RNA despite the high RNAse extracellular environment. In several embodiments, the sensitivity of methods disclosed here is improved (vis-à-vis isolation of nucleic acids from tissues and/or collection of naked nucleic acids) based on the use of the vesicle-associated RNA.
[0066] A variety of methods can be used, according to the embodiments disclosed herein, to efficiently capture and preserve vesicle associated RNA. In several embodiments, centrifugation on a density gradient to fractionate the non-cellular portion of the sample is performed. In some embodiments, density centrifugation is optionally followed by high speed centrifugation to cause vesicle sedimentation or pelleting. As such approaches may be time consuming and may require expensive and specialized equipment in several embodiments, low speed centrifugation can be employed to collect vesicles. Vesicle capture devices and systems are disclosed in more detail below.
[0067] In several embodiments, filtration (alone or in combination with centrifugation) is used to capture vesicles of different sizes. In some embodiments, differential capture of vesicles is made based on the surface expression of protein markers. For example, a filter may be designed to be reactive to a specific surface marker (e.g., filter coupled to an antibody) or specific types of vesicles or vesicles of different origin.
[0068] In some embodiments, the markers are unique vesicle proteins or peptides. In some embodiments, the severity of liver transplant rejection is associated with certain vesicle modifications which can be exploited to allow isolation of particular vesicles. Modification may include, but is not limited to addition of lipids, carbohydrates, and other molecules such as acylated, formylated, lipoylated, myristolylated, palmitoylated, alkylated, methylated, isoprenylated, prenylated, amidated, glycosylated, hydroxylated, iodinated, adenylated, phosphorylated, sulfated, and selenoylated, ubiquitinated. In some embodiments, the vesicle markers comprise non-proteins such as lipids, carbohydrates, nucleic acids, RNA, DNA, etc.
[0069] In several embodiments, the specific capture of vesicles based on their surface markers also enables a “dip stick” format where each different type of vesicle is captured by dipping probes coated with different capture molecules (e.g., antibodies with different specificities) into a patient urine sample.
[0070] In several embodiments, vesicle-associated RNA is captured and RNA markers are detected that correspond to certain markers or groups of markers and/or certain stages of liver rejection. For instance, in several embodiments, markers may be detected that are related to an early stage of acute rejection or early stage of acute infection of a liver, including, but not limited to one or more of IL1B, IL6, IL8, or other markers. Additionally, in several embodiments, markers that correspond to acute rejection or acute infection of a transplanted liver are detected, including, but not limited to one or more of TNF-alpha, FasL, IFNG, granzyme B, CD16 DEFA3, PRG2, or other markers. In several embodiments, markers that correspond to sustained rejection or sustained infection of a transplanted liver are detected, including, but not limited to one or more of IL2, IL4, GMCSF, or other markers. In several embodiments, RNA markers that correspond to a recovery phase after liver transplant or recovery phase from acute rejection or acute infection of a transplanted liver are detected, including but not limited to, one or more of IL10, TGF beta, CTLA4, PD-1, FOXP3, or other markers. Depending on the embodiment, markers from more than one group are detected. For example, markers related to acute rejection or infection may still be detected when a subject is in the recovery phase after a liver transplant, for example due to lag time in changes in gene expression.
[0071] Sometimes when one or more of IL1B, IL6 or IL8 is detected using the methodology described herein, liver rejection is ruled out. On the other hand, in some instances rejection may not be ruled out when IL1B, IL6 or IL8 is detected. For instance, in some cases, IL1B, IL6 or IL8 may be detected in combination with a marker from another group of markers that also corresponds to liver rejection or liver infection. At least one of the markers from the group of TNF-alpha, FasL, IFNG, granzyme B, CD16 DEFA3, and PRG2 may be detected in combination with at least one marker from the group of IL1B, IL6 or IL8. Or alternatively, at least one of the markers from the group of IL2, IL4 and GMCSF may be detected in combination with at least one of the markers from the group of IL1B, IL6 or IL8. In another example, at least one of the markers from the group of TNF-alpha, FasL, IFNG, granzyme B, CD16 DEFA3, and PRG2 may be detected in combination with at least one of the markers from the group of IL2, IL4 and GMCSF. In some instances, the particular phase of liver rejection (or recovery) is corroborated by other methods, as the transition from one phase to the next is not necessarily an acute change, but could be more gradual (e.g., with overlapping marker expression). In some embodiments, the identification of one or more markers allows an individual to specifically pinpoint whether a liver is subject to rejection or infection, and what phase the rejection or infection is in. In some instances, the identification of one or more markers may allow an individual to rule out rejection or infection.
Methodology
[0072] Free extracellular RNA is quickly degraded by nucleases, making it a potentially poor diagnostic marker. As described above, some extracellular RNA is associated with particles or vesicles that can be found in various biological samples, such as bile excreted from the liver. This vesicle associated RNA, which includes mRNA, is protected from the degradation processes in the bile. Microvesicles are shed from most cell types and consist of fragments of plasma membrane. Microvesicles contain RNA, mRNA, microRNA, and proteins and mirror the composition of the cell from which they are shed. Exosomes are small microvesicles secreted by a wide range of mammalian cells and are secreted under normal and pathological conditions. These vesicles contain certain proteins and RNA including mRNA and microRNA. Several embodiments evaluate nucleic acids such as small interfering RNA (siRNA), tRNA, and small activating RNA (saRNA), among others.
[0073] In several embodiments the RNA isolated from vesicles from the bile of a patient with liver transplant rejection is used as a template to make complementary DNA (cDNA), for example through the use of a reverse transcriptase. In several embodiments, cDNA is amplified using the polymerase chain reaction (PCR). In other embodiments, amplification of nucleic acid and RNA may also be achieved by any suitable amplification technique such as nucleic acid based amplification (NASBA) or primer-dependent continuous amplification of nucleic acid, or ligase chain reaction. Other methods may also be used to quantify the nucleic acids, such as for example, including Northern blot analysis, RNAse protection assay, RNA sequencing, RT-PCR, real-time RT-PCR, nucleic acid sequence-based amplification, branched-DNA amplification, ELISA, mass spectrometry, CHIP-sequencing, and DNA or RNA microarray analysis.
[0074] In several embodiments, rejection of a transplanted liver by the recipient (or other issues with the received liver, such as infection, relapse of original disease, etc.) induces the expression of one or more markers. In several embodiments, the increased expression is measured by the amount of mRNA encoding said markers (in other embodiments, DNA or protein are used to measure expression levels). In some embodiments bile is collected from a patient and directly evaluated. In some embodiments, vesicles are concentrated, for example by use of filtration or centrifugation. Isolated vesicles are then incubated with lysis buffer to release the RNA from the vesicles, the RNA then serving as a template for cDNA which is quantified with methods such as quantitative PCR (or other appropriate amplification or quantification technique). In several embodiments, the level of specific marker RNA from patient vesicles is compared with a desired control such as, for example, RNA levels from a healthy patient population, or the RNA level from an earlier time point from the same patient or a control gene from the same patient.
[0075] In several embodiments, the disclosed methods allow the detection of various clinical problems with a transplanted liver (e.g., rejection, infection, relapse of original disease, etc.) by measuring the levels of mRNA encoding one or more markers related to various liver functions. In several embodiments, the disclosed methods allow the assessment of the progression (or regression) of liver transplant by measuring the levels of mRNA encoding one or more markers related to liver function. To determine these mRNA levels, in some embodiments, mRNA-containing vesicles are isolated from bile using a device for isolating and amplifying mRNA, such as those described above. Additional devices that can also be used for at least part of the isolation and/or amplification process are described in more detail in U.S. Pat. Nos. 7,745,180, 7,939,300, 7,968,288, 7,981,608, 8,076,105, 8,101,344, each of which is incorporated in its entirety by reference herein.
[0076] FIG. 1 shows a general schematic of one embodiment of a process for capturing vesicles from a bile sample and preparing the samples for subsequent analysis. In brief, a bile sample is loaded into a vesicle capture device (discussed in more detail below) and centrifuged (though other forces can be applied in other embodiments). Centrifugation causes the bile to pass through a vesicle capture membrane, wherein the vesicles are retained on the membrane and the remainder of the bile (now vesicle-depleted) passes on to the bottom of the centrifuge tube (also referred to as the receiving vessel, depending on the embodiment). Thereafter, the internal portion of the capture device is separated and the filter-containing portion is placed in communication with a multi-well microplate (a 96-well plate is depicted, though other size plates can be used). A lysis buffer is added to each individual vesicle capture portion (e.g., each portion is in an individual well of the microplate) in order to release RNA from the captured exosomes. Thereafter, the RNA is transferred to a plate comprising, for example immobilized oligo-dT, in order to allow subsequent production of complementary DNA (cDNA) and analysis of marker expression for markers related to liver function, liver rejection, liver infection, etc.
[0077] FIG. 2 depicts additional details regarding one embodiment of a capture device 100 used for capturing vesicles from patient bile samples. The embodiment of capture device 100 depicted in FIG. 2 comprises a first hollow body 1 in functional communication with a second hollow body 2 . “Functional communication” shall be given its ordinary meaning and shall also refer to the two hollow bodies being coupled in such a manner that bile can pass from the first hollow body to the second hollow body.
[0078] For example, in several embodiments, a bile sample 3 is loaded into first hollow body 1 and passed to second hollow body 2 , thereby passing through a capture material 4 . In some embodiments, capture material 4 retains at least some of the target vesicles contained in the bile sample, for example vesicles comprising nucleic acid or protein that can be used to assess the current physiological state of a subject's liver.
[0079] In some embodiments, the capture material (glass fiber filter in some embodiments) is located within second hollow body 2 . In several embodiments, after the bile sample has passed through capture material 4 , second hollow body 2 is removed from first hollow body 1 , and second hollow body 2 is then processed to retrieve the vesicles retained in capture material. In at least one embodiment, exosomes that have been retained by capture material 4 are subsequently recovered from capture material 4 by passing a small amount of liquid (e.g., a lysis buffer) through capture material 4 . In some embodiments, another solution (e.g., a washing buffer) is optionally passed through capture material 4 before and/or after application of the liquid used to recover the retained exosomes.
[0080] In some embodiments, gravitational force, positive, or negative pressure drives the bile sample through capture material 4 . However, in several embodiments, no negative or positive pressure is used, rather, in several embodiments, centrifugal force drives the bile sample through capture material 4 . In some embodiments, a wicking-type material drives the bile sample 3 through capture material 4 . In some embodiments, capillary action drives the bile sample through capture material 4 .
[0081] FIG. 3 depicts additional details found in one embodiment of first hollow body 1 . In several embodiments, first hollow body 1 has an inlet opening 101 , an outlet opening 102 , an outer surface 130 , and an inner surface 140 . In some embodiments, inlet opening 101 is a circular opening having an inlet diameter 111 . In some embodiments, outlet opening 102 is a circular opening having an outlet diameter 112 . In several embodiments, inlet opening 101 and outlet opening 102 are circular openings that are axially-aligned, with outlet diameter 112 being smaller than inlet diameter 111 .
[0082] In some embodiments, first hollow body 1 comprises an upper region 132 , an intermediate region 134 , and a terminal region 136 . In some embodiments, upper region 132 and terminal region 136 are cylindrical or substantially cylindrical, and intermediate region 134 is tapered (e.g., conical). In some embodiments, the taper of intermediate region 134 is configured to facilitate passage of a bile sample through outlet opening 102 . In some embodiments, first hollow body 1 includes a collar 105 that extends beyond outer surface 130 of an adjacent portion of first hollow body 1 . In some embodiments, collar 105 is configured to support first hollow body 1 when first hollow body 1 is inserted into a storage rack or a receiving vessel (not shown).
[0083] FIG. 4 depicts an embodiment of second hollow body 2 . In several embodiments, second hollow body 2 has an inlet opening 201 , an outlet opening 202 , an outer surface 230 , and an inner surface 240 . In some embodiments, inlet opening 201 is a circular opening having an inlet diameter 211 . In some embodiments, outlet opening 202 is a circular opening having an outlet diameter 212 . In several embodiments, inlet opening 201 and outlet opening 202 are circular openings that are axially-aligned, with outlet diameter 212 being smaller than inlet diameter 211 .
[0084] In several embodiments, first hollow body 1 and second hollow body 2 are made of material that has a low binding affinity for nucleic acids and/or for vesicles (thereby increasing the efficiency of capture of vesicles on the filter material. Suitable materials include, but are not limited to, plastics such as polypropylene, polystyrene, and polyethylene, among others. In some embodiments, first hollow body 1 and second hollow body 2 are made of metal or composite material. In some embodiments, inner surfaces 140 , 240 are coated with one or more substances that lowers the binding affinity of the surfaces for nucleic acids (and/or vesicles).
[0085] In some embodiments, second hollow body 2 comprises an upper region 232 , an intermediate region 234 , and a terminal region 236 . In some embodiments, terminal region 236 is tapered. In at least one embodiment, the taper of terminal region 236 is configured to facilitate passage of fluid sample 3 out of second hollow body 2 .
[0086] In several embodiments, second hollow body 2 has a tab 260 that extends from outer surface 230 . In some embodiments, tab 260 is located in upper region 232 . Tab 260 has an upper surface 262 . In some embodiments, upper surface 262 is substantially co-planar with inlet opening 201 . In several embodiments, upper surface 262 is sufficiently dimensioned to serve as a platform for labeling second hollow body 2 . In at least one embodiment, upper surface 262 is between about 1 mm to about 5 mm wide and about 1 mm to about 5 mm long. In some embodiments, a label 264 is affixed to upper surface 262 . In several embodiments, upper surface 262 is marked by any suitable means including ink, or etching. In at least one embodiment, label 264 or the marking of upper surface 262 denotes the identity (e.g., the source patient) of the fluid sample 3 that has been passed through second hollow body 2 . In some embodiments, label 264 or marking of upper surface 262 encodes a bar code (e.g., a 2D or 3D bar code). In several embodiments, RFID tags or other identifiers may be used to denote the patient identity from which the sample was obtained.
[0087] In several embodiments, upper region 232 of second hollow body 2 is configured to functionally communicate with terminal region 136 of first hollow body 1 . First hollow body 1 and second body 2 may functionally communicate by any number of ways including but not limited to mating screw threads, a luer fitting, an interference fit, and a compression fitting (though other types of fittings may be used in additional embodiments). In some embodiments, terminal region 136 of first hollow body 1 is configured to fit inside upper region 232 of second hollow body 2 . In some embodiments, upper region 232 of second hollow body 2 is configured to fit inside terminal region 136 of first hollow body 1 . In some embodiments, at least a portion of outer surface 130 is surrounded by at least a portion of inner surface 240 . In some embodiments, at least a portion of outer surface 230 is surrounded by at least a portion of inner surface 140 . In some embodiments, outlet diameter 112 is smaller than inlet diameter 211
[0088] In some embodiments, first hollow body 1 has at least one pin 150 that protrudes from outer surface 130 of terminal region 136 , and second hollow body 2 has at least one channel 250 in upper region 232 of second hollow body 2 (see e.g., FIG. 4 ). In at least one embodiment, pin 150 is configured to reversibly cooperate with channel 250 . Channel 250 has a longitudinal portion 252 , a transverse portion 254 , and a retrograde portion 256 . In some embodiments, first hollow body 1 is coupled to second hollow body 2 by sliding pin 150 into longitudinal portion 252 of channel 250 . First hollow body 1 and second hollow body 2 are positioned to allow pin 150 to reach transverse portion 254 of channel 250 . Second hollow body 2 is then rotated to bring pin 150 into transverse portion 254 until pin 150 lines up with retrograde portion 256 of channel 250 . The compressive force between first hollow body 1 and second hollow body 2 is then reduced, allowing pin 150 to slide into retrograde portion 256 , thereby securing a coupling between first hollow body 1 and second hollow body 2 . In some embodiments, second hollow body 2 is removed from first hollow body 1 by squeezing the two hollow bodies together and allowing pin 150 to retrace channel 250 .
[0089] In some embodiments, the at least one channel 250 in upper region 232 of second hollow body 2 comprises a longitudinal portion 252 and a transverse portion 254 . In some embodiments, first hollow body 1 is coupled to second hollow body 2 by sliding pin 150 into longitudinal portion 252 of channel 250 . First hollow body 1 and second hollow body 2 are positioned to allow pin 150 to reach transverse portion 254 of channel 250 . Second hollow body 2 is then rotated to bring pin 150 into transverse portion 254 thereby securing a coupling between first hollow body 1 and second hollow body 2 . After processing, second hollow body 2 is removed from first hollow body 1 by rotating the two hollow bodies in the opposite direction and allowing pin 150 to retrace channel 250 , thereby allowing the first and second hollow bodies to disengage.
[0090] In several embodiments, capture material 4 is made from any suitable material that can retain the vesicles to be captured from the bile sample. In several embodiments, the material used for capture material 4 is optimized to balance the attractive nature of the material for the vesicles (or naked nucleic acids and/or proteins) and the ability of the material to release the target component under appropriate conditions (e.g., lysis and/or elution).
[0091] In some embodiments, capture material 4 is optionally modified to tailor the profile of the vesicles retained by capture material 4 . In some embodiments, capture material 4 is electrocharged (e.g., electrostatically charged), coated with hydrophilic or hydrophobic materials, chemically modified, and/or biologically modified. In several embodiments, the zeta potential of capture material 4 is used as a basis for modification (e.g., electrostatic charging) of the material. In some embodiments, capture material 4 (based on its zeta potential) does not require modification. In some embodiments, capture material 4 is modified by attaching a nucleotide sequence to the surface of capture material 4 . In some embodiments, a protein is attached to the surface of capture material 4 . In some embodiments, biotin or streptavidin is attached to the surface of capture material 4 . In some embodiments, an antibody or antibody fragment is attached to capture material 4 . Any of such embodiments can be employed to advantageously increase the efficiency of capture of a target.
[0092] In some embodiments, differential capture of vesicles is achieved based on the surface expression of protein markers on the vesicles and a complementary agent on capture material 4 which identifies that marker (e.g., an antibody that recognizes an antigen on a particular vesicle). In some embodiments, the markers are unique vesicle proteins or peptides. In such embodiments, capture material 4 may be configured in a manner which allows for recognition of specific vesicle modifications that may occur under certain physiologic conditions (e.g., vesicles may be modified in a manner consistent with liver transplant rejection). Modification of the vesicles may include, but is not limited to the addition of lipids, carbohydrates, and other molecules such as acylated, formylated, lipoylated, myristolylated, palmitoylated, alkylated, methylated, isoprenylated, prenylated, amidated, glycosylated, hydroxylated, iodinated, adenylated, phosphorylated, sulfated, and selenoylated, ubiquitinated. In some embodiments, capture material 4 is configured to recognize vesicle markers comprising non-proteins such as lipids, carbohydrates, nucleic acids, RNA, mRNA, siRNA, microRNA, DNA, etc.
[0093] In some embodiments, the interactions between vesicles and capture material 4 are based on electrostatic interaction, hydrophobic interaction, van der Waals force, or a combination of these interactions.
[0094] In some embodiments, the materials used for capture material 4 may comprise unwanted materials that inhibit the capture of vesicles. Thus, in several embodiments, capture material 4 is pre-treated to remove such inhibitory materials in advance of using the capture material to capture the vesicles. For example, high concentrations of proteins such as albumin may lower the capture efficiency of vesicle capture. In such cases, albumin can be removed by various techniques, such as, for example, passing materials or solutions through or over capture material 4 , the materials or solutions comprising a compound (e.g., Blue Trisacryl M resin) with a greater affinity for the albumin than the albumin has for capture material 4 . The techniques used to remove contaminants may also include heating, acid bath, basic bath, ultrasonic cleaning, and the like.
[0095] In several embodiments, capture material 4 is made of glass-like material. In some embodiments, capture device 100 optionally includes a filter material 5 (shown in FIG. 3 ) that is configured to filter fluid sample 3 before fluid sample 3 passes through capture material 4 . In some embodiments filter material 5 is placed in second hollow body 2 between capture material 4 and inlet opening 201 . In some embodiments, filter material 5 is placed in first hollow body 1 between intermediate region 136 and outlet opening 102 . In several embodiments, however, no filter material is used.
[0096] In several embodiments, combinations of filter material 5 and capture material 4 are used. In some embodiments, capture material 4 comprises a plurality of layers of material. In several embodiments, capture material 4 comprises at least a first layer and a second layer of glassfiber. In some embodiments, a bile sample is passed through filter material 5 to capture components that are about 1.6 microns or greater in diameter. In some embodiments, a bile sample is passed through capture material 4 so as to capture vesicles having a minimum size from about 0.6 microns to about 0.8 microns in diameter, and having a maximum size of less than about 1.6 microns. In several embodiments, the retention rate of capture material 4 is greater than about 50%, about 75%, about 90%, or about 99% for vesicles having a diameter of from about 0.6 microns to about 1.5 microns in diameter. In at least one embodiment, capture material 4 captures vesicles sized from about 0.7 microns to about 1.6 microns in diameter. In at least one embodiment, capture material 4 captures exosomes or other vesicles ranging in size from about 0.020 microns to about 1.0 microns.
[0097] In several embodiments, capture material 4 comprises combinations of glass-like and non-glass-like materials. For example, in one embodiment, a non-glass-like material comprising nitrocellulose is used. In some embodiments, capture material 4 comprises glass-like materials, which have a structure that is disordered, or “amorphous” at the atomic scale, such as plastic or glass. Glass-like materials include, but are not limited to, glass beads or fibers, silica beads (or other configurations), nitrocellulose, nylon, polyvinylidene fluoride (PVDF) or other similar polymers, metal or nano-metal fibers, polystyrene, ethylene vinyl acetate or other co-polymers, natural fibers (e.g., silk), alginate fiber, or combinations thereof. Other suitable materials for capture material 4 include zeolite, metal oxides or mixed metal oxides, aluminum oxide, hafnium oxide, zirconium oxide, or combinations thereof.
[0098] In some embodiments, vesicles are retained in capture material 4 by virtue of the vesicle having physical dimensions that prohibit the vesicle from passing through the spaces of capture material 4 (e.g., physical retention based on size). In some embodiments, vesicles are retained in capture material 4 by bonding forces between the vesicle and capture material 4 . In some embodiments, vesicles form antigen-antibody bonds with capture material 4 . In several embodiments, vesicles form hydrogen bonds with capture material 4 . In some embodiments, van der Waals forces form between the vesicle and capture material 4 . In some embodiments, nucleotide sequences of the vesicle bind to nucleotide sequences attached to capture material 4 .
[0099] In several embodiments, capture device 100 is used in conjunction with a receiving vessel 500 (see FIG. 6 ) that receives a bile sample in a receiving compartment 600 after fluid sample 3 has passed through capture device 100 . In some embodiments, the receiving vessel also includes a cap 700 , to secure the capture device 100 within the receiving vessel 500 during processing. In several embodiments, the cap is a press-fit cap, while in other embodiments the cap comprises a screw-fit cap. In several embodiments, the receiving vessel comprises a centrifuge tube, thus, in some embodiments, first hollow body 1 and second hollow body 2 are sized to fit within a receiving vessel/centrifuge tube. In some embodiments, collar 105 serves as a means for holding capture device 100 in a fixed position relative to the receiving vessel. In several embodiments, capture device 100 and collar 105 are sized to permit use of capture device 100 with a receiving vessel such as a 10 mL, 12 mL, 15 mL, 30 mL, 50 mL, 175 mL, or 225 mL centrifuge tube, though centrifuge tubes of other sizes and capacities are also contemplated. In some such embodiments, collar 105 is sized to fit over the mouth of the centrifuge tube without obstructing the function of the threaded cap of the centrifuge tube. In several embodiments, capture device 100 is placed within a centrifuge tube, and centrifugal force is applied to drive fluid sample 3 from first hollow body 1 through capture material 4 and into second hollow body 2 .
[0100] In some embodiments, capture device 100 is sized so that outlet opening 202 of second hollow body 2 does not contact fluid sample 3 after fluid sample 3 has passed through capture device 100 and accumulated in the receiving vessel. In some embodiments, the volume capacity of the receiving vessel is greater than the volume capacity of capture device 100 by about 2-fold, by about 3-fold, by about 4-fold, or by about 5-fold.
[0101] In some embodiments, capture device 100 has a volume sufficient to receive a bile sample and optionally other reagents to facilitate binding of vesicles and/or nucleic acids to capture material 4 . In some embodiments, capture device 100 is sized to accommodate a bile sample volume of between about 1 mL and 1000 mL, including between about 1 mL and 100 mL, between about 5 mL and 50 mL, between about 10 mL and 20 mL, and any volumes between those ranges. In some embodiments, capture device 100 accommodates a volume of about 15 mL.
[0102] In some embodiments, the capacity of first hollow body 1 is greater than the capacity of second body 2 by about 100-fold, or by about 50-fold, or by about 20-fold, or by about 10-fold, or by about 5-fold. In some embodiments, the capacity of first hollow body 1 is about the same as the capacity of second hollow body 2 .
[0103] In many embodiments, the dimensions of capture material 4 are optimized to balance having sufficient capture material 4 to adequately capture vesicles from the bile sample while also allowing a small volume of liquid (e.g., microliter scale) to be used to lyse/elute bound vesicles components. Reducing the volume of recovery liquid allows, in certain advantageous embodiments, the content of vesicles to be extracted at higher concentrations. In some embodiments, the volume of capture device 100 is greater than the volume of capture material 4 by about 1000-fold, by about 500-fold, by about 300-fold, or by about 100-fold. In embodiments where the material of capture material 4 includes interstitial spaces, the meaning of the phrase “volume of capture material 4 ” shall be taken to include the volume of these interstitial spaces. In several embodiments, the lysis or elution volume ranges from about 5 to about 500 microliters, including about 5 microliters to about 10 microliters, about 10 microliters to about 20 microliters, about 20 microliters to about 50 microliters, about 50 microliters to about 100 microliters, about 100 microliters to about 150 microliters, about 150 microliters to about 200 microliters, about 200 microliters to about 300 microliters, about 300 microliters to about 400 microliters, about 400 microliters to about 500 microliters, and overlapping ranges therebetween.
[0104] In some embodiments, capture material 4 is cuboidal. In some embodiments capture material 4 is wafer-shaped, spherical, or some combination thereof. In some embodiments capture material 4 has a surface area to thickness ratio of about 50:1, about 25:1, about 10:1, about 5:1, or about 3:1. In some embodiments, capture material 4 is a cylindrical wafer having a diameter to length ration of about 20:1, about 10:1, about 5:1, or about 2:1. In at least one embodiment, capture material 4 is cylindrical and has a diameter of about 9 mm and a thickness of about 1 mm.
[0105] In some embodiments, terminal region 236 of second hollow body 2 is sized to fit within a well of a standard multi-well plate. In several embodiments, terminal region 236 is sized to fit within a well of a standard 6-well plate, or a standard 12-well plate, or a standard 24-well plate, or a standard 96-well plate, or a standard 384-well plate, or a standard 1536-well plate, etc. Such plates are commercially available from various manufacturers, including but not limited to, Corning, Nunc, Fisher, BD Biosciences, etc. In several embodiments, the plates have well dimensions that are shown in Table 1.
[0000]
TABLE 1
Example Microplate Dimensions for Use with Capture Systems
Number
Plate
Plate
Well Diameter
of Wells
Length (mm)
Width (mm)
(mm, at top of well)
6
127.76
85.47
35.43
12
127.89
85.6
22.73
24
127.89
85.6
16.26
48
127.89
85.6
11.56
96
127.8
85.5
6.86
[0106] In several embodiments, a “carrier” or frame is used to facilitate the stable positioning of the second hollow body in a well of a microplate. In several embodiments, the frame has the same number of wells as the microplate, and functions to align a particular second hollow body with a corresponding well in the microplate. In several embodiments, the frame is removed after the lysis and transfer of the nucleic acid content of the vesicles to the microplate. In several embodiments, the microplate is treated so that is has immobilized oligo(dT) in each well of the microplate.
[0107] In some embodiments, tab 260 of second hollow body 2 extends over at least a portion of a neighboring well of a multi-well plate when second hollow body 2 interacts with a first well of the multi-well plate. In at least one embodiment, tab 260 is configured to allow half of the wells of a multi-well plate to be occupied at a time by second hollow bodies 2 without tabs 260 overlapping with one another. In some embodiments, second hollow body 2 has a protrusion 270 that interacts with a wall of a well of a multi-well plate and secures second hollow body 2 to a well of the multi-well plate. In several embodiments, tab 260 is dimensioned so that each well of a multi-well plate can be used to receive a sample.
[0108] In several embodiments, a method for isolating a biomarker comprises taking a fluid sample 3 from a patient, passing the fluid sample 3 through capture material 4 , removing non-vesicle material from capture material 4 , and lysing the vesicles in or on capture material 4 with a lysis buffer, thereby isolating a biomarker from the vesicles. In some embodiments, the biomarker is selected from the group consisting of RNA, DNA, protein, and carbohydrate. In several embodiments, the RNA is of a type selected from the group consisting of mRNA, miRNA, rRNA, tRNA, and vRNA.
[0109] In some embodiments, capture device 100 is placed within a centrifuge tube, and collar 105 holds capture device 100 in a fixed position relative to the centrifuge tube. Fluid sample 3 is loaded into capture device 100 before or after placing capture device 100 within the centrifuge tube. Capture device 100 is subjected to centrifugation. The centrifuge tube serves as a receiving vessel and receives fluid sample 3 after it has passed through capture device 100 . In some embodiments, low-speed centrifugation is used to drive fluid sample 3 through capture device 100 .
[0110] In several embodiments, each second hollow body is positioned in a well of a microplate (either with or without use of a carrier/frame) and the captured vesicles on the filter within the second hollow body are then lysed with a lysis buffer, thereby releasing RNA from the captured vesicles. The RNA is then transferred to the microplate (e.g., by centrifugation and/or vacuum pressure). Optionally, the wells of the microplate are treated with oligo(dT) that is immobilized in the well, such that the RNA will hybridize to the well of the microplate via the oligo(dT). In such embodiments, the RNA-oligo(dT) complex can be washed, with the RNA being retained within the well of the plate. Further detail regarding the composition of lysis buffers that may be used in several embodiments can be found in U.S. Pat. No. 8,101,344, which is incorporated in its entirety by reference herein. In several embodiments, cDNA is synthesized from the oligo(dT)-immobilized RNA. In some embodiments, the cDNA is then amplified using real time PCR with primers specifically designed for amplification of liver function or disease-associated markers. Primers that are used in such embodiments are shown in Table 2. Further details about the PCR reactions used in some embodiments are also found in U.S. Pat. No. 8,101,344, which is incorporated in its entirety by reference herein.
[0000]
TABLE 2
Primer Sequences for RT-PCR Amplification
SEQ ID
SEQ ID
Target
No.
FWD Sequence (5′-3′)
No.
REV Sequence (3′-5′)
β-
1
CCTGGCACCCAGCACAAT
2
GCCGATCCACACGGAGT
Actin
ACT
ALB
3
TGCAAGGCTGACGATAAGGA
4
GTAGGCTGAGATGCTTT
TAAATGTGA
HGF
5
TCCACGGAAGAGGAGATGAGA
6
TCATTAAAACCAGATCT
GATCCTTCA
VEGF
7
CGCAGCTACTGCCATCCAAT
8
TGGCTTGAAGATGTACT
CGATCTC
IL1B
9
GAAGATGGAAAAGCGATTT
10
GGGCATGTTTTCTGCTTG
GTCTT
AGA
IL2
11
GAACTAAAGGGATCTGAAA
12
TGTTGAGATGATGCTTT
CAACATTC
GACAAAA
IL4
13
CACAGGCACAAGCAGCTGAT
14
CCTTCACAGGACAGGAA
TTCAAG
IL6
15
TCATCACTGGTCTTTTGGAG
16
TCTGCACAGCTCTGGCT
TTTG
TGT
IL8
17
TGCTAAAGAACTTAGATGTC
18
TGGTCCACTCTCAATCA
AGTGCAT
CTCTCA
IL10
19
GCCATGAGTGAGTTTGACAT
20
GATTTTGGAGACCTCTA
CTTC
ATTTATGTCCTA
TNFSF2
21
CGAAGGCTCCAAAGAAGAC
22
CAGGGCAATGATCCCAA
AGT
AGT
TNFSF6
23
TGGCAGCATCTTCACTTCTA
24
GAAATGAGTCCCCAAAA
AATG
CATCTCT
DEFA3
25
CCAGGCTCAAGGAAAAACATG
26
CTGGTAGATGCAGGTTC
CATAGC
CD16
27
GTTTGGCAGTGTCAACCATCTC
28
AAAAGGAGTACCATCAC
CAAGCA
GMCSF
29
GGCCCCTTGACCATGATG
30
TCTGGGTTGCACAGGAA
GTTT
IFNG
31
GGAGACCATCAAGGAAGAC
32
GCTTTGCGTTGGACATT
ATGA
CAA
PRG2
33
ACTGCGTGGCCCTGTGTAC
34
CAGTAGGAACAGATGAA
AGGAAGTCTT
[0111] After the completion of the PCR reaction, the mRNA (as represented by the amount of PCR-amplified cDNA detected) for one or more markers is quantified. In certain embodiments, quantification is calculated by comparing the amount of mRNA encoding a liver marker to a reference value. In some embodiments the reference value will be the amount of mRNA found in healthy non-diseased patients. In other embodiments, the reference value is the expression level of a house-keeping gene. In certain such embodiments, beta-actin, or other appropriate housekeeping gene is used as the reference value. Numerous other house-keeping genes that are well known in the art may also be used as a reference value. In other embodiments, a house keeping gene is used as a correction factor, such that the ultimate comparison is the expression level of marker from a diseased patient as compared to the same marker from a non-diseased (control) sample. In several embodiments, the house keeping gene is a tissue specific gene or marker, such as those discussed above. In still other embodiments, the reference value is zero, such that the quantification of the markers is represented by an absolute number. In several embodiments a ratio comparing the expression of one or more markers from a diseased patient to one or more other markers from a non-diseased person is made.
[0112] In some embodiments, a kit is provided for extracting target components from fluid sample 3 . Kits often allow better management of quality control and better consistency in results. In some embodiments, a kit comprises a capture device 100 and additional items useful to carry out methods disclosed herein. In some embodiments, a kit comprises reagents selected from the group consisting of lysis buffers, chaotropic reagents, washing buffers, alcohol, detergent, or combinations thereof. In some embodiments, kit reagents are provided individually or in storage containers. In several embodiments, kit reagents are provided ready-to-use. In some embodiments, kit reagents are provided in the form of stock solutions that are diluted before use. In some embodiments, a kit comprises plastic parts that are useful to carry out methods herein disclosed. In some embodiments, a kit comprises plastic parts selected from the group consisting of racks, centrifuge tubes, vacuum manifolds, and multi-well plates. Instructions for use are also provided, in several embodiments.
[0113] In several embodiments, the analyses described herein are applicable to human patients, while in some embodiments, the methods are applicable to animals (e.g., veterinary diagnoses).
Rejection Therapies
[0114] When the methods disclosed herein are employed, in several embodiments, they enable a medical professional to make a more patient-specific and diagnosis and symptom-tailored treatment plan, if needed. For example, in several embodiments wherein liver rejection is detected, various rejection therapies can be investigated and/or implemented. For example, if early stage chronic rejection is detected by way of increased or decreased expression of rejection-associated markers, a retransplant can be considered. Acute rejection may be treated with mmunosuppressive therapy (e.g., corticosteroids, calcineurin inhibitors, anti-proliferative agents, mTOR inhibitors, ciclosporin, tacrolimus, azathioprine, mycophenolic acid, sirolimus, everolimus, and combinations thereof can be administered. In several embodiments, antibody-based treatments can be employed to supplement (or replace) immunosuppressive therapy. Antibody drugs may include, monoclonal anti-IL-2Rα receptor antibodies, basiliximab, daclizumab, anti-thymocyte globulin (ATG), anti-lymphocyte globulin (ALG), monoclonal anti-CD20 antibodies, rituximab. In severe cases, blood transfusion may be given to those subjects who are refractory to immunosuppressive or antibody therapies. Also, in several embodiments, bone marrow transplant may be employed, for example, replacement of the transplant recipient's immune system with the donor's, thereby allowing the recipient to accept the liver without rejection. The systems, methods, and devices disclosed herein facilitate the diagnosis and treatment of such clinical situations.
[0115] In some instances, diagnosis of a patient or subject is based on the result of RNA markers identified from vesicle-associated RNA collection. In some instances, the RNA markers detected indicate that a patient is in an early phase, acute phase, or sustained phase of liver rejection or liver infection. Based on the phase of rejection, a medical professional or other individual may administer an appropriate treatment. In some instances when the patient or subject is determined to be in an early phase of rejection, the therapy administered is antibiotic therapy.
[0116] In some embodiments, a medical professional may be in need of genetic testing in order to diagnose, monitor and/or treat a patient. Thus, in several embodiments, a medical professional may order a test and use the results in making a diagnosis or treatment plan for a patient. For example, in some embodiments a medical professional may collect a sample from a patient or have the patient otherwise provide a sample for testing. The medical professional may then send the sample to a laboratory or other third party capable of processing and testing the sample. Alternatively, the medical professional may perform processing and testing of the sample himself/herself (e.g., in house). Testing may provide quantitative and/or qualitative information about the sample, including data related to the presence of disease or liver rejection. Once this information is collected, in some embodiments the information may be compared to control information (e.g., to a baseline or normal population) to determine whether the test results demonstrate a difference between the patient's sample and the control. After the information is compared and analyzed, it is returned to the medical professional for additional analysis. Based on the results of the tests and the medical professional's analysis, the medical professional may decide how to treat or diagnose the patient.
EXAMPLES
Example 1
Assessment of Post-Transplant Liver Condition
[0117] As discussed above, transplanted organs are subject to numerous potential clinical problems, including but not limited to rejection, infection, relapse of original disease, drug toxicity, etc. Early diagnosis and differential diagnosis are important for the timing of treatment as well as the choice of appropriate drugs and/or drug combinations. Clinical symptoms are often non-specific in nature and do not allow of accurate diagnosis. Biopsy provides a definite diagnosis, but is invasive and generally cannot be routinely performed. The present example demonstrates how the methods disclosed here allow for improved assessment of liver condition post-transplant.
Methods
[0118] In some cases, after a liver transplant, bile is collected for several days (or up to a few weeks) after surgery. In most cases drained bile is considered a medical waste, however the methods disclosed herein advantageously employ this “waste” as a source of information related to the status of a subject's liver.
[0119] Six recipients of liver transplantation were studied. Bile was collected from an external drainage tube after liver transplantation. Daily, approximately 5 mL bile was collected in a sterile tube and stored at −80° C. The characteristics of the subjects are summarized in Table 3.
[0000]
TABLE 3
Liver Transplant Recipient Characteristics
#
Disease
Age
Gender
Blood type
Donor
Biliary reconstruction procedure
360
Biliary atresia
10
F
A?A
Live
choledochojejunostomy
361
Primary biliary cirrhosis
48
F
AB? A
Live
choledochocholedochostomy
362
Hepatitis C, liver cirrhosis,
50
M
B?A
Live
choledochocholedochostomy
hapatocellular caricinoma
363
Biliary atresia
0
F
O?O
Live
choledochojejunostomy
364
Biliary atresia
0
M
AB?A
Live
choledochojejunostomy
365
Fluminant hepatitis
19
F
A?A
Brain death
choledochocholedochostomy
[0120] Bile (1.5 mL) was mixed with 4 mL 5× PBS to equalize pH and salt concentrations (though in some embodiments, no equalization is required), and mixed vigorously to homogenize mucous materials. The diluted bile solution was applied to an exosome collection device (discussed in detail above) and centrifuged for 5 min at 2000×G at 4° C. Briefly, the dilute bile solution was added to the inlet of a first hollow body that was coupled to a second hollow body that contained an exosome capture membrane. That assembly (first and second hollow bodies) was placed in a centrifuge tube and centrifuged to cause the dilute bile solution to pass through the exosome capture membrane within the second hollow body. The exosome-depleted bile was collected in the bottom of the centrifuge tube, and later discarded (though in some embodiments, the bile could be reloaded back into the first hollow body and passed through the exosome filter one or more additional times, in order to capture additional exosomes). The second hollow body was de-coupled from the first hollow body and placed in a multiwell frame (e.g., a 96-well frame) (see, e.g., FIG. 1 ).
[0121] 100 μL of lysis buffer was added to each capture membrane and incubated at 37° C. for 10 minutes to release mRNA from exosomes captured on the membrane. The 96-well frame was then placed onto oligo(dT)-immobilized plate ( FIG. 1 ), and centrifuged for 5 min at 2000×G at 4° C., thereby transferring the mRNA liberated from the exosomes to the corresponding well of the 96-well plate. The resultant mRNA-containing oligo(dT)-immobilized plate was stored at 4° C. overnight to allow hybridization between poly(A) + tail of mRNA and the immobilized oligo(dT) in each well of the plate. Subsequently, the plate was washed with wash buffer several times to remove non-mRNA materials, and cDNA was synthesized on the plate by adding dNTP and reverse transcriptase. The cDNA was used then used for real time PCR to evaluate gene expression of markers associated with liver function. Primer sequences are shown in Table 2 above.
Results
[0122] Among 6 patients, a single patient developed acute rejection as shown in FIG. 7 . FIG. 7 depicts the body temperature, serum levels of total bilirubin and alanine aminotransferase (ALT), each of which were elevated around 1 week after surgery. The rejection was confirmed by the pathological analysis of biopsy specimens (see FIG. 8 ) that were scored on the Banff classification rejection activity index (RAI) at 6-8, indicating a moderate to severe rejection. FIG. 8A shows lymphocyte, eosinophils, and neutrophil infiltration to portal area and associated endothelitis. FIG. 8B shows lymphocyte infiltration to bile ducts. After steroid pulse therapy, the physiological parameters were controlled and the subject was discharged on post-operative day 92 (see FIG. 7 ).
[0123] Using the methods for capture and analysis of exosomal mRNA disclosed herein, bile samples from each of the subjects were assessed. As shown in FIG. 9A , the control housekeeping gene (β-actin, ACTB) was detected in bile samples from all patients, thus confirming that bile contained exosomes, and mRNA was preserved in exosomes, despite the harsh condition in bile. ACTB expression levels were not correlated with the development of rejection. Similarly, as shown in FIG. 9E , liver-specific albumin (ALB) mRNA was also detected in the bile exosome. This data confirms that the bile samples contained liver-derived exosomes. However, ALB expression did not correlate to the presence or absence of acute rejection.
[0124] In contrast to ACTB and ALB, various chemokine mRNAs were increased at the time of rejection (see FIG. 9B for IL1B, FIG. 9J for IL6, and FIG. 9N for IL8), whereas these mRNAs were undetected in the other patients that did not have acute rejection. Interestingly, the levels of IL8 were very prominent, and higher than ACTB. These data suggest that IL8 may be useful as an early marker of rejection. The induction of IL2 mRNA ( FIG. 9F ) indicated that immune cascades were activated in the rejected liver. The detection of tumor necrosis factor superfamily (TNFSF) mRNAs (TNFSF2=TNFα, FIG. 9C and TNFRSF6=FasL, FIG. 9G ) suggested that cytotoxic T-cell activity was involved in the acute rejection. The detection of hepatic growth factor (HGF, FIG. 9I ) and vascular epidermal growth factor (VEGF, FIG. 9M ) mRNAs, relate to regrowth of liver tissue and associated vasculature and thus indicate that the recovery process was started in the rejected liver. Since IL4 mRNA was not induced ( FIG. 9P ), this acute rejection episode was not strong enough to induce immunoglobulin synthesis, which further suggested that the rejection would be controlled by immunosuppressant therapy (see FIG. 7 , mycophenolate mofetil administration). Expression levels of the anti-inflammatory cytokine, IL10, were not induced ( FIG. 9D ). This suggests that the inhibition cascades of immune activation were relatively weak in this patient having acute rejection. Interestingly, neutrophil marker DEFA3 (defensin α3, FIG. 9O ) was present in the first 1 week after transplantation in 3 cases, which suggests that there is some degree of neutrophil infiltration after transplantation, even if rejection does not develop. DEFA3 and the eosinophil marker PRG2 (Proteoglycan 2, a natural killer cell activator, eosinophil granule major basic protein, FIG. 9Q ) were both induced in the subject having acute rejection. These data correspond to the neutrophil and eosinophil infiltration identified in the biopsy findings ( FIG. 8A / 8 B). CD16 is the marker of NK cells, and the induction of this gene ( FIG. 9K ) also indicated the contribution of NK cells at the time of rejection. Together, these data indicate that the methods disclosed herein and employed in the present example allow for the capture of exosomes from bile samples, and subsequent isolation and detection of mRNA from the exosomes. Moreover, detection of various immune markers is possible, and are indicative of various aspects of immune activity (or lack thereof) in transplanted livers. As such, the methods disclosed herein allow the assessment of the clinical status of a subject's liver, and in some embodiments, early detection of rejection and/or other disease (e.g., prior to manifestation of clinical symptoms). These methods therefore enable earlier diagnosis of liver maladies and treatment (or prevention) regimes to be implemented in a fashion that results in better clinical outcomes and improved patient care.
[0125] It is contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments disclosed above may be made and still fall within one or more of the inventions. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with an embodiment can be used in all other embodiments set forth herein. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above. Moreover, while the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the various embodiments described and the appended claims. Any methods disclosed herein need not be performed in the order recited. The methods disclosed herein include certain actions taken by a practitioner; however, they can also include any third-party instruction of those actions, either expressly or by implication. For example, actions such as “administering a treatment to a subject after determining the subject is suffering from liver transplant rejection” include “instructing the administration of a treatment to a subject after determining the subject is suffering from liver transplant rejection.”
[0126] The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers preceded by a term such as “about” or “approximately” include the recited numbers. For example, “about 10 nanometers” includes “10 nanometers.”
|
Methods and devices allow assessment of the status of a transplanted liver during the post-transplant period. The methods are particularly beneficial for identifying if a transplanted liver is subject to rejection, by what mechanisms, and thereby developing and implementing a specific treatment regime to reduce the rejection of the transplanted liver.
| 1
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The U.S. Government has certain rights in this invention pursuant to Contract No. W-31-109-Eng-38 of the Department of Energy.
The present invention is concerned generally with a method of manufacture and a product ceramic superconductor. More particularly, the invention is concerned with a method of controlling oxygen gas pressure and temperature in a treatment protocol to control the microstructural makeup of ceramic superconductors, such as YBa 2 Cu 3 O x to obtain single phase materials with good mechanical properties as well as a high critical current capacity.
Ceramic superconductors constitute an important group of materials having substantial potential applications arising from their very high superconducting critical temperature. YBa 2 Cu 3 O x (YBCO) is one of the most widely studied and potentially useful high-temperature superconductors. For these ceramic materials to be useful in commercial applications, they must however possess good superconducting and mechanical properties. However, the mechanical strength of such ceramics as YBCO processed by conventional methods is generally unacceptably low. The low strength values have been attributed to the fact that the density of bulk YBCO specimens sintered in a 100% oxygen atmosphere is generally low (80-90% theoretical). Sintering at temperatures above about 950° C. results in higher densities, but gives rise to degradation in critical current density (J c ), partly due to the presence of second phases. Furthermore, sintering at higher temperatures also results in grain growth and accompanying microcracking. Such microcracking results in reduced strength and will also act as weak links and substantially degrade the J c .
Improvement in density, as well as mechanical and superconducting properties, has been achieved recently but only by making composites of YBCO with silver additions. Another approach to improving density and mechanical properties has been the fabrication of monolithic YBCO through the control of processing parameters, such as powder particle size and heat treatment. Sintering at lower p(O 2 ) has the potential for producing specimens with relatively small grains. However, it has been observed that YBCO becomes unstable at very low pO 2 and may precipitate undesirable phases, with a consequent degradation in J c .
It is therefore one object of the invention to provide an improved method of manufacturing high temperature ceramic superconductors.
It is another object of the invention to provide a novel method of making high temperature ceramic superconductors using well controlled sintering techniques.
It is still another object of the invention to provide an improved method of manufacture and ceramic superconductor substantially free of impurity and second phases of the YBa 2 Cu 3 O x system.
It is yet another object of the invention to provide a novel method of manufacture and ceramic superconductor product prepared by solid phase formation and dissolution as needed to control grain growth, density and J c capacity.
It is a further object of the invention to provide an improved method of manufacture and product ceramic superconductor having high density, high strength and high J c capacity.
It is an additional object of the invention to provide a novel method of manufacture of superconducting ceramics by use of variable oxygen partial pressure during sintering of the superconductor.
It is yet another object of the invention to provide an improved method of manufacture and product ceramic superconductor having a balance of good mechanical strength with small grain size, high density and high J c capacity.
It is still another object of the invention to provide a novel ceramic superconductor and method of manufacture to produce a substantially single phase ceramic superconductor sintered to high density while sustaining high J c capacity.
Other objects and advantages of the invention will become apparent from the Detailed Description and the drawings described hereinbelow and also from a copending application of the assignee of this application filed on the same day and incorporated by reference herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates an optical micrograph of YBa 2 Cu 3 O x specimens prepared by sintering in flowing oxygen at 910° C. for 10h; FIG. 1B shows an optical micrograph of YBa 2 Cu 3 O x sintered at 925° C. for 10h; FIG. 1C likewise shows YBa 2 Cu 3 O x sintered at 935° C. for 12h and FIG. 1D shows YBa 2 Cu 3 O x sintered at 950° C. for 20h;
FIG. 2 shows grain length distributions in YBa 2 Cu 3 O x wires sintered in flowing oxygen at 925° for 10h (FIG. 2A); 935° C. for 12h (FIG. 2B); 935° C. for 20h (FIG. 2C) and 950° C. for 20h (FIG. 2D);
FIG. 3 illustrates grain width distribution in YBa 2 Cu 3 O x wires sintered in flowing oxygen at 925° C. for 10h (FIG. 3A); 935° C. for 12h (FIG. 3B), 935° C. for 20h (FIG. 3C) and 950° C. for 20h (FIG. 3D);
FIG. 4 shows optical micrographs of a YBa 2 Cu 3 O x sintered at 910° C. for 10h at p (O 2 ) of 0.05 MPa (FIG. 4A); 0.001 MPa (FIG. 4B); 0.0001 MPa (FIG. 4C) and 42 pa (FIG. 4D);
FIG. 5 illustrates X-ray diffraction peaks for YBa 2 Cu 3 O x specimens sintered at about 910° C. at p(O 2 )=42 Pa;
FIG. 6 shows the dependence of strength on grain size wherein rectangles represent specimens with over 90% density sintered at p(O 2 ) greater than or equal to 0,001 MPa; triangles represent specimens with density over 90% interest at p(O 2 ) equal to 0.0001 MPa;
FIG. 7 is an optical micrograph of a YBa 2 Cu 3 O x specimen showing intergranular propagation of an indentation crack. The specimen was sintered at 950° C. for 10h in flowing oxygen;
FIG. 8 shows the dependence of electrical resistivity on temperature for typical YBa 2 Cu 3 O x produced by the method of the invention;
FIG. 9 illustrates representative microstructures of YBa 2 Cu 3 O x with FIG. 9A showing impurity phases sintered at 990° C. in O 2 ; FIG. 9B showing phase pure YBa 2 Cu 3 O x sintered at 990° in O 2; and FIG. 9C showing phase pure YBa 2 Cu 3 O x sintered at 910° C. in 1% O 2 ;
FIG. 10 illustrates differential thermal analysis plots of phase pure YBa 2 Cu 3 O x (top curve) and YBa 2 Cu 3 O x containing additional phases (bottom curve), both being heated in O 2 at 5° C./m; and
FIG. 11 shows the p(O 2 ) stability line for YBa 2 Cu 3 O x .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
It is well understood and accepted that ceramic superconductors behave in substantially the same predictable manner as any multielement containing ceramic insofar as methods of formation of the ceramic compound, kinetics of diffusion in the ceramic, and phase formation and phase conversion pursuant to acceptable phase diagrams. Mindful of the applicability of these basic concepts to all ceramic superconductors, the invention will be described for the preferred system of YBa 2 Cu 3 O x prepared in a form having high critical current capacity as well as good mechanical properties.
YBa 2 Cu 3 O x powder can be synthesized, for example, by solid-state reaction of the constituent oxides Y 2 O 3 , CuO, and BaO. Powders of Y 2 O 3 , and BaCO 3 were mixed in appropriate proportions and were wet-ball-milled for approximately 12h. The resulting slurry was dried in air and then vacuum-calcined in flowing oxygen at a reduced total pressure of ≃0,003 MPa. The heating schedule included slowly heating in flowing oxygen at a reduced total pressure of ≃0.0003 MPa to 810° C. for 20h and holding at this temperature for 8h. Subsequently, the powder was cooled at 450° C. in a 100% flowing oxygen atmosphere in 10h. The powder was held at 450° C. for 3h and then slowly cooled to room temperature. This method results in the decomposition of BaCO 3 at lower temperatures (starting at 650° C and completed at 800° C.) and eliminates formation of undesired impurity phases as indicated by conventional differential thermal analysis (DTA). No melting events associated with impurity phases were observed. The calcined powder was ground in a tungsten carbide rotary mill. The milled powder had an average particle size of ≃3 μm. Phase composition was confirmed as the expected phase pure form of YBa 2 Cu 3 O x by X-ray diffraction analysis.
The YBa 2 Cu 3 O x powder was mixed with appropriate solvent, dispersant, binder, and plasticizer to form a slip mixture for extrusion. The slip mixture was milled for ≃16h in a plastic bottle containing ZrO 2 balls. Subsequently, the solvent in the slip was partially evaporated to obtain a plastic mass. The plastic mass was then forced through a die at high pressures to produce flexible wires of YBa 2 Cu 3 O x . The wire was extruded in a continuous mode from which approximately 30 cm long pieces were cut and dried in air to achieve rigidity. These dried wires had a typical density of approximately 52% theoretical.
The extruded wires (after drying) were cut into approximately 3 cm long pieces and were sintered in a tube furnace at different temperatures (910°-950° C.) and various p(O 2 ) levels (42 Pa-0.1 MPa). The wires were placed on a flat alumina tray which was subsequently introduced in the hot zone of the furnace. The p(O 2 ) was controlled by using a mixture of oxygen and argon gases as the sintering environment in which the ratio of oxygen and argon was appropriately varied. Sintering was done in three stages: binder burnout, densification, and oxygen anneal. The initial binder burnout involved heating the specimens slowly to 240° C. and holding for 15h to completely remove the organics, after which the temperature was raised to 910°-950° C. at a rate of 1°C./min. In the densification step, specimens were sintered at various temperatures for various lengths of time (10-20h) and subsequently cooled to 450°C. at ≃1°C./min. Finally, the wires were annealed at 450° C. for 12h in flowing oxygen at 0.1 MPa. The wires were then allowed to cool slowly in the furnace to room temperature, at which time the oxygen was turned off and the specimens removed. The sintered wires were reasonably straight, and the phase purity of the sintered wires was confirmed by X-ray diffraction analysis to be YBa 2 Cu 3 O x .
Bulk density of the relatively dense (≧90% theoretical) sintered wires was measured by the Archimedes method while the apparent density of relatively porous (≦85% theoretical) specimens was measured by the geometrical method. Typically, four to six specimens were used for each set of preparation conditions. The microstructure was evaluated by both optical and electron microscopy. Grain microstructures were evaluated in polished longitudinal sections by polarized light in order to reveal grain sizes. The fracture surface of specimens was characterized by scanning electron microscopy. The specimens were composed of ≃3 cm long (≃1.14 mm or 45mil diameter) wires, and the strength was measured in an Instron mechanical testing machine in a three-point bending mode with a loading span of 1.825 cm and a crosshead speed of 0.127 cm/min. At least six specimens were tested for each set of conditions. The resistivity was measured by a conventional four-probe technique. Critical current density values were determined with a criterion of 1.0 μmV/cm at 77K and zero applied magnetic field. Typically four specimens were again tested for each condition. These results will be described hereinafter and presented in tabular form.
1. YBa 2 Cu 3 O x sintered at p(O 2 )=0.1 MPa.
The YBa 2 Cu 3 O x wires were sintered in flowing oxygen at a p(O 2 ) of 0.1 MPa, and the wires had a range in density from ≃79 to 98% theoretical, as shown in Table I. The specimens (with density ≧90%) had primarily closed porosity, as indicated by the microstructure. These wires consisted of substantially pure YBa 2 Cu 3 O x phase, as indicated by X-ray diffraction. As expected, the density increased with increasing sintering temperature. Typical micrographs of the polished sections of specimens sintered in the temperature range of 910°-950° C. are shown in FIG. 1. The grains are clearly twinned as a result of internal strains from tetragonal-to-orthorhombic transformations.
The grains in FIG. 1 are generally elongated and have varying aspect ratios. Measured distributions of grain length and width are shown in FIGS. 2 and 3. Based on the grain-length distribution shown in FIG. 2, average grain length also increased with increasing sintering time and temperature. It can be seen in Table I that the largest grain length increases from 5μm for specimens sintered at 910° C. for 10h to 182 μm for specimens sintered at 935° C. for 20h. A slight decrease in the largest grain size for the specimens sintered at 950° C. for 20h is probably due to sample variations as well the difficulty in locating the absolutely largest grain size in a sample. Although grain length increased with increasing sintering temperature, the increase in grain length was minimal for specimens sintered at temperature above 935° C., due probably to large grains impinging on one another. On the other hand, grain width increased monotonically in the transverse direction. As indicated in Table I, grain width increased from 5 μ m for specimens sintered at 910° C. for 10h to 68 μm for specimens sintered at 950° C. for 20h. The specimens sintered at 910° C. had a very low density of 79% theoretical, and this resulted in reduced strength and J c .
TABLE I______________________________________ Maxi- Maxi-Sintering Average Average mum mumtemperature Density grain grain grain grainand time (% theo- length width length width(°C.)/(h) retical) (μm) (μm) (μm) (μm)______________________________________910/10 79 ± 2.0 ≅4.0 ≅4.0 5 5925/10 90 ± 2.5 6.0 2.0 20 6935/12 96 ± 0.6 16.0 4.5 171 18935/20 96 ± 1.7 16.5 4.5 182 26950/20 98 ± 1.3 23.0 7.0 150 68______________________________________
2. YBa 2 Cu 3 O x specimens sintered at p(O 2 ) ≦0.1 MPa.
To obtain small grain microstructures, the specimens were sintered at relatively low temperatures. However, as discussed above, it was observed that sintering at lower temperatures (approximately 910° C.) and a p(O 2 ) of 0.1 MPa resulted in the relatively low density of ≃79% theoretical. Such a low density is undesirable for both superconductivity by causing low Jc and inadequate mechanical properties. Therefore, experiments were conducted to evaluate the effects of p(O 2 ) on the sintering behavior of YBa 2 Cu 3 O x in order to establish a high density while maintaining a small-grain microstructure. The YBa 2 Cu 3 O x wire specimens were sintered at 910° C. for 10h at different p(O 2 ). The p(O 2 ) was varied between about 0.1-0.000042 MPa. Table II shows the variation of measured density as a function of p(O 2 ) for the specimens sintered at 910° C. for 10h. Generally, density increased with decreasing p(O 2 ). It is believed that the increase in density with decrease in p(O 2 ) is likely the result of enhanced sintering kinetics, due to increase in defect concentration and decrease in activation energy of the rate controlling species undergoing diffusion.
TABLE II______________________________________Dependence of density on p(O.sub.2) for YBa.sub.2 Cu.sub.3 O.sub.xspecimens sintered at 910° C. for 10 hp(O.sub.2) (MPa) Density (% theoretical)______________________________________0.100000 79 ± 2.00.050000 85 ± 2.00.001000 91 ± 0.70.000100 94 ± 0.80.000042 83 ± 0.4______________________________________
The microstructures for the specimens sintered at various p(O 2 ) values are shown in FIG. 4. These specimens have small grain microstructures, with the largest grains being ≃5 μm, which is equal to the particle size in the original powder. Although grain microstructures are similar for the specimens sintered at various p(O 2 ), the specimens sintered at a very low p(O 2 ) such as (42×10 -6 MPa) had a relatively low density (83%) and show the presence of second-phase impurities (see FIG. 4). These phases are primarily Y 2 BaCuO 5 , Cu 2 , BaCuO 2 and BaCO 3 , as detected by X-ray analysis (see FIG. 5). The low density and the presence of these second phases is the result of decomposition of YBa 2 Cu 3 O x at a low p(O 2 ). At a given temperature, YBa 2 Cu 3 O x becomes thermodynamically unstable below a critical p(O 2 ). The instant data indicate the critical value of p(O 2 ) is ≃10 -4 to 10 3 MPa at 910° C. The data of Table II thus shows that in range of 10 -4 to 10 -3 MPa, the desired density of at least 90% is achieved.
It is this decomposition to second phases in the solid state that can (if properly utilized) give rise to important advantages, such as stabilizing grain size during the various thermal treatments of the YBa 2 Cu 3 O x . Furthermore, once the densification has been accomplished, these second phases can then be subsequently thermally treated to obtain a substantially pure YBa 2 Cu 3 O x material having the desired superconductor phase with good J c . If properly executed, this methodology will thus allow solving the long standing problem of obtaining a ceramic superconductor having excellent mechanical properties without sacrificing the high J c capacity needed for commercially useful ceramic superconductors.
Phase purity of these YBa 2 Cu 3 O x specimens was verified by X-ray diffraction analysis made over the same angular range shown in FIG. 5 (illustrating the YBa 2 Cu 3 O x specimens sintered at 910° C. at p(O 2 ) of 42 Pa showing the presence of second phases). The resulting X-ray diffraction pattern therefore showed only the expected diffraction peaks for phase pure YBa 2 Cu 3 O x . This pattern thus appeared the same as FIG. 5 except the second phase peaks were all removed.
Post sintering appeals are then performed at various intermediate temperatures of about 800°-875° C. for 12-24 hours in an oxygen containing atmosphere. The phase pure YBa 2 Cu 3 O x was formed and no grain growth occurred. The resulting material exhibited a density of at least about 91% and a critical current density capacity of more than about 300A/cm 2 .
The microstructural appearances of a phase pure specimen of YBa 2 Cu 3 O x and a muiltiphase specimen are shown in FIG. 9. FIG. 9A illustrates a large grained YBa 2 Cu 3 O x , including second phases wherein substantial, unwanted grain growth has occurred. As can be noted in FIG. 10 some liquid second phase has likely formed and can enhance grain growth. The effects of changing the p(O 2 ) are shown in FIGS. 9B and C. In FIG. 9B is shown a phase pure YBa 2 Cu 3 O x annealed at 990° C. in O 2 wherein some grain growth has occurred but not nearly as much as in FIG. 9A. In FIG. 9C a substantially uniform, fine grained microstructure is shown after phase pure YBa 2 Cu 3 O x was sintered at 910° C. in a 1% O 2 atmosphere. No liquid second phase was formed during this sintering procedure. Sintering kinetics thus increase as p(O 2 ) decreases, even if no liquid phase is present. If p(O 2 ) is lowered sufficiently, the YBa 2 Cu 3 O x decomposes to produce solid state second phases. As shown in FIG. 11 for the YBa 2 Cu 3 O x the p(O 2 ) level can be used to selectively create or transform second phases as needed in the processing and manufacture of ceramic superconductors. The solid second phases are primarily Cu 2 O and Y 2 BaCuO 5 which are finely dispersed phases and can act to pin grain growth during the preferred manufacturing process. Therefore, the YBa 2 Cu 3 O x can be sintered to very high density (90-100%) without causing appreciable grain growth. Fine grained product can be produced with good strength (about 200-230 MPa fracture strength) with at least 90% of theoretical density. By performing post sintering anneals described hereinbefore, the solid second phases can be converted to YBa 2 Cu 3 O x (superconducting phase) without appreciable grain growth (the grain size in FIG. 9C is substantially unchanged after undergoing a post sintering anneal to remove second phases).
It is therefore important firstly to avoid heating at temperatures which can cause excessive grain growth. Further, the presence of the second phases can lead to forming liquid second phases at lower temperatures than the melting point of the YBa 2 Cu 3 O x phase (see FIG. 10). Such melting of second phases can result in excessive grain growth (see FIG. 9A). Consequently, in order to achieve a good balance of fine grain size and acceptable density (good mechanical properties) without detrimental effect on critical current density capacity, it is important to dictate in the manufacturing process the presence (or absence) of second phases in the method of the invention, as well as the thermal treatments and P(O 2 )
The flexural strengths of specimens sintered at different temperatures and p(O 2 ) are shown in Table III. A dependence of strength on grain size is plotted in FIG. 6. For the purpose of illustrating the effects of grain size, strength data for only the specimens with density ≧90% have been considered in FIG. 6. Specimens with low density ≅85% have open porosity, and the large effect of open porosity on strength degradation can mask the effect of grain size. For the specimens with density over 90% sintered at p(O 2 ) ≧0.001 MPa (shown by rectangles), the strength increases with decreasing grain size and reaches a maximum value of 191 MPa at an average grain size of ≃4 μm. As indicated by X-ray diffraction patterns, these specimens were phase-pure and did not show any noticeable impurity or second phases. On the other hand, specimens sintered at 910° C./10h and p(O 2 )=0.0001 MPa (shown by a triangle) had a relatively low strength in spite of having small grain size. As discussed in the previous section, at lower p(O 2 ), YBa 2 Cu 3 O x becomes unstable and second phases begin to appear, as shown in FIGS. 4 and 5. We believe that p(O 2 )=0.0001 MPa represents, a region in which thermodynamic instability begins. Although at p(O 2 )=0.0001 MPa the specimens do not show signs of bulk decomposition, local decomposition could occur. The local decomposition could have resulted in large critical flaws and observed low strength, in spite of small grain size.
TABLE III__________________________________________________________________________Dependence of density, grain size,and strength on heat treatment.Sintering temperature and time (°C.)/(h) p(O.sub.2) (MPa) Density (% theoretical) Average grain length Strength__________________________________________________________________________ (MPa)910/10 0.100000 79 ± 2.0 ≅4.0 120 ± 10925/10 0.100000 90 ± 2.5 6.0 141 ± 09935/12 0.100000 96 ± 0.6 16.0 91 ± 07935/20 0.100000 96 ± 1.7 16.5 95 ± 06950/20 0.100000 98 ± 1.3 23.0 83 ± 05910/10 0.050000 85 ± 2.0 3-5 N A910/10 0.001000 91 ± 0.7 3-5 191 ± 07910/10 0.0001000 94 ± 0.8 3-5 72 ± 19910/10 0.000042 83 ± 0.4 3-5 73__________________________________________________________________________ ± 38
The increase in strength with decrease in grain size (FIG. 6) is associated with a decrease in microcracking with decrease in grain size. Due to the grain anisotropy in YBa 2 Cu 3 O x , large internal residual stresses (σ i ) are developed. FIG. 7 shows a micrograph of YBa 2 Cu 3 O x illustrating the propagation of an indentation crack. The crack propagates primarily along the grain boundaries, probably due to the presence of intergranular stresses due to grain anisotropy. It has been observed that these stresses can be partially or fully relieved by forming microcracks. The crack size (c) will be proportional to grain size, and it can be shown that microcracks will form if the grain sizes are larger than a critical value. Failure will initiate when the applied stress, σ a , becomes equal to or greater than the strength, σ f , of the material given by Griffith relation σ f =(2γE/πc) 1/2 (where γis the fracture surface energy and E is the elastic modulus). Therefore, in the presence of an internal stress, σ i ,
σ.sub.a +σ.sub.i =σ.sub.f =(2γE/πc).sup.1/2
Because crack size, c, is proportional to grain size, d,
σ a +σ i =σ f =(2γE/πc) 1/2 which is proportional to (2γE/πc) 1/2 or
σ a is proportional to (1/√d) -σ i
It is to be noted that although failure is generally expected to be controlled by the largest grain size, the proportionality of critical flaw size with average grain size is a reasonable assumption.
The above equation concludes that applied failure stress is inversely proportional to the grain size, in accordance with the observed data shown in FIG. 6.
The electrical properties, specifically J c and critical temperature (T c ), of the sintered wires were examined to determine the effects of heat treatments and grain size on J c and T c . The onset of critical temperature was ≃91K. A typical resistivity plot showing resistivity as a function of temperature is shown in FIG. 8; the transition is sharp, with a typical width of ˜3K.
Table IV shows J c variation as a function of grain size. The J c data for specimens sintered at 925°-950° C. represent an average for four specimens in each case. The specimens sintered at 910° C. had a low density and only two specimens were evaluated for J c . The standard deviation was generally less than 15%. It was noted that for dense specimens (density ≧90% theoretical) sintered at a p(O 2 ) of 0.1 MPa, the J c changed from 155 A/cm 2 for specimens with average grain size of 23 μm to 359 A/cm 2 for specimens with average grain size of 6 μm Although the absolute magnitude of J c may not have much significance, the result indicates a substantial relative decrease occurs in J c at large grain size. This observation has an important implication for microstructural development of good quality superconductor material.
While not limiting the scope of claim coverage, the reduced J c at large grain size can derive from the presence of microcracking. Due to grain anisotropy, internal stresses are developed which may result in microcracking in YBa 2 Cu 3 O x if the grains are not properly aligned. The reduced grain size decreases the occurrence of microcracking, while the increase in grain size results in increased microcracking and hence increased number of weak links. This will tend to decrease J c at increased grain sizes. On the other hand, increase in grain size decreases the number of grain boundaries which will tend to increase J c . In the present study, the observed decrease in J c at large grain size is believed to be due to the predominant effect of increased weak links arising from increased microcracking.
High density (≧90% theoretical) YBa 2 Cu 3 O x specimens can be fabricated by sintering at relatively low temperature (˜910° C.) in a low p(O 2 ) (0.001 MPa). These specimens have small-grain microstructures, with an average grain size of 4 μm. The small-grain microstructure results in reduced microcracking, and hence strength as high as 191 MPa is achieved. Reduced microcracking can have important implications for developing microstructures with improved J c .
TABLE IV__________________________________________________________________________Variation of Jc with grain size for specimen sintered at 0.1 MPaSintering temperature and time (°C.)/(h) p(O.sub.2) (MPa) Density (% theoretical) Average grain length Strength__________________________________________________________________________ (MPa)910/10 0.1 79 ± 2.0 4.0 28925/10 0.1 90 ± 2.5 6.0 359935/20 0.1 96 ± 1.7 16.5 351950/20 0.1 98 ± 1.3 23.0 155__________________________________________________________________________
The instant invention is concerned with a method of manufacture and product ceramic superconductor. The method of manufacture utilizes second phases of a base superconductor to control grain growth during sintering process to obtain a desired fine grained microstructure which does not diminish the critical current density capacity. The second phases can selectively be removed after controlled sintering to provide the desired density and mechanical properties. By controlled removal of the second phases to form only the ceramic superconductor of highest J c , the high J c can also be achieved without sacrificing mechanical properties. Such a process results in a combination of properties for high temperature superconductors, such as YBa 2 Cu 3 O x , heretofore unachievable although many attempts have been made to obtain such a result.
Other advantages and features of the invention will become apparent from the claims set forth hereinafter with the scope of the claims determined by the embodiments described herein and by those reasonable equivalents as understood by those of ordinary skill in the art.
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A ceramic superconductor is produced by close control of oxygen partial pressure during sintering of the material. The resulting microstructure of YBa 2 Cu 3 O x indicates that sintering kinetics are enhanced at reduced p(O 2 ) and that because of second phase precipitates, grain growth is prevented. The density of specimens sintered at 910° C. increased from 79 to 94% theoretical when p(O 2 ) was decreased from 0.1 to 0.0001 MPa. The increase in density with decrease in p(O 2 ) derives from enhanced sintering kinetics, due to increased defect concentration and decreased activation energy of the rate-controlling species undergoing diffusion. Sintering at 910° C resulted in a fine-grain microstructure, with an average grain size of about 4 μm. Post sintering annealing in a region of stability for the desired phase converts the second phases and limits grain growth. The method of pinning grain boundaries by small scale decompositive products and then annealing to convert its product to the desired phase can be used for other complex asides. Such a microstructure results in reduced microcracking, strengths as high as 230 MPa and high critical current density capacity.
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